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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 10-2016-0006290, filed on Jan. 19, 2016, entitled “METHOD FOR CONTROLLING OPERATION OF MOVING AVERAGE FILTER”, which is hereby incorporated by reference in its entirety into this application.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to a method for controlling the operation of a moving average filter, which is capable of optimizing the ability to cope with a surge noise through reasonable control of a tracking speed with respect to a change in an input value.
[0004] 2. Description of the Related Art
[0005] Information, which is continuously changed with time, such as sound, light, temperature, pressure, position and the like, can be converted into an analog electrical signal (voltage or current) by means of a transducer or a sensor. An electronic circuit configured to deliver the information by amplifying, detecting and converting a voltage, current, frequency or the like of the analog electrical signal obtained thus is referred to as an analog circuit.
[0006] Such an analog circuit may contain a noise. As a randomly-varying external signal, the noise is generated by random heat vibration of particles such as atoms. The noise is mainly generated due to use of poorly designed parts, repeated radiation of a signal for remote transmission, introduction of an external electric signal, etc. Such a noise may decrease a level of an original signal by decreasing a irregular change in the signal.
[0007] If a random external noise is added to an analog signal, it is difficult to distinguish from the original signal. This problem may be solved by a separate circuit or algorithm adapted to cope with such a difficulty.
[0008] A noise filter is often used to block a noise. As a kind of the noise filter, a moving average filter has a trade-off relationship between a response speed and a noise blocking performance. That is, a higher response speed of the moving average filter provides a lower noise blocking performance thereof. Therefore, in order to increase the noise blocking performance, it is necessary to decrease the response speed.
[0009] Accordingly, the present invention suggests a novel algorithm which is capable of efficiently controlling a response speed and a noise blocking performance of a moving average filter.
SUMMARY
[0010] The present invention has been made to overcome the above problems and it is an aspect of the present invention to provide a method for controlling the operation of a moving average filter, which is capable of optimizing the ability to cope with a surge noise through reasonable control of a tracking speed with respect to a change in an input value.
[0011] The present invention is not limited to the above aspect and other aspects of the present invention will be clearly understood by those skilled in the art from the following description. The above and/or other aspects and advantages of the present invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings. It should be understood that the objects and advantages of the present invention can be realized by features and combinations thereof set forth in the claims.
[0012] In accordance with one aspect of the present invention, there is provided a method for controlling the operation of a moving average filter to block a noise, including: (a) a step of setting a stability reference value and a corresponding sampling interval; (b) a step of inputting measurement data; (c) a step of calculating a first moving average using the measurement data input in the step (b) by applying a basic sampling interval; and (d) a step of calculating a second moving average for the measurement data by applying the sampling interval corresponding to the stability reference value set in the step (a) if the first moving average is equal to or larger than the stability reference value.
[0013] In some embodiment, the stability reference value set in the step (a) may include two or more different reference values, and two or more different sampling intervals corresponding the tow or more different reference values are set.
[0014] In some embodiment, the stability reference value and the sampling interval set in the step (a) may be automatically set according to the filtering environments including the current noise situations.
[0015] In some embodiment, the step (d) may return to the step (c) if the second moving average is maintained below the stability reference value for more than a specified reference time.
[0016] According to the present invention, it is possible to efficiently change a response speed and a noise blocking performance of a moving average filter to cope with a change in input conditions.
[0017] In addition, according to the present invention, it is possible to provide a moving average filter capable of providing both of a high response speed and an improved noise blocking performance
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a conceptual view for explaining the meaning of a moving average and a process of calculating the moving average.
[0019] FIGS. 2A to 3B are graphs for explaining a process of operation of a conventional moving average filter.
[0020] FIG. 4 is a flow chart for explaining a method for controlling the operation of a moving average filter according to one embodiment of the present invention.
[0021] FIGS. 5A and 5B are graphs for explaining a process of operation of the moving average filter according to one embodiment of the present invention.
[0022] FIGS. 6A and 6B are graphs for explaining a response speed of the moving average filter to which an embodiment of the present invention is applied.
DETAILED DESCRIPTION
[0023] The above objects, features and advantages will become more clearly apparent from the following detailed description in conjunction with the accompanying drawings. Therefore, the technical ideas of the present invention can be easily understood and practiced by those skilled in the art. In the following detailed description of the present invention, concrete description on related functions or constructions will be omitted if it is deemed that the functions and/or constructions may unnecessarily obscure the gist of the present invention.
[0024] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. Throughout the drawings, the same or similar elements are denoted by the same reference numerals.
[0025] FIG. 1 is a conceptual view for explaining the meaning of a moving average and a process of calculating the moving average.
[0026] A moving average means a real time average on a certain number (average number) of input values. Referring to FIG. 1 , in a situation where the average number (1) is set to 4, in order to calculate the moving average, an average on recent four input values is calculated every sample point.
[0027] A moving average filter uses the calculated moving average to perform a noise filtering operation. That is, the moving average filter has an algorithm which accumulates input values by the average number (1) and outputs an average of the sum of the accumulated input values every sampling point. In other words, the moving average filter has, as an input, an AD conversion value (digital value) into which an input analog electrical signal is converted by means of an AD converter or the like, and generates an output value corresponding to the AD conversion value. Here, the average number (1) is referred to as a moving average filter value. Accordingly, in FIG. 1 , the moving average filter value is 4.
[0028] The following equation 1 is a moving average calculation equation based on which the moving average filter uses the moving average filter value (1) to calculate an output value (moving average).
[0000] Input filter output value[ n ]=(AD conversion value[ n ]+AD conversion value[ n− 1]+ . . . AD conversion value[ n− 1+1])/1 [Eq. 1]
[0000] where 1 denotes the average number and n>1.
[0029] According to the moving average calculation equation expressed by the equation 1, the output value can be calculated by adding (1-1) previous input values to the current input value (the AD conversion value[n] in the equation 1) and then dividing the sum by the moving average filter value (the average number (1)).
[0030] FIGS. 2A to 3B are graphs for explaining a process of operation of a conventional moving average filter. In these graphs, a y axis represents measurement data such as a voltage, a weight or the like and an x axis represents time divided by a certain interval unit. For example, if a measurement cycle for the input data such as a voltage, a weight or the like is one second, the scale unit of the x axis may mean time of one second, which may be expressed as a ‘sample period.’
[0031] Specifically, FIGS. 2A and 2B show an output value (indicated by a signal in red) in a case where the moving average filter value is 100 and 50 when an input value (indicated by a signal in blue) is instantaneously changed from 0 to 100, respectively, and FIGS. 3A and 3B show an output value (indicated by a signal in red) in a case where the moving average filter value is 100 and 50 when an external electrical signal (indicated by a signal in blue) such as a surge noise is input during 8 sampling intervals, respectively.
[0032] First, referring to FIGS. 2A and 2B , when the input value is instantaneously changed from 0 to 100, a response speed (tracking speed) for this change becomes higher as the moving average filter value becomes smaller. In other words, in FIG. 2A where the moving average filter value is 100, the filter output value is 100, which is equal to the input value, nearly at a 120 sampling point, whereas, in FIG. 2B where the moving average filter value is 50, the filter output value is 100, which is equal to the input value, nearly at a 70 sampling point. That is, the response speed of the moving average filter is in inverse proportion to the moving average filter value.
[0033] Next, referring to FIGS. 3A and 3B , when a noise is input during about 8 sampling intervals, if the moving average filter value is 100 ( FIG. 3 a ), the output value is about 8 during about 90 to 100 sampling intervals, whereas, if the moving average filter value is 50 ( FIG. 3 b ), the output value is about 16 during about 40 to 50 sampling intervals.
[0034] In other words, when a system employing such a moving average filter determines whether or not an error for a noise or the like is allowed, on the basis of an output value of 10 (e.g., 10 v or 10 dB), in a case where the moving average filter value is 100 ( FIG. 3A ), there occurs no problem since the output value does not exceed 10 in any intervals. On the contrary, in a case where the moving average filter value is 50 ( FIG. 3B ), there may occur a problem such as system shutdown or the like since the output value is 16 in some intervals, which is out of an error range. That is, the blocking performance of the moving average filter against the surge noise or the like is in proportion to the moving average filter value.
[0035] Accordingly, since a smaller moving average filter value provides a lower noise blocking performance although it provides a higher response speed of the moving average filter, there is a difficulty in determining an appropriate moving average filter value. Accordingly, the present invention suggests a method for controlling the operation of a moving average filter, which is capable of providing both of a high response speed and a high noise blocking performance.
[0036] FIG. 4 is a flow chart for explaining a method for controlling the operation of a moving average filter according to one embodiment of the present invention. FIGS. 5A and 5B are graphs for explaining a process of the operation of the moving average filter shown in FIG. 4 .
[0037] First, referring to FIG. 4 , a method for controlling the operation of a moving average filter according to one embodiment of the present invention includes a step S 410 of setting a stability reference value and a corresponding moving average filter value, a step S 420 of inputting measurement data, a step S 430 of calculating an output value by applying a basic moving average filter value, a step S 440 of comparing the output value and the stability reference value, and a step S 450 of calculating an output value by applying the moving average filter value set in the step S 410 if the output value calculated in the step S 430 is equal to or larger than the stability reference value.
[0038] The step S 410 of setting a stability reference value and a corresponding moving average filter value is a step of adjusting a basic moving average filter value to a first moving average filter value if an output value of the moving average filter is equal to or larger than a predetermined reference value. That is, the step S 410 is a step of making a setting such that the output value of the moving average filter can have a fast response to an input value by setting the moving average filter value to be smaller than a basic setting value at normal if the moving average filter outputs an output value having a variation width larger than that of an output value stabilized at normal. Accordingly, the stability reference value may be a certain reference value set in consideration of a noise allowable range according to a system design standard or the like in order to change the response speed of the moving average filter but does not mean a specific numeral or a limited range.
[0039] For example, FIG. 5A shows a stability reference value set to 8 and FIG. 5B shows a stability reference value set to 16. That is, FIG. 5A shows a case where the basic moving average filter value is 100, the stability reference value is 8 and the first moving average filter value is 50, and FIG. 5B shows a case where the basic moving average filter value is 100, the stability reference value is 16 and the first moving average filter value is 50. In each graph, a y axis represents measurement data such as a voltage, a weight or the like and an x axis represents time divided by a certain interval unit, as described earlier.
[0040] Next, in the measurement data inputting step S 420 , measurement data such as a voltage, a weight or the like measured by means of a separate measuring instrument is input. Thereafter, in the step S 430 , the moving average filter calculates an output value by applying the basic moving average filter value.
[0041] Next, in the step S 440 , the output value is compared with the stability reference value. As a result of the comparison, if the output value is equal to or larger than the stability reference value, in the step S 450 , an output value is calculated by applying the first moving average filter value. The steps S 430 and S 450 are repeated until data are not input any longer in the measurement data inputting step S 420 .
[0042] Referring to FIGS. 5A and 5B , when a surge noise is input in the measurement data inputting step S 420 , the moving average filter of FIG. 5A first uses a basic moving average filter value 100 to calculate an output value and then, at the moment (P 1 ) that the output value reaches a stability reference value of 8, uses a first moving average filter value of 50 to calculate an output value. Thereafter, at the moment (P 2 ) that the output value is again below the stability reference value of 8, the moving average filter uses the basic moving average filter value of 100 to calculate the output value.
[0043] At this time, when the output value of the moving average filter is changed to be smaller than the stability reference value of 8, it is possible to provide an additional configuration for adjusting the moving average filter value only if the output value smaller than the stability reference value is calculated continuously during a certain reference sampling interval. Here, setting of the certain reference sampling interval may be achieved by an input from a system administrator or the like or preferably automatically according to the system environments or the like.
[0044] Next, the moving average filter of FIG. 5B continues to use the basic moving average filter value of 100 to calculate an output value. That is, since the output value has not reached a stability reference value of 16, the moving average filter of FIG. 5B can calculate the output value only with the basic moving average filter value of 100 without a need to use the first moving average filter value of 50 to calculate the output value.
[0045] For example, when a system is designed to determine whether or not a noise or the like is allowed for the moving average filters of FIGS. 5A and 5B , on the basis of an output value of 10 (e.g., 10 v or 10 dB), the moving average filter of FIG. 5A shows an output value of 16 exceeding a noise allowable range during about 15 sampling intervals, whereas the moving average filter of FIG. 5B achieves appropriate noise blocking during the entire sampling intervals.
[0046] In other words, for the same input signal as those shown in FIGS. 3A and 3B , the moving average filters of FIGS. 5A and 5B can perform noise blocking equally stably or reduce an interval exceeding the noise allowable range.
[0047] In this manner, in the method for controlling the operation of the moving average filter according to the embodiment of the present invention, it is possible to determine the noise blocking performance depending on a level of setting of the stability reference value and the corresponding first moving average filter value. In addition, the stability reference value and the corresponding first moving average filter value can be set by directly inputting a specific value determined through a field test or the like from a system administrator but may be more preferably automatically set according to the system installation environments, corresponding noise situations, etc.
[0048] In this case, it is possible to provide a configuration in which the stability reference value and the corresponding first moving average filter value are changed with a change in the noise situations and the like. Further, it is possible to maintain the optimal balance state of the response speed and the noise blocking performance of the moving average filter through setting of stability reference values in additional several steps and corresponding second and third moving average filter values.
[0049] That is, although not shown in these figures, by setting another stability reference value different from the above-mentioned stability reference value and designating a second moving average filter value corresponding to the set another stability reference value, which is different from the first moving average filter value, it is possible to apply a variety of moving average filter values depending on a level of the output value of the moving average filter.
[0050] FIGS. 6A and 6B are graphs for explaining a response speed of the moving average filter to which an embodiment of the present invention is applied. Like FIG. 5A , FIG. 6A shows a case where the basic moving average filter value is 100, the stability reference value is 8 and the first moving average filter value is 50. Like FIG. 5B , and FIG. 6B shows a case where the basic moving average filter value is 100, the stability reference value is 16 and the first moving average filter value is 50.
[0051] That is, referring to FIG. 6A , at the moment (P 1 ) that the output value of the moving average filter reaches a stability reference value of 8, the moving average filter value is changed to 50, which shows a higher response speed. Referring to FIG. 6B, at the moment (P 2 ) that the output value of the moving average filter reaches a stability reference value of 16, the moving average filter value is changed to 50, which shows a higher response speed.
[0052] Accordingly, as can be seen from a comparison between the graphs of FIGS. 6A and 6B and the graphs of FIGS. 2A and 2B for the operation of the conventional moving average filter, the moving average filter operation controlling method of the present invention can greatly increase the response speed of the moving average filter. That is, when the moving average filter operation controlling method according to the embodiment of the present invention is applied, the response speed of the moving average filter shows a result similar to a case where the moving average filter value is small, .e., 50, and the noise blocking performance of the moving average filter shows a result similar to a case where the moving average filter value is large, .e., 100.
[0053] In other words, the present invention can provide a moving average filter which is capable of providing both of a high response speed and an improved noise blocking performance
[0054] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention. The exemplary embodiments are provided for the purpose of illustrating the invention, not in a limitative sense. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | The present invention relates to a method for controlling the operation of a moving average filter, which is capable of optimizing the ability to cope with a surge noise through reasonable control of a tracking speed with respect to a change in an input value. The method includes: (a) a step of setting a stability reference value and a corresponding sampling interval; (b) a step of inputting measurement data; (c) a step of calculating a first moving average using the measurement data input in the step (b) by applying a basic sampling interval; and (d) a step of calculating a second moving average for the measurement data by applying the sampling interval corresponding to the stability reference value set in the step (a) if the first moving average is equal to or larger than the stability reference value. | 7 |
SCOPE OF THE INVENTION
[0001] This invention relates to a filing cabinet, and in particular, to a filing cabinet with a locking system.
BACKGROUND OF THE INVENTION
[0002] Filing cabinets are known having drawers that open forwardly to provide access to paper files and the like inside. One example of a filing cabinet structure is shown in U.S. Pat. No. 4,480,883 to Edwards issued Nov. 6, 1984 which is directed to an internal anti-tip blocking device that permits only one drawer of a stacked column of drawers to be opened at any one time.
[0003] Filing cabinets are known to have internal lock structures which are internal of the cabinet and prevents any of the drawers from being opened. For added security, it is also known to provide external locking devices with a metal bar which extends vertically across the height of a column of drawers and is secured at the top and bottom of the cabinet to prevent opening of any drawers. Such external bar has the disadvantage that it must be removed and stored when not in use.
SUMMARY OF THE INVENTION
[0004] To at least partially overcome the disadvantages of previously known devices, the present invention provides an external locking mechanism for a filing cabinet incorporating two hinged blocking plates at each side of the cabinet and a locking bar which is movable without removal from attachment to the cabinet to positions such that the blocking plates can be selectively prevented from being moved to unblocked positions or permitted to be moved to unblocked positions.
[0005] An object of the present invention is to provide an improved external locking system for a filing cabinet.
[0006] Another object of the present invention is to provide a filing cabinet with a locking system which is very simple to use, and also relatively easy and inexpensive to manufacture.
[0007] In one aspect, the present invention provides a filing cabinet having a compartment with at least one drawer slidably mounted in the compartment between retracted and withdrawn positions. Blocking plates are hinged to each opposite side of the compartment rotatable on a vertical axis between: (i) a blocked position in the path of the drawer to prevent the drawer from withdrawal from the retracted position; and (ii) an unblocked position out of the path of the drawer to permit withdrawal to the withdrawn position. A locking bar is mounted to the cabinet movable between: (i) a locked position where at least a portion of the locking bar is in the path of both of the blocking plates and prevents each of the blocking plates from movement from the blocked position to the unblocked position; and (ii) unlocked positions where the locking bar is out of the path of the blocking plates and does not prevent the blocking plates from movement from the blocked position to the unblocked position.
[0008] In a preferred embodiment, the cabinet has a framework comprising by two opposite sidewalls, a back wall, a top wall, and a bottom wall which define a compartment therein containing sliding drawers and with an opening from the compartment from which the drawers are slidable through the opening.
[0009] The framework preferably includes a crossbeam which has ends that are secured to the opposite side walls of the framework preferably to extend horizontally between two drawers and with the locking bar mounted to the crossbeam, preferably for sliding or pivotal movement thereto.
[0010] The crossbeam preferably has a forward facing surface and the locking bar is mounted to the forward facing surface of the crossbeam.
[0011] In one preferred embodiment, the two opposite side walls each have a forward facing surface. A continuous hinge is mounted to the forward facing surface of the side wall with one hinge plate of the continuous hinge forming or carrying blocking plate.
[0012] In another preferred embodiment, the two opposite side walls each have a forward facing gable surface and a continuous hinge is mounted to the gable panel with one hinge plate mounted flush with the gable surface and the other hinge plate of the piano hinge pivotable relative the fixed hinge plate and forming a blocking plate which extends inwardly in front of the drawers.
[0013] Preferably, the length of the locking bar is such that it does not extend past the two opposite side walls, regardless of the position of the locking bar.
[0014] In an alternative embodiment, the filing cabinet comprises two locking bars mounted at opposite sides of the compartment. Each of the two locking bars is movable between: (i) a locked position where at least a portion of the locking bar is in the path of one of the blocking plates and prevents the blocking plate from movement from the blocked position to the unblocked position; and (ii) an unlocked position where the locking bar is out of the path of the blocking plate and does not prevent the blocking plate from movement from the blocked position to the unblocked position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Further aspects and advantages will become apparent from the following description taken together with the accompanying drawings in which:
[0016] FIG. 1 is a front pictorial view of a filing cabinet in accordance with a first embodiment of the present invention showing the drawers closed and locked;
[0017] FIGS. 2 to 5 are front pictorial views of a filing cabinet in accordance with the first embodiment of the present invention, wherein the drawers and associated slides have been removed;
[0018] FIGS. 6, 8 , 10 and 12 are partially cut-away top views of FIGS. 2 to 5 , respectively;
[0019] FIGS. 7, 9 , 11 , and 13 are partially cut-away front perspective views of FIGS. 2 to 5 , respectively;
[0020] FIGS. 14 to 17 are front pictorial views of a filing cabinet in accordance with a second embodiment of the present invention, wherein the drawers and associated slides have been removed;
[0021] FIGS. 18 and 20 are partially cut-away top views of FIGS. 14 and 17 , respectively;
[0022] FIGS. 19 and 21 are partially cut-away front perspective views of FIGS. 14 and 17 , respectively;
[0023] FIG. 22 is a partially cut-away top view of FIG. 14 ;
[0024] FIG. 23 is a cross-sectional view along section line A-A of FIG. 22 ;
[0025] FIG. 24 is a cross-sectional view along section line B-B of FIG. 22 ;
[0026] FIGS. 25 to 28 are front pictorial views of a filing cabinet in accordance with a third embodiment of the present invention, wherein the drawers and associated slides have been removed;
[0027] FIG. 29 is a front view similar to FIG. 1 but unlocked and with one drawer open;
[0028] FIG. 30 and 31 are cross-sectional plan views along section lines D-D′ and E-E′ in FIG. 2 ;
[0029] FIGS. 32 and 33 are partially cut-away top views of a fourth embodiment of the present invention;
[0030] FIG. 34 is a front pictorial view of a left locking bar in accordance with the fourth embodiment illustrated in FIGS. 32 and 33 ; and
[0031] FIG. 35 is a front pictorial view of a right locking bar in accordance with the fourth embodiment illustrated in FIGS. 32 and 33 .
[0032] Throughout all the drawings and the disclosure, similar parts are indicated by the same reference numerals.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Preferred Embodiment
[0033] Reference is made to FIGS. 1 to 13 and 29 which illustrate a first embodiment of a filing cabinet in accordance with the present invention.
[0034] As seen in FIGS. 1 to 13 and 29 the cabinet 10 has a framework comprising opposite side walls 12 and 13 , a back wall 52 , a top wall 54 and a bottom wall 56 . The framework defines a compartment therein. As seen in FIGS. 1 and 29 three drawers 60 are mounted in the compartment for horizontal sliding between closed, retracted positions shown in FIG. 1 and open, extended positions. FIG. 29 shows a middle of the three vertically stacked drawers in an open, extended position. The drawers 60 are slidable on associated slides (not shown) mounted to the interior of the side walls 12 and 13 on each side of each drawer 60 . The framework of the filing cabinet 10 includes a horizontal crossbeam 20 . The crossbeam 20 has both of its ends permanently secured to the opposite side walls 12 and 13 . The crossbeam 20 extends horizontally between the sidewalls 12 and 13 vertically between two of the drawers 60 and presents a forward facing surface 62 best seen in FIG. 24 . Each of sidewalls 12 and 13 carry a forward facing gable surface 14 and 15 effectively forming a gable or post extending vertically beside each drawer 60 throughout the height of the cabinet.
[0035] FIGS. 2 to 13 illustrate the filing cabinet 10 of FIGS. 1 and 29 from which the drawers 60 and associated slides have been removed.
[0036] As seen in FIG. 30 and 31 two continuous hinges 80 and 81 also known as piano hinges are mounted to the forward facing gable surface 14 and 15 of each side wall 12 and 13 . Each hinge 80 and 81 has two hinge plates namely a base plate 82 , 83 , a blocking plate 16 , 17 joined by a hinge pin 84 , 85 with the base plate 82 , 83 and blocking plate 16 , 17 pivotable relative each other about the pin 84 , 85 . The base plate 82 , 83 is fixedly secured to the respective gable surface 14 and 15 of the side walls as by screws, nuts, welding or the like with the hinge pin 84 disposed to not extend laterally beyond the respective side wall 12 and 13 . Each blocking plate 16 , 17 is thus hinged to its relative side wall 12 , 13 for pivoting about the vertical hinge pin 84 , 85 .
[0037] The blocking plates 16 , 17 are adapted to be rotatable from: (i) a blocked position, as shown in FIG. 2, 6 and 7 , in which the blocking plates 16 , 17 lie forward of the drawers 60 in the front plane of the front face of the cabinet 10 to (ii) an unblocked position, as shown in FIG. 5, 12 and 13 , in which the blocking plates 16 , 17 are rotated to extend forwardly preferably perpendicular to the front face of the cabinet 10 and thus parallel to side walls 12 and 13 . FIGS. 30 and 31 show the blocking plates 16 , 17 in solid lines in an unblocked position and in dashed lines in a blocked position.
[0038] A locking bar 22 is slidably mounted to the forward facing surface 62 of the crossbeam 20 for sliding in the horizontal direction relative the crossbeam 20 . FIGS. 2, 6 and 7 show a middle locked position in which the locking bar 22 overlaps both of the blocking plates 16 , 17 and prevents opening of the drawers. As seen in FIG. 6 which is a top view of FIG. 2 , the left end 30 of the locking bar 22 is forward of the left blocking plate 16 and prevents its movement from the blocked position shown and the right end 31 of the locking bar 22 is forward of the right blocking plate 17 and prevents its movement from the blocked position.
[0039] The locking bar 22 is slidable from the position shown in FIG. 2t o the right to the position shown in FIGS. 3, 8 and 9 such as to be clear of the blocking plate 16 thus allowing the blocking plate 16 to be rotated between the blocked and the unblocked position. FIGS. 4, 10 and 11 show a position which after the locking bar 16 has been rotated to the unblocked position, the locking bar 22 has been slid to the left to a position shown in FIG. 4 such as to be clear of blocking plate 17 thus allowing the blocking plate 17 to be rotated between the unblocked position and a blocked position. FIGS. 5, 12 , 13 and 14 show a condition which from the position of FIG. 4 , the blocking plate 17 is pivoted to the unblocked position and the locking bar 22 is slid back to the middle position. As seen in FIG. 12 in a top view the hinged blocking plates 16 , 17 are in a position where they are out of the path of the drawers 60 and therefore, do not prevent the opening of the drawers 60 , as shown in FIG. 29 with one drawer open.
[0040] The length of locking bar 22 is such that when it is slid to the right, as shown in FIG. 3 , the left end 30 of the locking bar 22 is clear of the blocking plate 16 on the left side of the filing cabinet 10 , and the right end 31 of the locking bar 22 does not extend past the edge of side wall 13 . Similarly, when the locking bar 22 is slid to the left, as shown in FIG. 4 , the right end 31 of the locking bar 22 is clear of the blocking plate 17 on the right side of the filing cabinet 10 , and the left end 30 of the locking bar 22 does not extend past the edge of side wall 12 . Therefore, the locking bar 22 is designed such that it does not extend laterally past vertical planes of the side walls 12 and 13 of the filing cabinet 10 , and does not move into, for example, a wall adjacent the filing cabinet 10 or into the path of the drawers of any other filing cabinets which are adjacent to filing cabinet 10 .
[0041] In the middle locked position of FIGS. 2, 6 and 7 , the locking bar 22 is adapted to be fixed in the position to prevent movement of the locking bar 22 . In this regard as best seen in FIG. 6 and 7 , a lock bracket 36 is secured to a central portion of the crossbeam 20 providing a horizontally extending flange with a vertical opening therethrough which is to align with vertical opening in the lock bar 22 such that a locking device such as a padlock may lock the locking bar 22 to the crossbeam 20 against movement. The locking bar 22 shown in FIGS. 1 to 13 has a L-shaped in cross-section with one flange vertical and the other flange horizontal. The horizontal flange carries the vertical opening to receive a padlock.
[0042] As seen, for example, in FIG. 29 , the locking bar 22 has a vertical extent which is not greater than the vertical extent of the crossbeam 20 such that with the locking bar 22 itself doe not interfere with movement of the drawers 60 on either side of the crossbeam 20 to an open extended position.
Second Preferred Embodiment
[0043] FIGS. 14 to 24 illustrate a second embodiment of the filing cabinet 10 of the present invention in which the drawers and associated slides have been removed.
[0044] In this embodiment, the locking bar 22 is pivotally mounted to the crossbeam 20 for pivoting about an axis or pivot indicated generally as 26 . This configuration allows for pivoting of the locking bar 22 between: (i) a horizontal position in which it overlies the crossbeam 20 , as seen in FIGS. 14 and 17 ; and (ii) a vertical position parallel to side wall 13 , as seen in FIGS. 15 and 16 . The locking bar 22 is spaced forwardly from the crossbeam 20 such that each blocking plate 16 , 17 may be received in a space between the locking bar 22 and the crossbeam 20 .
[0045] In the locked position illustrated in FIGS. 14, 18 , 19 and 22 , the blocking plates 16 and 17 are in a blocked position forward of the drawers and extending in the front plane of the front face of the cabinet 10 . Referring first to the left side, the locking bar 22 is in a horizontal position in which the end 30 of the locking bar 22 is forward of and overlaps the blocking plate 16 on the left side of the cabinet 10 . Thus the locking bar 22 prevents the blocking plate 16 from being moved from the blocked position to the unblocked position. The locking bar 22 does not extend laterally past the side wall 12 of the filing cabinet.
[0046] Referring to the right side, the length of the locking bar 22 is such that in the position shown in FIG. 14 , the left end 31 of the locking bar 22 is forward of and overlaps the blocking plate 17 on the right side of the filing cabinet 10 . Thus the locking bar 22 prevents blocking plate 17 from being moved from the blocked position to the unblocked position. The locking bar 22 does not extend laterally past side wall 13 of the filing cabinet 10 .
[0047] From the position of FIG. 14 , the locking bar 22 has been pivoted about pivot pin 26 to a vertical position parallel to sidewall 14 as shown in FIG. 15 . In this vertical position, the locking bar 22 does not prevent the blocking plates 16 and 17 on either side of the cabinet 10 from being moved from the blocked position to the unblocked position, and the blocking plates 16 and 17 are each able to be moved between the blocked and unblocked positions. FIG. 16 shows a condition in which from the position of FIG. 15 , the blocking plates 16 and 17 have been moved to the unblocked position shown in FIG. 16 with the locking bar maintained vertical. The locking bar 22 is pivotally connected to the crossbeam 20 at pivot axis 26 with the pivot pin 26 is spaced inwardly from an end 30 of the locking bar 22 sufficiently that when the locking bar 22 is in the vertical position shown in FIGS. 15 and 16 the locking bar 22 is spaced laterally inwardly from the blocking plate 16 as in necessary that the blocking plate 16 be free to pivot between the blocked and unblocked positions. From the position of FIG. 16 the locking bar 22 can be pivoted about the pivot pin 26 to assume the horizontal position shown in FIGS. 17, 20 and 21 with the blocking plates 16 , 17 in the unblocked position and extending forwardly parallel to the side walls 12 and 13 of the cabinet. In the position of FIGS. 17, 20 and 21 , the blocking plates 16 , 17 are out of the path of the drawers and do not prevent the drawers from being withdrawn and retracted.
[0048] FIG. 23 is a cross-sectional view along section line A-A of FIG. 22 showing a preferred configuration by which the locking bar 22 is pivotally mounted to the crossbeam 20 for pivoting about pivot axis 26 . The locking bar 22 is L-shaped is cross-section having vertical leg 40 and horizontal leg 41 . The crossbeam 20 has a vertical portion 61 presenting a forward face 62 . A top flange 63 and a bottom flange 64 extending rearwardly from the vertical portion 61 . At the location of pivot axis 26 , a strengthening plate 66 is secured to the rear of the vertical portion 61 . A screw 65 carrying washers 67 and 68 extends through an aperture the plate 66 and the vertical portion 61 and into a threaded nut 69 welded to a rear of the vertical leg 40 of the locking bar 22 .
[0049] FIG. 24 is a cross-sectional view along section line B-B of FIG. 22 illustrating a lock bracket 36 which is fixedly secured to the crossbeam 20 by reason of a vertical leg 37 being welded to the vertical portion 61 of the crossbeam 20 to present a horizontal leg 38 projecting forwardly. The locking bar 22 is shown with its horizontal leg 42 resting on the horizontal leg 38 of the lock bracket 36 . Vertical openings 90 and 91 in through the horizontal leg 30 of the lock bracket 36 and the horizontal leg 42 of the locking bar 22 align to receive a padlock 93 or other locking mechanism to lock the locking bar 22 against movement relative to the crossbeam 20 and, therefore, to secure the hinged blocking plates 16 in the closed position shown in FIGS. 14, 18 , 19 , 22 and 24 . FIG. 24 shows the blocking plate 17 as disposed in a blocked position rearward of the locking bar 22 .
[0050] In FIG. 14 to 24 the pivot axis 26 is show as located proximate to one side of the cabinet 10 . This is preferred but not necessary and the pivot axis 26 could be in the centre middle of the crossbeam between two sides.
Third Preferred Embodiment
[0051] FIGS. 25 to 28 illustrate a third embodiment of the filing cabinet 10 of the present invention. The drawers and associated slides have been removed.
[0052] The third preferred embodiment is a variation of the second embodiment illustrated in FIGS. 14 to 24 . In the third embodiment, however, there are two separate locking bars 22 and 23 . Each locking bar 22 , 23 is pivotally mounted opposite ends of the crossbeam 20 by a pivot mechanism for pivoting about pivot axis 26 and 27 .
[0053] In a horizontal position, as shown in FIG. 25 , both locking bars 22 , 23 overlie the crossbeam 20 . The ends 32 , 33 of the locking bars 22 , 23 which are farthest away from the pivot axes 26 , 27 overlap in the middle of the cabinet where they can be secured, as preferably to the crossbeam 20 for locking as with a padlock and locking bracket, not shown, but similar to that in FIG. 24 . In FIG. 25 , the blocking plates 16 , 17 are in a blocked position extending in the front plane of the front face of the cabinet 10 and each locking bar 22 , 23 is in a horizontal position with the end 30 , 31 of the locking bar 22 that is nearer to pivot axes 26 , 27 in front of one of the blocking plates 16 , 17 to prevent the blocking plate 16 , 17 from being moved from a blocked position to an unblocked position.
[0054] The length of each of the locking bars 22 , 23 is such that when the locking bars 22 are in the horizontal position shown in FIG. 25 , the near ends 30 , 31 overlap the blocking plates 16 , 17 but do not extend past either of the side walls 12 and 13 .
[0055] In FIGS. 26 and 27 , both of the locking bars 22 , 23 have been pivoted about their pivot axes 26 , 27 to a vertical position parallel to side walls 12 and 13 . In this vertical position, neither of the locking bars 22 , 23 prevent the blocking plates 16 , 17 from being moved from the blocked position to the unblocked position. FIG. 28 illustrates a position in which from the position of FIG. 27 , the locking bars 22 , 23 are pivoted to a horizontal position. In the position of FIG. 28 the drawers 60 may be opened.
[0056] In the third embodiment, when the locking bars 22 , 23 are in the vertical position shown in FIGS. 26 and 27 , the length of the locking bars 22 , 23 are limited such that the far ends 32 , 33 of the locking bars 22 do not extend upwardly past top wall 54 .
[0057] While the second and third embodiments have been illustrated with the locking bars 22 , 23 moved to a vertical position extending upwardly from the pivot axis 26 , 27 to permit the blocking plates 26 , 27 to be moved between the blocked and unblocked positions, the locking bars 22 , 23 could be moved to vertical position with the locking bars 22 , 23 extending downwardly from the pivot axis 26 , 27 provided sufficient vertical spacing is available above a floor on which the cabinet rests.
Fourth Preferred Embodiment
[0058] FIGS. 32 to 35 illustrate a fourth preferred embodiment of the filing cabinet 10 of the present invention.
[0059] The fourth preferred embodiment has elements of both the first preferred embodiment illustrated in FIGS. 1 to 13 and 29 and the third preferred embodiment illustrated in FIGS. 25 to 28 .
[0060] Similar to the third preferred embodiment, the fourth preferred embodiment has two separate locking bars, a left locking bar 22 and a right locking bar 23 . Like the first preferred embodiment, each locking bar 22 , 23 of the fourth preferred embodiment is slidably mounted to the forward facing surface 62 of the crossbeam 20 for sliding in the horizontal direction relative to the crossbeam 20 .
[0061] FIGS. 34 and 35 provide isolated views of the left locking bar 22 and the right locking bar 23 , respectively.
[0062] As shown in FIGS. 34 and 35 , each locking bar 22 , 23 is divided into three portions. For example, the left locking bar 22 divided into a main portion 114 , a shoulder portion 116 , and an end portion 118 . The main portion 114 is substantially parallel to the crossbeam 20 of the filing cabinet 10 . The left locking bar 22 is bent at a substantially right angle to the main portion 114 in order to form the shoulder portion 116 . Therefore, the shoulder portion 116 is substantially perpendicular to both the main portion 114 and the crossbeam 20 . The left locking bar 22 is then bent again at a substantially right angle to the shoulder portion 116 in order to form the end portion 118 . Therefore, the end portion 118 is substantially parallel to both the main portion 114 and the crossbeam 20 .
[0063] The right locking bar 23 is almost a mirror image of the left locking bar 22 . The right locking bar 23 is divided into a main portion 120 , a shoulder portion 122 , and an end portion 124 . The main portion 120 is substantially parallel to the crossbeam 20 of the filing cabinet 10 . The right locking bar 23 is bent at a substantially right angle to the main portion 120 in order to form the shoulder portion 122 . Therefore, the shoulder portion 122 is substantially perpendicular to both the main portion 120 and the crossbeam 20 . The right locking bar 23 is then bent again at a substantially right angle to form to the shoulder portion 122 in order to form the end portion 124 . Therefore, the end portion 124 is substantially parallel to both the main portion 120 and the crossbeam 20 . A right reinforcement bracket 162 is placed between the main protion 120 and the shoulder portion 122 . The reinforcement bracket 162 maintains the substantially right angle between the main portion 120 and the shoulder portion 122 . Therefore, the reinforcement bracket 162 prevents the right locking bar 23 from being manually bent or pried away from its position forward of the right blocking plate 17 . A corresponding left reinforcement bracket 160 for the left locking bar 22 is shown in FIGS. 32 and 33 .
[0064] FIG. 32 shows a locked position of the fourth preferred embodiment. The left locking bar 22 is in a left most position, such that the left end 30 of left locking bar 22 is forward of the left blocking plate 16 and prevents its movement from the blocked position shown. Similarly, the right locking bar 23 is in a right most position, such that the right end 31 of the right locking bar 23 is forward of the right blocking plate 17 and prevents its movement from the blocked position shown.
[0065] The left locking bar 22 is designed such that when it is in the left most position shown in FIG. 32 , the left shoulder portion 116 abuts with a corresponding shoulder portion 110 formed in crossbeam 20 . The corresponding shoulder portion 110 of the crossbeam 20 is similar to the left shoulder portion 116 in that both of these structures are defined by two substantially right angle bends. The left locking bar 22 is prevented from sliding any further to the left. As such, the left end 30 of the left locking bar 22 does not extend past the edge of side wall 12 . Similarly, the right locking bar 23 is designed such that when it is in the right most position shown in FIG. 32 , the right shoulder portion 122 abuts with a corresponding shoulder portion 112 formed in crossbeam 20 . The corresponding shoulder portion 112 of the crossbeam 20 is similar to the right shoulder structure 122 in that both of these structures are defined by two substantially right angle bends. The right locking bar 22 is prevented from sliding any further to the right. As such, the right end 31 of the right locking bar 23 does not extend past the edge of side wall 13 . Therefore, the locking bars 22 , 23 are designed such that they do not extend laterally past the vertical planes of side walls 12 , 13 of the filing cabinet 10 .
[0066] Tabs 130 , 132 are formed adjacent the far ends 32 , 33 of each locking bar 22 , 23 . Each tab 130 , 132 is bent at a substantially right angle to the main portion 114 , 120 such that the tab 130 , 132 lies in the horizontal plane. Each tab 130 , 132 has a top surface 134 , 136 and a bottom surface 138 , 140 . Vertical openings 102 , 104 extend from the top surface 134 , 136 of the tabs 130 , 132 through to the bottom surface 138 , 140 of the tabs 130 , 132 . Preferably, the vertical opening 102 in the left locking bar 22 has the same size and shape as the vertical opening 104 in the right locking bar 23 . The size and shape of the vertical openings 102 , 104 is not particularly limited, but should be designed such that a padlock can be received through said vertical openings 102 , 104 .
[0067] When in the locked position shown in FIG. 32 , the vertical opening 102 of the left locking bar 22 is aligned with the vertical opening 104 of the right locking bar 23 . When desired, a locking mechanism, such as a padlock, can be inserted through both openings 102 , 104 and secure both locking bars 22 , 23 in the locked position.
[0068] Preferably, the ends 32 , 33 of the locking bars 22 , 23 form finger gripping means, as shown in FIGS. 34 and 35 . This allows a user to grasp the ends 32 , 33 and manually slide each locking bar 22 , 23 in the horizontal direction.
[0069] FIG. 33 illustrates an unlocked position of the fourth preferred embodiment. The left locking bar 22 is slidable from the left most position shown in FIG. 32 to a right most position shown in FIG. 33 , such that the left end 30 of the left locking bar 22 is laterally inwardly of the left blocking plate 16 and the left blocking plate 16 is free to be rotated between the blocked and the unblocked positions. The right locking bar 23 is slidable from the right most position shown in FIG. 32 to a left most position shown in FIG. 33 , such that the right end 31 of the right locking bar 23 is laterally inwardly of the right blocking plate 17 and the right blocking plate 17 is free to be rotated between the blocked and the unblocked positions.
[0070] Each of the embodiments show a filing cabinet with a crossbeam 20 which is preferred but not necessary. The sliding locking bar 22 of FIG. 1 could be mounted to one or both of the gable-like crossbeams 95 and 96 forward as part of and adjacent top wall 10 and bottom wall 56 . The pivoting licking bars 22 , 23 of FIGS. 14 to 25 could similarly be mounted to the top crossbeam 95 and possibly the bottom crossbeam 96 .
[0071] The continuous hinges forming the blocking plates 16 , 17 are shown in each embodiment to extend the entire height of the cabinet 10 . This is not necessary but preferred. The hinges need to only extend adjacent a portion of each drawer 60 whose opening is to be blocked.
[0072] Although this disclosure has described and illustrated preferred embodiments of the invention, it is to be understood that the invention is not restricted to these particular embodiments. Rather, the invention includes all embodiments that are functional or mechanical equivalents of the specific embodiments and features that have been described and illustrated herein. Many modifications and variations will now occur to those skilled in the art. For a definition of the invention, reference is made to the following claims. | An external locking mechanism for a filing cabinet incorporating two hinged blocking plates at each side of the cabinet and a locking bar which is movable without removal from attachment to the cabinet to positions such that the blocking plates can be selectively prevented from being moved to unblocked positions or permitted to be moved to unblocked positions. | 4 |
FIELD OF THE INVENTION
The present invention relates to an improved machine for the liquid treatment (with water, solvents etc.) or gaseous treatment (for example with foam) of textiles, and especially for the washing, bleaching or dyeing of textiles in different forms: flock, combed tops, spun fiber yarns, filament, flat, textured or shrunk yarns, spun fiber yarns with a filament yarn core, woven fabrics or knitted fabrics.
PRIOR ART
The present invention relates to a machine with a horizontal tank. Machines are known for the washing, bleaching and dyeing of textiles at a high temperature capable of reaching 140° C., in which the treatments are carried out by circulating the bath through the static textile. In this case, the textile is loaded horizontally into the machine: packing, flock, bobbins of combed tops, stacked bobbins of spun fiber yarns or filament yarns, beamed yarn lap, or beamed knitted fabrics or woven fabrics, i.e. fabrics wound around a perforated tube called a beaming slide.
In these machines, the static pressurization of the bath heated to a high temperature is carried out by several known methods:
circuit of the external bath in an expansion vessel which is either closed or open. In this case, the bath of the expansion vessel is generally taken up by an injection and static pressurization pump in order to be returned to the autoclave apparatus via pipes.
In the case where the expansion vessel is open, there is a device for cooling the bath upstream of the expansion vessel to below 100° C., for example to 80° C.
expansion of the bath inside the autoclave itself, in a space located above the material: in this case, the holder for the material is offset downwards so that, with the material covered by the bath, there remains sufficient space available above it for expansion.
Although the technical performance characteristics of these machines are good, it proves necessary to improve them further by making the greatest possible reduction in the volume of the treatment bath in circulation, while at the same time avoiding the systematic cooling of the bath, and consequently by reducing the energy consumption.
SUMMARY OF THE INVENTION
The object of the present invention was consequently to design a machine for the treatment of textiles or other fibrous or porous materials in a liquid or gaseous medium, such as a washing, bleaching or dyeing treatment, which satisfies the practical requirements even better than the machines of the same type proposed in the prior art, by permitting a substantial reduction in the energy consumption of this type of machine, this being associated with a reduction in the volume of the treatment bath in circulation, with its expansion circuit and with the regulation of its flow rate through the material, as a result of improvements made to these machines.
The present invention relates to a machine for the liquid or gaseous treatment of textiles or other fibrous or porous materials, and especially for the washing, bleaching and dyeing of textiles, which is of the type having a tank with a horizontal axis which houses a treatment zone equipped with at least one holder for the material to be treated, and an expansion zone for the treatment fluid, which is located in the end zone of the tank opposite the end zone possessing the tank cover, and is separated from the treatment zone by a partition, which machine also comprises means for circulating the treatment fluid and a heat exchanger for the treatment fluid in circulation, wherein the partition which delimits firstly the expansion zone and secondly the treatment zone, in the machine, is a non-leaktight partition allowing communication between the said two zones and the passage of the whole of the bath from one zone to the other, the means for circulating the treatment fluid comprise, in combination, a pipe with a horizontal axis, which is mounted essentially along the axis of the machine and one of the ends of which is housed in the partition, a side opening made in the bottom of the machine, and a pump for circulating the bath, which is arranged on the outside of the machine and connected firstly to the other end of the pipe and secondly to the side opening by a pipe, the said means for circulating the bath constituting a short and compact circuit of low energy consumption, the said short and compact circuit includes a heat exchanger in which the whole of the treatment fluid taken up by the pump circulates, and communicates with the expansion zone by way of the opening, and means for bringing the treatment zone into direct communication with the expansion zone are provided inside the machine in order to allow the whole of the bath to circulate between the said zones.
The arrangement of an expansion zone of this type in a leaktight box delimited by the bottom of the machine and the said partition permits a reduction in the bath ratio and hence savings of energy (a smaller volume of heated bath), water and treatment products (for example dyeing products), and consequently a reduction in pollution.
In an advantageous embodiment of the treatment machine forming the subject of the present invention, the heat exchanger is mounted in a housing provided for accommodating it in the said expansion zone and associated with the means for bringing the treatment tank into communication with the expansion zone.
In an advantageous arrangement of this embodiment, the said housing is non-leaktight and ensures communication between the treatment tank and the expansion zone.
In another advantageous arrangement of this embodiment, the said housing is leaktight and the connection between the treatment tank and the expansion zone is ensured by a tube, at least part of which passes through the expansion zone and comes out in the said leaktight housing.
In another advantageous embodiment of the treatment machine forming the subject of the present invention, the heat exchanger is mounted in a connection pipe between the pump for circulating the treatment fluid and the treatment tank.
In yet another advantageous embodiment of the treatment machine forming the subject of the present invention, the machine comprises means for automatically controlling the pressures prevailing respectively in the expansion zone and the treatment tank, which make it possible to control the heights of the treatment bath level in the expansion zone and in the treatment tank and also, if appropriate, to work with a reduced volume of bath in the treatment tank, which is proportional to a quantity of material to be treated which is introduced into the said tank, this quantity being less than the treatment capacity of the machine.
In an advantageous arrangement of this embodiment, the said means for automatically controlling the pressures prevailing respectively in the expansion zone and in the treatment tank consist of means for introducing controlled quantities of a compressed gas into the treatment tank and/or into the expansion zone.
In another advantageous embodiment of the machine according to the present invention, the pump for circulating the treatment fluid is a centrifugal pump allowing the said fluid to circulate in only one direction.
In an advantageous arrangement of the invention, the pump for circulating the treatment fluid is a centrifugal pump equipped with a reversing device in order to allow the said fluid to circulate alternately in two opposite directions.
In another advantageous arrangement of the invention, the pump for circulating the treatment fluid is a propeller pump which allows the said fluid to circulate alternately in two opposite directions.
In yet another advantageous arrangement of the invention, the pump for circulating the treatment fluid is driven by a variable-speed motor.
In an advantageous embodiment of the said partition, the latter consists of an internal metal wall which possesses an axial opening capable of accommodating the corresponding end of the abovementioned axial pipe in order to bring the treatment tank into communication with the circulating pump.
In another advantageous embodiment of the treatment machine forming the subject of the invention, the machine is equipped with a device for accommodating the holders for the material, which is located at the inner end of the abovementioned axial pipe and comprises a plinth fixed to the said pipe and carrying a cone for accommodating the said holders.
In an advantageous arrangement of this embodiment, the holder is joined to the accommodating device by means of a suitable device which makes it possible to position a holder of reduced capacity, not occupying the whole of the said first zone of the machine tank, at any level in the machine and especially as low as possible therein so as to reduce the volume of the bath even more.
According to the invention, packing bodies are provided on the holders in order to occupy the dead zones situated between the stacks of material to be treated which are carried by the holders, thus additionally reducing the internal volume of the machine and consequently the volume of bath in circulation.
In an advantageous arrangement of this embodiment, the said packing bodies are fixed to the holders.
In another advantageous arrangement of this embodiment, the packing bodies provided between the holders are fixed not to the holders but to the partition.
This arrangement offers an important advantage in the case of a detachable partition fixed to the packing bodies, in view of the fact that it is possible to position in the machine a detachable unit of partition/packing bodies for the treatment of materials on a given type of holder and remove it in order to replace it with another unit, also detachable, suitable for types of holders having different dimensions, for example carrying bobbins having a different diameter from those capable of being carried by the previous type of holder.
Also according to the invention, the boxes for distributing the treatment bath, which are associated with the holders in a known manner, are provided with perforations which ensure that the bath returns more rapidly to the bottom of the machine and that, as a result, it is taken up more rapidly by the pump.
Apart from the foregoing arrangements, the invention also includes other arrangements which will become apparent from the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be understood more clearly with the aid of the following complementary description referring to the attached drawings; in these drawings:
FIG. 1 is a schematic view in longitudinal section of an embodiment of the machine for the treatment of textiles or the like, according to the present invention, in which the heat exchanger is outside the machine,
FIG. 2 is a schematic view in longitudinal section of an embodiment of the treatment machine according to the invention which contains a holder of reduced capacity, i.e. not occupying the entire autoclave tank, and in which the heat exchanger is outside the machine,
FIGS. 3 to 5 are schematic views in longitudinal section of embodiments of the treatment machine according to the invention in which the heat exchanger is housed in the expansion zone of the machine,
FIG. 6a is a schematic view in longitudinal section of a holder carrying stacks of bobbins, with packing bodies fixed to the holder,
FIG. 6b is the corresponding view in cross-section,
FIG. 7 is a schematic view in longitudinal section of packing bodies fixed to the partition, according to the invention, of the autoclave, and
FIG. 8 is a schematic view in longitudinal section of an embodiment of the machine for the treatment of textiles or the like, according to the present invention, in which the heat exchanger is housed in part of the connecting pipe between the pump for circulating the treatment fluid and the treatment tank, which is located inside the expansion zone.
It must be clearly understood, however, that these drawings and the corresponding descriptive sections are given solely as an illustration of the subject of the invention and they in no way imply a limitation thereof.
DETAILED DESCRIPTION
The machine shown in FIGS. 1 to 5 for the liquid or gaseous treatment of textiles or other fibrous or porous materials consists of a horizontal autoclave designated as a whole by reference number 1, for the treatment of textiles or the like contained in a tank 10 and carried by holders 3, by the circulation of a treatment bath in the said tank 1. This machine is closed by a cover 2 and has a bottom 5 at its end opposite the cover 2. A partition 9 is arranged in the autoclave 1, in the vicinity of the bottom 5, in a position essentially perpendicular to the horizontal axis of the autoclave 1. This partition 9 delimits, in the autoclave, a first zone between the cover 2 and this partition 9, which constitutes the actual treatment tank 10, and a second zone defined by this partition 9, the bottom 5 and the corresponding part of the side wall 14 of the autoclave, which constitutes a chamber 13 containing the expansion zone for the treatment bath.
The partition 9 possesses an essentially axial opening 15 intended for accommodating one of the ends of a pipe 16 having a horizontal axis. A side opening 17 is made in the bottom 5 of the machine. At its other end, the pipe 16 is joined to an external pump 8 by a pipe 18 and the opening 17 is also joined to the said pump 8 by a pipe, as described below.
In the embodiments shown by way of non-limiting examples in FIGS. 1, 2 and 8, a heat exchanger 6A, 6D is mounted in the pipe 19 which joins the side opening 17, made in the bottom 5 of the autoclave 1, to the pump 8. However, whereas in the embodiments shown in FIGS. 1 and 2 the heat exchanger 6A is arranged in the pipe 19 outside the autoclave 1, in the embodiment shown in FIG. 8 the heat exchanger 6D is housed in a pipe 35 which joins the pump 8 to the treatment tank 10, and, more precisely, inside the expansion zone 35 which is located inside the expansion zone 13, the inner end of the said pipe 35 coming out in the partition 9.
In the embodiments shown by way of non-limiting examples in FIGS. 3 to 5, the opening 17 is joined directly to the pump 8 by a pipe 21 and the heat exchanger is placed in a housing provided in the expansion zone 13, in the lower part of the latter, facing the opening 17. In the embodiment shown in FIG. 3, the heat exchanger 6B is placed in a non-leaktight housing 22 which joins the treatment tank 10 to the expansion zone 13. In the embodiment shown in FIGS. 4 and 5, the heat exchanger 6C is placed in the housing 23, which is leaktight in relation to the treatment tank 10, and the connection between the latter and the expansion zone 13 is ensured by an opening 25 made in the partition 9 (cf. FIG. 4), or by a tube which can join the housing 23 to the opening 25 made in the partition 9, or by a tube 26 (cf. FIG. 5) which joins the tank 10 to the housing 23 via an extension 27 of the said tank 10 located between the wall 14 of the autoclave and a wall 28 which delimits the expansion zone 13 in conjunction with the partition 9, the bottom 5 and the upper wall of the housing 23.
Another variant (not shown) for bringing the tank 10 into communication with the expansion zone 13 can provide for the arrangement of an external pipe having a horizontal axis, which runs along the autoclave above the tank 1 and is joined to the latter by one or more tubes, this pipe undergoing a 90° change in direction, beyond the partition 9, so that it can enter the expansion zone 13, through a leaktight opening made for this purpose in the upper part of the said zone, as far as its connection to the housing 23.
The pump 8 for circulating the treatment bath is of any suitable type and can be, in particular, either a centrifugal pump which may or may not be equipped with a reversing tap system capable of ensuring a reversible circulation, or a propeller pump ensuring that the bath circulates from the opening 17 in the direction of the pipe 16 or in the opposite direction. In the case of the centrifugal pump not equipped with a reversing tap, the bath can circulate only in the direction from the opening 17 towards the pipe 16, which is generally suitable for the treatment of yarns, woven fabrics or knitted fabrics wound onto beaming slides.
The drive motor of the pump 8 can be a variable-speed motor.
The use of a variable-speed motor to drive the bath-circulating pump makes it possible to control and adjust the flow rate of the bath through the material, as well as the variations in flow rate, for example when the pump is started.
A plinth 20 fixed to the pipe 16 carries a cone or the like (not shown) for accommodating the holders 3 for the material, through which the bath can be distributed, as required, for example for the treatment of bobbins, via a box 30 (cf. FIG. 6a) provided with perforations 34 so that the bath returns rapidly to the bottom of the tank 10 in order to be taken up by the pump 8.
The autoclave 1 is placed under static pressure by means of a compressed gas, such as compressed air, which is introduced through the valves 12 each fitted with an air bleed. The introduction of compressed gas makes it possible to control the heights of the bath level in the expansion zone 13 and in the treatment zone 10. In fact, if the autoclave 1 is filled with compressed gas by bleeding near the tank 10 and closing near the partition 9, the level will settle in the said partition in such a way that the pressure of compressed gas prevailing in the partition is equal to the difference in level between the tank 10 and the partition 9. To reduce the volume of bath, i.e. to prevent the bath level from rising into the partition 9, it is desirable, in such a case, to inject compressed air into the partition during filling, so as to stabilize the level at the desired value.
The machine according to the invention can operate at full capacity or at reduced capacity. In the latter case, a device 29 makes it possible to join the holders 3 of reduced capacity to the accommodating cone, while at the same time placing them as low as possible in the tank 10, which makes it possible to adjust the level of the bath to the top part of the holders without it being necessary to fill the tank 10 completely. In the case of reduced production, it is thus possible to reduce the volume of bath and the consumption of water, treatment chemicals and heat energy, these consumptions being adapted to the reduction in the quantity of textiles 4 to be treated which are present in the tank 10. In this case, expansion takes place not only in the expansion zone 13 but also in the zone 16 of the tank 10 which surmounts the holders 3.
In this case where the volume of bath is reduced in order to adapt to reduced production, the pressure difference between the expansion zone 13 and the treatment zone 10 corresponds to the difference in bath level between these two zones 13 and 10, to which there should be added or from which there should be subtracted, according to the direction of circulation of the treatment bath, the pressure losses across the communication circuit between the treatment zone 10 and the expansion zone 13; to obtain the desired bath levels, it is thus necessary to control the pressures between these two zones by regulating the respective introduction of compressed gas into these two zones by means of the valves 12, as indicated above.
It is also possible to reduce the volume of bath by equipping the autoclave with horizontal packing bodies 31 which occupy the dead zones between stacks 32 of textiles to be treated which are carried by holders 3 (FIGS. 6 and 7).
By virtue of the combination of the partition 9 and the packing bodies 31, a machine for the liquid or gaseous treatment of textiles or other fibrous or porous materials is obtained in which the volume of bath, or bath ratio, necessary for the treatment is considerably reduced by comparison with the known machines of the prior art, this reduction affording a saving of water and a saving of energy as a result of the reduction in the quantities of water required for the treatment, and an improved productivity.
Furthermore, the polluting effluents (chemicals, colorants) are consequently reduced, representing a considerable decrease in environmental pollution.
Moreover, the particular arrangement of the pump and the use of a variable-speed drive motor have the effect of optimizing the performance characteristics of the pump and reducing the energy consumption for operating the pump, taking account of the treatment bath circuit.
In addition, the internal expansion of the bath makes it possible to save the heat energy lost by cooling due to external expansion.
The experiments performed by the Applicant Company have shown that the machine according to the invention permits water and energy savings of 20 to 30% compared with the performance characteristics of the best of the known machines intended for the same purpose.
As is apparent from the foregoing text, the invention is in no way limited to those embodiments and methods of application which have now been described more explicitly; on the contrary, it includes all the variants thereof which may occur to those skilled in the art, without deviating from the framework or the scope of the present invention. | A machine for the liquid or gaseous treatment of textiles or other fibrous or porous materials, which comprises a partition (9) located in its end zone opposite its cover (2), which partition (9) forms, with the bottom of the machine (1) and the corresponding part of its side walls (14), a leaktight box which delimits an expansion zone for the treatment fluid, that part of the machine which is located between the cover (2) and the partition (9) forming the actual treatment zone (10), which accommodates at least one holder for the material, the machine further comprising a device for the circulation of the treatment fluid. | 3 |
FIELD OF THE INVENTION
This invention relates to a catch basin structure which enables at least partial interception of contaminants which may be present in surface drainage to prevent such contaminants, alone or with stormwater, from entering a storm sewer system and subsequently polluting the environment.
BACKGROUND OF THE INVENTION
Airports in northern climates are obliged to employ deicing procedures on aircraft when either hoarfrost or freezing precipitation is encountered. The use of deicing fluid (traditionally propylene glycol or ethylene glycol) results in residue on the ground which, if allowed to enter a stormsewer system, would contaminate the natural environment. Other environmentally unacceptable liquids encountered at airports are fuels, hydraulic fluids, lavatory truck spills, oils and snow melting chemicals such as urea. The discharge of such substances into receiving streams and lakes has been ruled environmentally unacceptable. Accordingly, such substances should be prevented from entering the storm sewer systems which can happen most commonly at storm water catch basins. Such catch basins located at airports, or vehicle service stations, should be equipped with implements, or structures, for intercepting harmful contaminants with subsequent removal or discharge into holding or treatment facilities, while permitting uncontaminated rain water to drain into the sewer system.
U.S. Pat. No. 4,136,010 to Pilie et al. describes an exemplary catchbasin structure having a peripheral trough connected through a valve to a receiver system. The structure enables a selective interception and recovery of contaminants entering the catchbasin. The structure fulfils its function satisfactorily except during heavy rainfalls where the runoff, sometimes carrying pollutants such as deicing fluid, cannot be accommodated by the capacity of the trough and the associated conduits, the result being an overflow of contaminated water into the storm sewer system.
Canadian Patent No. 38,412 issued in 1892 describes a concrete gully for installation in a catchbasin, the gully having a hinged trap for allowing the flow of liquids into the catchbasin but preventing or reducing the emission of sewer gas therefrom.
Various catchbasin constructions are also described in U.S. Pat. No. 5,032,264 to Geiger, U.S. Pat. No. 2,993,600 to Ressler and in Canadian Patent No. 307,563 to Egan.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a catchbasin structure designed to substantially prevent the flow of liquid contaminants into the storm sewer system via the catchbasin from the ground level adjacent the catchbasin.
It is another object of the invention to provide a catchbasin structure enabling, selectively, a discharge of unpolluted rainwater into the storm sewer system or a retention of contaminants flowing into the structure from the ground level adjacent the catchbasin.
It is still another object of the invention to provide a system for automatic operation of the structure of the invention in accordance with the above objects.
According to the invention, there. is provided, in one embodiment, a catchbasin structure for placement in a catchbasin cavity disposed below ground level and connected to a storm sewer system, the structure comprising a receptacle mounted around the upper periphery of the catchbasin cavity in a manner to receive all the liquid flowing by gravity from the adjacent ground surface and extending downwardly from said upper periphery, a perforated cover placed over said receptacle, said receptacle having in its lowermost portion an outlet and a valve associated with said outlet and adapted to selectively open or close said outlet, and valve control means operable to selectively open or close said valve. When the valve is closed, the flow of a liquid from ground level through said receptacle into the cavity and the sewer system is positively prevented.
Alternatively, the receptacle may have in its lowermost portion two outlets, each associated with a valve adapted to open or close the respective outlet, wherein a first of the outlets is connected to a liquid retention system and the second outlet is in communication with the cavity and the sewer system.
The receptacle of the structure may comprise two or more parts which are interconnected in a detachable manner while still providing a sealed container for any liquid residing in the receptacle when the valve or valves are closed. This allows a part of the receptacle to be disassembled from the rest and removed from the structure thereby allowing an access to the catchbasin for maintenance and repairs.
The structure may also comprise sensing means installed in a manner to detect and signal the presence of contaminants within the receptacle. Control means for selectively closing the valve or valves on response to a signal from the sensing means may be provided. Alternatively, the valves may be operated manually according to the conditions at the catchbasin.
It is a feature of the invention to provide a structure adapted to completely seal off, by closing its valve or valves, the catchbasin cavity from the ingress of liquid from the ground level around the catchbasin. While this may create a temporary "flooding" of an area surrounding the catchbasin, e.g. during a heavy rainfall and simultaneous spill of a contaminating liquid, the advantage, particularly in comparison with U.S. Pat. No. 4,136,010, is an effective prevention of contamination of the environment by the spilled substances and a possibility of retention of the contaminants for treatment or recovery.
The invention is believed to be particularly useful at airports where the accumulation of sprayed deicing liquids, or spills of fuel or hydraulic fluids can happen and where it can be installed in catchbasins at specific areas of the apron.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail in conjunction with the accompanying drawings in which
FIG. 1 is a diagrammatic cross-sectional view of a catchbasin with an exemplary structure of the invention, and
FIG. 2 is a diagrammatic cross-sectional view of a catchbasin with another embodiment of the structure.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1 and 2, a typical catchbasin 10 features a cavity 12 which is usually covered with a grate 14 detachably disposed on a peripheral ledge 15. The ground adjacent to the catchbasin, in this case a section of airport apron 16, is usually sloped to facilitate the drainage. Liquid entering the cavity will flow into the storm sewer system, not shown, through an opening indicated for that purpose.
FIG. 1 illustrates a simple embodiment of the structure of the invention. The structure has a frame 18 which is mounted on its periphery to the ledge 15 in a manner preventing leaks between the ledge and the frame 18. This can be accomplished simply by welding or other known means.
As seen in FIG. 1, the frame 18 extends downwardly from the ledge 15 and ends with a peripheral lip 20. A bottom plate 22 is mounted to the frame 18 through a gasket 24 by means of screws 25 or other removable connecting means. The plate 22 has an opening 26 with a tubular section to which is attached a butterfly valve 28 with an actuator 30. The valve is manually operable using an operating key 32. An operating shaft of the valve actuator 30 protrudes through a watertight seal in the plate 22.
The frame 18 and the plate 22 in both the embodiments illustrated herein form a receptacle which may be fully closed at the bottom by the closure of the valve or valves.
In the embodiment of FIG. 1, with manually operated valve, there is little need for a sensor to detect the presence of a contaminant, e.g. PEG, as this embodiment is particularly suited to a situation such as aircraft deicing where the appearance of a contaminated liquid at the catchbasin is predictable and the valve can be closed manually before deicing commences. Furthermore, the valve can be kept closed until virtually all contaminated liquid has been cleaned off the apron surface and the receptacle. However, such a sensor may be installed, for instance at the opening 26, to guard against an accidental spill entering the catch basin. A signal generated by the sensor, as described below, could be sent to a remote location to alert the operator.
In a second embodiment, illustrated in FIG. 2, where like elements are designated with same numerals as in FIG. 1, the plate 22 has two openings 36, 38 with corresponding valves 40, 42 installed on the respective tubular sections. The opening 36 is in communication with a storage tank system via a flexible tube 44, shown in broken lines. The other opening 38 enables storm water to enter the cavity 12 when the valve 42 is open and to overflow to the storm sewer system through a separate opening indicated.
A gravity piping system, pump assisted or central vacuum system may be connected to the flexible tubing 44 and the storage tanks to facilitate the retrieval of large amounts of contaminants.
The frame 18 and the plate 22 as well as the valves 28, 40 and 42 are made of known materials, typically corrosion-resistant metals.
In the embodiment of FIG. 2, the valves 40, 42 are remotely operated as indicated by the respective electrical lines 45, 46 which connect the valves to a control unit, not shown. A sensor 34, adapted to detect the presence of PEG or other contaminants, is mounted at the opening 36 of the plate 22 and is also connected to the control unit and it can produce an acoustic signal or an optical signal at the catchbasin, and an additional signal at the control unit via an electric line 48. The control unit may be arranged to automatically operate the valves 40, 42 in response to the signal from the sensor 34.
The positioning of the sensor 34 is a matter of engineering choice. Many types of sensors are available on the market, and they can be installed at various locations depending on their type of operation. It may not be possible, in the embodiments illustrated herein, to avoid entirely the ingress of the initial flow of the contaminant into the catchbasin, but a substantial reduction of the hazard can be achieved.
In operation of the embodiment of FIG. 2, under normal circumstances, when no contaminants are present in or entering the receptacle, the valve 40 is normally closed and the valve 42 is normally open to allow for the run-off from the apron surface, or pavement, to flow directly through the valve 42 into the storm sewer system.
Should an accident occur whereby a contaminating fluid such as aircraft jet fuel, hydraulic fluid, lavatory truck spill or other contaminant be accidentally discharged onto the apron surface 16 and flow by gravity to the receptacle, the sensor 34 will detect its presence and immediately generate a signal to the control unit which in turn will automatically close the valve 42 and open the valve 40 to the storage tanks or to the central vacuum system. The control unit can also serve other functions:
start up the central vacuum system
cause an alarm to sound at a manned facility so that an appropriate agency can be contacted to investigate the spill and arrange a cleanup if necessary, and
illuminate an indicating light on a display panel to show the location of the catchbasin from which the signal originated.
In both embodiments, a manual or automatic routine may be arranged whereby all the valves (valve 28 in the embodiment of FIG. 1) are closed upon the detection of an emergency e.g. a large spill or a spill combined with a heavy rainfall. This will cause, as discussed above, a flooding of the area adjacent to the catchbasin until mobile trucks or other preventive measures are arranged for to remove the hazardous medium from the receptacle and the vicinity of the catchbasin.
While the embodiment of FIG. 2 employs two valves, the objects of the invention can be met by using a single three-way valve having a single inlet and two outlets, one to the storm sewer system and one to the storage tanks or a central vacuum system. An actuator for such valve would function to open and close the respective routes according to above-described requirements.
The manually operated version illustrated in FIG. 1 is not arranged for an automatic closure of the valve to intercept contaminants, but can be operated to provide a satisfactory closure and 100% seal of the catchbasin against the entry of deicing fluids during winter deicing operations.
The detachable connection between the frame 18 and the plate 22 plus the provision of a flexible tubing 44 allows for disassembling of the plate 22 with the valve 28 or valves 40, 42 and optionally the tubing 44 for the purpose of gaining access to the valves, actuators, and the cavity 12 for inspection and maintenance. | In order to prevent hazardous substances--oils, fuels, deicing liquids--spilled onto the ground or pavement, e.g. at an airport, to enter storm sewer system with subsequent contamination of the environment, a catchbasin structure is provided comprising a receptacle with an opening closable with a valve in a manner to seal off the entry of the liquid into the storm sewer system. Instead, the liquid can be kept in the receptacle and on the ground in the area adjacent to the catchbasin, or selectively directed to a storage tank system for treatment or recovery. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to offshore oil spill collection devices and particularly to offshore oil spill collection devices that operate below the surface of the sea to collect oil and gas.
2. Description of the Prior Art
Damage to the environment by leaking oil or gas from underwater pipelines or oil wells has become a serious problem. Costs to remove oil coming to the surface via these leaks from an underwater well or pipeline are tremendous. In addition, the loss of the oil can be in hundreds or thousands of barrels a day, which is a significant loss of a vital natural resource. Recent events in the Gulf of Mexico illustrate the extent and seriousness of this problem.
The main techniques for dealing with such leaks or spills have been removing the oil from the surface of the water and land, and cleaning wildlife. However, simply cleaning up the oil is not sufficient to prevent or reduce the loss of a vital natural resource. In the recent Gulf spill, millions of gallons of oil were burned off or simply disbursed into the sea, where they may be accumulating on the sea floor.
In addition to oil leaks, there are natural methane and oil seeps located below the surface of the sea. Such seeps can provide a source of gas and oil, while the recovery of such gas helps control the emission of a greenhouse gas into the environment.
Oil recovery apparatus can be effective in preventing the contamination caused by oil and oil/gas leakage from underwater pipelines or oil wells. For example, a large number of oil wells are located offshore in deep water and rupture of a well casing, etc., causes the oil/gas to be discharged upwardly under pressure from the oil well, resulting in a loss of oil. Presently, there are few devices that are used to collect leaked or spilled oil from the sea. One such device is found in U.S. Pat. No. 5,213,444 to Henning. This device is a housing that is positioned above an underwater leak and anchored in place. As the oil and gas rise in the water column, the device can trap the oil and gas within the housing. The device has a vent with a burner that can be used to burn off the gas. It also has a pump to remove the oil that is collected. Although this device seems to be a good solution, it has several problems. First, the device must be positioned so that the top of the housing is above the water. This is to allow the gas to be burned off and the oil to be pumped onto barges or other vessels. However, it is difficult to maintain such a device in such a position because of currents, wave action and storms. Moreover, in many cases the oil pipelines or wells are at great depths (the gulf well in the recent spill was over a mile deep). A column of oil rising from that great a depth will be dispersed by currents and wave action long before it breaks the surface. Even a large number of such devices placed on the surface will only collect minor amounts of such oil.
At present, there is no such device for capturing such gas and oil from undersea seeps. Therefore, there is a need for a collection system that can operate under the surface so that it can be positioned to collect both leaking and seeping oil and gas from the sea floor.
BRIEF DESCRIPTION OF THE INVENTION
The instant invention solves these problems by providing an apparatus for collecting seeps, and spills from producing oil wells and ground seeps. It is a collection device that is placed near the sea floor over a leak or seep. The device is anchored to the seabed. It has a long body into which oil and gas can flow and be captured. An extraction system is attached to the collector that utilizes long tubes to collect both the oil and gas and bring them to the surface. The collector can be used singly or it can be combined with many others to form a complete collection system. The overall system can include a gathering plant where the oil and gas are separated, cleaned and stored for transport. This system is the subject of our copending applications entitled “System for Capturing Oil And Gas Below the Surface of the Sea” and “Method for Capturing Oil And Gas Below the Surface of the Sea using a Collection system”.
In this application the collector is placed over a seep or a leaking well below the surface, and a temporary subsea storage/recovery of methane gas vessel is positioned on the surface to collect the gas and oil.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a detail side view of an undersea collector.
FIG. 2 is a detail side view of an undersea collector shown installed.
FIG. 3 is a detail view of an undersea lift device showing water displacement within the device.
FIG. 4 is an enlarged inset view of the float inside the undersea lift device.
FIG. 5 is a detail view of a temporary subsea methane gas recovery system.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a detail side view of an undersea collector 10 . The collector 10 has a domed top 11 and a chute 12 that is attached to the dome using any number of fasteners known in the art. The top 11 includes an oil port 13 and a float 14 (which are shown in detail in FIG. 3 and discussed below.
The chute 12 has flaps 12 a that are provided to quickly vent in case of an excessive blowout from the source (see, e.g., FIG. 2 ).
The dome has a means for determining the level of oil contained in it. In the preferred embodiment, this means is an underwater specific gravity sensor 15 that can measure oil level. Other sensors, such as a light refraction sensor or any other similar suitable sensor can be used. The sensor 15 also contains a means for transmitting data from the sensor, and thus has the ability to transmit data to the service. When the sensor detects a sufficient of oil in the dome, the data transmitter initiates operation of a pump (see below).
The collector has a number of float rings 16 (see also FIG. 3 ) that can be filled with gas and water to help displace the weight of the domed top 11 . In addition, buoyancy rings 17 can be attached to the chute to help support chutes made of heavy material or for extremely long chutes. A ring 18 is attached to the bottom of the chute to keep the chute open and allows anchoring via cable lines to weights.
In normal use the collector 10 is anchored to the seafloor with concrete anchors 20 ( FIG. 2 ) and cables 21 .
Note also that all of the materials used for the collector 10 are made to be corrosion free in the environment used. For example, the domed top 11 is preferably made of heavy plastic or fiberglass. The chute 12 is preferably made of vinyl or polyethylene. The valves, cables anchors, pick-up tube and float are preferably stainless steel.
FIG. 2 is a detail side view of an undersea collector shown installed on the seafloor. In this view the collector is used as a stand-alone device. FIG. 2 shows a collector 10 anchored to the sea floor positioned above a seep 100 in the ocean floor.
The seep emits oil 101 and gas 102 , which enter the chute 12 as shown. The gas and oil rise to the top of the dome 11 . Although the collector can be used for oil and gas recovery, here, the collector is used for oil recovery. Oil 101 collects at the top of the dome as shown. Methane 102 is vented out of the top vent 22 . A shut-off valve, attached to vent 22 is used to stop the venting when oil is being recovered, if desired for safety. Note that the vent can be connected to a flexible pipe for recovery, as well. The figure shows a diver 103 attaching a hose 104 to the port 23 for transfer to a ship 105 . Note that for safety, a tethered buoy 25 having an offloading port 25 a and sign 25 b are used to warn of venting whenever a collector is positioned on the sea floor.
In the preferred embodiment, the oil transfer is done using a seawater injected transfer pump that injects seawater into the collector's vane pump, sucking the oil from the collector via a pick up tube.
FIG. 3 is a detail view of an undersea lift device showing water displacement within the device. This figure shows the float rings 26 and the float 27 . As noted above, float rings 26 are positioned around the domed top of the collector. Note that although two rings 26 are shown, more can be used to provide greater stability for the unit. The float rings have a one-way valve 28 installed to allow the introduction of gas into the rings through hose 29 . The gas is added until sufficient water has been displaced to achieve the desired level of neutral buoyancy for the collector.
Also as noted above, the domed top has the float 27 installed. The float 27 has a ball 31 that has a fill port 32 like that of the float rings. The float 27 also has a cone shaped end 33 that is used to seat the top vent 22 as shown. The float is designed to pivot. The ball 31 is attached to a swing arm 34 , which is secured by a pivot pin 35 in a bracket 36 . The pivot arm allows the float to move with the amount of water and oil vs. gas in the collector. As in the case of the float rings, buoyancy is obtained by injecting gas into the ball 31 using a hose 37 or similar apparatus.
FIG. 4 is an enlarged inset view of the float inside the undersea lift device. In this figure, the fill port 32 is shown enlarged. Although preferably the ill port is a one-way valve for ease of use, it is possible to use threaded plug 38 a to make a seal, if desired.
FIG. 5 is a detail view of a temporary subsea methane gas recovery system. As shown in FIG. 2 , the collector 10 can be used as a stand-alone device. In FIG. 2 , an oil recovery system was disclosed. In this figure, a gas recovery system, with a means for temporarily storing methane is disclosed. Here, a collector 10 is shown with a line 40 attached to the gas outlet 42 . A large methane bladder (balloon) 41 is attached to the line 40 . The balloon 41 has an outlet 42 that has a pressure relief valve 43 attached. An outlet hose 44 is attached to the outlet. Note that the outlet hose 44 can be a hose or line. It is preferably a flexible line. The outlet hose rises to the surface, where it is connected to a buoy 45 that is anchored with cables 47 and weights 48 . A discharge nipple 46 is installed on the buoy for collection of the gas by a vessel. To secure the balloon and keep it below the surface, a net 49 is used. The net is also anchored to the bottom using cables 47 and weights 48 . In this way, gas can be accumulated in the balloon and loaded when conditions permit.
Collectors are ideally installed above leaks and seeps to allow natural induction flow. They are set 20-100 meters below ocean surface depending on ocean currents (avoid currents where possible). Lower is better, but the dome should be set above the free methane/methane hydrate interface boundary.
The collectors are marked for passing vessels as a danger area with underwater obstacles and are monitored regularly. Oil is recovered at regular intervals with or without use of specific gravity sensors.
The collector is manufactured in different diameters to handle different flow rates and in different lengths to handle greater depths. Additionally, the collectors can be made with different dome shapes to cover a variety of seep shapes for maximum collection—as long as float and gas vent remain at the highest points available. Multiple collectors of circular design, set side by side, would generally suffice for most seeps.
The collectors can be used independently or in conjunction with a Compressed Natural Gas (CNG) facility. If the device is not used in conjunction with a process facility it is recommended that it be used with apparatus for temporary subsea storage/recovery of methane gas.
The present disclosure should not be construed in any limited sense other than that limited by the scope of the claims having regard to the teachings herein and the prior art being apparent with the preferred form of the invention disclosed herein and which reveals details of structure of a preferred form necessary for a better understanding of the invention and may be subject to change by skilled persons within the scope of the invention without departing from the concept thereof. | A collection device for collecting oil and gas that is placed near the sea floor over a leak or seep. The device is anchored to the seabed. It has a long body and a head into which oil and gas can flow and be captured. An extraction system is attached to the collector that utilizes long tubes to collect both the oil and gas and bring them to the surface. The collector can be used singly or it can be combined with many others to form a complete collection system. | 4 |
REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 12/505,705 filed Jul. 20, 2009, which is a continuation of U.S. patent application Ser. No. 11/165,115, filed Jun. 23, 2005, now U.S. Pat. No. 7,582,258, which is a continuation of International Patent Application No. PCT/EP2003/014708 filed Dec. 22, 2003, which claims foreign priority to European Patent Application No. 02 028 894.0 filed Dec. 23, 2002, which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
The present invention relates to body fluid testing devices and more specifically, but not exclusively, concerns a body fluid testing device that incorporates a test media cassette which contains test media used to test body fluid.
General Fluid Testing
The acquisition and testing of body fluids is useful for many purposes and continues to grow in importance for use in medical diagnosis and treatment and in other diverse applications. In the medical field, it is desirable for lay operators to perform tests routinely, quickly and reproducibly outside of a laboratory setting, with rapid results and a readout of the resulting test information. Testing can be performed on various body fluids, and for certain applications is particularly related to the testing of blood and/or interstitial fluid. Such fluids can be tested for a variety of characteristics of the fluid, or analytes contained in the fluid, in order to identify a medical condition, determine therapeutic responses, assess the progress of treatment, and the like.
General Test Steps
The testing of body fluids basically involves the steps of obtaining the fluid sample, transferring the sample to a test device, conducting a test on the fluid sample, and displaying the results. These steps are generally performed by a plurality of separate instruments or devices.
Acquiring—Vascular
One method of acquiring the fluid sample involves inserting a hollow needle or syringe into a vein or artery in order to withdraw a blood sample. However, such direct vascular blood sampling can have several limitations, including pain, infection, and hematoma and other bleeding complications. In addition, direct vascular blood sampling is not suitable for repeating on a routine basis, can be extremely difficult, and is not advised for patients to perform on themselves.
Acquiring—Incising
The other common technique for collecting a body fluid sample is to form an incision in the skin to bring the fluid to the skin surface. A lancet, knife, or other cutting instrument is used to form the incision in the skin. The resulting blood or interstitial fluid specimen is then collected in a small tube or other container, or is placed directly in contact with a test strip. The fingertip is frequently used as the fluid source because it is highly vascularized and therefore produces a good quantity of blood. However, the fingertip also has a large concentration of nerve endings, and lancing the fingertip can therefore be painful. Alternate sampling sites, such as the palm of the hand, forearm, earlobe, and the like, may be useful for sampling and are less painful. However, they also produce lesser amounts of blood. These alternate sites therefore are generally appropriate for use only for test systems requiring relatively small amounts of fluid, or if steps are taken to facilitate the expression of the body fluid from the incision site.
Various methods and systems for incising the skin are known in the art. Exemplary lancing devices are shown, for example, in U.S. Pat. No. Re 35,803, issued to Lange, et al. on May 19, 1998; U.S. Pat. No. 4,924,879, issued to O'Brien on May 15, 1990; U.S. Pat. No. 5,879,311, issued to Duchon et al. on Feb. 16, 1999; U.S. Pat. No. 5,857,983, issued to Douglas on Jan. 12, 1999; U.S. Pat. No. 6,183,489, issued to Douglas et al. on Feb. 6, 2001; U.S. Pat. No. 6,332,871, issued to Douglas et al. on Dec. 25, 2001; and U.S. Pat. No. 5,964,718, issued to Duchon et al. on Oct. 12, 1999. A representative commercial lancing device is the Accu-Chek® Softclix lancet.
Expressing
Patients are frequently advised to urge fluid to the incision site, such as by applying pressure to the area surrounding the incision to milk or pump the fluid from the incision. Mechanical devices are also known to facilitate the expression of body fluid from an incision. Such devices are shown, for example, in U.S. Pat. No. 5,879,311, issued to Duchon et al. on Feb. 16, 1999; U.S. Pat. No. 5,857,983, issued to Douglas on Jan. 12, 1999; U.S. Pat. No. 6,183,489, issued to Douglas et al. on Feb. 6, 2001; U.S. Pat. No. 5,951,492, issued to Douglas et al. on Sep. 14, 1999; U.S. Pat. No. 5,951,493, issued to Douglas et al. on Sep. 14, 1999; U.S. Pat. No. 5,964,718, issued to Duchon et al. on Oct. 12, 1999; and U.S. Pat. No. 6,086,545, issued to Roe et al. on Jul. 11, 2000. A representative commercial product that promotes the expression of body fluid from an incision is the Amira AtLast blood glucose system.
Sampling
The acquisition of the produced body fluid, hereafter referred to as the “sampling” of the fluid, can take various forms. Once the fluid specimen comes to the skin surface at the incision, a sampling device is placed into contact with the fluid. Such devices may include, for example, systems in which a tube or test strip is either located adjacent the incision site prior to forming the incision, or is moved to the incision site shortly after the incision has been formed. A sampling tube may acquire the fluid by suction or by capillary action. Such sampling systems may include, for example, the systems shown in U.S. Pat. No. 6,048,352, issued to Douglas et al. on Apr. 11, 2000; U.S. Pat. No. 6,099,484, issued to Douglas et al. on Aug. 8, 2000; and U.S. Pat. No. 6,332,871, issued to Douglas et al. on Dec. 25, 2001. Examples of commercial sampling devices include the Roche Compact, Amira AtLast, Glucometer Elite, and Therasense FreeStyle test strips.
Testing General
The body fluid sample may be analyzed for a variety of properties or components, as is well known in the art. For example, such analysis may be directed to hematocrit, blood glucose, coagulation, lead, iron, etc. Testing systems include such means as optical (e.g., reflectance, absorption, fluorescence, Raman, etc.), electrochemical, and magnetic means for analyzing the sampled fluid. Examples of such test systems include those in U.S. Pat. No. 5,824,491, issued to Priest et al. on Oct. 20, 1998; U.S. Pat. No. 5,962,215, issued to Douglas et al. on Oct. 5, 1999; and U.S. Pat. No. 5,776,719, issued to Douglas et al. on Jul. 7, 1998.
Typically, a test system takes advantage of a reaction between the body fluid to be tested and a reagent present in the test system. For example, an optical test strip will generally rely upon a color change, i.e., a change in the wavelength absorbed or reflected by dye formed by the reagent system used. See, e.g., U.S. Pat. Nos. 3,802,842; 4,061,468; and 4,490,465.
Blood Glucose
A common medical test is the measurement of blood glucose level. The glucose level can be determined directly by analysis of the blood, or indirectly by analysis of other fluids such as interstitial fluid. Diabetics are generally instructed to measure their blood glucose level several times a day, depending on the nature and severity of their diabetes. Based upon the observed pattern in the measured glucose levels, the patient and physician determine the appropriate level of insulin to be administered, also taking into account such issues as diet, exercise, and other factors. A proper control of the blood glucose level avoids hypoglycemia which may lead to insomnia and even sudden death as well as hyperglycemia resulting in long term disorders as blindness and amputations. Blood glucose is therefore a very important analyte to be monitored.
In testing for the presence of an analyte such as glucose in a body fluid, test systems are commonly used which take advantage of an oxidation/reduction reaction which occurs using an oxidase/peroxidase detection chemistry. The test reagent is exposed to a sample of the body fluid for a suitable period of time, and there is a color change if the analyte (glucose) is present. Typically, the intensity of this change is proportional to the concentration of analyte in the sample. The color of the reagent is then compared to a known standard which enables one to determine the amount of analyte present in the sample. This determination can be made, for example, by a visual check or by an instrument, such as a reflectance spectrophotometer at a selected wavelength, or a blood glucose meter. Electrochemical and other systems are also well known for testing body fluids for properties on constituents.
Testing Media
As mentioned above, diabetics typically have to monitor their blood glucose levels throughout the day so as to ensure that their blood glucose remains within an acceptable range. Some types of sampling devices require the use of testing strips that contain media for absorbing and/or testing the body fluid, such as blood. After testing, the testing media contaminated with blood can be considered a biohazard and needs to be readily disposed in order to avoid other individuals from being exposed to the contaminated test strip. This can be especially inconvenient when the person is away from home, such as at a restaurant. Moreover, individual test elements can become easily mixed with other test strips having different expiration dates. The use of expired test elements may create false readings, which can result in improper treatment of the patient, such as improper insulin dosages for diabetics.
Test Media Cassettes
Analytical systems with test media cassettes which allow multiple testing have been described in the prior art. There are available dispensers which contain a limited number of test elements; as for example, 1 to 2 dozen strips which are individually sealed. Blood glucose meter using such a test strip dispenser are in the market under the names AccuChek Compact (Roche Diagnostics GmbH) and DEX (Bayer Corporation). Consumers, however, demand systems that contain even more strips to reduce loading actions to be performed by the user. A suitable way to package a higher number of test elements are test films as e.g., described in U.S. Pat. No. 4,218,421 and U.S. Pat. No. 5,077,010. These test systems are, however, designed to be used in the environment of automated laboratory systems and are therefore not suited for patient self testing. DE 198 19 407 describes a test element cassette employing a test media tape for use in the patient self testing environment. A number of practical problems are, however, still unsolved when relying on the device described in DE 198 19 407. Test media used for blood glucose testing as well as for other analytes are prone to deterioration by humidity from the environmental air. It is therefore a serious problem to keep unused test media free from humidity to avoid deterioration which would lead to incorrect analytical results. U.S. Pat. No. 5,077,010 discloses containers for test media tape which have an outlet for the tape which is sealed by a blocking member or a resilient member (see in particular FIGS. 21 to 33 and corresponding disclosure). This way of sealing is comparable to the type of sealing known from photographic film boxes. The automated analytical instruments of U.S. Pat. No. 5,077,010 have a high throughput and therefore the required onboard stability is short (typically one or two days only). Contrary to that, the required onboard stability in the home diagnostic market is much longer. Considering a patient doing two testings a day and a test media capacity of a cassette in the range of 100, stability of the test media cassette after insertion into a meter (i.e. the onboard stability) needs to be in the range of 50 days. The situation, however, may be even worse considering that the patient may have a second meter and uses the present meter only from time to time. In the field of blood glucose testing, onboard stability therefore has to be shown for at least three months. It has been shown that the type of sealing as disclosed in U.S. Pat. No. 5,077,010 is insufficient to achieve the onboard stability as required in the home monitoring environment.
It is an aim of the present invention to propose body fluid testing devices and test media cassettes which contain a larger number of test media than the body fluid testing systems currently on the market and which guarantee long onboard stability of the test media. Further, it is an aim to propose meters for multiple testing which are easy to operate and which have a handheld size.
SUMMARY OF THE INVENTION
According to the present invention, it was found that the concept of test tape meters can be highly improved. A test media tape is employed on which the individual test media are spaced one from the other so that free tape portions are located between successive test media. Such a test media tape is contained in a supply container which shelters the test media tape against humidity. Test media can be taken out of the container via an opening by using the tape as a transporting means. The test media which are still located within the supply container are protected against humidity by using a sealing means for sealing the opening of the container while a free tape portion is located between the sealing means and a surface of the supply container. This type of sealing enables very practical testing devices which can provide numerous test media without the need for the user to load the testing device with separate individual test elements.
Due to the spacing of the test media, the material of the free tape portion can be chosen mostly independent from the test media material to achieve a proper sealing with the described sealing means. It has been shown that tape materials as e.g., plastics for audio cassettes are well suited for this purpose. Suitable tape materials are plastic foils from polyester, polycarbonate, cellulose derivatives, and polystyrene. It is, however, preferred to choose non-hygroscopic materials which do not transport water or water vapour to a high degree. According to this, tapes without free tape sections between successive test media cannot be sealed properly since the test media material is porous and thus would allow humidity to flow into the supply container even when the tape is sealed according to the present invention. Further, the thickness of the tape in the free tape portion is an important parameter to control proper sealing. It has been shown by the inventors of the present invention that leakage of humidity into the storage housing decreases with decreasing tape thickness. While there are a number of interacting parameters, the particular effect of the tape thickness can be seen from FIG. 1 . The tape (T) is located between a sealing means (S) having a deformable gasket (G) and a surface of the container housing (H). The sealing means applies pressure in the direction of the housing, thus pressing the gasket onto the tape and housing surface. The gasket is stronger compressed in the region of the tape as it is right and left from the tape. The leakage regions (L) which are not filled by tape or gasket material allow influx of humid air. Decreasing the tape thickness hence reduces the cross section of the leakage regions. It has been shown that a tape having a thickness below 100 micrometers is well suited to limit humidity influx into the housing even if the gasket is relatively rigid. Even more preferred are tape thicknesses below 50 micrometers.
The sealing means is a means that closes the opening of the housing (container) in which uncontaminated test media tape is stored. The sealing means preferably is a body from a gasket material or a body of a material to which a gasket is fixed. Alternatively, the gasket may be fixed to the surface onto which the sealing means presses to close the container opening. Also embodiments are possible where gasket material is present on the surface as well on the body of the sealing means.
Further, it can be understood with view to FIG. 1 that an increasing flexibility of the gasket reduces humidity influx. It has shown that gaskets with a shore hardness (A) of less than 70, preferably in a range of 30 to 50 are well suited. The shore hardness (A) is defined by DIN 53505 (June 1987). Gasket materials which are well suited to practice the present invention are thermoplastic elastomers. Especially suited are such elastomeres which comprise polystyrene as the hard component and polymerisates of butadiene or isoprene as the soft component. Suitable gasket materials can be obtained under the tradenames Kraton D, Kraton G and Cariflex TR from Shell and Solprene from Philips.
Gaskets are referred which have an annular shape such that they annularly surround the container opening. It has been found that with such annular gaskets, proper sealing can be achieved, while sealing with non-annular gaskets (e.g., straight-line shaped gaskets), proper sealing is much harder to achieve since it is harder to close the leakage at the ends of such gaskets.
The body of the sealing means as well as the body of the storage container should be made from materials which are mostly impermeable to humidity. This can be achieved by numerous materials. Due to production aspects, plastics such as polypropylene, polyethylene, and polystyrene are, however, preferred. The materials, however, do not need to be totally impermeable to humidity since it is possible to capture humidity which has diffused in by drying agents.
The sealing means further comprises a pressure means that serves to apply pressure to the sealing means body so as to achieve the sealing. Such pressure means are e.g., coil springs, pneumatic actuators, motors, electromagnets, compressed materials, or stressed materials. From the preferred embodiments, it will become clear that in particular elastic sealing means which in their rest position press onto the sealing means body are easy and cheap to manufacture.
The pressure necessary for proper sealing largely depends on the shore hardness of the employed gasket as well as the area to be sealed. The required pressure, however, typically is in the range of a few Newton or below.
Further optional measures to increase onboard stability of the test media will be described later on in connection with the specific embodiments.
A first general concept of the present invention concerns a body fluid testing device that incorporates a test media tape. The test media tape holds test media that are used to collect body fluid samples which are analyzed with a sensor. Advantageously the test media tape is housed in a cassette so that after the test media of a cassette are used up, a fresh test media cassette can be inserted into the testing device. The test media tape is indexed before or after each test so that successive tests can be performed without requiring disposal of the used test media. The test media can be indexed manually or automatically.
The test medium is a medium which contains a test chemistry that with analyte from a sample leads to detectable results. For further details of test chemistry and testing, see section “Testing General”. Preferably, the test media are designed to soak up the test fluid sample. This prevents the testing device from becoming contaminated by the body fluid sample. As will be described in more detail later on, it is preferred to employ a test media tape which comprises a tape on which test media are arranged with free tape regions between successive test media. The preferred arrangement therefore has a structure with regions as follows: tape with test medium—tape without test medium—tape with test medium—and so on. The tape can be made e.g., from conventional plastic tape as used for audio cassettes. The test media are attached to the tape, e.g., by gluing, welding, or by use of an adhesive tape.
In accordance with one aspect of the present invention, there is provided a body fluid testing device for analyzing a body fluid. The testing device includes a test media cassette that includes a test media tape adapted to collect the body fluid. The cassette includes a supply portion that stores an uncontaminated section of the test media tape. A storage portion for storing a contaminated section of the test media tape may be further employed. Contrary to the supply portion which is designed to shelter the test media tape from humidity from the surrounding environment, it is preferred to design the storage section for contaminated tape to be open to some extent so that the test media which are soaked with sample can dry out. Such an open design may be realized by a plastic container having slits or recesses for gas exchange with the surrounding environment.
An important measure which advantageously can be used with embodiments of the present invention is a drying material within the test media tape supply container. Humidity which has entered the container by diffusion through wall materials or during an opening cycle is absorbed and cannot deteriorate test media. The sealing concepts of the present invention are, however, not obsolete due to the use of drying material since the amount of humidity entering without sealing means during the onboard time would be much too high to be cared for by rational amounts of drying material. Suitable drying materials are well known in this field of art, these are e.g., molecular sieves, silica gel, etc.
The present invention further proposes one-way devices where the test media tape belongs to the testing device so that the whole device is discarded when the test media tape is used up. Alternatively the test media tape may be arranged in a disposable cassette which is removably received in the testing device.
The term “body fluid testing device” will be used for both embodiments (e.g., with and without cassette) within this patent application. However, when embodiments employing a test media cassette are concerned the term will also be used to designate the device into which the cassette is inserted.
As described in European Patent Application No. 02026242.4 (European Publication No. EP 1 424 040 A1), which is hereby incorporated by reference in its entirety, the test media tape onto which body fluid will be applied advantageously can be exposed in a tip-like shape to simplify body fluid application to a test medium. For this purpose the test media tape can be guided over a convex tip portion which may belong to the testing device or to the test media cassette.
The testing device further may comprise a pricking unit for pricking a body portion. The lancing opening of that pricking unit advantageously can be arranged in or close to the convex portion so that the tip portion (if present) can be used for convenient pricking as well. The pricking unit may be arranged below the test media tape and a lancing device can either penetrate the test media tape or can extend through a recess in the test media tape.
The testing device further may employ visual user guidance for application of body fluid samples. According to this embodiment, the testing device comprises an illumination unit which indicates by illumination a portion of a test element where body fluid has to be applied. The illumination serves for a timely and/or spatial guidance of the user to apply body fluid. Further the illumination may serve to indicate the location where to position a body portion for pricking. An illuminated area on the test medium may further indicate the amount (or the droplet size) of body fluid which is required by the testing device.
Another aspect of the present invention concerns a test cassette for collecting a body fluid sample. The cassette includes a housing that has a supply portion in which uncontaminated test media tape is enclosed. The housing further includes a storage portion in which a contaminated section of the test media tape is enclosed after contamination. For sealing unused test media against humidity, a tape is employed which has free tape portions between successive test media as already described above such that the sealing concept of the present invention can be employed. The sealing means of the present invention may belong to the test media cassette or to the testing device. Further embodiments are possible where parts of the sealing means, as e.g., a pressure application plate, belong to the testing device while other parts, as e.g., a gasket, belong to the cassette. Advantageously the container which houses the uncontaminated test media tape is closed against humidity with the exception of the opening which can be closed by the sealing means.
The cassette further may include a convex tip portion over which the test media tape runs and at which the test media tape is exposed to the body fluid.
In a particular embodiment, a supply reel is disposed in the supply portion of the housing around which the uncontaminated section of the test media tape is wrapped, and a storage reel is disposed in the storage portion of the housing around which the contaminated section of the test media tape can be wrapped. In embodiments which employ a reel for storing uncontaminated test media tape, it is preferred that the axis of this supply reel does not penetrate the supply container housing to avoid the leakage of humid air into the container.
Most test media are destroyed or altered by humidity, sunlight, etc. Therefore measures have to be taken to shelter the test media before they are used onboard of a testing device. A first measure is to package the whole test media cassette before use such that contact with humidity from the surrounding is prevented. This can be achieved by e.g., a blister package. Alternatively the cassette housing can be made being closed against humidity with the exception of the region where test media are exposed for body fluid application. Embodiments can be contemplated which employ a humidity proof cover over the exposure region which can be removed prior to use of the cassette.
Further this invention concerns a method of using a testing device comprising the steps of:
providing a supply portion comprising a container in which uncontaminated test media tape is contained, said container further having an opening for withdrawing test media tape from the container, providing a sealing means which can close said opening against the surrounding, actuating the sealing means to open said opening of the container, and removing a portion of test media tape from the container to expose an unused test medium.
The method further may include the steps of:
actuating the sealing means to close said opening of the container, and testing. Actuation preferably means pressing the sealing means onto a surface of the supply portion container.
A further step may be included in the above method which concerns a pricking for generating a body opening prior to testing.
It is preferred when the closing means can assume two distinct positions.
In a first, closed position the sealing means sealingly engages a surface of the supply container so as to close it and to shelter test media within it against humidity.
In a second, open position the sealing means is opened to allow test media tape to leave the supply container. The opening has to be wide enough to allow test media tape portions with test media (which are normally thicker than the tape alone) to pass through.
A method for providing test media therefore may comprise the steps of:
providing a supply container in which uncontaminated test media tape is contained, said container further having an opening for withdrawing test media tape from the container, providing a sealing means which closes said opening against the surrounding, moving the sealing means from a first, closed position into a second, open position to open said opening of the container, removing a portion of test media tape from the container to expose an unused test medium, and moving the sealing means from said second, open position to said first, closed position to close said opening of the container.
Again it has to be understood that, when the sealing means is closed, a free tape portion is located between the sealing means and a surface on which the tape is resting. Said surface is typically a surface of the supply container.
The closing via the sealing means preferably means that the sealing means is pressed onto another surface (typically a container surface) to generate a sealing of the uncontaminated test media tape against humidity.
Other forms, embodiments, objects, features, advantages, benefits, and aspects of the present invention shall become apparent from the detailed drawings and description contained herein.
SHORT DESCRIPTION OF THE FIGURES
FIG. 1 : Schematic drawing showing leakage regions.
FIG. 2 : Perspective view of a testing device.
FIG. 3 : Perspective view of a sealing concept.
FIG. 4 : A cross-sectional view along line A-A of FIG. 3 .
FIG. 5 : Test media cassette with trapezoidal sealing means.
FIG. 6 : Test media cassette with form fitting sealing means.
FIG. 7 : Test media cassette having a lever for opening the supply container by tensioning test media tape.
FIG. 8 : Test media cassette having a lever for opening the supply container by tensioning test media tape.
FIGS. 9A , 9 B, 9 C, and 9 D: Testing device during various stages of operation.
FIG. 10 : Testing magazine with self-sealing sealing means.
FIG. 11 : Hydraulic sealing means.
DETAILED DESCRIPTION
For the purposes of promoting and understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. It will be apparent to those skilled in the art that some of the features which are not relevant to the invention may not be shown for the sake of clarity.
The humidity sealing principle is shown in FIG. 1 . On the housing surface (H) which preferably has a low roughness the test-carrier-tape (T) is pressed by the sealing material (G). The sealing force (F) presses the flexible gasket around the test media tape. The remaining leakage channels (L) are minimized by selection of Gasket material, tape thickness, sealing force and the time pattern in which the sealing means is being moved.
A body fluid testing device ( 10 ) is shown in FIG. 2 . The drawing of the device shows a housing ( 11 ) and a display ( 12 ) for displaying test results as well as instructions of use. At the front end of the device there can be seen a tip portion ( 20 ) over which the test media tape ( 30 ) runs. A test medium at the front end of the testing device is exposed by the tip portion in a tip like manner which facilitates the application of body fluid. The tip portion for this reason at least partially projects out of the contour of the housing ( 11 ) of the testing device to be accessible for a body portion (e.g., finger or arm). At the tip portion there can be seen an illuminated area ( 30 ′) which indicates the position for sample application.
FIG. 3 shows an improved embodiment of the sealing concept of the present invention. A portion of the test media tape ( 30 ) is located outside the housing ( 50 ) of the supply portion. The housing has an opening ( 51 ) via which tape can be taken out. The squares ( 52 , 53 ) depicted on the housing show the locations on the housing surface onto which gaskets of the sealing means (not shown) press during sealing of the opening. Using two (or more) gaskets for sealing improves leakage protection. It is preferred to employ annular gaskets as shown, which annularly presses onto a region around the opening ( 51 ) to include the opening within the cross-sectional area of the annular gaskets. When two or more annular gaskets are employed, it is preferred when an annulary gasket fully includes the next smaller annular gasket.
In FIG. 4 there is depicted a cross-sectional view of FIG. 3 taken along line A-A. FIG. 4 only shows the portion of FIG. 3 which is left to the container opening as well as the opening. It can be seen that the gaskets are not aligned vertical to the surface of the housing ( 50 ) but that they are inclined or angled relative to vertical. The exterior gasket ( 53 ) in direction from its base portion ( 53 b ) to its free end ( 53 e ) is inclined away from the opening ( 51 ). The interior gasket ( 52 ) is inclined in direction from its base portion ( 52 b ) to its end portion ( 52 e ) towards the opening. Inclination of the exterior gasket serves to block incoming air more efficiently as a gasket without such inclination would achieve. Due to the inclination the sealing is strengthened when air tries to enter the housing (this is the case when the pressure inside the housing is lower than the outside pressure) since the air pressure increases the pressure of the end portion ( 53 e ) of the gasket onto the surface ( 54 ) of the container ( 50 ). The same principle applies to the interior gasket for the inverse case when the pressure inside the housing is higher than the outside pressure.
As can be further seen in FIG. 4 it is advantageous when the gaskets taper from their base portion towards their free end portion. The smaller the gasket at the end portion, the more flexible it is to match with the shape of the tape thus reducing the cross section of the leakage areas. The smaller the area covered by the annular gasket around said opening ( 51 ), the lower the required force to achieve a small leakage channel (L).
In this embodiment the pressure means ( 55 ) has the shape of a plate to whose underside the gaskets are fixed. It is particularly preferred to fix the gaskets to the plate by two component molding of plate and gasket. A spring means (not shown) for applying pressure to the pressure plate ( 55 ) belongs to the testing device.
Further in FIG. 4 there can be seen that the test media tape does not necessarily need to be wrapped on a reel. The arrangement of the tape within the storage container is more or less arbitrary but needs to avoid jams or blockage.
FIG. 5 shows a cross-sectional view of an embodiment having a trapezoidal sealing means ( 60 ) which presses onto an inclined surface ( 62 ) of the supply container ( 50 ). The sealing means itself can be made from a sealing material (e.g., rubber gum) or a sealing material (gasket) can be present on the surface of the sealing means which presses onto the surface of the supply container. Sealing in this embodiment again is made when a free tape portion is located in the region where the sealing means presses against the test media tape. The angle shown in FIG. 5 preferably is in the range from 0 to 45 degree.
FIG. 6 is a similar embodiment as shown in FIG. 5 . Instead of a trapezoid sealing means, a form fitting sealing means ( 61 ) is employed. The surface of the housing ( 50 ) has a contour ( 62 ) at the opening which fits to a contour ( 63 ) of the sealing means ( 61 ). The contours of the sealing means can be made from a material functioning as a gasket itself (e.g., rubber gum) or a gasket can be present on the surface of the sealing means. However, even the inverse sealing principle with a gasket fixed on the surface of the housing can be employed.
FIG. 7 shows a cross-sectional view of a test media tape container ( 50 ) having a sealing means. The test media tape ( 30 ) is wrapped on a reel ( 57 ). From the reel the tape is guided through a diffusion channel ( 70 ) and leaves the container via the opening of the container. In rest the opening is sealed by an annular gasket ( 53 ) which is fixed to a first arm of a lever ( 80 ). Such levers are also known as a “dancer” in the art. The lever has a center of rotation ( 81 ). A spring element ( 82 ) keeps the gasket pressed onto the container surface. The test media tape ( 30 ) is located between gasket and container surface in the way already described (i.e. a free tape portion is located between gasket and container surface). The tape located outside the container is guided over a wheel at the other arm of the lever. When tape is drawn in the direction as shown in FIG. 7 the tape tension rotates the lever ( 80 ) against the spring force ( 82 ) around (81). This movement reduces the contact pressure of the gasket ( 53 ). The tape starts slipping through the gasket. Thus the tape section inside the housing gets tensioned. On further movement the friction of the reel increases the tape tension and thus causes a larger lift of the gasket. The opening created is large enough to leave through a test medium without touching the gasket. The tape now can be drawn out of the container. When a sufficient tape portion has been taken out of the container, the testing device (or a user) stops tearing the tape and the sealing is closed due to a movement of the lever caused by the spring element. In this embodiment it is advantageous when the reel ( 57 ) is friction loaded since the force acting on the lever is created by retention of the tape. In other embodiments a friction loading of the supply reel is also advantageous since it may avoid uncontrolled winding-up of the tape which can lead to jamming. Furthermore a tape properly wound on a reel has the advantage that test media underneath the outermost tape layer are shielded against humidity which already may have entered the housing.
A further important (but optional) measure to keep humidity away from unused test media is the diffusion channel ( 70 ) of FIG. 7 . This channel serves to decrease the convectional exchange of air between the interior of the container and the surrounding environment during opening of the sealing. The channel limits the air exchange at the opening and thus the amount of humidity intake during the time of taking out a new test medium from the container. The humidity in the channel decreases along the way from the opening to the reel. The prevention of convection by the channel limits the intake of humidity into the container to diffusion which is a much slower material transport than convection.
FIG. 8 shows a further embodiment of a self sealing test media cassette. Self sealing in this context means that the cassette itself closes its opening without the need for forces from the outside acting on it to close its sealing. The cassette further opens the sealing on tensioning of the test media tape which is a preferred embodiment. The lever ( 80 ′) of this embodiment has a first lever arm mostly inside the test media supply container ( 50 ). As in the foregoing figure the test media tape ( 30 ) is guided over a roller at one arm of the lever while the other arm of the lever holds an annular sealing gasket for sealing the container opening. When the test media tape is tensioned the lever is actuated and opens the sealing to free the tape so that a fresh portion of test media tape with an unused test medium can be taken out. After this the tension force applied to the tape can be reduced and the lever rotates driven by the spring means ( 82 ′) of the cassette to close the container opening.
FIGS. 9A , 9 B, 9 C, and 9 D shows a testing device ( 10 ) with a test media cassette ( 50 ) inserted into it as well as steps of using this device.
As can be seen from FIG. 9A , the testing device comprises a housing ( 100 ) in which the cassette is received. The cassette has a supply portion ( 50 a ) containing a supply reel ( 57 ) onto which uncontaminated test media tape ( 30 ) is wrapped. FIG. 9 depicts the test media portions ( 31 ) as pads which are fixed to a tape. The test pads are fixed to the tape via a double sided adhesive tape. Production of the test media tape therefore can easily be achieved by first removing a protection foil from a first side of an double side adhesive, applying a test medium pad to it and then removing a protection foil from a second side of the double sided adhesive and applying the compound structure of test medium pad and adhesive to the tape. This process can be easily automated. Alternatively, a double sided adhesive can first be applied to the tape and then applying a test medium pad to the adhesive. Other production methods, such as gluing test media to the tape, are possible as well.
Used (contaminated) test media tape is wrapped onto a storage reel ( 58 ) in the storage section of the test media cassette. Transport of the test media tape is made by a motor ( 110 ) of the testing device ( 10 ) which has a gear wheel for engaging with the gears of the storage reel and to rotate the storage reel. It is normally sufficient to employ only a single motor for winding the storage reel in a direction to move tape from the supply reel to the storage reel. For proper positioning of test media for sampling and/or testing it may be advantageous to move the tape in inverse direction as described before. This may be achieved by a separate motor winding the supply reel or a mechanics allowing a movement of the supply reel with the motor for rotating the storage reel. Further it is possible to employ a spring mechanically coupled to a friction loading means which is coupled to the supply reel. When tape is withdrawn from the supply reel by winding tape onto the storage reel the spring is loaded and the spring tension may be used to move back the tape a bit. This can be achieved by rotating back the motor and the supply reel will also rotate back caused by the spring tension so that the tape is still held under a sufficient stress to press it onto the tip for proper detection as well as to avoid jams caused by loose tape. By such a mechanism it is possible to properly position a test medium e.g., on the tip ( 20 ) when it has been moved too far at first.
However, it is preferred to avoid such a process by positioning of the test media by proper movement in one direction (the transport direction) only. Positioning of the test media on the tip may be achieved by the same optics as employed for reading the test media. It is, however, also possible to employ a separate position detection means which preferably operates optically. Detection of proper positioning can be achieved by employing test media and tape of different reflectance so that a reflectance monitoring during tape transport indicates by a change in reflectance when a test medium comes into reading position. However, it may also be advantageous to employ indication marks—as e.g., black bars—to the tape which are detected optically when they are detected by the positioning detection means.
The testing device further comprises a control unit which controls the steps of tape transport, opening and closing of the sealing, and reading of test media. The control unit or a separate calculation unit is further employed for calculation of analytical results from the obtained readings. The position detection means may also be controlled by the control unit.
The cassette further comprises a tip ( 20 ) over which the tape is guided. This (optional) tip serves for a convenient sample application by e.g., the finger tip. For more details of the tip and how the tape is prevented from falling off the tip reference is made to the copending European Patent Application No. 02026242.4, which is hereby incorporated by reference in its entirety. The cassette further has a recess for receiving a metering optics ( 102 ) belonging to the testing device. The part of the optics visible in FIG. 9A is a light coupling element for coupling light into the tip ( 20 ) to illuminate a test medium located on the tip. When sample is applied to this test medium the intensity of light reflected back from the underside of the test medium changes and the reflection intensity (preferably at a particular wavelength) can be read by a detector (not shown) and the intensity can be converted by the control unit or a calculation unit into an analytical concentration. With the aim to get optical readings from the test medium, it is either preferred to employ a tape material which is mostly transparent for the light to be detected or to employ a tape with a recess below the test medium as known from optical test elements as e.g., sold under the brand name Glucotrend.
(Departing from the embodiment shown in FIG. 9A it is, however, also possible to employ test media which operate as known from electrochemical test elements. In such embodiments the testing device contacts the test medium in use with electrodes and employs a test device controlling the application and measurement of current or power to obtain readings which can be converted into analyte concentrations.) Optical as well as electrochemical concentration measurement with disposable test elements is, however, well known in the art and therefore will not be described in more detail.
FIG. 9A shows the testing device (could also be called a testing system since the testing device houses a test media cassette) in its storage position with the sealing ( 52 , 55 ) closed. The testing device comprises a pressure actuator (e.g., a coil spring) which presses the sealing plate ( 55 ) having an annular gasket ( 52 ) at the side facing away from the actuator onto an opening of the cassette ( 50 ). It can be seen that a free tape portion is located between the opening of the cassette and the gasket when the sealing is closed. This embodiment has a diffusion channel ( 70 ) connecting the opening with the supply section in which the uncontaminated test media tape is contained. It can be further seen that the supply section ( 50 a ) is closed against the surrounding when the sealing is closed, while the storage section ( 50 b ) is partially open to the surrounding. The test media cassette further has rollers or pins ( 59 ) over which the tape is guided.
FIG. 9B shows the testing device with the sealing opened. Opening can be achieved by moving the pressure plate ( 55 ) away from the opening against the force of the pressure actuator. This can be done by a reverse attractor which withdraws the pressure plate from the opening (e.g., an electromagnet which attracts the pressure plate). FIG. 9B also shows that the test medium ( 31 a ) has been moved from a position on the supply reel (see FIG. 9A ) into a position within the diffusion channel but still located within the supply section. It has to be understood that FIG. 9B is a snapshot of in between a test medium transport phase. The depicted position of the test medium is no typical waiting position but a position to last only shortly to keep the time period of opening the sealing as short as possible. The arrow shows the direction of tape transport.
In FIG. 9C the sampling position for sampling body fluid can be seen. The test medium ( 31 a ) is located on the tip and the sealing is again closed. After body fluid application to the test medium on the tip, the testing device reads light reflected from the underside of the test medium to obtain a reading which can be converted into analyte concentration. It has to be understood that it is preferred if the body fluid application and reading are conducted in the same tape position so that no additional tape transport requiring opening of the sealing is necessary. However, it may also be advantageous to employ a reading position which is apart from the sampling position since this enables a reading optic or electrochemical analysis unit within the testing device at a different place. The closed sealing of FIG. 9C can be obtained by deactivating the reverse actuator so that the pressure actuator again presses the pressure plate onto the opening of the supply section.
FIG. 9D again is a snapshot taken during the transport of the used test medium into the storage section ( 50 b ). When the used test medium is located inside the storage section, the sealing again is closed. As shown in FIG. 9 D it is preferred when the distance between two successive test media is so large that a succeeding test medium is still located within the supply section when the preceding test medium is already within the storage section. It is even more preferred when the succeeding test medium is still on the reel, covered by a layer of tape so that it is protected against humidity.
FIG. 10 shows a test media cassette ( 50 ) with a supply section ( 50 a ) in which a supply reel ( 57 ) is being located. The test media tape leaves the supply section via a diffusion channel ( 70 ). At the opening of the supply section which is located at the outer end of the diffusion channel a sealing means ( 80 ′) is located. This sealing means has an axis ( 81 ′) by which it is rotationally fixed to the housing of the cassette. The sealing means has a sealing section to which an annular gasket (not shown) is fixed. When the cassette is in rest (i.e. no tearing force applied to the tape) the sealing section presses onto a surface surrounding the opening of the cassette (i.e. at the outer end of the diffusion channel in this embodiment). The force to achieve this pressing action is applied to the sealing means ( 80 ′) via a spring means ( 59 ) which integrally belongs to the cassette (non-integral or even spring means not belonging to the cassette may also be contemplated). The integral spring means in the shown case is a nose of plastic material which can be produced in the same production step as the cassette housing (e.g., by injection molding). When the sealing means ( 80 ′) is assembled, the nose ( 59 ) is deformed and spring tension acting onto the sealing means is created by the nose which attempts to get back into unstressed condition. When tape ( 30 ) is withdrawn from the supply section the tape needs to be tensioned to overcome the holding forced of the sealing means and/or the friction of the supply reel. As can be seen the sealing means has a rounded section which together with the cassette housing creates a wound channel in which the tape runs. When the tape is stressed it tries to assume a straight direction and therefore it acts on the rounded section of the sealing means so as to move the sealing means against the force of the spring means ( 59 ). This movement opens the sealing and lets the test media tape pass through. FIG. 10 further shows a chamber connected to the supply section which is filled with a drying agent ( 71 ), which is a molecular sieve in the depicted case.
FIG. 11 shows the hydraulic sealing concept. The housing has an upper section 100 a and one lower section ( 100 b ) which form a channel at the outlet of the storage section through which the test media tape runs. Within this channel region, there is located a pouch 105 filled with fluid. The pouch is made of a flexible material (e.g., polyethylene) which in its rest position has the shape as depicted in FIG. 11 . In this position, the channel is opened so that test media tape can be withdrawn from the supply section and test media ( 31 ) can pass through. When pressure is applied to a portion of the pouch located outside the channel, the portion of the pouch located in the channel region expands and form fittingly engages the tape within the channel. Pressure application can e.g. be made by a stamp ( 110 ). For obtaining a tight sealing of the supply section against humidity, the channel is closed by the pouch when no unused test media are to be withdrawn. In this closed position, a free tape region between two successive test media is located in the channel and is form fittingly sealed by the hydraulic sealing means.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes, equivalents, and modifications that come within the spirit of the inventions defined by following claims are desired to be protected. All publications, patents, and patent applications cited in this specification are herein incorporated by reference as if each individual publication, patent, or patent application were specifically and individually indicated to be incorporated by reference and set forth in its entirety herein. | Body fluid testing device for analyzing a body fluid comprises a test media tape adapted to collect the body fluid. The test media tape comprises a tape and test media portions. A free tape portion without test medium is located between successive test media portions. The testing device further comprises a supply portion. The supply portion comprises a housing in which uncontaminated test media tape is contained. The housing further has an opening for withdrawing test media tape from the housing. The testing device further has a sealing means for closing the opening against the surrounding. A free tape portion of the test media tape is located between a wall of the housing and the sealing means when the sealing means closes the opening. Further aspects concern a test media cassette with sealing means and a method for providing test media while holding them sealed against humidity during onboard storage. | 0 |
TECHNICAL FIELD
[0001] The present invention concerns a method for controlling a supply parameter of a percussion apparatus actuated by a pressurized incompressible fluid, and an assembly for implementing this method.
BACKGROUND
[0002] A percussion apparatus, called hydraulic rock breaker, is commonly used for various applications, such as quarry blocks breaking, demolition works or trenching. A hydraulic rock breaker includes particularly a striking piston arranged to cyclically strike a tool so as to produce impact energy on the material to be demolished. When using a rock breaker, the latter generates a significant running noise that propagates within the immediate environment of the rock breaker in the form of sound waves likely to induce noise nuisances for people located in the vicinity of the rock breaker.
[0003] In order to limit the impact of these noise nuisances, the use of a rock breaker can be limited, even forbidden, below a minimum distance around sensitive areas, that is to say around areas inhabited or occupied by third parties, such as residential areas, areas of industrial, commercial or agricultural activities, or even education, care or rest areas.
[0004] Furthermore, the choice of a rock breaker model can be conditioned by the type of work to be performed. For example, when work must be carried out in the vicinity of sensitive areas, it may be necessary to select a low-powered rock breaker to limit the noise nuisances.
[0005] These noise nuisances can be significantly variable, particularly in urbanized environment, due to the field variability, thus to the materials absorption coefficients, and due to the site configuration with possible reflections of the sound waves on buildings or neighboring structures. As a result, it is very difficult to predict the sound levels perceived within a predetermined area located in the vicinity of the rock breaker.
[0006] Under these conditions, the variability of these noise nuisances makes the use of rock breaker particularly delicate. To overcome this problem, it is common for a project manager to impose the use of a very low-powered rock breaker, the speed of execution of work is then slow and the costs of work become significant.
[0007] To overcome this drawback, it is known to record, for the whole duration of the work carried out in the vicinity of sensitive areas, the sound levels of sound waves propagating in the vicinity of these sensitive areas, thanks to the use of a detection system particularly comprising one or more microphone(s) and a recorder arranged to check the sound levels measured by the microphone(s).
[0008] Thus, the rock breaker operator can be informed of the noise nuisance he caused on the environment, and he may if necessary replace the rock breaker used by a lower-powered model of rock breakers.
[0009] In all cases, the use of a rock breaker in the vicinity of sensitive areas remains subject to human error, and it is common that the maximum permissible sound levels are exceeded.
BRIEF SUMMARY
[0010] The present invention aims to remedy these drawbacks by providing a control method and an assembly for its implementation, allowing to limit the noise nuisances generated during the work accomplishment using a percussion apparatus, below a maximum permissible value.
[0011] To this end, the present invention concerns a control method for controlling a supply parameter of a percussion apparatus actuated by a pressurized incompressible fluid, characterized in that it comprises the following steps:
providing a control device arranged to adjust a supply parameter of the percussion apparatus, providing a control unit arranged to apply a control instruction to the control device, switching on the percussion apparatus, measuring at least one sound data in the vicinity of a predetermined area, transmitting the at least one measured sound data to the control unit, comparing the at least one sound data received by the control unit with a predetermined threshold value, correcting the control instruction of the control device depending on the at least one received sound data, and applying, by means of the control unit, said corrected control instruction to the control device so as to adjust the supply parameter of the percussion apparatus depending on the measured sound data.
[0020] Thus, the control method according to the invention allows adjusting automatically, via the control unit and the control device, a supply parameter, such as the supply flow rate or the supply pressure, of the percussion apparatus depending on the measured sound data in the vicinity of the predetermined area. These dispositions allow optimizing the operation of the percussion apparatus, while avoiding that the sound levels of the sound waves generated by the percussion apparatus and propagating in the vicinity of sensitive areas do not exceed the predetermined threshold value.
[0021] According to one mode of implementation of the control method, the predetermined area is an area inhabited or occupied by third parties, such as a residential area, an area of industrial, commercial or agricultural activities, or even an education, care or rest area.
[0022] According to one mode of implementation of the invention, the predetermined area is moved relative to the percussion apparatus.
[0023] According to one mode of implementation of the control method, the control instruction is corrected such that the supply parameter adjusted by the control device induces sound data, advantageously in the vicinity of the predetermined area, lower than the predetermined threshold value.
[0024] According to one mode of implementation of the control method, the control instruction is corrected taking into account the predetermined threshold value.
[0025] According to one mode of implementation of the control method, the latter comprises iteratively repeating the measurement, transmission, comparison, correction and application steps.
[0026] According to one mode of implementation of the control method, the latter comprises setting, particularly by an operator input, the predetermined threshold value. These dispositions allow adapting the predetermined threshold value depending on the predetermined area to be protected.
[0027] According to one mode of implementation of the control method, if the at least one received sound data is greater than the predetermined threshold value, the correction step comprises correcting the control instruction of the control device so as to decrease the supply parameter of the percussion apparatus.
[0028] According to one mode of implementation of the control method, if the at least one received sound data is lower than the predetermined threshold value, the correction step comprises correcting the control instruction of the control device so as to increase the supply parameter of the percussion apparatus.
[0029] According to one mode of implementation of the control method, if the at least one received sound data is lower than the predetermined threshold value and if the difference between the at least one received sound data and the predetermined threshold value is greater than a predetermined limit value, the correction step comprises correcting the control instruction of the control device so as to increase the supply parameter of the percussion apparatus.
[0030] According to one mode of implementation of the control method, if the at least one received sound data is lower than the predetermined threshold value and if the difference between the at least one received sound data and the predetermined threshold value is lower than the predetermined limit value, the correction step comprises maintaining the value of the previously applied control instruction.
[0031] According to one mode of implementation, the control method comprises a interrupting the supply of the pressurized incompressible fluid to the percussion apparatus when the at least one sound data received by the control unit is greater than the predetermined threshold value and when simultaneously the supply parameter of the percussion apparatus is adjusted to its minimum by the control device. These dispositions allow automatically interrupting the supply of the pressurized incompressible fluid to the percussion apparatus so as to protect the predetermined area from the sound waves produced by the percussion apparatus. In such case, the operator must for example take the percussion apparatus away from the predetermined area before restarting said percussion apparatus.
[0032] According to one mode of implementation of the invention, the measurement step comprises measuring the sound level of the sound waves propagating in the vicinity of the predetermined area.
[0033] According to one mode of implementation of the control method, the latter comprises providing means for measuring sound data in the vicinity of the predetermined area.
[0034] According to one mode of implementation of the invention, the measurement step is carried out with one or more microphone(s) disposed in the vicinity of the predetermined area.
[0035] According to one mode of implementation, the control device is arranged to adjust, for example stepwise or continuously, the supply parameter of the percussion apparatus between a minimum value and a maximum value. According to one mode of implementation, the control device is arranged to adjust the supply parameter of the percussion apparatus in different values comprised between the minimum and maximum values.
[0036] According to one mode of implementation, the control method comprises moving a control member comprised in the control device between a first control position corresponding to a maximum value of the supply parameter and a second control position corresponding to a minimum value of the supply parameter.
[0037] According to one mode of implementation of the control method, the control instruction initially applied to the control device, that is to say, upon switching-on the percussion apparatus, is determined so as to adjust the supply parameter to a minimum value.
[0038] According to one mode of implementation of the control method, the step of moving the control member is carried out continuously or stepwise.
[0039] According to one mode of implementation of the control method, the latter comprises determining the predetermined area and of providing means for measuring the sound data in the vicinity of the predetermined area.
[0040] The present invention further concerns an assembly comprising:
a percussion apparatus actuated by a pressurized incompressible fluid, including a striking piston arranged to strike a tool during each operating cycle of the percussion apparatus, a control device arranged to adjust a supply parameter of the percussion apparatus, a control unit arranged to apply a control instruction to the control device, sound data measuring means intended to be disposed in the vicinity of a predetermined area, transmission means connected to the sound data measuring means and arranged to transmit the sound data measured by the measuring means,
[0046] the control unit being arranged to:
receive the sound data transmitted by the transmission means, compare the received sound data with a predetermined threshold value, correct the control instruction of the control device depending on the received sound data, and apply said corrected control instruction to the control device so as to adjust the supply parameter of the percussion apparatus depending on the received sound data.
[0051] According to one embodiment of the invention, the predetermined area is an area inhabited or occupied by third parties, such as a residential area, an area of industrial, commercial or agricultural activities, or an education, care or rest area.
[0052] According to one embodiment of the invention, the control unit is arranged to correct the control instruction such that the supply parameter adjusted by the control device induces sound data, advantageously in the vicinity of the predetermined area, lower than the predetermined threshold value.
[0053] According to one embodiment of the invention, when the sound data received by the control unit are greater than the predetermined threshold value, the control unit is arranged to correct the control instruction of the control device so as to decrease the supply parameter.
[0054] According to one embodiment of the invention, when the sound data received by the control unit are lower than the predetermined threshold value, the control unit is arranged to correct the control instruction of the control device so as to increase the supply parameter.
[0055] According to one embodiment of the invention, when the sound data received by the control unit are lower than the predetermined threshold value and when simultaneously the difference between the received sound data and the predetermined threshold value is greater than a predetermined limit value, the control unit is arranged to correct the control instruction of the control device so as to increase the supply parameter.
[0056] According to one embodiment of the invention, the assembly comprises a high-pressure supply circuit intended to supply the pressurized incompressible fluid to the percussion apparatus, and a low-pressure return circuit.
[0057] According to one embodiment of the invention, the percussion apparatus comprises a body delimiting a cylinder in which the striking piston is movably mounted in an alternative manner.
[0058] For example, the striking piston and the cylinder delimit at least one lower chamber permanently connected to the high-pressure supply circuit and an upper chamber alternately linked to the high-pressure supply circuit and the low-pressure return circuit.
[0059] According to one feature of the invention, the control unit is arranged to control the supply interruption of the pressurized incompressible fluid to the percussion apparatus when the sound data received by the control unit are greater than the predetermined threshold value and when simultaneously the supply parameter is adjusted to its minimum by the control device.
[0060] According to one embodiment of the invention, the assembly comprises a blocking device arranged to block the high-pressure supply circuit.
[0061] According to one embodiment of the invention, the blocking device is mounted on the high-pressure supply circuit.
[0062] According to one embodiment of the invention, the blocking device comprises a movable blocking member between a blocking position wherein said blocking member blocks the high-pressure supply circuit, and a release position wherein said blocking member releases the high-pressure supply circuit.
[0063] According to one embodiment of the invention, the control unit is arranged to control the movement of the blocking member between its blocking and release positions.
[0064] According to one embodiment of the invention, the blocking device comprises an actuating element arranged to move the blocking member between its blocking and release positions.
[0065] According to one embodiment of the invention, the actuating element is arranged to receive a control instruction from the control unit, and to move the blocking member depending on the control instruction.
[0066] According to one embodiment of the invention, the blocking device is a solenoid valve, and for example an on-off solenoid valve, such as a normally open solenoid valve or a normally closed solenoid valve.
[0067] According to one embodiment of the invention, the measurement means are arranged to measure the sound levels of the sound waves propagating in the vicinity of the predetermined area.
[0068] According to one feature of the invention, the measurement means include one or more microphone(s) intended to be disposed in the vicinity of the predetermined area.
[0069] According to one feature of the invention, the control device comprises a control member movable between a first control position corresponding to a maximum value of the supply parameter and a second control position corresponding to a minimum value of the supply parameter.
[0070] According to one embodiment of the invention, the control device is external to the percussion apparatus.
[0071] According to one embodiment of the invention, the control device is hydraulic.
[0072] According to one embodiment of the invention, the control unit is arranged to control the movement of the control member between its first and second positions, and for example continuously or stepwise.
[0073] According to one embodiment of the invention, the control device is provided so with an actuating member arranged to move the control member between its first and second control positions.
[0074] According to one embodiment of the invention, the actuating member is arranged to receive the corrected control instruction from the control unit, and to move the control member depending on the corrected control instruction.
[0075] According to one embodiment of the invention, the control device comprises a pressure regulator, and for example a proportional control-type pressure regulator.
[0076] According to one embodiment of the invention, the control device is mounted on the high-pressure supply circuit.
[0077] According to one feature of the invention, the control device is arranged to adjust the supply pressure, also called operating pressure, of the percussion apparatus between a minimum supply pressure and a maximum supply pressure.
[0078] According to one embodiment of the invention, the control device is arranged to adjust continuously or stepwise the supply pressure of the percussion apparatus between the minimum and maximum supply pressures.
[0079] According to one embodiment of the invention, the control unit is arranged to correct the control instruction of the control device so as to decrease the supply pressure of the percussion apparatus when the sound data received by the control unit are greater than the predetermined threshold value.
[0080] According to one embodiment of the invention, the control unit is arranged to correct the control instruction of the control device so as to increase the supply pressure of the percussion apparatus when the sound data received by the control unit are lower than the predetermined threshold value.
[0081] According to one embodiment of the invention, the control device comprises a flow rate regulator, and for example a proportional control-type flow rate regulator.
[0082] According to one embodiment of the invention, the control device is arranged to adjust the supply flow rate of the percussion apparatus between a minimum supply flow rate and a maximum supply flow rate.
[0083] According to one embodiment of the invention, the control device is arranged to adjust continuously or stepwise the supply flow rate of the percussion apparatus between the minimum and maximum supply flow rates.
[0084] According to one embodiment of the invention, the control unit is arranged to correct the control instruction of the control device so as to decrease the supply flow rate of the percussion apparatus when the sound data received by the control unit so are greater than the predetermined threshold value.
[0085] According to one embodiment of the invention, the control unit is arranged to correct the control instruction of the control device so as to increase the supply flow rate of the percussion apparatus when the sound data received by the control unit are lower than the predetermined threshold value.
[0086] According to one embodiment of the invention, the assembly comprises a variable displacement supply pump connected to the high-pressure supply circuit, and the control device is arranged to adjust the displacement of the supply pump between a minimum displacement and a maximum displacement.
[0087] According to one embodiment of the invention, the control unit and the percussion apparatus are intended to be mounted on a carrier machine, such as a hydraulic shovel.
[0088] According to one embodiment of the invention, the assembly comprises setting means arranged to set, particularly by an operator input, the predetermined threshold value.
[0089] According to one embodiment of the invention, the control unit includes a receiver arranged to receive the sound data transmitted by the transmission means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0090] Anyway, the invention will be better understood using the following description with reference to the appended schematic drawing showing, by way of non-limiting examples, three embodiments of this assembly.
[0091] FIG. 1 is a schematic view of an assembly according to a first embodiment of the invention.
[0092] FIG. 2 is a schematic view of an assembly according to a second embodiment of the invention.
[0093] FIG. 3 is a schematic view of an assembly according to a third embodiment of the invention.
[0094] FIG. 4 is a schematic view of an assembly according to a fourth embodiment of the invention.
DETAILED DESCRIPTION
[0095] FIG. 1 shows an assembly according to a first embodiment of the invention comprising a percussion apparatus 2 , such as a hydraulic rock breaker, mounted on a carrier machine 3 , such as a hydraulic shovel.
[0096] The percussion apparatus 2 comprises a stepped striking piston 4 slidably mounted in an alternative manner within a cylinder 5 arranged in a body 6 of the percussion apparatus 2 . During each operating cycle of the percussion apparatus 2 , the striking piston 4 strikes the upper end of a tool 7 slidably mounted in a bore 8 arranged in the body 3 coaxially to the cylinder 5 . The striking piston 4 and the cylinder 5 delimit for example a lower chamber (not shown in the figures) fluidly connected permanently to a high-pressure supply circuit 9 intended to supply the pressurized incompressible fluid to the percussion apparatus 2 and an upper chamber (not shown in the figures) with a more significant section arranged above the striking piston 4 .
[0097] The percussion apparatus 2 further comprises a distributor (not shown in the figures) mounted in the body 6 and arranged to alternately link the upper chamber to the high-pressure supply circuit 9 , during the striking stroke of the striking piston 4 , and with a low-pressure return circuit 11 during the rising stroke of the striking piston 4 .
[0098] The assembly further comprises at least one microphone 12 intended to be disposed in the vicinity of an area to be protected 13 such as a building inhabited or occupied by third parties, so as to measure sound data, such as the sound level, related to sound waves 14 propagating in the vicinity of the area 13 and generated by the operation of the percussion apparatus 2 . According to one embodiment of the invention, the assembly may comprise several microphones 12 .
[0099] The assembly also comprises a transmitter 15 connected to the microphone 12 , and arranged to transmit the sound data measured by the microphone 12 . The transmitter 15 is preferably disposed in the vicinity of the microphone 12 , and thus of the area to be protected 13 .
[0100] The assembly further comprises a control device 16 external to the percussion apparatus 2 and arranged to adjust the supply flow rate of the percussion apparatus 2 , and a control unit 17 arranged to apply a control instruction to the control device 16 .
[0101] According to the embodiment shown in FIG. 1 , the control device 16 is hydraulic and formed by a proportional control flow rate regulator 18 mounted on the high-pressure supply circuit 9 downstream of a supply pump 19 disposed on the carrier machine 3 .
[0102] The flow rate regulator 18 comprises a control member 20 movable between a first control position corresponding to a maximum supply flow rate of the percussion apparatus 2 and a second control position corresponding to a minimum supply flow rate of the percussion apparatus 2 . The flow rate regulator 18 further comprises an actuating coil 21 arranged to receive the control instruction from the control unit 17 , and to move the control member 20 between its first and second control positions depending on the received control instruction.
[0103] The assembly further comprises a return line 22 fluidly connected on the one hand to a low-pressure tank 23 and on the other hand to the flow rate regulator 18 . The return line 22 and the upstream and downstream portions of the high-pressure supply circuit 9 advantageously open into a cylinder (not shown in the figures) in which the control member 20 is slidably mounted.
[0104] The flow rate regulator 18 is particularly arranged to deviate towards the return line 22 , a more or less significant part of the fluid flow rate provided by the supply pump 19 depending on the position of the control member 20 , and thus of the control instruction applied to the actuating coil 21 by the control unit 17 .
[0105] The control unit 17 is arranged to:
receive the sound data transmitted by the transmitter 15 . compare the received sound data with a predetermined threshold value, correct the control instruction of the control device 16 depending on the received sound data, and apply the corrected control instruction to the control device 16 so as to adjust the supply flow rate of the percussion apparatus 2 .
[0110] The control unit 17 is more particularly arranged to:
correct the control instruction of the control device 16 so as to decrease the supply flow rate of the percussion apparatus 2 when the sound data received by the control unit 17 are greater than the predetermined threshold value, and correct the control instruction of the control device 16 so as to increase the supply flow rate of the percussion apparatus 2 when the sound data received by the control unit 17 are lower than the predetermined threshold value.
[0113] Thus, when the percussion apparatus 2 is operating, the sound levels values, or the maximum of these sound levels values, sound waves 14 generated by the percussion apparatus 2 and propagating in the vicinity of the area 13 are measured by the microphones 12 and transmitted by the transmitter 15 to the control unit 17 . These values are then compared to the predetermined threshold value. When these values exceed the predetermined threshold value, then the control unit 17 applies a control instruction to the control device 16 so as to decrease the supply flow rate of the percussion apparatus 2 , and thus the percussion apparatus power, and this in order to limit the noise nuisances generated by the percussion apparatus. On the contrary, when these values are lower than the predetermined threshold value, then the control unit 17 applies a control instruction to the control device 16 so as to increase the supply flow rate of the percussion apparatus 2 so as to increase the percussion apparatus power, and this in order to optimize the operation of the percussion apparatus 2 without exceeding the maximum permissible sound values within the sensitive area to be protected.
[0114] According to the embodiment shown in FIG. 1 , the assembly also comprises a pressure switch 24 arranged to measure the pressure in the high-pressure supply circuit 9 . The pressure switch 24 is advantageously connected to the control unit 17 so as to transmit to the latter the measured pressure values.
[0115] FIG. 2 shows an assembly according to a second embodiment of the invention which differs from the assembly shown in FIG. 1 mainly in that the supply pump 19 is a variable displacement pump, and in that the control device 16 is formed by a control device 25 arranged to adjust the displacement of the supply pump 19 between a minimum displacement and a maximum displacement. The control device 25 is thus arranged to adjust, via the supply pump 19 , the supply flow rate of the percussion apparatus 2 between a minimum supply flow rate and a maximum supply flow rate.
[0116] The control device 25 comprises a control member 26 , such as an actuator, arranged to cooperate with the supply pump 19 and movable between a first control position corresponding to a maximum supply flow rate of the percussion apparatus 2 and a second control position corresponding to a minimum supply flow rate of the percussion apparatus 2 .
[0117] The control device 25 further comprises a control unit 27 arranged to receive the control instruction from the control unit 17 , and to move the control member 26 between its first and second control positions depending on the received control instruction.
[0118] According to this embodiment of the invention, the control unit 17 is arranged to:
correct the control instruction of the control device 16 so as to decrease the displacement of the supply pump 19 , and thus the supply flow rate of the percussion apparatus 2 , when the sound data received by the control unit 17 are greater than the predetermined threshold value, and correct the control instruction of the control device 16 so as to increase the displacement of the supply pump 19 , and thus the supply flow rate of the percussion apparatus 2 , when the sound data received by the control unit 17 are lower than the predetermined threshold value.
[0121] FIG. 3 shows an assembly according to a third embodiment of the invention which differs from the assembly shown in FIG. 1 mainly in that the control device 16 is formed by a proportional control pressure regulator 28 mounted on the high-pressure supply circuit 9 , and arranged to adjust the supply pressure of the percussion apparatus 2 between a minimum supply pressure and a maximum supply pressure.
[0122] The pressure regulator 28 comprises a control member 29 movable between a first control position corresponding to the maximum supply pressure of the percussion apparatus 2 and a second control position corresponding to the minimum supply pressure of the percussion apparatus 2 . The pressure regulator 28 further comprises an actuating coil 30 arranged to receive the control instruction from the control unit 17 , and to move the control member 29 between its first and second control positions depending on the received control instruction.
[0123] According to this embodiment of the invention, the control unit 17 is arranged to:
correct the control instruction of the control device 16 so as to decrease the supply pressure of the percussion apparatus 2 when the sound data received by the control unit 17 are greater than the predetermined threshold value, and correct the control instruction of the control device 16 so as to increase the supply pressure of the percussion apparatus 2 when the sound data received by the control unit 17 are lower than the predetermined threshold value.
[0126] FIG. 4 shows an assembly according to a fourth embodiment of the invention which differs from the assembly shown in FIG. 3 mainly in that the control unit 17 is arranged to control the interruption of the supply of the pressurized incompressible fluid to the percussion apparatus 2 when the sound data received by the control unit 17 are greater than the predetermined threshold value and when simultaneously the supply pressure of the percussion apparatus 2 is adjusted to its minimum by the control device 16 .
[0127] According to the embodiment shown in FIG. 4 , the assembly comprises a blocking device 31 mounted on the high-pressure supply circuit 9 , and arranged to block the high-pressure supply circuit 9 . The blocking device 31 is for example disposed between the supply pump 19 and the control device 16 .
[0128] The blocking device 31 is advantageously formed by a solenoid valve 32 and for example an on-off solenoid valve, such as a normally open solenoid valve or a normally closed solenoid valve.
[0129] The solenoid valve 32 advantageously comprises a blocking member 33 movable between a blocking position wherein the blocking member 33 blocks the high-pressure supply circuit 9 , and a release position wherein the blocking member 33 releases the high-pressure supply circuit 9 . The solenoid valve 32 further comprises an actuating coil 34 arranged to receive a control instruction from the control unit 17 , and to move the blocking member 33 between its blocking and release positions depending on the received control instruction.
[0130] Thus, when the supply pressure of the percussion apparatus is adjusted to its minimum by the control device 16 , and when simultaneously the sound data received by the control unit 17 are greater than the predetermined threshold value, the control unit 17 applies a control instruction to the solenoid valve 32 , and particularly to its actuating coil 34 so as to control movement of the blocking member 33 towards its blocking position. These dispositions allow automatically interrupting the supply of the pressurized incompressible fluid to the percussion apparatus 2 , and then protecting the area 13 of the sound waves produced by the percussion apparatus 2 .
[0131] According to variant of the invention, the blocking device 31 could be integrated with the assemblies according to the invention shown in FIGS. 1 and 2 . In this case, the control unit 17 would be arranged to control interruption of the supply of pressurized incompressible fluid to the percussion apparatus 2 when the sound data received by the control unit 17 are greater than the predetermined threshold value and when simultaneously the supply flow rate of the percussion apparatus 2 is adjusted to its minimum by the control device 16 .
[0132] It goes without saying that the invention is not limited to the sole embodiments of this assembly, described above as example, it encompasses on the contrary all the variants. | A control method including providing a control device arranged to adjust a supply parameter of a percussion apparatus, providing a control unit arranged to apply a control instruction to the control device, switching on the percussion apparatus, measuring at least one sound data in the vicinity of a predetermined area, transmitting the at least one measured sound data to the control unit, comparing the at least one sound data received by the control unit with a predetermined threshold value, correcting the control instruction of the control device depending on the at least one received sound data, and applying, by means of the control unit, the corrected control instruction to the control device. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The application claims priority of provisional patent application serial No. 60/372,494 which was filed on Apr. 12, 2002.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to an apparatus for carrying percussion musical instruments, particularly drums of various kinds, and more particularly, to an a carrier hardware providing an attachment structure for the tension members of percussion instruments and to a vibration isolation system for supporting the carrier on a person while standing, walking, or marching.
[0004] The prior art discloses many examples of apparatus for supporting percussion instruments such as drums, but none providing the combination of features disclosed and claimed herein. Structures for carrying percussion musical instruments must provide a balance between the comfort of the person walking, standing, or marching while wearing the instruments, and the mounting of the instruments in a desired playing position. Where the instruments are rigidly maintained at a particular playing position, the straps or structure associated with the carrier can cause painful discomfort to the marcher. Thus it is important to provide an instrument carrier with an apparatus which maintains the playing instruments in a given playing position while at the same time providing an increased measure of player comfort. Additionally, the manner in which the instruments are mounted to the carrier is of great importance. The mounting should not affect the musical characteristics of the instruments nor position them in such a manner that the person carrying them cannot properly play the instruments. In the past, marching tom drums, for example, generally were mounted to support structures by drilling openings in the drum shell and making the interconnection to the support through the shell. I believe the breech of shell integrity may affect the sound characteristics of the drum. Even if that is not the case, however, attachments through the shell make it difficult to mount and/or remove the drum from the support structure.
[0005] U.S. Pat. No. 3,106,123 to Johannsen discloses a holder for a single marching drum which clasps adjacent vertical drum rod members and is attached to the drum through those members. The holder is further secured to a pair of shoulder straps and a bracing strap configured to rest on the chest or stomach of a person wearing the holder.
[0006] U.S. Patent No. 4,256,007 to Streit discloses a percussion instrument carrier for securing a single percussion instrument in a playing position while being carried by a person standing, walking, or marching. The single percussion instrument is secured in place to a structure worn on the person by a flexible tie-down cord and a number of L-clamps affixed at opposite corners of the instrument.
[0007] U.S. Pat. No. 6,329,583 to May discloses a carrier for percussion instruments comprising a supporting vest of composite material, rigid removable shoulder straps of light metal, and a back bar of light metal such as aluminum or magnesium. The percussion instruments are supported on a pair of J-bars mounted on the carrier in an adjustable manner. The shoulder straps specifically are intended for removal for the substitution of straps of different sizes. The straps are secured with adjustable connections permitting removal, replacement, longitudinal, and angular adjustment for comfort.
[0008] Accordingly, there is a need for a wearable carrier for percussion musical instruments which provides an adjustable attachment structure for detachably positioning a number of musical instruments in proper playing locations, and for providing a vibration attenuating supporting structure.
BRIEF SUMMARY OF THE INVENTION
[0009] Briefly stated, the percussion musical instrument carrier and vibration isolation support assembly of the present invention provides a person with an apparatus by which a plurality of percussion musical instruments such as marching tom drums may be supported on the person while standing, walking, or marching. Each of the percussion musical instruments is detachably secured between upper and lower plates of an instrument support utilizing the casings of one or more tension elements located about the circumference of each instrument. The support frame, in turn, is secured to a supporting vest having vibration isolated shoulder straps adapted to be worn by the person.
[0010] The foregoing and other objects, features, and advantages of the invention as well as presently preferred embodiments thereof will become more apparent from the reading of the following description in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] In the accompanying drawings which form part of the specification:
[0012] [0012]FIG. 1 is a front perspective view of the drum carrier and vibration isolation support system of the present invention;
[0013] [0013]FIG. 2 is a front view of the drum carrier and vibration isolation support system of the present invention;
[0014] [0014]FIG. 3 is a side perspective view of the drum carrier and vibration isolation support system of the present invention;
[0015] [0015]FIG. 4 is a rear view of the drum carrier of the present invention supporting a plurality of drums;
[0016] [0016]FIG. 5 is a top view of the drum carrier of the present invention shown in FIG. 4;
[0017] [0017]FIG. 6 is a enlarged perspective view of the vibration isolation components of the present invention;
[0018] [0018]FIG. 7 is a side view of a percussion musical instrument showing the installation the tension lug bushing; and
[0019] [0019]FIG. 8 is a perspective view of the bushing.
[0020] Corresponding reference numerals indicate corresponding parts throughout the several figures of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] The following detailed description illustrates the invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the invention, describes several embodiments, adaptations, variations, alternatives, and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.
[0022] Referring to FIGS. 1 and 2, a shoulder supported percussion musical instrument carrier and vibration isolation support system of the present invention is shown generally at 10 . The carrier comprises a belly-plate or vest portion 12 adapted to fit the torso of a wearer, a pair of shoulder straps 14 , each secured to the vest portion 12 at a first end, and a back bar 16 linking the opposite ends of the shoulder straps 14 together. A pair of support rod receptacles 18 are secured to the front surface of the vest portion 12 by bolts or rivets 19 . Support rods 20 , preferably J-rods, are supported in the receptacles 18 and secured in position by set screws 21 . Each J-rod 20 may be adjusted vertically and rotationally within the support rod receptacle 18 , providing vertical movement for height adjustment, and rotational movement in a horizontal plane for altering the spacing between the opposite ends of the J-rods 20 . A percussion instrument support frame 22 is secured to the J-rods 20 , opposite the front surface of the vest portion 12 .
[0023] Each of the shoulder straps 14 is secured to the vest portion 12 with a vibration attenuating element 24 to provide vibration isolation between the vest portion 12 upon which the percussion instruments are carried, and the shoulder straps 14 . The vibration attenuating element 24 , shown in FIG. 6, is preferably composed of a rubber or similar material having vibration isolating or attenuating properties interposed between the vest portion 12 and each shoulder strap 14 . A bolt or rivet 25 integral with, or passing through, the vibration attenuating element 24 secures the respective shoulder strap 14 to the vest portion 12 . Those of ordinary skill in the art will recognize that a wide variety of materials having vibration isolating properties may be utilized as the vibration attenuating elements 24 . Correspondingly, the bolt or rivet 25 may be replaced by other conventional connectors to secure each shoulder strap 14 to the vest portion 12 .
[0024] The percussion instrument support frame 22 comprises an upper instrument support plate 30 and a lower instrument support plate 32 , secured in a predetermined spaced relationship by a pair of C-brackets 34 . In the embodiment shown in FIGS. 1 and 2, the upper instrument support plate 30 is secured to the upper extensions of each of the C-brackets 34 by bolts or rivets 35 . Correspondingly, the lower instrument support plate 32 is secured to the lower extensions of each of the C-brackets 34 by bolts or rivets 36 . One or more support rods 38 are secured between the upper instrument support plate 30 and the lower instrument support plate 32 , to increase the stability thereof, and to facilitating maintaining the spaced relationship.
[0025] To secure the percussion instrument support frame 22 to the J-rods 20 , each of the C-brackets 34 includes a rod receiver 40 . Each C-bracket 34 is a mirror image of the other, and accordingly, the following description will describe only one C-bracket 34 . Corresponding reference numerals in the figures identify corresponding components on each C-bracket.
[0026] The rod receiver 40 comprises a section of tube 42 having an inner diameter sized to receive an end of the J-rod 20 in a friction fit. The tube 42 is secured to the C-bracket 34 by an adjustable bolt 44 passing diametrically through the tube 42 adjacent an upper end 43 . The orientation of the longitudinal axis of tube 42 may be adjusted parallel to the face of the C-bracket 34 by pivoting the tube 42 about the adjustable bolt 44 , thereby permitting the percussion instrument support frame 22 to be orientated at an angle relative to either the ground or the J-rod 20 . A stop 46 is secured to the C-bracket to provide for perpendicular alignment between the planes defined by the upper and lower instrument support plates 30 , 32 and the longitudinal axis of tube 42 .
[0027] During use, the upturned end of each J-rod 20 is seated within a corresponding rod receiver 40 from the lower end of each tube 42 . The percussion instrument support frame 22 is oriented at a desired angle relative to the J-rods 20 , by pivoting each tube 42 about the adjustable bolts 44 . Once the desired angle is achieved, the adjustable bolts 44 are tightened to secure each tube 42 in a fixed relationship to the C-bracket 34 on which it is mounted.
[0028] Turning to FIG. 3 through FIG. 5, there is shown one or more percussion musical instruments 100 secured to the percussion instrument support frame 22 . Each percussion musical instrument 100 includes a cylindrical body or shell 102 and a drum head 104 stretched over the upper end of the shell 102 . The drum head 104 is secured to the shell 102 by a rim 106 which bears on the upper edge of the shell 102 . A plurality of equidistantly spaced tension lugs 108 extend through the rim 106 and are threaded into casings 110 fastened to the side of the shell 102 . Each casing 110 has a predetermined length L, and an axially disposed threaded bore 112 , open at each end, into which a tension lug 108 is threaded.
[0029] Referring to FIG. 1, it is shown that the upper and lower instrument support plates 30 , 32 each include, along corresponding peripheral edges 114 , a plurality of vertically aligned curved recesses 116 . Each curved recess 116 has a radius and a radial dimension. The radial dimension corresponding to an outer radial dimension of a percussion musical instrument 100 intended for attachment at that location. Further shown in FIG. 1 are a plurality of vertically aligned instrument attachment points 120 , preferably bolt receiving bores, adjacent each curved recess 116 , and spaced about each curved recess 116 in positions corresponding to the placement of casings 110 about the shell 102 of a percussion musical instrument 100 intended for attachment at that location.
[0030] The predetermined spaced relationship between the upper and lower instrument support plates 30 , 32 , as defined by the dimension of the C-brackets 34 , is greater than the predetermined length L of the casings 110 on the percussion musical instruments 100 intended for attachment to the percussion instrument support frame 22 . To secure a percussion musical instrument 100 to the support frame 22 , one or more of the tension lugs 108 are removed from the rim 106 and casings 110 . The percussion musical instrument 100 is then positioned within a curved recess 116 in the upper and lower instrument support plates 30 , 32 , such that the peripheral edges 114 of the support plates 30 , 32 abut the shell 102 . Next, the percussion musical instrument 100 is rotated to bring the threaded bore 112 of at least one casing 110 from which the tension lug 108 has been removed into alignment between the upper and lower support plates 30 , 32 with a vertically aligned pair of bolt receiving bores 120 . The tension lug 108 is then replaced through the rim 106 , passing through a bolt receiving bore 120 in the upper support plate 30 , and threaded into the threaded bore 112 of the casing 110 .
[0031] During installation of the tension lug 108 , one vibration isolation washer 123 is installed above the casing 110 and one vibration isolation washer 123 is installed below the casing 110 . While the two vibration isolation washers may be made from any resilient material, it is preferred that the vibration isolation washers 123 be made from neoprene material. A bushing 124 (FIGS. 7 and 8) are placed into the opening within the rims 106 prior to installation of the tension lugs 108 . The bushing 124 reduces the friction between the tension lugs 108 and the rim 106 to provide a finer ability to adjust the tension in the tension lug 108 . Additionally, the bushings 124 act to keep the vertical axial tension loads perpendicular to the upper surface of the rim 106 , thereby greatly reducing the tendency to create a bending moment in the tension lug 108 as the tension lug is tightened. While the bushing 124 made be made of any material which reduces the friction coefficient between the metal of the rim 106 and the tension rod 108 , it is preferred that the bushing be made from a brass material. It will also be appreciated that while the bushing 124 is part of the drum carrier 10 , the bushing may also be used on any drum percussion instrument having a rim 106 used for tightening a drum head 104 onto a drum shell 102 .
[0032] A retaining bolt 122 is correspondingly passed upward through a bolt receiving bore 120 in the lower support plate 32 and threaded into the threaded bore 112 of the casing 110 , opposite the tension lug 108 . Preferably, at least two casings are secured between the upper and lower support plates 30 , 32 in this manner for each percussion musical instrument 100 .
[0033] In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results are obtained. As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A shoulder supported percussion musical instrument carrier and vibration isolation support assembly providing support for a plurality of percussion musical instruments on a person while standing, walking, or marching. Each of the percussion musical instruments is detachably secured between upper and lower plates of an instrument support frame utilizing one or more tension element casings located about the circumference of each instrument. The instrument support frame, in turn, is secured to a supporting vest including vibration isolated shoulder straps. | 6 |
FIELD OF THE INVENTION
The present invention relates to the installation of the upper skive plate in the fuser section of a electrophotographic copier/printer apparatus and in one of its aspects relates to an upper skive plate and to an assembly for removing and replacing the upper skive plate in the fuser section of an electrophotographic machine wherein the assembly prevents the blades on the skive plate from cutting or digging into the pressure roller of the fuser section while the upper skive plate is being installed and/or removed.
BACKGROUND OF THE INVENTION
In a typical electrophotographic machine (e.g. copier, duplicators, printers, etc.), a continuous loop of photoconductor film is commonly used to transfer an image from an input section onto a receiving medium (e.g. a sheet of paper). The film is initially charged and then passes through an input section where an image (i.e. analog or digital) is projected onto the charged film. The film then moves through a developing section where a toner is applied to the charged image, and on through an image transfer section where the image is transferred to the sheet of paper or other medium. The paper is subsequently passed through a fuser section where the toner forming the image is fixed to the paper by elevated temperature and pressure. This is typically accomplished by passing the paper between two, opposed rollers in the fuser section, i.e. a pressure roller and a fuser roller, one of which is heated.
In fuser sections such as described above, the nip between the pressure and fuser rollers is extremely tight. To ensure that the paper will continue on through this nip and not stick to one or the other of the rollers, “skive plates” (i.e. upper and lower skive plates) are normally provided to strip the paper off the rollers (i.e. fuser and pressure rollers, respectively) after the toner is fused onto the paper. Each plate carries a plurality of thin, extremely sharp “skives” (i.e. blades) (e.g. 0.004 inches thick) which effectively ride on its respective roller. These plates are rigidly mounted near the rollers at a precise location and angle to provide the proper stripping force without digging or gouging into the roller. As will be appreciated in this art, during assembly and service of the electrophotographic machine, the skive plates are frequently removed and then reinstalled. During this operation, the skive plates must be carefully handled so that the sharp skives do not gouge the respective rollers.
In known, prior art machines of this type, the installation of these skive plates presents a number of problems for a service technician, since there is usually nothing in the fuser section which prevents the skives from touching and possibly damaging the rollers if a technician mishandles the skive plate during a service operation. For example, in prior art fuser sections, the upper skive plate, to which the present invention is directed, must be carefully manipulated and then held in the proper position by a single service technician until he can secure the upper plate with screws or the like. While a competent technician can be trained to carry out the required, precise procedures, they still require the use of special tools and more importantly, involve the risk of human error which can lead to severe damage to the pressure roller.
Accordingly, those skilled in this art will recognize the need of simplifying the installation of the upper skive plate in the fuser section of an electrophotographic machine and making such installation effectively “fool-proof” to prevent the accidental gouging of the pressure and fuser rollers during the installation. Further, it is highly beneficial if the servicing of the upper skive plate can be carried out by a single technician without the need of special tools.
SUMMARY OF THE INVENTION
The present invention provides a fuser section for an electrophotographic apparatus which includes an upper skive plate which, in turn, can be easily and quickly installed in and removed from within the fuser section without the risk of accidentally damaging the pressure roller and the method for installing the skive plate in the fuser section. The upper skive plate carries a plurality of skives (i.e. sharp blade-like elements) thereon which are designed to ride on the pressure roller which, in turn, is rotatably mounted between two pivoted, load arms in the fuser section and strip sheets of paper off the pressure roller as the paper passes thereover.
Basically, the upper skive plate of the present invention is comprised of a plate having a front, rear, top, bottom, and two ends. A plurality of skives (i.e. sharp blade-like members) are mounted on and spaced across said bottom of said base plate so that the skives will ride on said pressure roller when said upper skive plate is in its operable position within the load arms of the fuser section. The skive plate has guide openings which cooperate with locator pins on the load arms to guide the plate to its operable position. The plate has at least one releasable latch thereon which releasably latches the plate in place once the plate has been properly positioned.
More specifically, the upper skive plate has a pair of releasable latches, one on each end of the plate. Each of these latches has a locking pawl which is affixed to one end of a shaft which, in turn, extends through the plate. A handle is fixed on the other end of the shaft and can move longitudinally with respect to the shaft but can not rotate with respect thereto. A spring, e.g. Belleville washer, is positioned between the handle and the shaft, the compression of which provides the clamping force necessary to latch the plate in place.
A guide assembly is affixed to each of the load arms and is comprised of a vertical guide element and a lateral guide element, the latter having a back surface thereon. A tapered, locator pin extends from the front of the back surface and is adapted to cooperate with guide openings in the upper skive plate to guide the plate to its operable position between the load arms. Once the plate is moved along the locator pins and against the front of the back surface, the latches are rotated to move the locking pawls in behind a respective clamping surface which, in turn, is on the rear of the back surface. As the pawls are moved onto the clamping surfaces, they will compress their respective springs thereby providing the force necessary to securely latch the upper skive plate in its operable position. To remove the upper skive plate, the procedure is merely reversed.
BRIEF DESCRIPTION OF THE DRAWINGS
The actual construction operation, and apparent advantages of the present invention will be better understood by referring to the drawings, not necessarily to scale, in which like numerals identify like parts and in which:
FIG. 1 . is a schematic view of an electrophotographic apparatus (e.g. copier/printer machine) in which the present invention can be incorporated;
FIG. 2 is a simplified, partial sectional view of the fuser section lying within line 2 — 2 of FIG. 1 showing the upper skive plate of the present invention in its operable position therein;
FIG. 3 is a perspective, rear view of the upper skive plate of the present invention;
FIG. 4 is a perspective view of a portion of one of the pivoted arms on which one end of the pressure roller (removed) is carried and on which one of the locating pins for the upper skive plate is affixed;
FIG. 5 is a top view of one of the latch members on the upper skive plate of FIG. 3 :
FIG. 6 is a cross-sectional view taken along line 6 — 6 of FIG. 5;
FIG. 7 is an enlarged, front perspective view, partly broken away, of one end of the upper skive plate of FIG. 3 in a latched, operable position within the fuser section; and
FIG. 8 is an enlarged, rear perspective view, partly broken away, of the upper skive plate of FIG. 3 in a latched, operable position within the fuser section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring briefly to FIG. 1, a typical electrophotographic apparatus or machine 10 (e.g. copier, duplicator, printer) of the kind that has an endless photoconductor member 11 (e.g. photographic film) which moves through a closed loop past a charging station 12 , a an expose or input station 13 , a developing station 14 , a transfer station 15 , and an erase/clean section 16 . A copy medium (e.g. a sheet S of paper) is fed from a supply (not shown) through transfer station 15 where the toner image on the film 11 is transferred to the paper S. The paper S is then fed between a fusing roller 21 and a pressure roller 22 in fuser section 20 to fix the toner image on the paper S before the paper exits the machine.
FIG. 2 is a simplified, sectional view of a portion of the fuser section 20 of FIG. 1 to which the present invention is directed. As illustrated, fuser section 20 is comprised of a frame or housing 25 in which pressure roller 21 and fuser roller 22 are rotatably mounted. Pressure roller 21 is rotatably mounted between two load arms 23 (only one shown) which, in turn, are pivoted in housing 25 about pivot 24 and each is biased towards the fuser roller 22 to thereby maintain contact between the pressure and fuser rollers during operation of the fuser section.
An upper skive plate 26 and a lower skive plate (removed and not shown in FIG. 2) carry a plurality of skives which in turn, are positioned to effectively ride on pressure roller 21 and fuser roller 22 , respectively. These skives are thin blades (e.g. 0.004 inch thick) and are extremely sharp and are designed to strip the paper S from the respective rollers as the paper passes therethrough. Front and rear latches 28 , 29 are used to releasably latch the lower skive plate in its operable position within housing 25 . For a complete description of the lower skive plate and its positioning and latching mechanism 27 , see U.S. Pat. No. 6,295,436 issued Sep. 25, 2001.
Upper skive plate 26 is positioned and secured in housing 25 as shown in FIG. 4 . As best seen in FIG. 3, upper skive plate 26 is comprised of a substantially, rectangular plate 30 having an upturned portion 31 at either end thereof. Plate 30 also has an elongated, perpendicularly-extending base element 32 which is secured to the bottom of plate 30 and which extends substantially across the width thereof. Base element 32 has a plurality of spaced openings 34 therein (seven shown), each of which is adapted to receive a skive plate 33 . Skives 33 (two shown in dotted lines in FIG. 3) are thin (e.g. 0.004 inches) blade-like members which are very sharp and which, when in an operable position, are adapted to strip a sheet of paper off pressure roller 21 and thereby keep it from sticking thereto.
Base plate 30 has a releasable latch 35 at each end therein near the top thereof. As best seen in FIG. 5, latch 35 is comprised of a locking pawl 36 having a shaft 37 extending therefrom. Shaft 37 has a reduced and “D-shaped” portion 37 a (FIG. 6) which, in turn, extends through a matching Dshaped opening 39 in handle 40 . It can be seen that while shaft 37 a is free to move longitudinally or axially within opening 39 , it can not rotate therein. While a D-shaped connection between shaft portion 37 and handle 40 has been shown, it should be recognized that other shaped connections (e.g. square, triangular, etc.) could be used so long as the shaft will not rotate with respect to handle 40 but will still allow longitudinal movement therebetween. Since the area within housing 25 in which the upper skive plate is located may be extremely hot, at least the knob on handle 40 is preferably molded from a heat-resistive material (e.g. plastic) to alleviate the possibility of a technician burning himself during servicing of the skive plate.
Pawl 36 is positioned from the rear through an opening in plate 30 and the opening 39 in handle 40 is positioned over portion 37 a of shaft 37 on the front side of plate 30 . A compression spring, e.g. Belleville washer 41 , is positioned around shaft 37 a and on top of handle 40 and is secured in that position by screw 42 which, in turn, forms an extension of shaft 37 a. Washer 41 will normally bias shaft 37 away from handle 40 (i.e. biases locking pawl 36 towards the rear of plate 30 , for a purpose discussed below. Plate 30 has a handle or grip 43 centrally mounted thereon which is used by a technical in handling the upper skive plate 26 . Also, a guide opening 44 is provided through plate 30 at one end and a guide slot 45 is provided at the other end for purposes described below. Plate 30 has two tabs 46 thereon for limiting the rotation of handle 40 between a fully latched position and a fully released position.
Affixed to each load arm 23 is a guide and locator assembly 50 (FIG. 4 ). It is important to mount assemblies 50 on the pivoted load arms 23 since the exact position of the pressure roller 21 and the fuser roller 22 may vary subtly whereon the axes of the two rollers may not always be exactly parallel to each other. When this occurs, the upper skive plate 26 must, nevertheless, remain exactly parallel to axis of the pressure roller 21 and not dig into and constrain movement of the pressure roller. Since each end of the pressure roller 21 is mounted by means of bearings on the end of each respective load arm 23 and since the skive plate is carried by these same load arms, a constant relationship between the upper skive plate and the pressure roller will be maintained even when the axes of the roller are not parallel.
Since each assembly 50 is a mirror-image of the other, only one will be described in detail. Each assembly 50 is comprised of a lateral guide element 51 , affixed to the inside of respective load arm 23 , and having a back surface 52 thereon and a vertical guide element 53 affixed to the top of arm 23 . Back surface 52 has a tapered, locator pin 55 extending from the front thereof and has a clamping surface (i.e. button 56 ) on the rear thereof.
In installing upper skive plate 26 , it is extremely important that the plate not be inadvertently tipped towards the pressure roller 21 and thereby risk that the sharp skives 33 come into contact with the roller. With the present invention, this is not likely to ever happen. To install upper skive plate 26 into housing 25 , the technician holds plate 26 by grip 43 and positions it against lateral guides 51 and vertical guides 53 on respective load arms 23 . As upper plate 26 is moved forward, lateral guides 51 will keep the plate effectively centered while vertical guides 53 will direct opening 44 and slot 45 onto their respective locator pins 55 . Opening 44 is substantially the same diameter as that of pin 55 while slot 45 allows some tolerance in lining up the plate between load arms 23 .
Once upper plate 26 is pushed all the way onto pins 55 and is flush against back surface 52 of assembly 50 , the handles of latches 35 are rotated downward to rotate locking pawls 36 in behind respective clamping surfaces 56 , thereby releasably latching upper skive plate 26 in an operable position within fuser section 20 . Belleville washer 41 is compressed as handle 40 is rotated and pawl 36 is moved behind surface 56 . The compression of washer 41 provides the high clamping force which is necessary to tightly hold plate 26 in place during operation. Further, by locating the upper skive plate on the locator pins 55 and clamping directly behind the pins, the upper skive plate 26 will rotate on a respective pin when either side of the pressure roller 21 moves up or down relative to the fuser roller 22 . This ensures that the skive plate will remain parallel to the axis of the pressure roller during operation.
To remove upper skive plate 26 , the above procedure is reversed. The grip 43 is held by the technician and both latches 35 are rotated to release the skive plate from the assembly 50 . The plate can then be moved back off locator pins 55 and out of housing 25 to complete the removal operation. | An upper skive plate and a method for quickly installing and removing the skive plate in the fuser section of an electrophotographic apparatus without damaging the roller therein. The skive plate carries a plurality of skives which strip a sheet of paper from the roller during operation of the apparatus. To install the skive plate, guide openings in the plate are positioned on locator pins which are affixed to the load arms which, in turn, support the roller. The plate is moved forward on the pins and is releasably latched in position by a pair of rotatable pawls on the plate which cooperate with clamping surfaces on the load arms. To remove the skive plate, this procedure is reversed. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to ignition systems for internal combustion engines and, in particular, to inductively coupled ignition systems for rotary combustion engines.
2. Description of the Prior Art
While rotary combustion engines offer some significant advantages over conventional reciprocating engines for automotive use, fuel economy and emission problems have delayed the widespread application of these power plants. The precise causes of poor fuel economy and emission difficulties are still being studied. It is clear, however, that the relatively large surface area to combustion volume ratios, shrouded ignition sources, and poor flame front propagation are primary causes of economy and emission problems in the Wankel engine, which is perhaps the most highly developed rotary to date.
Conventional rotary spark ignition engines such as the Wankel generally consist of a stationary outer housing and an internal rotating or oscillating member. As in conventional reciprocating engines, the spark duration is very short, for example, on the order of milliseconds, so that a plurality of plugs and plug holes are required for extended ignition periods. Spark ignition to such rotary engines is usually provided by one or more circumferentially located stationary spark plugs mounted in the outer housing assembly.
Recent engine designs included two spark plug ignition sources, a leading and trailing plug to assure adequate ignition of the mixture. Spark timing is a function of rotor speed and is controlled by two conventional distributors or by one "dual" distributor. The spark plugs communicate with the combustion chamber by means of touch holes in the trochoid housing. In practical engine designs, these holes are at a location and of a diameter which is at best a compromise of performance and efficiency. Ideally, the spark plug holes should be as large as possible so as not to shroud the plug yet not large enough to increase the unswept combustion volume or provide a leakage path past the apex seals.
In the Wankel engine, the spark plugs fire three times per rotor revolution and are never subjected to the cooling of the intake mixture. This continuous high temperature environment requires special premium plugs. Moreover, the shrouded plug tip is particularly susceptible to carbon fouling, since the electrodes are not located in the combustion volume per se and oil is added to the combustion mixture for seal lubrication.
Several attempts by various investigators have been made to remedy the difficulties encountered with peripheral plugs by locating the spark source on the rotor body. Means for high voltage transmission to the rotor assembly have been incorporated on the rotor shaft. Separate high voltage slip rings and sliding contacts must be provided for each spark plug to prevent the spark plugs from firing simultaneously. In this case, spark timing still required an external distributor or a mechanical spark advance mechanism on a high voltage commutator while insurmountable difficulties in high voltage insulation and distribution precluded the effective transmission of spark voltages to the rotor. As a result, no successful application of rotor mounted spark plugs has been made to date.
The invention described herein makes possible the use of rotor mounted spark plugs with none of the attendant difficulties in handling the high voltages. In addition, the invention eliminates the use of distributors or mechanical spark timing apparatus, while permitting spark durations of up to 90° of crank rotation.
SUMMARY OF THE INVENTION
An apparatus and method are provided for igniting a fuel-air mixture in an internal combustion engine. The fuel-air mixture is ignited in a combustion chamber defined by first and second components which move through repetitive cycles relative to one another. Generating means is adapted to be attached to the first component for generating a magnetic flux. Ignition means is adapted to be attached to the second component and is responsive to the generating means when it is magnetically coupled thereto through the magnetic flux generated by the generating means. The magnetic flux coupling occurs during a predetermined portion of the relative movement between the first and second components within each repetitive cycle and, as a result of the magnetic flux coupling, an ignition signal is provided in the combustion chamber.
The generating means is provided with a first coil means and an oscillator means while the ignition means includes a second coil means. Magnetic flux coupling occurs during the predetermined portion of the relative movement when the first coil means and the second coil means are in alignment for magnetic flux coupling and the oscillator means energizes the first coil means.
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view of a Wankel engine piston housing showing the rotary piston within the trochoid housing and the position of the ignition means within the piston;
FIG. 2 is a fragmentary perspective view of one corner of the triangular rotating piston and the upper cover plate of the housing showing the primary transformer core half and its primary winding in the housing and secondary transformer core half and its secondary winding in the rotary piston in proper alignment for magnetic flux coupling at T.D.C.;
FIG. 3 is a fragmentary cross-sectional view of a Wankel engine showing a spark plug with left and right handed threads and a tool for removing the spark plug from the rotary piston through the exhaust port of the Wankel;
FIG. 4 is a block diagram showing the inductive ignition system of the invention with the first and second coil means in proper alignment for magnetic flux coupling, and the second coil means disposed 180° from T.D.C.; and
FIG. 5 shows graphs of the log of the voltage that appears in one secondary winding as a function of the degrees of crank rotation of the rotary piston within the housing.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to an ignition assembly for use in an internal combustion engine and, more particularly, for use in a rotary piston engine. The engine has first and second components which define an ignition chamber and which move through repetitive cycles relative to one another. The second component is a triangular or rotary piston generally indicated at 2 and the first component is a housing generally indicated at 4 whose internal cross section is epitrochoid in shape. The triangular piston 2 and the housing 4 define a combustion chamber 6 and move through repetitive cycles relative to one another. In other words, the combustion chamber 6 is formed between first and second corners 8 of the triangular piston 2 in a predetermined portion of the housing 4 such as shown in FIG. 1 wherein the triangular piston 2 of a Wankel rotary engine is shown in T.D.C. (top dead center) position wherein maximum mixture compression is achieved. The combustion chamber 6 is further formed by the lower cover plate 10 of the housing 4 and the upper cover plate 12 of the housing 4 (not shown in FIG. 1, but shown in a broken view in FIG. 2).
The ignition assembly is comprised of the generating means generally indicated at 14 in FIG. 4, which is adapted to be attached to the housing 4 for generating a magnetic flux and ignition means responsive to the generating means 14. The ignition means includes second coil means such as the secondary transformer core half generally indicated at 16 and its secondary winding 18 electrically connected to the fuel ignition means or spark plug means such as the spark plug generally indicated at 20. The ignition means is adapted to be attached to the triangular piston 2 such as within the hollow triangular piston 2 and is responsive to the generating means 14 when it is magnetically coupled to the generating means 14 through the magnetic flux during a predetermined portion of the rotary movement between the triangular piston 2 and the housing 4 such as at T.D.C. At T.D.C. the combustion chamber 6 is formed, and the ignition means provides an ignition signal such as a 30,000 volt spark within the combustion chamber 6.
Generating means 14 includes the first coil means generally indicated at 22 and which includes the primary transformer core half 24 and its primary winding 26. The first coil means 22 and the second coil means are in proper alignment for magnetic flux coupling during a predetermined portion of rotary movement between the triangular piston 2 and the housing 4 while the combustion chamber 6 is formed. In other words, as long as faces 28 of primary transformer core half 24 of first coil means 22 overlap and portion of faces 32 of secondary transformer core half 16, the first coil means 22 will be in alignment for magnetic flux coupling with the second coil means. The first coil means 22 and the second coil means are thus formed in the housing 4 and in the rotary piston 2 respectively, such that they are in proper alignment for a magnetic flux coupling during the time which the rotary movement between the triangular piston 2 and the housing 4 has caused the combustion chamber 6 to be formed.
As seen in FIG. 4, the generating means 14 includes an oscillator means such as the high frequency gated power oscillator 34. The oscillator 34 is gated and operates at approximately 25 kilohertz and energizes the first coil means 22 to produce the magnetic flux at T.D.C. to magnetically couple the first coil means 22 to the second coil means. Spark plug 20, adapted to be disposed in the combustion chamber 6, is electrically connected to the second coil means for providing the spark within the combustion chamber 6.
A reference means such as pick-up coil 35 provides a reference signal such as a reference or trigger pulse when the triangular piston 2 is in a predetermined position, as is shown in FIG. 5, relative to the housing 4, or, in other words, 30° B.T.D.C. (before top dead center). It is to be understood that FIG. 5 only shows the reference pulse to fire one spark plug. This reference pulse is emitted by the pick-up coil 35, positioned 180° B.T.D.C., whenever magnet 36 mounted on rotary fly wheel 37 rotates past pick-up coil 35 to induce a current in pick-up coil 35. Since the Wankel rotary piston engine has three rotary pistons the fly wheel 37 rotates at three times the speed of triangular piston 2 and, as seen in FIG. 4 which shows the triangular piston 2 in T.D.C. position, magnet 36 has moved 90° from pick-up coil 35.
The generating means 14 also includes control means 40 which is responsive to the trigger pulse. The control means 40 controls the power oscillator 34 which, in turn, energizes the first coil means 22 in response to the trigger pulse. The trigger pulse is amplified and shaped by trigger circuit 41 in order to put the pulse in proper form to control power oscillator 34.
The control means 40 includes programmable delay means, such as programmable delay generator 43, for delaying the energization of the first coil means 22 for a predetermined time period after the occurrence of the reference pulse such as until triangular piston 2 is in T.D.C. position, as seen in FIG. 4. At this point the first coil means 22 will be in proper alignment for magnetic flux coupling with the second coil means.
The control means 40 further includes sensing means such as tachometer circuit 42 for sensing the frequency that triangular piston is positioned 30° B.T.D.C. and for changing the predetermined time period in response to a change in the frequency by programming the delay generator 43 to delay the trigger pulse. The tachometer circuit 42 programs the advance speed characteristic of the ignition system in much the same way that centrifugal and vacuum advance operate in conventional Kettering ignition systems. For example, at low engine r.p.m. tachometer circuit 42 programs the delay generator 43 to delay the trigger pulse a greater period than that at higher r.p.m. The effect is that at low r.p.m. the spark plug 20 is fired at or after T.D.C. (retard) and at higher r.p.m., the spark plug 20 is fired before T.D.C. (advance).
With reference to FIG. 5, it can be seen that the number of degrees of crank rotation before the spark plug 20 fires after the occurrence of the reference pulse, is a function of the rotations per minute of the rotary piston 2 within the housing 4. In general, it can be said that as the rotations per minute of rotary piston 2 increase, the delay generator 43 causes the length of time between the reference pulse and the firing of the spark plug 20 to decrease. This is desirable since the faster the rotating piston 20 moves there is less and less time during which the combustion chamber 6 exists between the rotary piston 2 and the housing 4. Therefore, the fuel-air mixture which enters through intake port 45 must be pre-ignited, before T.D.C., to insure that as much of the fuel-air mixture burns as possible about T.D.C. It is also noted from FIG. 5 that when the rotations per minute for the rotary piston 2 is at a low figure, spark plug 20 ignites the fuel-air mixture slightly after T.D.C. in order to overcome the inertia of the rotary piston 2. Furthermore, the duration of the spark is totally independent of spark timing, and may, in fact, be as long as the burn cycle or as long as combustion chamber 6 is formed at any given r.p.m., the duration of the spark being dependent on the width of the trigger pulse and the geometric configuration of faces 28 and faces 32. In other words, the spark plug 29 is fired as long as trigger pulse gates oscillator 34 at the same time faces 28 and faces 32 are aligned for magnetic flux coupling.
A variation of the positioning of the first coil means 22 and second coil means can be seen in FIG. 4 wherein the second coil means is disposed adjacent the third corner of rotary piston 2 opposite combustion chamber 10. The first coil means 22, while not shown, is in position for magnetic flux coupling with the second coil means in FIG. 5. That is, the first coil means 22 is generally disposed 180° from T.D.C. in the upper cover plate 12 (not shown). The placement of the first coil means 22 and the second coil means is such as to take advantage of the approximate 1:3 ratio in relative motion at 180° vs. 0°. The arc described by the relative motion between the first coil means 22 and second coil means is small compared to the larger arc described by the spark plug 20, as the spark plug 20 travels through T.D.C. position.
Spark plug 20 has a sparking end 44, a connector end 46 and an intermediate portion 48 which electrically connects the sparking end 44 and the connector end 46. The sparking end 44 provides the spark for ignition while the connector end 46 is electrically connected to the secondary winding 18 of the second coil means. The intermediate portion 48 has a first outer surface 50 threaded in a predetermined direction such as left-handed as shown in FIGS. 1, 2 and 3 adjacent the sparking end 44. The intermediate portion 48 also has a second outer surface 52 threaded in a direction opposite the left-handed threaded direction of the first outer surface or, in other words, in a right-handed direction, adjacent to the connector end 46 for screwing spark plug 20 into triangular piston 2.
The first and second outer surfaces 50 and 52 are formed in this way so that a removal tool 54 which is threaded in the same direction as the first outer surface 50 within its removing head 56 so that the spark plug 20 can be securedly screwed within the removing head 56 before the spark plug 2 is unscrewed by tool 54 which extends through exhaust port 58. Therefore, after the first outer surface 50 is securedly screwed within the removing head 56, the continued unscrewing motion of the tool 54 unscrews the second outer surface 52 from triangular piston 2 to remove spark plug 20 from the rotary combustion engine. It is easy to see how the reverse procedure can be used to position a new spark plug within the rotary combustion engine.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A method and apparatus for igniting the air-fuel mixture within a rotary combustion engine. A primary transformer core half and its primary winding are positioned in the upper cover plate of a Wankel rotary engine. Three spark plugs are electrically connected to their own secondary transformer core halves and secondary windings in a hollow rotor piston. The transformer core halves are arranged so that whenever the rotor is in correct position for ignition to occur (around T.D.C.) the primary transformer core half and one secondary transformer core half are in proper alignment for magnetic flux coupling between the two transformer core halves. When so coupled, high voltage necessary for spark plug firing is induced in the secondary winding whenever the primary winding is excited with an alternating current generated by a gated power oscillator. The high voltage induced in the secondary winding is permitted to form a spark across the spark plug gap as long as the primary winding is so excited and the transformer core halves are magnetically coupled. | 5 |
This is a divisional of U.S. Ser. No. 080,332 entitled "One-Step Polymerization of Polyanhydrides" filed July 31, 1987 by Abraham J. Domb, Robert S. Langer, Eyal Ron, Steven Giannos, Rohit Kothari and Edith Mathiowitz.
BACKGROUND OF THE INVENTION
This invention is generally in the area of polyanhydride synthesis and is in particular a method and reagents for polymerizing extremely pure polyanhydrides using solution polymerization.
Polyanhydrides are particularly useful for biomedical applications, especially in drug delivery devices, since they are biodegradable, undergo surface erosion and have erosion rates that can be changed several thousandfold by simple changes in the choice of the monomers. However, the methods for preparing highly pure polyanhydrides frequently require a number of processing steps, involve compounds which can leave toxic residues in the polyanhydride to be used in making the drug delivery device, and yield low molecular weight polymers due to hydrolysis of the anhydride bonds during purification.
At the present time, polyanhydrides are most commonly prepared by melt polycondensation. In this method, dicarboxylic acid monomers (the diacids) are first converted to the mixed anhydride with acetic acid and then polymerized under vacuum at elevated temperatures to yield the polyhydrides. In the preferred method, the temperature is limited and a dry ice trap is used to maximize the molecular weight of the final product. Purer polymers are obtained using highly purified diacids and prepolymers. Unfortunately, due to the high temperatures, this method is limited to heat-stable monomers.
A second method for polymerizing polyanhydrides is solution polymerization. Solution polymerization appears to be the method of choice for heat sensitive monomers. A variety of solution polymerizations of polyanhydrides at ambient temperatures have been reported, fpr example, by Yoda, et al., Bull. Chem. Soc. Japan 32, 1120 (1959) and Subramanyam, et al. Macromol. Sci. Chem. 822 (1), 23 (1985). Since the formation of an anhydride is essentially a dehydrative coupling of two carboxyl groups, it can be effected at room temperature by a dehydrochlorination between a diacid and a dicarboxylic acid in the presence of a base to yield the polyanhydride and the base.HCl, a reaction known as a Schotten-Bauman condensation. Polymerization at low temperatures in solution is also possible using a powerful dehydrative coupling reagent.
As described by Leong, et al., in Macromolecules 20(4), 705 (1987), this method also has a number of limitations. Leong et al examined melt-polycondensation, dehydrochlorination, and dehydrative coupling, focusing on the use of organophosphorus catalysts in the latter. He noted a number of specific disadvantages to the methods. The molecular weight of the polymer which is produced is frequently low, for example, polyterephthalic anhydride synthesized by dehydrative coupling has a molecular weight of only about 2100. Further, there are problems with the isolation and hydrolysis of the final product. Partial hydrolysis of the diacid chloride in the presence of pyridine as an acid acceptor is one cause of low molecular weight polymers. The dehydration coupling agents may also detrimentally affect polyanhydride formation, as reported for N,N-Bis(2-oxo-3-oxazolidinylphosphinic chloride, phenyl N-phenylphosphoramidochloridate, dicyclohexylcarbodiimide, and chlorosulfonyl isocyanate, which yielded impure polymers of low molecular weight. Further, the final products contain polymerization byproducts such as amine-hydrochloride and dehydrative agent residues which have to be removed by washing with protic solvents. The washing step may cause hydrolysis of the polymer.
It is therefore an object of the present invention to provide a method for polymerization of heat sensitive monomers including dipeptides and therapeutically active diacids.
It is another object of the present invention to provide coupling agents for use in solution polymerizations of polyanhydrides.
It is a further object of the present invention to provide a method using the coupling agents to provide a single-step polymerization method for polyanhydrides, not requiring additional steps for the removal of byproducts.
SUMMARY OF THE INVENTION
A method for synthesizing polyanhydrides in solution using coupling agents and a removable acid acceptor to effect a one-step polymerization of dicarboxylic acids. As used in the method, these coupling agents include phosgene, diphosgene, and acid chlorides. Insoluble acid acceptors include insoluble polyamines and crosslinked polyamines such as polyethyleneimine and polyvinylpyridine and inorganic bases such as K 2 CO 3 , Na 2 CO 3 , NaHCO 3 , and CaCO 3 . The only byproduct formed is a removable hydrochloric acid-acid acceptor.
Examples are provided of the polymerization of highly pure polyanhydrides using phosgene, diphosgene or an acid chloride as the coupling agent, in combination with either an insoluble acid acceptor or a soluble acid acceptor in a solvent wherein the polymerization byproduct or polymer is insoluble.
A particularly important application of these polyanhydrides is in the formation of drug delivery devices containing bioactive compounds. The method is also useful in the polymerization of dicarboxylic acids including heat labile dipeptides of glutamic or aspartic acid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is the reaction of dicarboxylic acids, a coupling agent, phosgene, and an insoluble acid acceptor, crosslinked polyvinylpyridine;
FIG. 1B is the reaction of dicarboxylic acids, a coupling agent, phosgene, and a removable acid acceptor, triethyleneamine, where either the polyanhydride product or the hydrochloric acid-acid acceptor salt is insoluble in the solvent, depending on the selection of the solvent;
FIG. 1C is the proposed mechanism for the polymerization of polyanhydrides using diphosgene as the coupling agent in the presence of an acid acceptor.
FIG. 2 is the formation of polyanhydrides from dipeptides containing glutamic or aspartic acid which are polymerized using a coupling agent and a removable acid acceptor.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a one-step solution polymerization of dicarboxylic acids using a coupling agent and a removable acid acceptor to yield extremely pure polyanhydrides. There are essentially two embodiments of the invention: the first, using an insoluble acid acceptor, and the second, using a solvent system wherein the solubilities of the polyanhydride and the acid acceptor by-product are so different that one is easily separated from the other.
Coupling agents include dehydrative agents such as phosgene and diphosgene and acid chlorides such as sebacoyl chloride. Phosgene and diphosgene are preferred over the acid chlorides since they are not incorporated into the resulting polymer. The advantage is that the coupling agent can be used to form a variety of polymers, not just a polymer containing the acid residue from the acid chloride.
In the preferred embodiment, the acid acceptor is insoluble in the reaction solution. Examples of useful insoluble acid acceptors include insoluble polyamines and crosslinked polyamines such as polyethyleneimine and poly(4-vinylpyridine) and inorganic bases such as K 2 CO 3 , Na 2 CO 3 , NaHCO 3 , and CaCO 3 . The latter react in solution with the acid to yield the salt, which is insoluble in organic solution, and CO 2 .
The reactions of the diacids with the coupling agent in the presence of a removable acid acceptor, where the acid acceptor is insoluble (e.g., a crosslinked polyamine or inorganic base) is shown in FIG. 1A. The reaction using a solvent which dissolves either the polyanhydride product or the hydrochloric acid-acid acceptor salt is shown in FIG. 1B. The suggested polymerization mechanism using diphosgene as the coupling agent is shown in FIG. 1C.
Using either embodiment, where the polyanhydride in soluble and the corresponding acid acceptor-acid is insoluble or where the polymer is insoluble and the corresponding acid acceptor-acid is soluble, allows one to purify the product using a single filtration step.
Dichloroformate (phosgene) is a common reagent in organic synthesis and available commercially from suppliers such as Morton Thiokol. Trichloromethyl chloroformate (diphosgene) is a considerably less toxic phosgene dimer which is also commercially available. Other advantages include the characteristic that it is a liquid with low vapor pressure at room temperature, not requiring elaborate traps, and can be weighed directly It has been used in a number of organic syntheses. For example, alcohols react with diphosgene to yield the corresponding trichloromethyl carbonate or, in the presence of pyridine, the chloroformate. Further reaction of the trichloromethyl carbonate with alcohol or amine produces the expected carbonate carbamate or carbonate. Isocyanates, ureas and isocyanides are prepared with either diphosgene or phosgene N-carboxy-alpha-amino acid anhydrides can be prepared from alpha amino acids using diphosgene. Diphosgene reacts with amino acids to form isocyanato acid chlorides without the need for additional reagents such as HCl, as are required in the analagous reaction with phosgene. Diphosgene has also been used to prepare phosphine dichlorides.
Despite the variety of methods these reagents have utility with, the only polyanhydrides synthesized using phosgene were low molecular weight sebacic acid oligomers, not useful for medical applications In addition to the fact that high molecular weight polyanhydrides have not been produced using phosgene, it was not apparent until actually tested that diphosgene could be used as a coupling agent since all of the reported reactions occurred at much higher temperatures (approximately 60° C.), in contrast to the lower temperatures desired in the present method to prevent loss of bioactivity of heat sensitive compounds. Diphosgene is not as active as phosgene and there was concern that the reaction would not continue on to form the second molecule, shown in FIG. 1C. The simpler reaction with phosgene is shown in FIG. 1A and FIG. 1B.
The following nonlimiting examples further describe the present invention.
Compounds that were used are: phosgene gas (Matheson, MA), diphosgene (Martin Thiokol, MA), crosslinked poly(4-vinylpyridine) (PVP), sebacic acid (SA), sebacoyl chloride, adipic acid (AA), dodecanedioic acid (DD), terephthalic acid (TPA), 1,4 phenylenedipropionic acid (PDP), triethylamine (TEA), pyridine, tetramethylethylenediamine (TMEDA) (all from Aldrich Fine Chemicals, Milwaukee, Wis.). The amine bases were dried over KOH and freshly distilled prior to use. The following solvents were used: dioxane, toluene, N,N'dimethylformamide (DMF), dimethylsulfoxide (DMSO), and toluene (gold label, Aldrich, Fine Chemical, Milwaukee, Wis.). Chloroform and hexanes (petroleum ether) were dried over activated alumina (ICN Biomedical, Eschwege, West Germany) and distilled before use. All experiments were performed under anhydrous condition.
1,3-bis(p-carboxyphenoxy)propane was synthesized according to Conix, A., J. Polymer Sci 29, 343 (1958), followed by extraction with ether prior to use. Phosgene solution was prepared by bubbling phosgene gas into toluene and adjusting the concentration to 1.0M by dilution. The concentration of this solution was determined by titration with a standard solution of 0.1N NaOH.
Infrared spectroscopy was performed on a Perkin-Elmer 1430 spectrophotometer (Perkin-Elmer, MA). Polymeric samples were film cast onto NaCl plates from a solution of the polymer in chloroform. Prepolymer samples were either pressed into KBr pellets or dispersed in nujol onto NaCl plates. The melting points of prepolymers were determined on a Fisher Johns melting point apparatus. The molecular weight of the polymers was estimated on a Perkin-Elmer GPC system (Perkin-Elmer, MA) consisting of the Series 10 pump and the 3600 Data Station with the LKB 214 - rapid spectral detector at 254 nm wavelength. Samples were eluted in chloroform through two PL Gel columns (Polymer Laboratories; 100 A and 1000 A pore sizes) in series at a flow rate of 1.5 ml/min. Molecular weights of polymers were determined relative to polystyrene standards (Polysciences, PA., molecular weight ranges, 500 to 1,500,000) using CHROM 2 and GPC 4 computer programs (Perkin-Elmer, MA). Elemental analysis were performed by Galbraith Laboratories (Knoxville, Tenn.). H NMR spectra were obtained on a Varian 250 MHz spectrophotometer using chloroform-d 1 as a solvent and tetramethylsilane (TMS) as an internal reference.
EXAMPLE 1
Solution Polymerization of Sebacic Acid Using Phosgene or Diphosgene as the Coupling Agent
A solution of 1 eq. diacid and 2.5 to 3 eq. base in an organic solvent was prepared. Either PVP or K 2 CO 3 was added as an insoluble acid acceptor. The resulting insoluble solid, PVP.HCl or KCl, respectively, was removed by filtration. The filtrate was added dropwise to a sufficient volume of petroleum ether to precipitate the polymer out of solution. The precipitated polymer was then isolated by filtration and dried in a vacuum oven for 24 hours at 40° C.
The results of the polymerization of sebacic acid, as a model, using either phosgene or diphosgene as coupling agents with various acid acceptors are shown in Table I. The poly(sebacic anhydride) has a weight average molecular weight up to 16,300. The results are similar for the (SA) using either phosgene or diphosgene. All of the p(SA) formed has the same melting point and IR absorbance characteristics of anhydride bonds. Insoluble polyamines, poly(4-vinylpyridine) (PVP), as well as soluble amines, TEA, pyridine, and TMEDA were used. The polymers formed with these reagents have similar molecular weights, indicating a similar role for the different amine bases as acid acceptors. Using a heterogeneous acid acceptor, PVP, does not affect the polymerization, as shown in Table I.
A non-amine heterogeneous base, K 2 CO 3 , yields a lower molecular weight polymer. This may be due to the formation of a soluble intermediate complex of acid-amine which increases the interaction with the coupling agent under homogeneous conditions. Although the PVP is insoluble in the reaction medium, it swells and forms a similar acid-PVP complex. K 2 CO 3 , however, forms a heterogeneous mixture with the acid and thus reacts slower with the coupling agents to form the polymer.
TABLE I__________________________________________________________________________Polymerization of Sebacic Acid Using Phosgene and Diphosgene as CouplingAgents..sup.aCoupling Acid Molecular Weight IR MPAgent Acceptor Mw Mn (cm.sup.-1) (°C.)__________________________________________________________________________1. Phosgene Sol. TEA.sup.b 14800 6250 1800 1740 75-772. Phosgene Sol. pyridine.sup.b 13700 5950 1800 1735 76-783. Phosgene Sol. TMEDA.sup.b 16300 6600 1805 1735 76-784. Phosgene Sol. PVP 13950 5350 1805 1735 80-815. Phosgene Gas Pyridine.sup.b 14100 6820 1805 1735 75-776. Phosgene Gas PVP 13200 6150 1800 1735 79-807. Diphosgene TEA.sup.b 12250 5780 1805 1735 76-788. Diphosgene Pyridine.sup.b 14300 6100 1805 1740 75-789. Diphosgene PVP 10900 5300 1800 1735 79-8010. Phosgene Sol. K.sub.2 CO.sub.3 6200 2700 1800 1740 76-7811. Diphosgene K.sub.2 CO.sub.3 6900 3500 1800 1740 77-78__________________________________________________________________________ .sup.a Polymerization in chloroform, at 25° C., for 3 hours. .sup.b Molecular weight and IR spectra were taken of the crude polymer. The IR spectra contained amineHCl absorbance peaks at 2900-2600 cm.sup.-1 GPC output contained an isolated peak attributed to the amineHCl salt. Mw was determined for the polymer peak only. The melting point was determine for the pure polymer.
EXAMPLE 2
Comparison of Solution Polymerization Using Soluble and Insoluble amines
A method similar to that of Example 1 was used to polymerize the dicarboxylic acids. However, when either triethylamine (TEA) or pyridine was used as the acid acceptor, the polymerization reaction was quenched in petroleum ether and the polyanhydride, not the acid acceptor, precipitated from solution. The precipitated polymer was redissolved in chloroform and washed rapidly with a cold solution of water at pH 6. The chloroform solution was dried over MgSO 4 and the polymer re-precipitated by the dropwise addition of petroleum ether.
Several solvents, toluene, DMF, DMSO, and dioxane, were tested using TEA as the acid acceptor. The precipitated solids were removed by filtration. The filtrate was evaporated to dryness in vacuo at 25° C. The resulting solid was dissolved in chloroform, the polymer precipitated out by slow addition into petroleum ether, the precipitated polymer isolated by filtration and washed with diethyl ether to remove any traces of phosgene or diphosgene. The composition, yield and melting points of the products formed with the various monomers and solvent mixtures are shown in Table II.
TABLE II__________________________________________________________________________Solution Polymerization of Diacids in Various Solvents. Analysis of Yield.sup.c mp.sup.bMonomer.sup.f Solvent Solution.sup.a Solid.sup.b (%) (°C.)__________________________________________________________________________1. SA Chloroform.sup.e pSA/TEA.HCl -- d2. Toluene.sup.e pSA pSA + TEA.HCl 20 78-793. N,N'-Dimethyl- pSA TEA.HCl 100 80-81 formamide4. Dimethylsulfoxide -- -- --5. Pyridine pSA/TEA.HCl -- d6. Dioxane pSA/TEA.HCl TEA.HCl d --7. CPP Chloroform TEA.HCl pCPP 100 2658. TPA Chloroform TEA.HCl pTPA 100 >300__________________________________________________________________________ .sup.a The solvent was evaporated and the residue was analyzed. .sup.b Analysis of the precipitated solid. .sup.c Pure polymer. .sup.d Yield cannot be determined due to the presence of TEA.HCl. .sup.e Polymerized using either diphosgene or sebacoyl chloride as coupling agents. .sup.f SA is sebacic acid, CPP is 1,3bis(p-carboxyphenoxy)propane, TPA is Terephthalic acid.
The use of a solvent system wherein the polymer is in one reaction phase (either as a precipitate or in solution), and the acid acceptor-hydrochloride acid complex is in a second phase, complementary to the polymer, is an alternative to the use of an insoluble acid acceptor. Table II describes polymerization of SA in several solvents with TEA as an acid acceptor, Polyanhydrides were obtained in good yield in toluene and in DMF. TEA in toluene or DMF is complementary to the use of PvP in chloroform. In both approaches, the p(SA) is soluble in the reaction media. The insoluble hydrochloric acid-acid acceptor complex, whether an insoluble amine, PVP.HCl, or TEA.HCl salt, is removed by filtration, leaving a polymer of greater than 99.7% purity with no need for further purification.
EXAMPLE 3
Solution Polymerization comparing an Acid Chloride as the Coupling Agent with Phosgene and Diphosgene as the Coupling Agent
Solution polymerization was performed as before, using either phosgene, diphosgene or an acid chloride as the coupling agent and an acid acceptor Reactions between sebacic acid (1 eq.) and sebacoyl chloride (1 eq.) were performed in chloroform and toluene in the presence of either PVP (insoluble) or TEA (soluble).
In a typical polymerization, 0.5 g (0.5 eq.) diphosgene was added dropwise into a stirring mixture of 2.02 g (1.0 eq.) sebacic acid and 3 g (2.5 eq.) poly(4-vinylpyridine) in 20 ml chloroform. After 3 hours at 25° C., the insoluble PVP.HCl was removed by filtration. The filtrate was quenched in 100 ml petroleum ether. The precipitated polymer was isolated by filtration, washed with anhydrous diethyl ether and dried for 24 hours at 40° C. in a vacuum oven.
A comparison of the purity of p(SA) synthesized using soluble and insoluble amines, TEA and PVP, respectively, with diphosgene or sebacoyl chloride as coupling agents, as shown in Table III, demonstrates that when soluble base, TEA, was used as an acid acceptor, the polymer contains a significant amount of TEA.HCl salt. The ratio of the salt to the polymer was 4:1 and 2:1 for the coupling agents diphosgene and sebacoyl chloride, respectively. When PVP, an insoluble acid acceptor, was used p(SA) of greater than 99.7% purity was obtained for both coupling agents.
PVP has another advantage besides high purity of the end product. It can be regenerated by neutralization with a sodium bicarbonate solution. Recycled PVP has a similar activity to that of the original PVP as an acid acceptor and forms a polyanhydride identical to the original polyanhydrides.
TABLE III__________________________________________________________________________Presence of Amine hydrochloride in Solution Polymerized pSA as a Functionofthe Acid Acceptor.Polymerization Yield TEA:PSA mp ElementalMethod.sup.a (%).sup.e IR.sup.b 'H NMR.sup.c /Elemental GPC.sup.d (°C.) (% N, % Cl)__________________________________________________________________________ A f + 4.3:1/3.5:1 + 70-185.sup.g 7.21, 19.63 B 62 - -- - 81-82 0.18, <0.10 C f + 1.9:1/2.4:1 + 68-185.sup.g 5.26, 13.14 D 65 - -- - 81-83 0.11, 0.027 E 60 - -- - 81-83 0.11, 0.015__________________________________________________________________________ .sup.a A is TEA/diphosgene; B is PVP/diphosgene; C is TEA/sebacoyl chloride; D is PVP/sebacoyl chloride, E is regenerated PVP/diphosgene. .sup.b Typical absorbance of TEAHCL follows (film cast); 2740 (w), 2600 (s, broad), 2530 (w, sharp), 2500 (s, sharp) cm.sup.-1. .sup.c 'H NMR of TEAHCl (CDCl.sub.3): 3.11 (q, 2, J = 7.3 Hz), 1.42 (t, 3 J = 7.3 Hz); 'HNMR of PSA (CDCl.sub.3): 2.45 (t, 4, J = 7.3 Hz), 1.66 (br t, 4, J = 7.3 Hz), 1.33 (br s, 8). .sup.d Sharp peak at Rt = 12.3 min. .sup.e Pure poly(sebacic anhydride) .sup.f Yield cannot be determined due to the presence of TEA.HCl. .sup.g m.p. of TEA.HCl is 261° C.
Attempted purification of polymers synthesized with TEA as the acid acceptor using rapid water extraction results in a decrease in molecular weight and hydrolysis, as evidenced by GPC and IR spectra. The IR spectra of the polymer before and after purification reveals the disappearance of the amine salt (2740-2500 cm -1 ). The IR spectra of polyanhydrides prepared with PVP as an acid acceptor reveals pure unhydrolyzed polymer.
EXAMPLE 4
Solution Polymerization of an Insoluble Polyanhydride with a soluble Acid Acceptor
Insoluble polyanhydrides, poly(1,3-bis(p-carboxyphenoxy)propane) and poly(terephthalic anhydride), were polymerized as above but using only soluble amines such as TEA or pyridine as the acid acceptors. The polymers precipitated during the reaction and were isolated by filtration. The results are shown in Table IV.
TABLE IV__________________________________________________________________________Solution Polymenzation of Insoluble Polymers Using Phosgene andDiphosgeneas Coupling Agents. Coupling Acid Molecular Weight IR MPAcid.sup.c Agent.sup.b Acceptor.sup.c Mw Mn (cm.sup.-1) (°C.)__________________________________________________________________________1. Adipic acid P TEA 7600 3350 1820 1735 70-732. " P PVP 8300 3600 1810 1740 70-743. " D TEA 6900 3200 1820 1740 69-734. Dodecanoic acid P TEA 14100 6500 1810 1740 92-955. " P PVP 12600 5900 1810 1740 90-956. " D PVP 13750 4800 1805 1740 92-947. Terephthalic acid.sup.a P TEA -- -- 1780 1735 >3008. " P Pyridine -- -- 1780 1735 >3009. " D TEA -- -- 1780 1730 >30010. PDP P TEA 8400 3650 1800 1735 98-101 " P PVP 7950 2100 1805 1740 100-102 " D TEA 9200 2350 1805 1735 98-102 CPP.sup.a P TEA -- -- 1780 1730 262-265 " P TEA -- -- 1780 1735 265-266 " D TEA -- -- 1780 1735 264-266 PHE--GLU D TEA 7500 2800 1800 1740 -- " D PVP 4680 2400 1800 1740 --__________________________________________________________________________ .sup.a P is phosgene solution, D is diphosgene, .sup.b Polymers are insoluble. .sup.c PDP is phenylenedipropionic acid, CPP is 1,3bis(p-carboxyphenoxy)propane, GLU--PHE is Ncarbobenzoxy-L-phenylalanyl-L-glutamic acid.
Isolation of the polymer using an insoluble acid acceptor is preferred over the two phase solvent separation method since high boiling point solvents such as DMF or toluene do not have to be removed at ambient temperature to avoid decomposition of the formed polyanhydride. In contrast to the traditional use of dehydration agents, the use of insoluble acid acceptors such as poly(4-vinylpyridine) or inorganic bases yield highly pure polymers. The use of various solvent systems is complementary to the use of the insoluble bases in chloroform. The choice of the right solvent system can be used to precipitate exclusively either the polymer or the amine-acid salt, using filtration to yield pure polymers. These methods are advantageous for the polymerization of heat sensitive dicarboxylic acids such as therapeutically active diacids and polyanhydrides of dipeptides.
EXAMPLE 5
Solution Polymerization of Polyanhydrides from Dipeptides of Aspartic or Glutamic Acid
Polyanhydrides formed of dipeptides of an amino acid and either glutamic acid or aspartic acid can be prepared using the present method. For example, as shown in FIG. 2, phenylalanine-Z-glutamic acid or phenylalanine-Z-aspartic acid can be prepared. Z represents a protecting group.
The starting material, N-carbobenzoxy-L-phenylalanyl-L-glutamic acid, for the synthesis of poly(N-carbobenzoxy-DL-phenylalanine glutamic) anhydride, was synthesized according to The Practice of Peptide Synthesis, Bodanszky, et al., Editors (Springer-Berlag, New York 1984). One gram monomer (2.5 mmol) was dissolved in a solution of 0.51 g TEA (5 mmol) in 10 ml chloroform, followed by the slow addition of 1.25 mmol diphosgene over 15 minutes. The resulting polyanhydride was isolated and purified. The analysis is shown as part of in Table IV.
The present invention has been described with respect to specific embodiments. Variations and modifications of the method for synthesizing polyanhydrides using a coupling agent and an insoluble acid acceptor or two phase solvent separation will be obvious to those skilled in the arts in the foregoing detailed description. Such modifications and variations are intended to come within the scope of the appended claims. | A method for synthetizing polyanhydrides in solution using coupling agents and a removable acid acceptor to effect a one-step polymerization of dicarboxylic acids. As used in the method, these coupling agents include phosgene, diphosgene, and acid chlorides. Insoluble acid acceptors include insoluble polyamines and crosslinked polyamines such as polyethyleneimine and polyvinylpyridine and inorganic bases such as K 2 CO 3 , Na 2 CO 3 , NaHCO 3 , and CaCO 3 . The only byproduct formed is a removable hydrochloric acid-acid acceptor.
Examples are provided of the polymerization of highly pure polyanhydrides using phosgene, diphosgene or an acid chloride as the coupling agent, in combination with either an insoluble acid acceptor or a soluble acid acceptor in a solvent wherein the polymerizaiton byproduct or polymer is insoluble.
A particularly important application of these polyanhydrides is in the formation of drug delivery devices containing bioactive compounds. The method is also useful in the polymerization of dicarboxylic acids including heat liable dipeptides of glutamic or aspartic acid. | 2 |
This is a division, of application Ser. No. 576,687, filed May 12, 1975 now U.S. Pat. No. 4,043,140.
BACKGROUND OF THE INVENTION
This invention relates to a method and machine for cleaning sandy beaches which have been contaminated by an oil spill; and more particularly, to the use of liquid nitrogen in such a method and machine.
Ecological damage to beaches from oil spills presents a serious problem to people and water fowl, and it is desirable to restore the beaches to their pre-spill condition as promptly and as efficiently as possible. Heretofore much concentration and effort have been directed toward the solution of handling an oil spill on a water surface, but unfortunately, little effort has been directed toward the handling of the contaminated shoreline.
In the past if the penetration of the oil into the sand was comparatively shallow and the oil was not too fluid the contaminated area has been manually raked into windrows, which were subsequently manually shoveled into a front-end loader or dump truck. If the penetration was comparatively deep, mechanical scrapers and bulldozers have been required to remove the contaminated area. Furthermore, if oil was still washing ashore, a series of deep pits or trenches were dug along the shoreline to catch incoming oil. The oil in the trenches has then been removed by a vacuum tank truck. All of these techniques have been expensive, time-consuming and inefficient.
Another technique for oil removal has been to burn off the oil, but this requires rigid control of the oil fire and the smoke pollutes the atmosphere. Still another prior art method included pouring dispersants and emulsifiers onto the oil spill, but unfortunately, this causes penetration of the oil dispersant/emulsifier mixture into the sand to a depth of at least three times as great as the penetration depth of the untreated oil.
It is, therefore, an object of this invention to provide an efficient and ecologically unharmful method and associated equipment for restoring sandy beaches which have been contaminated by an oil spill.
This and other objects of this invention will become apparent from the following description and appended claims.
SUMMARY OF THE INVENTION
There is provided by this invention a method and machine for efficiently and effectively removing the oil contaminated area from a sandy beach in an ecologically desirable manner and transporting the contaminated materials to a disposal or treatment site. The method and machines eliminate the problems heretofore encountered in cleaning the beaches.
The method of this invention includes spraying liquid nitrogen onto the contaminated area so as to solidify the oil and sand into a mixture which can be easily separated from the clean underlying sand. A cryogenic beach-cleaning apparatus or vehicle is provided which includes a spray-head positioned forwardly of the vehicle for spraying the contaminated area and shovel means for separating the solidified mixture from the underlying sand. Conveyors transport the separated mixture from the shovel means and deliver it to trailers or trucks which are used to transport the mixture to a treatment or disposal site.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cryogenic beach-cleaning vehicle made in accordance with the present invention;
FIG. 2 is a side view of the beach cleaner with a portion of a trailer hitched to the rear end of the cleaner; and
FIG. 3 is a schematic diagram of a fluid circuit for the cryogenic beach cleaner for handling a liquid cryogen.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is shown a cryogenic beach-cleaning vehicle 10 generally, shown moving toward an area 12 of a sandy beach which has been contaminated by an oil spill. The beach cleaner is a tracked vehicle which includes a body portion 14 generally, that is carried on a pair of endless tracks 16 and 18. The body includes a cab positioned at the forward end of the vehicle and a liquid nitrogen reservoir 22 on the underside of the body and beneath the cab. A shovel or scoop 24 is mounted on the body at the front end and extends forwardly of the tracks 16 and 18. The leading edges of the scoop define a wide-mouthed portion 24a for directing contaminated sand rearwardly toward the narrow or throat portion 24b adjacent the body 14.
A discharge chute 26 is mounted on the body at the rearward end and extends in a generally rearward and upward direction therefrom. The terminus for the discharge chute is rearward of the back edge of the tracks 16 and 18.
A conveyor 28 generally, extends from the scoop through the body and to the discharge chute for delivering the contaminated sand from the scoop to the discharge end. The conveyor includes a belt 30 which is trained about: a forward roller 32 that is mounted laterally across the scoop near the mouth; a first intermediate roller 34, that is mounted to the body of the vehicle adjacent the discharge end of the scoop; a second intermediate roller 36, which is mounted on the body adjacent the inlet end of the discharge chute 26; and a discharge end roller 38 at the discharge end of the discharge chute 26. A trailer 40 is hitched to the rear end of a vehicle and receives contaminated material discharged from the chute 26.
The liquid nitrogen sprayer 42 generally, is connected to the liquid nitrogen reservoir 22. The sprayer is a box-like framework of hollow piping which includes the conduit sections 44 and 46, each of which connects at its inner end to the reservoir 22 and extends laterally outwardly from the reservoir through one of the endless tracks and terminates outwardly of the endless track. Side conduit sections 48 and 50 are each connected at one end to a lateral conduit section and extend forwardly therefrom to a position forward of the scoop 24. The spray-head 52 is connected at each end to one of the side conduit members 48 and 50 and includes a plurality of spray apertures, such as 54, for spraying liquid nitrogen in a forward direction. A boom 56 is connected at one end to the spray-head 58 and at the other end to the body 14 for supporting the sprayer and for controllably raising and lowering the sprayer.
The liquid nitrogen system includes the reservoir 22, which is connected through a line 58 to a pump 60. The discharge from the pump 60 passes through line 62 to a control valve 64 and then through a line 66 to the sprayer 42.
Liquid nitrogen is particularly advantageous as the liquid cryogen since it is available in commercial quantities, and after spraying it merely evaporates into the atmosphere with no ecological damage. However, it will be appreciated that other gases which are liquid at less than -100 degrees C. can be used.
In operation, as the vehicle moves forwardly into the contaminated area 12, the liquid nitrogen is sprayed onto that area. This spray causes the oil and sand mixture in the contaminated area to solidify, and the scoop is then able to lift and readily separate the solidified mixture from the uncontaminated dry sand which will not solidify. The solidified mixture is then directed by the scoop onto the conveyor 28, which moves the contaminated material up through the throat of the scoop 24b, through the body along the conveyor and out the discharge end 26 into a trailer 40.
The contaminated material collected in the trailer can then be taken to a separation point where the oil can be separated from the sand and the oil returned to a refinery for further processing and the sand returned to the beach for restoration of the beach.
Controls for the vehicle, the raising and lowering of the spray-head, the conveyor, and the liquid nitrogen pump and valve are all provided for the operator within the cab 20. Standard control mechanisms and linkages are known to those in the art.
It will be appreciated that numerous changes and modifications can be made to this apparatus without departing from the spirit and scope of this invention. | A method and machine are disclosed herein for cleaning and restoring sand beaches which have become contaminated by oil spills. The machine travels on the beach and sprays liquid nitrogen onto the contaminated area, thereby solidifying the oil and sand mixture so that the mixture can be separated from the underlying uncontaminated sand and be efficiently removed from the beach and transported to a remote site for disposal or further treatment. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a transparent thermoplastic blend of polycarbonate (PC) and a copolymer of methyl methacrylate (MMA) and naphthyl methacrylate or a substituted naphthyl methacrylate. This copolymer has excellent miscibility with polycarbonate resin, even at elevated temperature, producing transparent polycarbonate blends. The blend provides an improved scratch resistance of polycarbonate while maintaining its excellent optical properties.
BACKGROUND OF THE INVENTION
[0002] Polycarbonate (PC) resin has good mechanical and thermal properties such as excellent resistance to impact, stiffness, transparency and dimensional stability at relatively high temperatures. These properties make polycarbonate useful in a variety of applications including glazing containers, glass lenses and medical devices.
[0003] One notable drawback of polycarbonate is its susceptibility to scratching. Poly(methyl methacrylate) (PMMA) has excellent scratch resistance and clarity, but it suffers from less dimensional stability, low impact strength and relatively poor thermal stability when compared to polycarbonate. Blends of PC and PMMA can produce the best properties of both materials. Although PMMA is considered to be compatible with polycarbonate, it normally is miscible only at low temperatures, and then separating at elevated temperatures. This results in a compounded article that is heterogeneous in nature and a final molded product that is opaque.
[0004] It is desirable to have a miscible and transparent blend of polycarbonate and polymethyl methacrylate. Transparent, single phase blends of PC and PMMA over a wide range of ratios are described in U.S. Pat. No. 4,743,654 and U.S. Pat. No. 4,745,029. The blend is formed by a solvent blending process, and the blend remains miscible at low temperatures.
[0005] U.S. Pat. No. 4,906,696 describes copolymers of methylmethacrylate and a carbocyclo methacrylate, such as phenyl methacrylate or cyclohexyl methacrylate. The polycarbonate/copolymer blends are described as clear and colorless at the test conditions used. However, at higher temperatures typically employed in industrial processing applications (280° C. and above) the copolymers separate from the polycarbonate forming a heterogeneous and opaque composition, especially in blends having higher levels of the copolymer. Thus, such copolymers are not particularly useful and cannot provide the above-mentioned benefits. While the '696 application lists naphthyl methacrylate as a usable monomer for the copolymer, the surprising advantage of copolymers formed from this monomer in producing a clear blend at high processing temperatures was not recognized.
[0006] Surprisingly it has now been found that a stable, homogeneous, transparent blend of polycarbonate and a methyl methacrylate/naphthyl methacrylate can be produced which does not phase separate at 280° C.
SUMMARY OF THE INVENTION
[0007] The invention relates to a thermoplastic homogeneous blend comprising:
a) 10 to 99.5 weight percent of polycarbonate; and b) 0.5 to 90 weight percent of a copolymer comprising:
1) 5-98 weight percent of methyl methacrylate units; and
2) 2 to 95 weight percent of naphtyl (meth)acrylate units and/or substituted naphtyl (meth)acrylate units,
wherein said composition does not phase separate at 280° C.
BRIEF SUMMARY OF THE DRAWINGS
[0012] FIG. 1 . Shows the appearance of compound bars of Example 3 made from polycarbonate 1 (PC-1, melt flow ˜11, GE Lexan® 141) and poly(methyl methacrylate) or its copolymers
[0013] FIG. 2 . Shows the appearance of polymer blend made from PC-1 (melt flow ˜11) and poly(2-napthyl methacrylate) (Example 6)
[0014] FIG. 3 . Compares the appearance of compound bars made from PC-1 (melt flow ˜11) and copolymers of methyl methacrylate and phenyl methacrylate or 2-Naphthyl methacrylate.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention relates to a transparent thermoplastic blend of polycarbonate (PC) and a copolymer of methyl methacrylate (MMA) and naphthyl methacrylate (NpMA).
[0016] The term “polycarbonate (PC)” denotes a polyester of carbonic acid, that is to say a polymer obtained by the reaction of at least one carbonic acid derivative with at least one aromatic or aliphatic diol. The preferred aromatic diol is bisphenol A, which reacts with phosgene or else, by transesterification, with ethyl carbonate. It can be homopolycarbonate or copolycarbonate based on a bisphenol of formula HO-Z-OH for which Z denotes a divalent organic radical which has from 6 to 30 carbon atoms and which comprises one or more aromatic group(s). As examples, the diphenol can be:
dihydroxybiphenyls, bis(hydroxyphenyl)alkanes, bis(hydroxyphenyl)cycloalkanes, indanebisphenols, bis(hydroxyphenyl)ethers, bis(hydroxyphenyl) ketones, bis(hydroxyphenyl) sulphones, bis(hydroxyphenyl) sulphoxides, α,α′-bis(hydroxyphenyl)diisopropylbenzenes.
It can also relate to derivatives of these compounds obtained by alkylation or halogenation of the aromatic ring. Mention will more particularly be made, among the compounds of formula HO-Z-OH, of the following compounds:
hydroquinone, resorcinol, 4,4′-dihydroxybiphenyl, bis(4-hydroxyphenyl) sulphone, bis(3,5-dimethyl-4-hydroxyphenyl)methane, bis(3,5-dimethyl-4-hydroxyphenyl) sulphone, 1,1-bis(3,5-dimethyl-4-hydroxyphenyl)-para/meta-isopropylbenzene, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 1,1-bis(3,5-dimethyl-4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3-methylcyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3-dimethylcyclohexane, 1,1-bis(4-hydroxyphenyl)-4-methylcyclohexane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 2,2-bis(3,5-dichloro-4-hydroxyphenyl)propane, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)propane (or bisphenol A), 2,2-bis(3-chloro-4-hydroxyphenyl)propane, 2,2-bis(3,5-dibromo-4-hydroxyphenyl)propane, 2,4-bis(4-hydroxyphenyl)-2-methylbutane, 2,4-bis(3,5-dimethyl-4-hydroxyphenyl)-2-methylbutane, α,α′-bis(4-hydroxyphenyl)-o-diisopropylbenzene, α,α′-bis(4-hydroxyphenyl)-m-diisopropylbenzene (or bisphenol M).
[0050] The preferred polycarbonates are the homopolycarbonates based on bisphenol A or 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane and the copolycarbonates based on bisphenol A and 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane. The polycarbonate generally has a weight average molecular weight of 10,000 to 200,000.
[0051] The copolymer has the structural formula:
[0000]
[0000] where x and y are integers calculated to result in a content of PMMA in the copolymer in the range of 5 to 98 weight percent and where R 1 denotes —CH 3 or H and R 2 is a naphthyl and/or substituted naphthyl group.
[0052] The naphthyl or substituted naphthyl (meth)acrylate is present in the copolymer at from 2 to 95 weight percent, and preferably from 10 to 70 weight percent, with the methyl methacrylate at 5 to 98, and preferably 30-90 weight percent. This would also apply to a mixture of naphthyl and substituted napthyl (meth)acrylate monomer units. The (meth)acrylate designation is meant to include both the acrylate, the methacrylate, and mixtures thereof. Examples of substituted naphthyl groups useful in the invention include, but are not limited to, alkyl and aryl side groups, and functional groups such as carboxyls, OH, and halides.
[0053] In addition to the methyl methacrylate and napthyl (meth)acrylate, up to 40 weight percent of the copolymer can be one or more other ethylenically unsaturated monomer units that are copolymerizable with the methyl methacrylate and napthyl (meth)acrylate. The term “copolymer” as used herein is intended to include both polymers made from two monomers, as well as polymers containing three or more different monomers. Preferred termonomers include acrylates, methacrylates and styrenic, including but not limited to linear, or branched C 1-12 alkyl and aryl (meth)acrylates, styrene and alpha-methyl styrene.
[0054] The polymethyl methacrylate copolymer may be produced by free radical polymerization, using techniques known in the art. A preferred method of polymerization is a bulk free radical polymerization or in an organic solvent, producing a viscous polymer solution. The polymer could also be made by emulsion, inverse emulsion and suspension polymerization, as a batch polymerization or with delayed feeds.
[0055] The copolymer has a weight-averaged molecular weight in the range of 5,000 g/mol to 4,000,000 g/mol, and preferably 50,000 to 2,000,000 g/mol.
[0056] The copolymer of the invention is blended with polycarbonate at from 10 to 99.5, and preferably from 50 to 99 weight percent of polycarbonate with 0.5 to 90, and preferably from 1 to 50 weight percent of the copolymer. At low levels of copolymer, the copolymer primarily acts as a process aid. In addition to the copolymer and polycarbonate, other common additives may also be blended into the composition. The additives could include, but are not limited to pigments, dyes, plasticizers, antioxidants, heat stabilizers, UV stabilizers, processing additives or lubricants, inorganic particles, cross-linked organic particles, and impact modifiers. In one embodiment, the copolymer is used as a dried pellet or powder and is blended with polycarbonate pellets along with any other additives to form a polycarbonate composite through melt compounding and extrusion.
[0057] The polycarbonate/copolymer blend or composite of the invention stays miscible up to at least 320° C. This results in a clear composition, even under high temperature processing conditions. This same high-heat homogeneous behavior is not seen with other methyl methacrylate/aryl methacrylate copolymers, such as with benzyl methacrylate phenyl methacrylate and cyclohexyl alkyl methacrylates.
[0058] The polycarbonate/copolymer blend or composite of the invention can be used to form articles, and especially transparent articles by means known in the art, including, but not limited to melt extrusion, injection molding, thermoforming, blown films, fiber spinning, and blow molding.
[0059] Some of the useful articles that can be formed from the blend of the invention include, but are not limited to transparent films, optical discs such as DVDs and CDs, sheet, rods, pellets, films for use as an outer layer in a flat panel display or LED, membrane switches, decals or transfer films, instrument panels, smart cards, glazing containers, glass lenses and medical devices
[0060] In one embodiment, the polycarbonate/copolymer blend is melt compounded by extrusion, then injection molded directly into articles, or into sheets, films, profiles, or pellets that can be further processed into articles.
EXAMPLES
Example 1
Synthesis of Copolymer of MMA and NpMA
[0061] Methyl methacrylate (MMA) and naphthyl methacrylate (NpMA) were dissolved in toluene. The amount of naphthyl methacrylate is calculated to yield the random copolymers having 80 to 95 wt % of PMMA. Polymerization was initiated with about 0.5% of AIBN. The polymerizations were carried out at 70° C. with stirring. In a similar manner, a copolymer of PMMA with 30 weight percent of phenyl methacrylate was synthesized as a Comparative example.
Example 2
Characterization of the Copolymers
[0062] The resulting copolymers were isolated by precipitation into methanol, and dried in a vacuum oven at 80° C., and then characterized by 1 H NMR and by DSC cycling from −50 to 175° C. at 20° C./min. The resulting copolymers have glass transition temperatures that are higher than that of PMMA (=105° C.).
[0000]
TABLE 1
Tg of copolymer of methyl methacrylate
and naphthyl methacrylate.
MMA content
Tg
(mol %)
(° C.)
95
—
90
—
80
124
Example 3
Compounding Polycarbonate with the Copolymers
[0063] The copolymers of Example 2 were compounded with PC-1 at 280° C. followed by injection molding with Nozzle temperature at 310° C. and mold temperature at 140° C.
[0064] The appearances of these compound bars are shown in FIG. 1 . MMA-20NpMA denotes a copolymer of methyl methacrylate and naphthyl methacrylate (NpMA) which containing 20 wt % of NpMA whereas PC-1/MMA-20NpMA denotes a blend of PC-1 and MMA-20NpMA. The weight percent indicated below the compound bar is the amount of copolymer in the blend. Comparative examples containing PC-1 and homo PMMA were prepared by the same procedure. A summary of the physical appearance of pure PMMA (comparative), MMA/PhMA copolymer (comparative) and MMA/NpMA copolymer of the invention are shown in Table 1.
[0000]
TABLE 1
Summary of results
Experiment
Blend with PC-1
Appearance
1
5% PMMA
Translucent
2
10% PMMA
Opaque
3
20% PMMA
Opaque
4
5% Poly(MMA-co-30% PhMA)
Clear
5
10% Poly(MMA-co-30% PhMA)
Translucent
6
20% Poly(MMA-co-30% PhMA)
Opaque
7
5% Poly(MMA-co-10% NpMA)
Clear
8
10% Poly(MMA-co-10% NpMA)
Clear
9
20% Poly(MMA-co-10% NpMA)
Clear
Example 4
DSC Analysis Results
[0065] The compound samples of PC-1 and MMA-20NpMA in present invention were also examined by DSC. When the loading of MMA-20NpMA increases from 5 to 10, and then 20 wt %, the Tg of compound decreases from 148 to 146 and then 140° C. (see Table 2). The observation of a single glass transition temperature also supported the optical observation that a homogeneous miscible blend was formed.
[0000]
TABLE 2
Tg of polycarbonate compounds containing copolymer
of methyl methacrylate and naphthyl methacrylate.
PC-1
Tg
(wt %)
(° C.)
100
149
95
148
90
146
80
140
Example 5
Synthesis of Homopolymer of 2-naphthyl Methacrylate
[0066] Naphthyl methacrylate (NpMA) was dissolved in toluene. Polymerization was initiated with about 0.5% of AIBN. The polymerizations were carried out at 70° C. with stirring until a viscous solution was obtained.
Example 6
Compounding Polycarbonate with the Homopolymers of 2-naphthyl Methacrylate
[0067] The homopolymer of 2-naphthyl methacrylate was compounded with PC-1 at 280° C. followed by injection molding with Nozzle temperature at 310° C. and mold temperature at 140° C. The polymer blends were opaque as collected (shown in FIG. 2 ).
Example 7
Comparative Examples
[0068] Other MMA/aryl methacrylate polymers were made in a manner similar to that of Example 1, and compounded with polycarbonate as described in Example 3. The aryl methacrylate comonomers sed were represented by the formulas:
[0000]
[0069] For all those copolymers, compounding experiments with polycarbonate resins (up to 20 wt % loading of such copolymers) did not produce transparent polycarbonate blends under normal polycarbonate processing conditions.
Example 8
Synthesis of Copolymers of MMA and PhMA (Comparative)
[0070] Methyl methacrylate (MMA) and phenyl methacrylate (PhMA) were dissolved in toluene. The amount of phenyl methacrylate is calculated to yield the random copolymers having 6 wt %, 9 wt %, 11 wt %, and 13 wt % of phenyl methacrylate, respectively. Polymerization was initiated with about 1%, 0.5%, 0.25%, and 0.125% of AIBN, a free radical initiator, respectively. The polymerizations were carried out at 70° C. with stirring until a viscous solution was obtained. Polymers were collected after the precipitation into methanol solution.
Example 9
Synthesis of Copolyners of MMA and 2-NpMA
[0071] Methyl methacrylate (MMA) and 2-naphthyl methacrylate (NpMA) were dissolved in toluene. The amount of 2-naphthyl methacrylate is calculated to yield the random copolymers having 6 wt %, 9 wt %, 11 wt %, and 13 wt % of 2-naphthyl methacrylate, respectively. Polymerization was initiated with about 1%, 0.5%, 0.25%, and 0.125% of AIBN, a free radical initiator, respectively. The polymerizations were carried out from 25 to 70° C. with stirring until a viscous solution was obtained. Polymers were collected after the precipitation into the methanol solution. Polymers were collected after the precipitation into methanol solution.
Example 10
Compounding Polycarbonate with the Copolymers
[0072] The copolymers of Examples 8 and 9 were compounded (50/50 blends) with PC-1 at 280° C. followed by injection molding with Nozzle temperature at 310° C. and mold temperature at 140° C.
[0073] The appearances of these compound bars are given in FIG. 3 . The results are summarized in Table 3.
[0074] Clearly, 2-naphthyl methacrylate is superior to phenyl methacrylate as a comonomer with methyl methacrylate to improve the miscibility (transparency) with polycarbonate.
[0000]
TABLE 3
Summary of results
Experi-
Initiator
ment
Blend with Polycarbonate 1
Level
Appearance
1
50% Poly(MMA-co-6% PhMA)
1%
Opaque
2
50% Poly(MMA-co-9% PhMA)
0.5%
Opaque
3
50% Poly(MMA-co-11% PhMA)
0.25%
Opaque
4
50% Poly(MMA-co-13% PhMA)
0.125%
Opaque
5
50% Poly(MMA-co-6% NpMA)
1%
Clear
6
50% Poly(MMA-co-9% NpMA)
0.5%
Clear
7
50% Poly(MMA-co-11% NpMA)
0.25%
Clear
8
50% Poly(MMA-co-13% NpMA)
0.125%
Clear
Example 11
Compounding with Polycarbonate of Different Melt Flow
[0075] The copolymers of Examples 9 were compounded (50/50 blends) with PC-2 (melt flow ˜4) at 280° C. followed by injection molding with Nozzle temperature at 310° C. and mold temperature at 140° C. The results are summarized in Table 4.
[0000]
TABLE 4
Summary of results
Experiment
Blend with PC-2
Appearance
1
50% Poly(MMA-co-6% NpMA)
Clear
2
50% Poly(MMA-co-9% NpMA)
Clear
3
50% Poly(MMA-co-11% NpMA)
Clear
4
50% Poly(MMA-co-13% NpMA)
Clear
Example 12
Cloud Point
[0076] Cloud point measurement quantifies the upper temperature for a given blend to maintain a single phase. Cloud points of PC-1 blends with PMMA copolymers containing 2-napthylmethacrylate and phenylmethacrylate are compared in Table 5. The results correspond to the upper temperature when the blend turns cloudy. The result indicated that 2-napthylmethacrylate is superior to phenylmethacrylate in maintaining the transparency of the polycarbonate matrix at elevated temperature.
[0000]
TABLE 5
Cloud point measurement
Cloud Point (° C.)
5 wt % in PC-1
20 wt % in PC-1
PMMA
<250
<250
P(MMA-co-35 wt % PhMA)
280
260
P(MMA-co-35 wt % NpMA)
>325
>325 | The invention relates to a transparent thermoplastic blend of polycarbonate (PC) and a copolymer of methyl methacrylate (MMA) and naphthyl methacrylate or a substituted naphthyl methacrylate. This copolymer has excellent miscibility with polycarbonate resin, even at elevated temperature, producing transparent polycarbonate blends. The blend provides an improved scratch resistance of polycarbonate while maintaining its excellent optical properties. | 2 |
THE FIELD OF APPLICATION OF THE INVENTION
The present invention relates to a novel process for treating various textile fabrics with water repellent, characterized in reacting said textile fabrics with fluorine water repellent and melamine resin by heating, in the presence of curing catalyst.
BACKGROUND OF THE INVENTION
Heretofore, several kinds of fluorine resin products have been known as water repellent for the treatment of textile fabrics, but the water repellency of textile fabrics treated therewith is easily aged or disappears after being washed four times. Accordingly in the past, a number of researches and experiments have been made to improve the life of textile products without satisfactory results, and the conventional methods are still employed despite their inconvenience in the textile industries.
DETAILED DESCRIPTION OF THE INVENTION
Therefore, the object of the present invention is to eliminate such disadvantages of the conventional process using fluorine resin, and to provide a novel process for the water repellent treatment of various textile fabrics such as cotton, wool, hemp and silk fabrics. The present invention may best be understood by reference to the following description and the subject matter which I regard as my invention particularly pointed out and distinctly claimed in the concluding portion of this specification.
In accordance with the present invention, textile fabrics are reacted with fluorine water repellent, using a medium of the reactive intermediate resin, to obtain an outstanding water repellency with a good fastness to washing.
Furthermore, if the water repellent treatment is conducted while using at the same time various processing materials such as preservatives, deodorizers, wrinkle-proofing agents, and anti-electrostatic agents which are hitherto known only as simple textile processing agents, the textile treating processes will be then substantially simplified in one and the same process, and said melamine resin medium, being composed of the afore-mentioned various textile processing materials including a touch-improving agent, produces outstanding textile fabrics of high quality having excellent touch, and at the same time allowing the various different secondary textile treatments to be carried out in a single process.
In accordance with the present invention, textile fabrics to be treated may include all kinds of textiles made of not only synthetic fiber such as polyester fiber but also natural fiber, particularly animal fibers such as wool and silk which have been heretofore considered extremely difficult or almost impossible of processing with chemicals.
As for the textile processing material, one must select proper treating agents such as an intermediate resin medium, water repellent catalyst, penetration catalyst, anti-electrostatic agent and mold repellent, according to the fabrics to be processed, such as synthetic, cotton, woolen, and silk fabrics as well as according to the requirements of the finished products, such as wrinkle-proof, contractility, water repellency and touch.
The reactive intermediate resin medium according to the present invention reacts with the water repellent fluorine compound, such as a polyfluoroethylene acrylic acid copolymer. It is essential that the reaction be carried out at the processing temperature. Since said intermediate resin medium easily causes the dimethanization reaction at a pH acid by heating, the hardener polymethoxymethylmelamine and the like are often employed. Particularly, the organo-thyalsol compounds are effectively employed as disinfectants or moth-repellents.
Penetrants are essential for the treatment of animal fibers which is considered one of the important features of the present invention. Ethylene oxide polymers having a molecular weight of several million are generally used. Besides, polyvinyl pyrrolidone employed in connection with the penetrants is particularly important in view of its various functions such for as touch-improvement and acting as an anti-electrostatic agent. Furthermore, it is also important that potassium bichromate is used for silk fabrics.
Preferred embodiments of the process in accordance with the present invention are described as follows:
EXAMPLE 1
According to the present invention, two samples A and B of polyester fabrics were treated with water repellent by utilizing the following treatment bath and tested for the water repellency in the Textile Industry Laboratory in Tokyo City. The test results are as follows: The following materials were mixed to prepare a water repellent bath.
______________________________________SKG-620 (water repellant flourine-containing 3-9%compound):T-30 (amine catalyst produced by SAM JEONG 1-4%CHEMICALS Co.):P (methylol melamine mixing agent produced by 0.1-0.3%SAM JEONG CHEMICALS Co.):Water: Remainder %______________________________________
The above sample fabrics were tested with the said water repellent bath.
______________________________________No. ofCleaning 5 10 15 20 30 40 45 50 50______________________________________Dry CleaningA 90 90 90 80 80 80 80 70 80B 100 100 90 83 80 70 70 70 93Wet CleaningA 93 90 90 80 80 80 80 80 90B 100 100 100 100 100 100 100 100 100______________________________________ Note: The test method was based on JISL 1097-1977, 1018 E2 and 0217103. The symbol * represents that the sample fabrics were pressed by means of household electric iron at the temperature for polyester fabrics.
EXAMPLE 2
Three sample fabrics were treated with water repellent in the treating bath having the same composition as in Example 1, and these three samples and an untreated sample were subjected to a durability test conducted by Technical Laboratory of the SAM JEONG CHEMICALS Co., Ltd. The results of the above test are as follows:
Said samples were cleaned in the soapy water of 0.2% of neutral detergent, at 40° C., for 10 minutes, by means of a household electric washing machine, and then washed with water for 10 minutes, by subjecting to severe washing for 5 minutes, and to soft washing for 5 minutes while automatically reversing, and after squeezing water, the sample fabrics were dried for 5 minutes at 100° C.
______________________________________ Number of washing timesTest No. Color 0 3 5 10______________________________________1 blue 100 100 100 1002 blue 100 100 100 1003 light 100 100 100 100 brownUntreated blue -- -- -- --______________________________________
EXAMPLE 3
Cotton and hemp fabrics were tested in the treating bath containing the following compositions. The fabrics treated by the above composition bath were all ascertained to have remarkable durabilities.
__________________________________________________________________________ Bath No.Constituents of the bath No. 1 No. 2 No. 3 No. 4 No. 5 No. 6__________________________________________________________________________SKG-620 (Name of fluorine product) 6 6 6 6 6 6T-30(name of melamine product) 2 2 2 2 2 2P (name of methylol melamine 0.2 -- -- 0.1 0.1 0.1productKR-58 (flexibilizer) 1 1 1 1 1 1SFZ (catalyst) 0.2 0.2 -- 0.15 0.15 0.15Potassium bichromate (catalyst) -- 0.1 0.1 0.25 0.25 0.25__________________________________________________________________________
EXAMPLE 4
In order to treat woolen fabrics with water repellent, the following treating baths containing respective compositions as given in the table below were employed. According to the above test results, all woolen fabrics treated by the above baths have shown better durabilities than those of any other woolen fabrics processed by conventional methods, and the touch of said fabrics were excellent while retaining the peculiar properties of wool.
______________________________________ Bath No. No. No. No. No. No. No.Constituents of Bath 1 2 3 4 5 6______________________________________SKG-620 5 5 5 5 5 5T-30 2 2 2 2 2 2P 0.2 -- -- 0.1 0.1 0.1HS (catalyst) 1 1 1 1 1 1KR-58 (plasticizer) 2 2 2 2 2 2AS (polyethelene oxide- -- 0.1 0.1 0.25 0.35 0.35containing polymer)______________________________________
EXAMPLE 5
In order to treat silk fabrics with water repellent, treating baths containing the following compositions were employed. The fabrics treated with said treating baths showed better durabilities than those of silk fabrics treated by the conventional methods, while retaining the original touch peculiar to silk goods as prior to the treatments.
______________________________________ Bath No.Constituents of Bath No. 1 No. 2______________________________________SKG-620 6 8T-30 2 2P 0.1 0.1KR-58 (plasticizer) 1 1SFZ (catalyst) 0.15 0.15Potassium bichromate 0.25 0.25Z-FF (polyvinyl pyrrolidone) 2 2DIRTPTAT 1600(catalyst) 0.01 0.01AS (catalyst) -- 0.5Water Remainder % Remainder %______________________________________
EXAMPLE 6
A woolen fabric dyed with an acid dye was treated with water repellent, by means of a treating bath containing the following composition.
______________________________________Preparation of treating bath______________________________________SKG - 620 4-8%T - 30 1-3%P 0.1-0.3%Water Remainder %______________________________________
According to the above test results of said sample fabrics, the untreated fabrics became moldy whereas the treated fabrics did not become moldy at all.
After adding 4-8% of Excell 700 to the treating bath in Example 6, synthetic and woolen fabrics were treated with said water repellent in the above bath, and then subjected to the electrostatic charge test, the results of which are as follows:
______________________________________ Value of the surface resistanceSample No. Untreated Treated______________________________________1 (wool) 2.6 × 10.sup.12 Ω 2.1 × 10.sup.12 Ω2 (polyester) 2.4 × 10.sup.9 Ω 5.5 × 10.sup.8 Ω______________________________________ Note: For measuring the surface resistance, the superinsulation tester (VE40) and the normal temperature measuring box (RC02) both by the KAWAKUCHI DENKI Company in Japan were employed, and the value of surface resistance was measured while applying a voltage of 500 W to the surface of the sample fabrics for one minute, at a temperature of 22° C., and under the relative humidity of 45%.
As can be clearly understood in the above examples, the present invention shall provide a novel process wherein the textile products can be not only easily treated to obtain excellent water repellency, but also various secondary treatments can be effectively conducted simultaneously in a single process, which treatments were otherwise separately conducted using the conventional processes. | A process for treating textile fabrics comprising contacting said fabrics at an elevated temperature with a fluorine-containing polymer composition comprising form 3 to 7 weight percent of fluorine-containing polymer, 0.1 to 0.3 weight percent of melamine resin and 1 to 4 weight percent curing catalyst. | 3 |
This application is a continuation of prior application Ser. No. 08/873,152, filed Jun. 11, 1997, now U.S. Pat. No. 5,927,526, which is application was a continuation of prior application Ser. No. 08/551,186, filed Oct. 31, 1995, now U.S. Pat. No. 5,671,853.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a child-resistant container closure system which provides easy opening by adults, even debilitated adults, but nevertheless requires manipulation which renders the closure resistant to opening by children. The present invention is composed of an easy-to-manufacture one-piece container and a closure for that container.
2. Discussion of the Prior Art
Child-resistant packaging is used to prevent inadvertent access by children to potentially dangerous materials such as medications, chemicals or poisons. Providing child-resistant packaging often adds cost and can result in the packaging being difficult for an adult user to open. This difficulty in opening child-resistant packaging is compounded when an adult attempting to open the package is debilitated or has reduced manual dexterity in one or more hands as a result of, e.g., arthritis. Elderly persons tend to rely on medication more than the average person, and also tend to have impaired manual strength and dexterity because of arthritis or age. Therefore, elderly persons can have a more difficult time opening child-resistant packaging.
Child-resistant packages exist in the prior art. For example, U.S. Pat. No. 3,917,097 to Uhlig describes a closure with internal flanges engaging abutments on the container- Disengagement of the abutments and flanges is accomplished by pressing opposing finger indentations to flex the flanges out of engagement with the abutments, and thereafter rotating the closure. Flexing of the flanges in this device requires deformation of the circumference of the closure by the user's fingers.
U.S. Pat. No. 3,984,021, also to Uhlig, and U.S. Pat. No 3,941,268 to Owens et al. describe closures with internal tabs which engage abutments on the container. Again, disengagement of the tabs and abutments is accomplished by flexing opposing sides of the closure until the tabs and abutments disengage, and then rotating the closure. A similar concept is described in U.S. Pat. No. 3,993,208 to Ostrowsky. These devices also require flexing of the closure circumference to disengage the locking feature.
Finally, U.S. Pat. No. 5,230,433 to Hamilton et al. describes a closure with pawls which engage push-tab extensions projecting from a sleeve mounted on the container. Disengagement is accomplished by pressing the opposing push-tabs and rotating the closure.
Each of the above prior art closures suffer from at. least the disadvantage that they are not easy to remove by debilitated adults, because they require significant force to flex the outer circumference of the closure portion to disengage the locking mechanisms between the closure and the container.
U.S. Pat. No. 4,948,002 and U.S. Design Pat. No. 330,677 also disclose child-resistant packages. These packages suffer from the disadvantage that the part of the package which must be manipulated to disengage the locking portion is on the container. As a result, the user must manipulate the container in one hand to disengage the locking feature, and must manipulate the closure in the other hand by rotating the closure to unscrew it from the container. Thus, manual dexterity in both hands is required to remove the closure, making the closure difficult to remove for those who may be more debilitated in one hand. These packages are also difficult to manufacture because they use a complicated two-piece container assembly as well as a one-piece closure assembly fitting on the container assembly.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a child-resistant closure and container combination that prevents access to the contents of the container by children yet is relatively easy to remove by an adult, even by a debilitated adult having manual dexterity in only one hand. In addition, it is an object of the present invention to provide a child-resistant package which is easy and economical to manufacture and assemble.
The present invention is a combination of a closure and a container. The closure has a top wall, an annular skirt, and a closure thread located in the interior of the closure. At least one depressible moveable panel is molded into the annular skirt, and one locking tab is formed on each moveable panel. The moveable panels are spaced from the skirt by gaps, which make the moveable panels more easily radially deformable by the user's fingers. Preferably two or more moveable panels and locking tabs are provided on the closure.
The container includes a receptacle portion for holding the contents. A threaded neck projects upwardly, from the receptacle portion. An annulus encircles the neck, and includes at least one stationary locking lug. The annulus may be formed by the top shoulder of the container. Preferably two stationary locking lugs are provided on the annulus. The stationary locking lugs engage the locking tabs on the closure such that the locking tabs prohibit rotation of the closure off of the container neck unless the movable panels are depressed.
The closure and the container may each be made of plastic, although the container may alternatively be made of glass. The closure thread which secures the closure to the container may be on an annular threader skirt which projects from the top wall of the closure. The annular threaded skirt and the annular skirt are substantially concentric.
The annular skirt may be serrated or have ribs for ease of gripping by the user. Advantageously there are two each of the moveable panels, the locking tabs, and the stationary locking lugs. The movable panels are advantageously each located 180 degrees apart on the circumference of the closure.
Typical products which may be held inside the child-resistant container of the present invention include, but are not limited to, liquid or solid medicines, pills, prescriptions, treatments, as well as soaps, detergents, pesticides, poisons, solvents, industrial chemicals and the like.
The closure and container combination according to the present invention is capable of manufacture with conventional equipment used in the manufacture of containers, both glass and plastic, without any substantially burdensome modifications to that equipment. Conventional plastic or glass molding techniques may be used to construct the package of the present invention without difficulty. The container may be manufactured, e.g., by standard bottle injection molding machines.
The closure and container combination of the present invention has numerous advantages. First, it can be easily manufactured as a one-piece bottle and one-piece closure. Second, there is no need to manipulate both the bottle and closure to open the package. The closure of the present invention is advantageously designed with movable panels, which allows the closure to be threaded onto the container using automatic threading machinery without additional equipment for manipulating the closure or the container. Finally, the package does not require significant flexing force to disengage the locking portions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a first embodiment of the container portion of the present invention;
FIG. 2 shows a side view of a first embodiment of a closure of the present invention;
FIG. 3 shows a top view of the closure of FIG. 2;
FIG. 4 shows a cross-sectional view, along line IV—IV, of the closure of FIG. 2, and shows the locking tabs of the closure;
is FIG. 5 shows a cross-sectional side view, along line V—V, of the closure of FIG. 3;
FIG. 6 shows a cross-sectional side view, along line VI—VI, of the closure of FIG. 3;
FIG. 7 shows a top view of the container of FIG. 1;
FIG. 8 shows a detail cross-sectional view, along line VIII—VIII, of the moveable panel area of the closure of FIG. 6;
FIG. 9 shows a side detail view of a stationary locking lag of the present invention;
FIG. 10 shows a top detail view of a stationary locking lag of the present invention;
FIG. 11 shows an end-on detail view of a stationary locking lag of the present invention;
FIG. 12 shows an alternative embodiment of the locking tab of the present invention; and
FIG. 13 shows an alternative embodiment of the container of the present invention.
DETAILED DESCRIPTION
FIGS. 1-13 show the construction of a child-resistant closure and container combination of the present invention. A closure 110 is mounted on a container 150 through interengaging threads 154 , 232 , so as to prevent access to the contents of the container.
The closure 110 includes top wall 112 , which is generally circular in shape. Projecting from top wall 112 is annular skirt 114 . In the closure so FIG. 2, annular skirt 114 is flared out, allowing a wider range of radial movement of the moveable panels 116 , 116 ′. A wider range of radial movement for moveable panels 116 , 116 ′ makes them less easily manipulable by the small hands of children, thereby ensuring that the closure is especially secure against removal by a child. Annular skirt 114 includes at least one radially-flexible locking device, such as moveable panel 116 . Preferably two moveable panels 116 , 116 ′ are provided, although other numbers are possible. Annular skirt 114 may include serrations or ribs 114 a , which make gripping the closure 110 easier. The outer surface of the movable panels 116 , 116 ′ should preferably not include serrations or ribs, thereby distracting children from gripping or manipulating the movable panels 116 , 116 ′. Molded to a radially inner surface of each of the moveable panels 116 , 116 ′ is a locking tab 120 , which may have a rectangular cross-section, or may have one. surface formed as a circular arc 300 . (see FIGS. 8 and 12) The circular arc 300 , 300 ′ of locking tabs 120 , 120 ′ can, ease the locking tab 120 , 120 ′ over the stationary locking lugs 164 , 164 ′ during tightening of closure 110 on container neck 152 . A portion of the locking tabs 120 , 120 ′ closest to the top wall 112 is molded integrally to the moveable panels 116 , 116 ′ at web 301 , 301 ′. The other portion of the locking tabs 120 , 120 ′ is spaced from the moveable panel 116 , 116 ′ by gaps G, G′. The gaps G, G′ between the locking tabs 120 , 120 ′ and the moveable panels 116 , 116 ′ allow the locking tabs 120 , 120 ′ to flex in the radial direction, thereby allowing the locking tabs 120 , 120 ′ to flex around stationary locking lugs 164 , 164 ′ during tightening of the closure 110 on container 150 . The stationary locking lugs 164 , 164 ′ pass through the gaps G, G′ during tightening of the closure 110 on the container neck 152 .
FIG. 6 shows a cross-section of the closure, showing the interior of the closure. Annular threaded skirt 132 projects from the top wall 112 and is generally concentric with annular skirt 114 . The threads 232 on threaded skirt 132 engage corresponding threads 154 on a container neck 152 to hold the closure 110 onto the container 150 . The threads 232 must be of sufficient length to ensure that locking tabs 120 , 120 ′ ride over stationary locking lugs 164 , 164 ′ when the closure 110 is tightened on container neck 152 . The closure 110 may include stabilization webs 700 , which provide stability between the annular skirt 114 and the annular threaded skirt 132 .
In addition, the thread system on the closure 110 and container 150 may include multiple threads. Two or more separate threads may be included on each of the closure 110 and the container 150 . U.S. Pat. No. 5,213,225 teaches such a system, in which the threads only circle the closure and container neck a fraction of a circumference. Using this system, the closure only requires a partial rotation in order to be removed from the container neck. This “quick-off” feature may be advantageous for those users who encounter difficulty when opening containers.
The structure of a container according to an embodiment of the present invention is generally shown in FIGS. 1 and 7. In FIG. 1, container 150 is shown as having a containing portion 158 . The neck 152 extends upwardly from the container shoulder 168 . This neck 152 has an annular lip 162 defining an opening through which the contents of the container 150 may be dispensed. Surrounding neck 152 is at least one container thread 154 . Thread 154 engages a corresponding thread 232 on the closure 110 to secure the closure 110 on the container 150 .
Flaring outward from neck 152 is annulus or extension 160 . Extension 160 has an outer perimeter 156 which merges with container body 158 . Extension 160 may be defined by a generally flat ring-shaped annulus or floor concentric with the axis of the container 150 (FIG. 1 ), or may be a flange projecting from the container neck 152 (FIG. 13 ). Mounted onto extension 160 is at least one stationary locking lug 164 . In FIG. 1, two stationary locking lugs are shown, 164 and 164 ′. As shown in FIG. 10, the stationary locking lugs 164 , 164 ′ have a radially outer surface 400 . Outer surface 400 is shaped in the form of a circular arc with a centerpoint corresponding to the axis of the container 150 . A locking face 402 extends along a radius of the container 150 axis. An inner surface 401 is preferably formed perpendicular to the locking face 402 . Inner surface 401 need not be perpendicular to locking face 402 , however, and need only be a surface which, from its leading edge 405 to its trailing edge 406 , projects radially inwardly. This radial inward projection of inner surface 401 ensures that the locking tabs 120 , 120 ′ will be deformed radially inwardly as they ride over the stationary locking lugs 164 , 164 ′. The inner surface 402 is preferably formed on a parting line of the mold used to make the container 150 .
In operation of the closure 110 of the present invention, as the closure 110 is rotated on the threads 154 in a tightening direction, the circular arc 300 , 300 ′ of locking tabs 120 , 120 ′ (or in the embodiment of FIG. 12, the leading corner 303 of locking tab 120 ) contacts the inner surface 401 of the stationary locking lug 164 at leading edge 405 . Further rotation of the closure 110 in the tightening direction flexes the locking tabs 120 , 120 ′ radially inwardly, such that the radially outer surface of locking tabs 120 , 120 ′ slides along the inner surface 401 . As the locking tabs 120 , 120 ′ slide along the inner surface 401 , the stationary locking lugs 164 , 164 ′ pass into the gap G between the moveable panels 116 , 116 ′ and the locking tabs 120 , 120 ′. After the locking tabs 120 , 120 ′ have slid over inner surface 401 , the locking tabs 120 , 120 ′ snap radially outwardly, such that the trailing surfaces 304 of locking tabs 120 , 120 ′ engage locking face 402 of stationary locking lugs 164 , 164 ′. The engagement between trailing surface 304 and locking face 402 , both of which are located along a radius of the container 150 axis, prevents reverse rotation of the closure 110 relative to the container without manipulation of the moveable panels 116 , 116 ′.
To disengage the closure 110 from the container 150 , a user places a finger on each moveable panel 116 , 116 ′ and depresses the moveable panels 116 , 116 ′. The moveable panels 116 , 116 ′ easily flex radially inwardly because of is the gaps 500 between the moveable panels 116 , 116 ′ and the annular skirt 114 . These gaps ensure that the force necessary to disengage the locking lugs 120 , 120 ′ is only that force necessary to flex the moveable panels 116 , 116 ′ against the resistance of the moveable panel hinge 600 . This radial movement causes the radially outward face of locking tabs 120 , 120 ′ to be placed radially inward of the inner face 401 of the stationary locking lugs 164 , 164 ′. Rotation of the closure in an untightening direction causes the stationary locking lugs 164 , 164 ′ to pass into the gaps G between the moveable panels 116 , 116 ′ and the locking tabs 120 , 120 ′. In this position, the locking tabs 120 , 120 ′ may be rotated past the stationary locking lugs 164 , 164 ′, upon an untightening rotation of the closure 110 relative to the container 150 . After the locking tabs 120 , 120 ′ pass the stationary locking lugs 164 , 164 ′, the closure 110 may be unscrewed off the container neck 152 in a known manner.
The use of locking tabs 120 allows depression of moveable panels 116 to directly move each locking tab 120 out of engagement with stationary locking lugs 164 and 164 ′. In this way, the user has far more control over the disengagement of the child-resistant feature than when the locking tab is only indirectly manipulated. Furthermore, because perimeter 156 may be made to be flush with annular skirt 114 , a pleasing overall appearance is provided by the continuous character of the container 150 and closure 110 . However, because of the gaps 500 between the moveable panels 116 , 116 ′ and the annular skirt 114 as well as the moveable panel hinge 600 connecting the moveable panels 116 , 116 ′ to the top wall 112 , the locking mechanism is much easier to disengage than a closure in which the circumference of the closure must be deformed to unlock the locking mechanism.
It is, of course, understandable and to be expected that variations in the principles of construction disclosed herein in the embodiment may be made by one skilled in the art and it is intended that such modifications, changes, and substitutions are to be included within the scope of the present application. For example, while two stationary locking lugs and two locking tabs have been shown in the pictured embodiments, any number of such features are contemplated by the closure and container combination of the present invention. The scope of the present application is limited only by the language of the claims appended hereto. | A child-resistant closure container system allowing easy opening by debilitated adults. The closure has moveable panels on the side wall which, when depressed, allow the unscrewing of the closure from the neck of the jar or vial. The moveable panels include gabs engaging stationary locking lugs on the neck finish annulus, which prevent removal of the closure without depressing the tabs. The annulus and stationary locking lugs can be an integral part of the jar or vial. | 1 |
FIELD OF THE INVENTION
The present invention relates to microwave antenna structure and is particularly directed to a waveguide fed horn antenna for use in severe thermal stress environments (e.g. a space-deployed structure).
BACKGROUND OF THE INVENTION
The successful operation of satellite communication systems requires the use of components that are capable of withstanding severe, and often rapid, changes in environmental conditions (e.g. rapid thermal transients in response to changes in solar exposure (full sun-vs-eclipse)). Because of these demands, structural elements that are acceptable for terrestrial use are often unsuited for spaceborne applications, without a substantial modification of hardware design. This problem is particularly accute with respect to the electrical components of antenna structures which employ metallic surfaces for signal coupling functions (e.g. aluminum waveguide feeds) and for the radiating components (e.g. aluminum/copper-surfaced horn elements). Because of the substantial magnitudes of their coefficients of thermal expansion, the metallic structures suffer from inherent dimensional instability; the resulting physical distortion (e.g. warping, bowing of the horn and feed structures) changes the field pattern characteristics of the antenna, thereby adversely affecting its performance. Moreover, repeated thermal cycling of the structures may lead to structural fatigue and eventual separation of components of the antenna structure.
One approach for dealing with this problem has been to provide error tolerance performance through the use of a large number of radiator and intercoupled feed elements for which a complex support framework is required. This approach is, in effect, a brute force solution, adding to the antenna considerable size and weight, precious commodities from an earth to space transport standpoint.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a horn antenna configuration that offers considerably improved dimensional stability over conventional waveguide-fed horn structures, yet is lightweight, high gain and of reduced size, thereby satisfying both performance and payload objectives of space-deployed antennas. To this end, the present invention couples to a waveguide-fed horn structure a constraining mechanism that enjoys an extremely high degree of dimensional stability over a wide thermal range. Preferably the constraining mechanism comprises a composite graphite and honeycomb structure that forms a support backing for the waveguide feed and for the conductive surface sections of the horn radiator. The conductive surface of the horn radiator is supported on a first section of graphite epoxy laminate while a second section of graphite epoxy laminate supports the honeycomb backing and is bonded to the first section of laminate, thereby effectively surrounding the feed-horn structure with a thermally tolerant, physical distortion constraining support. The graphite epoxy support provides sufficient mass and mechanical stiffness to prevent performance degrading distortion of both the waveguide feed and the horn radiator surface in spite of the severe transient thermal conditions encountered in a spaceborne environment, thereby maintaining structural integrity of the components of the structure during extreme thermal cycling conditions (full sun to eclipse). An epoxy adhesive is employed to secure the waveguide feed to the graphite epoxy laminate and a syntactic filter is injected between the regions of the enveloping composite laminate wherein the honeycomb backing is provided. Because the resulting structure has high gain, lighter weight and has considerably improved thermal stability than conventional horn structures, it is especially suited to a wide variety of spacecraft applications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of a waveguide-fed composite horn antenna having corrugated horn surface configuration;
FIG. 2 is a cross-sectional side view of a waveguide-fed composite horn antenna having a flat horn surface configuration; and
FIG. 3 is a cross-sectional side view of a mandrel for forming the corrugated antenna horn configuration of FIG. 1.
DETAILED DESCRIPTION
Referring now to FIG. 1, a cross-sectional side view of a waveguide-fed composite horn antenna in accordance with the present invention is shown as comprising a metallic (e.g. aluminum) waveguide feed element 10 and a surrounding constraining composite horn structure 20. In the exemplary embodiment of the invention illustrated in FIG. 1, the antenna is a vertically polarized antenna having a corrugated horn surface. The waveguide 10, which forms the radiator feed component for the horn, has a top surface 11 facing the direction of electromagnetic radiation emission, side surfaces 12 and 13, and a bottom surface 14. Slot openings (not shown) are periodically distributed (in a direction normal to the plane of the drawing) in the top surface 11 of the waveguide 10 for launching the vertically polarized wave.
The horn component of the antenna is comprised of a flared section of graphite epoxy laminate having a first flared portion 34 and a second flared portion 35 which extend from the outer extremities 47, 48 of the horn to a third, pocket portion 30. Pocket portion 30 is comprised of side walls 32 and 33 and bottom wall 36, contiguous with one another and being sized to receive and provide a snug fit for the side walls 12 and 13 and the bottom wall 14 of the aluminum waveguide feed element 10. A thin layer 25 of bonding epoxy is provided between the outer wall surface portions 12, 13, 14 of the waveguide 10 and the inner wall surface portions 32, 33, 36 of the pocket portion 30 to secure waveguide feed 10 in pocket portion 30.
Electrically contiguous with the top surface 11 of the waveguide feed element 10 is a thin conductor layer (e.g. copper) 80, which extends over a pair of enlarged launch defining portions 74 and 75 and a plurality of corrugations 71 and 72, spaced apart from the enlarged portions 74 and 75 and extending to the outer extremities of the flared portions 34 and 35 of the graphite epoxy laminate horn. The corrugations 71 and 72 and enlarged portions 74 and 75 of the copper surface are filled with a syntactic filler material or graphite roving to provide sufficient support and lightweight mass for the corrugations and the enlarged portions in their completed structural form. The copper surface 80 of the interior of the horn is electrically and physically connected to the top surface 11 of the waveguide 10 by respective layers of conductive adhesive 21 and 22.
In order to constrain the waveguide feed 10 and the conductive surface 80 of the flared portion of the horn, honeycomb backing sections 52 and 53 of graphite composite material (e.g. Nomex honeycomb) are provided as backing layers along flared sections 34 and 35 of the epoxy laminate walls of the horn, and a bottom section 54 of honeycomb graphite composite material is provided along the bottom wall portion 36 of the pocket 30 of the graphite epoxy laminate horn structure. The depth of the bottom section 54 of graphite composite material is greater than the thickness of each of the side sections 52 and 53 adjacent to the flared sections 34 and 35 of the epoxy horn laminate and is sufficiently large so as to effectively shift the center of mass of the pocket portion 30 (including the waveguide 10) to a location beneath the bottom wall 36 of the pocket portion 30. This shifting of the center of mass of the aluminum waveguide feed elements to a location in backing section 54, that undergoes no substantial mechanical distortion for changes in thermal input, effectively assists in constraining the waveguide from distortion in response to thermal changes.
An outer skin member 41, comprised of the same graphite epoxy laminate structure as the flared wall portions of the horn itself, extends from the outer extremities 47, 48 of the horn and surrounds the backing sections 52, 53 and 54 of graphite composite honeycomb. Those portions of the volume of space with the horn structure defined by outer skin member 41 and flared wall members 34 and 35 and not occupied by backing sections 44, 52, 53 are filled with a syntactic filler at regions 62 and 63 adjacent the sides of the bottom layer of honeycomb composite 54 and the outer extremity portions of the flared walls of the horn at regions 64 and 65.
Because the coefficient of thermal expansion of the graphite epoxy material of walls 34 and 35, pocket portion 30 and outer skin member 41, as well as that of the honeycomb backing material 52, 53 and 54, is extremely low (less than 1×10 -6 in./in./degree F.), the aluminum waveguide feed element 10 is substantially surrounded with a constraining member that undergoes almost no distortion for the significant temperature swings encountered in a spaceborne environment for which the present invention is intended. Moreover, as mentioned above, because of the substantial thickness of the honeycomb graphite backing section 54 adjacent to the bottom wall of the pocket 30 in which the aluminum waveguide feed element 10 is constrained, the effective center of mass of the waveguide feed 10 is displaced outside the waveguide to a location which undergoes almost no displacement for substantial changes in temperature. As a result, deformation of the waveguide feed is effectively minimized.
FIG. 2 shows an embodiment of the present invention wherein the waveguide is disposed to provide horizontally polarized radiation and the surface of the horn is essentially flat or smooth, (i.e. without the corrugations employed in the embodiment shown in FIG. 1). In this configuration, the aluminum waveguide feed 110 is also essentially of rectangular cross-sectional configuration with one of the narrow edges forming the top surface 111 and acting as a radiation launching surface. Side walls 113 and 112 of feed 110 extend from the top surface 111 to a bottom wall 114 of the waveguide. Portions of the side walls 112 and 113 of waveguide 110 are electrically and physically joined via a suitable conductive adhesive to a metallic (e.g. copper) layer 180 which is formed on a pair of flared wall portions 134 and 135 of an epoxy graphite laminate horn structure 120, a pocket portion 130 of which receives the waveguide 110. A layer of epoxy adhesive 122 is provided on side walls 112, 113 and on bottom wall 114 to secure waveguide 110 in pocket portion 130.
Side walls 132, 133 of the pocket portion 130 and the flared wall portions 134, 135 of the epoxy laminate are backed with respective sections 155, 156 and 152, 153 honeycomb structured graphite material (e.g. Nomex honeycomb) to provide a thermal response constraint mechanism for the interior metallic surfaces of the foreign structure. Similarly, a bottom section 154 of graphite honeycomb material is disposed adjacent bottom wall 114 of the waveguide 110 and side sections 155 and 156. This honeycomb graphite backing structure is surrounded by an outer skin member 141, formed of a layer of graphite epoxy laminate which extends from the outer extremities 171 and 172 of the flared horn portion to a bottom wall portion 144 and envelops the sections of backing material 152-156. Regions of syntactic filler 161-165 are disposed in the vacant space of the interior of the horn structure adjacent to the sections of honeycomb graphite composite so as to provide a completely solid interior of the composite horn structure.
As is the case with the embodiment of the composite structure shown in FIG. 1, described above, through the use of the epoxy laminate layers and the honeycomb graphite backing sections, the waveguide-fed horn structure is surrounded with a distortion constraining mechanism having an extremely low coefficient of thermal expansion, with the constraining mechanism effectively shifting the center of mass of the waveguide launching feed to a location in the graphite honeycomb material, thereby preventing distortion of both the waveguide feed and the flared sections of the horn itself.
Manufacture of the composite horn structure preferably employs a mandrel, shaped to conform with the flared horn section. An illustration of a suitable mandrel for forming the corrugated horn structure of FIG. 1 is shown in FIG. 3. As shown therein, on the top surface 210 of a base plate 201 respective mandrel sections 202, 203 and 204 are secured by way of threaded dowel pins 231, 232 and 233, which extend through respective slots 261, 262 and 263 in base plate 201 and engage threaded (tapped) slots 241, 242 and 243 in sections 202, 203 and 204, respectively.
Each of outer sections 202 and 204 is shaped to provide respective corrugations 212, 214 spaced by gaps 213 and 216 therebetween, as shown. The central section 203 of the mandrel has a top surface 253 from which extend vertical side walls 252 and 254 and inclined walls 251 and 255. Inclined walls 251 and 255 intersect and walls 245 and 246 of the respective sections 202 and 203 at vertices 271 and 272, as shown, thereby providing outer surface outline regions 281, 282 of enlarged launching regions 74 and 75 of the horn configuration shown in FIG. 1.
After the mandrel sections have been secured to the base plate in the configuration shown in FIG. 3, a thin layer of copper (preferably on the order of 1-to-2 mils thickness) is deposited (either electro deposited or electroless deposited) on the mandrel. Next, in regions 281 and 282 and within the gaps 213 and 216 of the corrugation portions, an epoxy-impregnated graphite carbon cord is formed and allowed to cure, thereby providing a syntactic filler for sections 74 and 75 and corrugations 71 and 72 of the configuration shown in FIG. 1.
Thereafter, a portion of the copper which has been deposited on top surface 253 of the central mandrel section 203 is removed and a conductive adhesive is applied at regions 267 and 268 to secure a section of waveguide feed having openings therein facing the top surface 253 of the central mandrel section 203. Next, a structural adhesive is applied to the outer walls 12 and 13 and bottom wall 14 of the waveguide and a laminated structure comprising successive layers of resin-impregnated bidirectional graphite is formed over the waveguide and mandrel structure. Preferably, the graphite is caused to conform to the surface under vacuum. It is then allowed to cure at room temperature, so as to complete the formation of the pocket portion 30 and the flared wall portion 34 and 35 of the horn configuration shown in FIG. 1.
Next, Nomex honeycomb graphite backing sections 52, 53 and 54 are adhesively bonded to the backs of flared epoxy laminate sections 34 and 35 and the bottom wall portion 34 of the pocket 30. After the bonding adhesive for the honeycomb epoxy graphite section has been allowed to cure at room temperature, clamps which have secured the honeycomb backing to the graphite laminate structure are removed and the honeycomb backing is trimmed to the desired final shape. Open areas of the structure between the honeycomb backing layers and at the extremities of the horn are filled with a syntactic filler, thereby providing sections 62, 63, 64 and 65, as shown in FIG. 1. After the structure has been allowed to cure at room temperature, successive layers of resin-impregnated bidrectional graphite are formed over the resulting structure to build up the skin 41. This graphite skin structure is caused to conform to the outer surface of the honeycomb and syntactic filter regions under vacuum; it is then cured at room temperature.
Through the use of air stripping ports, one 221 of which is shown in mandrel section 202 of FIG. 3, the horn configuration is then lifted off the mandrel. The resulting structure, when inverted, corresponds identically to what is shown in FIG. 1.
In the manufacture of the configuration shown in FIG. 2, substantially the same procedure described above for the horn structure shown in FIG. 1 is carried out, except that the outer surface of the mandrel employed is shaped to conform with the intended smooth surface of the configuration of FIG. 2 (i.e. there being no corrugations).
As will be appreciated from the foregoing description, the present invention provides an improved waveguide-fed horn antenna structure that is especially suitable for a spaceborne environment. By the provision of an effectively thermally insensitive mechanical distortion constraining mechanism, bowing or warping of both the metallic waveguide feed element and the horn radiator itself are avoided. Thus, a considerable improvement in performance is obtained. Moreover, because of its light weight and reduced physical size, the constraining mechanism yields an overall horn antenna configuration that is "practical" in terms of both launch payload and deployment, as contrasted with the bulky and complex structures heretofore employed.
While we have shown and described several embodiments in accordance with the present invention, it is understood that the same is not limited thereto but is susceptible of numerous changes and modifications as known to a person skilled in the art, and we therefore do not wish to be limited to the details shown and described herein but intend to cover all such changes and modifications as are obvious to one of ordinary skill in the art. | A waveguide-fed horn structure includes a constraining mechanism having an extremely high degree of dimensional stability over a wide thermal range. The constraining mechanism comprises a composite graphite honeycomb structure that forms a support backing for the waveguide feed and for the conductive surface sections of the horn radiator. The conductive surface of the horn radiator is supported on a first section of graphite epoxy laminate while a second section of graphite epoxy laminate supports the honeycomb backing and is bonded to the first section of laminate, thereby effectively surrounding the feed-horn structure with a thermally tolerant, physical distortion constraining support. The graphite epoxy support provides sufficient mass and mechanical stiffness to prevent performance degrading distortion of both the waveguide feed and the horn radiator surface in spite of the severe transient thermal conditions encountered in a spaceborne environment, thereby maintaining structural integrity of the components of the structure during extreme thermal cycling conditions (full sun to no sun). | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a semiconductor device comprising a plurality of functional elements arranged on a substrate.
2. Related Background Art
To date, thin film transistors prepared by using an amorphous silicon thin film for functional elements have a wide variety of applications as switching devices including display devices such as liquid crystal panels and organic EL panels as well as optical sensor panels where they are used in combination with PIN photodiodes comprising an amorphous silicon thin film like TFT elements or photoelectric conversion elements (to be referred to as optical sensor elements hereinafter) such as MIS photocapacitors and TFT optical sensors.
In recent years, efforts have been paid to develop medical applications for optical sensor panels. Particularly, indirect-type radiation imaging apparatus adapted to transform radioactive rays into visible light by means of fluorescent substances to indirectly read the obtained optical information by means of an optical sensor panel and direct type radiation imaging apparatus comprising TFT devices and amorphous selenium to directly transform radioactive rays into electric signals have been developed.
FIG. 15 shows an equivalent circuit diagram of an optical sensor panel comprising TFT elements and PIN photodiodes and FIG. 16 shows a schematic cross sectional view of such an optical sensor panel. In FIG. 15, reference numerals 1010 , 1020 and 1030 respectively denote a PIN optical sensor, a TFT and a signal wire, whereas reference numerals 1040 and 1050 respectively denotes a TFT drive wire and a bias wire of the PIN optical sensor.
In FIG. 16, reference numerals 2010 , 2020 , 2030 , 2040 , 2050 , 2060 , 2070 and 2080 respectively denote a glass substrate, a gate wire, a gate insulating film, an i-type a-Si layer, an SiN layer, an n+ ohmic contact layer, a source/drain electrode and a sensor lower-electrode whereas reference numerals 2100 , 2110 , 2120 respectively denotes P-, I- and N-type a-Si layers. Reference numeral 2090 denotes a sensor upper-electrode and reference numeral 2130 denotes an SiN protection film.
The incoming beam that is carrying image information is subjected to photoelectric conversion by the PIN optical sensor 1010 and its electric charge is stored in a sensor capacity C 1 . Subsequently, when the TFT 1020 is turned on, the electric charge is distributed to a capacity C 2 formed at the crossing of the signal line 1030 and the TFT drive wire 1040 so that the change in the potential of the signal line 1030 is read and output.
Currently, improvements are required of the above-described optical sensor panels in terms of substrate size and process precision in order to meet the demand for a larger display area and a higher degree of definition. However, any such improvements may inevitably entail a huge amount of investment in plant and equipment and a long introductory pre-operational period so that doubts may be cast on such an idea.
In view of this problem, there have been proposed semiconductor devices adapted to produce a large display area by bonding a plurality of relatively small panels. Such semiconductor devices may be realized by using existing plants and equipment for manufacturing small substrates.
FIG. 17 is a schematic perspective view of a radiation image reading apparatus having a large display area and formed by bonding four optical sensor panels. FIG. 18 is a schematic cross sectional view of the device of FIG. 17 . In FIG. 17, reference numerals 3010 , 3020 , 3050 , 3060 and 3400 respectively denote an optical sensor panel, a base, a fluorescent panel, a flexible substrate and a chassis.
Referring to FIG. 18, the base 3020 is used to rigidly hold four optical sensor panels 3010 and typically made of lead that absorbs radioactive rays and protects the electric components arranged therebelow. The sensor panels 3010 are bonded to the base 3020 by way of a first adhesive layer 3030 , while the fluorescent panel 3050 for transforming radioactive rays into visible light is bonded to the sensor panels 3010 by way of a second adhesive layer 3040 . In FIG. 18, reference numeral 3070 denotes a printed substrate for driving the sensor panels and reference numeral 3060 denotes a flexible substrate for connecting the printed substrate 3070 and the sensor panels 3010 .
In FIG. 18, there are also shown a cabinet 3200 , a lid 3210 , a cover 3230 typically made of lead and adapted to protect the electric components, feets 3240 for rigidly securing the printed substrate 3070 and angles 3250 firmly securing the base 3020 to the cabinet 3200 . Note that the chassis 2400 comprises members denoted by 3200 , 3250 . A sensor unit is formed by firmly securing the radiation sensor 3300 within the chassis.
However, when bonding a plurality of panels in a manner as described above, the precision level of the boundaries and that of the clearances separating them are of vital importance.
FIG. 19 is a schematic plan view of four bonded panels. FIG. 20 is an enlarged schematic plan view of a central part of the four bonded panels of FIG. 19, illustrating the boundaries of the panels. In FIG. 20, P denotes the pitch of arrangement of pixels and Pc denotes the distance between the centers of two pixels that belong to different panels and are arranged adjacently relative to each other. In general, correction by way of image processing can properly be carried out, when Pc<2P or the clearance between two panels is made to be less than the size of one pixel. In other words, each sensor panel has to be cut with a margin of several tens of micrometers from the edges of the pixels.
Any attempt for meeting the above requirement is accompanied by the problems as listed below and can end up with a poor manufacturing yield and a poor performance unless they are solved to a satisfactory extent.
1. Some of the pixels of an optical sensor panel can be adversely affected by a cutting operation due to problems such as chipping and/or displacement. Then, the reliability of the sensor panel is lowered after assembling. FIG. 21 is a schematic plan view of a cut area of a sensor panel comprising a pixel 4010 and a protection film 4020 typically made of SiN. In FIG. 21, 4030 denotes a notch formed typically by chipping and 4040 denotes an end facet produced by the cutting. As seen from FIG. 21, the protection film 4020 is partly damaged by notches 4030 . As a result, although the sensor panel operates properly in the initial stages, it has been confirmed that its output fluctuates when it is subjected to high temperature and high humidity.
2. Pixels can be destructed by static electricity appearing in the course of assembling of the panels. Normally, insulating items such as glass substrates can become electrically charged with ease when peeled off in a vacuum chuck stage and/or scrubbed by blown air. When the panel is just brought close to an object having an electric potential difference such as a grounded cabinet, an electric discharge occurs to destroy some or all of the pixels of the panel, particularly those arranged at the corners. Then, a poor manufacturing yield can result.
3. A pixel of the assembled sensor panels can be destroyed along the cut edges, particularly at the corners, when static electricity is accumulated to 2 to 3 kV in the course of handling the panels in the assembling process.
SUMMARY OF THE INVENTION
In view of the above identified problems, it is an object of the present invention to provide a semiconductor device with which a panel having a large area or a narrowly margined panel with the circumferential space minimized can be manufactured stably with a high yield.
More specifically, it is a first object of the present invention to provide a semiconductor device provided with a slice check wire for determining the acceptability of the operation of cutting the panels in order to ensure that the panels to be bonded are cut and bonded accurately, said slice check wire being located at a position with which reliability can be secured to electrically check any possible damages such as chippings to the protection film and other components produced in the cutting process in order to secure the reliability of the product after the assembling process.
A second object of the present invention is to provide a semiconductor device in which any electric cross talks are suppressed by fixing the electric potential of the slice check wire to a constant level.
A third object of the present invention is to provide a semiconductor device having an anti-charge feature for securing the stability and the reliability of the device, which can be achieved by electrically connecting the slice check wire to the drive wires of TFTs or the bias wires of the optical sensor in order to improve the resistance against electrostatic discharge failures and also by fixing the electric potential of the slice check wire to a constant level.
According to the invention, the above objects are achieved by providing a semiconductor device comprising a TFT substrate having a plurality of pixels of a plurality of TFT (thin film transistors) provided on the substrate, slice lines for cutting the TFT substrate being arranged along the periphery of said TFT substrate, peripheral wires being arranged between said slice lines and said TFT substrate.
Preferably, said peripheral wires are connected to at least the drive wires or the signal wires of said TFTs. Preferably, each pixel of said TFT substrate comprises a TFT element and a photoelectric conversion element and said peripheral wires are electrically connected to the bias wires of the photoelectric conversion element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic circuit diagram of an equivalent circuit of a first embodiment of the invention.
FIGS. 2A, 2 B, 2 C, 2 D and 2 E are schematic cross sectional views of the panel section of the first embodiment of the invention including TFTs and photoelectric convesion elements, illustrating different manufacturing steps.
FIG. 3 is an enlarged schematic plan view of a central part of the four bonded panels of the first embodiment, illustrating the boundaries of the panels.
FIG. 4 is an enlarged schematic plan view of one of the panels of the first embodiment, illustrating a corner thereof.
FIG. 5 is a schematic plan view of bonded panels of a second embodiment of the invention.
FIG. 6 is a schematic plan view of a single panel of the second embodiment.
FIG. 7 is a schematic circuit diagram of an equivalent circuit of a third embodiment.
FIG. 8 is a schematic circuit diagram of another equivalent circuit of the third embodiment.
FIG. 9 is a schematic circuit diagram of an equivalent circuit of the third embodiment, illustrating the electric potential of the peripheral area of the driver for driving a TFT.
FIG. 10 is a schematic partial plan view of the third embodiment, illustrating the connection between TFT drive wires.
FIG. 11 is a schematic cross sectional view of the third embodiment taken along line 11 — 11 in FIG. 10 .
FIG. 12 is a schematic partial plan view of the third embodiment, illustrating the connection between a TFT drive wire.
FIG. 13 is a schematic cross sectional view of the third embodiment taken along line 13 — 13 in FIG. 12 .
FIG. 14 is a schematic circuit diagram of an equivalent circuit of a fourth embodiment of the invention.
FIG. 15 is a schematic plan view of a known optical sensor.
FIG. 16 is a schematic cross sectional view of a known PIN optical sensor.
FIG. 17 is a schematic perspective view of a known radiation image reading apparatus.
FIG. 18 is a schematic cross sectional view of the known radiation image reading apparatus of FIG. 17 .
FIG. 19 is a schematic plan view of bonded panels.
FIG. 20 is an enlarged schematic plan view of a central part of the bonded panels of FIG. 19 .
FIG. 21 is a schematic plan view of a cut area of a sensor panel.
FIG. 22 is a schematic illustration of a system using a semiconductor device according to the invention for an X-ray examination apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be described in greater detail by referring to the accompanying drawings that illustrate preferred embodiment of the invention.
(First Embodiment)
The first embodiment of a semiconductor device according to the invention will be described which comprises TFT elements and MIS optical sensors and are applied to a radiation image reading apparatus. FIG. 1 is a schematic circuit diagram of an equivalent circuit of a first embodiment of the invention. In FIG. 1, reference numerals 11 , 12 and 13 respectively denote a driver for driving a TFT, a signal processing amplifier and another driver for driving an MIS optical sensor. FIG. 1 also shows MIS sensors C 11 through C 35 , TFTs T 11 through T 35 , TFT drive wires Vg 1 through Vg 3 , signal wires Sig 1 through Sig 5 and bias wires Vs 1 and Vs 2 .
The MIS optical sensors C 11 through C 35 are provided to receive optical signals to be applied to the bias wires Vs 1 and Vs 2 from the driver 13 . The electric charges of each optical signal is stored in the MIS optical sensor. The accumulated electric charges are then sequentially read out by the TFTs (T 11 through T 35 ) by way of the signal lines Sig 1 through Sig 5 and the signal processing amplifier. The TFTs are sequentially turned on/off by signals applied thereto by the TFT driver 11 by way of the TFT drive wires Vg 1 through Vg 3 . In FIG. 1, Sc denotes a slice check wire whose electric potential is held to the ground level by the TFT driver and the MIS optical sensor driver.
Now, the preparing steps of the embodiment will be briefly described by referring to FIGS. 2A through 2E, showing schematic cross sectional views of an optical sensor panel.
(1) As shown in FIG. 2A, a Cr film is formed on a glass substrate 101 to a thickness of 1,000 Å by sputtering and then lower electrodes 102 of the MIS optical sensors, gate electrodes 103 and gate wires 104 of the TFTs, slice lines for cutting the panel and slice check wire are provided there by means of a patterning operation.
(2) Then, as shown in FIG. 2B, a silicon nitride (SiN) film 105 , an amorphous silicon (Si) film 106 , an ohmic (n+) layer 107 are successively formed by plasma CVD to respective thicknesses of 3,000 Å, 5,000 Å and 1,000 Å and then contact holes 108 for connecting the lower electrodes of the MIS optical sensors and the TFTS-D electrodes and those for drawing wires are provided typically by CDE.
(3) Thereafter, as shown in FIG. 2C, an aluminum (Al) film is formed by sputtering to a thickness of 1 μm and TFTS-D electrodes 109 , signal lines 110 and bias wires 111 of the optical sensors are formed there by way of wet etching.
(4) Subsequently, as shown in FIG. 2D, the ohmic (n+) layer 107 at the TFT gap is removed by means of RIE to form a TFT channel 112 .
(5) Then, as shown in FIG. 2E, the panel is processed for element isolation and a silicon nitride (SiN) film 113 is formed as a protection film by plasma CVD to a thickness of 9,000 Å. Thereafter, openings are formed therethrough for the pads of the drawn wires typically by RIE.
As a result of the above steps, a single panel is produced and then checked for any defects to determine if the panel is acceptable or not, thereby completing the early stage of the process.
Then, in the middle stage of the process, the components of the optical sensor panel are electrically mounted.
(6) Polyimide is applied by spin coating and then cured by heat. Subsequently, the panel is cut along the slice lines to predetermined dimensions.
(7) The conductivity of the slice check wire is examined.
(8) Electric connections including TAB connections and PCB connections are established and subsequently the slice check wire is checked again for electric conductivity.
With the above steps, modules to be bonded together are produced. Then, in the final stage of the process, they are assembled to produce a large panel.
(9) The panels are bonded to the base and then a fluorescent panel is bonded thereto. Thereafter, an Al sheet is bonded.
(10) The resulting assembly is housed in a cabinet and subjected to a final examination.
Thus, a complete semiconductor device to be used for a radiation image reading apparatus is produced. Since the risk of damage due to static electricity is reduced after connecting the drivers, the slice check wire may be cut and removed after mouting the drivers in position, although it may be left there if it does not give rise to any problem.
FIG. 3 is an enlarged schematic plan view of a central part of the four bonded panels of the first embodiment, illustrating the boundaries of the panels. The pixel size of this embodiment is 160 μm. In FIG. 3, the center of pixel refers to the center of gravity of the optical sensor, which agrees with the optical center of the pixel. Therefore, so far as the distance separating the centers of any two adjacently located pixels of two adjacent panels is smaller than the size of two pixels or 320 μm, the area to be used for the bondig can be increased so that the panels can be cut safely. This can be achieved when the centers of the optical sensors are positioned toward the center of the bonded panels by appropriately arranging TFTS. With this embodiment, the distance separating the pixel regions of two adjacent panels can be increased from 160 μm to 188 μm or 202 μm.
FIG. 4 is an enlarged schematic plan view of one of the panels of the first embodiment, illustrating a corner thereof. In FIG. 4, reference numerals 41 , 42 and 43 respectively denotes a slice line, a slice check wire and an SiN protection film, whereas point “a” shows the center of gravity of the pixel.
The SiN protection file 43 is separated from the edges of the pixel by 25 μm and the slice check wire 42 is arranged in the SiN protection film with the minimal width to secure its performance in a reliability test under high temperature/high humidity. The panel is sliced so as to cut off the slice lines. Note that the slice liens are separated from the corresponding respective edges of the SiN protection film by 45 μm to provide a margin for accommodating it to any displacement of chipping or slicing. The margins are made free from the SiN protection film, because, if cracks appear in the SiN protection film, they can be extended to the pixel.
How, the slice check line of this embodiment is used will be discussed below. As pointed out above, if the SiN protection film is damaged by any unexpected displacement due to slicing or chipping, the slice check line can also be damaged. However, by checking electric conductivity by means a pad Cp arranged on the slice check wire shown in FIG. 1, any abnormal condition of the panel is detected so that any defective sensor panels can be prevented from being mingled with good ones.
As a result, it is now possible to by far reliably detect defective devices if compared with conventional visual examination processes. Additionally, it is also possible to examine each device by means of the slice check wire at significant points in the subsequent steps so that absolutely no defective devices may be detected after bonding a plurality of optical sensor panels for each device.
Particularly, since pixel destructions due to static electricity can occur anytime until the TFT driver and the photoelectric conversion element driver are mounted and become electrically operable, the examination using the slice check wire may have to be repeated until that time.
While the above embodiment is described in terms of TFTs used as functional elements, the present invention is by no means limited thereto and the TFTs may be replaced by diodes or thin film diodes.
(Second Embodiment)
While the circuits for driving the elements of the first embodiment are arranged only on are side of the substrate, this embodiment is provided with drive circuits arranged on both sides of the panel in order to perform a high speed drive operation. In this embodiment, a pair of sensor panels are bonded together. FIG. 5 is a schematic plan view of the panel section of a second embodiment of the invention, illustrating how panels are bonded. In FIG. 5, reference numerals 101 , 102 denotes respective sensor panels and reference numeral 103 denotes an amplifier side leading wire connected to an amplifier IC, whereas reference numeral 104 denotes a driver side leading wire connected to a driver IC. For each of the sensor panels of this embodiment, a driver side leading wire is arranged on each side of the panel to realize a high speed drive operation.
As in the case of the first embodiment, after a slice check wire is arranged along the periphery of the TFT substrate and cut at the slice lines, it is possible to check the electric conductivity to detect any defective device. If a single sensor panel has dimensions sufficiently large for forming a semiconductor device, no bonding operation is required and hence the drivers may be arranged on both sides of the panel. If it is desirable to locate the pixel region extremely near the chassis, a single sensor panel is used in which the cutting section is arranged in the direction that is required. Then, pixels may be read in areas close to the chassis. FIG. 6 is a schematic plan view of the panel section of the second embodiment realized by using a single panel. In FIG. 6, there are shown a signal reading circuit 105 , a sensor drive circuit 106 and a chassis 107 . As seen from FIG. 6, it is possible to arrange a peripheral pixel area A close to the chassis and to read the image in the region close to the chassis.
While the above embodiment is described in terms of TFTs used as functional elements, the present invention is by no means limited thereto and the TFTs may be replaced by diodes or thin film diodes.
(Third Embodiment)
The third embodiment of semiconductor device is applied to a radiation image reading apparatus and comprises TFT elements and MIS photoelectric conversion elements. FIG. 7 is a schematic circuit diagram of an equivalent circuit of the second embodiment. In FIG. 7, reference numeral 11 denotes a TFT driver and reference numeral 12 denotes a signal processing amplifier, whereas reference numeral 13 denotes an MIS photoelectric conversion element driver.
In this embodiment, wires Vs 1 , Vs 2 , which are bias wires of optical sensors, are connected to each other by way of resistance Rvs. Additionally, TFT drive wires Vg 1 through Vg 3 are connected to each other by way of resistance Rs, while wires Vs 1 and Vg 1 are connected to each other by way of resistance Rv. Slice check wire Sc is connected to wire Vs 4 by way of resistance Rvc and to wire Vg 1 by way of resistance Rgc. Alternatively, it may be connected to the signal lines or only to the TFT drive wires as shown in FIG. 8 . While not shown, it is also possible to connect it only to the bias wires.
If the resistance between the TFT driver and the first TFT is set to Ro and the resistance between the Vg wires is set to Rs, a resistance with which the ON voltage Vgh applied to the Vg wires does not affect any adjacent lines may be selected for the resistance Rs. Note that the adjacent lines are held to the OFF voltage Vg 1 .
FIG. 9 is a schematic circuit diagram of an equivalent circuit of the second embodiment, illustrating the electric potential of the peripheral area of the driver for driving a TFT. Referring to FIG. 9, the adjacent lines can be held OFF if the potential Va of point “a” is lower than the threshold voltage Vth of the TFTS.
Vth>Va=Vg 1 +( Vgh−Vg 1 )× Ro /( Rs+ 2 Ro )(1) Rs>Ro ( Vg 1 − Vth− 2 Vth )/( Vth−Vg 1 )
Since Vg 1 =−5V, Vgh=15V, Vth=2V and Ro=100 Ω; then Rs>86 Ω.
Similarly, as for the resistance Rv, since Vsh=9V at the time when the bias wires Vs of the optical sensors are used to read light, Vsh−Vg 1 =15V in conparison with Vgh−Vg 1 =20V above. Thus, any failure of the TFTs can be prevented by driving the Vs wires if at least Rv>Rs. If fluctuations of the Vs potential are to be held within the range in which no problem is caused with respect to the performance, they have to be less than 1%. Then, the resistance Rv needs to satisfy Rv>100×Ro. In this embodiment, it is satisfied if Rv>10 kΩ. As for Rvs, in order that fluctuations of the bias voltage of the optical sensors are less than 1%, Rvs need to statify Rvs>100×Ro.
Furthermore, if Vg 1 =0V in formula (1) above, the connection resistance Rgc between the Sc wire, or the slice check wire, and the Vg 1 wire is equal to 550 Ω, or Rgc=550 Ω. Fluctuations of the bias voltage of the optical sensors can be held less than 1% if the connection resistance Rvs between the Sc wire and the Vs 4 wire is greater than 100×Ro, or Rvs>100×Ro.
In this embodiment, any related wires can be connected by way of an ohmic (n+) layer. A standard value of 1MΩ is selected to provide each resistance with an enough margin.
FIG. 10 is a schematic partial plan view of the third embodiment, illustrating how Vg wires are connected. In FIG. 10, reference numerals 51 and 52 respectively denote an Al wire and a Cr wire, whereas reference numerals 53 and 54 respectively denote a contact hole and an n+ connecting wire.
When connecting the Vg wires by way of an n+ layer, the Al wires are connected to the respective Cr wires by way of respective contact holes in order to reduce the wire resistance of the Vg wires in the areas other than the pixel region. The Al wires are connected by way of an n+ layer.
FIG. 11 is a schematic cross sectional view of the third embodiment taken along line 11 — 11 in FIG. 10 . In FIG. 11, reference numerals 58 and 55 respectively denotes a glass substrate and a gate insulating film and reference numerals 56 and 57 respectively denotes a semiconductor layer and an n+ ohmic contact layer. In this embodiment, the n+ layer is made to have a thickness of 1,000 Å as in the case of Embodiment 1 and has a sheet resistance of 100 kΩ/□. Since the pitch of pixel arrangement is 160 μm, the value of 1MΩ can be achieved by using ten or more than ten sheets. In this embodiment, any wires are connected with a clearance of 10 μm. Similarly, the Vs wires are connected by way of an n+ layer.
Now, the technique of connecting a Vg wire and a slice check wire will be described below. FIG. 12 is a schematic partial plan view of the third embodiment, illustrating how a TFT drive wire and a slice check wire are connected. The slice check wire that is a Cr wire is connected to the Vg wire by way of a contact hole. FIG. 13 is a schematic cross sectional view of the third embodiment taken along line 13 — 13 in FIG. 12 . The Vg wire 51 and the slice check line 52 are connected by way of contact hole 53 . Here again, the n+ layer is so drawn as to make the wire resistance equal to 1MΩ. The slice check wire may be cut and removed in the area connecting the TFT drive wires and the photoelectric conversion element drive wires after checking the conductivity of the slice check line or simply left there if it does not interfere with the operation of the related elements by appropriately adjusting the connection area.
While the above embodiment is described in terms of TFTs used as functional elements, the present invention is by no means limited thereto and the TFTs may be replaced by diodes or thin film diodes.
(Fourth Embodiment)
Now the fourth embodiment of the invention will be described. In this embodiment, the slice check line and the Vs wires are connected without specifically providing any resistance. FIG. 14 is a schematic circuit diagram of an equivalent circuit of a fourth embodiment of the invention. In this embodiment, the Vs 4 wire and the slice check wire Sc are connected in the same layer, although they may be alternatively arranged in different layers and connected between the different layers. Still alternatively, the Vs 1 or Vs 2 wire may be connected to the Sc wire. In this embodiment, the electric conductivity of the slice check wire is checked with a pad Cp for conductivity check to check defectives after cutting the panels, so that the slice check wire may be firmly held to a constant potential, which is not the ground potential, and hence the elements of the device can be protected against damages due to static electricity.
The present invention is also effective for narrowing the margins of liquid crystal panels. A liquid crystal panel is prepared by arranging a pair of glass substrates, forming elements on the substrates, cutting the substrates to desired dimensions, subsequently bonding the substrates and pouring liquid crystal in the space between the substrates. Then, electric components including drivers are mounted therein. Therefore, in the case of a liquid crystal again, defective products can be prevented from being mingled with good ones by connecting the slice check wire to the drive wires and examining the electric conductivity of the slice check wire. Additionally, the pixels can be protected against demages due to static electricity by connecting the TFT control lines to the slice check wire. Since normally a pair of substrates are bonded together and liquid crystal is poured into the gaps separating the substrates in the process of manufacturing liquid crystal panels, the conductivity check may be conducted either before or after bonding the substrates. For a liquid crystal panel, it is not necessary to keep the potential of the slice check wire constantly to the same level.
While the above embodiment is described in terms of TFTs used as functional elements, the present invention is by no means limited thereto and the TFTs may be replaced by diodes or thin film diodes.
(Fifth Embodiment)
FIG. 22 is a schematic illustration of a system using a semiconductor device according to the invention for an X-ray examination apparatus.
Referring to FIG. 22, X-rays 6060 generated by an X-ray tube 6050 are made to be transmitted through the chest 6062 of a patient or subject 6061 , and enter the photoelectric converter 6040 provided on the surface with a fluorescent substance. For apparatus in which a substance (e.g. GaAs) having sensibility to radioactive rays such as X-ray is employed, however, the apparatus can sense radioactive rays and can be used as a radiation detection apparatus without providing a wavelength converter such as a fluorescent substance. The incoming X-rays contain information of the interior of the patient 6061 . The fluorescent substance emits light as a function of the incoming X-rays and the photoelectric converter 6040 converts the emitted light into electric information, which is digitized and processed by an image processor 6070 so that it can be observed on a display 6080 in the control room.
The obtained information can be transferred to a remote site by way of an appropriate transmission means such as a telephone wire 6090 so that it may be displayed on a display 6081 in a doctor room of the remote site or stored in a storage means such as an optical disk. Therefore, the doctor at the remote site can diagnose the patient. The information may also be recorded on a film 6110 by means of a film processor 6100 . | A semiconductor device with which a panel having a large area or a narrowly margined with the circumferential space minimized can be manufactured stably with a high yield. The semiconductor device comprises a TFT substrate having a plurality of pixels of a plurality of TFT (thin film transistors) provided on the substrate in which a peripheral wire is arranged along the outer periphery of the TFT substrate and connected to a constant potential. | 7 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/196,172, filed Mar. 4, 2014, which is a continuation of U.S. application Ser. No. 12/215,713, filed Jun. 27,2008, now issued as U.S. Pat. No. 8.730,321, which claims priority on U.S. Provisional Application Ser. No. 60/937,618, filed Jun. 28,2007, all disclosures of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0002] An apparatus and method for insuring the proper alignment of a defected vein pattern and a projected vein pattern in a apparatus that enhances the visual appearance of veins so that an error that can lead to improper patient care or injury can be avoided.
BACKGROUND OF THE INVENTION
[0003] It is known in the art to use an apparatus to enhance the visual appearance of the veins and arteries in a patient to facilitate insertion of needles into those veins and arteries as well as other medical practices that require the identification of vein and artery locations. Such a system is described in U.S. Pat. Nos. 5,969,754 and 6,556,858 incorporated herein by reference as well as publication entitled “The Clinical Evaluation of Vein Contrast Enhancement”. Luminetx is currently marketing such a device under the name “Veinviewer Imaging System” and information related thereto is available on their website, which is incorporated herein by reference.
[0004] The Luminetx Vein Contrast Enhancer (hereinafter referred to as LVCE) utilizes a light source for flooding the region to be enhanced with near infrared light generated by an array of LEDs. A CCD imager is then used to capture an image of the infrared light reflected off the patient. The resulting captured image is then digitally enhanced and then projected by a visible light projector onto the patient in a position that must be closely aligned with position of the captured image. The practitioner uses this projected image to determine the position in which to insert a needle. Should the image be misaligned, the patient can be injured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 shows an embodiment of a vein contrast enhancer.
[0006] FIG. 2 is a representation of a patient's arm.
[0007] FIG. 3 shows an embodiment of a laser contrast enhancer.
DETAILED DESCRIPTION OF THE INVENTION
[0008] As shown in FIG. 1 , a typical embodiment of a vein contrast enhancer (VCE) 100 contains a camera 101 which is used to capture an image of a patient's body 105 , a processing system (not shown) that enhances the image captured by the camera to highlight the positions of veins, and a projector 102 that shows an image of the enhanced vein pattern back onto the patient's body 105 . Since the camera and projector are physically separate devices they reach the patient's body front different source points along different paths 103 , 104 . In some embodiments, the paths are made coaxial within the body of the VCE, however at some point the paths are separate since the devices (camera and projector) are physically separate devices. Since the purpose of a VCE is to allow the practitioner to insert a needle into the highlighted vein, it is critically important that the projected image and the actual vein location be aligned. Typically this alignment is done as a separate step in the use of the VCE. A card with a known pattern is placed with the viewing/projecting field of the VCE. This card has a florescent material applied to it so that when it is struck by green light, it emits infrared light that can be seen by the camera. This image is used to align the VCE.
[0009] This invention describes methods for achieving this alignment without requiring the operator to take a separate step.
[0010] Referring to FIG. 2 , a representation of the patient's arm 201 is shown along with several veins. A bounding box is shown around a single vein 200 . In FIG. 3 , a schematic representation of the bounded area of the single vein is shown 305 . Typically, the enhancement image will light up the area around the vein and will be dark on the vein. When properly aligned, the bright part of the image 300 will have edges that property align with the edges of the vein 303 , 304 . As previously described, the VCE will typically have an alignment mode wherein a known pattern, typically presented on an alignment card, will be placed in front of the VCE and an alignment will be performed. This alignment can either be automatically performed by the VCE or manually performed by the operator. The weakness of this kind of implementation is that it relies on the expectation that the alignment will be maintained over time. If the alignment should shift, patient injury can occur.
[0011] In a typical VCE, an infrared light source and a camera that is sensitive only to infrared light is used to detect the vein position. Furthermore, the projected image is often green in color to insure that the light from the projector is ignored since the camera is sensitive only to light near the infrared region. This selectivity can be implemented either with filters or with selectively sensitive camera elements.
[0012] Referring back to FIG. 3 , in a typical LCE, the camera, by design, is blind to the projected light. In our invention, the camera is by design, able to selectively see the projected light. In a preferred embodiment, a multi-color capable projector is used. As usual, green is used to fill the area outside of the vein 500 . That green projection goes to the edges of the vein position 303 , 304 and the vein area itself is left dark. A camera that is sensitive to red and infrared light is used in this embodiment. In addition to the green fill, red lines are drawn at the edges of the veins 303 , 304 . Since the camera can see these red lines, the image enhancement software can look to see if the red lines are at the proper position and if needed automatic alignment can be performed. An alternative embodiment would be to paint a red line 306 down the middle of the vein position. An alternative embodiment would be to paint some pattern of red light over a desired portion of the vein.
[0013] Typically the cameras used in an LCE are monochrome and unable to discriminate between light of different wavelengths. Depending on the sensitivity of the camera and the brightness of the projector compared to the infrared flood lighting provided by the LCE, various techniques can be used to aid the camera in the detection of the red lines. One method is to simply look for the brightening caused by the addition of the red lines to the reflected infrared light. A second method is to periodically turn off the infrared lighting such that only ambient infrared and the projected red are seen by the camera. This can make it easier for the system to detect the red lines.
[0014] Although, we've described the invention using red and green limits, various combinations of colors can be used. Red and infrared light are known in the art to be useful for vein detection. Any combinations of colors of shorter wavelengths can be used for projection and alignment images as long as the camera selected is properly selected or filtered to achieve the desired discrimination between wavelengths. Furthermore, while discrimination between projection, detection and alignment signals in the preferred embodiment has been described using different wavelengths to separate the signals, in an embodiment with less freedom of projected color, time division can be used where the projected image is shown most of the time and the alignment image is shown interspersed on a lower duty cycle basis. Properly implemented, the alignment image will be quite visible to the VCE's camera, but invisible to the operator of the VCE.
[0015] Projectors in VCEs can be either monochrome (e.g., projecting green only) or multicolor (e.g., projecting RGB). The advantage of a monochrome implementation is that since an array of single color LEDs can be used in place of white bulbs and a color wheel typically found in a multicolor projector the system can be Of lower cost, generate less heat and have higher reliability. In such an embodiment, the time division scheme describe above would be appropriate. In this monochrome configuration, an alternative embodiment would be to add a smaller array of a second color of LEDs (i.e., red). This alignment array can be smaller than the projection array in that it doesn't need to be visible to the operator, just to the camera. The projection LEDs and the alignment LEDs could then be time multiplexed as previously described. | An apparatus and meted for insuring the proper alignment of a detected vein pattern, and a projected vein pattern are disclosed. The apparatus enhances the visual appearance of veins so that an error that can lead to improper patient bare or injury can be avoided. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to a filter insert including a material permeable to fluid and having a number of planar fold walls arranged in a substantially continuous zigzag shape and including depressions and/or elevations stamped into the plane of at least a part of a respective one of the fold walls in order to stiffen the fold walls, the depressions and/or elevations of adjacent fold walls being connected to one another at least partially and being supported on one another.
Filter inserts of the above types are used to remove contamination from a fluid flowing through a filter, particularly air or industrial gasses, but theoretically liquids as well. At present, filter elements consisting of a micro fibre fleece, particularly glass fibres, are predominantly used in air filters.
In order to increase the effective filter area relative to the inflow surface of the air filter which forms a filter element or filter area, the filter medium is folded in a zigzag shape so as to produce a number of folds adjoining one another via fold edges, which are located at an acute angle to the walls of the folds and through which the medium to be purified flows at right angles to the direction of the fold edges.
As a result of the depositing of material, and particularly the settling of larger particles, on the inflow side of the filter, turbulence in the inflowing fluid, slight irregularities in the folds, etc, inhomogeneities may occur in the fluid flow as the fluid flows through the filter, thereby subjecting the fold arrangement to strong mechanical alternating stresses and possibly bringing about deformation of the fold arrangement.
In order to hold the folds at a specified distance from one another and mechanically stabilise the fold arrangement of the filter insert, the folds are therefore provided with projections protruding from the plane of the fold walls, as described for example in U.S. Pat. No. 3,531,920 or, according to another special embodiment, in DE 41 26 126 A1, in such a way that the projections of adjacent fold walls abut on one another and the fold walls support one another. In order that the fold walls are directed at an inclined angle to the incoming fluid, ie. the fold layers are substantially triangular in cross section, the projections must also be approximately triangular or trapezoidal in cross section.
These arrangements have proved suitable for filter inserts with a fold height up to about 100 mm, with relatively tightly packed folds. Beyond this fold height and with larger fold spacings, however, the depth of impression required is so great that, with conventional filter materials, there is the risk of the folds being punched through, thereby unacceptably increasing the number of rejects.
It is also known from DE 40 38 966 to place separate spacers with the same function on the fold walls or to insert said spacers therein. The spacers may be adhesive aggregates, particularly in fibre form, as mentioned as a possibility in the specification referred to above or as illustrated in DE 30 37 019 A1. In addition to acting as spacers, they also have the effect of connecting the fold walls and thus further increasing the rigidity of the filter insert.
The adhesive is applied before the folding of the filter material onto the flat strip, and the fold walls are adhered by the contact of the adhesive threads with one another during the folding operation. This solution is therefore only suitable for very densely packed folds. In addition, the fold layers formed in this way tend to have a meandering configuration in cross section, which does not lead to optimum flow qualities.
DE 39 03 730 A1 describes how an adhesive thread which joins the fold layers together and stabilises them and which may be applied to the edge area after folding, is combined with impressions in the fold walls. This solution results in mechanically very stable filter inserts, but is subject to essentially the same restrictions as the solutions without adhesive in terms of the fold height and fold spacing which can be achieved.
DE 42 06 407 describes how the fold edge area of a previously folded length of filter material is covered with a fine web of adhesive threads in order to join the folds together and stabilise the filter insert. This solution is no longer practical for larger fold spacings since the fine adhesive web cannot produce a sufficiently stable attachment of fold edges which are spread further apart and the filaments of the web "sag" (particularly when applied from below to a folded material located above during the manufacturing process) and do not assume a defined position relative to the fold edges.
From EP 0 377 419 A1 an arrangement is known in which adhesive aggregates of varying sizes (larger at the top and smaller at the bottom) located in the top and bottom areas of a fold wall arrangement which is to be formed are to be used to adhere walls of folds in a manner such as to produce a substantially triangular cross section of fold. However, larger fold spacings and heights cannot be achieved by this method because extremely bulky adhesive aggregates would be required which would greatly reduce the effective filter surface.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a filter insert of the kind described which, by virtue of its very construction, makes it possible to produce filter inserts of considerable height and/or considerable fold spacings, as well as a process for producing this filter insert.
The above and other objects are accomplished according to the invention by the provision of a filter insert for a fluid filter, comprising: a material permeable to fluid and having a number of planar fold walls arranged in a substantially continuous zigzag shape and including depressions and/or elevations stamped into the plane of at least a part of a respective one of the fold walls in order to stiffen the fold walls, wherein the depressions and/or elevations each have a longitudinal extent and adjacent fold walls connected at a common fold edge define a fold; and rigid spacers joining a part of the longitudinal extent of the depressions and/or elevations of adjacent fold walls.
According to a further aspect of the invention there is additionally provided a process for preparing a filter insert for a fluid filter, comprising steps of: providing a length of fluid-permeable material with a layer of impressions which determine future fold edges that define future fold walls when the material is folded along the impressions; stamping depressions and/or elevations into a plane of at least a part of the future fold walls in order to reinforce the future fold walls; folding the material along the impressions to form fold edges and to form a substantially continuous zigzag shape of fold walls so that the depressions and/or elevations of adjacent fold walls are placed together; and applying, before or during the folding, a spacer material to the depressions and/or elevations placed together as a result of the folding.
The invention includes the idea of producing the considerable height of spacers between the folds which are required for large fold spacings or a high fold height (with consequent areas having a large fold spacing) by a combination of spacers stamped into the filter material and separate spacers applied to the filter material. This means that, when using the application of adhesive, known per se, this must be of appreciable thickness or height at least on those areas where the fold walls to be connected together have a considerable spacing, and it also means that the height of the separate spacer need not be constant over the length of a fold wall, ie. from the bottom or "point of the fold" to the very tip of the fold.
This can be achieved in particular by making the separate spacers continuously thinner towards the "point of the fold" in harmony with the reduction in the cross section of the fold in question.
It can also be achieved by providing two or more separate spacers in the direction of the longitudinal extent of the depressions or elevations in the filter material and by having one spacer, adjacent to the "point of the fold", thinner than a spacer located further away. If the application of adhesive is used for production, this may have a constant thickness within the two (or more) separate areas or islands of adhesive, so that there is no need to change the cross section continually.
In another embodiment, an applied (adhesive) spacer may be provided solely in those areas where the fold walls are at a large spacing, whilst in the tighter areas of the fold walls there is no spacer or the adhesive is of negligible thickness, the quantity applied being such that it essentially penetrates into the filter material.
The spacers may be constructed in their overall height so that the height of the recesses or elevations stamped into the material is substantially constant in the direction of the longitudinal extent thereof, ie. the change in height required according to the zigzag shape of the fold cross section results exclusively from the change in thickness of the separate spacer (of the applied layer). The filter material may, for example, be provided with substantially continuously grooves.
On the other hand, however, the construction may be such that the height of the recesses or elevations in two fold walls resting against each other decrease towards the fold edge connecting these fold walls together. Thus, both the indentations and the added spacers help to achieve the change in spacing.
The embodiments mentioned are suitable both for filter inserts in which the folding secures a body shaped like a block, ie. for use as an air or gas filter in the natural gas and petroleum industry, in energy saving or for air ventilation and air conditioning plant. However, they are also suitable for cylindrical filter inserts in which the folding secures a body shaped like a hollow cylinder, ie. for use in air filters for motor vehicles.
In an advantageous special embodiment of the depressions or elevations stamped into the filter material, the latter have a first section of increasing height and a second section of constant height, arranged one after the other in the direction of longitudinal extent.
In a preferred embodiment thereof, at least in part of the second portion of elevations facing one another, there is a spacer (adhesive aggregate), the thickness of which, together with the sum of the heights of the elevations (which are constant in this part) correspond to the spacing to be achieved between adjacent fold walls at the site of the adhesive aggregate. The adjacent fold walls are simply supported on one another by means of the elevations and the adhesive aggregate and at the same time join together with a degree of stability which is adequate for numerous applications.
It is also possible for a number of adhesive aggregates located at individual points and having different heights to be provided in the second part of the length of the elevations.
The adhesive aggregate may, in particular, be a layer of adhesive running along the longitudinal extent of the elevation, substantially covering the second part of the length thereof (ie. the part having a constant height) and becoming increasingly thicker as its distance from the fold edge or from the first part of the elevation increases. Compared with one or more adhesive aggregates applied only at isolated points, adhesion is more stable, but this embodiment requires more precise control of the application of adhesive.
A further increase in the stability of the filter insert can be achieved if a cohesive layer of adhesive is provided along the entire length of elevations facing one another, this layer then having a constant thickness, which is minimal compared with the height of the elevations, in the first part of its length and having a thickness which increases as the spacing of the fold walls increases, in the second part of its length.
With regard to the exact location of the elevations or depressions, there are two basic possibilities to distinguish:
On the one hand, the first part of the depressions or elevations may start immediately at a fold edge, the height thereof then increasing from this point to the maximum height with a pitch which corresponds to half the pitch of the wall spacing.
On the other hand, the depressions or elevations may begin at a predetermined spacing (a) from a fold edge and then have a third part located between the fold edge and the above-mentioned first part in which their height initially increases more than half the spacing of the fold walls until it reaches a height corresponding to half the wall spacing. This embodiment has the technological advantage that there is no need for numerous indentations in the immediate vicinity of the fold edge, which in any case is provided by an indentation in the filter fleece. This reduces the risk of damage to the filter fleece at this point and hence the reject quota.
For reasons of stability, indentations or elevations facing in two directions will be stamped into the fold walls, so that the fold walls are supported on adjacent fold walls. However, this is not absolutely necessary.
Depending on the particular construction of the spacers, the process according to the invention may be carried out so that the quantity of adhesive applied per unit of length in the direction of the longitudinal extent of the indentation of elevation carrying the spacer with decreased thickness is designed to decrease towards the indentation which marks the eventual "point of the fold".
Alternatively, or in conjunction therewith, the application of adhesive may be interrupted at least once in the direction of the longitudinal extent of the indentation or elevation carrying it and the quantity of adhesive applied per unit of length of the strip of filter material, beyond the interruption, towards the indentation which marks the position of the "point of a fold" may be less than the amount used this side of the interruption, ie. in the wide open part of the fold, where the spacer has to be higher up.
According to an advantageous combination of both possibilities, the adhesive is supplied continuously, one after another (through a plurality of nozzles or in some cases by simply guiding the same nozzle over the area in question) and above or below this adhesive is applied discontinuously. Using this principle, a variety of spacer profiles can be produced.
For the filtering performance it is beneficial if the smallest possible surface of the filter material is covered with the spacer (the adhesive).
This can be achieved if the application is spatially precisely defined, preferably essentially linear, ie. smaller in width than the length of the layer. This presupposes the choice of a suitable adhesive--with wetting properties matched to the filter material--and the correct choice of a pasty to gel-like consistency, so that at least the adhesive is spread broadly over the filter material before it hardens, but if possible a spatially precisely defined adhesive aggregate can be applied to the filter material.
The quantity of adhesive applied per unit of length of the filter material can be varied--as a theoretical possibility--by varying the quantity of adhesive delivered per unit of time from an applicator device to the length of material travelling past. In order to vary the quantity of adhesive per unit of time, the cross section of the outlet opening of the applicator device can be adjusted accordingly, ie. specifically its cross section can be reduced as it comes closer to the fold lines which are to mark out the future "points of the folds" and enlarged again as it moves away from these lines.
Additionally or alternatively, in order to very the quantity of adhesive per unit of time, it is possible to control the delivery pressure from the applicator device accordingly.
Another possibility, which may in turn be combined with the other possibilities, is to apply the adhesive in several layers one on top of the other over partial areas of the longitudinal extent of the spacers. This can again be achieved by means of a plurality of nozzles of by simply spreading the areas over an dover again with the same nozzle.
Finally, again in combination with one or more of the other possibilities, the quantity of adhesive applied per unit of length of the strip of filter material can be changed by varying the relative speed between the length of material and the outlet opening of an applicator device.
Specifically for producing the filter insert with indentations having one area of increasing height and one area of constant height, the quantity of adhesive applied per unit of length of the material, in the direction of the longitudinal extent of the elevations, is appropriately maintained at a predetermined first level over the first part and increased steadily from the first level upwards over the second part, the first value particularly being 0, ie. there is no need for any application of adhesive in the first part.
It should be noted that, in the present embodiments, the material which is permeable to the fluid includes any conventional filter materials or those which may be used for certain fluids, particularly fibre fleeces of cellulose, glass fibres, mineral fibres or ceramic fibres, fine-meshed fabrics with or without impregnation, etc, and the adhesive referred to include the materials which can be used together in order to form a material connection between such materials, especially adhesives in the narrower sense, but also thermoplastic or foam materials or the like which will adhere to the filter material.
The essentially zigzag-shaped continuous folding also includes two fold arrangements in which the fold cross section perpendicular to the fold edges is substantially trapezoidal or the fold edges are rounded.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantageous features of the invention are described hereinafter by the following description of the preferred embodiment of the invention, with reference to the drawings, wherein:
FIGS. 1a to 1d are perspective schematic diagrams of filter inserts according to the embodiments of the invention,
FIGS. 2a and 2c are diagrammatic cross sectional views of the fold arrangements (perpendicularly to the fold edges) in special embodiments of filter inserts similar to that in FIG. 1a,
FIGS. 3a to 3c are diagrammatic cross sectional views of the fold arrangements (at right angles to the fold edges) in particular embodiments of filter inserts similar to that in FIG. 1b,
FIGS. 4a to 4d are diagrammatic cross sectional views of the fold arrangements (at right angles to the fold edges) in particular embodiments of filter inserts similar to that in FIG. 1c,
FIGS. 5a to 5d are diagrammatic cross sectional views of the fold arrangements (at right angles to the fold edges) in particular embodiments of filter inserts similar to that in FIG. 1d,
FIG. 6 is a diagrammatic cut-away view of a stamped length of filter material as an intermediate product for producing a filter insert according to FIGS. 5a to 5d,
FIGS. 7a and 7b are diagrammatic cross sectional views of the fold arrangements (parallel to the fold edges) in a filter insert according to FIG. 1d or a modified embodiment thereof and
FIG. 8 is a diagrammatic cross sectional representation of the fold arrangement (perpendicular to the fold edges) in an embodiment of a hollow cylindrical filter insert.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1a shows, in highly simplified form, a filter insert 1A, which is substantially box-shaped in its outer configuration, consisting of a glass fibre filter fleece 2 impregnated with synthetic resin, which is provided with corrugation-like depressions 3 stamped on one side and is folded in a substantially zigzag-shaped with (slightly rounded) upper and lower fold edges 4a and 4b, so that the depressions 3 stamped in face each other in every two adjacent fold walls 5. The depressions or corrugations 3 are at an increasing distance from the lower fold edges 4b, ie. as the width of opening of the folds increases.
The fold spacings of the folds are made so great (in order to achieve certain parameters of use) that the top surfaces of depressions 3 located opposite one another do not touch one another.
On each of the top surfaces 3a is a layer of adhesive 6 which becomes thicker towards the lower fold edges 4b. The adhesive layers of top surfaces 3a lying opposite one another are joined together, as a result of which (once the adhesive has cured) the opposing depressions 3 and hence the corresponding fold walls 5 are firmly joined together and support one another substantially rigidly so that the filter insert 1 is mechanically rigid.
FIG. 1b shows a filter insert 1B modified from the embodiment in FIG. 1a, in which corrugations 3a and 3b and spacers (adhesive aggregates) 6a and 6b are provided on both sides of each fold wall 5; see also the description of FIGS. 3a and 3c hereinafter.
FIG. 2a shows a cross sectional representation of the fold arrangement of the filter insert 1A shown in FIG. 1a in a sectional plane parallel to the longitudinal extent of the spacers. Here, the increase in height of both the corrugations (depressions) 3 and also the adhesive layers 6 from the upper to the lower fold edges can be seen very distinctly.
FIG. 2b shows an alternative embodiment of a filter insert 1A', in which, in a basic arrangement similar to FIG. 2a, the fold walls are constructed as wells 5' with corrugations 3' having a substantially constant height over their longitudinal extent, whilst the increase in thickness of the adhesive layers 6' from the upper fold edge area 4a' to the lower fold edge area 4b'--with about the same fold angle--is more marked than in the arrangement according to FIG. 2a.
FIG. 2c shows a filter element 1A" according to another embodiment, in which the cross section of the fold is trapezoidal, so that two fold lines 4a.1, 4a.2 (upper fold edges) and 4b.1, 4b.2 (lower fold edges) are provided between successive fold walls 5". The fold walls 5" have corrugations 3" impressed therein, which extend from the upper fold edges to the lower fold edges and have a constant height over this extent. In the upper part, the corrugations 3" each have a relatively small dot of adhesive 6.2 and near the lower end next to the lower fold edges they have a substantially bulkier, hemispherical adhesive aggregate 6.3, in accordance with the fold spacing which is larger here. The individual adhesive aggregates on the corrugations 3" of adjacent fold walls are fused together, so that the fold walls 5" are fixedly connected to one another by this means.
FIG. 3a shows a cross sectional view of the filter element 1B according to FIG. 1b, wherein fold walls are provided which have corrugations 3a and 3b on both sides, ie. both depressions and elevations. (the other reference numerals from FIGS. 1a and 3a have been retained in the interest of simplicity.) The opposing elevations or recesses 3a and 3b are joined together, as in FIG. 3a, by means of a composite adhesive aggregate, whilst as a result of the attachment of adjacent fold walls at every point, a filter bundle is obtained which has a high degree of compressive and tensile strength and is also strongly constructed to withstand strong flows with turbulent components or substantial changes in pressure over the course of time.
An analogous construction with corrugations and adhesive aggregates provided on each side of each fold wall is also possible in the arrangements according to FIGS. 2b and 2c. These embodiments are shown in FIGS. 3b and 3c, in which the same reference numerals have been used to denote components similar to those in the preceding figures, so that no special description is required here.
FIG. 1c shows, in a view corresponding to FIG. 1a, a substantially box-shaped filter insert 11A made up of a glass fibre filter fleece 12 with corrugation-like recesses or elevations 13 stamped on one side, which is folded in an approximately zigzag shaped, with slightly rounded upper and lower fold edges 14a and 14b, so that the elevations 13 stamped into adjacent fold walls 15 face one another.
Referring additionally to FIGS. 4a to 4d in which the shape of the corrugations can be seen more clearly, the corrugations 13 begin at a spacing from the fold edges 14a which are at the top (in the drawing) and, in addition to the short approach area which is technologically necessary in stamped-in depressions and elevations, they have a first section l 2 the height of which increases towards the lower fold edges 74b, ie. as the width of opening of the folds increases, and a second section l 3 of constant height.
FIG. 1d shows a filter insert 11B which is modified from the embodiment in FIG. 1c and wherein corrugations 13a and 13b and spacers (adhesive aggregates) 16a and 16b are provided on both sides of each fold wall 15; see also FIGS. 5a to 5d and the corresponding description hereinafter.
In both filter inserts 11A and 11B, on each of the top surfaces of the corrugations is provided a layer of adhesive 16 which is in initially thin in the first section l 2 , but become steadily thicker in the second section l 3 in the direction of the lower fold edges. The adhesive layers on opposing corrugations are joined together, as a result of which, once the adhesive has cured, these corrugations and hence the corresponding fold walls are firmly joined together and the filter insert forms a mechanically rigid structure.
FIGS. 4a to 4d are diagrammatic cross sectional views of the fold arrangements and additional spacers of filter inserts (perpendicular to the fold edges) in box-shaped filter inserts according to various embodiments essentially corresponding to FIG. 1c in their overall appearance.
FIG. 4a, first of all, shows the embodiment according to FIG. 1c, again in cross section, using the reference numerals provided therein.
FIG. 4b shows another filter insert 11A' with a basic arrangement identical to FIG. 4a (the elements of which are marked with corresponding reference numerals). However, here, the elevations 13' of the fold walls 15' only have spacers 16' connected them and resting on one another in the region l 3 of constant height, whereas in the region l 2 they are in direct contact with one another and rest on one another. Here, if securing to prevent lateral movement seems necessary in addition to the fixing in the region l 3 , suitable profiling of the facing top surfaces of the corrugations may be provided to enable them to lock together during folding.
The spacers 16' may be produced by the application of adhesive of a correspondingly increasing thickness to the top surfaces of one or both of the facing corrugations 13, followed by curing of the adhesive in the area l 3 . However, it is also possible to use prefabricated spacers of the triangular cross sectional shape shown in the drawing during or possibly immediately after the folding into the bundle of folds.
Another filter insert 11A", in which the folds are of a completely different shape and the elevations 13" are not joined together over their entire length, is shown in FIG. 4c. (Here again, parts corresponding to those in FIGS. 4a and 4b have been given the same reference numerals.) Adjacent fold walls 15" are joined together here by means of a double fold edge 4a.1", 4a.2" or 4b.1", 4b.2", as obtained by forming the fold edge impression lines by roller-stamping using rectangular stamping strips. Once again, the elevations in the section l 2 in which they rest against one another are adhered together by means of a thin layer of adhesive 16.1", and additionally a highly viscous drop of adhesive 16.2" is applied to each elevation on the end of the section l 3 remote from the section l 2 , this drop being of such dimensions that two drops of adhesive 16.2" coming into contact will precisely bridge the gap between the fold walls at the site of application thereof and will join these walls together.
FIG. 4d shows another embodiment very similar to the arrangement according to FIG. 4b, in which again the same reference numerals are used as in FIG. 4b, but wherein the spacers have a section 16.1' located between the corrugations 13', and a section 16.2' overlapping the fold edges. This construction can be achieved by a single application of adhesive of suitable magnitude--before or after folding--but it is also possible for an additional continuous thread of adhesive to be applied to the fold edge section subsequently. Instead of adhesive, a (previously crosslinked) plastics or foam filament or the like may be used, according to another modified embodiment.
FIG. 5a shows a cross sectional view of the filter element 11B according to FIG. 1d, in which fold walls are provided which have on both sides corrugations 13a and 13b, ie. both indentations and elevations. (The other reference numerals used in FIG. 1d have been retained in the interest of simplicity.) The opposing elevations or indentations 3a and 3b are joined together, as in FIG. 4a, by a composite adhesive aggregate, so as to obtain, by means of the overall attachment of adjacent fold walls, a filter bundle having a high degree of compressive and tensile strength and consequently good resistance to deformation even when subjected to strong currents with turbulent components or considerable pressure variations in the course of time.
An analogous construction with corrugations and adhesive aggregates provided on both sides of each fold wall is also possible in the arrangements according to FIGS. 4b to 4d. These embodiments are shown in FIGS. 5b and 5e, in which reference numerals for similar components correspond to those used in the preceding figures and no separate description is required.
FIG. 6 is a diagrammatic perspective view of the impressed filter fleece 12 for the filter insert 11B according to FIG. 1d or 5a.
The figure shows that the filter fleece 12 (shown cut away) consisting of short glass fibres impregnated with a small amount of synthetic resin, has indication lines 40a,40b running in the direction of its longitudinal dimension 1, at a spacing a, perpendicular to the longitudinal dimension, these lines 40a,40b determining the position of the fold edges 14a and 14b during subsequent folding (cf FIG. 1d). Moreover, indentations 13a and elevations 13b are stamped into the filter fleece 12 between two adjacent indentation lines 40a,40b, these indentations and elevations extending longitudinally (as shown exaggeratedly in the other figures), the indentations and elevations alternating at right angles to the longitudinal direction of the fleece.
In the embodiment shown, the indentations 13a and elevations 13b start at a spacing a 1 from an adjacent fold edge indentation line 40a or 40b with a relatively sharply ascending section l 1 , followed by a more gently ascending section l 2 , and then continue, in a section l 3 parallel to the surface of the unstamped areas of the fleece, with a height h which is followed by a transitional section l 4 of steep pitch which returns to the unstamped surface, before the next fold edge indentation line 40a or 40b follows (at a spacing a 2 ).
In the indentation of the fleece, the magnitude a determines the height of the fold and consequently the height of the filter insert 11B after folding, whereas the rise in the section l 1 , in which according to FIG. 1d the fold walls 15 abut on one another after folding, determines the angle enclosed by the fold walls. The magnitude h is chosen so that there is no risk of punching through, taking account of the properties of the particular filter fleece. The greater h is, for a given rise in the section l 1 , the longer l 1 can be made, ie. the longer the distance over which the top surfaces of the elevations or depressions facing one another during folding can abut on one another.
Fundamentally, in order to produce the most rigid possible filter insert, a high value for the ration l 1 /a is desirable--the greater the value of a in order to provide highly efficient filters, the more critical the effect of the fact that, as l 2 increases and the angle of inclination of the fold walls remains constant, h increases as well and thus the risk of tearing of the filter fleece is increased. In arrangements according to the prior art having substantially wedge-shaped corrugations, in cross section, with no additional spacers, this meant that the achievable fold height and hence the height of the filter insert were subject to narrow limits, for a given angle of inclination of the fold walls.
With the construction of the invention as described, the height h of the corrugations is limited to a value which is not critical in terms of the risk of tearing, and after this value is achieved in the course of the rise in the region l 2 the corrugations have a constant height h as they continue their path (area l 3 ); starting from this constant height, additional elements may be added which support the adjacent fold walls against one another in this area and join them together.
FIG. 7a shows a cross sectional view of two folds of a folded construction according to FIG. 4a in a plane parallel to the fold edge section (along the line a--A in FIG. 3a) in an embodiment in which the reduced width in the central part of the adhesive aggregates can be seen.
FIG. 7b shows a modification of this arrangement, in which the corrugations 33a and 33b in the fold walls 35 are profiled so as to have a central longitudinal groove 36a in which a ribbon of adhesive 36 of relatively narrow width is located, having a substantially semi-circular contact surface with the corrugation, in section, which is precisely defined by the walls of the groove. Here, corrugations facing one another are joined only by one application of adhesive, in the form of the thread 36 in a groove 36a which is formed adjacent thereto as a result of the folding operation. The final bone-like cross sectional shape of the spacer is formed as a result of the fact that this thread is first brought into contact with the opposing groove and adhered thereto and then stretched transversely, whilst still plastic, in a two-step folding process.
The arrangement according to FIG. 7b with inherently profiled corrugations has the advantage that the adhesive is applied over the minimum extent with a precisely defined lateral dimension, so as to avoid smearing on the filter material and maximise the effective filter surface.
FIG. 8 is a diagrammatic cross sectional view of part of a filter insert 21, which is hollow cylindrical in its outer configuration, according to another embodiment of the invention. The inner structure is roughly equivalent to that of a box-shaped filter insert; the parts are therefore numbered in accordance with the above drawings and the structure is provided only where it differs from the box-shaped filter insert.
As can be seen from FIG. 8, the hollow cylindrical outer configuration of the filter insert 21 is asymmetrical both between the shape of the depressions 23a and elevations 23b in the fold walls 25 and also in terms of the application of adhesive to the surfaces of the fold walls facing the inside of the insert compared with those facing the outside:
The depressions 23a facing the outside are of the same shape and have a very similar application of adhesive 26a to the elevations and depressions in the filter inserts shown in FIGS. 1c and 1d. On the other hand, the elevations 23b of the filter fleece 22 facing the inside of the filter insert are simply wedge-shaped in cross section, on account of the smaller maximum spacing of the fold walls which is essential here, and they are adhered together using a thin, uniform application of adhesive 26b.
This construction can also be modified, depending on the fold height and the permitted height of indentation of the filter fleece, so that the corrugations facing the inside of the filter are also other than wedge-shaped and in particular are shaped similar to the corrugations in FIG. 2, but in the hollow cylindrical filter insert the shape of the elevations will generally differ from that of the depressions.
The invention is not restricted in its embodiments to those given here by way of example. Rather, a variety of alternatives are conceivable, particularly with regard to the geometry and combination of impressions in the filter material and the layers applied thereto, which make use of the solution illustrated but in a fundamentally different form. | A filter insert (1A) for a fluid filter with an outer square or hollow cylindrical shape has a plurality of continuous zigzag folded walls (5) made of a fluid-permeable material (2) and provided in the plane of at least part of the folded walls with stiffening embossed depressions (3) and/or projections for keeping the walls folded. The depressions and/or projections of adjacent folded walls are interconnected at least in part and supported on each other. Stiff spacers are provided between the depressions or projections in at least part of their length for interconnecting them and supporting them on each other. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a machine for effecting the transfer of objects in the space between positions having predetermined co-ordinates. In particular, this invention relates to a manipulating machine programmable by numerical control.
SUMMARY OF THE INVENTION
An object of this invention is to provide a machine for effecting the transfer of objects in the space and capable of controlling with accuracy not only the position but the attitude as well of the objects transferred, so as to be able, in general, to transfer pieces, tools and/or semimanufactured products from a processing line or machine to another, and in particular, to pack finished goods of any kind, transferring them from a conveying line directly inside boxes and arranging them, in these boxes, according to a predetermined lay-out.
A further object of this invention is to provide a machine of the above-mentioned kind, the moving parts of which are connected to drive means that, due to their structure and assembly, are not affected in terms of end result precision by the movement of other moving parts.
Said objects are attained by this invention in that it relates to a machine for effecting the transfer of objects in the space between positions having predetermined co-ordinates, characterized in that it comprises a supporting head mounted rotating about a first axis, sliding means connected to said supporting head in order to slide relative to the same in a direction substantially perpendicular to said first axis, an object-holding head connected to said sliding means and rotating relative to this about a second axis substantially parallel to said first axis, a first and a second driving shafts coaxial with said first axis, and first and second transmission means to transmit a rotation between parallel axes; said first and second transmission means being respectively connected to said first and said second shaft and being both connected to said object-holding head, and numerical control means being provided to selectively control the angular positions of said supporting head and said two shafts about said first axis.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be now described with reference to the accompanying drawings, in which:
FIG. 1 represents an axonometric view of a first embodiment of a manipulating machine realized according to this invention;
FIG. 1A represents an enlarged, partially cut-away view of the slide of the manipulating machine of FIG. 1;
FIG. 2 represents a cutaway view of a detail of the machine in FIG. 1;
FIG. 3 represents an alternative of the same detail in FIG. 2;
FIG. 4 represents an axonometric view of a second embodiment of the manipulating machine according to this invention;
FIG. 4A represents an enlarged, partially cut-away view of the slide of the manipulating machine of FIG. 4;
FIG. 5 is a plan view of a detail in FIG. 4;
FIG. 6 is a cross-section view along cross-section lines VI--VI in FIG. 5; and
FIG. 7 represents a plan view of an alternative detail in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, denoted in general at 1 is a manipulating machine suited to effect the transfer of objects in the space from a first to a second position having predetermined co-ordinates. In particular, the machine 1 is suited to draw finished products of relatively small size and weight, such as chocolates, cookies, bars of chocolate and other alimentary products loose and/or packed, or tools or mechanical small items, from a line or a store, and to transfer them directly into boxes and/or packages, laying them down in an orderly way, in sequence, in the same. Furthermore, among other things, the machine 1 is able to transfer pieces and/or semimanufactured products from a processing line or machine to another, changing or keeping unmodified the orientation of the transferred element, according to instructions previously programmed.
The machine 1 comprises a fixed base 2 provided, at an extremity, with a turret 3 integral with the base 2, and with at least a numerical control device or unit 4 realized in any known and convenient way, for example by means of microprocessors, and mounted integral with the base 2, or, according to an alternative construction not represented, arranged far away from the base 2 and connected with the same by means of transducers. Referring also to FIG. 2, inside of cylindrical housing 5 of the turret 3 is accomodated a rotating carousel 6 substantially cylindrical and coaxial with a longitudinal axis 7 of the housing 5. From the housing 5 protrudes, through a hole 8 in a cover 9 of the turret 3, an end head 10 substantially parallelpiped of the carousel 6. Conveniently, the hole 8 is sealed with a dust cover 11.
The head 10 has angularly integral two arms 12 rectilinear and parallel to each other, and is provided with two pairs of rectilinear and facing guides 13, between each pair of which is mounted in a sliding way one of the arms 12. These arms are arranged perpendicularly to the axis 7 and are axially moving between the guides 13, being provided with respective slideways 14 connected in a sliding way to the guides 13. In short, the arms 12 extend cantilevered from the carousel 6, are angularly integral with the same and at the same time form as a whole an articulated slide 12a able to translate perpendicularly to the axis 7. At the respective end 15 opposite the head 10, the arms 12 support a slide 16 mounted sliding along the slide 12a perpendicularly to the axis 7.
The slide 16 is provided with a cylindric bush 18 mounted idle on the slide 16 and supported by the same so as to be free to rotate about an axis 19 coaxial with the bush 18. Outside the bush 18 is formed a cylindric pinion 20, that is coaxial and angularly integral with the bush 18 and is apt to engage simultaneously two rectilinear racks 21a and 21b, parallel to each other, carried by the arms 12. The racks 21a and 21b are integral with a respective arm 12, extend along facing surfaces 22 and lie in different planes parallel to each other. The pinion 20, engaging both the racks 21a and 21b, constrains axially the slide 16 at the ends 15 of the arms 12. Therefore the slide 16 can be approached or moved away from the carousel 6 by only translating the two arms 12 along the guides 13.
Inside the bush 18 is mounted axially sliding and angularly integral with the same a cylindric rod 23 coaxial with the axis 19 and provided at one end 24 with an object-holding head 25 angularly and axially integral with the rod 23. The latter is partially arranged in the interior of a guiding shell 26 and is connected in a way known and not illustrated to a flexible wire 27 suitable to impart to the head 25 a translating movement between two limit positions illustrated in FIG. 1. The wire 27 receives the translating movement from an actuator 28 mounted on the base 2 and integral with the same. Possibly, actuator 28 can be interlocked to the unit 4 realizing a numerical control on the head 25 along the axis 19. The head 25 is coaxial with the axis 19 and is apt to be provided with any manipulating device, known and not illustrated, in order to grip and hold the objects that are displaced by the machine 1, such as a mechanical collet, an electromagnet or a pneumatic suction cup.
With reference to FIG. 2, the carousel 6 is mounted idle in the housing 5 through two bearings 29 placed at opposed ends of spacing rings 30 and 31 and axially clamped on the carousel 6 by means of a ring nut 32. The assembly of the carousel 6 and the bearings 29 is supported by the spacing ring 30, which is in turn supported by a wall 33 of the housing 5 through a pin 34. Inside and coaxial with the carousel 6 is mounted idle by means of bearings 35 an hollow cylindric shaft 36, inside and coaxially to which is mounted idle, by means of bearings 37, a cylindric shaft 38. The shafts 36 and 38 and the carousel are therefore free to rotate around themselves about the axis 7 independently one from the other.
The shafts 36 and 38 are provided, at their opposed ends, with respective bevel pinions 39 and 40 and with respective cylindric pinions 41 and 42 angularly integral with them. The pinions 41 and 42 are coaxial, have the same diameter and are mounted side by side so as to each engage a respective rack 21a and 21b. The conical pinions 39 and 40 permanently mesh with two respective bevel gears 43 and 44 carried by the wall 33 of the housing 5 and therefore integral with the base 2. The gears 43 and 44 are keyed on the output shafts of respective motors 45 and 46, which are fixedly supported by the turret 3.
Inside the turret 3 is arranged a third fixed motor 47 having its axis parallel to the axis 7. The motor 47 operates, by means of a pinion 48, a pair of gears 49 and 50 supported idle by the turret 3. The pinion 50 meshes with a gear-wheel 51 angularly integral with the carousel 6 and mounted on a flange 52 of the same, so as to control the rotation of the carousel 6 and consequently of the slide 12a carried by the same. Conveniently, the motors 47, 45 and 46 are interlocked to the unit 4 that controls their operation according to a predetermined program.
The operation of the machine is as follows. In order to displace the head 25 above an object situated in whatever position and however oriented relative to a plane perpendicular to the axis 7, it will suffice for the head 25 to accomplish four basic movements, illustrated by arrows in FIG. 1, namely:
translate the head 25 parallelly to the axis of the arms 12 so as to change the distance between the axes 7 and 19;
translate the head 25 parallelly to the axis 19 so as to change the dimension denoted as Z;
rotate the head 25 about the axis 19 so as to change an attitude angle W; and
rotate the head 25 about the axis 7 so as to change the angular position of the same and of the axis 19 relative to the axis 7.
In the machine 1, in order to rotate the head 25 about the axis 7 of the desired angle, it is only necessary to operate the motor 47 to rotate the carousel 6 by the same angle and consequently rotate the arms 12 and the slide 16 angularly integral with it and carrying the head 25. Such a rotation movement can be limited only by the support 28 and therefore can even be very large, equal or greater than 180° and included, for example, between the two positions shown in FIG. 1 as dotted lines. In order to change the dimension Z of the head 25 it is on the contrary enough to operate the actuator 28.
In order to change the distance between the axes 7 and 19 it is instead necessary to operate simultaneously and with like and opposite speeds the two motors 45 and 46. They rotate the bevel pinions 39 and 40 and consequently the shafts 36 and 38, rotating the cylindric pinions 41 and 42, which, meshing with the respective racks 21a and 21b and revolving in opposite directions, cause the concordant and at the same speed translation of the arms 12 along the guides 13 approaching (or moving away) the slide 16 to the (or from the) head 10. At least, in order to rotate the head 25 about itself, about the axis 19, it will suffice to operate simultaneously and in the same direction of rotation the motors 45 and 46. In this case in effect the arms 12, that are completely independent from one another, will translate in opposite directions taking an asymmetrical position. As a consequence, the pinion 20, which when the arms 12 move concordantly serves only as a constraint to fix the slide 16 to the ends 15, is compelled to rotate because there is a relative sliding movement of the two racks 21a and 21b and of the corrsponding arms 12 relative to the slide 16. Since the movements of the arms 12 are like and opposite, the distance between the slide 16 and the carousel 6 does not change, while the head 25 is rotated by the pinion 20 of the required angle.
From what has been described, it is obvious that the rotation of the head 25 about the axis 19 can take place also automatically, without operating the motors 45 and 46. Indeed, if these motors are kept still and the motor 47 is operated instead, the consequent rotation of the carousel 6 causes the rotation of the arms 12 about the axis 7 while the pinions 41 and 42 are kept still by the bevel gears 43 and 44, the rotation of which is prevented by the stopping of the motors 45 and 46. Therefore the pinions 41 and 42, being coaxial with the rotation axis of the arms 12 and meshing with the racks 21a and 21b, force the arms 12 to translate in an opposite direction along the guides 13 simultaneously with the rotation movement of the carousel 6 and the arms 12. The pinion 20 is therefore forced to rotate, rotating the head 25 of an angle proportional to the rotation angle of the carousel 6. By properly choosing the gear ratio of the different gears, it is possible to obtain that the head 25 rotates of an angle equal and opposite to the rotation angle of the carousel 6, keeping constant the attitude angle W of a gripped object.
Due to this feature of the machine 1, it is possible, according to the alternative embodiment illustrated in FIG. 3, to surpress the motor 46 and control both the pinions 39 and 40 with the gear 43 alone. In such alternative embodiment, the shaft 38 will be shortened so that both the pinions 39 and 40 mesh with the pinion 43.
According to the alternative embodiment of FIG. 3, in order to change the distance of the axes 19 and 7, it will suffice to operate only the motor 45, which rotates in opposite directions, through the bevel gear 43, the pinions 39 and 40. Consequently the arms 12 will be translated in the same direction. In order to keep costant the attitude angle W of the objects gripped by the head 25 during the rotation of the carousel 6, it will suffice to keep still the motor 45, so as to prevent the rotation of the pinions 41 and 42 in the manner previously described, and produce therefore, simultaneously with the rotation of the carousel 6, the translation in opposite directions of the arms 12 and hence the rotation of the pinion in a direction opposite to that of the carousel 6. It is obvious that the number of teeth of the latter must be such as to rotate the head 25 about the axis 19 of an angle equal to that of rotation of the same about the axis 7.
FIGS. 4 through 7 relate to a manipulating machine 53 mostly similar to the machine 1, and for which are used the same reference employed to indicate the corresponding parts of the machine 1.
In the machine 53, the head 10 is laterally provided with two grooves 54 perpendicular to the axis 7 and engaged each slidingly by a longitudinal ridge 56 of a respective arm 12.
The two arms 12 are interconnected at the extremities by two cross members respectively indicated with 56 and 57 to form a slide 58. This latter is the main member of a transfer unit 59, comprising the slide 58, the head 10, the carousel 6 and the object-holding head 25. The bush 18 of this latter extends through the cross-member 56 along the axis 19 and carries integrally connected a double toothed sprocket 60 coaxial with the axis 19 and cooperating with a double toothed switching sprocket 61, forming the sheave of a pulley 62 connected through a bolt 63 to the cross-member 57, to subtend two ring chains 64 and 65 extending substantially from one end to the other of the slide 58 and through the head 10.
According to an alternative embodimento not illustrated, the chains 64 and 65 are toothed belts.
The head 10 is internally hollow and is limited by two end plates 66 and 67, the second of which supports integrally the carousel 6. Between the plates 66 and 67, the shafts 38 and 36 support respectively two sprockets 68 and 69 respectively meshing with the chains or toothed belts 64 and 65.
Between the plates 66 and 67 are mounted two further shafts 70 and 71 parallel to the shafts 36 and 38 and carrying keyed respective guide pulleys 72 meshing with the chain or toothed belt 64. On each of the shafts 70 and 71 is further mounted idle an other guide pulley 73 meshing with the chain or toothed belt 65.
On the head 10 are further mounted two electromagnetic jaws 74 which, when activated, can lock the slide 58 relative to the head 10.
The alternative embodiment illustrated in FIG. 7, relates to a transfer unit 75 substantially similar to the transfer unit 53, from which it differs in that the chains or toothed belts 64 and 65 of the unit 59 are substituted with two half-chains or toothed belts 76 and 77 extending between sprockets 60 and 61 and partially wound around the same and the respective sprockets 68 and 69. In particular, the opposed ends of the half-chains or toothed belts 76 and 77 are integrally connected to the sprockets 60 and 61 by means of the attachment devices 79. Further, in unit 75 the two shafts 70 and 71 are placed both on the same side of the shafts 36 and 38 and support the first a guide pulley 72 and the second a guide pulley 73.
Since, at least from an ideal point of view, the operation of the chains or toothed belts 64 and 65 is exactly the same as that of the half-chains or toothed belts 76 and 77, the operation of the machine 53 will be now described with reference to FIGS. 1, 5 and 6 and to the transfer unit 59.
In the case the sprockets 68 and 69 are kept locked relative to a fixed reference, a rotation of the carousel 6 in one direction, for example clockwise, causes the winding of the chain or toothed belt 64 on the sprocket 68 and the unwinding of the chain or toothed belt 65 from the sprocket 69 with simultaneous rotation of the sprocket 61 and, therefore, of the head 25 counterclockwise through an angle equal to the angle of rotation of the carousel 6. In this manner, it is possible for the head 25 to seize an object and deposit it, after having rotated it about the axis 7, keeping inalterated its original attitude.
Except for the above-mentioned event, the rotation about the axis 19 and the translation along the line joining the axes 7 and 19 are solely controlled by the chains or toothed belts 61 and 65 and by the corresponding powered sprockets 68 and 69.
With reference in particular to FIGS. 5 and 6, if the sprockets 68 and 69 are operated at the same speed and in the same direction, and actuating simultaneously the jaws 74 to lock the slide 58 on the head 10, the sprocket 61 will be rotated in the same direction as the chains or toothed belts 64 and 65 and will rotate the head 25 about the axis 19.
However, if the two sprockets 68 and 69 are rotated at the same speed, but in opposed directions, the two chains or toothed belts 64 and 65 tend to give to the sprocket 61 like and opposite rotations keeping it, in effect, angularly locked relative to the slide 58 and causing the axial sliding of the later relative to the head 10 and, therefore, a displacement of the head 25 along the line joining the axes 7 and 19.
From the foregoing, it is possible to argue that, by controlling the motors 47, 45 and 46 for the operation of the pinion 50 and of the sprockets 68 and 69 through the unit 4, it is possible to seize, by means of the head 25, an object from an initial position having predetermined coordinates imparting to it a desired attitude and, in particular, keeping its original attitude. | A machine (1) (53) (75) for effecting the transfer of objects in the space between positions having predetermined co-ordinates, in which said objects are supported by a head (25) integral with a pinion (20) (60) mounted rotatable on a slide (12a) (59) sliding in a direction perpendicular to the axis of said pinion (20) (60); the pinion (20) (60) meshing by opposing means with teeth (21) (64, 65) (76, 77) extending along said slide (12a) (59) and axially moving under the bias of driving apparatus (41, 42) (68, 69). | 1 |
FIELD OF THE INVENTION
The present invention relates to the field of magnetic recording; in particular, to structures for supporting and positioning a magnetic transducer over a recording disk medium.
BACKGROUND OF THE INVENTION
In a hard disk drive, normally a transducer is positioned by a suspension apparatus over a magnetic disk to facilitate reading and writing of information to the disk. The suspension apparatus is commonly coupled to a rotary actuator which can position the transducer in a radial direction across the magnetic disk. As is well known, the transducer itself is commonly attached to a slider which, in turn, is mounted to the head suspension assembly. During normal operation, the slider actually flies over the surface of the disk due to the hydrodynamic pressure generated by the rotation of the disk. For optimum performance, the flying height must be kept uniform to minimize errors in the reading and writing of data to the disk. Because the magnetic disks themselves are often flawed by imperfections, the slider must be able to pitch and roll over the surface of the disk in order to maintain a uniform flying height. If the slider were inhibited from pitching and rolling over the surface of the disk, then the slider would not be able to accommodate the height variations on the disk. If such were the case, errors in the read/write operations would result.
One of the ways that conventional suspension assemblies have achieved pitch and roll motion is by the incorporation of a dimple which contacts both the top surface of the slider and the load arm of the suspension apparatus. The dimple has a rounded contact point about which the slider can pivot in order to accommodate variations in the topography of the disk. The problem with these types of assemblies is that the radial stiffness of the suspension assembly is generally insufficient to resist rapid motions of the actuator. As is well known, the actuator includes an electromagnetic coil which, when energized, causes the head to be moved from one radial position to another (i.e., from one data track to another). What happens is that as the head is moved across the disk, the dimple slides in a lateral direction to a point on a load arm where the transducer is positioned off-track. Obviously, when this occurs, errors in the reading and writing of data often result. This problem of dimple movement resulting from rapid actuator motion is commonly referred to as the "stick-slip" problem.
One approach to the stick-slip problem has been to increase the stiffness of the load beam and flexure elements of the arm assembly. However, this adds considerable mass to the arm assembly resulting in significantly slower seek times.
Another approach described in U.S. Pat. No. 4,868,694 involves increasing the radial stiffness of the arm assembly by means of a completely redesigned flexure for the rotary actuated load arm. Basically, the flexure is designed to have a U-shaped slot which is perpendicular to the longitudinal axis of the load arm. The drawback of this approach, however, is that it requires a complete redesign of the head suspension apparatus. This means that existing disk drives cannot easily be retrofitted.
Thus, there is a need for a simple solution to the stick-slip problem which does not involve a substantial increase in the mass of the arm, or a major redesign of the head suspension assembly. As will be seen, the present invention provides a solution to the stick-slip problem which is easy to implement and can be incorporated into existing disk drive units.
SUMMARY OF THE INVENTION
A rotary actuated arm assembly is described for positioning a transducer over a data track of a rotating magnetic disk. The arm assembly includes a slider having a top surface with the transducer being affixed to a side surface of the slider. The slider flies above the surface of the disk due to the hydrodynamic pressure generated by the rotation of the magnetic disk. An elongated load beam is attached to a flexure at one end. The flexure comprises a thin piece of metal having a first end attached to the top surface of the slider and a second end attached to the end of the load beam. The load beam itself is connected to a rotary actuator which pivots about a point so as to position the slider radially across the surface of the disk.
The flexure includes a dimple for contacting the load beam at a point to allow the slider to pitch and roll as it flies over the surface of the disk. An elastomeric material is bonded to both the flexure and the load beam at a location near or surrounding the dimple. The elastomeric material imparts radial stiffness to the assembly so that the load beam maintains contact with the dimple at the desired point, despite sudden start/stop movements of the assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements, and in which:
FIG. 1 is a perspective view of a head suspension assembly for positioning a transducer above the surface of a rotating magnetic disk.
FIG. 2A is a top view of the head suspension assembly currently used in one embodiment of the present invention.
FIG. 2B is a side view of the head suspension assembly of FIG. 2A.
FIG. 2C is an enlarged side view of the flexure element of the assembly shown in FIG. 2B.
FIG. 3 is a front side view taken along cut lines 3-3' of the flexure element shown in FIG. 2C. The view of FIG. 3 shows one embodiment of the present invention.
FIG. 4 is a front side view taken along cut lines 3-3' of the flexure element shown in FIG. 2C. The view of FIG. 4 shows an alternative embodiment of the present invention.
DETAILED DESCRIPTION
A head suspension assembly with improved pitch and roll characteristics is described. In the following description numerous specific details are set forth such as material types, dimensions, processes, etc., in order to provide a thorough understanding of the present invention. It will be obvious, however, to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well known elements and processing techniques have not been shown in particular detail in order to avoid unnecessarily obscuring the present invention.
With reference to FIG. 1, there is shown a perspective view of a head suspension assembly comprising a slider 17 having top, bottom and side surfaces. Along the trailing side surface, a transducer is attached to the slider so that information can be written to and read from the rotating magnetic disk 15, over which the slider flies. Note that the top surface of the slider body is attached to a flexure element 14 which typically comprises a thin piece of metal. Most often, flexure 14 includes various shaped slots which increase its flexibility; this is one way that the slider is allowed to pitch and roll over height variations present on the surface of the disk. Flexure 14 is shown attached to load beam 12, which is mounted to the actuator arm via mounting block 11.
The basic requirement of flexure 14 is that it be mechanically strong enough to hold slider 17 rigidly in place as it is positioned over the magnetic disk, and at the same time provide enough flexibility so as to allow the slider to pitch and roll over topological variations present on the surface of the disk.
As explained above, one of the ways in which the pitch and roll characteristics of the slider has been improved is by the incorporation of a bump or dimple disposed on a central portion of flexure 14 (not visible in FIG. 1). The dimple contacts both the top surface of the slider and the load beam so that, in effect, the slider is continuously pressed against the contact point formed by the dimple. Because the dimple is formed to have a semi-spherical or rounded surface the slider can easily pivot about the contact point formed by the dimple. This, in turn, facilitates a pitching and rolling motion of the slider.
The problem with prior art designs is that as the actuator rotates to position the transducer over a desired track of disk 15, the start/stop force can cause the slider to slide and stick in a position where the transducer cannot read or write data on the desired track. The solution to this problem offered by the present invention is to apply an elastomeric material between the load beam and the flexure at a location near or surrounding the dimple. The elastomeric material adheres to both the load beam and the flexure to prevent any lateral or radial movement relative to the load beam as result of the acceleration of the actuator mechanism. Because of its adhesive properties, the elastomeric material causes the dimple to stay in place so that the slider cannot slide to an off-track position. It is appreciated by practitioners in the art that as little as 70 to 80 microinches of movement of the slider can cause track misalignment resulting from the radial acceleration of the actuator arm.
An additional benefit of the present invention is that the presence of the elastomeric material at or near the dimple contact point helps to dampen mechanical resonances. Obviously, mechanical resonances on the head suspension assembly can adversely affect the drive's servo system as well as impair the setting of the data heads.
It should be understood that the elastomeric material should have properties which allow it to adhere to the surfaces of the load beam and the flexure while maintaining a sufficient measure of flexibility so that the slider can still pitch and roll about the contact point where the load beam and dimple meet. This means that the elastomeric material must have both compressive and expansive properties in order to accommodate topographical variations in the surface of the disk. The elastomeric material must also have adequate adhesive properties in order to maintain the correct position of the dimple in relation to the load beam.
Referring now to FIGS. 2A-2C, one embodiment of the invented head suspension assembly is shown. FIG. 2A is a top view of the head suspension showing the load beam 21 having at one end an orifice 22 that is used during the mounting process for mounting the load beam to the actuator arm. The common procedure for mounting the load beam to the arm is a ball staking method wherein a hollow pin is inserted within orifice 22 and a ball is driven through the hollow pin to expand the pin laterally. This forces the flexure into firm contact with the mounting pad. Load beam 21 also includes a tapered end 20 which attaches to flexure 24. As discussed earlier, flexure 24 is attached between end 20 of load beam 21 and the top surface of slider 23.
The side view of the head suspension assembly shown in FIG. 2B illustrates how the load beam is pre-loaded so that a downward pressure is applied on the slider against the disk recording medium. The downward pressure also forces the dimple into contact with the load beam. This contact point is maintained at the same location relative to the load beam as the slider flies over the surface of the magnetic disk. (Note that in FIG. 2B, slider 23 is not shown to simplify the illustration.)
FIG. 2C is an expanded view of the flexure portion of the invented suspension. The view of FIG. 2C shows the location of dimple 25 as it contacts end 20 of load beam 21. The relation of dimple 25 to flexure 24 is also shown. It should be apparent that dimple 25 is actually a rounded protuberance or semi-spherical bump formed on one surface of flexure 24.
FIG. 3 is a side view of the flexure portion of the suspension illustrated in FIG. 2B, as taken along sectional cut lines 3-3'. The view of FIG. 3 illustrates the relationship between end 20 of load beam 21 and flexure 24. As shown, dimple 24 is centrally located between flexure 24 and end 20, and includes a deposit of elastomeric material 28 attached to both members 20 and 24 at a point near the side of dimple 25. Similarly, FIG. 4 illustrates another embodiment in which the elastomeric material 28 completely surrounds dimple 25; essentially forming a ring around dimple 25 so as to prevent any undesirable sliding motion of the dimple against the load beam during acceleration of the actuator.
In a preferred embodiment, a two-stage polyurethane is utilized as elastometric material 28. This material is applied at room temperature to the interface between flexure 24 and end 20 of load beam 21. The application of material 28 takes place at room temperature, followed by a curing process wherein the apparatus is heated to a temperature of approximately 70°-100° C. for about 4-6 hours. Practitioners in the art will appreciate that this curing temperature is sufficiently high enough above the drive's normal operating temperature so as to insure that material 28 will not melt or otherwise alter its characteristics when in use in the recording system. Preferably, the polyurethane material has durometer (i.e., measure of hardness) of about 50-60 A. This level of hardness permits the material to have sufficient flexibility while still constraining any lateral movement tendencies. It has been determined that the above-prescribed range of hardness is sufficient to overcome lateral load forces of approximately 1.5 grams, in addition to any acceleration and windage forces on the arm which may be on the order of 0.5 to 2.5 grams.
It should be understood that elastomer 28 could comprise a wide variety of materials, since numerous materials provide the properties described above. That is, there exist many commercially-available adhesives and other compounds which could be used to overcome the lateral forces typically generated during the drive's normal operation, while maintaining the requisite flexibility so as to allow the slider to pitch and roll over the surface of the disk.
It is also worth noting that the elastomeric material can be applied to the interface between the flexure and the load beam according to many different application methods. By way of example, one simple application method for delivering the elastomeric material to the dimple contact point is by means of a syringe. The end of the syringe is placed at or near the dimple and an adequate amount of the elastomeric material is then delivered to the interface. Once applied, the material can then be cured as described above. It is appreciated that the application of the elastometric can occur at just about any point of the disk drive manufacturing process. In this respect, for example, the elastomer could alternatively be applied either during the sub-assembly of the head stack, following attachment of the slider to the suspension, or even after the drive has been completely manufactured. It should be understood that this later application method would be the one employed in order to eliminate the stick-slip problem in existing disk drive systems.
Whereas many alternations and modifications to the invention will no doubt become apparent to the person of ordinary skill in the art after having read the forgoing disclosure, it should be understood that the particular embodiments shown and described by way of illustration are in no way intended to be limiting. Therefore, reference to the details of the illustrated diagrams is not intended to limit the scope of the claims which themselves recite only those features regarded as essential to the invention. | A rotary actuated arm assembly for positioning a transducer over a data track of a rotating magnetic disk includes a flexure attached to a load beam at one end and to a slider at the other end. The flexure comprises a thin piece of metal having dimple which contacts the load beam at a point. The dimple allows the slider to pitch and roll about the point to accommodate height variations across the surface of the disk. An elastomeric material is bonded to both the flexure and the load beam at a location near or surrounding the dimple. The elastomeric material imparts radial stiffness to the assembly so that the load beam maintains contact with the dimple at the desired point, regardless of the radial movements of the assembly. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 365,424, filed Apr. 5, 1982, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is in the field of plastic films or sheets and more particularly relates to porous or liquid permeable thermoplastic films.
Porous or perforated thermoplastic films have many useful applications. Such films are useful in gardening and farming to prevent the growth of grass or weeds while permitting moisture to be transmitted through the film to the solid beneath. They are used for making disposable diapers and other various absorbent structures and for packaging of foods and other materials.
The invention also relates to absorptive structures made from the porous film, such as diapers, sanitary napkins, bed pads, incontinent pads, towels, bandages and the like. The invention particularly relates to porous film used as topsheets for such structures.
The invention especially relates to an improved porous film or topsheet which allows fluid to pass to the interior of the absorptive device but which inhibits the reverse flow of the fluid. In general, the topsheet is the portion of an absorptive device which covers one face of the absorbent element of the absorptive structure and which in some applications contacts the skin of a person using the absorptive device.
2. Description of the Prior Art
Particularly useful absorptive devices are articles of manufacture designed to receive and retain fluid discharges from the body within an absorbent element of the absorptive device. Absorptive devices such as sanitary napkins, catamenial tampons, bed pads, incontinent pads, towels, bandages and the like are well known articles of commerce. In recent times, single use disposable absorptive devices have significantly replaced permanent absorptive devices which were designed to be laundered and reused. While the improved absorptive structure of this invention can be used with reusable absorptive devices, it finds great utility when used with disposable absorptive devices.
Perforated thermoplastic films of polyethylene, polypropylene, polybutene-1, polyvinyl chloride, and other flexible thermoplastics normally extruded into such films or thin sheets have been made by various methods. One method is to extrude the thermoplastic material, e.g., polyethylene, from a conventional slot extrusion die onto a continuously moving, smooth, cooled casting surface, e.g., a chill roll. A pattern may be applied to the chill roll and the film pressed to the roll while in the amorphous or molten stage by press rolls. Alternatively, the chill roll may be very smooth and a desired pattern in the film may be mechanically impressed into the film on the chill roll by pressing the roll against the film and the chill roll to impress the pattern into the film as it is cooled on the chill roll. The softness of the film produced by chill casting is directly related to the density of the polyethylene resin used. In order to obtain different degrees of softness or stiffness, it is necessary to use a number of polyethylene resins having different densities. Thus, if it is desired to produce a relatively stiff embossed film, it is necessary to use more expensive polymers having high densities as the feed material to the slot die.
Film rolls of poor conformation produce problems when running the film through fabricating machines or through a film printing apparatus.
An example of a method and apparatus for producing film according to the foregoing slot die-chill cast roll technique is shown in U.S. Pat. No. 3,374,303.
Another technique used for making plastic film has been the utilization of a heated engraved embossing roll in conjunction with a backup roll. The preformed strip of thermoplastic film normally at room temperature, is passed between the nip of a heated engraved roll and a backup roll and is embossed by being heated while in contact with the heated, engraved roller. The resultant embossed film usually has a very shallow and poorly defined pattern. An example of an apparatus and process for carrying out a process of this type is shown in U.S. Pat. No. 3,176,058.
Still another process for making thermoplastic film has been to pass the film over a heated roll or a series of heated rollers in order to heat the film to a softened state and then to contact the film with an embossing roller and to press the film against the embossing roller by a backup roller. Normally, the embossing roller and the backup rollers are cooled in order to freeze the pattern into the film so that it may be immediately wound up into rolls, if desired. An apparatus and process for preparing an embossed film according to the foregoing is shown in U.S. Pat. No. 3,246,365.
A more recent process for making plastic material is shown in U.S. Pat. No. 3,950,480, wherein the film is heated by a non-direct contact heat source to raise the temperature of the film above its softening point and the film is then immediately fed between adjacent, counter-rotating rollers, and thereby embossed.
A method for perforating thermoplastic sheet or film is disclosed in U.S. Pat. No. 3,054,148, issued to Zimmerli, which reference is hereby incorporated herein. The Zimmerli patent discloses a stationary drum having a molding element mounted around the outer surface of the drum which is adapted to rotate freely thereon. A vacuum chamber is employed beneath the screen or molding element to create a pressure differential between the respective surfaces of the thermoplastic sheet to cause the plasticized sheet to flow into the perforations provided in the molding element and thereby cause a series of holes to be formed in the sheet.
U.S. Pat. No. 4,155,693 and U.S. Pat. No. 4,157,237 illustrate types of screens or molding elements.
U.S. Pat. No. 4,252,516 and U.S. Pat. No. 4,317,792 disclose apparatus and method, respectively, for manufacturing thermoplastic sheet having elliptical holes.
Disposable absorptive devices comprising an absorbent pad covered with a topsheet which contacts the body are well known. Covering the outer portion of the absorptive device with a fluid-impermeable backsheet to prevent absorbed fluids from leaking out of the absorptive device and soiling clothing, bed clothes, etc. is equally well known. The absorbent pad component of disposable absorptive devices can comprise well known materials such as creped cellulose wadding, airlaid felt or the like. The liquid impermeable backsheet can comprise any of various materials well known in the art such as polyethylene film.
One of the principle disadvantages of conventional absorptive devices is the maceration of the skin caused by prolonged contact with absorbed fluids. One especially common manifestation of this maceration is diaper rash generally occurring about the base of the trunk of infants. In order to minimize the effect of prolonged liquid contact with the skin, absorptive devices such as diapers have been produced with the body contacting topsheet thereof designed to exhibit a greater or lesser degree of surface dryness. For example, U.S. Pat. No. 3,327,625 issued to Johnson on Mar. 1, 1966, teaches that any hydrophobic material in the crotch area of the diaper will cause moisture to wick away from the skin of an infant wearer and thereby provide a substantially dry surface in contact with the infant's skin. U.S. Pat. No. Re. 26,151 issued to Duncan et al. on Jan. 31, 1967 teaches the use of porous, hydrophobic, nonwoven fabrics as topsheets. U.S. Pat. No. 2,916,037 issued to Hansen on Dec. 8, 1959, is a further example of the use of a nonwoven topsheet.
U.S. Pat. No. 3,814,101 issued to Kozak on June 4, 1974 illustrates still another type of disposable absorbent article. Such patent discloses a topsheet of non-fibrous hydrophobic film which has a plurality of valvular openings or slits therein and a system of depressed areas disposed across the surface of the topsheet. The openings permit the flow of liquid in one direction of the absorbent but reduce the flow of the liquid in the opposite direction.
U.S. Pat. No. 3,989,867 which issued to Sisson on Nov. 2, 1976, describes a breathable liquid impervious backsheet containing apertured bosses. The apertures therein, in order to maintain the liquid impervious character of the backsheet, are smaller in diameter than the capillaries of U.S. Pat. No. 3,929,135 hereinafter described.
U.S. Pat. No. 3,929,135 issued to Thompson on Dec. 30, 1975, relates to absorptive devices utilized a topsheet having tapered capillaries of critical diameters and tapers which allow fluid to pass into the interior of an absorptive device and which inhibit the reverse flow of such fluid.
SUMMARY OF THE INVENTION
The present invention relates to a unique porous sheet of thermoplastic material, a perforated porous sheet or film and an absorptive device made from such sheets or film. The porous film comprises a liquid permeable material formed from particles of non-dissolvable polymeric materials partially fused together to form a continuous sheet. The sheet may also have a multiplicity of additional openings or perforations therein of a predetermined size and shape so as to direct the flow of fluids in one direction or into an absorbent element and to inhibit the flow of fluids in the other direction or from the absorbent element through the sheet. The backsheet is substantially impervious to liquids. The perforations or additional holes may be added to the sheet by slitting, perforating, or any other suitable means.
The sheet of the instant invention is an improvement over prior art sheets in that it enhances the free transfer of fluids into an absorbent substrate and more effectively inhibits the reverse flow of the fluids from the substrate. The sheet or film closely resembles and feels like very soft cloth.
It is therefore a principal object of the present invention to provide a porous plastic film constructed of partially heat fused fine polymeric particles.
It is another object of the invention to provide a porous plastic film which has an additional multiplicity of small perforations or openings therein.
Still another object of the present invention to provide an absorptive structure for absorptive devices which enhances the free transfer of fluids from an exterior source into a substrate absorbent element while effectively inhibiting the reverse flow of fluids from the absorbent element.
An important object of the present invention is to provide a sheet or topsheet for absorptive devices or other use which feels smooth to the human touch and has the feeling of cloth.
BRIEF DESCRIPTION OF THE DRAWINGS
The construction designed to carry out the invention will be hereinafter described, together with the features thereof.
The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:
FIG. 1 is a perspective representation of an absorptive structure of the invention with a portion of its components cut away.
FIG. 2 is an enlarged cross-section in elevation of the absorptive structure taken along line 2--2 of FIG. 1;
FIG. 3 is an enlarged cross-section of a porous sheet or film of the invention and the topsheet of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The absorptive structure of the invention is generally referred to by the reference numeral 10. The novel porous film or topsheet of this invention is shown at 11. The other major components of the absorptive structure 10 are the absorbent element or pad 12 and the backsheet sheet 13. In the drawings, like characters of references designate like parts throughout the several views.
In general, the side flaps 14 of the backsheet 13 are folded so as to cover the edges of the absorbent pad 12 and topsheet 11. Such arrangement completely seals in the absorbent pad 12. Any other arrangement for sealing the edges of the absorbent structure may be used without departing from the scope of the invention.
The structure of the porous film or topsheet 11 comprises a plurality of particles 20 of non-dissolvable materials partially fused together at 21 to form a continuous sheet. The continuity of the particles is further interrupted by a multiplicity of openings 22 which may be in the shape of slits, dimples, funnels, tapered capillaries, cylinders or other geometric and asymmetric shapes and may be varied in size and frequency to suit the particular viscosity, density, mass and flow rates of the fluid to be absorbed. U.S. Pat. No. 3,929,135 and U.S. Pat. No. 3,814,101 illustrate openings or holes of a suitable size and shape, and such references are specifically incorporated herein.
It can readily be seen in FIG. 3, that fluids flow directly through the porous film or topsheet from A to B and also may flow indirectly from C to D.
Aesthetically, the structure of the porous film or topsheet closely resembles and feels like very soft cloth. Ideal particle sizes are those which are small enough to feel smooth to a human touch. Particles from about 0.003 inches to about 0.004 inches in diameter are suitable. Sizes as small as 1 or 2 microns and as large as 2000 microns are also suitable.
It is not necessary, of course, that the particles all be of the same size. A mixture of particles of various sizes within the desired range of sizes is quite suitable. In fact, such particles are normally obtained as mixtures of various sizes of particles. Materials which have been found to meet the specifications and which are generally supplied in particle form are polymeric materials such as the new so-called linear low density polyethylenes, high density polyethylenes, polypropylene and polyvinylchloride (PVC).
Fusing sintered particles of all sorts of materials that melt with heat and pressure are well known and old in the art. The porous film of the invention is made by the application of such art in a continuous process. Although the particles are relatively small, heat and pressure are applied thereto only in an amount sufficient to provide a desired fusion which in turn provides a desired degree of porosity. The particles themselves are not permeable. It is only the spaces provided from partially fusing the particles which provides permeability to the sheet. Perforating the finished sheet provides additional permeability, if such is desired.
Additional strength may be imparted to the porous film or sheet by post orienting in one or two directions by the use of a tentering frame which also increases the rate of fluid flow through the sheet.
The manufacture of the porous sheet may be by any suitable method such as dispersion of the polymeric particles on a moving belt followed by heating to a temperature appropriate for the desired degree of fusion of the polymeric particles thereby forming the porous sheet. Then passing the sheet through a set of pressure rollers, cooling and then stripping the sheet from the belt and winding the sheet into a roll. A variation of such process provides for preheated particles being distributed into the nip of an embossing set of rollers wherein the particles under pressure from the embossed rolls are fused and simultaneously embossed with a pattern of holes designed to increase the porosity of the sheet. Selection of the particular embossed pattern along with variations in particle size may be combined over a wide range of shapes, frequency and sizes to impart not only increased flowability through the topsheet but improved functionality and aesthetically pleasing and comfortable surfaces. Post orientation may further enhance such properties while improving the strength characteristics of the sheet.
Excluding the area of holes formed by the vacancies between partially fused particles, a porous sheet with total projected open area resulting from the geometrically or asymmetrically shaped holes added to the sheet by embossing, perforating, piercing, vacuum forming or other processes used to impart holes and prior to post orienting of from less than about 1% to about 64% of the total area, satisfies the requirements of the practical uses of the invention and also satisfies the requirements of servicability for strength applications. Beginning with such percentages of open areas, post orienting can double the stated projected areas on the minimum side up to increasing the projected area to about 50 times on the maximum side. The maximum would represent a seven-fold stretch of the base sheet in both transverse and machine direction. Such amount has been found to enhance the desired properties from the olefin polymers found to be most suitable in such applications.
A projected open area in the porous sheet of about 5% represents holes, whether geometric in design or asymmetric. The holes or openings have a mean diameter of 0.005 inches spaced and average of 0.020 inches apart. A projected area of about 20% may be obtained by holes with a mean diameter of either 0.005 inches, 0.010 inches, 0.020 inches, 0.50 inches, or 0.10 and with respective spacing of 0.010 inches, 0.20 inches, 0.040 inches, 0.10 inches and 0.20 inches. A practical maximum projected hole area for a non-oriented, porous sheet is about 70% due to the fragility of the connecting pieces between holes. Projected area percentages are based on square inch sized areas.
The topsheet of the invention is constructed of finely divided particles which range from a size of about 0.003 inches to a size of about 0.004 inches or from about 1 to about 2000 microns. These finely divided particles are partially fused together by heat to provide a thin porous sheet having a thickness of from about 0.0005 inches to about 0.25 inches.
If the porous sheets hereindescribed are post oriented through a tentering apparatus to high degree, projected areas must be based on units larger than square inches, e.g., square feet.
The thickness of the non-oriented porous sheet varies from about 0.0005 inches to about 0.250 inches depending upon the particle size and the particular embossing pattern. Orientation also reduces these thicknesses in direct proportion to the degree of orientation.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof and various changes in the illustrated structure may be made within the scope of the appended claims without departing from the spirit of the invention. | An absorptive structure for absorbing and containing fluids from a source exterior of said structure comprising a topsheet, an absorbent element and a back sheet, wherein said topsheet is a liquid permeable material formed from particles of non-dissolvable polymeric materials partially fused together to form a continuous sheet and has a multiplicity of openings therein of a predetermined size and shape so as to direct fluid flow into the absorbent element and inhibit fluid flow from the absorbent element through the topsheet, and said back sheet is impervious to liquids. | 0 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a method and apparatus for rapid formation of a highly uniform nonwoven web of staple fibers and is particularly suitable for the formation of the low bases weight webs of thermoplastic fibers at a high rate of speed.
[0002] Nonwoven fabrics are produced by a variety of methods, and in general, such methods involve the continuous laydown of fibers or filaments in the form of an unconsolidated flat web on a conveyor, followed by consolidation of the web, such as by bonding or locking the fibers together to form the web into a cohesive fabric.
[0003] The carding of staple fibers into an unconsolidated web followed by point bonding with a hot calender is one well known method of producing a nonwoven fabric. In such a process the fibers, which are received in bales, are first opened with standard textile opening equipment. The opened fibers are then fed to single or multiple cards which are installed in line, each forming a thin web. The webs are then layered together, then usually spread to increase web width, and fed to a hot calender for thermal bonding. The customary calender consists of two heated rolls, one being a smooth steel anvil roll, the other being a roll with an embossed pattern. The high points of the pattern are the area where the fibers are bonded together through partial melting. Such systems can produce webs which are reasonably uniform at a given speed and basis weight. Typically, a reduction in unit weight or an increase in speed results in a noticeable degradation in the uniformity of the fiber distribution. More precisely, at lower basis weights the web develops a more blotchy appearance due to areas of higher and lower concentrations of fibers. In the worst case, holes will form where the concentration of fiber is low. The degradation in web uniformity for the traditional system is also linked to the need of additional draw on the unbonded web to eliminate the bulging of the web which would otherwise occur at various points in the process. The amount of draw used to control the web during transport to the calender is inversely proportional to the cohesion of the unbonded web. A low cohesion web will require a higher draw. The spreading section and the calender nip point are prime areas where the bulging occurs. This bulging, if not eliminated, causes extremely poor web uniformity. A lighter web, when submitted to such increase in draw, develops even greater defects because the extremely light areas are now deformed into holes in the web.
[0004] The prior art has tried to minimize the requirement for draw by using equipment transfer geometry and higher cohesion fiber to produce nonwoven material at higher production speeds. Both modifications have produced only moderate improvements in speed or uniformity.
[0005] Other prior art has been the development of a machine which reorganizes the carded unbonded web (with minimal or no increase in output speed) by reforming it on a vacuum collector such as described in U.S. Pat. No. 4,475,271. This process can produce a web with a more uniform balance in tensile strength between the MD and CD direction but, it does not deliver the desired level of uniformity in fiber distribution as judged by visual appearance.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, a slow moving thick or high basis weight web of fibers having a high degree of cohesion, is formed using conventional cards, or other mechanisms. This web may be first spread in the cross machine direction.
[0007] The thick web is fed into a relatively fast moving toothed reforming roll, which carries a layer of excess recirculating fibers needed to form the final web. A uniform portion of the layer of fibers is continuously removed from the reforming roll by a toothed web forming roll, and this web layer is transferred as a web to a conveyor by a transfer roll. The web is subsequently bonded.
[0008] In the preferred embodiment, the reformed web is fed from the conveyor around an air control transfer roll, which allows the web to change direction without lifting or disruption, with the exit of the air control roll being located closely adjacent the upper heated roll of the rotating calender rolls.
[0009] The web is not fed directly into the nip between the calender rolls. Rather, the web is transferred to the upper hot calender roll into a secondary nip between the transfer roll and hot calender roll, in an area upstream of the nip. The unconsolidated web is then heated and compressed in the secondary nip and is supported on the hot roll prior to entry into the calender nip to become thermally bonded.
[0010] As the web passes through the secondary nip, the web is compressed, causing fibers to move relative to each other in a more uniform arrangement. This effect is aided by contact of the web with the heated roll in which individual heated fibers may shrink, curl or relax as they are being physically rearranged by compression. The rearranged web is partially wrapped and supported on the heated roll, which tends to eliminate any bulging of the web due to passage through the calender.
[0011] Downstream of the reformer roll, all rolls and conveyor operate at substantially the same surface speed, and no substantial machine direction draw is imparted to the reformed web due to transport or thermal bonding. Thus, very light weight or low cohesive webs may be processed at high speeds without any loss in uniformity, and, in fact, uniformity is increased in the final stages of processing.
[0012] In summary, the invention can be considered as having several general aspects. First, a web of staple fibers having a first basis weight and moving at a first speed is converted into a second, more uniform web having a second, lower basis weight and moving at a second, higher, surface speed. This is accomplished by continuously metering a layer of fibers from the first web onto a rapidly rotating toothed cylinder and removing a uniform portion of said layer to form the second web moving at the second speed. The second web is subsequently bonded.
[0013] In a broad second aspect, a web of individual fibers, including at least some thermally bondable fibers, is subjected to preconditioning immediately prior to passage through a nip of a bonding calender. The preconditioning involves subjecting the web to heat and compression which is sufficient to at least partially rearrange the fibers in a more uniform array, but insufficient to thermally bond the fibers.
[0014] A third broad aspect comprises supporting a web of unbonded thermoplastic fibers on a heated surface immediately prior to entry into the nip of a calender. The second and third aspects are preferably accomplished using a heated roll of the calender to heat, compress and support the web upstream of the bonding nip.
[0015] A fourth broad aspect is to support the web of individual fibers to be thermally bonded at a substantially constant surface speed between the zone of formation and into and through the bonding zone in order to minimize any draw on the web after final web formation and to prevent loss of uniformity due to draw.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a side schematic view of the overall apparatus for carrying out the method of the present invention.
[0017] [0017]FIG. 2 is an enlarged portion of a first part of the apparatus shown in FIG. 1.
[0018] [0018]FIG. 3 is an enlarged portion of a second part of the apparatus shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] [0019]FIG. 1 shows the overall apparatus representative of a production line capable of carrying out the various aspects of the present invention.
[0020] A relatively thick or high basis weight of a web 10 of unconsolidated fibers is first prepared. The web 10 may be formed by use of one and preferably a series of a plurality of conventional cards 12 which serve to separate clumps of fibers from a bale into individual fibers and to deposit the fibers via a take-off roll 14 onto a moving conveyor 16 .
[0021] The web 10 comprises individual staple fibers which are capable of being bonded by conventional techniques. The initial part of the present method may be used to form uniform webs of fibers which are subsequently consolidated by thermal or non-thermal means. Non-thermal methods include techniques in which the surfaces of the fibers are not melted or softened to achieve bonding, including techniques such as chemical or adhesive (liquid or solid) bonding and hydraulic entanglement. In such cases, polymer fibers having higher melting points can be employed, such as polyester and polyamide, as well as other fibers such as polyolefin.
[0022] The web as initially formed may also be bonded by thermal methods such as the application of heat, pressure and heat, or by the use of sonic techniques. Thermal bonding methods include, for example, through-air bonding using hot air, and passage of the web through the nip of a pair of heated calender rolls, one having an embossed surface with raised areas to define the bond sites. In such a case, fibers which have a relatively low melting point are used alone or in admixture with other fibers. Suitable thermoplastic fibers of this nature include polyolefins, such as polyethyle and polypropylene, multi-component fibers having an outer polyolefin surface, uand mixtures thereof. In the preferred embodiment, the fibers or fiber mixtures are capable of being bonded by passage through a conventional bonding calender.
[0023] The initially formed web 10 , typically having a basis weight of from about 30 to about 90 grams per square meter (gsm) may be conveyed from the conveyor 16 to a conventional spreader 18 , which functions to increase the width of the web 10 in the cross machine direction. Since the web is relatively thick and cohesive at this stage, the spreading operation does not cause excessive loss in gross uniformity. At this stage, the web will be moving at a speed in the order of from about 50 to about 80 meters per minute.
[0024] The above apparatus is conventional in nature and provides an initial feed web for subsequent processing in accordance with the present invention. The use of any known process for opening and individualizing fibers to form the initial web 10 is expected to suffice for the purpose of the present invention.
[0025] In accordance with the present invention, the initial web 10 is first processed through a web reformer station 20 which results in a highly uniform web 22 having a basis weight of from about 20 to about 70 percent of the basis weight of the initial web, typically 10 to 30 gsm, and moving at a line speed of from about 150 to 500 percent greater than the line speed of the initial web, typically in the order of 150 to 250 meters per minute. The web 22 is then conveyed to a final fiber rearrangement and bonding station 24 , wherein the fibers are subjected to additional mechanical and thermal rearrangement shortly prior to bonding.
[0026] The reformer station 20 is shown in FIG. 2, with the feed web 10 and reformed web 22 being omitted between rolls for the sake of clarity. The initial web 10 exits a conveyor 26 and is deposited between a lower curved support 28 and a toothed feed roll 30 . The feed roll 30 meters fibers onto a toothed cylinder 32 operating at substantially a faster surface speed and in the same direction (see arrows) than the feed roll. Semi-cylindrical covers 34 are preferably provided around the moving periphery of cylinder 32 in a closely spaced relation to uniformly guide the flow of air created by the cylinder and to prevent disturbance of fibers residing thereon by outside influences. The fibers are not carded by the cylinder 32 , as this would reduce production speed.
[0027] A toothed forming roll 36 is provided, at a close distance from the cylinder 32 and rotates in an opposite rotary direction. The cylinder 32 deposits a uniform layer of fibers resident as the outer layer of fibers on the cylinder onto the forming roll 36 . Thus, the cylinder 32 carries an amount of fibers in excess of that required to establish the reformed or second web 22 . As the cylinder 32 rotates past the feed roll 30 , areas lacking a sufficient population of fibers to form a uniform layer will tend to pick up more fibers from the feed. Thus, the feed roll, cylinder and forming roll work in dynamic conjunction to provide a highly uniform web of unbonded fibers at a high rate of speed. The surface speed of the cylinder 32 is substantially greater than the surface speed of the forming roll 36 , preferably in the order of from about 3.5 to about 10 times faster.
[0028] A toothed take-off roll 38 , located at a close distance from the forming roll 36 and rotating in an opposite direction, removes the entire reformed web 22 from the forming roll and deposits the same on a moving conveyor 40 , which is preferably upwardly inclined relative to horizontal machine direction travel.
[0029] The reformed web of individual fibers 22 , which is now in a highly uniform and fast moving state, may be consolidated or bonded by any suitable thermal or non-thermal technique as described hereinabove. Preferably, however, the web 22 comprises heat bondable fibers and is subjected to additional conditioning, followed by bonding by passage through a conventional heated calender having one or two pattern rolls.
[0030] In the preferred embodiment, the reformed web 22 is subjected to final processing and bonding at the station 24 as shown in FIG. 3. The conveyor belt 40 is preferably of mesh construction allowing air flow therethrough of at least 300 CFM per square foot. An air flow transfer roll 42 supports the exit return loop of the conveyor belt 40 . A pair of spaced fixed radial air seals 44 and 46 are provided across the width of the roll 42 . The first seal 44 intersects the belt 40 and the supported web 22 at approximately the 12 o'clock position on roll 42 , as shown.
[0031] A calender apparatus is provided closely adjacent the air transfer roll 42 and comprises an upper smooth heated roll 48 and a lower embossed or patterned roll 50 , rotating in opposite directions as indicated by the arrows as shown. In the alternative, the upper roll 48 may have an embossed or patterned surface, and the lower roll 50 may be patterned or smooth. The upper roll 48 is in tangential relation with the air transfer roll 42 and is slightly spaced therefrom, as will be explained in greater detail. A first nip 52 is defined between the calender rolls 48 and 50 , where thermal/pressure bonding occurs, and a second nip 54 , upstream of the first nip, is defined between the air transfer roll 42 and the upper calender roll 48 . The second seal 46 intersects the second nip 54 .
[0032] Suitable means, such as an air pump 56 , are connected to a plenum chamber 58 to cause a uniform flow of air to be drawn through the porous conveyor belt 40 and into and across the web 22 in the zone between the fixed seals 44 and 46 . Since the web will typically be light in weight and highly porous, the purpose of this air flow is not to provide a positive pressure drop or seal for the transfer process. Rather, the purpose is to control the boundary layer air which would normally move away from the roll as speed is increased. The negative air flow allows the web to be transferred without disturbance and also prevents the possibility of turbulence and hence disruptive forces at the second nip 54 .
[0033] It has been found that the nip 54 established between the rolls 42 and 48 should be in the order or 0.250 in. (0.635 cm)or less. As the reformed web 22 enters the nip 54 , the web is compressed between the two rolls, and the fibers in the web are heated by the hot calender roll. The simultaneous heating and compression causes at least a partial rearrangement of the fibers due to mechanical and thermal influences, allowing the fibers to shrink and relax as well as to move relative to one another and in three dimensions into the most efficiently packed or uniform arrangement while the fibers remain unbonded.
[0034] The web 22 adheres to and is supported by the heated calender roll through a quadrant of rotation 60 until the web passes through the first nip 52 where permanent point bonding between the fibers occurs. In prior art arrangements the web passes through an unsupported area prior to the nip of the calender, and due to compressive forces at the nip, a bulge in the web can form prior to the nip, with the only available solution being to increase the machine direction draw on the web by increasing the speed of the calender rolls relative to the speed of the web feed. In the present arrangement, the final rearrangement of the fibers and the support of the web on the roll 48 serve to eliminate any tendency to bulge.
[0035] Apparatus of the prior art requires a substantial amount of draw to enable processing. In the present apparatus, the draw between the forming roll 36 and the bonding nip 52 , if any, is less than 5% and most preferably less than 3%. Thus, the surface speed of all components downstream of the cylinder 34 is substantially the same. As a result, bonded webs of a low basis weight and uniformity can be formed at a speed up to 30-40% greater than available on a conventional line. As a result, it is possible to produce light weight nonwoven webs of very high uniformity and at high production rates and low cost, in comparison to prior art methods. | In the production of a nonwoven fabric of thermally bonded fibers, a heavy web of fibers is continuously fed to a toothed cylinder at a slow speed to form a layer of fibers, and a portion of this layer is removed and formed into a lightweight uniform web at a faster speed. The second web is conveyed without draw to a calender having a bonding nip, and the fibers of the web are rearranged by compression and heating and are supported on a hot surface of one of the calender rolls prior to entering the nip to additionally improve uniformity. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my copending application, Ser. No. 897,170, filed Aug. 15, 1987, now abandoned.
BACKGROUND
This invention relates to elliptical footballs, and more specifically to a soft, lightweight, easier handling and safer football.
Oval footballs must be gripped lengthwise to be thrown correctly, which may be difficult for those with small hands. Conventional football lacing is often inadequate for a grip. Several prior art football designs improve handling with surface texturing or spiral ribs, which may also stabilize spinning passes.
In U.S. Pat. No. 1,931,429, spiral grooves in an inflatable leather football are filled flush with an abrasive compound to increase surface friction. U.S. Pat. No. 2,194,674 describes a football with spiral cords wound around a "rubberized canvas carcass", which is inflated by a bladder, wherein the cords project through a leather casing to form ribs. An inflatable football is described in Canadian patent No. 578,533 with diagonal ribs (FIG. 10 of Canadian patent) for enhanced gripping similar to that described above in U.S. Pat. No. 2,194,674. U.S. Pat. No. 3,884,466 describes a molded plastic football with an axial air passage, straight grooves outside, and weights inside to stabilize flight trajectories. These inflatable leather covered or molded plastic footballs are heavy, hard, and unsatisfactory for childrens' use.
U.S. Pat. No. 3,119,618 describes a football with sub-surface sponge padding which compresses for a better grip. U.S. Pat. No. 4,241,918 describes a solid football with a core of soft polyester batting and a plastic casing including simulated lacing to assist gripping.
Solid foam rubber, or "NERF" type footballs, for example the Model 777 Cosom football, are softer, lighter, and easier to grip and throw. These footballs do not gain the momentum to travel as far as conventional inflatable footballs, and, thus, minimize the risk of injury or property damage.
SUMMARY
It is an object of this invention to provide a soft, lightweight, better handling and safer football. The invention achieves this object in an elastic foam football with spiral lengthwise grooves which increase in depth towards the middle of the football. The grooves make the ball easier to hold, throw, and catch, and have a rifling effect to stabilize passes.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of a football in accordance with the invention;
FIG. 2 is a side view of a football in accordance with an alternative embodiment;
FIG. 3 is a cross-sectional view of the football of FIGS. 1 and 2, showing the football bisected along its major axis perpendicular to line 2--2;
FIG. 4 is a cross-sectional view along line 2--2 in FIG. 1;
FIG. 5 is a cross-sectional view along line 3--3 in FIG. 1.
FIG. 6 shows a child's hand grasping the football of FIG. 2.
DETAILED DESCRIPTION
Referring to FIG. 1, a one piece molded elliptical type football 10 of, for example, polyurethane, foam rubber, or other type of soft, lightweight elastic foam, weighing approximately 0.3 lbs, has preferably twelve equally spaced elliptic-helical grooves 20 in its surface. Football 10 has a selected nominal length of approximately 93/8 inches and a nominal maximum outside diameter of approximately 5 9/16 inches.
Grooves 20 are deepest in the middle of football 10, the football's maximum diameter, for better gripping at the larger diameter. In the preferred embodiment, the grooves become narrower and shallower towards the ends of football 10 and extend to each end of football 10, as shown in FIG. 1. In an alternate embodiment, the grooves end at a distance from each end of football 10, as shown in FIG. 2. The grooves centered depth at the maximum diameter of the football is in the range of 0.2 to 0.3 inches, with the width of the grooves at the maximum diameter of the football being in the range of 0.4 to 0.6 inches.
FIG. 3 shows a cross-section of the football of FIGS. 1 and 2 bisected along its major axis perpendicular to line 2--2, illustrating that the football of FIGS. 1 and 2 is of solid foam construction. FIGS. 4 and 5 illustrate that the grooves become narrower and shallower towards the ends of football 10, with FIG. 4 showing a cross-section of football 10 in FIG. 1 along line 2--2, and FIG. 5 showing a cross-section along line 3--3.
Grooves 20 preferably have a rounded V shape, as shown in FIGS. 4 and 5, with a helical curvature of approximately twelve degrees per inch along centerline CL, and are at an angle of approximately 30° to centerline CL at the major diameter 2--2, as shown in FIG. 1, for conformance to the placement of fingers when gripping football 10. Grooves 20 differ from the prior art ribs and abrasives used to enhance gripping of a football in that grooves 20 are wide enough and deep enough for a child's fingertips, and most adults' fingertips, to enter a groove and, thus, enable a higher degree of gripping than prior art ribs or abrasives. The twelve grooves 20 enable firm gripping of the football with a broad range of hand sizes, wherein the fingertips are placed in one groove, as shown in FIG. 6, and the tip of the thumb is placed in another groove. With the cited prior art footballs, a small child's fingertips could not exert sufficient gripping pressure to maintain an adequate grip for throwing the football. Grooves 20 thus provide for fingertips to more easily, more quickly, and more securely grip football 10. This results in more forceful, longer, and better passes and easier receiving and carrying than prior art footballs.
FIG. 4, showing a cross-section of football 10 in FIG. 1 along line 2--2, serves to illustrate the increased rotational force capable of being applied to football 10, resulting in more accurate passes. Force F, applied by fingers gripping football 10, is applied downward essentially perpendicular to a wall of one of the rounded V-shaped grooves 20. As is apparent, the force F applied to the side of a groove does not require much friction to rotate football 10 in a clockwise direction, since force F is almost perpendicular to the side of the groove. If force F was not applied to a wall of a groove but to the round surface of football 10, a number higher degree of friction would be required to impart a rotation to football 10. This higher degree of friction requires a stronger grip on football 10, which children may be lacking. This problem with prior art footballs is exacerbated by the fact that a football should be thrown at, or close behind, its center diameter, which is the widest and most difficult place to grasp a regular shaped football. When football 10 is thrown with a spinning motion, flight is also stabilized by grooves 20 in surface 12 acting as rifling or fins. This permits more consistent and accurate passes.
A preferred and alternative embodiment of the irvention have been illustrated. Modifications and adaptations within the scope of the invention will occur to those skilled in the art. The invention is limited only by the scope of the following claims. | An elastic foam football 10 with lengthwise spiral grooves 20 increasing in width and depth towards the middle of the ball for improved handling. | 0 |
This application claims the benefit of Provisional Application No. 60/421,337, filed Oct. 25, 2002.
BACKGROUND OF THE INVENTION
The present invention relates generally to the drying and setting of materials, and more particularly, but not limited to, the drying ink and paint coatings.
A variety of industrial, commercial and consumer goods require a solidification process, either removal of liquids contained in the structure of the goods, or a coating applied thereon, or by catalysis of the goods themselves or their coatings. Some materials require a curing process that may is usually initiated by the addition of some form of energy. In the case of many inks and coatings, the removal of some or all of the liquid portion to initiate solidification releases a large perfusion of fumes and vapors, many having known health risks. Commonly, a large volume of high-velocity heated air is directed at the surface, even though only a fraction of the air actually comes even near the surface, due to the difficulty in penetrating through the “boundary layer effect” of vapors and gasses near the surface. The countercurrent of fumes and vapors clinging to the surface also create a barrier against convective heating as well as preventing radiation from reaching the surface of the material to be dried.
Electrostatic precipitators generally will not remove gasses, so an odor would remain. Large high-pressure fans are required to even partially penetrate the boundary layer near the surface of the material, and once the blast of hot air, fume and vapors has left the surface it is not usually reused, but is “cleaned up” and exhausted into the atmosphere. Due to the huge volumes of air contaminated with vapors and fumes produced by this process, removal of the contaminants through incineration or high-temperature catalysis is expensive and wasteful, often doubling the energy expenditure of the initial drying operation. Water based coating drying systems, while not requiring as much “clean-up” of the effluent, still require substantial amounts of energy and process time due to the high latent h at of vaporization of water, thus slowing production rates.
SUMMARY OF THE INVENTION
The present invention discloses a drying system comprising: a blower that passes air over flames electrically charged to a high-voltage source, ionizing rods containing rows of pins, some of which are connected to ground and some to a high-voltage DC supply, and insulated strands of wire in the effluent stream for collecting the ionized fumes and solvents.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a semi diagrammatic view of the system for drying one side of a continuous web using the concepts of this invention.
FIG. 2 shows a pictorial view of the invention showing an overall external view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now specifically to the drawings, FIG. 1 shows diagrammatically a drying system in accordance with the present invention. The purpose of the illustrated system is to rapidly dry and cure printing inks or coatings applied upstream on the web by a printing press or coater of common design and construction which is located upstream (not shown). Although the illustrations depict a paper web with uncured or wet printing ink applied thereto, the present method and apparatus will be understood to apply to objects of various shapes and compositions. These objects may themselves be solidified, dried of cured, or they may have a surface or internal coating to be altered. Inks, coatings, films and plastics may be formulated which are particularly susceptible to being selectively altered by the ultraviolet radiation and ozone produced by this system.
As illustrated in FIG. 1 , the web enters from the right and passes under the outlet from duct 2 that encloses preheated air 1 descending past heated tubes 4 that are maintained at a high voltage negative potential by wire 5 connected from DC power supply to said tubes thereby causing an electrostatic field 8 between the flames 7 in serrated channel 6 to the web 10 and the ink image 9 applied thereto, and thence to charge bars 11 connected to the power supply ground by wire 12 .
These heated tubes are referred to hereinafter as “charge tubes” and may or may not have flames emitting therefrom. “Charge bars” are elongated, insulated structures have exposed conductive surfaces from which an electrostatic charge emanates, usually in the form of a row of oxidation-resistant pins usually internally electrically interconnected. There are commercially available variations, some having the individual pins connected to a common bus by resistors, which serves to even out the electrostatic field and reduce arcing. They are usually constructed of an insulating material, and have an internal electrical connection from the conducting surfaces to a connection plug or terminal.
The flow of electrical current through said electrostatic field and web to the charge bars 11 creates additional heating added to the convective heat from the airstream 1 , and said heating impinging on the web and the ink applied thereon, causes vaporization and oxidizing of some of the ink components. With sufficiently high voltage, a corona may be caused to occur on the surfaces being treated, which may solidify certain inks. Ozone may also be produced which may rapidly oxidize certain inks and coatings. The gasses vapors and fumes 16 emanating from said web and ink into the electrostatic field acquire a charge. Convective movement away from the web by said ionized gasses, fumes and vapors 16 is assisted by said acquisition of a negative charge 15 , said charge causing them to be repelled from the surface of the web that now passes over negatively charged bars 14 . Said ionized gasses, fumes and vapors move into up into duct 20 by a combination of suction airstream 21 and repulsion from a negative charge on the plurality of charge bars 14 , said bars being connected to the power supply by wire 13 . Said ionized gasses, vapors and fumes 16 are attracted to wires 18 that are at a positive high-voltage potential, said vapors and fumes adhering to said wires in the form of liquid and solids 19 that runs down said wires into receptacles 17 for removal and recycling. Special inks may be formulated that are particularly sensitive to exposure to electrons in the electrostatic field, said inks adhering to said web undergoing a reaction so disposed as to cause curing and solidification. Removal of the fumes and vapors attracted to wires 18 may be facilitated by wires that are formed into an endless belt, whereby said wires may be continuously cleaned by moving past a cleaning means such as a brush or scraper.
Although drying of only one side of a web is depicted, it is understood that by inverting or re-orienting the structures of the present invention, drying or curing my be effected on opposing sides of any object, the top and bottom of a web printed or coated on both sides in this instance.
FIG. 2 shows the present invention in an overall view of the preferred embodiment for drying or curing the top of a web. Blower 25 driven by motor 26 draws environmental air into adjustable aperture 1 and expels said air through preheater 27 , into duct 2 where it moves across ionizing bars 4 and impinges against the top of web 10 which enters housing 7 through elongated aperture 28 . High-voltage supply 29 is connected by ground wire 12 to the housing. Insulated negative high-voltage wires 5 and 13 connect to the ionizing bars 4 and 14 respectively. Collector wires 18 (shown in FIG. 1 ) are connected to the positive high-voltage terminal of said power supply by insulated wire 24 . Liquid captured from the airstream 21 is conveyed by drain tube 30 into an appropriate container. Remaining contaminants in the airstream 21 are removed by conventional filtering means 22 . A portion of the air exiting from said filtering means is recycled into the inlet of blower 26 by duct 23 . | An improved apparatus and method for drying materials. A hot surface in a strong electrostatic field is used to ionize a stream of heated gasses passing over the surface, which assists in directing the stream against the object to be dried, and ionizes the vapors and gasses emitted from surface of the material being dried, which assists in their separation and removal. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cosmetic sampler and, more specifically, to a disposable unit dose or single application package for providing a cosmetic sample.
2. Description of the Related Art
Cosmetics have typically been available for sampling in department stores in the very containers in which the product is sold, or in smaller versions of the same container. This method generally works well with fragrances, where the product is applied by spraying onto the skin of the consumer such that the product reservoir remains untouched. Such method is less effective in marketing cosmetics, however, because many consumers feel uneasy about sampling a product from a container from which others have previously sampled due to the fear of contracting disease or infection.
The prior art has attempted to provide a more inexpensive and convenient means of marketing cosmetics by hand-outs or by mail, e.g., as inserts in department store bills or magazines. One such sampling means is a cosmetic "strip", which consists merely of make-up samples deposited on a substrate covered by a paper mask, as disclosed in U.S. Pat. No. 4,752,496 to Fellows et al. Such "strips" do not allow for the presentation of the cosmetic sample in a design pattern, however, nor do they allow for the simultaneous presentation of a number of colors in a single design.
In another example, U.S. Pat. No. 4,884,719 to Levine et al. describes a cosmetic sampler wherein the product is deposited on a substrate and is covered with a transparent cover sheet. While this invention allows the consumer to fully view the color of the product without any initial manipulation of the package, the sample is subject to offset or smearing between the two layers, thus ruining any design pattern of the product sample.
An attempt has been made to address the problem of offset in U.S. Pat. No. 4,824,143 to Grainger. In this sampler package, a transparent bubble insert is disposed in a window over the product sample. The package is formed with multiple panels and window cutouts surrounding the bubble through which the sample is viewed. This invention, however, is complicated in design and is cumbersome to use for the consumer. Furthermore, the sampler would not be suitable for distribution in mail inserts or magazines due to its relatively bulky dimensions.
If the product to be sampled requires an applicator, such as a cosmetic powder or blush, the consumer often has to resort to using her fingers to apply the sample, as with the sampler disclosed in U.S. Pat. No. 5,072,831 to Parrotta et al. The drawback, of course, is that the application process is messy; moreover, it is difficult to achieve an even coverage of the product using one's fingers.
The problems described above arise in the distribution of samples of creams, lipsticks, fragrances, pharmaceuticals, lotions, and other types of high viscosity, waxy materials.
SUMMARY OF THE INVENTION
The present invention overcomes the drawbacks of the prior art discussed above by providing a cosmetic sampler package comprising a slurry of cosmetic and solvent which is printed onto a transparent or translucent film overlay. The film overlay includes opaque portions printed in the negative image of the desired pattern or design on the surface opposite that of the cosmetic, so as to form a display window for the sample. A protective backing is then sealed to the film, covering the sample. The protective backing is additionally provided with an applicator material on the surface of the protective backing facing the sample to serve as a built-in applicator.
Individual samplers of the present invention contain enough product for one "unit dose" application of the cosmetic, and can be used to sample creams, lipsticks, fragrances, pharmaceuticals, lotions, and other high viscosity, waxy materials.
Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side cut-away view of an embodiment of the present invention.
FIG. 2 shows an exploded top view of an embodiment of the present invention.
FIG. 3 shows a top-side view of another embodiment of the present invention.
FIG. 4 shows the bottom view of the film 4 shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts an exemplary embodiment of the present invention which comprises a transparent or translucent cover film 1, onto which a sample of cosmetic product 2 is printed on the bottom surface B in any desired pattern or design 10, as shown in FIG. 3. A protective backing 4 is sealed or laminated to film 1 around the cosmetic 2, covering the same to protect the sample until ready for use by the consumer. Protective backing 4 is also designed to function as the applicator for the cosmetic sample and includes an applicator material 6 covering the surface of backing substrate 5. Protective backing 4 is sealed to the film 1 with the applicator material 6 facing the cosmetic sample 2.
Film 1 may be any type of flexible plastic sheet or thermoformable film having a thickness of 0.5-12.0 mils, such as amorphous polyester, co-polyester, PVC, PET, polycarbonate, high density polyethylene, polypropylene, high impact polystyrene, or derivatives thereof, but is preferably formed of a treated polyester resin film such as "MYLAR"™. The top surface A of cover film 1 may be printed with at least one window 8, through which the color of sample 2 may be viewed. Window(s) 8 may be of any shape, pattern, or design 10, such as a pair of windows in the shape of a pair of lips, as shown in FIG. 3. In the example shown in FIG. 3, cover film 1 is printed with the negative image of a pair of lips, so that lip-shaped windows 8 remain transparent while the rest of cover film 1 is blocked with print. In this manner, several shades or colors of the product may be displayed in one sampler with each color occupying one window. Additionally, cover film 1 may contain copy print on both the opaque and transparent sections, such as for labeling the product or providing directions for application. Alternatively, cover film 1 may be translucent with no windows and with copy print on the top surface A.
Product sample 2 is printed onto the bottom surface B of the film at a location opposite each window 8 in an area at least slightly larger than the corresponding window, as shown in FIG. 4. This arrangement allows for a sharp presentation of the colors and designs, since the edges of each design or pattern section are hidden behind the window borders. Thus, any irregularities in the edges of printed cosmetic 2 or any offset of the cosmetic is not seen from the topside A of cover film 1. Preferably, the cosmetic is screen printed onto film 1, although other known printing methods such as flexography or lithography may be used. In a further embodiment, film 1 may be embossed to form a well in the shape of the desired pattern, and the cosmetic product is deposited therein.
In the preferred process for making the invention where the cosmetic sample to be distributed is a powder-based product such as a pressed compact, eye shadow or blush, cover film 1 is run through a screen printing press and printed with as many colors of make-up 2 as desired and allowed by the press configuration. These deposits of make-up may be in virtually any shape and size compatible with the press and may be in proximity and registered with each other. In one example process, a moderately coarse mesh (125 threads per inch) from Majestech and a sharp 80-85 durometer squeegee are used to deposit the make-up onto the film. The mesh has an unusually fine thread for its count resulting in a smooth screen with a high percentage of open area.
The make-up slurry is formed by wetting the make-up with a solvent compatible with the chemistry of the powder. For instance, a pearlescent eye shadow with inorganic pigments that wet well can be used with an evaporating solvent such as ethyl alcohol or isopropyl alcohol. If a coarse screen and a poorly lubricated powder are used together, additional wetting agents or lubricants such as glycerine or silicone oil may be added to the slurry. The viscosity of the slurry and the amount of solvent added must be tailored to the individual powder, as is the choice and amount of lubricant or wetting agent, although the amount of lubricant should preferably be kept below 5%. Following screen printing of the slurry, the solvent evaporates to leave a sample of make-up 2 on film 1.
Substrate 5 of protective backing 4 may be comprised of board, paper, or plastic, and may be coated with a polymer film such as polypropylene, polyethylene, Mylar™, high impact polystyrene, or derivatives thereof. The protective backing 4 additionally includes an applicator material 6 covering the surface of substrate 5 which faces cosmetic sample 2. Applicator material 6 may be applied in an embossed/debossed pattern 9, as shown in FIG. 2, onto backing substrate 5. It has been discovered that by applying the applicator material in a pattern, adherence of the applicator material to the backing substrate is improved so that the applicator material does not pull away from the substrate upon separation of the backing and the film during use. Furthermore, the patterned applicator provides for more even coverage of the cosmetic sample upon application.
In one embodiment, an adhesive 3 is printed on the backing substrate. Fibers such as cotton, nylon, acrylic, or combinations thereof, are introduced into a chamber and, by electrostatic assist, the fibers are flocked on the substrate. Using flocking, the fabric fibers can be applied in a chosen register or pattern to form the applicator. The applicator may then be die cut to the desired shape while still attached to the unit. Optionally, the applicator backing may additionally be embossed in the die cut shape. In other embodiments, the applicator material may comprise a woven fiber or a reticulated or nonreticulated foam, and may be attached to the backing substrate by lamination.
Next, perimeter adhesive 3 is printed on cover film 1, and applicator backing 4 is then laminated to the printed film 1, with the applicator side 6 facing cosmetic sample 2. Adhesive 3 is preferably, but not necessarily, pressure sensitive. Other forms of adhesives which are consistent with the present invention include anaerobic, self crosslinking, U.V. curable, or heat curable adhesives, or the adhesive material can simply be dried by evaporation. Alternatively, applicator backing 4 may be sealed to cover film 1 using other methods such as hermetic sealing with heat or fusion or sonic sealing, and may be accomplished either with or without the addition of an adhesive as detailed above.
The use of screen printing techniques according to the preferred embodiment of the present invention for preparing make-up samples is not limited to samples of eyeshadows or other inorganically pigmented powders. Organically pigmented powders may also be sampled by adjusting the solvent system and by, if necessary, reducing the pigment loading to compensate for the tendency of some organic pigments to develop in a liquid medium. Such a technique would also allow the sampling of blush, for example. The present invention is additionally applicable to sampling non-liquid but oily products, such as lipstick, sunscreen stick, stick deodorant, or any oily, non-liquid pharmaceutical product.
Where the cosmetic sample is a wax-based product such as lipstick, an effective method of screen printing the sample onto cover film 1 is described below. Although this process is directed to the screen printing of lipstick, the method is similarly applicable to any type of wax-based product.
First, the lipstick bulk is heated above its melting point of approximately 195° to 205° F. to ensure that the highest melting point waxes are dispersed, and that the lipstick is uniform. The formulation is then augmented by the addition of molten waxes and other additives which are mixed until uniform and poured while still in a molten state into a stainless steel jacketed kettle or a suitably sized plastic container. The mixture is then allowed to cool to return to a solid state. The purpose of introducing additional waxes to the formula is to prevent the lipstick from melting or bleeding oil when exposed to subsequent environmental conditions.
After cooling, the mixture forms a hard waxy product which is not printable. Thus, the next step is to change the material to a paste-like consistency using a conventionally recognized method of grinding or shearing, such as by a rollermill or planetary mixer.
The paste-like processed bulk is added to the screen press at room temperature and printed in a pattern onto the bottom surface of a cover film 1 as described above.
Since the material in the form of a printed paste is not yet a lipstick, the material is then heated to approximately 195° to 200° F. to re-melt, then chilled to form a lipstick. The resulting physical appearance of the lipstick print is shiny, glossy, and liquefied.
Optionally, to ensure that the lipstick will maintain its integrity when exposed to environmental conditions of heat or pressure, a protective overcoat (not shown) may be applied over the printed lipstick. As disclosed in U.S. Pat. No. 5,562,112, this overcoat is printed in the exact pattern as the printed lipstick and serves not only to maintain the integrity of the lipstick, but also to prevent product transfer to applicator backing 4. The overcoat can be selected from a series of polymers which are printed from a solvent system, allowing rapid drying and forming of a uniform film over the lipstick surface. The overcoat material is dried to a uniform film by use of air knives or moving room temperature air. Polymer systems, based upon cellulosics, polyvinyl pyrollidone, pyrollidone ester blends, acrylics, nitrocellulose, have been shown to have certain degrees of effectiveness; however, the material of choice for the overcoat is "NO'TOX"™ from Colorcon Incorporated, Philadelphia, Pa.
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims. | A cosmetic sampler package comprising a slurry of cosmetic and solvent which is printed onto a transparent or translucent film overlay. The film overlay includes opaque portions printed in the negative image of the desired design on the surface opposite that of the cosmetic, so as to form a display window for viewing the cosmetic sample. A perimeter adhesive may be printed on the film overlay around the sample and a protective backing is sealed to the film. The entire surface of the protective backing which faces the cosmetic sample is covered with a texturized layer of flocked fabric fibers so that the backing may be used as an applicator for the cosmetic sample. | 8 |
TECHNICAL FIELD
This invention relates to a fully fiber optics based sensor system using a Faraday crystal to detect magnetic permeability anomalies of target elements—such as well string casings, casing collars or casing joints—in well holes from a remote location. The sensing element uses principles of optical diffraction and polarization shift to sense and telemeter permeability changes in the target elements which are subjected to changes in external magnetic fields. The magnitude of the measured permeability within the well hole is a function, among other things, of the mass of the ferromagnetic material present in the target element. A target such as a casing collar presents an additional mass which will appear as permeability anomalies along the length of the casing. Similarly, a corroded section of borehole casing has less mass than a corresponding section of uncorroded casing. The invention permits detection of the permeability anomalies that exist as a result of the differences in mass and, therefore, enables accurate location of downhole collars and casing corroded portions.
BACKGROUND OF THE INVENTION
In the petroleum drilling and production industry, a string of casing pipe is cemented into a wellbore to provide structural integrity for the bore hole and prevent vertical migration of fluids between formation zones. An additional string of pipe with a smaller chamber, commonly known as production tubing, is usually placed within the casing string as a conduit for the production of fluids out of the well. The downhole string of casing pipe, which may be thousands of feet in length, is made of a plurality of pipe sections which are joined end to end by threaded connections. The pipe joints, also called collars, have increased mass as compared to the pipe sections. After the sections of pipe have been cemented into the well, logging tools are run to determine the location of the casing collars. The logging tools used include a pipe joint locator whereby the depth is recorded of each of the pipe joints through which the logging tools are passed. The logging tools generally also include a gamma ray logging device which records the depths and the levels of naturally occurring gamma rays that are emitted from various well formations. The casing collar and gamma ray logs are correlated with previous open hole logs which results in an accurate record of the depths of the pipe joint across the subterranean zones of interest and is typically referred to a tally log.
It is often necessary to accurately determine the location of one or more casing collar joints in a well. This need arises, for example, when it is desired to isolate strata with packers and perforate the well casing between the packers within a producing stratum of the formation, or to identify expansion joints, gas-lift valves, etc.
In order to identify casing collar joints, an appropriate well tool is lowered into well casing on a length of tubing, either coiled or jointed. Given the need for precision as to the depth, pipe joint depth information available from previously recorded joint and tally logs taken during well drilling is not sufficiently accurate. Regardless of the care and precision taken during the drilling process, true depth measurements are affected by tubing elasticity, stretch, thermal expansion, non-linearity of the well bore and the casing itself, and other variable regularities. Similarly, the accurate depth of the tubing string lowered into the well is also subject to error from the same causes. In the case of coiled tubing used to lower well tools, there is a tendency to spiral due to forcing the coil down or along a horizontal section of the well.
A variety of pipe string joint indicators have been developed including slick line indicators that can produce drag inside the pipe string and wire line indicators that send an electronic signal to the surface by the way of electric cable and others. These devices, however, either cannot be utilized as a component in a coiled tubing system or have disadvantages when so used. Wireline indicators do not work well in highly deviated holes because they depend on the force of gravity to position the tool. In addition, the wire line and slick line indicators take up additional rig time when used with jointed tubing.
In recent years, there have been more sophisticated systems and methods devised to improve accuracy of collar locators. These include systems and methods employing magnetic field measurements. While such inventions have advanced the art, there remain problems in the field. For example, certain collar locators operate on the well known principle that an electromotive force (emf) is induced in a coil that is either stationary in a magnetic field that varies in intensity or is moving with respect to a constant magnetic field. Conventional casing collar locators of this type typically rely on the generation of a relatively powerful magnetic field from the locator using either permanent magnet or a coil through which electrical current is passed to induce magnetism. In the latter case, a significant amount of power is required to generate a magnetic field. As the coil passes adjacent to a collar, the flux density of the magnetic field is changed by the additional thickness of the collar. This change is detected by the sensor in the form of a variation in the electromotive force (emf) generated in a coil. The electrical signal is telemetered to the surface and analyzed to determine sensor depth.
Conventional casing collar locators are subject to operational disadvantages and limitations of their effectiveness. They operate, for example, only in a dynamic mode, because the current induced in the coil requires that the sensor move with respect to the casing. If the device is moved too slowly, the changes in emf become subject to signal-to-noise ratio problems, effectively degrading their accuracy. On the other hand, in a rapidly moving sensor, signal strength may be problematic. In any event, the precise location of the sensor is itself lowered by the necessity of pinning down the position of a moving object at any given moment. Other problems are associated with the generation of strong magnetic fields in the wellhole, such as interfering with other instrumentation.
Although methods and apparatus has been known in the past to identify downhole casing collars and problem points of casing corrosion, a need exists for enhanced joint locator and/or pipe corrosions locator information. The foregoing is not intended to identify all of the problems and limitations of previously known systems but should be sufficient to demonstrate that collar and corrosion location systems existing in the past will admit to worthwhile improvement.
SUMMARY OF THE INVENTION
By use of Faraday crystals through which de-polarized light is passed in the presence of an imposed magnetic field, diffraction effects inherent in such crystals permit sensing of magnetic field anomalies which are a function of the mass of nearby casings, tubes and pipes of material with high magnetic permeability. As the casing collars are associated with changes of mass, the system and methods of the present invention are useful as a casing collar locator. Since corrosion and other defects in well casings, tubes and pipes present similar magnetic anomalies, the present invention has further utility in locating zones of corrosion in in-situ well pipe.
THE DRAWINGS
Other aspects of the present invention will become apparent from the following detailed description of embodiments taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a representation of the system of the invention in the context of its application at an oil well site;
FIG. 2 is a schematic diagram of the components of a preferred embodiment of the invention;
FIG. 3 represents the schematic details of a sensor employed in the invention using a reflected light source;
FIG. 4 depicts a typical plot of Faraday crystal losses (in dB) as a function of an applied magnetic field intensity (in Oersteads) wherein a bias point may be located within the regions of linearity on the curve, thus permitting more convenient determinations of magnetic field anomalies;
FIG. 5 is a representative signal output from a sensor which uses polarized light;
FIG. 6 is a representative signal output from a sensor which uses light that has been depolarized;
FIG. 7 a depicts illustrative positions of a sensor which has been lowered in a well casing in the vicinity of a casing collar;
FIG. 7 b is a signal output corresponding to such positions, shown as an oscilloscopic trace of voltage (v) as a function of time (t);
FIG. 7 c depicts illustrative positions of the sensor indicated in FIG. 7 a as it is retrieved by raising it within the casing and thus passing it again through the region of a casing collar;
FIG. 7 d is a sensor signal output corresponding to the indicated positions, shown as an oscilloscopic trace of voltage (v) as a function of time (t);
FIG. 8 depicts a differentiation (dv/dt) of the data presented in FIGS. 7 c and 7 d , as a result of which the permeability anomalies present in the vicinity of a casing collar are reflected as sharply defined optical output variances when the sensor traverses either a downward pass ( FIG. 7 a ) or an upward pass ( FIG. 7 c ) in the wellhole; and
FIG. 9 depicts another embodiment of the sensor in which the light beam from a light source is not reflected backwards after passing through the Faraday crystal but is instead guided through an optical fiber loop coupled to the descending optical fiber from the surface.
DETAILED DESCRIPTION
Context of the Invention
Turning now to the drawings wherein like numerals indicate like parts, FIG. 1 is a representation of an oil well drilling system which identifies an operative context of the invention. A conventional drilling derrick 102 is shown positioned above an oil well borehole. A casing 104 has been installed within the borehole and cemented in place as at 106 . The borehole may extend thousands of feet into the earth's crust, perhaps 25,000 feet or so, into an oil and/or gas bearing formation. Ambient conditions at this depth may be twenty thousand pounds pressure per square inch and 150-175° C. in temperature.
Oil well logging managers are able to determine and map, on a real time and historical basis, vast amounts of well and formation data using oil well logging tools. In this a wire line cable 108 is connected to a logging tool 110 which has one or more instrumentation sonde sections 112 and a sensing section 114 . The logging tool is lowered into the wellhole on the wireline 108 using techniques well known to those in the art. The sensing section or sections 114 are positioned within a formation zone 116 where logging is to occur. An optical fiber (not shown) is run along with the wireline to the casing collar locator sensor (not shown) within the sensor section 114 .
A source of coherent light 118 is directed through an optical fiber cable 110 containing a first optical fiber (not shown). An optical de-polarizer 122 is connected in line with said first optical fiber. An optical coupler or optical circulator 124 couples the first optical fiber with a second optical fiber (not shown) within a cable 120 which second optical fiber is connected to a signal detection and analyzer stage 126 .
Fiber Optic Sensing System Employing Diffraction Effect of Faraday Rotator.
One preferred embodiment of the invention is schematically illustrated in FIG. 2 . A coherent source of light 202 is output into a first optical fiber 204 . The depolarizer 206 is connected in line with the first optical fiber 204 , which in turn is coupled with an optical coupler or optical circulator 208 to a second optical fiber 210 . The light is completely depolarized using any one of a number of commercial depolarizing devices well known in the art.
De-polarized light emerging from the depolarizer 206 is guided within the first optical fiber 204 downhole and passed through a magnetooptical sensor (not shown, but described more fully below) within the instrumentation section 212 of the sonde. The sensor is lowered by the wireline (not shown) or other means to a depth in the wellhole within the vicinity of a casing collar 214 . The sensor is placed close to the casing inner wall, approximately 25 mm (one inch). For example, the sensor may be mounted on a caliper arm to maintain a fixed distance relative to the casing inner wall regardless of the casing diameter. Therefore, sensitivity of sensor to the casing inner wall will not change. Once within the vicinity of the casing collar, the sensor is further lowered so that it passes below the casing collar. The sensor is then raised to a position above the casing collar.
Light returning from the sensor is guided upward through the optical fiber 204 . At the optical coupler or optical circulator 208 , the second optical fiber 210 branches the light returning from the sensor and directs it to an optical detector 216 where it is transformed into an electrical signal 218 and subjected to analysis.
Description of Magnetooptical Sensor.
The invention employs a magnetooptical sensor to detect magnetic permeable anomalies caused by the presence of varying masses of ferromagnetic material present in casings, tubing, and pipe in the downhole environment. Such anomalies are sensed by a sensor comprising at least one optical collimator, a Faraday crystal, and magnets which may be used to create a magnetic field in the vicinity of the sensor. One preferred embodiment of such a sensor is shown in FIG. 3 .
De-polarized light 302 is guided into a sensor 304 through a first optical fiber (not shown) and passes through a co-axially mounted magnet 306 . The fiber is connected to a collimator 308 , which assures that light entering a Faraday crystal 310 positioned after the collimator consists of parallel rays. An optical reflective medium 312 is positioned adjacent to and downstream of the Faraday crystal 310 and reflects incident light 180 degrees back through the first optical fiber 302 , as a beam 314 where it is guided back to the surface and through the path described in FIG. 2 . For example, the optical reflective medium 312 may be a corner cube or a mirror. A second magnet 314 is placed adjacent to and downstream of the corner cube such that lines of magnetic flux exist between the magnets 306 and 318 .
Other devices to accomplish the same light guides, such as using reflecting devices other than a corner cube 312 , will readily present themselves to one of skill in the art. One Faraday crystal employed in the embodiment described is an iron garnet. Other magnetooptical crystals are well known in the art.
The sensor is preferably housed within a cylindrical capillary 316 to maintain alignment of its components and to protect it from the often harsh ambient temperature and pressure conditions within a bore hole. In one preferred embodiment, the capillary 316 has an outside diameter of 2.7 mm. and a length of about 30 mm total, with the Faraday crystal centered within the length of the capillary. Magnets are positioned in a manner which allows adjustment, as a means of affecting sensitivity of the sensor and of biasing the baseline signal. The sensor unit may be packaged into a pressure-sealed non-magnetic metal housing (not shown) in order to withstand downhole pressure conditions.
FIG. 4 is a plot of the attenuation of the light, i.e., insertion loss, (in dB) traversing a Faraday crystal as a function of the applied magnetic field (in Oersteads). Adjustments of the magnetic field strength surrounding the sensor can be made by adjusting the positions of the magnets within the sensor. Such adjustments permit biasing the sensor output so as to establish convenient base line responses from the sensor in regions when the casing, but not casing collars, influence the intensity of the light beam passed through the sensor. Sharper delineation of the effect of the greater mass of a casing collar (or the lesser mass of a zone of corrosion) is thus produced when the sensor is positioned near collars or zones of corrosion.
The use of non-polarized light is preferred in the operation of the sensor 304 . FIG. 5 shows an oscilloscope trace of a baseline 502 of a returned signal in which polarized light was employed. FIG. 6 , by contrast, shows a baseline 602 of the returned signal in which de-polarized light was used. De-polarized light provides a cleaner, more stable baseline from which magnetic anomalies may be more accurately determined.
FIGS. 7 a and 7 c illustrate the positions of a sensor as it is first lowered ( FIG. 7 a ) and then retrieved ( FIG. 7 c ) within a borehole casing. The positions 702 through 708 correspond to positions in a region 702 where there is little influence from the lower flux density of the magnetic field in the vicinity of the casing collar; at position 704 where the sensor is in a region of higher flux density due to its location closer to the casing collar; then at position 706 in a region of highest flux density; and finally at position 708 where the sensor has been lowered to a position where the collar has little influence on flux density. The intensity of light passing through the sensor is affected by the magnitude of the field, which is, in turn, a function of the mass of ferromagnetic material in the vicinity. Similarly, the positions 710 through 716 in FIG. 7 c correspond to equivalent positions as the sensor is retrieved by raising it in the casing from a position 710 below the casing collar 712 to a position 716 above the casing collar.
The data illustrated in FIGS. 7 b and 7 d are oscilloscope traces which plot an electrical analogue of the intensity of light passing through the Faraday crystal in the various positions of the sensor indicated in FIGS. 7 a and 7 c , respectively.
The reader of ordinary skill in the art will note that the deflections or magnitude of the voltage reflected in the traces of data shown in FIGS. 7 b and 7 d are not necessarily directly linearly relatable to the mass of the ferromagnetic material in the pipe. The actual magnetic flux strengths may be affected by ambient magnetic effects which can increase or decrease the actual flux density at a given point. Notwithstanding, the effectiveness of the invention lies in the relative impact upon light intensity of the magnetic field imparted by the magnets associated with the sensor.
Furthermore, it is not to be suggested the utility of the invention requires that the sensor be lowered or raised at constant speeds. Indeed, the sensor may be moved in increments or at varying speeds, the only limitation being that the sensor not be moved so swiftly as to present signal to noise deterioration of data. Indeed, the ultimate aim in the use of the sensor is to provide, in effect, a plot of data which correlates to light intensity as a function of distance along the observed section of well casing, pipe or tube, as the case may be.
In the preceding several paragraphs, the embodiment described relates to the use of the invention to detect the location of casing collars, but the invention is not so limited. It is a fundamental feature of the disclosed invention that changes in magnetic flux affect the diffraction of light passing through a Faraday crystal of magnetooptical properties, as discussed by G. B. Scott and D. E. Lacklison, “Magnetooptic Properties and Applications of Bismuth Substituted Iron Garnets,” IEEE Transactions on Magnetics , Vol. Mag. 12, No. 4, July 1976, and T. R. Johansen et al, “Variation of Stripe Domain Spacing in a Faraday Effect Light Deflector,” Journal of Applied Physics , Vol. 42, No. 4, Mar. 15, 1971. The disclosures of these publications are hereby incorporated herein by reference. Changes in flux are presented where anomalies occur in the magnetic permeability of well casings, pipes and tubes. Such anomalies are present near casing collars which typically involve greater concentrations of mass over that of the casing tubing they join. They are also presented by the presence of corrosion or other defects in the walls of in-situ casings, pipes and tubes. Therefore, the invention may be used to detect corrosion and such other defects.
Returning to the analysis of data obtained by use of the sensor described above, the data presented in FIGS. 7 c and 8 d may be used directly to determine the position of the casing collar. It may also be useful to mathematically differentiate the data so as to present a starker, more sharply defined location of the anomalies. FIG. 8 reflects such a treatment of the data reflected in FIGS. 7 a and 7 c . The figure is a plot of dv/dt of the data in FIGS. 7 a and 7 b . The first (left) spike 802 in FIG. 8 delineates a magnetic anomaly detected as the sensor is moved down the casing through the region where the magnetic flux is affected by the presence of the casing collar; the second (right) spike 804 delineates the same anomaly as the sensor is retrieved upwardly past the same collar. The wellhole depth, and hence the location of the casing collar, is then determined by cross calibrating the position of the sensor with other well logging data, such as a gamma log.
In the sensor described above, light traverses the Faraday crystal twice, due to its reflection by the corner cube 312 in FIG. 3 . This double passage of the light results in larger insertion losses. The loss may be lessened, and sensitivity of the results improved, by the use of a single pass of the light. Such a sensor is depicted in FIG. 9 .
A fiber optic light beam 902 is passed through a collimator 904 , a Faraday crystal 906 , and a second collimator 908 . Instead of being reflected backward, an optical fiber loop 910 is created by means of a mini-bend fiber 912 capable of a bending radius of less than 15 mm. The loop is re-coupled to the first optical fiber 902 through an optical coupler 914 . The sensor is housed in a capillary 916 , which may be composed of glass or other material capable of withstanding ambient temperature and pressure conditions within the well hole, and is provided with magnets 918 and 920 necessary for the operation of the Faraday crystal. As the sensor depicted in FIG. 9 does not involve dual passage of the sensing beam through the Faraday crystal, the beam experiences reduced insertion losses, and, therefore, the sensor is more sensitive.
The foregoing embodiments have each employed a single optical fiber through which light is transmitted downhole to a sensor and simultaneously returned to a photo-detector located at the surface. Other embodiments may be employed in which separate optical fibers are used for insertion of light to a sensor and as a return guide of the light after its passage through a Faraday crystal. Such an embodiment would not require optical couplers which also entail insertion losses and, thus, the embodiment may present more sensitive data results.
To the extent that operations described in the embodiments above may be performed by different components, it should be apparent to those of ordinary skill in the art, that different components may be used. For example, a light beam shaping device is not intended to be limited to a collimator, but such shaping may also be performed by a focuser, a lens, or a particular extremity of an optical fiber. Similarly, a light reflection element is not limited to a corner cube but may be performed by other devices known in the art.
In this application and claims, the terms casing, pipe and tubing are used in their broadest sense to include all forms of well casing, pipes and tubes and of all compositions, limited only by requirement that they exhibit magnetic permeability sufficient to affect the light intensity of unpolarized coherent light passing through magnetooptical crystals exhibiting a Faraday diffraction effect.
The various aspects of the invention were chosen and described in order to best explain principles of the invention and its practical applications. The preceding description is intended to enable those of skill in the art to best utilize the invention in various embodiments and aspects and with modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims. | Systems and methods for optically determining casing collar and/or corrosion locations within boreholes, using the diffraction effect of Faraday crystals through which depolarized continuous light is transmitted within optical fibers. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims benefit under 35 USC 199(e) of provisional application 60/320,144, filed Apr. 25, 2003, the entire file wrapper contents of which provisional application are herein incorporated by reference as though fully set forth at length.
FEDERAL RESEARCH STATEMENT
The inventions described herein may be manufactured, used and licensed by or for the U.S. Government for U.S. Government purposes.
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates in general to the field of Missiles and Munitions used by the Armed Forces, and it particularly relates to a new design method for a fin deployment system that enables a substantial reduction in the volume of munitions as compared to those employing conventional fin deployment systems. More specifically, the present invention incorporates a novel wrap-around fin concept that is capable of achieving a straight fin deployment which is necessary in maintaining a proper roll control authority during flight while substantially reducing the volume, hence weight, of missiles and munitions. The volume reduction thus translates into significant tactical advantages of these new missiles and munitions incorporating the present invention by enabling more electronic payload or lethality to be packaged into the volume savings.
2. Background of the Invention
High explosive missiles and munitions are an essential part of the arsenals of the Armed Forces. Missiles and munitions are highly complex systems generally used for deploying projectiles capable of high-speed and long-range maneuvers to deliver lethality to a target or to intercept an incoming threat. A missile projectile is normally discharged by means of a gun tube, or a missile launcher, or the like. Upon exiting a muzzle of a gun tube, the projectile gains a rapid increase in speed and altitude. At a high speed flight, the trajectory and stability of a missile projectile are actively controlled by navigation and guidance electronics to operate various control surfaces such as fins and canards.
Fins are control surfaces generally deployed in the aft of a missile projectile to provide roll stability during flight. On the other hand, canards are control surfaces typically mounted in front of a missile projectile to enhance its maneuverability. Fins are normally deployed lengthwise and with a circular symmetry with respect to the projectile body to minimize asymmetric aerodynamic loading which can adversely affect the stability of the projectile. To provide a control authority, fins are constructed with hinges to allow them to be actuated individually so as to modify the aerodynamic forces on the projectile for guidance purposes.
A conventional missile projectile typically employs a fin deployment system that is housed within the projectile body and rotated perpendicular to the projectile body axis. Upon exiting a gun muzzle, the fins are activated to open up lengthwise on the projectile body to provide the roll stability. A conventional fin deployment system occupies a significant interior volume of the projectile body. For example, the boom part of a 105 mm tank projectile, which is the portion of the projectile body containing the fin deployment system, is typically about 8 inches in length and weighs approximately 11 lbs. This represents a 25% of the total volume of the projectile body. The volume taken up by a conventional fin deployment system generally is viewed as a non-utilizable space within a projectile body that could otherwise be used for carrying additional volume of warheads or other explosive materials as well as electronics packages such as guidance and control electronics. Therefore, it is a well-known design objective to minimize the take-up volume of the fin deployment system by alternate design methodologies.
Attempts to improve a fin deployment system for missiles and munitions have been considered. One such exemplary methodology utilizes a wrap-around fin deployment system on the 2.75-inch rockets. The wrap-around fin deployment system is housed in the exterior of the projectile body with the fins folded circumferentially around a center body. In theory, this conventional design is able to reduce the take-up volume of the fin deployment system. In practice, problems with this conventional fin deployment system have been encountered whereby the deployed fins have curved surfaces upon deploying from their housing, the fin itself is shaped to the profile of the missile projectile for a semi-circular fin shape. The curved fins can significantly compromise the roll control authority of a missile projectile, which is not an issue on non guided systems. Roll control authority is needed for guided missile projectile systems; therefore the deployment system used by the 2.75 inch rocket is not viable.
Thus, it is realized that the current attempts to provide a fin deployment systems that can achieve a considerable projectile volume savings while maintaining a good roll control authority heretofore remains unfulfilled. Consequently, it is therefore recognized that a further enhancement in the design methodology for a fin deployment system is still needed to achieve the foregoing objectives. Preferably, the new design methodology would provide a space saving fin deployment system capable of deploying straight fins to maintain a good roll control authority while achieving the design objective of reducing the volume of the projectile taken up by the fin deployment system.
SUMMARY OF INVENTION
It is a feature of the present invention to provide a new design methodology for fin deployment system for missiles and munitions that substantially reduces the volume taken up by the fin deployment system within a projectile body. Further, it is a novelty of the present invention to provide a new method for deploying and activating straight flat fins for roll control authority. In summary, the new design method for a space-saving straight fin deployment system employs a number of novel design features as follows:
1. A wrap-around fin concept generates space-savings within a projectile body whereby the fins are arranged in a wrapped configuration around a boomtail structure. 2. The fins may be constructed of a super-elastic material such as Nickel Titanium or Multi functional Alloy in a preferred embodiment to enable the fins to assume straight flat surfaces upon deployment without inducing any radius of curvature during in-flight trajectories. Material selection for the fin system is missile projectile size dependent. Alternatively, the fins may be made of spring steel. 3. The system eliminates mechanical means of deploying the wrapped fins, no springs are needed to deploy the fins. Physics of system generates equal deploying fins.
The space-saving fin deployment system affords advantages over a conventional fin deployment system in achieving substantial space savings for increasing the onboard towing capacity of electronic packaging or lethality in the missiles and munitions systems, while at the same time providing a good roll control authority during flight by enabling a straight fin deployment resulting from the use of super-elastic materials. In some particular applications, the space savings could be reduced by a factor of two as compared to a conventional design.
BRIEF DESCRIPTION OF DRAWINGS
The features of the present invention and the manner of attaining them will become apparent, and the invention itself will be understood by reference to the following description and the accompanying drawings, wherein:
FIG. 1 is an external view of a missile or munitions system according to a smart cargo concept, shown attached to its aft end by a space-saving fin deployment system of the present invention for roll control authority;
FIG. 2 is an exploded view of a preferred embodiment of the space-saving fin deployment system of FIG. 1 , comprising of an obturator assembly, a cant-boomtail, a fin system, a hinge assembly, a back assembly, and a cover assembly;
FIG. 3 illustrates various views of the back assembly of FIG. 2 ; comprising of a cant-back plate, a plurality of retaining bolts and O rings, and a plurality of alignment pins;
FIG. 4 illustrates the fin system of FIG. 2 made according to the present invention;
FIG. 5 illustrates an assembly view of the fin system of FIG. 4 and the hinge assembly of FIG. 2 that is comprised of a plurality of cant hinges, a plurality of retaining bolts, a plurality of lock pins, and a plurality of compression springs;
FIG. 6 illustrates various orthogonal and perspective views of the cant hinges of FIG. 5 ;
FIG. 7 illustrates an isometric and cross sectional views of the lock pins of FIG. 5 ;
FIG. 8 illustrates various views of the cover assembly of FIG. 2 ;
FIG. 9 illustrates various orthogonal and perspective views of the cant-boomtail of FIG. 2 ; and
FIG. 10 is a perspective view of the space-saving fin deployment system of FIG. 3 , shown with the cover and fins in the stowed position as viewed when the projectile is loaded into the cartridge.
Similar numerals in the drawings refer to similar elements. It should be understood that the sizes of the different components in the figures might not be in exact proportion, and are shown for visual clarity and for the purpose of explanation.
DETAILED DESCRIPTION
FIG. 1 illustrates a missile or munitions system 10 incorporating a space-saving fin deployment system 12 made according to the present invention. An exemplary munitions system 10 may be based upon a smart cargo concept that includes a 105-mm tank munitions used in the U.S. Armed Forces. The munitions system 10 is generally comprised of a number of major components; namely: a projectile body 14 , a nose cone 16 , and a preferred embodiment of the space-saving deployment system 12 that constitutes a novelty of the present invention. Each of these major components is further described as follows:
The projectile body 14 is generally made of a thin steel shell having a cylindrical shape. The interior volume of the projectile body 14 typically contains flammable propellant charges that provide a thrust force upon ignition to propel the munitions system 10 forward during flight. In addition, the interior volume also houses electronics packages such as guidance and control or lethality component.
The nose cone 16 is generally formed of an ogive shape designed to reduce the aerodynamic drag on the munitions system 10 during flight. The nose cone 16 normally holds an explosive charge or other payload materials to destroy a target upon impact.
With reference to FIG. 2 , the space-saving fin deployment system made in accordance with a preferred embodiment of the present invention is comprised of an obturator assembly 18 , a cant boomtail 20 , a fin system 22 , a hinge assembly 24 , a back assembly 26 , and a cover assembly 28 . Referring to FIG. 3A , the back assembly 26 is designed to provide a retention structure for holding the hinge assembly 24 in place. The back assembly 26 is comprised a number of components: a cant-back plate 30 , a plurality of retaining bolts 32 with corresponding O-rings 34 , an O-ring 36 , an O-ring 38 , and a plurality of alignment pins 40 . In a preferred embodiment, 8 retaining bolts 32 and O-rings 34 are used to connect the cant-boomtail 20 to the back assembly 26 . Further, two alignment pins 40 are used for precise positioning of the cant-boomtail 20 with respect to the back assembly 26 .
With further reference to FIG. 3B , the cant-back plate 30 is geometrically defined by a saw tooth-like cam shape 42 having a circular symmetry on the outer surface and an inner circular opening 44 . According to a preferred embodiment, the cam shape is divided into four equal segments; each is formed by a quarter circular arcs with an offset radius. A plurality of pairs of bolt holes 46 are machined through the cant-back plate 30 to allow the corresponding retaining bolts 32 to be inserted through for connecting the cant-boomtail 20 with the back assembly 26 . FIG. 3B illustrates four such pairs of bolt holes 46 . A plurality of corresponding circular O-ring grooves 48 are present to accommodate the corresponding O-rings 34 to seal out potential gas leakage from underneath the retaining bolts 32 which may bleed into the cover assembly 28 to cause failure of the fin system 10 . The placement of the O-rings ensures the generation of a forward pressure force on the cover assembly. This is needed to keep the cover assembly on during gun launch. The outside profile of the back plate mimics the shape of the boomtail.
A circular O-ring groove 50 inscribing the bolt holes 46 is designed to accommodate the O-ring 36 to seal potential gas leakage between the cant-boomtail 20 and the cant-back plate 30 . Similarly, with reference to FIG. 3D , a circular O-ring groove 52 circumscribing the bolt holes 46 is present on the other side of the cant back plate 30 to receive the O-ring 38 to seal out potential gas leakage between the cover assembly 28 and the cant-back plate 30 .
With further reference to FIGS. 3B and 3C , a plurality of small cylindrical bores 54 are formed at a partial depth through and equidistance around the periphery of the cant-back plate 30 . In a preferred embodiment, there are four such cylindrical bores 54 . The cylindrical bores 54 are designed to provide an engagement of the hinge assembly 24 into the back assembly 26 . Moreover, a plurality of smaller pin holes 56 are machined into the cant-back plate 30 to allow the alignment pins 40 to be inserted through for precise positioning of the cant-boomtail 20 and the back assembly 26 . In particular, two pin holes 56 are used according to the present invention. A plurality of threaded bolt holes 57 are also formed in the cant-back plate 30 . For the present invention, two such threaded bolt holes 57 are used for attaching the back assembly 26 to the cover assembly 28 . Moreover, the cant back plate 30 also includes a plurality of lock pin holes 59 for the purpose of providing a fin locking mechanism upon deployment. For a preferred embodiment, four such lock pin holes 59 are employed as shown in FIG. 3B .
Referring now to FIGS. 2 and 4 , the fin system 22 is comprised of a plurality of fins 58 . According to the present invention, four such fins 58 are used in the space-saving fin deployment system 12 . The shape of the fins 58 is normally determined by an aerodynamic analysis to provide the stability needed for in-flight trajectories. According to a preferred embodiment, the fins 58 generally are constructed from thin structural plates shaped in a rectangular plan form with a radius corner cutout 60 . Alternatively, the shape of the fins 58 may also assume other forms as necessary.
According to a preferred embodiment, the fins 58 may be constructed from a super elastic metallic alloy of nickel titanium or a multifunctional alloy. Other materials of similar characteristics such as iron manganese silicon or even spring steel may also be used as alternate fin materials to provide a desirable radius of curvature of the fins 58 when in the stowed position. The super-elasticity of the fin material is an essential and enabling feature of the present invention in allowing the fins 58 to undergo a substantial deflection without suffering any permanent deformation resulting from the wrap-around towed position, thereby enabling the fins 58 to spring open flat upon deployment without introducing any undesirable curvature into the surfaces of the fins 58 . Hence, good roll control authority of the munitions system 10 is therefore achievable.
With further reference to FIG. 4 , a plurality of bolt holes 62 perforate the fins 58 on one of its sides adjoining the radius corner cutout 60 . These bolt holes 62 are designed to secure the fins 58 to the hinge assembly 24 as illustrated in FIG. 5 .
With further reference to FIG. 5 , the hinge assembly 24 is comprised of a plurality of cant hinges 64 , each with a plurality of retaining bolts 66 , a plurality of lock pins 68 , and a plurality of compression springs 70 . In a preferred embodiment, four each of cant hinges 64 , lock pins 68 , and compressor springs 70 are employed in the space-saving fin deployment system 12 . Referring now to FIG. 6A , the cant hinge 64 includes a hinge portion 72 , a larger end plug 74 , and a smaller end plug 76 . Both the end plugs 74 and 76 have a cylindrical construction disposed at either distal end of the hinge portion 72 .
With reference to FIG. 6B , the hinge portion 72 is shaped is a form of a nearly circular cross section with a 270-degree circular arc tangent at either end to two flat sides 78 and 80 . A straight groove 82 is machined into the hinge portion 72 to span its entire length along the flat side 80 . The thickness of the groove 82 is substantially the same as the thickness of the fins 58 .
With reference to FIGS. 6A and 6C , a plurality of bolt threaded holes 84 perforate the flat side 80 and further penetrate into the hinge portion 72 with a substantial depth of thread relative to the width of the hinge portion 72 thereat. The threaded bolt holes 84 are precisely machined so as to match dimensions and positions of the bolt holes 62 of the fins 58 . The bolts also act as stopping reference for hinge rotation.
With reference to FIG. 6D , on a distal end surface 86 of the hinge portion 72 whereupon the smaller end plug 76 is formed, a straight cylindrical bore 88 is constructed lengthwise at a partial depth through the hinge portion 72 . The straight cylindrical bore 88 is designed to receive the lock pin 68 and the compression spring 70 .
With reference to FIG. 7A , the lock pin 68 is comprised of a taper blunt nose section 90 , a mid section 92 , and a cylindrical aft section 94 . The taper blunt nose section 90 has a conical section feature that transitions to a hemispherical nose. The taper nose allows for insertion of the pin quicker than if the pin was cylindrical. As well the taper pin wedges itself into the mating hole in the back plate to remove all machining tolerance from the system. The mid section 92 is shaped as a constant diameter section having a plurality of shallow right angle slots 96 spaced at equidistance around the periphery of the mid section 92 . In particular, there are four such right angle slots 96 in a preferred embodiment. The right angle slots 96 are designed to relieve pressure from the bore of the lock pin. The lock pin 68 has a posted section that goes through the middle of the compression spring. The post protects the spring from being compressed more than it is designed to be. The lock pin 68 also is designed to have a specific wheelbase length relative to the length of the conical section to provide more stability of the pin while locked. The cylindrical aft section 94 has a smaller diameter and is designed to accept the compression spring 70 as shown in FIG. 5 .
Referring now to FIG. 8A , the cover assembly 28 is shaped as a thin cylindrical cap having a cylindrical wall 98 and a circular end plate 100 . The cover assembly 28 is designed to enclose the fin system 22 when in the stowed position. A plurality of circular holes 102 are formed at equidistance around the periphery of the cylindrical wall 98 . In a preferred embodiment, four such circular holes 102 are employed. These circular holes 102 are designed to allow for pressure equalization around the inside ands outside of the cover, they also provide means to evacuate gas after muzzle exit. These holes are needed for structural survivability of the cover, without them the cover will collapse from gun pressure while in the gun.
With reference to FIG. 8B , a hollow cylindrical plug 104 is formed on the interior of the cover assembly and is integrally attached to the circular end plate 100 . The hollow cylindrical plug 104 is comprised of a cylindrical bore 106 and an O-ring groove 107 at the end. An O-ring 108 is installed on the O-ring groove 107 to maintain the gas pressure inside the reservoir for better deployment performance.
With further reference to FIG. 8B , a small meter orifice 110 is formed in and positioned at the center of the circular end plate 100 . With reference to FIG. 8C , the meter orifice 110 is comprised of a threaded hole 112 , a small circular aperture 114 , a thin cylindrical orifice 116 , and a conical opening 118 into the cylindrical bore 106 of the cylindrical plug 104 . Inside feature 112 is installed an orifice which determines amount of bleed pressure into the reservoir. The insert orifice is made from a copper tungsten material. This material does not erode as high velocity gas passes though the orifice.
With further reference to FIG. 8A , a plurality of bolt holes 120 are machined into the exterior of the circular end plate 100 . FIG. 8A illustrates two such bolt holes 120 disposed diametrically opposite to each other. A plurality of break screws 122 are designed to be inserted into the bolt holes 120 and then threaded into the threaded holes 57 of the back assembly 26 . The break screws 122 are designed to hold the cover assembly onto the boomtail during handling as well as to provide initial squeeze of the o-ring between the cover and the back plate. The break screws then fail at the muzzle exit due to the force within the cover pressure reservoir to release the cover assembly 28 from the back assembly 26 for fin deployment.
Referring now to FIG. 9A , the cant-boomtail 20 is the main structural component of the space-saving fin deployment system 12 . The cant-boomtail 20 is a structure of circular symmetry comprising of a number of features as follows: With further reference to FIGS. 9A–B , a cylindrical plug 124 is formed at one distal end of the cant-boomtail 20 and is designed to provide a means of engaging the space-saving fin deployment system 12 into the projectile body 14 . A circular landing area 126 is formed integrally at the base of the cylindrical plug 124 and extends to an adjoining circular indexing step portion 128 .
The circular indexing step portion 128 then adjoins a smaller circular indexing step portion 130 having a slightly smaller width and radius. Referring to FIGS. 9A–B , a plurality of indexing grooves 132 and 134 are formed at equidistance around the periphery of the circular indexing step portion 128 . With specific reference to FIG. 9C , the indexing grooves 132 are generally curved passages extending from the peripheral surface of the circular indexing portion 128 to the bottom surface 136 of the smaller circular step portion 130 . With further reference to FIG. 9B , the indexing grooves 134 are also formed of curved channels starting from the peripheral surface of the circular step portion 128 and terminating on a surface of a hinge pocket structure 138 . The purpose of feature 132 is to provide gas release from under the fin blades to outside the fin cover, this intern helps slow down deployment speed of the fin system.
Referring to FIG. 9A , the hinge pocket structure 138 is generally located in the aft section of the cant-boomtail 20 and integrally adjoins with the smaller circular indexing step portion 130 . The hinge pocket structure 138 is comprised of a plurality of hinge pockets 140 formed lengthwise along the hinge pocket structure 138 . In FIG. 9A , four such hinge pockets 140 are illustrated. The hinge pockets 140 are generally machined surfaces having nearly semicircular cavities recessed inward from the outer surface 142 of the hinge pocket structure 138 . The shape of the hinge pockets 140 is designed so as to provide a near zero-clearance fit with the hinge assembly 26 in order to maximize space savings. With specific reference to FIG. 9D , the outer surface 142 of the hinge pocket structure 138 is geometrically constructed by a plurality of eccentric circular arc segments interposed the hinge pockets 140 . Boomtail surface 138 has a specific contour to it for system function. The surface provides a constant curvature for the fin to rest upon, when the fin is wrapped it goes over the next adjacent hinge. The surface ramps the fin up to the hinge and allows for the fin to transition unto the hinge without any harsh transitions.
With further reference to FIG. 9D , a plurality of cylindrical bores 144 are machined at a partial depth through the bottom surface 136 of the smaller circular indexing step portion 130 within each hinge pocket 140 . There are four such cylindrical bores 144 as illustrated in FIG. 9D . These cylindrical bores 144 are designed to enable the cant hinges 64 to be positively retained within the hinge pockets 140 by engaging the large end plugs 74 therein. Further, a plurality of pairs of smaller threaded bolt holes 146 are machined into the distal end surface 148 of the hinge pocket structure 138 . In a preferred embodiment, four such pairs of threaded bolt holes 146 are employed as shown in FIG. 9D . These pairs of threaded bolt holes 146 are designed to enable a bolted joint connection between the back assembly 26 and the cant boomtail 20 via the retaining bolts 32 .
With further reference to FIG. 9D , two diametrically opposed alignment holes 150 are formed on the distal end surface 148 and are located near the periphery of the hinge pocket structure 138 . These alignment holes 150 enable a precise positioning of the boomtail 20 with respect to the back assembly 26 via the alignment pins 40 . With reference to FIG. 9C , a large cylindrical bore 152 is integrally formed within the hinge pocket structure 138 at a substantial depth from the distal end surface 148 . The cylindrical bore 152 extends beyond the distal end surface 148 to form a small hollow cylindrical plug 154 .
Referring now to FIG. 2 again, the assembly sequence of the space-saving fin deployment system 12 is as follows: The obturator assembly 18 is shaped as a circular ring with an outer diameter nominally equal to that of the circular indexing portion 128 and an inner diameter nominally equal to that of the circular landing area 126 . The width of the obturator assembly 18 is also nominally equal to that of the circular landing area 126 . The obturator assembly 18 is slipped onto the circular landing area 126 abutted against the circular indexing portion 128 of the cant boomtail 20 to form a flush, tight tolerance fit.
With reference to FIG. 5 , the fins 58 are slip fitted into the grooves 82 of the cant hinges 64 . Upon aligning the bolt holes 62 of the fins 22 with the threaded bolt holes 84 of the cant hinges 64 , retaining bolts 66 are torqued to secure the fin system 22 to the hinge assembly 24 . The compression springs 70 are fitted onto the cylindrical aft section 94 of the lock pins 68 , which are then inserted into the cylindrical bores 72 of the cant hinges 64 .
The hinge assembly 24 is now engaged with the cant boomtail 20 on one end by means of insertion of the larger end plugs 74 of the cant hinges 64 into the cylindrical bores 144 of the cant boomtail 20 . On the other end, the hinge assembly 24 is engaged with the back assembly 26 by means of insertion of the smaller end plugs 76 into the cylindrical bores 54 of the cant back plate 30 . The hinge assembly 24 is free to pivot while being axially restrained by the cant boomtail 20 and the back assembly 26 .
The back assembly 26 is then secured to the cant boomtail 20 via the retaining bolts 32 inserted through the pairs of bolt holes 46 of the cant back plate 30 and threaded into the corresponding pairs of threaded bolt holes 146 of the hinge pocket structure 138 . FIG. 10A illustrates the combined assembly of the cant boomtail 20 , the fin system 22 , the hinge assembly 24 , and the back assembly 26 .
With reference to FIG. 10B , the hinge assembly 24 is rotated while the fins 58 are simultaneously curved into circular arcs to wrap around the hinge pocket structure 138 as illustrated in FIG. 10C . The cover assembly 28 is then slipped onto the wrap-around fins 58 and abutted against the circular indexing step portion 128 . The break screws 122 are then inserted through the bolt holes 120 of the cover assembly 28 and threaded to into the threaded bolt holes 57 of the cant back plate 30 to secure the cover assembly 28 to the back assembly 26 . The space-saving fin deployment system 12 is now completed as illustrated in FIG. 10D and is ready to be assembled to the projectile body 14 via the cylindrical plug 124 of the cant boomtail 20 as shown in FIG. 1 .
The functionality of the present invention may be appreciated by considering the following deployment sequence:
Upon exiting the muzzle of the gun tube, the base pressure on the munitions system 10 begins to decrease. The gas pressure inside the pressure reservoir of the cover assembly 28 and the cant boomtail 20 is maintained. The resulting differential pressure exerts a force onto the circular end plate 100 inside the pressure reservoir. As base pressure drops from behind the projectile the pressure within the reservoir deploys the cover from the fin system releasing the fin system. The cover retention screws 122 are broken as the cover ejects. The cover retention screws are designed as a low tensile strength material. The cover retention screws do not provide the strength required keeping the cover on the projectile during launch; rather that is the job of the base pressure inside the gun tube. The cover retention screws provide a mechanical means to squeeze the o-ring between the cover and cant back plate. The stored energy in the wrapped fin is all that is needed to rotate the hinge assembly and deploy the fin.
Upon exposure, the fins 58 begin to unwrap themselves from the cant boomtail 20 . The unwrapping of the fins 58 also inputs into the hinge assembly 24 a torque. This torque causes the cant hinges 64 to rotate 107 degrees from a closed position to a lock position whereupon the spring loaded lock pins 68 are propelled forward into the lock pin holes 59 of the cant back plate 30 . Upon locking, due to the super elasticity of the fin material, the fins 58 are now straightened themselves into zero-curvature surfaces. The space-saving fin system 12 is now in a fully deployed state for mission readiness.
It should be understood that the geometry, compositions, and dimensions of the elements described herein can be modified within the scope of the invention and are not intended to be the exclusive; rather, they can be modified within the scope of the invention. Other modifications can be made when implementing the invention for a particular environment. | A fin deployment system for missiles and munitions that deploys and activates straight flat fins for roll control authority. The fin deployment system employs numerous design features, among which are the following: A wrap-around fin concept generates space-savings within a projectile body whereby the fins are arranged in a wrapped configuration around a boomtail structure. The fins may be constructed of a super-elastic material; the system eliminates mechanical means of deploying the wrapped fins, eliminating the need for springs to deploy the fins. The fin deployment achieves substantial space savings for increasing the onboard towing capacity of electronic packaging or lethality in the missiles and munitions systems, while at the same time providing a good roll control authority during flight by enabling a straight fin deployment resulting from the use of super-elastic materials. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. Nos. 60/673,790, filed Apr. 22, 2005; 60/678,187, filed May 6, 2005; and 60/765,761, filed Feb. 7, 2006, which are incorporated herein.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of vaccines.
DESCRIPTION OF THE BACKGROUND ART
[0003] Humans, livestock and pets often are vaccinated to prevent disease, or reduce the severity of disease. Vaccination results in the production of antibodies, which are serum proteins capable of binding specifically to antigen substances used in the vaccine. This humoral response involves the selection of specific lines of B lymphocytes, and the proliferation and differentiation of the selected cells to yield clones of antibody-producing plasma cells.
[0004] Antibody production reaches a peak within several weeks after immunization, and then gradually declines. Because of a constant turnover of serum proteins, the decline in antibody production is accompanied by a corresponding decline in the circulating level of antibodies. However, if the patient is challenged again with the same antigen, a new response curve is initiated more rapidly and more intensely than the first one. This is called a secondary, booster, or anamnestic response, and in healthy patients results in much higher antibody levels with higher affinity to the antigen than the first exposure, or primary immunization. The increased rate of antibody synthesis is the result of an increased number of antibody-producing plasma cells. These cells are scarce in the lymph nodes of the unimmunized patient, which contain mostly small lymphocytes. However, in healthy patients, plasma cells constitute up to 3% of the total lymph node cells after a primary immunization, and as much as 30% of the lymph node cells after a secondary immunization.
[0005] The secondary response is said to be due to immunological memory. That is, the healthy organism is able to “remember” its prior exposure to the antigen, and react more promptly and efficiently the second time it is exposed, even if the amount of specific antibodies in the serum has declined to a very low level in the meantime.
[0006] Certain conditions such as aging, malnutrition, drug addiction, alcoholism, and certain disease states such as diabetes and AIDS, lead to immunodeficiency, in which many immune responses are quenched and vaccination is of reduced effectiveness. Thus, there remains a need in the art for improved vaccination techniques, particularly among the elderly or otherwise immunodeficient.
SUMMARY OF THE INVENTION
[0007] In one embodiment the present invention provides a pharmaceutical combination that may be utilized in a vaccination method to enhance vaccine effectiveness. The pharmaceutical combination comprises an immune response-triggering vaccine capable of stimulating production in an immunodeficient animal of antibodies to a disease-causing agent foreign to the animal and a vaccine effectiveness-enhancing amount of an immunomodulator compound, which enhances production and affinity of the antibodies in the animal in response to the vaccine. The vaccine and the immunomodulator may be administered separately or together.
[0008] In a preferred method, the vaccination method comprises administering to an immunodeficient animal a first dose of an immune response-triggering vaccine capable of stimulating production in an animal of antibodies to a disease-causing agent foreign to the animal. In a further preferred embodiment a vaccine effectiveness-enhancing amount of an immunomodulator compound may be administered to enhance production of the antibodies in the animal in response to the vaccine at the time of or in the time period immediately after and about 2 months after administration of said first dose. Alternatively, a booster dose of the vaccine, along with a vaccine effectiveness-enhancing amount of the immunomodulator compound may be administered to enhance effectiveness of the vaccine in said animal. In an alternative embodiment the pharmaceutical composition may be used to enhance the production of antibodies in an animal in response to administration of decreased quantities of vaccine.
[0009] Immunomodulator compounds in accordance with the present invention, comprise immunomodulator compounds of Formula A:
[0000]
[0000] In Formula A, n is 1 or 2, R is hydrogen, acyl, alkyl or a peptide fragment, and X is an aromatic or heterocyclic amino acid or a derivative thereof. Preferably, X is L-tryptophan or D-tryptophan.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 provides the results of assays which validate the low-dose aerosol infection of mice with BCG.
[0011] FIG. 2 provides a graphical representation of lung bacterial burden of mice treated with SCV-07 prior to receiving a low-dose aerosol of virulent M. tuberculosis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The present invention is applicable to animals capable of forming antibodies in an immune reaction, such as mammals including humans, livestock and pets, as well as birds such as domesticated fowl.
[0013] As animals age, their immune response is reduced, and vaccination effectiveness diminished due to the prevalance of low affinity antibody response. Accordingly, the invention is particularly applicable for use with humans over the age of 45, particularly those of age 50 and above.
[0014] The invention is also applicable to persons whose immune systems are compromised due to illness, surgery or medication, such as transplant patients who are immunodeficient as a result of administration of anti-rejection drugs such as cyclosporin.
[0015] It is believed that the present invention is applicable to all vaccines, and vaccine types, including killed or inactivated virus, DNA vaccines, peptide subunit vaccines and recombinant vaccines. Examples of suitable vaccines include Influenza vaccine, Hemophilus influenzae vaccine, Hepatitis A virus vaccine, Hepatitis B virus vaccine, Hepatitis C virus vaccine, Tuberculosis vaccine, Herpes-Zoster virus vaccine, Cytomegalovirus vaccine, Pneumococcal pneumonia vaccine, Meningococcal meningitis vaccine, Diphtheria vaccine, Tetanus vaccine, Rabies vaccine, Helicobacter pylori vaccine, polio vaccine and smallpox vaccine.
[0016] In one preferred embodiment the present invention provides a pharmaceutical composition for enhancing effectiveness of a Tuberculosis vaccine, such as the Calmette and Guérin Bacillus (BCG) vaccine. BCG is used in many countries with a high prevalence of TB to prevent childhood tuberculosis, meningitis and miliary disease. While BCG vaccine may protect children from contracting tuberculosis, it provides variable efficacy in adults. In this embodiment a tuberculosis vaccine such as BCG is administered together with the immunomodulator SCV-07 to provide enhanced vaccine efficacy in both adults and children.
[0017] It also is believed that the invention is applicable to any future vaccine, such as a vaccine which may be developed for vaccination against the AIDS virus, SARS or the avian influenza virus.
[0018] Generally, vaccines are administered in amounts within the range of from about 1×10 −9 g to about 1×10 −3 g, and more typically within the range from about 1×10 −8 g to about 1×10 −4 g.
[0019] Vaccine effectiveness-enhancing amounts of the immunomodulator compound of Formula A generally are administered in amounts within the range of about 0.001-1000 ug/kg body weight of the recipient, preferably in amounts of about 0.1-100 μg/kg, more preferably about 0.3-30 μg/kg, and most preferably about 10 μg/kg.
[0020] Immunomodulator compounds in accordance with the present invention, comprise immunomodulator compound of Formula A:
[0000]
[0000] In Formula A, n is 1 or 2, R is hydrogen, acyl, alkyl or a peptide fragment, and X is an aromatic or heterocyclic amino acid or a derivative thereof. Preferably, X is L-tryptophan or D-tryptophan.
[0021] Preferred derivatives of the aromatic or heterocyclic amino acids for “X” are: amides, mono- or di-(C 1 -C 6 ) alkyl substituted amides, arylamides, and (C 1 -C 6 ) alkyl or aryl esters. Preferred acyl or alkyl moieties for “R” are: branched or unbranched alkyl groups of 1 to about 6 carbons, acyl groups from 2 to about 10 carbon atoms, and blocking groups such as carbobenzyloxy and t-butyloxycarbonyl. Preferably the carbon of the CH group shown in Formula A has a stereoconfiguration, when n is 2, that is different from the stereoconfiguration of X.
[0022] Preferred embodiments utilize compounds such as γ-D-glutamyl-L-tryptophan, γ-L-glutamyl-L-tryptophan, γ-L-glutamyl-N in -formyl-L-tryptophan, N-methyl-γ-L-glutamyl-L-tryptophan, N-acetyl-γ-L-glutamyl-L-tryptophan, γ-L-glutamyl-D-tryptophan, β-L-aspartyl-L-tryptophan, and β-D-aspartyl-L-tryptophan. Particularly preferred embodiments utilize γ-D-glutamyl-L-tryptophan, sometimes referred to as SCV-07. These compounds, methods for preparing these compounds, pharmaceutically acceptable salts of these compounds and pharmaceutical formulations thereof are disclosed in U.S. Pat. No. 5,916,878, incorporated herein by reference.
[0023] In accordance with one aspect of the present invention, the immunomodulator compound of Formula A may be administered before and/or concurrently with administration of the vaccine.
[0024] The present invention may be particularly effective when administered in connection with a secondary (booster) vaccination dose. Secondary or booster vaccination doses typically are administered within a time period of beginning at the time the first (primary) dose of the vaccine is administered to about 2 months after administration of the first vaccine dose, preferably within about 0-45 days of the first vaccine dose, more preferably within about 10-30 days of administration of the first vaccine dose, and according to some embodiments within about 10-20 days of administration of the first vaccine dose.
[0025] In accordance with one embodiment, a dose of the immunomodulator compound of Formula A is administered to a recipient several days prior to administration of a secondary (booster) vaccine dose, most preferably about 3-4 days prior to administration of the secondary (booster) vaccine dose. In another preferred embodiment, an immunomodulator compound also is administered concurrently with administration of the secondary (booster) vaccine dose. In a particularly preferred embodiment, an immunomodulator compound is administered concurrently with administration of the first vaccine dose and with administration of the secondary (booster) vaccine dose. In an additional preferred embodiment the immunomodulator may be administered with administration of the first vaccine dose and with each subsequent vaccine booster dose that is administered.
[0026] Administration of the immunomodulator compound of Formula A and vaccine may take place by any suitable means, such as injection, infusion or orally. It has been found that compounds of Formula A are effective when administered orally as peroral dosage forms.
[0027] Pharmaceutical compositions containing the immunomodulators of the present invention or their pharmaceutically acceptable salts may be prepared according to conventional pharmaceutical compounding techniques. See, for example, Remington's Pharmaceutical Sciences, 18th Ed. (1990, Mack Publishing Co., Easton, Pa.). Typically, an immunomodulating amount of the active ingredient will be admixed with a pharmaceutically acceptable carrier to form a composition suitable for administration per os.
[0028] For oral administration, the compounds may be formulated into solid or liquid preparations such as capsules, pills, tablets, lozenges, melts, powders, suspensions or emulsions. In preparing the compositions in oral dosage form, any of the usual pharmaceutical media may be employed, such as, for example, water, glycols, oils, alcohols, flavoring agents, preservatives, coloring agents, suspending agents and the like in the case of oral liquid preparations (such as, for example, suspensions, elixirs and solutions); or carriers such as starches, sugars, diluents, granulating agents, lubricants, binders, disintegrating agents and the like in the case of oral solid preparations (such as, for example, powders, capsules and tablets). Because of their ease in administration, tablets and capsules represent the most advantageous oral dosage unit form, in which case solid pharmaceutical carriers are obviously employed. If desired, tablets may be sugar-coated or enteric-coated by standard techniques. The active agent may be encapsulated to make it stable for passage through the gastrointestinal tract.
[0029] The pharmaceutically acceptable carrier may include non-toxic, inert solid, semi-solid liquid fillers, diluents, encapsulating material, formulation auxiliary of any type, or simply a sterile aqueous medium, such as saline. Examples of materials that may serve as pharmaceutically acceptable carriers include sugars, such as lactose, glucose and sucrose; starches such as corn starch and potato starch; cellulose and its derivatives such as sodium carboxymethyl cellulose, ethyl cellulose and cellulose acetate; magnesium stearate; powdered tragacanth; malt; gelatin; talc; excipients such as cocoa butter and suppository waxes; oils; such as peanut oil, cottonseed oil, safflower oil, sesame oil, olive oil, corn oil and soybean oil; glycols, such as propylene glycol; polyols such as glycerin, sorbitol, mannitol and polyethylene glycol; esters such as ethyl oleate and ethyl laurate, agar; buffering agents such as magnesium hydroxide and aluminum hydroxide; alginic acid collidons, such as collidon 30 and collidon CL; pyrogen-free water; isotonic saline, Ringer's solution; ethyl alcohol and phosphate buffer solutions, as well as other non-toxic compatible substances used in pharmaceutical formulations.
[0030] Wetting agents, emulsifiers and lubricants such as sodium lauryl sulfate and magnesium stearate, as well as coloring agents, releasing agents, coating agents, sweetening, flavoring and perfuming agents, preservatives and antioxidants may also be present in the composition, according to the judgment of the formulator. Examples of pharmaceutically acceptable antioxidants include, but are not limited to, water soluble antioxidants such as ascorbic acid, cysteine hydrochloride, sodium bisulfite, sodium metabisulfite, sodium sulfite, and the like; oil soluble antioxidants, such as ascorbyl palmitate, butylated hydroxyanisole (BHA), butylated hydroxytoluene (BHT), lecithin, propyl gallate, aloha-tocopherol and the like; and the metal chelating agents such as citric acid, ethylenediamine tetraacetic acid (EDTA), sorbitol, tartaric acid, phosphoric acid and the like.
[0031] For oral administration, the compounds may be formulated into solid or liquid preparations such as capsules, pills, tablets, lozenges, melts, powders, suspensions or emulsions. In preparing the compositions in oral dosage form, any of the usual pharmaceutical media may be employed, such as, for example, water, glycols, oils, alcohols, flavoring agents, preservatives, coloring agents, suspending agents and the like in the case of oral liquid preparations (such as, for example, suspensions, elixirs and solutions); or carriers such as starches, sugars, diluents, granulating agents, lubricants, binders, disintegrating agents and the like in the case of oral solid preparations (such as, for example, powders, capsules and tablets). Because of their ease in administration, tablets and capsules represent the most advantageous oral dosage unit form, in which case solid pharmaceutical carriers are obviously employed. If desired, tablets may be sugar-coated or enteric-coated by standard techniques. The active agent may be encapsulated to make it stable for passage through the gastrointestinal tract.
[0032] Effective amounts of Formula A compound may be determined by routine dose-titration experiments. Exact individual dosages, as well as daily dosages of the pharmaceutical composition may be determined according to standard medical principles under the direction of a physician or veterinarian for use in humans or animals. In one aspect the pharmaceutical composition may be used to enhance the production of antibodies in an animal in response to administration of decreased quantities of vaccine.
[0033] When a vaccine and the immunomodulator compound of Formula A are administered concurrently, they may be provided as a single composition including the vaccine and the immunomodulator compound of Formula A.
[0034] Compositions including a vaccine and/or the immunomodulator compound of Formula A may also include one or more pharmaceutically acceptable carriers and optionally other therapeutic ingredients. Formulations suitable for injection or infusion include aqueous and non-aqueous sterile injection solutions which may optionally contain antioxidants, buffers, bacteriostats and solutes which render the formulations isotonic with the blood of the intended recipient, and aqueous and non-aqueous sterile suspensions which may include suspending agents and thickening agents. The formulations may be presented in unit-dose or multi-dose containers, for example, sealed ampoules and vials, and may be stored in a freeze-dried (lyophilized) condition requiring only the addition of the sterile liquid carrier, for example, water for injection, immediately prior to use.
[0035] Administration of SCV-07 produces significant immunomodulatory effects, including dose-dependent changes in the subpopulation composition of thymic cells. The percentage of immature CD4 − CD8 − and CD4 + cells increases, while the percentage of double positive CD4 + CD8 + cells decreases. Changes in cytokine production which occur following administration of SCV-07 are consistent with an increase in Th1 helper T cell subsets. The intimate involvement of Th1 CD4 cells in supporting antibody responses and the effect of SCV-07 on Th1 cells are consistent with the properties of the compound as a vaccine response enhancer. The largest effect of SCV-07 administration is seen at a dose of 1 μg/kg for per os administration and at dose of 0.1-1.0 ug/kg for i/p administration.
[0036] Changes in cytokine production following administration of SCV-07 suggest that the immunomodulatory effects of SCV-07 administered either i/p or per os are mediated by influencing events in Th1-dependent immune responses. It has been found that SCV-07 produces essentially identical effects when administered either orally or intraparenterally. Thus, administration of the compound can produce immunomodulatory effects when administered in a vaccine-effectiveness-enhancing amount to enhance production and affinity of antibodies in an animal in response to a vaccine administered either in an initial or a subsequent booster dose.
Example 1
Evaluation of the Efficacy of Oral versus Parenteral Administration of SCV-07 for Augmenting Immune Response in Mice
[0037] Materials and Methods: Eighteen (18) to twenty (20) gram (g) male mice, purchased from the Rappolovo Animal Facility, Russia, were used in the studies described below. C57BL/6 (B6) mice were used to evaluate the effect of SCV-07 in non-immunized mice. CBAxC57BL/6 (F1) mice were used for studies of the effects of SCV-07 on the antigen-specific immune response. Mice were kept under the standard animal facility conditions and were provided with a standard diet and water ad libitum. Each treatment group included 4-5 mice.
[0038] To evaluate the oral administration of SCV-07, tablets composed of 0.1 mg SCV-07; 2.0 mg magnesium stearate; 6.0 mg collidon 30; 10.0 mg collidon CL; and sufficient D-mannitol were prepared. Tablets of approximately 205 mg SCV-07 were formulated such that they readily dissolved in the stomach of test animals.
[0039] A 205 mg tablet having 0.1 mg SCV-07 per tablet was crushed and suspended in 200 ul of distilled water and administered to mice at does of 0.01, 1.0, 10.0 and 100.0 μg of SCV-07 per kg of body mass. A suspension containing filling agents alone, which corresponded to the maximum amount of filling agents in the doses of SCV-07 administered to experimental animals, was used a control.
[0040] Immunization with ovalbumin (OvA): To study antigen-specific immune response to SCV-07, mice were immunized with 5 μg/mouse of OvA obtained from Sigma. The OvA was administered subcutaneously to the crest in a volume of 200 μl. Mice were immunized on day 1 with OvA in complete Freund's adjuvant (CFA; Sigma) and on day 15 with the antigen in incomplete Freund's adjuvant (IFA; Sigma). The immune response was analyzed on day 29. Mice were also immunized with 10 μg/mouse of OvA using Alum as an adjuvant.
[0041] SCV-07 was administered peroral to the groups of mice at doses from 0.01 μg per kg to 100 μg per kg per os through an esophageal catheter on days 1 to 3 following administration of OvA and again on days 15 to 17. Other groups received SCV-07 by intraperitoneal injection (i/p) at doses of either 0.1 or 1.0 μg/kg of body mass, administered at the same times following immunization with QvA. In addition, groups of animals were immunized with OvA in FA as above, but only received one round of three SCV-07 treatments (either on days 1-3, days 15-17, or days 24-26) to evaluate the effects of a single treatment.
[0042] Isolation of thymocytes and splenocytes: Mouse thymuses and spleens were removed from treated animals under aseptic conditions 72 hours after the last administration of SCV-07. Thymuses and spleens from mice of each treatment group were pooled, and then minced with scissors. The minced tissues were suspended in sterile PBS to form cell suspensions, filtered through a double gauze layer and centrifuged. Cells were washed twice with PBS, re-suspended in RPMI-1640 (Sigma) with 2.0 mM of L-glutamine, 50 μM of mercaptoethanol, and 10 μg/ml of gentamycin (complete medium); and cell counts were made. (The splenocyte suspension was washed with a 0.86% solution of NH 4 Cl to pre-lyse erthrocytes.)
[0043] Thigh bones were removed from treated mice under aseptic conditions, and the medullary cavities were lanced and washed with PBS. Fragments of the bone marrow were minced by passing the tissue through a syringe needle. The resulting cell suspension was filtered through a double gauze layer and washed in PBS. After erythrocytes were lysed, the cells were counted and transferred to flat bottom culture plates. Due to an almost complete lack of spontaneous proliferation, the absolute values of proliferation, which were expressed as counts per minute (CPM), were determined and the Con A-induced proliferation of thymic cells from animals of different groups were compared.
[0044] Assessment of Mitogen- and Antigen-Induced Proliferation: Thymocytes (1×10 6 /well) and splenocytes (5×10 5 /well) in 96-well flat-bottom culture plates (Costar, Cambridge, Mass.) and stimulated with 0.5 or 1.0 μg/ml of ConA (Sigma) in complete medium supplemented with either 10% or 2% fetal calf serum (FCS), respectively, and incubated in a CO 2 -incubator for 72 hours at a temperature of 37° C., under absolute humidity. Antigen-specific proliferation was studied by stimulating thymocytes and splenoctyes in vitro with different concentrations of OvA for 96 h.
[0045] Twenty (20) to twenty-four (24) hours prior to completion of incubation, 3H-labeled thymidine (5 μCi/ml) was added to the cells. The cells were then transferred to fiberglass filters with a Titertek® semi-automatic cell harvester. Thymidine uptake was measured using a RackBeta 1217 (Wallac) liquid scintillation β-counter. For quantitative analysis of proliferation, the stimulation index (SI) was calculated as a ratio of the intensity of label inclusion in the stimulated cells to that in non-stimulated cells.
[0046] Assessment of Mitogen- and Antigen-Induced Production of Cytokines: Thymic cells (1×10 6 /well) in complete medium with 2% FCS were stimulated with ConA (0, 1, and 2 μg/ml). Splenocytes (1×10 6 /well) in complete medium with 5% FCS were stimulated with ConA (0, 1, and 5 μg/ml) and with OvA (0-100 μg/ml). Supernatants from ConA-stimulated cultures were collected after 24 hours. Supernatants from OvA-stimulated cultures were collected after 72 hours. Supernatants from both cultures were frozen, and kept at 20° C. Concentrations of IL-2, IL-4, IL-10, IL-12R40 and IFNγ in the supernatants were determined by solid-phase EIA with EIA Expansion Kits, available from BD Biosciences (formerly Pharmingen), in accordance with the manufacturer's instructions. In addition, biological activity of IL-2 in the supernatants was estimated in a bioassay using the IL-2-dependent CTLL-2 cell line.
[0047] Analysis by Flow Cytometry: Suspensions of thymocytes and splenocytes were washed twice with PBS/1% FCS, incubated with monoclonal antibodies direct to the specific antigens indicated in Table 1 below at concentrations recommended by the manufacturer. The cells were incubated with the antibodies for 20 min. at 4° C., washed 2 times with PBS/1% FCS, and analyzed with the EPICS® XL™ flow cytometer (Beckman Coulter) with the gate set to analyze mononuclear cells using side and forward scatter plots.
[0000]
TABLE 1
mouse anti-mouse CD90.1
Thy1
Caltag
rat anti-mouse CD8a-PE
clone 5H10
Caltag
rat anti-mouse CD25-PE
clone PC61 5.3
Caltag
rat anti-mouse CD4-FITC
clone CT-CD4
Caltag
hamster anti-mouse CD3-FITC
clone 500A2
Caltag
hamster anti-mouse CD69-FITC
clone H1.2F3
Pharmingen
FITC-conjugated hamster IgG
isotype control
Caltag
FITC-conjugated rat IgG2a
isotype control
Caltag
PE-conjugated rat IgG2b
isotype control
Caltag
PE-conjugated rat IgG1
isotype control
Caltag
[0048] Statistical analysis: Statistical analyses were performed with Microsoft Office Excel 2003 (Microsoft Corp.) and SPSS v.12.0 for Windows (SPSS Inc.). To calculate the confidence of differences in thymocyte proliferation, the paired Student test with unequal deviation was used. The confidence of anti-OvA antibody titers differences was determined with non-parametric Mann-Whitney test for two samples. The differences were considered to be significant if p<0.05.
[0049] Immunomodulatory Activity of SCV-07 After Oral Administration: Thy1-positive lymphocytes, the precursors of T-cells in the bone marrow, increased in a dose-dependent manner in mice after treatment with SCV-07 per os. These increases were analogous to those observed in mice which received SCV-07 i.p (Table 2).
[0000]
TABLE 2
Influence of SCV-07 on expression of Thy1 marker
by bone marrow cells
Route of
SCV-07 μg/kg
administration
Thy-1 positive cells, %
0
i/p
11.5 ± 1.6
1.0
i/p
15.4 ± 0.1
0.1
per os
12.9 ± 1.2
1.0
per os
14.9 ± 1.3
10.0
per os
16.0 ± 0.7
100.0
per os
16.0 ± 1.2
[0050] The expression of T-cell subpopulation markers (CD3, CD4, and CD8) and activation markers (CD69 and CD25) on thymic cells and splenocytes was studied ex vivo 72 hours after the last treatment with SCV-07. No significant differences in the subpopulation composition of T-cells or in expression of their activation markers were revealed in mice which received SCV-07 i/p or per os (data not shown). However, on subsequent cultivation for 48 hours without stimulation, the number of thymic cells which expressed CD69 and CD25 markers significantly increased. The expression of the CD69 marker increased after oral administration of SCV-07 tablets at doses of 0.1 and 1.0 μg/kg of body mass as well as after i/p administration at a dose of 1.0 μg/kg. The number of cells which expressed CD25 markers increased in mice that received SCV-07 either per os at all the doses or i/p at a dose of 1.0 μg/kg of body mass (Table 3).
[0000]
TABLE 3
Influence of SCV-07 on expression of activation markers
on thymic cells cultured in vitro
SCV-07
Route of
μg/kg
administration
CD69-positive, %
CD25-positive cells, %
0
i/p
3.28
0.38
0.1
i/p
2.03
0.30
1.0
i/p
7.86
1.72
Filling
Tablet, per os
2.46
0.28
agents
0.1
Tablet, per os
3.35
0.7
1.0
Tablet, per os
4.61
0.79
10.0
Tablet, per os
2.24
0.71
[0051] Evaluation of the proliferation of thymic cells stimulated by different doses of ConA demonstrated that in mice which received SCV-07 either per Os or i/p, proliferation of thymic cells stimulated by a suboptimal dose of ConA (1 μg/ml) significantly increased (Table 4) while proliferation of cells stimulated by the optimal dose of ConA did not significantly change (data not shown). The minimal SCV-07 dose (0.1 μg/kg) which caused significant increase in proliferation of thymic cells after oral administration was the same as that for i/p administration.
[0000]
TABLE 4
Influence of SCV-07 on Proliferation of Thymic Cells
Stimulated by ConA (1 μg/ml)
Spontaneous
Induced
proliferation
proliferation
SCV-07
Route of
(cpm)
(cpm)
Stimulation
μg/kg
administration
M ± SD
M ± SD
index
0
—
265 ± 23
6314 ± 432
23.8
0.1
i/p
268 ± 114
14261 ± 1400***
53.3
1.0
i/p
342 ± 83
20995 ± 6425*
61.4
0.01
per os
238 ± 64
6698 ± 1465
28.1
0.1
per os
250 ± 75
9754 ± 1633*
39.1
1.0
per os
198 ± 44
20658 ± 5873*
104.6
10.0
per os
246 ± 51
13905 ± 2443**
56.6
100.0
per os
272 ± 98
27589 ± 1331***
101.4
*p < 0.05 as compared to control;
**p < 0.01 as compared to control;
***p < 0.001 as compared to control
[0052] The influence of SCV-07 tablets on thymic cell proliferation was compared to the effect of tablet filing agents alone. As evident from Table 5, SCV-07 at doses of 0.1 to 10 μg/kg significantly augmented proliferation of cells stimulated by a suboptimal dose of ConA, as compared with filling agents at the maximum concentration. The minimal dose of SCV-07 given as a crushed tablet which caused significant enhancement of proliferation (Table 5; 0.1 μg/kg) was the same as that for SCV-07 without filling agents (Table 4).
[0000]
TABLE 5
Influence of SCV-07 on proliferation of thymic cells
stimulated by ConA (1 μg/ml)
Spontaneous
Induced
proliferation
proliferation
Stim-
SCV-07
Route of
(cpm)
(cpm)
ulation
μg/kg
administration
M ± SD
M ± SD
index
0
i/p
494 ± 58
6354 ± 1426
12.9
0.1
i/p
251 ± 36
9897 ± 678 #
39.4
1.0
i/p
555 ± 20
33418 ± 3490 ##
49.7
Filling
Tablet, per os
220 ± 41
3842 ± 705
17.5
agents
0.01
Tablet, per os
308 ± 104
3144 ± 582
10.2
0.1
Tablet, per os
395 ± 136
9900 ± 2021**
25.1
1.0
Tablet, per os
355 ± 62
10248 ± 1913*
28.9
10.0
Tablet, per os
317 ± 77
7675 ± 1456*
24.2
*p < 0.05 as compared to control (filling agent - per os)
**p < 0.01 as compared to control (filling agent - per os)
# p < 0.05 as compared to control (i/p)
## p < 0.01 as compared to control (i/p)
[0053] Considering that significant enhancement of proliferation by SCV-07 might be due to its influence on IL-2 production, IL-2 activity was studied with the IL-2-dependent CTLL-2 line. It was demonstrated that SCV-07 received either per os or i/p at doses of 0.1 and 1.0 μg/kg significantly enhanced IL-2 production by thymic cells stimulated by ConA (Table 6).
[0000]
TABLE 6
Influence of SCV-07 on IL-2 production by
ConA-stimulated thymic cells
SCV-07
Route of
IL-2 production (U/ml), M ± SD
μg/kg
administration
ConA 1 μg/ml
ConA 2 μg/ml
0
—
0.00 ± 0.00
0.42 ± 0.16
0.1
i/p
0.25 ± 0.08
1.40 ± 0.38*
1.0
i/p
0.92 ± 0.06*
1.60 ± 0.15*
0.01
per os
0.00 ± 0.00
0.44 ± 0.11
0.1
per os
0.10 ± 0.13
1.00 ± 0.13*
1.0
per os
1.06 ± 0.37
3.31 ± 0.01*
10.0
per os
0.25 ± 0.12
0.39 ± 0.12
100.0
per os
0.31 ± 0.15
1.19 ± 0.30
*p < 0.05 when compared to PBS-treated group
[0054] IL-2 production by splenocytes stimulated by ConA, especially at the suboptimal dose of 1 μg/ml, also was significantly enhanced in mice which received SCV-07 per os at doses of 0.1-100.0 μg/kg and was slightly higher after i/p injection of SCV-07 at doses of 0.1 and 1.0 μg/kg (Table 7).
[0000]
TABLE 7
Influence of SCV-07 on IL-2 production by
ConA-stimulated splenocytes
IL-2 production (U/ml), M ± SD
SCV-07
Route of
ConA
μg/kg
administration
Spontaneous
ConA 1 μg/ml
2 μg/ml
0
—
0.6 ± 0.3
4.5 ± 0.3
50.2 ± 0.1
0.1
i/p
2.0 ± 0.3
16.1 ± 0.8*
93.4 ± 28.3
1.0
i/p
2.7 ± 0.3
15.6 ± 0.3**
99.3 ± 6.1*
0.01
per os
0.0 ± 0.0
10.4 ± 1.1
66.9 ± 12.6
0.1
per os
0.0 ± 0.0
7.5 ± 0.1*
85.8 ± 6.6
1.0
per os
0.3 ± 0.5
10.0 ± 0.4**
60.8 ± 1.2*
10.0
per os
0.0 ± 0.0
9.1 ± 1.3
56.4 ± 2.1
100.0
per os
0.3 ± 0.5
14.9 ± 2.4
79.3 ± 16.3
*p < 0.05 when compared to PBS-treated group
**p < 0.01 when compared to PBS-treated group
[0055] In all animal groups which received SCV-07 per os or i/p, the IFN-γ and IL-4 content was enhanced in supernatants of splenocytes stimulated by a suboptimal dose of ConA. However, if splenocytes were stimulated by a higher dose of ConA (5 μg/ml), IFN-γ production was enhanced only after i/p treatment with SCV-07, and production of IL-4 in cell supernatants of all mice treated with SCV-07 was lower than the control group (Table 8). Splenocytes stimulated by a high dose of ConA (with decreased IL-4 production) also had a tendency for a decrease in IFN-γ after SCV-07 per os. After i/p treatment with SCV-07, the level of IFN-γ increased, while that of IL-4 was significantly reduced, compared to that in control.
[0000]
TABLE 8
Influence of SCV-07 on IFN-γ and IL-4 production by
ConA-stimulated splenocytes
IFN-γ (pg/ml)
IL-4 (pg/ml)
SCV-07
Route of
ConA
ConA
ConA
ConA
μg/kg
administration
Spontaneous
1 μg/ml
5 μg/ml
Spontaneous
1 μg/ml
5 μg/ml
0
—
1368
6344
84358
34.7
40.4
312.3
0.1
i/p
1393
13089
87051
4.2
62.1
277.5
1.0
i/p
1738
30951
142155
0.0
52.8
152.9
0.01
per os
0
15499
63227
6.1
98.7
284.9
0.1
per os
0
15695
65692
0.0
78.9
229.6
1.0
per os
1629
11411
47683
25.3
95.8
260.0
10.0
per os
0
8238
66185
19.4
53.8
275.0
100.0
per os
0
12990
43670
27.1
83.1
192.0
[0056] Immunomodulatory activity of SCV-07 in animals pre-immunized with ovalbumin: F1 mice were immunized with ovalbumin, either with Freund's adjuvant (FA), which is known to stimulate a cell-mediated response (Th1 T-cell polarization), or with Alum adjuvant (Alum), which is known to stimulate the antibody response (Th2 T-cell polarization). Results of the studies of mice immunized with 5 μg of OvA with FA, and treated with SCV-07 per os or i/p, are shown in Tables 8-16.
[0057] SCV-07, administered either per os or i/p, produced no significant effect on OvA-specific proliferation of splenocytes (Table 9), although the stimulation indices of animal groups which received SCV-07 were slightly lower than those in control groups after incubation with OvA at 50 μg/ml.
[0000]
TABLE 9
Influence of SCV-07 on OvA-induced proliferation of splenocytes
SCV-
Proliferation of splenocytes
07
Route of
Spontaneous
OvA 10 μg/ml
OvA 50 μg/ml
Immunization
μg/kg
admin.
cpm, M ± SD
cpm, M ± SD
SI
Cpm, M ± SD
SI
PBS
0
i/p
1583 ± 716
1674 ± 598
1.06
3188 ± 604
2.01
OvA/FA
0
i/p
6492 ± 1410
11207 ± 1895
1.73
11345 ± 1618
1.75
OvA/FA
0.1
i/p
10726 ± 1947
11683 ± 2285
1.09
14195 ± 3304
1.32
OvA/FA
1.0
i/P
9760 ± 1650
10260 ± 2808
1.05
16313 ± 1057
1.67
OvA/FA
0.1
per os
8786 ± 1259
11304 ± 1317
1.29
11923 ± 1623
1.36
OvA/FA
1.0
per os
7013 ± 1698
8864 ± 2675
1.26
10457 ± 1740
1.49
OvA/FA
10.0
per os
10665 ± 887
13585 ± 1102
1.27
12903 ± 881
1.21
[0058] Levels of IL-2 production in splenocytes stimulated by OvA are shown in Tables 10 and 11. As evident from Table 11 (data are shown as percent, compared to spontaneous production), in splenocytes of mice which received SCV-07 at a dose of 0.1 μg/kg i/p or per os, IL-2 production was significantly reduced. In animals which received SCV-07 at a dose of 1.0 μg/kg i/p and of 1.0 μg/kg and 10 μg/kg per os, the level of IL-2 production increased compared to that of control after stimulation by low doses of antigen, and yet decreased after stimulation by the higher doses of antigen.
[0000]
TABLE 10
Influence of SCV-07 on OvA-stimulated production of
IL-2 by splenocytes
Production of IL-2 by splenocytes,
pg/ml
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin.
0
1
10
25
100
PBS
0
i/p
81.4
68.5
83.9
80.2
89.5
OvA/FA
0
i/p
125.6
51.4
217
442.2
404
OvA/FA
0.1
i/p
78.4
10.2
72.7
85.8
95.5
OvA/FA
1.0
i/p
147.7
116.5
317.3
363.1
564.4
OvA/FA
0.1
per os
211.8
68.7
92.9
252.5
94.8
OvA/FA
1.0
per os
122.4
82.7
304.2
152.9
282.8
OvA/FA
10.0
per os
163
80.2
305.4
287.2
478.2
[0000]
TABLE 11
Influence of SCV-07 on OvA-stimulated production
of IL-2 by splenocytes (% of control)
Production of IL-2 by
splenocytes, %
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin.
0
1
10
25
100
PBS
0
i/p
100
84.2
103.1
98.5
110.0
OvA/FA
0
i/p
100
40.9
172.8
352.1
321.7
OvA/FA
0.1
i/p
100
13.0
92.7
109.4
121.8
OvA/FA
1.0
i/p
100
78.9
214.8
245.8
382.1
OvA/FA
0.1
per os
100
32.4
43.9
119.2
44.8
OvA/FA
1.0
per os
100
67.6
248.5
124.9
231.0
OvA/FA
10.0
per os
100
49.2
187.4
176.2
293.4
[0059] IFN-γ levels in supernatants of in vitro antigen-stimulated splenocytes from mice immunized with OvA/FA are shown in Tables 12 and 13. The spontaneous production of IFN-γ significantly increased in control as compared to that in non-immunized animals. In all groups which received SCV-07, spontaneous production of IFN-γ increased even more significantly (Table 11). At the same time, OvA-stimulated production of IFN-γ decreased in SCV-07 treated animals compared to control.
[0000]
TABLE 12
Influence of SCV-07 on OvA-stimulated IFN-γ production by splenocytes
Production of IFN-γ by splenocytes, %
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
SCV-07 μg/kg
admin.
0
10
25
50
100
PBS
0
i/p
1090
1305
1563
2090
3424
OvA/FA
0
i/p
4477
6705
5761
6216
6074
OvA/FA
0.1
i/p
8442
10691
7542
9959
10490
OvA/FA
1.0
i/p
8191
11386
9194
8110
7340
OvA/FA
0.1
per os
7784
9292
9427
11056
10548
OvA/FA
1.0
per os
7693
9860
6720
8884
8683
OvA/FA
10.0
per os
7870
6586
5209
5971
5888
[0000]
TABLE 13
Influence of SCV-07 on OvA-stimulated IFN-γ production
by splenocytes (% of control)
Production of IFN-γ by
splenocytes, %
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin.
0
10
25
50
100
PBS
0
i/p
100
119.7
143.4
191.8
314.1
OvA/FA
0
i/p
100
149.8
128.7
138.8
135.7
OvA/FA
0.1
i/p
100
126.6
89.3
118.0
124.3
OvA/FA
1.0
i/p
100
139.0
112.2
99.0
89.6
OvA/FA
0.1
per os
100
119.4
121.1
142.0
135.5
OvA/FA
1.0
per os
100
128.2
87.3
115.5
112.9
OvA/FA
10.0
per os
100
83.7
66.2
75.9
74.8
[0060] In all animals, the levels of IL-4 in supernatants of OvA-stimulated splenocytes were below the sensitivity of the test-system used (6 pg/ml). The levels of IL-10 in OvA stimulated splenocytes of mice immunized with OvA/FA are shown in Tables 14 and 16. In animals which received SCV-07 i/p at a dose of 0.1 μg/kg, a relative decrease of OvA-stimulated IL-10 content was observed, while in mice which received SCV-07 per os the levels of IL-10 moderately increased.
[0000]
TABLE 14
Influence of SCV-07 on OvA-stimulated IL-10 production by splenocytes
Production of IL-10 by splenocytes, pg/ml
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
SCV-07 μg/kg
admin.
0
10
25
50
100
PBS
0
i/p
102.2
129.8
199
210.9
306.8
OvA/FA
0
i/p
424.2
643.9
732.6
783.7
879.9
OvA/FA
0.1
i/p
785.1
989.4
1234.3
1194.2
1502.4
OvA/FA
1.0
i/p
457.4
813.4
774.1
852.4
963.8
OvA/FA
0.1
per os
702.5
958.9
1478.2
1739.2
1895.4
OvA/FA
1.0
per os
407.6
953.1
984.1
1120.7
1292.2
OvA/FA
10.0
per os
627.3
831.6
1092.7
1356.1
1569.3
[0000]
TABLE 15
Influence of SCV-07 on OvA-stimulated IL-10
production by splenocytes (% of control)
Production of IL-10 by
splenocytes, %
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin.
0
10
25
50
100
PBS
0
i/p
100
127.0
194.7
206.4
300.2
OvA/FA
0
i/p
100
151.8
172.7
184.7
207.4
OvA/FA
0.1
i/p
100
126.0
157.2
152.1
191.4
OvA/FA
1.0
i/p
100
177.8
169.2
186.4
210.7
OvA/FA
0.1
per os
100
136.5
210.4
247.6
269.8
OvA/FA
1.0
per os
100
233.8
241.4
275.0
317.0
OvA/FA
10.0
per os
100
132.6
174.2
216.2
250.2
[0061] Levels of IL-12r40 in supernatants of OvA-stimulated splenocytes are shown in Tables 16 and 17. In the control group, a decrease in antigen-specific IL-12R40 production was found compared to that in non-immunized animals. In animal groups which received SCV-07 i/p (at both doses) and in groups which received SCV-07 per os at a dose of 10.0 μg/kg, there was less of a decrease.
[0000]
TABLE 16
Influence of SCV-07 on OvA-stimulated production of IL-12R40 by splenocytes
Production of IL-12R40 by splenocytes, pg/ml
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin.
0
10
25
50
100
PBS
0
i/p
1288.6
1366.8
1278.5
1162.9
1079.1
OvA/FA
0
i/p
1508.3
500.4
424.5
401.8
460.9
OvA/FA
0.1
i/p
1285.7
492.4
499.6
420.8
522.8
OvA/FA
1.0
i/p
1524.0
933.8
739.7
630.3
616.4
OvA/FA
0.1
per os
1307.6
478.1
317.4
267.0
246.5
OvA/FA
1.0
per os
1362.3
366.3
324.5
360.8
342.4
OvA/FA
10.0
per os
1455.1
769.3
592
471.9
464.8
[0000]
TABLE 17
Influence of SCV-07 on OvA-Stimulated IL-12r40
Production by Splenocytes (% of control)
Production of IL-12R40 by
SCV-
splenocytes, %
07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin
0
10
25
50
100
PBS
0
i/p
100
106.1
99.2
90.2
83.7
OvA/FA
0
i/p
100
33.2
28.1
26.6
30.6
OvA/FA
0.1
i/p
100
38.3
38.9
32.7
40.7
OvA/FA
1.0
i/p
100
61.3
48.5
41.4
40.4
OvA/FA
0.1
per os
100
36.6
24.3
20.4
18.9
OvA/FA
1.0
per os
100
26.9
23.8
26.5
25.1
OvA/FA
10.0
per os
100
52.9
40.7
32.4
31.9
[0062] Results of the study of mice immunized with 10 μg of OvA with Alum adjuvant and treated with SCV-07 per os or i/p, are shown in Tables 18-23. No significant differences in proliferation of splenocytes were seen in mice of the control group compared to those which received SCV-07 (data not shown).
[0063] Antigen-specific production of IL-2 by splenocytes is shown in Tables 18 and 19. IL-2 production in OvA-stimulated splenocytes increased in all groups which received SCV-07, compared to control. The IL-2 production was the highest in mice which received SCV-07 at a dose of 1.0 μg/kg (i/p) and of 10.0 μg/kg (per os), Table 18.
[0000]
TABLE 18
Influence of SCV-07 on OvA-stimulated production
of IL-2 by splenocytes
Production of IL-2 by
SCV-
splenocytes, pg/ml
07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin
0
1
10
25
100
PBS
0
i/p
124.0
243.7
103.5
99.3
92.8
OvA/Alum
0
i/p
303.1
246.6
109.8
122.9
209.2
OvA/Alum
0.1
i/p
163.0
190.3
87.5
83.5
84.8
OvA/Alum
1.0
i/p
113.4
173.7
167.9
353.8
205.8
OvA/Alum
0.1
per os
172.9
163.0
124.5
255.5
90.8
OvA/Alum
1.0
per os
160.9
92.8
181.9
121.3
120.2
OvA/Alum
10.0
per os
289.4
551.9
252.5
218.7
300.8
[0000]
TABLE 19
Influence of SCV-07 on OvA-stimulated production
of IL-2 by splenocytes (% of control)
Production of IL-2 by
splenocytes, %
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin
0
1
10
25
100
PBS
0
i/p
100
196.5
83.5
80.1
74.8
OvA/Alum
0
i/p
100
81.4
36.2
40.5
69.0
OvA/Alum
0.1
i/p
100
116.7
53.7
51.2
52.0
OvA/Alum
1.0
i/p
100
153.2
148.1
312.0
181.5
OvA/Alum
0.1
per os
100
94.3
72.0
147.8
52.5
OvA/Alum
1.0
per os
100
57.7
113.1
75.4
74.7
OvA/Alum
10.0
per os
100
190.7
87.2
75.6
103.9
[0064] A significant increase of OvA-specific production of IFN-γ by splenocytes was observed only in mice which received SCV-07 per os at a dose of 0.1 μg/kg. In other animal groups, production of IFN-γ did not differ compared to that in control (Tables 20 and 21).
[0000]
TABLE 20
Influence of SCV-07 on OvA-stimulated production
of IFN-γ by splenocytes
Production of IFN-γ by
splenocytes, pg/ml
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin.
0
10
25
50
100
PBS
0
i/p
8580
8729
7471
7471
8406
OvA/Alum
0
i/p
4932
4975
5844
5844
5228
OvA/Alum
0.1
i/p
9365
8816
8028
8028
8048
OvA/Alum
1.0
i/p
7129
9986
7982
7982
8155
OvA/Alum
0.1
per os
4642
5775
6969
6969
7310
OvA/Alum
1.0
per os
5620
5523
5795
5795
6860
OvA/Alum
10.0
per os
4266
2045
5066
5066
5976
[0000]
TABLE 21
Influence of SCV-07 on OvA-stimulated production of IFN-γ
by splenocytes (% of control)
Production of IFN-γ by
splenocytes, %
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin
0
10
25
50
100
PBS
0
i/p
100
101.7
87.1
87.1
98.0
OvA/Alum
0
i/p
100
100.9
118.5
118.5
106.0
OvA/Alum
0.1
i/p
100
94.1
85.7
85.7
85.9
OvA/Alum
1.0
i/p
100
140.1
112.0
112.0
114.4
OvA/Alum
0.1
per os
100
124.4
150.1
150.1
157.5
OvA/Alum
1.0
per os
100
98.3
103.1
103.1
122.1
OvA/Alum
10.0
per os
100
47.9
118.8
118.8
140.1
[0065] Similar to experiments with the use of FA, in all animal groups the levels of IL-4 production in supernatants of OvA-stimulated splenocytes were below the sensitivity of the test system.
[0066] The antigen-specific production of IL-10 by splenocytes from mice which received SCV-07 was significantly lower than that of control. This effect was the strongest in animal groups which received SCV-07 i/p (doses of 0.1 and 1.0 μg/kg), and was slightly less pronounced in groups which received SCV-07 per os at the same doses (Table 22).
[0000]
TABLE 22
Influence of SCV-07 on OvA-stimulated production of IL-10 by splenocytes
Production of IL-10 by splenocytes, pg/ml
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin
0
10
25
50
100
PBS
0
i/p
1042.7
1403
1432.2
1515.6
1266.5
OvA/Alum
0
i/p
784.8
1942.4
1780.1
1815.5
2268.6
OvA/Alum
0.1
i/p
2177.8
1762.5
1946.1
1851.3
2189.5
OvA/Alum
1.0
i/p
2035.7
1758.9
1829.8
1584.7
1840.7
OvA/Alum
0.1
per os
1351.1
1587.9
1419.5
1783.6
1741.5
OvA/Alum
1.0
per os
1741.5
2220.9
1957.2
1920.4
1898.4
OvA/Alum
10.0
per os
816.4
1127.5
1272.5
1608.4
1780.1
[0000]
TABLE 23
Influence of SCV-07 on OvA-stimulated production of IL-10
by splenocytes (% of control)
Production of IL-10 by
splenocytes, %
SCV-07
Route of
Stimulation in vitro by OvA, μg/ml
Immunization
μg/kg
admin.
0
10
25
50
100
PBS
0
i/p
100
134.6
137.4
145.4
121.5
OvA/Alum
0
i/p
100
247.5
226.8
231.3
289.1
OvA/Alum
0.1
i/p
100
80.9
89.4
85.0
100.5
OvA/Alum
1.0
i/p
100
86.4
89.9
77.8
90.4
OvA/Alum
0.1
per os
100
117.5
105.1
132.0
128.9
OvA/Alum
1.0
per os
100
127.5
112.4
110.3
109.0
OvA/Alum
10.0
per os
100
138.1
155.9
197.0
218.0
[0067] No significant differences in OvA-induced production of IL-12r40 by splenocytes were observed in control versus mice which received SCV-07 either per os or i/p (data not shown).
Example 2
Evaluation of the Ability of SCV-07 to Enhance BCG-Induced Protection in a Murine Model of Pulmonary Tuberculosis
[0068] The dipeptide SCV-07 (gamma-D-glutamyl-L-tryptophan) was evaluated in a murine pulmonary tuberculosis model and found to enhance the protective effect of M. bovis Bacillus Calmette-Guerin (BCG) when administered as a vaccine.
[0069] Mice of about 20-25 grams in weight were allowed to acclimate for three weeks prior to initiation of the study. The mice were divided into sixteen treatment groups containing five (5) mice each. SCV-07 was administered as a 0.1 ml injection into the right flank of each treated animal. The treatment groups received either 0.01 μg, 0.2 μg or 2.0 μg of the dipeptide, which corresponds to doses of 0.4 μg/kg, 8 μg/kg and 80 μg/kg. Groups 2 to 15 were vaccinated subcutaneously with 0.1 ml (10 5 colony forming units (CFUs)) of BCG vaccine, which was administered into the left flank of the animal on day 5 of the study.
[0070] Control groups 1, 2, 15 and 16 received no SCV-07. Groups 1 and 16 also received no BCG vaccination. Group 15 was vaccinated with BCG on day 5 and received daily injections of saline.
[0071] Treatment groups 3, 7 and 11 received daily injections of the immunomodulator SCV-07 on days 1 to 5; groups 4, 8, and 12 received daily injections on days 1 to 30 and groups 5, 9, and 13 received daily injections on days 1 to 5 and on day 7, day 11, day 14, day 18, day 21, day 25 and day 28. Groups 6, 10 and 14 received daily injections of SCV-07 on days 6 to 30.
[0072] Groups 3, 4, 5, and 6 received 0.01 μg of SCV-07 a day according to the temporal administration schedule indicated above. Groups 7, 8, 9, and 10 received 0.2 μg and Groups 11, 12, 13 and 14 received 2.0 μg.
[0073] The treatment regimens used in the study are summarized below in Table 24.
[0000]
TABLE 24
Experimental Protocol
DAYS
GROUP
VACCINE
IMMUNOMODULATOR
ADMINISTRATED
1
—
2
BCG
—
—
3
BCG
0.01 μg SCV-07
D1-D5
4
BCG
0.01 μg SCV-07
D1-D30
5
BCG
0.01 μg SCV-07
D1-5, D7, 11, 14,
18, 21, 25, 28
6
BCG
0.01 μg SCV-07
D6-D30
7
BCG
0.20 μg SCV-07
D1-D5
8
BCG
0.20 μg SCV-07
D1-D30
9
BCG
0.20 μg SCV-07
D1-5, D7, 11, 14,
18, 21, 25, 28
10
BCG
0.20 μg SCV-07
D6-D30
11
BCG
2.0 μg SCV-07
D1-D5
12
BCG
2.0 μg SCV-07
D1-D30
13
BCG
2.0 μg SCV-07
D1-5, D7, 11, 14,
18, 21, 25, 28
14
BCG
2.0 μg SCV-07
D6-D30
15
BCG
saline
D1-D30
16
—
—
[0074] On day 31 all mice were exposed to a low-dose aerosol of virulent M. tuberculosis strain H 37 Rv. On the following day the animals of group 16 were sacrificed and their lung tissue harvested and plated on nutrient 7H11 agar to determine the number of colony forming units of M. tuberculosis in the initial challenge with antigen.
[0075] Bacterial colonies were counted three weeks after plating. FIG. 1A provides the mean CFU (+/−1 standard deviation) per total lung tissue received by control animals compared to the target dose of 100 CFU per lung, which was the desired dose for the murine pulmonary tuberculosis model. These results indicate that the desired low-dose aerosol infection in the murine model of pulmonary tuberculosis was achieved. FIG. 1B provides an analysis of aliquots of the actual inoculum used for the aerosol infection which indicates that the aliquots contained an infective dose of 2×10 6 CFU/ml. Data are expressed as mean CFU per plate (n=4).
[0076] On day 61, thirty days following infection, all rice in groups 1 to 15 were euthanized by CO 2 inhalation. The lungs and spleen of each mouse were removed. The right lung of each mouse was placed into a polypropylene tube and stored frozen at −80° C. The left lung was infused with five (5) ml of 10% neutral-buffered formalin (NBF) and placed in 5 ml of 10% NBF with the spleen from the same animal. On day 66 the right lung was homogenized in five (5) ml of sterile phosphate-buffered saline and subsequently plated onto nutrient 7H11 agar to determine the lung bacterial burden of M. tuberculosis for each mouse. The lung tissue homogenate was serially diluted, plated onto 7H11 agar and incubated at 37° C. for approximately three weeks. Individual colonies of BCG were counted. The results are presented in Table 25 below, expressed as log 10 CFU per milliliter (ml) of homogenate.
[0000]
TABLE 25
CFUs of BCG per ml of Lung Homogenate in Treated Mice
GROUPS
M1
M2
M3
M4
M5
MEAN
MEDIAN
1
6.6
6.6
5.8
5.4
5.9
6.1
5.9
2
5.5
5.5
5.2
5.2
5.2
5.3
5.2
3
4.8
5.3
4.9
5.3
4.8
5.0
4.9
4
5.1
4.8
5.0
4.3
4.8
4.9
5
5.1
5.0
4.6
5.1
4.8
4.9
5.0
6
5.4
5.5
5.5
5.7
5.5
5.5
7
4.8
4.8
5.0
5.1
5.0
4.9
5.0
8
4.5
4.7
4.6
4.7
4.6
4.6
9
4.6
4.4
4.9
5.1
4.8
4.8
4.8
10
5.4
5.2
5.3
5.3
11
5.1
4.8
5.1
4.8
5.1
5.0
5.1
12
5.1
4.8
5.3
5.3
4.6
5.0
5.1
13
4.8
4.8
4.7
5.1
5.3
4.9
4.8
14
5.3
5.4
5.3
5.5
5.4
5.4
15
5.5
5.7
5.6
5.9
5.8
5.7
5.7
Empty cells indicate mice for which CFU counts were not obtained due to contaminated lung homogenates.
[0077] As demonstrated by the results above, mice that received SCV-07 therapy prior to BCG vaccination had an enhanced immunological response against a subsequent challenge with a low dose of virulent M. tuberculosis . The optimal enhancing effect of SCV-07 for vaccination with BCG is seen with the intermediate 0.20 μg dose of the immunomodulator, which is about 8-10 μg/kg of SCV-07. These results are also presented graphically in FIG. 2 , which shows the mean (+/−1 standard deviation) lung colony forming units in panel A and the median CFUs in panel B.
[0078] This study confirms the ability of SCV-07 to enhance the protective effect of pre-inoculation vaccination with M. bovis BCG in a murine model of pulmonary tuberculosis. The study measured the effect of three different doses of the dipeptide, given according to four different administration schedules relative to the administration of BCG inoculation. The schedules included early administration, in which SCV-07 was administered before BCG vaccination (days 1 to 5); early/late administration, in which SCV-07 was administered both before and after BCG vaccination (days 1 to 30); early/late intermittent administration, in which SCV-07 was administered before BDG vaccination (days 1 to 5) and continued intermittently after vaccination (days 7, 11, 14, 18, 21, 25 and 28) and late administration, in which SCV-07 was administered only after BCG vaccination. As shown in Table 25 and in FIG. 2 , enhancement of the protective effect provided by BCG vaccination, was better when SCV-07 was administered prior to BCG vaccination. The 0.20 μg dose (approximately 8-10 μg/kg of SCV-07) provided the best enhancement of the BCG protective effect in the murine model.
Example 3
Influence of the Immunomodulator SCV-07 on the Effectiveness of Vaccination Against Viral Hepatitis B
[0079] The dipeptide SCV-07 (gamma-D-glutamyl-L-tryptophan) was evaluated in human subjects with the spontaneous form of secondary immunodeficiency and found to enhance the protective effect of vaccination against hepatitis B. The studies were the first use of SCV-07 as an immunomodulator for enhancement of vaccine effectiveness.
[0080] The protocol of the placebo-controlled, randomized study of the efficacy of vaccination against viral hepatitis B was approved by the committee of ethics of the Chelyabinsk State Medical Academy. Participants in the study had a spontaneous form of secondary immunodeficiency with clinical manifestations of infectious syndrome. Diagnosis of the infectious syndrome was made in accordance with the standards of diagnostics and treatment of secondary immunodeficiencies recommended by the institute of Immunology of the Ministry of Public Health of the RF, Moscow. (R. M. Kahaitov, N. I. Iljina, L. V. and Luss et al., 2002) All subjects gave their personal consent to participate in the study and submitted a signed informed consent form.
[0081] Criteria for participation in the study included the presence of one or more symptoms of infectious syndrome for one or more years and the absence of severe somatic pathology. Participants who had an acute disease or aggravated chronic disease, who were pregnant or nursing; who had used immuno-modulators or vaccines during a six month period prior to the study; who had been vaccinated against hepatitis, had a preceding case of hepatitis, or had hepatitis B markers in their blood; or who were participating in another study were excluded.
[0082] Study participants were students of the Chelyabinsk State Medical Academy, who were due to receive obligatory vaccination against viral hepatitis B as a priority group according to Order No. 226/79 dated Jun. 3, 1996, of the Ministry of Medical Industry of Russia and the State Committee for Sanitary Epidemiological Inspection of Russia. The study, including participant examinations, treatment and vaccination, was conducted at the medical training institution of Chelyabinsk State Clinical Hospital No. 2, the Clinic and the Research Institute of Immunology of the Chelyabinsk State Medical Academy. The participant group included sixty-nine (69) subjects between the ages of nineteen (19) and twenty-five (25). Eighteen (18) of the participants were male and fifty-one (51) were female.
[0083] The participants were divided into three groups, thirty-seven (37) subjects with infectious syndrome were immunized with the vaccine against hepatitis B without administration of the immunomodulator SCV-07 (Group I), thirty-two (32) subjects with infectious syndrome received SCV-07 and the vaccine (Group II) and a control treatment group that did not have infectious syndrome (Group III). This group, which received SCV-07 and hepatitis B vaccine, included thirty-three (33) essentially healthy students from the Chelyabinsk State Medical Academy.
[0084] The hepatitis vaccine Engerix-B® produced by SmithKlineBeecham-Biomed (Russia) was administered as a course of 3 doses given at months 0, 1, and 6. Immunological examinations of the subjects were carried out before the first administration of the vaccine and at one month after completion of the course of immunization. All participants were seen by an allergologist-immunologist once during the first three months following vaccine administration. Subjects receiving SCV-07 were examined daily by the allergologist-immunologist. If needed, immunocompromised subjects were also seen by doctors of different medical specialties, including gynecologists, gastroenterologists, ear nose and throat (ENT) specialists, infection specialists, dermatologists, surgeons, etc.
[0085] Data on the incidence of episodes and relapses of chronic diseases for each immunocompromised subject were recorded during pre- and post vaccination periods and used to compare the immunological clinical parameters of each subject in the pre- and post vaccination periods. Chronic diseases that were tracked included diseases of the ears, nose and throat, urinary systems, genital systems and gastrointestinal tract, and diseases of the skin, hair and nails (the integumentary tissues).
[0086] Participants were evaluated to determine levels of leukocytes in peripheral blood, leukocytary formula, the presence of marker specific lymphocytes (CD3, CD4, CD8, CD16, CD95 and CD20), lysosomal activity of neutrophils; oxygen-dependent metabolism with spontaneous and induced hematocrit (HCT) tests, phagocytary function of neutrophils according to the latex particle absorption model; immunoglobulin IgA, IgM, IgG concentrations; total hemolytic activity of complement (CH50) in blood serum and for circulating immune complexes. Titers of antibodies to HBAg in the blood serum were determined by immunoenzyme analysis in paired sera using the test system of Vector-Best, Ltd., Novosibirsk, Russia. A concentration of 10 MU/liter (l) was assumed to be a protective hepatitis B titer.
[0087] Participants in the study had the following clinical manifestations of infectious syndrome: sixty-seven percent (67%) had acute respiratory viral infections (ARVI) more than four times a year; forty-nine percent (49%) had chronic inflammatory diseases of the ears, nose and throat; forty-five percent (45%) suffered from recurrent herpes viral infections; thirty percent (30%) had chronic inflammatory diseases of the gastrointestinal tract; thirty-three (33%) had recurrent infections of the skin and subcutaneous adipose cellular tissues. Study participants with the spontaneous form of secondary immunodeficiency typically had more than one chronic inflammatory disease. Seventy-one percent (71%) of the subjects with infectious syndrome had three or more different clinical manifestations of a chronic inflammatory disease. Subjects with a single clinical manifestation made up only three percent (3%) of Groups I and II. Approximately fifty-nine percent (58.8%) of the participants had ARVI 5-9 times a year; 24.7% had ARVI 1 to 4 times a year and the remaining 13.4% of the immunodeficiency subjects had an ARVI less than once a year.
[0088] Approximately thirty percent (30%) of the study participants had symptoms of secondary immunodeficiency throughout their lives with a typical wave-form manifestation of symptoms where periods of relative wellness alternated with periods of frequent occurrence of disease. Approximately eleven percent (11.3%) of participants developed symptoms for five to ten years prior to the start of the study. Approximately thirty-eight percent (38.1%) of the participants developed symptoms during the 3 to 5 year period preceding the study. Approximately twenty-one percent (20.6%) of the study participants were diagnosed with secondary immunodeficiencies one to three years before initiation of the study.
[0089] The immunomodulator SCV-07 was administered at the same time as the hepatitis B vaccine to determine if SCV-07 increased the efficacy of vaccination and to determine if it would correct the immunity disorders of subjects with infectious syndrome. A one milligram (1 mg) dose of SCV-07 was administered as an intra muscular injection to the 32 subjects of Group 2 of the study on days one to five, where day one was the day the first dose of the hepatitis B vaccine was administered. One (1) mg of SCV-07 was also administered with the second and third doses of vaccine one month and 6 months following administration of the initial vaccine dose. Study participants in Group I received injections of physiological saline which were administered on the same schedule as the SCV-07 to provide a placebo control group.
[0090] The clinical manifestations of infectious syndrome changed considerably in vaccinated participants that also received SCV-07. The incidence of ARVI was sharply reduced in those subjects who previously had reported ARVI between 5 and 9 times a year. Incidence of ARVI was also reduced in those participants who had reported ARVI at a frequency of 1 to 4 times a year. The number of subjects who reported no occurrences of ARVI in the year following vaccination increased. Thirty-five percent (35%) of subjects who previously had aggravated chronic diseases of the ears, nose and throat three to four times a year had no aggravated incidents during the first year after vaccination.
[0091] The number of participants who experienced episodes of herpes infections or outbreaks did not change substantially following administration of SCV-07. However, there was a redistribution of episodes of infections or outbreaks. Before vaccination and treatment with SCV-07, 40% of the subjects suffered from herpes infections five times a year or more. After vaccination and SCV-07 administration no participants reported outbreaks of this frequency. However, the number of participants reporting outbreaks one to two times during a year increased from thirteen (13%) to fifty-three (53%). Thirty-four percent of participants who were vaccinated and received SCV-07 did not have episodes or outbreaks of herpes.
[0092] The frequency of chronic diseases of the gastrointestinal tract and the urogenital system did not change among vaccinated participants with infectious syndrome that received SCV-07.
[0093] The effect of SCV-07 on the immune status of subjects with spontaneous form of secondary immunodeficiency. The immune status of subjects with infectious syndrome that received SCV-07 at the time of hepatitis B vaccination was determined immediately before vaccination and at one month after the final dose of vaccine was administered (seven months after the initial dose was administered) with a series of clinical assays. The results of these assays allowed an assessment of the effects of vaccination in the presence of the immunomodulator on the immune status of the study participants. The experimental protocol allowed comparisons of date collected from participants who received SCV-07 with data from participants who received only the hepatitis vaccine and with untreated subjects. Data from the participants of Group II were also compared before and after vaccination.
[0000]
TABLE 26
Concentration of leukocytes and lymphocytes in
peripheral blood before and after vaccination
Studied groups
Patients
Healthy
Patients of group 2
of group
subjects
Before
After
After
After
Studied
Statistical
vaccination,
vaccination
vaccination
vaccination
Indices
Indices
n = 21
n = 21
n = 15
n = 22
Leukocytes ×
M + m p
5.455 ± 0.214
5.938 ± 0.351
5.08 ± 0.34
6.04 ± 0.31
10 9 /l
n = 22
p1 > 0.05
p2 > 0.05
p3 > 0.05
Lymphocytes %
M + m p
22.00 ± 1.86
27.81 ± 2.04
24.07 ± 2.43
19.05 ± 1.13
n = 22
p1 > 0.05
p2 > 0.05
p3 < 0.05
Lymphocytes ×
M + m p
1.440 ± 0.145
1.608 ± 0.096
1.179 ± 0.128
1.19 ± 0.11
10 9 /l
n = 22
p1 < 0.05
p2 < 0.05
p3 < 0.05
Note for Tables 26-30:
p1 - statistical confidence of differences in the group of subjects treated with SCV-07 before and after vaccination;
p2 - statistical confidence of differences between the group of subjects treated with SCV-07 and the group of untreated subjects after vaccination;
p3 - statistical confidence of differences between the group of subjects treated with SCV-07 and the group of healthy individuals after vaccination.
[0094] Determinations of the concentration of subpopulations of lymphocytes in the peripheral blood of participants with infectious syndrome after vaccination against heptatitis B indicated that in subjects who also received SCV-07, the population of CD3+ lymphocytes increases such that the level of CD3+ cells approaches the population of CD3+ cells seen in healthy participants after vaccination. In addition, there also appears to be an increase in the numbers of CD4+ lymphocytes in peripheral blood of participants treated with sCV-07 when compared to levels present before vaccination. While this difference does not appear to be a statistically significant increase in the assays used for participants who received SCV-07 at the time of vaccination, it may nonetheless contribute to the clinical improvements observed in the Group II participants.
[0000]
TABLE 27
Concentration of the subpopulations of
lymphocytes before and after vaccination
Studied groups
Patients of
group 2
Patients of
Healthy of
Before
After
group 1 after
group 3 after
Studied
Statistical
vaccination
vaccination
vaccination n =
vaccination
indices
indices
n = 21
n = 16
15
n = 22
CD3+ (%)
M + m p
26.81 ± 1.41
29.60 ± 2.41
22.67 ± 1.90
33.10 ± 1.88
p1 > 0.05
p2 < 0.05
p3 > 0.05
CD4+ (%)
M + m p
19.23 ± 1.08
20.13 ± 1.65
18.33 ± 0.97
22.86 ± 1.94
p1 > 0.05
p2 > 0.05
p3 > 0.05
CD8+ (%)
M + m p
19.82 ± 1.28
18.27 ± 1.01
18.40 ± 2.07
19.71 ± 1.53
p1 > 0.05
p2 > 0.05
p3 > 0.05
CD4+/CD8+
M + m p
1.050 ± 0.112
1.111 ± 0.086
1.135 ± 0.106
1.203 ± 0.094
conv. units
p1 > 0.05
p2 > 0.05
p3 > 0.05
CD16+ (%)
M + m p
15.41 ± 1.45
13.07 ± 1.18
13.93 ± 1.19
15.19 ± 1.24
p1 > 0.05
p2 > 0.05
p3 > 0.05
CD95+ (%)
M + m p
13.18 ± 0.97
12.60 ± 1.18
16.60 ± 1.94
14.62 ± 1.60
p1 > 0.05
p2 > 0.05
p3 > 0.05
[0095] Table 28 presents data from quantitative and functional studies of neutrophils present in healthy subjects (Group 3) and in subjects with infectious syndrome vaccinated against hepatitis (Group 1) and subjects who received SCV-07 at the time of vaccination. Vaccination against hepatitis B with or without the administration of SCV-07 did not substantially affect the quantitative characteristics of neutrophils in patients with infectious syndrome. Vaccination and treatment with SCV-07 did however change the functional activity of neutrophils significantly. As seen from the data, there was a tendency for the intensity and activity of phagocytosis of neutrophils to rise. The phagocytary number in examined patients also rose.
[0096] The spontaneous activity and intensity of neutrophils in the hemocrit (HCT) reaction in immunodeficient subjects increased somewhat in response to vaccination against hepatitis B and treatment with SCV-07. The activities were significantly lower (p<0.05) than comparable results obtained for subjects with the infectious syndrome who received only hepatitis vaccine and for healthy patients who received the vaccine and the immunomodulator SCV-07.
[0097] The data from the induced HCT test provide a different pattern of results. Neutrophils from subjects who received SCV-07 showed higher, more intense activities in the induced HCT test than neutrophils from those same subjects prior to vaccination. In addition, activities of neutrophils in the induced HCT test after completion of vaccination in subjects who received SCV-07 were significantly higher than the activities of neutrophils from subjects who were vaccinated but did not receive the immunomodulator (p<0.05). The healthy subjects of Group 3 had significantly higher activities in the induced HCT test that vaccinated subjects with infectious syndrome who received SCV-07.
[0098] The functional reserve of cells is an essential index of the performance of phagocytes. Vaccination lowers this index in all test groups. However, the index was essentially the same for subjects with infectious syndrome who received SCV-07 and for healthy patients. In these studies the functional reserve for phagocytes in vaccinated subjects was significantly lower that the functional reserve of phagocytes in subjects with infectious syndrome treated with SCV-07 and in healthy patients.
[0000]
TABLE 28
Concentration and functional activity of
neutrophils before and after vaccination
Studied groups
Group 2
Group 1
Group 3
Before
After
After
After
Studied
Statistical
vaccination
vaccination
vaccination
vaccination
indices
indices
n = 21
n = 16
n = 15
n = 22
Neutrophils %
M + m p
63.27 ± 2.15
56.56 ± 2.07
63.00 ± 2.83
63.55 ± 1.88
p1 > 0.05
p2 > 0.05
p3 > 0.05
Neutrophils ×
M + m p
4.036 ± 0.36
3.403 ± 0.27
3.217 ± 0.26
3.77 ± 0.21
10 9 /l
p1 > 0.05
p2 > 0.05
p3 > 0.05
Activity of
M + m p
34.23 ± 3.10
46.88 ± 4.92
65.93 ± 3.64
60.66 ± 3.72
phagocytosis %
p1 > 0.05
p2 < 0.05
p3 < 0.05
Intensity of
M + m p
0.94 ± 0.163
1.44 ± 0.189
2.79 ± 0.45
2.38 ± 0.204
phagocytosis,
p1 > 0.05
p2 < 0.05
p3 < 0.05
conv. units
Phagocytary
M + m p
2.64 ± 0.205
2.92 ± 0.255
4.35 ± 0.4
3.676 ± 0.22
number, conv.
p1 > 0.05
p2 < 0.05
p3 < 0.05
units
Spontaneous
M + m p
28.36 ± 4.23
34.50 ± 5.62
37.73 ± 4.10
47.41 ± 4.35
HCT-test,
p1 > 0.05
p2 < 0.05
p3 < 0.05
activity, %
Spontaneous
M + m p
0.379 ± 0.07
0.50 ± 0.093
0.555 ± 0.07
0.699 ± 0.08
HCT-test,
p1 > 0.05
p2 < 0.05
p3 < 0.05
index, conv.
Induced HCT-
M + m p
33.43 ± 3.60
48.63 ± 4.62
32.07 ± 4.68
60.0 ± 3.98
test, activity, %
p1 > 0.05
p2 < 0.05
p3 > 0.05
Induced HCT-
M + m p
0.526 ± 0.06
0.732 ± 0.08
0.463 ± 0.08
0.974 ± 0.08
test, index,
p1 > 0.05
p2 < 0.05
p3 < 0.05
conv. units
Functional
M + m p
2.411 ± 0.784
1.929 ± 0.225
0.92 ± 0.183
1.73 ± 0.181
reserve, conv.
p1 > 0.0
p2 < 0.05
p3 > 0.05
units
Lysosomal
M + m p
235.8 ± 23.7
198.7 ± 22.5
158.0 ± 16.4
267.7 ± 20.9
activity, conv.
p1 > 0.05
p2 > 0.05
p3 < 0.05
units
[0099] Studies of immune system components involved in humoral immunity in patients with secondary immunodeficiency disorders that result in infectious syndrome presented in Table 29 did not identify any substantial differences in patients before and after vaccination with concurrent administration of SCV-07. There was a tendency for concentrations of CD20+ lymphocytes and immunoglobulin of the Gig class to increase in the blood (p>0.05). However there was no significant difference in the data obtained for the concentration of CD20+ lymphocytes and IgA, IgM and IgG in the blood of patients with infectious syndrome who were treated with SCV-07 at the time of vaccination and the concentrations in patients who did not receive the immunomodulator and the healthy patients of Group III.
[0100] However administration of SCV-07 during vaccination against hepatitis produces changes in the immune system of patients characterized by a moderate rise in the concentration of CD3+, CD4+/CD8+ lymphocytes, a tendency towards reduction of spontaneous HCT, a stronger induced HCT reaction and a considerable increase in the reserve of functional neutrophils. Thus, the data show that administration of SCV-07 produces a positive immunomodulating effect in patients with the spontaneous form of secondary immunodeficiency.
[0000]
TABLE 29
Indices of humoral immunity before and after vaccination
Studied groups
Patients
Patients
Healthy of
of group
of group
group 3
Before
After
After
After
Studied
Statistical
vaccination
vaccination
vaccination
vaccination
indices
indices
n = 21
n = 16
n = 15
n = 22
CD20+ %
M + m p
14.45 ± 0.88
15.93 ± 1.20
14.67 ± 1.51
17.29 ± 1.44
p1 > 0.05
p2 > 0.05
p3 > 0.05
IgA
M + m p
2.292 ± 0.176
1.821 ± 0.087
1.897 ± 0.116
1.96 ± 0.135
(g/l)
p1 > 0.05
p2 > 0.05
p3 > 0.05
IgM
M + m p
1.440 ± 0.072
1.179 ± 0.089
1.229 ± 0.080
1.13 ± 0.06
(g/l)
p1 > 0.05
p2 > 0.05
p3 > 0.05
IgG
M + m p
8.196 ± 0.387
8.931 ± 0.481
8.47 ± 0.64
8.88 ± 0.36
(g/l)
p1 > 0.05
p2 > 0.05
p3 > 0.05
CH50,
M + m p
62.75 ± 2.40
64.53 ± 4.11
58.69 ± 2.64
59.88 ± 1.79
conv.
p1 > 0.05
p2 > 0.05
p3 > 0.05
units
CIC,
M + m p
65.95 ± 4.93
53.93 ± 8.03
64.50 ± 8.53
90.02 ± 13.1
conv.
p1 > 0.05
p2 > 0.05
p3 < 0.05
units
[0101] Assessment of the protective immunity against the hepatitis B virus. The effectiveness of vaccination against hepatitis B is assessed by the number of antibodies to HBsAg that an organism produces The defensive (protective) titer of the antibodies to hepatitis B is considered to be a level of antibodies no less than 10 MU per liter in blood serum. Antibody titers were determined in vaccinated patients one month after immunization using an immunoenzyme analysis provided by the test-system of Vector Best Ltd., Novosibirsk.
[0102] The results of the study show that the level of antibodies to HBsAg in the blood of subjects was lowest in the Group I patients vaccinated against hepatitis without SCV-07 immunotherapy. (Antibody titers of about 154.0 MU/L) The difference in antibody titers in the subjects of Group 1 were considerably lower than those of immunodeficient subjects who received SCV-07 and of healthy subjects. The concentrations of antibodies to HBsAg in the blood of immunodeficient patients treated with SCV-07 at the time of immunization and of healthy patients were approximately the same, 263.3 MU/L for immunodeficient patients who received SCV-07 at the time of vaccination and 253.6 MU/L for healthy subjects. Comparison of this index did not reveal any significant difference in Groups I, II and III.
[0103] The number of immunodeficient patients with protective titers of antibodies to HBsAg one month after vaccination against hepatitis in Group I, which did not receive SCV-07, was 29 or 78.4% of the group. The numbers of patients with protective immunity in the untreated group was significantly lower than the number of patients in Groups II and III. 96.9% of the immunodeficient subjects treated with SCV-07 seroconverted; 93.9% of the healthy subjects of Group II seroconverted.
[0000]
TABLE 30
Frequency of seroconversions one month after the end of vaccination
Examined groups
Group 1,
Group 2,
Group 3,
untreated
SCV-07
healthy
n = 37
n = 32
n = 33
Studied index
Abs
%
Abs
%
Abs
%
Protective titer
29
78.4
31
96.9**
31
93.9*
against HBsAg
(>10 mMU/mL)
Antibodies to
8
21.6
1
3.1**
2
6.1*
HBsAg not
detected
Note:
*statistically valid differences between the group of patients vaccinated without treatment and the group of healthy vaccinated patients;
**statistically valid differences between the group of patients vaccinated without treatment and the group of patients treated with SCV-07; (Fisher's exact test is applied).
[0104] Conclusion: Vaccination of patients with altered reactivity of the immune system has been recognized as a medical problem for decades. Human immune activity in respect to individual vaccines is different. It depends on many factors, the specific genetic features of the organism being the main factor. Moreover, the intensity of immune response is affected by the features of the introduced antigen, and the phenotypic features of an individual acquired throughout life. Different types of immunity disorders are largely significant, specifically the states of immunodeficiency.
[0105] Vaccination is less effective in patients with the infectious syndrome when vaccinated against hepatitis B without any immunotherapy. Administration of SCV-07 makes vaccination against hepatitis B more effective in patients with the spontaneous form of secondary immunodeficiency, with clinical manifestations of the infectious syndrome that is evidenced by significant increase of the proportion of patients with the protective level of titers of antibodies to HBsAg. The data presented make it apparent that the immunomodulator SCV-07 stimulates production of antibodies against the hepatitis B virus in patients with the infectious syndrome providing a higher level of protection against infections compared with patients vaccinated without immunocorrection.
[0106] Clinical manifestations of the infectious syndrome are altered when vaccination against hepatitis B is accompanied by administration of SCV-07. The number of patients with chronic diseases of ENT organs, frequent ARVI aggravations and herpes infection relapses are significantly reduced. Administration of SCV-07 in these patients is accompanied by improved immunological responses. The achieved clinical effects of SCV-07 probably relate to its immunostimulating action.
[0107] The studies discussed above indicate that it is advisable to administer SCV-07 to patients with secondary immunodeficiency infectious syndrome concurrently with administration of a vaccine, in particular the Engerix-B vaccine for hepatitis. The immunomodulator SCV-07 is a safe adjuvant which reinforces vaccination against infectious agents and other antigens. | A vaccination method utilizes a pharmaceutical combination for enhancing vaccine effectiveness. The method utilizes an immune response-triggering vaccine capable of stimulating production in an immunodefficicent animal of antibodies to a disease-causing agent foreign to the animal. As an adjuvant, a vaccine effectiveness-enhancing amount of an immunomodulator compound is administered, which enhances production and affinity of the antibodies in the animal, in response to the vaccine. | 0 |
[0001] The present invention claims priority from previously filed U.S. provisional patent application 61/378,074 filed Aug. 30, 2010 by Marsilia Didiodato under the title TRACHEOSTOMY BIB.
FIELD OF THE INVENTION
[0002] The present invention relates to devices for filtering and conditioning air inhaled through a stoma pipe and for collection of secretions emanating from the stoma pipe outlet.
BACKGROUND OF THE INVENTION
[0003] Tracheostomy and tracheotomy are surgical procedures on the neck to open a direct airway through an incision in the trachea (the windpipe). They are performed by paramedics, veterinarians, emergency physicians and surgeons. Tracheotomy and Tracheostomy refers to a procedure of cutting into the trachea and is an emergency procedure for reviving suffocating patients in order to open their airway.
[0004] In emergency situations where a patient is suffocating for any number of reasons, a trachea incision is made usually through the second and third tracheal ring and a tracheostomy tube is inserted into the incision in order to allow for the passage of air into the trachea. The opening created by the incision is often called the stoma and the tracheostomy tube is often referred to as a “stoma” and/or a “stoma pipe” and/or simply as a “pipe”. The tracheostomy tube (pipe) is placed into the incision created by the physicians in order to ensure that the stoma or the opening remains open and allows for the passage way of air there through.
[0005] Patients which have received tracheotomies with a pipe in place inhale and exhale the air required for breathing through the stoma pipe. This procedure circumvents the natural entryway of air into the lungs namely through either the mouth and/or the nose. The filtering and other functions that the nose and mouth carryout are no longer available to the passageway of air into the trachea.
[0006] Secretions of many kinds exit from the pipe, for example if the patient coughs and/or sneezes, mucus and/or other secretions may be exhaled from the pipe outlet in an uncontrolled manner.
[0007] Additionally during inhalation, there is no filtering of the air and/or prevention of particles entering directly into the lungs through the pipe. There is a need for a device which filters and conditions air inhaled through the stoma pipe and also collects and manages mucus and other secretions that are expelled from the pipe outlet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention will now be described by way of example only with reference to the following drawings in which:
[0009] FIG. 1 is a side elevational view of the present device a tracheostomy bib.
[0010] FIG. 2 is a front elevational view of the tracheostomy bib.
[0011] FIG. 3 is a cross sectional view of the tracheostomy bib.
[0012] FIG. 4 is a back elevational view of the tracheostomy bib.
[0013] FIG. 5 is a partial cross sectional schematic view showing portions of the outer top edge of the frame.
[0014] FIG. 6 is a front top schematic perspective view of the tracheostomy bib.
[0015] FIG. 7 is a side elevational view of an alternate embodiment of a tracheostomy bib.
[0016] FIG. 8 is a front elevational view of the tracheostomy bib.
[0017] FIG. 9 is a cross sectional view of the tracheostomy bib.
[0018] FIG. 10 is a back elevational view of the tracheostomy bib.
[0019] FIG. 11 is a top front schematic partial cut away perspective view of the tracheostomy bib shown in FIG. 8 .
[0020] FIG. 12 is a side elevational view of an alternate embodiment of the present device a tracheostomy bib.
[0021] FIG. 13 is a front elevational view of the tracheostomy bib.
[0022] FIG. 14 is a cross sectional view of the tracheostomy bib.
[0023] FIG. 15 is a back elevational view of the tracheostomy bib.
[0024] FIG. 16 is a partial expanded cross sectional schematic view showing portions of the outer top edge of the frame.
[0025] FIG. 17 is a front top schematic partial cut away perspective view of the tracheostomy bib.
[0026] FIG. 18 is a front schematic perspective view of the tracheostomy bib deployed onto the neck of a person.
[0027] FIG. 19 is a schematic side perspective view of the tracheostomy bib deployed onto a person.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] The present device a tracheostomy bib is shown generally as 100 , 200 and 300 in the attached figures.
[0029] Referring first of all to the first embodiment of the present invention which is shown in FIGS. 1 to 6 as well as in FIGS. 18 and 19 , tracheostomy bib 100 includes the following major components, namely back wall 102 , front wall 104 , bottom 106 , outer top edge 108 , inner top edge 110 , frame 112 , wire frame 114 , a right support strip 116 , a left support strip 118 , and hook and loop fasteners 120 .
[0030] Back wall 102 together with front wall 104 defines a pocket 122 having an opening 124 in the top thereof. The walls 102 and 104 may be made of any suitable material including but not limited to traditional cloths, absorbent materials, filter materials, synthetics such as nylon, polyester, polypropylene, and or other plastic materials.
[0031] Opening 124 preferably extends from the right side 130 over to the left side 132 and the boundary of the opening is defined roughly by the outer top edge 108 on the front wall 104 and inner top edge 110 on the back wall 102 .
[0032] Referring now to FIG. 5 , frame 112 preferably includes a wire frame 114 sewn into wire pocket 105 which in the drawings extends along the outer top edge 108 of front wall 104 . The wire frame 114 may also extend around the entire outer top edge 108 and inner top edge 110 . The purpose of wire frame 114 is to ensure that opening 124 is maintained in the open position 125 , thereby ensuring that there is a well defined pocket 122 having a large opening 124 as depicted in cross section in FIG. 3 . Wire frame 114 may in fact be metal, however it may also be plastic, wood or any other suitable material which has the necessary rigidity, stiffness and flexibility to maintain opening 124 in the open position 125 . Note that outer top edge 108 is curved or U shaped when viewed from above. The legs of the U 127 defining approximately the pocket depth 129 . Pocket depth 129 is the space between the front wall 104 and the back wall 102 at the center 3 - 3 in FIG. 2 of outer top edge 108 .
[0033] Referring now to FIGS. 7 to 11 , tracheostomy bib shown generally as alternate embodiment 200 includes almost of the all the same components as shown for tracheostomy bib 100 with the exception that frame 208 includes a plastic band 210 and plastic ribs 212 in addition to or instead of the wire frame 114 . The purpose of frame 208 which is comprised of plastic band 210 and plastic ribs 212 is to maintain opening 124 in the open position 125 , thereby maintaining a well defined pocket 122 . Plastic band extends around the outer top edge 108 of front wall 104 as shown in the drawings. Plastic ribs 212 are positioned in a bottom portion pocket 231 and are generally U or J shaped reinforcing and/or stiffening ribs wherein plastic band 210 together with plastic ribs 212 ensure that pocket opening 124 remains in the open position 125 having pocket depth of 129 and well defined bottom 206 having a bottom portion pocket 231 . Tracheostomy bib 200 includes the following major components, namely back wall 102 , front wall 104 , bottom 106 , outer top edge 108 , inner top edge 110 , frame 208 , a right support strip 116 , a left support strip 118 , a hook and loop fasteners 120 . Back wall 102 together with front wall 104 defines a pocket 122 having an opening 124 in the top thereof.
[0034] Referring now to an alternate embodiment namely tracheostomy bib 300 shown in FIGS. 12 through 17 includes almost all of the same components as tracheostomy bib 100 , except that the frame 312 includes a cardboard sheath 314 instead of or in addition to the wire frame 114 . Cardboard sheath 314 again functions to ensure that opening 124 is maintained in the open position 125 and that there is a well defined pocket 122 . Cardboard sheath 314 extends across the entire front wall 104 , except for a cut out portion 316 which may or may not be included. Tracheostomy bib 300 includes the following major components, namely back wall 102 , front wall 104 , bottom 106 , outer top edge 108 , inner top edge 110 , frame 312 , a right support strip 116 , a left support strip 118 , a hook and loop fasteners 120 . Back wall 102 together with front wall 104 defines a pocket 122 having an opening 124 in the top thereof.
[0035] Cardboard sheath 314 could be made of other materials including sheet paper board material, sheet plastic material, sheet metal materials as well plastic band 210 and plastic ribs 212 could also be made of other materials such as wood and/or metal and/or any other materials that may be suitable.
[0036] It is possible to use some features from one embodiment with another embodiment. For example tracheostomy bib 100 may include the plastic ribs 212 shown in tracheostomy bib 200 and/or the card board sheet 314 shown in tracheostomy bib 300 .
In Use
[0037] Referring now to FIGS. 18 and 19 , tracheostomy bib 100 is shown deployed on person 400 which has been subject to a tracheotomy and the insertion of a stoma pipe 410 . In this specification the words “stoma pipe” and simply the word “pipe” mean the same thing, namely the stoma pipe 410 which is inserted during the tracheotomy procedure as shown in FIG. 18 .
[0038] When a stoma pipe 410 is installed into the trachea of a person 400 in the neck region 402 just below the head 404 , the stoma pipe 410 is supported usually with a pipe support collar 414 as depicted in FIG. 18 . The pipe support collar 414 simply ensures that the pipe 410 is maintained in a certain orientation comfortable to the user and ensure that unobstructed breathing of the person with the tracheotomy. Stoma pipe 414 is normally a fairly short pipe being approximately ¾ to as much 2 inches long terminating at a pipe outlet 412 . Mucus and excretions are expelled out of pipe outlet 412 and air is inhaled through pipe outlet 412 into the trachea and lungs of person 400 . Tracheotomy bib 100 is releasably secured to the pipe support collar 414 which is hung around the neck 402 of person 400 . Each of the right support strip 116 and left support strips 118 are wrapped around pipe support collar 414 as depicted and releasably held in place with hook and loop fasteners 120 positioned suitably in order to support and hold tracheostomy bib 100 in place.
[0039] The outer top edge 108 of tracheostomy bib 100 is high enough such that the pipe outlet 412 terminates inside pocket 122 just below outer top edge 108 of tracheostomy bib 100 . In this manner if there are any mucus excretions expelled from pipe outlet 412 , they will be collected within pocket 122 and front wall 104 of tracheostomy bib 100 which will prevent uncontrolled disbursement of excretions from the pipe outlet 412 .
[0040] As best seen in FIGS. 18 and 19 , should person 400 sneeze or cough and expel mucus or other fluids from the pipe outlet 412 of stoma pipe 410 , they will caught and stored in pocket 122 .
[0041] Fluids which are expelled from stoma pipe 410 will be held and collected at the bottom 106 of pocket 122 thereby ensuring that these excretions are kept well away from pipe outlet 412 .
[0042] Similarly when a person is inhaling, the tracheostomy bib 100 acts as a filter ensuring that foreign particles are not accidentally ingested through stoma pipe 410 .
[0043] It should be apparent to persons skilled in the arts that various modifications and adaptation of this structure described above are possible without departure from the spirit of the invention the scope of which defined in the appended claims. | The combination of a tracheostomy bib and a pipe support collar includes a front wall connected to a back wall together defining a pocket which includes a pocket opening and a bottom. The front wall and back wall are connected at a right side and a left side and at the bottom to form an enclosed pocket having a pocket opening. The front wall includes an outer top edge which includes a frame for maintaining the pocket opening in an open position. The bib further includes supports for fastening the bib to the pipe support collar. | 0 |
CROSS REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application claims priority from Taiwan Patent Application No. 098117964, filed in the Taiwan Patent Office on Jun. 1, 2009, entitled “File System and File System Converting Method”, and incorporates the Taiwan patent application in its entirety by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to a file system converting method and a file system for managing a storage apparatus, and more particularly, to a method for converting a file allocation table (FAT) system to a data bulk system.
BACKGROUND OF THE PRESENT DISCLOSURE
[0003] In the prior art, an FAT system applied to a storage apparatus serves as a tool for managing storage space and memory data of the storage apparatus. However, when data is accessed via an FAT system, a next available cluster is first searched for with the aid of an FAT index table, which also needs to be updated. Under such a situation, a search time is different according to distribution (or a disk fragmentation) of used and available storage spaces of the storage apparatus. Generally speaking, the more dispersed the storage space is distributed, the longer the search time it takes. Moreover, the FAT index table is searched from a header every time the FAT index table is updated. Therefore, the time-consuming flow cannot meet read/write requirements of an apparatus (e.g., a personal video recorder (PVR)) which needs a fast data read/write speed.
[0004] In addition, certain environments supporting the FAT file system provide only one read or write authority to a same file at a time. Therefore, when a write operation is desired on a file which has just been read, the file needs to be first closed and then reopened to perform the write operation, and vice versa. However, the above approach inevitably reduces read/write efficiency of a storage apparatus using the FAT system.
SUMMARY OF THE PRESENT DISCLOSURE
[0005] Therefore, one object of the present disclosure is to provide a file system and a file system converting method for generating the file system to overcome disadvantages of having a low search speed and being unable to simultaneously read and write as associated with conventional solutions.
[0006] According to an embodiment of the present disclosure, a file system converting method is for converting a first file system to a second file system. The first file system manages a storage apparatus via an FAT. The file system converting method comprises formatting the FAT to divide the storage apparatus into a plurality of storage units, and establishing a storage unit index table for recording information of the plurality of storage units.
[0007] According to another embodiment of the present disclosure, a file system for managing file data stored in a storage apparatus comprises an FAT, formatted to a plurality of virtual files to divide the storage apparatus into a plurality storage units for storing data, wherein each of the virtual files corresponds to one of the plurality of storage units; and a storage unit index table, for recording information of the plurality of storage units.
[0008] From the above embodiments, a data access speed of a conventional file system is accelerated, and a disadvantage of being unable to simultaneously read and write according to the conventional file system is overcome.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a partial schematic diagram of formatting in advance a FAT index table to numerous data bulks by implementing a file system converting method in accordance with the present disclosure.
[0010] FIG. 2 is a schematic diagram of data bulk files and data bulks in accordance with an embodiment of the present disclosure.
[0011] FIG. 3 is a schematic diagram of a data bulk index table in accordance with another embodiment of the present disclosure.
[0012] FIG. 4 is a flow chart of a file system converting method in accordance with yet another embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] In the known art, file allocation table (FAT) system applies an FAT index table (file allocation table) to manage a storage apparatus. Data may be dispersedly stored into a storage apparatus using the conventional FAT system, and the addresses at which the data are stored are recorded in the FAT index table, which will be looked up when accessing a desired data.
[0014] In an embodiment of the present disclosure, under the structure of FAT system, file allocation table (FAT index table) is formatted in advance so that storage space of a storage apparatus is divided into a plurality of data bulks in a way that the data bulks can be regarded as different storage units. And a data bulk index table is generated to build a data bulk system for managing the storage apparatus. In other words, the bulk index table is a storage unit index table of the data bulk system of the embodiment in the present disclosure.
[0015] In particular, in a file system converting method provided by the present disclosure, appropriate values are filled in advance into a FAT index table to establish a plurality of data bulks, each of which is regarded as a file in a FAT system. That is, in the file system converting method provided by the present disclosure, a plurality of files are established in advance in the FAT index table, and each of the files (each of the data bulks) is allocated to a predetermined storage space of the storage apparatus. Therefore, each of the data bulks is regarded as a storage unit. In an embodiment, the data bulks are consecutively distributed in the storage apparatus, and each of the data bulks has a same size, that is, each of the data bulks occupies a storage space of the same size. Although the plurality of files are established in the FAT index table, at the beginning, each of the files in fact does not have any corresponding data in the storage apparatus, i.e., the plurality of files are regarded as virtual files. For example, FIG. 1 shows partial schematic diagram of the data bulks in the FAT index table of the present disclosure. This is achieved by formatting in advance the FAT index table to form a plurality of data bulks by implementing a file system converting method according to the present disclosure. A FAT index table 101 , formatted to form a plurality of 64 Mb-sized data bulks, is for managing file data of a storage apparatus 103 . After formatting the FAT index table, according to file system converting method of the present disclosure, the next step is generating a data bulk index table to record utilization conditions of the data bulks. The data bulks, the data bulk files and the data bulk index table are described below in detail.
[0016] FIG. 2 shows a schematic diagram of data files and data bulks in accordance with an embodiment of the present disclosure. At least one part of a storage space 200 in a storage apparatus is divided into a plurality of storage units, e.g., data bulks 201 to 217 ; storage space 218 is an unoccupied storage space. The data bulks 201 to 217 are provided in different sizes according to different requirements. Data files 219 , 221 , 223 , 225 and 227 are stored in the data bulks 201 to 217 . More specifically, the data file 219 is stored in two consecutive data bulks 201 and 203 , the data files 221 , 223 and 225 are respectively stored in the data bulks 207 to 211 , and the data file 227 is stored in two consecutive data bulks 215 and 217 . Accordingly, when a data file needs to be stored in more than two data bulks, the data file is successively stored in two consecutive data bulks instead of being stored dispersedly in a conventional FAT system. Moreover, in the present disclosure, address associated information of the data file is stored in a data bulk index table (storage unit index table), when the file system of the present disclosure is about to access certain data file, it only needs to look up the address information in the data bulk index table instead of searching data files again and again located in dispersed blocks (in other words, searching for different addresses in the system) as what is done in the conventional FAT system. Therefore, the data file system of the present disclosure provides an increase read/write speed of the storage apparatus. In an embodiment, each of the data bulk stores a single data file, i.e., if a data bulk already stores a data file, the data bulk will not be used to store other data files even if this data bulk still has storage space available. When the size of a data file is greater than a capacity of one data bulk, the data file is stored into a plurality of consecutive data bulks.
[0017] FIG. 3 shows a schematic diagram of a data bulk index table 300 in accordance with an embodiment of the present disclosure. The data bulk table 300 comprises header information 301 , start information 303 , an allocation table 305 , and a plurality of data bulk entry information 307 to 317 . In this embodiment, each part of the data bulk index table 300 (storage unit index table) is allocated to have a 4K space, and thus the whole data bulk index table 300 has a space of (3+N)*4K, where number 3 refers number of data bulks that header information 301 , start information 303 , and allocation table 305 occupy, and, N is number of data bulk entries each recording information of a data file stored in a data bulk. The header information 301 of data bulks is regarded as system information comprising various types of information of a data bulk system, e.g., a total number of data bulks of the data bulk system, a capacity of storage apparatus used by the data bulk system, number of data bulks already stored with data files, etc. The start information 303 records physical information of data bulks (storage units) in the storage apparatus, i.e., corresponding physical sector allocations of the storage apparatus of the data bulks (storage units) divided according to the embodiment of the present disclosure. For example, the start information 303 records the physical addresses of the start points of each of the data bulks in the storage apparatus; or, at which physical sector the data bulk starts.
[0018] The file allocation table 305 , having associated information of the storage units and the data files, records correlations between the storage units (e.g., the data bulks) and the data files. For example, the file allocation table 305 records a data bulk or data bulks in which each of the data files is stored. Each of the data bulk entry information 307 to 317 records detailed information of the data file stored in that data bulk. For example, the data bulk entry information 307 to 317 respectively records identification code, file name, file length, operation mode, and the like, of the stored data file.
[0019] When a data file is accessed, the data bulk system supports at least two access parameters (e.g., a read pointer and a write pointer) to record an access position of the data file. For example, the read pointer and the write pointer are dynamically stored in the data bulk system, and the access parameters are updated according to a data amount of the data files to be accessed. In particular, before writing the data file, an absolute address (a physical address in the storage apparatus) of the data file is determined by a file search function and the access address of the data file, so as to write the data file into the storage apparatus. Such step is in brief described as Formula 1.
[0000] accessing sector(s)=data start sector+(data bit length/bits per sector) Formula 1
[0020] “Sector” means the physical sectors in the storage apparatus. In short, Formula 1 represents that the data to be accessed can be located in the accessing sectors when the data start point and the length of data is provided. From the foregoing step, read and write sectors are calculated by Formula 2 and Formula 3.
[0000] read sector=read data start sector+(read data bit length/bits per sector) Formula 2
[0000] write sector=write data start sector+(write data bit length/bits per sector) Formula 3
[0021] According to the foregoing access operations, data file is directly accessed at an absolute position (physical address) instead of having to first search an FAT index to find a next available cluster as in a conventional FAT system, so that the access speed is accelerated. Further, the embodiments of the present disclosure are different from conventional FAT systems where only one read or write authority is provided to a same file at a time, and accordingly it is not necessary to continuously open or close the file, so that a time for accessing the file is reduced.
[0022] FIG. 4 shows a flow chart of a file system converting method in accordance with an embodiment of the present disclosure. In this embodiment, the file system converting method according to the present disclosure, for converting an FAT system to a data bulk system, comprises steps below.
[0023] The method includes Step 401 , formatting a file allocation table (FAT) of the FAT system to divide a storage apparatus into a plurality of data bulks, each of which being regarded as a storage unit. In this step, a plurality of virtual files is established in the FAT, with each of the virtual files corresponding to one of the storage units.
[0024] The method further includes Step 402 , establishing a data bulk index table (storage unit index table) to record information of the plurality of storage units. The data bulk index table comprises header information, start information, an allocation table, and a plurality of data bulk entry information.
[0025] Detail characteristics of the file system applied in the file system converting method according to the present disclosure are disclosed in the foregoing embodiments, and detailed description thereof shall not be described for brevity. In an embodiment, the foregoing steps are realized from executing predetermined firmware or software by a control circuit (e.g., a processor); however, other circuits can also be implemented to realize the foregoing steps.
[0026] According to a file system converting method of the present disclosure, an FAT system is converted to a data bulk system, and a data bulk system of the present disclosure can accelerate a data access speed as well as solving a problem that a file cannot be simultaneously read or written in a conventional FAT system.
[0027] While the present disclosure has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the present disclosure needs not to be limited to the above embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. | A file system converting method converts a first file system to a second file system. The first file system manages a storages apparatus via a file allocation table (FAT). The file system converting method includes formatting the FAT to divide the storage apparatus into a plurality of storage units, and establishing a storage unit index table to record information of the plurality of storage units. | 6 |
[0001] This application claims priority from provisional application No. 60/249,021 filed on Nov. 15, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to bleacher safety equipment to prevent injury to people who are occupying bleachers during sporting and other spectator events. More particularly, the present invention relates to bleacher end rails that protect bleacher occupants from falling off the edges of the bleachers wherein the end rails can be folded and stored when the bleachers are not in use.
PRIOR ART
[0003] Bleacher end rails are used to protect bleacher occupants during spectator events by preventing them from falling off of the edges of the bleachers. Bleachers are designed to allow each row of seated viewers to have a commanding view of the spectator area by elevating each subsequent row, with the first row having the lowest elevation and the last row having the highest elevation. The elevation of the upper bleacher rows can exceed twenty feet or more which could cause serious injury or death to a spectator who were to fall from such elevations.
[0004] For telescoping bleachers there are two basic types of end rail systems. The first is a self storing end rail system. The self storing end rail system has vertical pickets that are permanently mounted to the bleacher and are slanted outward from the bleacher at an angle. The angular orientation of the end rails allows the end rails to automatically stack and extend when ever the bleachers whenever the bleachers are operated. These systems are costly and are not concealed when the bleachers are not in use.
[0005] The second is a removable end rail system, usually made of aluminum in a post and picket design where all guards are in the vertical position except for the top rail, which is used for a hand rail. On telescoping bleachers, the post and pickets are in the vertical position and the top hand rail is on a diagonal, following the slope of the bleachers from row to row. With this post and picket guard rail, the end rail is removed from the bleachers as a single section and then it is compressed together in a scissor action and stored upon the deck of the bleacher. This end rail design is too heavy to be removed by a single individual and are very costly to produce. Prior art devices do not provide for a cost effective, light weight removable bleacher end rail system that stores out of site when not in use.
SUMMARY OF THE INVENTION
[0006] This invention may be described as a novel and improved removable end rail system that can be removed from the ends of a bleacher, folded and stored upon the bleacher deck so that the rail ends are concealed when the telescoping bleachers are closed. The end rail system is comprised of a base member and an end rail member. The end rail member includes vertical guards designed to protect occupants when used on telescoping bleachers in gymnasiums and other spectator areas. The end rail includes vertical pickets and is designed to be installed and then removed after each use of the bleachers. The end rail is fastened to the bleacher by use of the base member. The end rail is hinged through its vertical center so that it can then be folded and stored flat upon the deck of the bleacher for storage. The bleacher can then be moved rearward and compressed against the building walls. When the bleachers are to be used again for spectator seating the bleacher is extended. The guard rails are then fitted into the base member and secured with a thumb tightening screw rendering the bleachers ready for use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a perspective view of the end rail system of the present invention connected to a telescoping bleacher;
[0008] [0008]FIG. 2 is an elevational view of an end rail;
[0009] [0009]FIG. 3 is a perspective view of an end rail vertically displaced above a base member;
[0010] [0010]FIG. 4 is a perspective view of a partially folded end rail; and
[0011] [0011]FIG. 5 is a perspective view of an end rail showing one-half being folded over the other half.
DETAILED DESCRIPTION OF THE INVENTION
[0012] While the present invention will be described fully hereinafter with reference to the accompanying drawings, in which a particular embodiment is shown, it is understood at the outset that persons skilled in the art may modify the invention herein described while still achieving the desired result of this invention. Accordingly, the description which follows is to be understood as a broad informative disclosure directed to persons skilled in the appropriate arts and not as limitations of the present invention.
[0013] [0013]FIG. 1 illustrates an end rail system 10 for a telescoping bleacher 12 with a first end rail 14 vertically displaced from a base plate 16 . Also illustrated is another end rail 14 folded and laying on the deck 18 of the bleacher 12 . When the end rails 14 are connected to the bleacher 12 , the spacing between subsequent rows of end rails 14 is minimal. The telescoping bleacher 12 is a seating system that is designed to stage the elevation of seated spectators so that the entire audience would have a clear view of the center stage activities. When the telescoping bleacher 12 is not in use, it is longitudinally collapsed by moving the first row of the bleacher 12 toward an attachment wall. When fully collapsed, the bleacher 12 forms a wall with risers 20 of the bleacher visible. The telescoping bleacher systems 12 typically include a seat portion 22 , the deck portion 18 and the riser portion 20 . Each portion 18 , 20 , and 22 are comprised of longitudinal planks that are fastened to a framework (not shown). When the telescoping bleachers 12 are collapsed, the deck portion 20 and the seat portion 22 move rearward beneath the rearward riser 20 . When fully expanded, the seat portions 22 vary in elevation from row to row.
[0014] The removable end rail system 10 is comprised of the end rail 14 and the base plate 16 . The base plate 16 includes a plate member 28 , a first socket 30 and a second socket 32 as shown in FIG. 3. The plate member 28 is fabricated from steel plate stock and is rectangular in shape. The width of the plate member 28 is sized to be equal to or almost equal to the width of the deck portion 18 . The plate member 28 further includes a plurality of apertures 34 that allow the plate member 28 to be fastened to the deck portion 24 with bolts or other types of fasteners.
[0015] The first socket 30 has a square cross-section and has a top end 34 and a bottom end 36 , an exterior surface 38 and an interior surface 40 . The first socket 30 is fabricated from rectangular steel tubing but other materials could be used known to those skilled in the art. The top end 34 of the first socket 30 is adapted to accept the end rail 14 . The bottom end 36 of the first socket 30 is connected to the plate member 28 by welding or other fastening means known to one skilled in the art. The first socket 30 includes a threaded aperture (not shown) that extends from the exterior surface 38 through to the interior surface 40 . The threaded aperture (not shown) is adapted to accept a thumb screw 44 that secures the end rail 14 to the first socket 30 .
[0016] The second socket 32 is also square in shape and includes a top end 46 , a bottom end 48 , an exterior surface 50 and an interior surface 52 . The top end 46 of the second socket 32 is adapted to accept the end rail 14 . The bottom end 48 of the second socket 32 is connected to the plate member 28 by welding or other fastening means known to one skilled in the art. The second socket 32 includes a threaded aperture 54 that extends from the exterior surface 50 through to the interior surface 52 . The threaded aperture 54 is adapted to accept a thumb screw 56 that secures the end rail 14 to the second socket 32 . The second socket 32 also includes a support flange 58 that is connects the second socket 32 to the plate member 28 . The support flange 58 includes apertures 60 to allow the base plate 16 to be further connected to the bleacher 12 with fasteners for additional support.
[0017] The end rail 14 is comprised of a first rail section 62 and a second rail section 64 , as shown in FIG. 2. The end rail 14 is preferably fabricated from aluminum tube stock but could be made using other materials known to those skilled in the art. The end rail 14 is adapted to be connected to the base plate, as shown in FIG. 3, to secure the end rail 14 to the bleacher 12 . The first rail section 62 is comprised of an inboard picket 66 , a central picket 68 and an outboard picket 70 . The outboard picket 70 includes a horizontal end portion 72 and a vertical end portion 74 interconnected by a 90 degree bend 76 . The vertical end portion 74 includes a lower end stubshaft 80 that is connected to the first socket 30 of the base plate 16 . The stubshaft 80 is fastened to the first socket 30 by use of the thumb screw 44 . The horizontal end portion 72 ends at the interconnection with the inboard picket 66 .
[0018] The central picket 68 is oriented between the inboard picket 66 and the outboard picket 70 and includes an upper end 84 and a lower end 86 . The upper end 84 of the central picket 68 is connected to the horizontal end portion 72 of the outboard picket 70 and the lower end 86 is connected to a horizontal plate 82 that interconnects the three pickets 66 , 68 and 70 .
[0019] The inboard picket 66 includes an upper end 88 that connected to the horizontal end portion 72 of the outboard picket and further includes a lower end 90 connected to the horizontal plate 82 . The inboard picket 66 further includes a pair of hinge halves 92 to allow the first rail section 62 to be pivotally connected to the second rail section 64 .
[0020] The second rail section 64 is also comprised of an inboard picket 94 , a central picket 96 and an outboard picket 98 . The outboard picket 98 includes a horizontal end portion 100 and a vertical end portion 102 interconnected by a 90 degree bend 104 . The vertical end portion 102 includes a lower end stubshaft 106 that is connected to the second socket 32 of the base plate 16 . The stubshaft 106 is fastened to the second socket 32 by use of the thumb screw 56 . The horizontal end portion 100 ends at the interconnection with the inboard picket 94 .
[0021] The central picket 96 is oriented between the inboard picket 94 and the outboard picket 98 and includes an upper end 108 and a lower end 110 . The upper end 108 of the central picket 96 is connected to the horizontal end portion 100 of the outboard picket 98 and the lower end 110 is connected to a horizontal plate 112 that interconnects the three pickets 94 , 96 and 98 .
[0022] The inboard picket 94 includes an upper end 114 that connected to the horizontal end portion 100 of the outboard picket 98 and further includes a lower end 116 connected to the horizontal plate 112 . The inboard picket 94 further includes a pair of hinge halves 118 to allow the second rail section 64 to be pivotally connected to the first rail section 62 .
[0023] The first rail section 62 is pivotally connected to the second rail section 64 by hinges 120 and 122 . The hinges 120 and 122 allow the end rail 14 to be folded upon itself so that it can be stored upon the deck 18 when not in use, as shown in FIGS. 2, 4 and 5 . When the telescoping bleachers 12 are to be used, they are pulled out from a wall of a gymnasium and fully extended. The end rails 14 , one on each end of a row of seating are removed from the deck 18 of the bleacher 12 . The two rail sections 62 and 64 of the end rail 14 are unfolded and the stub shafts 80 and 106 are inserted into the first and second socket 30 and 32 . Once the end rail 14 is positioned in the first and second socket 30 and 32 , thumb screws 44 and 56 are tightened to secure the end rail 14 to prevent removal of the end rail 14 from the base plate 16 . The end rails 14 for each row of seating is installed in the same fashion until every row is completed.
[0024] When the event is over and the bleacher 12 is to be stored, the end rails 14 can be removed by loosening the thumb screws 44 and 56 and removing the end rails 14 from their respective base plate 16 . The end rails 14 are then folded in half and stored upon the deck portion 24 of the bleacher 12 . The benefit of the end rail 14 design is their light weight, allowing a single individual to set up the bleachers without the assistance of others. Also, if the entire bleacher 12 does not need to be used, it can be opened part way and the end rails 14 can be installed only for the open portion of the bleacher 12 .
[0025] Various features of the invention have been particularly shown and described in connection with the illustrated embodiment of the invention, however, it must be understood that these particular arrangements merely illustrate, and that the invention is to be given its fullest interpretation within the terms of the appended claims. | The invention is directed to a removable end rail system that can be removed from the end of a bleacher, folded and stored upon the bleacher deck so that the end rails are concealed when the telescoping bleacher are folded away for storage. The end rail system is comprised of a base member and an end rail member. The end rail member is designed to protect occupants when used on bleachers in gymnasiums and other spectator areas. The end rail member is comprised of vertical pickets and is designed to be installed and then removed after each use of the bleachers. The end rail member is fastened to the base member by using a set of thumb screws. The end rail is hinged through the vertical center so that it can then be folded and stored flat upon the deck of the bleachers for storage purposes. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to an improved polyurethane panel. The panel finds particular use, although not exclusive use, in building and construction.
BACKGROUND
[0002] Building panels are ubiquitous in the building industry and are used to form walls, doors or other partitions, either of a structural or non-structural nature. Building panels are conventionally made from wood, most commonly plywood, wood chips or a composite material such as medium density fibreboard (MDF).
[0003] Engineered wood products, such as MDF, are made by breaking down hardwood or softwood residuals into wood fibres, and combining the fibres with wax and a resin binder. Panels are formed therefrom by applying high temperature and pressure. It is has been found that the resin material used in the manufacture of wood chip or composite-type panels is carcinogenic. Such panels are further disadvantageous in that they are relatively heavy and require additional components in order to be moisture resistant.
[0004] An alternative type of composite building panel is that produced from sand, cement and cellulose fibres, otherwise known as a fibre cement panel. Fibre cement panels are most often manufactured in a sheet form and are commonly used as cladding, but can also be used as tile underlay on decks and in bathrooms. While water and fire resistant, fibre cement panels are disadvantageous in that they are typically very heavy, where only thick panels have good impact resistance. Thin fibre cement panels are very fragile and must be handled carefully to avoid chipping and breakage.
[0005] A further alternative type of building panel is that made from moulded polyurethane. Polyurethane can be formed into panel which can function in the same manner as conventional panels formed from wood and other material. The panel is able to be cut, screwed, drilled, painted, laminated or veneered. Panels made from polyurethane avoid the use of the carcinogenic resin used in MDF panels, and are considerably lighter than similarly sized panels made from, for example, MDF, plywood or fibre cement. Polyurethane panels are also non-toxic, waterproof, flexible, and thermoformable. Polyurethane panels provide superior, cost efficient applications across many industries including, for example, marine, building and construction, landscaping, signage, transportation and refrigeration. The panels have excellent thermal and acoustic properties, and can also be made fire resistant. While laminating or veneering polyurethane panels with, for example, melamine or plywood, improves strength and rigidity, this is at a cost to flexibility and, consequently, the applicability of panels.
[0006] A need exists to provide improved polyurethane panels for use in building an other applications. The present invention addresses this need.
[0007] Discussion or mention of any piece of prior art in this specification is not to be taken as an admission that the prior art is part of the common general knowledge of the skilled addressee of the specification in Australia or any other country.
SUMMARY OF THE INVENTION
[0008] According to one aspect of the invention there is provided a coated polyurethane panel wherein the coating comprises one or more polyurethane elastomers.
[0009] The coated polyurethane panel according to the present invention is advantageous as it has substantially improved characteristics which may be selected from, but not limited to, strength, compressibility, flexibility or resistance. Such improved characteristics substantially reduces the fracturing and/or breakage of coated panels when formed into shapes without first requiring that the panel be heated to deformation temperatures in comparison to uncoated panels. This therefore increases the applicability of the coated polyurethane panel according to the invention when compared to uncoated panels.
[0010] Preferably, the coated panel of the invention is comprised of one or more polyols.
[0011] Further preferably, the coated panel of the invention is also comprised of one or more diisocyanates.
[0012] Even further preferably, the coated panel of the invention is comprised of one or more diisocyanates selected from the group consisting of: tetramethylene, hexamethylene, octamethylene and decamethylene diisocyanates, and their alkyl substituted homologs, 1,2-, 1,3- and 1,4-cyclohexane diisocyanates, 2,4- and 2,6-methyl-cyclohexane diisocyanates, 4,4′- and 2,4′-dicyclohexyl-diisocyanates, 4,4′- and 2,4′-dicyclohexylmethane diisocyanates, 1,3,5-cyclohexane triisocyanates, saturated (hydrogenated) polymethylenepolyphenylenepolyisocyanates, isocyanatomethylcyclohexaneisocyanates, isocyanatoethyl-cyclohexane isocyanates, bis(isocyanatomethyl)-cyclohexane diisocyanates, 4,4′- and 2,4′-bis(isocyanatomethyl)dicyclohexane, isophorone diisocyanate, 1,2-, 1,3-, and 1,4-phenylene diisocyanates, 2,4- and 2,6-toluene diisocyanate, 2,4′-, 4,4′- and 2,2-biphenyl diisocyanates, 2,2′-, 2,4′- and 4,4′-diphenylmethane diisocyanates, polymethylenepolyphenylenepolyisocyanates (polymeric MDI), and 1,2-, 1,3-, and 1,4-xylylen diisocyanates.
[0013] Even further preferably, the coated panel of the invention is coated with a polyurethane elastomer which is comprised of one or more polyols.
[0014] Even further preferably, the polyurethane elastomer is comprised of one or more diisocyanates.
[0015] Even further preferably, the polyurethane elastomer is comprised of one or more diisocyanates selected from the group consisting of: tetramethylene, hexamethylene, octamethylene and decamethylene diisocyanates, and their alkyl substituted homologs, 1,2-, 1,3- and 1,4-cyclohexane diisocyanates, 2,4- and 2,6-methyl-cyclohexane diisocyanates, 4,4′- and 2,4′-dicyclohexyl-diisocyanates, 4,4′- and 2,4′-dicyclohexylmethane diisocyanates, 1,3,5-cyclohexane triisocyanates, saturated (hydrogenated) polymethylenepolyphenylenepolyisocyanates, isocyanatomethylcyclohexaneisocyanates, isocyanatoethyl-cyclohexane isocyanates, bis(isocyanatomethyl)-cyclohexane diisocyanates, 4,4′- and 2,4′-bis(isocyanatomethyl)dicyclohexane, isophorone diisocyanate, 1,2-, 1,3-, and 1,4-phenylene diisocyanates, 2,4- and 2,6-toluene diisocyanate, 2,4′-, 4,4′- and 2,2-biphenyl diisocyanates, 2,2′-, 2,4′- and 4,4′-diphenylmethane diisocyanates, polymethylenepolyphenylenepolyisocyanates (polymeric MDI), and 1,2-, 1,3-, and 1,4-xylylen diisocyanates.
[0016] Even further preferably, the coated panel of the invention is comprised of up to about 50% by weight polyether polyol, preferably about 20 to 40% by weight, further preferably about 30 to 40% by weight.
[0017] Even further preferably, the coated panel of the invention is comprised of up to 70% by weight diphenylmethane diisocyanate, preferably 30 to 60% by weight, further preferably 50 to 60% by weight.
[0018] Some polyurethane materials can be vulnerable to damage from, for example, heat, light, atmospheric contaminants, and chlorine. Therefore, stabilisers can be added for protection. A blowing agent may also be added during the formation of the panel to produce a cellular structure via a foaming process. Thus, even further preferably, the panel of the invention and/or polyurethane elastomer coating further comprise additives selected from the group consisting of catalysts, blowing agents, surfactants, flame retardants, stabilizers, anti-discolouration compounds and pigments.
[0019] Even further preferably, the coated panel of the invention is comprised of up to about 10% by weight of one or more blowing agents, preferably about 2 to 8% by weight, further preferably about 3 to 6% by weight.
[0020] Even further preferably, the coated panel of the invention is comprised of polyurethane elastomer which comprises up to about 80% by weight, preferably greater than about 60% by weight of polyethylene/polypropylene glycol glyceryl ether.
[0021] Even further preferably, the coated panel of the invention is comprised of polyurethane elastomer which comprises up to about 20% by weight diethylene glycol, preferably about 10 to 18% by weight.
[0022] Even further preferably, the coated panel of the invention is comprised of polyurethane elastomer which comprises up to about 5% by weight diethyltoluenediamine, preferably up to about 2 to 4% by weight.
[0023] Even further preferably, the coated panel of the invention is comprised of polyurethane elastomer which comprises up to about 80% by weight 4,4′-diphenylmethane diisocyanate (MDI), preferably about 50% to 60% by weight.
[0024] Even further preferably, the coated panel of the invention is comprised of polyurethane elastomer which comprises modified 4,4′-diphenylmethane diisocyanate up to about 60%, preferably 20 to 40%.
[0025] Even further preferably, the coated panel of the invention is comprised of polyurethane elastomer which comprises diisooctyl phthalate up to about 30%, preferably 5 to 20%.
[0026] Even further preferably, the coated panel of the invention is substantially reduced from fracturing and/or breaking when the coated panel is substantially formed without first heating the panel to a deformation temperature.
[0027] Even further preferably, the coated panel of the invention is substantially formable at a temperature less than about 100° C.
[0028] Even further preferably, the coated panel of the invention is substantially formable at ambient temperature.
[0029] According to an embodiment of the above aspect, there is provided a coated polyurethane panel comprising a polyurethane panel coated with a polyurethane elastomer, wherein the panel is comprised of the following components:
Polyether Polyol: up to about 50%, preferably about 20 to 40%, further preferably about 30 to 40% Diphenylmethane Diisocyanate: up to about 70%, preferably about 30 to 60%, further preferably about 50 to 60% Blowing Agent: up to about 10%, preferably about 2 to 8%, further preferably about 3 to 4% Fire Retardant: up to about 10%, preferably about 2 to 8%, further preferably about 3 to 4%
and the polyurethane coating is comprised of the following components:
[0000]
polyethylene/polypropylene
up to about 80%, preferably
glycol glyceryl ether
greater than 60%
diethylene glycol
up to about 20%, preferably
about 14%
diethyltoluenediamine
up to about 5%, preferably less
than 3%
4,4′-diphenylmethane
up to about 80%, preferably 50
diisocyanate (MDI)
to 60%
modified MDI
up to about 60%, preferably 20
to 40%
diisooctyl phthalate
up to about 30%, preferably 5
to 20%.
[0034] According to another aspect of the invention, there is provided a method of manufacturing a coated polyurethane panel as described above comprising the step of applying at least one layer of polyurethane elastomer to said panel.
[0035] According to another aspect, the invention provides for the use of the coated panel as described above for building and construction or blast mitigation.
[0036] According to this aspect, the coated panel of the invention may be used construct:
walls, floors, ceilings, windows, vents, doors, solar panels, rainwater catchment devices and septic holding tanks, water features, or planter boxes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] In order to better present the invention, preferred embodiments of the invention will be described, by way of example only, with reference to the accompanying figures in which:
[0041] FIG. 1 is an illustration of a transverse crossection of an embodiment of the coated polyurethane building panel according to the invention.
[0042] FIG. 2 shows a front perspective view of a water feature made from an embodiment of the coated polyurethane building panel according to the invention.
[0043] FIG. 3 shows a perspective view of a planter box made from an embodiment of the coated polyurethane building panel according to the invention.
[0044] FIG. 4 shows a perspective view of a large planter box made from an embodiment of the coated polyurethane building panel according to the invention.
[0045] FIG. 5 shows a front perspective view of housing made from an embodiment of the coated polyurethane building panel according to the invention.
[0046] FIG. 6 shows a rear perspective view of housing made from an embodiment of the coated polyurethane building panel according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] Except where otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term ‘about’. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, each numerical parameter should be construed in light of the number of significant digits and ordinary rounding conventions.
[0048] Additionally, the recitation of numerical ranges within this specification is considered to be a disclosure of all numerical values and ranges within that range. For example, if a range is from about 1 to about 50, it is deemed to include, for example, 1, 7, 34, 46.1, 23.7, or any other value or range within the range.
[0049] The flexural modulus is the ratio of stress to strain in flexural deformation, or the tendency for a material to bend. It can be determined from the slope of a stress-strain curve produced by a flexural test (such as the ASTM D 790), and uses units of force per area. The flexural modulus of rigid polyurethane panels is dependent on composition as well as the thickness of the panel.
[0050] The tensile strength is the resistance of a material to longitudinal stress (tension); a measure of the force required to pull it apart. A suitable test for measuring tensile strength includes ASTM C 297-94.
[0051] The compressive strength is the maximum stress a material can sustain under crush loading. Compressive strength may be calculated by dividing the maximum load by the original cross-sectional area of a specimen in a compression test (such as the ASTM D 1621-94).
[0052] The compressive modulus is the measure of the compression of a sample at a specified load. It may also be measured using the ASTM D 1621-94 test as described above.
[0053] The shear strength is the maximum shear stress that can be sustained by a material before rupture. It is the ultimate strength of a material subjected to shear loading. It can be determined in a torsion test where it is equal to torsional strength. The shear strength is the maximum load required to shear a specimen in such a manner that the resulting pieces are completely clear of each other. Tests for shear strength include ASTM D-732 or ISO 1922:2001(E).
[0054] The shear modulus is defined as the ratio of shear stress to the shear strain. Tests for shear modulus also include ASTM D-732 or ISO 1922:2001(E).
[0055] Thermal resistance is the measure of a material's ability to resist heat flow. The formula for Thermal Resistance is R=L/k where (L) is the material's thickness and (k) is the material's Thermal Conductivity constant.
[0056] Unless otherwise stated, ‘ambient temperature’ is a term which refers to the temperature in a room, or the temperature which surrounds the object under discussion. Preferably, ambient temperature falls within the range of 15° C. to 30° C., further preferably 20° C. to 25° C.
[0057] Comprises/comprising and grammatical variations thereof when used in this specification are to be taken to specify the presence of stated features, integers, steps or components or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.
[0058] Polyurethane panels and polyurethane elastomers comprise two separate components, namely a polyol component (A) and an isocyanate component (B), typically in the presence of a catalyst and other additives. A urethane linkage is produced by reacting an isocyanate group with a hydroxyl group of a polyol. Preferably, the isocyanate comprises at least two isocyanate functional groups and the polyol comprises at least two hydroxyl functional groups. The reaction product is a polymer containing the urethane linkage.
Polyols
[0059] Polyols can be derived from an initiator and monomeric building blocks. A preferred class of polyols are polyether polyols, which may be produced by the reaction of epoxides (oxiranes) with active hydrogen containing starter compounds. Another preferred class of polyols are polyester polyols, which may be produced by the polycondensation of multifunctional carboxylic acids and hydroxyl compounds. Polyols may be further classified as flexible or rigid polyols according to their end use, which may depend on the functionality of the initiator and their molecular weight. Initiator molecules having active hydrogens that will react with alkylene oxides to undergo polymerization may be selected to provide the polyol with a desired functionality and reactivity. Examples of active hydrogens, which are well known in the art, include the hydrogen on functional groups such as —OH, —NHR, —SH, —COOH, and —C(O)NHR, where R is hydrogen, alkyl, aryl, or aralkyl. Taking into account functionality, flexible polyols have molecular weights from 2,000 to 10,000 Daltons (number of OH groups from 18 to 56). Rigid polyols have molecular weights from 250 to 700 Daltons (number of OH groups from 300 to 700). Polyols with molecular weights from 700 to 2,000 Daltons (number of OH groups 60 to 280) may be used to add stiffness or flexibility to base systems, as well as increase solubility of low molecular weight glycols in high molecular weight polyols.
Polyether Polyols
[0060] Polyether polyols are available in a wide variety of grades based on their end use, but are all constructed in a similar manner. Polyols for flexible applications may employ low functionality initiators (‘f’) such as dipropylene glycol (f=2), glycerine (f=3) or a sorbitol/water solution (f=2.75). Polyols for rigid applications may employ high functionality initiators such as sucrose (f=8), sorbitol (f=6), toluenediamine (f=4), and Mannich bases (f=4). Preferably, rigid polyurethane foams may be produced from polyols having a nominal functionality of 2 to 8. It is desirable to produce rigid polyurethane foams from isocyanate-reactive compounds having functionality greater than 8 to achieve improved properties such as rigidity, density and dimensional stability. Preferable low molecular weight polyols for use as initiators for polyether polyols destined for rigid polyurethane foams synthesis are: glycerol, trimethylolpropane (TMP), triethanolamine, pentaerythritol, dipentaerythritol, α-methyl glucoside, xylitol, sorbitol and sucrose.
[0061] Polyols for use as initiators may have an aliphatic structure (glycerol, pentaerythritol, xvlirol, sorbitol) and others may have cycloaliphatic structures (α-methyl glucoside and sucrose). As a general rule, the polyether polyols derived from polyols with a cycloaliphatic structure, due to their intrinsic low mobility and higher rigidity, yield rigid polyurethane foams with superior physico-mechanical, thermal and fire resistance properties compared to the polyether polyols having aliphatic structures, at the same functionalities and hydroxyl numbers.
[0062] Another preferred group of initiators for use in the synthesis of polyurethane foams suitable for producing panels is the group of aliphatic or aromatic polyamines, having 2-3 amino groups/mol (primary or secondary groups) such as: ethylenediamine (EDA), diethylenetriamine, (DETA). ortho-toluenediamine (o-TDA) and diphenylmethanediamine (MDA).
[0063] Another preferred group of initiators, which may be used in the synthesis of polyether polyols for rigid polyurethane foams, is the group of condensates of aromatic compounds (for example phenols) with aldehydes (for example formaldehyde) such as Mannich bases or novolacs. The reaction of such initiators with alkylene oxides may yield aromatic polyols which confer to the resulting rigid polyurethane foams excellent physico-mechanical, thermal, and fire proofing properties as well as dimensional stability.
[0064] Propylene oxide may be added to the initiators until the desired molecular weight is achieved. Polyols extended with propylene oxide are terminated with secondary hydroxyl groups. In order to change the compatibility, rheological properties, and reactivity of a polyol, ethylene oxide is used as a co-reactant to create random or mixed block heteropolymers. Polyols capped with ethylene oxide contain a high percentage of primary hydroxyl groups, which are more reactive than secondary hydroxyl groups. Because of their high viscosity (470 OH groups sucrose polyol, 33 Pa·s at 25° C.), carbohydrate initiated polyols often use glycerine or diethylene glycol as a co-initiate in order to lower the viscosity to ease handling and processing (490 OH groups sucrose-glycerine polyol, 5.5 Pa·s at 25° C.). Graft polyols (also called filled polyols or polymer polyols) contain finely dispersed styrene-acrylonitrile, acrylonitrile, or polyurea (PHD) polymer solids chemically grafted to a high molecular weight polyether backbone. They may be used to increase the load bearing properties of low-density high-resiliency (HR) foam, or to add toughness to microcellular foams and cast elastomers. PHD polyols may also be used to modify the combustion properties of HR flexible foam. Preferably, solids content ranges from 14% to 50% by weight, further preferably 22% to 43% by weight. Initiators such as ethylenediamine and triethanolamine are used to make low molecular weight rigid foam polyols that have built-in catalytic activity due to the presence of nitrogen atoms in the backbone. They are used to increase system reactivity and physical property build, and to reduce the friability of rigid foam moulded parts. A special class of polyether polyols, poly(tetramethylene ether) glycols are made by polymerizing tetrahydrofuran. They may be used in high performance coating and elastomer applications.
Polyester Polyols
[0065] Polyester polyols are also suitable for making rigid polyurethane panels and fall into two distinct categories according to composition and application. Conventional polyester polyols are based on virgin raw materials and may be manufactured by the direct polyesterification of highpurity diacids and glycols, such as adipic acid and 1,4-butanediol. They may be distinguished by the choice of monomers, molecular weight, and degree of branching. While polyester polyols can be costly and difficult to handle because of their high viscosity, they offer physical properties not obtainable with polyether polyols, including superior solvent, abrasion, and cut resistance. Other polyester polyols may be based on reclaimed raw materials. They may be manufactured by transesterification (glycolysis) of recycled poly(ethyleneterephthalate) (PET) or dimethylterephthalate (DMT) distillation bottoms with glycols such as diethylene glycol. These low molecular weight, aromatic polyester polyols may be used in the manufacture of rigid foam, and can bring low cost and excellent flammability characteristics to polyisocyanurate (PIR) boardstock and polyurethane spray foam insulation.
[0066] Many polyols are polydispersive materials, being blends of two or more polyols each having specific molecular weights, so as to achieve a specific property balance. It is not unusual to find blends of polyether and polyester polyols, to give specific compromises in properties.
Specialty Polyols
[0067] Specialty polyols include polycarbonate polyols, polycaprolactone polyols, polybutadiene polyols, and polysulfide polyols. The materials may be used in elastomer, sealant, and adhesive applications that require superior weatherability, and resistance to chemical and environmental attack. Natural oil polyols derived from castor oil and other vegetable oils are used to make elastomers, flexible bunstock, and flexible moulded foam. Copolymerizing chlorotrifluoroethylene or tetrafluoroethylene with vinyl ethers containing hydroxyalkyl vinyl ether produces fluorinated (FEVE) polyols. Two component fluorinated polyurethane prepared by reacting FEVE fluorinated polyols with polyisocyanate may be applied to produce ambient temperature-curing paints/coatings. Fluorinated polyurethanes have excellent resistance to UV, acids, alkali, salts, chemicals, solvents, weathering, corrosion, fungi and microbial attack. Hence, such polyurethanes are highly preferred for high performance coatings/paints.
Isocyanates
[0068] As stated above, isocyanates with at least two functional isocyanate groups are desirable for the formation of polyurethane polymers. In this regard, an isocyanate that has two isocyanate groups is known as a diisocyanate. Diisocyanates are preferably manufactured for reaction with polyols in the production of polyurethanes. Volume wise, aromatic isocyanates account for the vast majority of global diisocyanate production. Aliphatic and cycloaliphatic isocyanates are also important building blocks for polyurethane materials, but in much smaller volumes. There are a number of reasons for this. First, the aromatically linked isocyanate group is much more reactive than the aliphatic one. Second, aromatic isocyanates are more economical to use. Aliphatic isocyanates are used only if special properties are required for the final product. For example, light stable coatings and elastomers can only be obtained with aliphatic isocyanates. Even within the same class of isocyanates, there is a significant difference in reactivity of the functional groups based on steric hindrance. In the case of 2,4-toluene diisocyanate, the isocyanate group in the para position to the methyl group is much more reactive than the isocyanate group in the ortho position.
[0069] Phosgenation of corresponding amines is the main technical process for the manufacture of isocyanates. The amine raw materials are generally manufactured by the hydrogenation of corresponding nitro compounds. For example, toluenediamine (TDA) is manufactured from dinitrotoluene, which then converted to toluene diisocyanate (TDI). Diamino diphenylmethane or methylenedianiline (MDA) is manufactured from nitrobenzene via aniline, which is then converted to diphenylmethane diisocyanate (MDI).
[0070] The two most preferred commercial, aromatic isocyanates are toluene diisocyanate (TDI) and diphenylmethane diisocyanate (MDI). TDI consists of a mixture of the 2,4- and 2,6-diisocyanatotoluene isomers. TDI-80 (TD-80) consists of 80% by weight of the 2,4-isomer and 20% by weight of the 2,6-isomer. This blend may be used in the manufacture of polyurethane flexible slabstock and moulded foam. TDI, and especially crude TDI and TDI/MDI blends may be used in rigid foam applications, but can be supplanted by polymeric MDI. TDI-polyether and TDIpolyester prepolymers may be used in high performance coating and elastomer applications. Prepolymers that have been vacuum stripped of TDI monomer have greatly reduced toxicity. Diphenylmethane diisocyanate (MDI) has three isomers, 4,4′-MDI, 2,4′-MDI, and 2,2′-MDI, and is also polymerized to provide oligomers of functionality 3 and higher.
[0071] Isocyanates will readily react with hydrogen atoms that are attached to atoms more electronegative than carbon. Of the many compounds fitting this description, those of primary interest for polyurethane forming reactions are listed in the table below.
[0000]
Relative Reaction
Rate
Active
Uncatalysed at
Hydrogen Compound
Typical Structure
25° C.
Primary Aliph. Amine
R—NH 2
100,000
Secondary Aliph. Amine
R 2 —NH
20,000-50,000
Primary Aromatic Amine
Ar—NH 2
200-300
Primary Hydroxyl
R—CH 2 —OH
100
Water
H—O—H
100
Carboxylic Acid
40
Secondary Hydroxyl
30
Ureas
15
Tertiary Hydroxyl
0.5
Urethane
0.3
Amide
0.1
[0072] The amount of isocyanate required to react with the polyol and any other reactive additives is calculated in terms of stoichiometric equivalents. This theoretically stoichiometric amount of isocyanate may then be adjusted upwards or downwards, depending on the foam system and the required final properties. The amount of isocyanate used relative to the theoretical equivalent amount is known as the Isocyanate Index:
[0000]
Isocyanate
Index
=
Actual
amount
of
isocyanate
used
Theoretical
amount
of
isocyanate
required
×
100
(
2.18
)
[0073] Variation of the index in a foam has a pronounced effect on the hardness of the final foam. This increase in hardness has been shown to be directly related to increased covalent cross-linking resulting from more complete consumption of isocyanate reactive sites caused by the presence of excess isocyanate groups.
[0074] In the production of flexible slabstock foams, the isocyanate index may range from 105 to 115. Within this range, the hardness of the foam can be readily and safely controlled. In general, foam becomes harder with increasing index. There is, however, a point beyond which hardness does not increase and other physical properties may suffer.
[0075] Increasing the isocyanate index may also affects the reaction profile. The presence of more unreacted isocyanate may also increases the tack-free time and slows the rate of foam cure.
[0076] The hardness of moulded foams may also be adjusted by varying the isocyanate index. In commercial processes, foam hardness may require adjustment from mould to mould. Isocyanate indexes in the range of 85 to 110 are known. By using suitable MDI-based isocyanates, it is possible to make foam that is stiffer at the edges than at the centre by using automatic index changing of the dispensed foam as it is poured into various sections of the mould.
[0077] Isocyanates may be further modified by partially reacting them with a polyol to form a prepolymer (‘modified isocyanate’). A quasi-prepolymer is formed when the stoichiometric ratio of isocyanate to hydroxyl groups is greater than 2:1. A true prepolymer is formed when the stoichiometric ratio is equal to 2:1. Important characteristics of isocyanates are their molecular backbone, % NCO content, functionality, and viscosity.
[0078] Organic polyisocyanates containing heteroatoms such as, for example, those derived from melamine, can also be used.
Polyurethane Elastomers
[0079] Polyurethane elastomers are versatile thermoset plastics which are typically applied by spraying. Depending on the intended use, polyurethane elastomers can provide resistance to abrasion, impact and shock, temperature, cuts and tears, oil and solvents, aging, mould, mildew and fungus, and most types of chemicals.
[0080] Polyurethane elastomers may be formed by mixing a polyol and an isocyanate component. The selection of polyol, isocyanate and catalyst are made according to the properties required from the final elastomer. Consideration must be given to the conditions under which the urethane will be applied or sprayed. Additives, such as antistatic agents, colorants, and conductive fillers, may be added to the elastomer mix depending on the application.
[0081] The thickness of elastomer to be applied to a vertical or horizontal surface greatly influences the catalyst levels used. Certain catalysts, with their fast gel characteristics, are highly suitable for formulations that will be applied to vertical surfaces. This type of fast gel formulation will show little tendency to sag or run.
[0082] Conversely, if a gel time is made too fast, the possibility exists of restriction in the mixing sector of the spray gun. This is particularly true of guns employing impeller and static mixing heads. Over-catalysing will also lead to very high exothermic reaction temperatures.
[0083] Good flow-out for mirror like finishes when sprayed onto horizontal surfaces is obtained by using less active catalysts. The level must, however, not be kept too low, or the full cure may be extended beyond practical limits. If this happens, polymer growth within the elastomer becomes too slow with consequent foaming. A good balance of catalysts is therefore necessary.
[0084] The viscosity of the two components should also receive considerable attention. While a minority of the types of spray equipment are capable of mixing materials of differing viscosities, it is considered safe practice to formulate the two components to within 100 cycles per second of each other. This ensures adequate mixing in all types of equipment.
Additives
[0085] Additives may be added to the rigid polyurethane panel or the elastomeric polyurethane depending on the function required. For example, a rigid polyurethane panel can be made fire resistant by incorporating a fire retardant during the mixing of the polyol and isocyanate components. For example, flame retardant compounds which may be employed may include tri(2-chloroethyl) phosphate, tri(2-chloroisopropyl)phosphate, tri(1,3-dichloroisopropyl)phosphate, pentabromodiphenyloxide, chloronated diphosphate ester, tris(2,3-dibromopropyl)-phosphate, tetrakis(2-chloroethyl)ethylene phosphonate, pentabromodipheny oxide, tris(1,3-dichloropropyl) phosphate, molybdenum trioxide, ammonium molybdate, ammonium phosphate, tricresyl phosphate, 2,3-dibromopropanol, hexabromocyclododecane, and dibromoethyldibromocyclohexane. Such agents can also be added to the elastomeric coating.
[0086] For example, to protect against oxidation reactions, antioxidants are may be added. Various antioxidants are available such as monomeric and polymeric hindered phenols. Compounds which inhibit discoloration caused by atmospheric pollutants may also be added. These are typically materials with tertiary amine functionality that can interact with the oxides of nitrogen in air pollution. Anti-mildew additives can also be added.
[0087] A distinction can be made between chemical and physical blowing agents. The chemical blowing agents include water, whose reaction with the isocyanate groups leads to the formation of CO 2 . The density of the foam is controlled by the amount of water added, with preferably used amounts being from 1.5 to 5.0 parts, based on 100.0 parts of polyol. In addition physical blowing agents, (e.g. chlorofluorohydrocarbons, methylene chloride, acetone, 1,1,1-trichloroethane, etc.) can also be used. Optionally, organic blowing agents may be used in conjunction with water although the use of such blowing agents is generally being curtailed for environmental considerations. The preferred blowing agent for use in the production of the present foamed isocyanate-based polymer comprises water.
[0088] Several different pigments can be used, preferably in the elastomeric compositions. Inorganic pigments which are useful include titanium dioxide, silica, iron oxides, talc, mica, clay, zinc oxide, strontium chromate, zinc chromate, carbon black, lead chromate, molybdate orange, calcium carbonate, and barium sulfate. Organic pigments can also be used.
[0089] In summary, additives for rigid polyurethanes or elastomers preferably include those selected from a group consisting of catalysts, blowing agents, surfactants, flame retardants, stabilizer, anti-discolouration compounds and pigments.
Thermoforming
[0090] The thermoforming of the polyurethane panels, particularly rigid panels, can be accomplished in various ways. Polyurethane panels may be heated to a deformation temperature of between about 100° C. to about 300° C. Preferably, the panel may be heated to a deformation temperature of between about 150° C. to about 200° C. The choice of deformation temperature will be dependent on the thickness and composition of the panels.
[0091] Thermoforming may be performed with the aid of infrared radiators, hot air ovens, contact hot plates or other heating means. Thermoforming may also be performed under vacuum. Heated polyurethane panels can be placed in a forming tool or mould which is maintained between about 20° C. to about 100° C., preferably between about 25° C. to about 75° C., and formed therein with or without the application of pressure. Preferably, pressure is applied to the mould to obtain the shape of the desired article. Alternatively, heated panels may be bent manually with the aid of a heat source, such as a heat gun or heat lamps, and without the use of a mould. In either case, the moulded panel is held in position until the panel cools. Importantly, bending a polyurethane panel without first heating the panel to an appropriate deformation temperature can result in fracturing or breakage.
[0092] Moulds may be made of economical materials such as wood, thermosetting plastics, gypsum or ceramics.
Coated Polyurethane Panels According to the Invention
[0093] A polyurethane panel that is suitable to construct the coated panel of the invention can be manufactured by preparing a homogenous mixture of the polyol and isocyanate components and dispensing the mixture into a mould. The mould can be of any shape, but is preferably rectangular. The method for forming the panel according to this example is as generally described in Australian Patent Application No. 2003200383. Briefly, the mould containing the mixture is closed by a lid. The mould is then conveyed to press table so that the mould is pressed closed until the mixture cures. Once cured, the mould is opened and the panel is removed. The moulded panel can then be processed in a similar manner to conventional wooden or fibre based panels by, for example, painting, veneering or laminating the panel and cutting the panel to size.
[0094] A preferred polyurethane panel that is used for the present invention includes the following components:
Polyether Polyol: up to about 50%, preferably about 20 to 40%, further preferably about 30 to 40% Diphenylmethane Diisocyanate: up to about 70%, preferably about 30 to 60%, further preferably about 50 to 60%
[0097] The panel may also include the following optional components:
Blowing Agent: up to about 10%, preferably about 2 to 8%, further preferably about 3 to 4% Fire Retardant: up to about 10%, preferably about 2 to 8%, further preferably about 3 to 4%.
[0100] A panel according to this example is manufactured as a high-density rigid polyurethane foam panel having the product name ‘Aptane™ P258/B900 Multipanel’ by Ariel Industries Pty. Ltd, 26 Kembla Street, Victoria 3192 Australia. The panel has a flexural modulus at 100 mm of about 120330 kPa, and at 50 mm of about 64035 kPa (ASTM D790).
[0101] A polyurethane elastomer that is suitable to coat polyurethane panels, particularly the above preferred panel, is comprised of the following components:
[0102] Component A
[0000]
polyethylene/polypropylene
up to about 80%, preferably
glycol glyceryl ether
greater than 60%
diethylene glycol
up to about 20%, preferably
about 14%
diethyltoluenediamine
up to about 5%, preferably less
than 3%
[0103] Component B
[0000]
4,4′-diphenylmethane
up to about 80%, preferably 50
diisocyanate (MDI)
to 60%
modified MDI
up to about 60%, preferably 20
to 40%
diisooctyl phthalate
up to about 30%, preferably 5
to 20%.
[0104] A polyurethane elastomer according to this example is manufactured by Rhino Linings Australasia Pty Ltd, 501-505 Olsen Avenue, Molendinar, Queensland 4214, Australia under the product name ‘Tuff Stuff™’ ‘Rhino Lining™’ trade marks.
[0105] Preferably, the Tuff Stuff™ elastomer is applied by spraying using a spray gun with a static mixing nozzle at a ratio of A:B of between about 1:1 to about 1:2, further preferably 1:1.5 to 1:1.9. Panels may be sprayed vertically or horizontally. An illustration of a transverse crossection of a coated panel according to the invention is shown in FIG. 1 . The figure shows a coated panel ( 1 ) which comprises a polyurethane panel ( 2 ) coated with a polyurethane elastomer ( 3 ).
[0106] The coated panel according to the invention has improved characteristics which can be selected from, but not limited to, flexibility, compressibility, shear strength, tensile strength, fire resistance, flammability, moisture resistance, mould resistance, water resistance, insect/parasite resistance, blast mitigation and/or acoustic properties. This enables use of the coated panel in building and construction, as well as other sectors, such as the military.
[0107] Further examples of the invention are described below. However, it should be noted that the invention should not be limited to these examples, and that the invention 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 scope of the claims.
Example 1
[0108] In one exemplary embodiment, FIG. 2 shows a water feature ( 10 ) made from an embodiment of the coated polyurethane panel according to the invention. Preferably, the water feature ( 10 ) according to this embodiment is first cut from Aptane™ P258/B900 Multipanel. Structures requiring curves ( 11 ) are deformed into shape using heat. The water feature ( 10 ) is then assembled by fixing flat structures ( 12 ) and curved structures ( 11 ) together using appropriate adhesives and fixings. The assembled water feature is then sprayed with Tuff Stuff™ polyurethane elastomer and the coating allowed to set.
[0109] Alternatively, the water feature ( 10 ) according to this embodiment may be cut from Aptane™ P258/B900 Multipanel, where structures requiring curves ( 11 ) are deformed into shape using heat. The separate pieces ( 11 and 12 ) are then sprayed with Tuff Stuff™ polyurethane elastomer, and the coating allowed to set. The water feature ( 10 ) can be shipped flat-packed which reduces transportation costs. It may be assembled onsite using appropriate fixings and adhesives, preferably water resistant or water proof adhesives.
[0110] The water feature ( 10 ) shown in FIG. 2 is 700 mm×600 mm×1300 mm and fabricated from 16 mm MultiPanel coated with at least a 1 mm thick layer of Tuff Stuff™ polyurethane elastomer. The water feature can be painted using an appropriate paint, preferably weather resistant paint, to achieve different colour finishes. Alternatively, the Tuff Stuff™ polyurethane elastomer may be pigmented to achieve different colour finishes.
Example 2
[0111] In another exemplary embodiment, FIGS. 3 and 4 show a planter boxes ( 20 and 30 , respectively) made from an embodiment of the coated polyurethane panel according to the invention.
[0112] Similarly to Example 1, pieces which form the planter box ( 20 or 30 ) are cut from a sheet of Aptane™ P258/B900 Multipanel, preferably 25 mm thick. Walls of the planter boxes ( 21 and 31 , respectively) are assembled using appropriate fixings and adhesives. According to the embodiments shown, the planter boxes may include a top edge ( 22 and 32 , respectively) made from 100 mm×500×5 mm thick Aluminium Angle which is mitred and welded. The Aluminium Angle adds strength to the top edge as well as providing an aesthetically pleasing finish. The boxes are then sprayed with at least a 1 mm thick layer of Tuff Stuff™ polyurethane elastomer.
[0113] Assembly of the planter boxes ( 20 or 30 ) can occur onsite using coated polyurethane panel pieces shipped flat-packed and appropriate adhesives and fixings as described in Example 1, with or without the added Aluminium Angle ( 22 or 32 ). The boxes ( 20 or 30 ) may be painted or the Tuff Stuff™ polyurethane elastomer may be pigmented to achieve different colour finishes as described above.
[0114] Large planter boxes ( 30 ) may include further support features to provide added strength. For example, as show in FIG. 3 , the large planter box includes 3× load bearing battens ( 33 ) secured equally spaced across width of planter box, and 2× gussets per corner ( 34 ) to provided added strength.
Example 3
[0115] In yet a further exemplary embodiment, FIGS. 5 and 6 show housing made from an embodiment of the coated polyurethane panel according to the invention. The unit ( 50 ) (or ‘Pod’) shown can be used to construct modular (‘Podula’) housing in which several Pods are attached together. Such housing can be either temporary or permanent.
[0116] The embodiment of the Pod ( 50 ) shown includes the following components:
An Aptane™ P258/B900 Multipanel of 1200 mm×2400 mm used as the floor ( 51 ). 1200 mm×2400 mm Aptane™ P258/B900 Multipanels used to form the walls ( 52 , 55 and 56 ). The tip of the arc ( 53 ) is 2400 mm high, and 6 m in length. Door frame and supports ( 54 ) are fabricated from stainless steel. Support angle to base ( 57 ) is fabricated from 50 mm×50 mm×1 mm galvanised steel.
[0121] The back ( 55 ) and front ( 56 ) walls are preferably fabricated 25 mm thick panels, whereas the floor ( 51 ) and side walls ( 52 ) are preferably fabricated from 16 mm thick panels. The panels may be coated prior to assembly with a layer of Tuff Stuff™ polyurethane elastomer of about 1 mm to 3 mm thick, preferably about 1.5 to 2 mm thick. Advantageously, the Pod housing may be shipped flat-packed and subsequently assembled onsite using appropriate adhesives and fixings. Alternatively, the Pod housing may be shipped prefabricated.
[0122] Basic Pod features include:
Floor Walls/Ceiling (1 arc) Door Window in door Vent Shelf Ground fixings Instructions
[0131] Range variants include:
Quantity Room Type Room Accessories—fixable to certain room types Colours—external and internal Flooring—rubber flooring for comfort Walls—add in and/or removable Doors—can be inserted/added to any panel Windows—1× standard size with vent option Solar Panels for electricity generation Rainwater catchment system—guttering to be approx ⅔rds way up unit on exterior, rain water storage unit to sit outside or possibly form the base of the unit. Septic holding tank system
Example 4
[0143] Preliminary testing for the coated panels was performed using a Hydraulic Bearing Press fitted with a 50 mm diameter press tool. Uncoated Aptane™ P258/B900 Multipanel was compared with panel coated with about 1 mm Tuff Stuff™ polyurethane elastomer. All panels were of the same size of 550 mm×385 mm and supported by support battens 90 mm thick placed 250 mm apart. Panels were bent until broken, or until signs of fatigue showed. The maximum deflection achieved was 150 mm.
[0000]
Panel
Lining
Deflec-
% Im-
Thickness
Thickness
tion
prove-
(mm)
(mm)
(mm)
Comments
ment
8
—
95
clean break to centre
—
8
1
150
unbroken with signs of fatigue
63.3
12
—
70
clean break to centre
—
12
1
150
unbroken with signs of fatigue
46.7
16
—
60
clean break to centre
—
16
1
150
unbroken with signs of fatigue
40.0
18
—
65
clean break to centre
—
18
1
120
unbroken with signs of fatigue
54.1
25
—
45
clean break to centre
—
25
1
70
clean break on underside
64.3
external to press, internal
side intact
30
—
30
broken in 3 pieces
—
30
1
50
clean break on underside
60.0
external to press, internal
side intact
[0144] Signs of fatigue included the formation of pressure lines under the surface of the Tuff Stuff™ polyurethane elastomer layer.
[0145] As shown, Aptane™ P258/B900 Multipanel coated with Tuff Stuff™ polyurethane elastomer has improved flexibility characteristics when compared to uncoated panels.
Example 5
[0146] Preliminary compression testing was performed using a Hydraulic Bearing Press fitted with a 50 mm diameter press tool. Uncoated Aptane™ P258/B900 Multipanel was compared with panel coated with about 1 mm Tuff Stuff™ polyurethane elastomer. Panels of the same size used in Example 4 were supported with 90 mm support blocks which were positioned directly under the press tool.
[0147] The press tool formed a crater 15 mm deep in uncoated panel when pressed with 3 tonnes of pressure. Conversely, the press tool formed a crater 11 mm deep in coated panel when pressed with the same 3 tonne weight. Both uncoated and coated panels showed surface penetration.
[0148] The above results show that Aptane™ P258/B900 Multipanel coated with Tuff Stuff™ polyurethane elastomer has improved compressibility characteristics when compared to uncoated panels. | Building panels are ubiquitous in the building industry and are used to form walls, doors or other partitions, either of a structural or non-structural nature. Polyurethane can be formed into a panel which is rigid and can function in the same manner as conventional panels formed from wood and other material. The panel is able to be cut, screwed, drilled, painted, laminated or veneered. While laminating or veneering polyurethane panels with, for example, melamine or plywood, improves strength and rigidity, this is at a cost to flexibility and, consequently, the applicability of panels. The invention defined herein therefore relates to an improved polyurethane panel which overcomes the disadvantages of those which have gone before. The panel of the invention finds particular use, although not exclusive use, in building and construction. | 2 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to material atomizers, specifically to improved spray head for dispensing coating materials used in electrostatic painting.
2. Description of Prior Art
Prior art rotating heads for atomizing and dispensing paint in the electrostatic power painting industry have relied on a variety of head and nozzle configurations. See for example U.S. Pat. Nos. 5,326,598, 5,353,995, 5,368,237, 5,632,448, 5,865,380 and 5,922,131.
U.S. Pat. No. 5,326,598 is directed to an electro-spray coating apparatus and process utilizing precise control of filament and misgeneration. The device applies voltage to the liquid forced to have a single continuous and substantially continuous radius or curvature around a shaping structure so as to produce a series of filaments which are spatially and temporarily fixed. The number of filaments being defined can be varied by adjustment of applied voltage with the filaments breaking into uniform mists of charged droplets and are driven towards the substrate by electric fields to produce a coating.
U.S. Pat. No. 5,353,995 claims a rotary ionizing head for electrostatic application of air powder mixtures on objects fused by heat. An ionizer head is rotated by a turbine having a deflector incorporated constituting a charging electrode.
U.S. Pat. No. 5,368,237 illustrates an improved spray nozzle for powder coating guns which has dual intersecting slot configurations so as under rotation to change the effective width of the coating being applied therethrough.
U.S. Pat. No. 5,632,448 shows a rotating power applicator for atomizing and dispensing powder utilizing a fluidized powered bed to entrain the powder fluidized in a bearing airstream and dispense same having a somewhat bell shaped interior.
U.S. Pat. No. 5,865,380 for a rotary atomizing electrostatic coating device having a plurality of discharge electrodes defining a band form pattern which extends outwardly along the rear side of the spray head's main body. A plurality of discharge electrodes rotate together with the spray head in the main body and charge current in the front side direction of the axis of rotation of the spray head is made uniform and increased by enhancing the painting efficiency.
Finally, in U.S. Pat. No. 5,922,131 an electrostatic power spray coating apparatus is disclosed with a rotary spray orifice of a slot configuration to impart a flat shape to an atomized material to be dispensed therethrough.
SUMMARY OF THE INVENTION
An improved rotary spray head to apply atomized fluid coating material in an electrostatic application process. The spray head has a plurality of annularly spaced dispensing openings of elongated equilateral longitudinal dimension, each defining an independent spray pattern in overlapping relation to one another imparted onto a dispersion disk surface with an improved material flow impingement area therewithin.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section on lines 1 - 1 of FIG. 5 .
FIG. 2 is a side elevational exploded assembly view of the spray head of the invention.
FIG. 3 is a bottom plan view of the assembly.
FIG. 4 is a top plan view of the assembly with portions broken away and material spray patterns depicted graphically thereon.
FIG. 5 is an enlarged top plan view with portions broken away of the spray head aperture dispensing configurations.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2 of the drawings, a rotary spray head assembly 10 can be seen used for the application of material coating fluids in an electrostatic painting system. The spray head assembly 10 has a main support drive and distribution body member 11 with a bowl shaped deflector top surface 12 terminating at a sharp tapered edge 13 thereabout. The body member 11 has a central annular receiving opening at 14 therein with an annular recess cap flange 15 formed in its oppositely disposed surface with a plurality of threaded bores 16 positioned therewithin define mounting surface 17 thereabout to receive corresponding threaded fasteners F as will be described in greater detail hereinafter.
An annular material dispersing head 18 , also seen in FIG. 4 of the drawings, has an apertured conical center portion 19 with an extending mounting hub portion 20 aligned therewith. A tapered depending annular flange wall 21 extends inwardly from a contoured perimeter edge 22 , best seen in FIG. 1 of the drawings.
The hub portion 20 defines a center mount shaft receiving opening 23 therewithin having a tapered interior surface at 23 A. The receiving opening 21 is in axial alignment with the aperture at 19 A in the conical center portion 19 which is of a proportionally increased diameter and is internally threaded at 19 B as will be well understood by those skilled in the art.
A plurality of radially spaced elongated material ejection dispersal openings 24 are formed within the depending annular flange wall 21 . Each of the ejection dispersal openings 24 , as best seen in FIGS. 4 and 5 of the drawings, is of an elongated slot-like configuration with oppositely opposing angularly disposed sidewalls 24 A and 24 B. The angular inclination of the respective sidewalls 24 A and 24 B indicated by the broken extension lines 25 in FIG. 6 of the drawings provide in combination with the proportional length to the height ratio of approximately two and a half to one are critical to the dispersion pattern DP imparted during operation in which the spray head is spun at relatively high revolutions per minute to afford the significant centrifugal force required to propel the material out through the respective ejection dispersal openings 24 as graphically illustrated in FIGS. 4 and 5 of the drawings. The material dispersal head 18 can be seen as assembled within the annular opening 14 of the body member 11 with a portion cut-away illustrated therefore graphically the radial pattern of the static dispersal spray pattern at DP shown in broken lines radiating outward from each of the spaced adjacent ejection dispersal openings 24 .
FIG. 6 of the drawings is an enlarged portion of the spray head 18 broken away to illustrate the angular orientation of the walls 24 A and 24 B, of each apertured spray opening 24 and their respective contoured end wall curvilinear surfaces also seen in FIGS. 1 and 2 of the drawings.
The deflector top surface 12 has an annular groove 26 therewithin, spaced approximately one-quarter the distance inwardly of the surface 12 at from the tapered edge 13 . The groove 26 is positioned so as to blend the respective multiple cross spray patterns DP of material as they emanate outwardly across the top surface 12 as hereinbefore described. Once the ejected material impinges the groove 26 , a continuous even sheeting action is achieved on the remainder of the surface 12 thereafter and is then released from the tapered edge 13 of the surface disk by a “sheer treatment” at 27 consisting of an annularly ribbed surface well known and used within the art.
It will be evident that given the rotation of the spray head assembly 10 , the actual material pattern DP as depicted are implicitly curved during operation as they are produced (not shown).
Referring back to FIGS. 1 and 2 of the drawings, an assembly disk cap 28 can be seen having a central opening at 28 A with a collar flange 28 B thereabout. A corresponding annularly recessed area 29 extends therefrom as best seen in FIG. 4 of the drawings. A continuous gasket receiving channel 30 is formed inwardly from the perimeter edge thereof defining a mounting surface engagement at 31 with a plurality of annularly spaced fastener receiving apertures 32 therewithin that align with the hereinafter described threaded bores 16 .
As to the assembly of the spray head 10 as illustrated in exploded assembly view in FIG. 2 of the drawings, the dispersal head 18 as hereinbefore described is thermally press fitted within the body member 11 's receiving opening so that the corresponding ejection dispersal openings 24 are exposed against the top deflector surface 12 . The assembled cap disk 28 is fitted within the mounting cap recess against the cap mounting surface 31 as hereinbefore described. The assembled cap disk 28 so fitted defines a material receiving chamber 32 about the corresponding hub into which coating material M is supplied during functional rotation of the spray head assembly 10 and is forced out through the ejection dispersal openings 24 by centrifugal force, as noted.
It will be seen that applicant's rotary spray head assembly 10 where the application of material coating fluid in an electrostatic painting system provides the unique combination of enhanced material dispersal patterns DP which provide selective interference therebetween onto the dispersal disk surface 12 having the unique impingement groove 26 therein so as to provide a homogenous sheeting pattern of coating material enhancing the effectiveness thereof and imparting additional benefit by reduced product material M usage afforded by improved product material cleaning proficiency within the head.
It will thus be seen that a unique and novel rotary spray head assembly has been illustrated and described and it will be evident to those skilled in the art that various changes and modifications may be made thereto without departing from the spirit of the invention. | A rotary spray head for atomizing and dispersing fluidized coating material within a bearing stream. The rotary spray head has a plurality of elongated contoured material dispersing portals positioned to define multiple overlapping product stream flow across a diffuser surface imparting translateral product stream homogenation and adaptive proportional edge shear for an improved coating dispersal pattern. | 1 |
BACKGROUND OF THE INVENTION
Field of the Invention
Fireproofing.
Description of the Prior Art
The prior art teaches a number of phosphorus-nitrogen compounds as flame retardants for various textile materials. Many of these known flame retardants are also treated with formaldehyde or trimethylolamine and a catalyst to give permanence to the bond of the phosphorus-nitrogen compound to the textile material against removal by washing; otherwise, much of the flame retardant property is lost as the material is periodically cleaned by detergent washing. The phosphorus-nitrogen compound of this invention apparently does not require this formaldehyde or the like treatment to be resistant to removal from the textile by detergent washing.
One of the older patents in this art is U.S. Pat. No. 2,782,133 teaching aminocyclophosphazene as a fireproofing agent for cellulosic fibers such as cotton. A recent patent is U.S. Pat. No. 3,711,542 teaching certain new N-methylol phosphazene compounds as flame retardants on cotton, and this patent under Background of the Invention contains a summary of certain phosphazene prior art on flameproofing.
SUMMARY OF THE INVENTION
The new product a Cl 3 P=N--N=PCl 3 +NH 3 reaction product has been found to be an excellent flame-retardant for material made from cellulose, such as cotton, paper and sponge; polyester, wool and blends thereof. Conveniently the material can be treated with an aqueous solution containing a sufficient amount of the product and the material dried to make the material self extinguishing. Then the treated and dried material is cured at a sufficient temperature to bond the product to the material. Alternatively and usually preferably, the drying and curing can be accomplished as a single operation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preparation of Cl 3 P=N--N=PCl 3 +NH 3 reaction product
This product shows excellent promise as a durable fire retardant for cotton, 65/35 polyester-cotton, 100% polyester and wool. It undergoes laundering successfully whether formulated with formaldehyde or aminoplasts or used alone; however, conventional formulation agents such as these may extend the number of times that the material can be laundered and still retain sufficient fire retardant properties.
The trichlorophosphazene precursor for this material is known and has been well characterized (M. Becke-Goehring, and W. Weber, Z. Anorg. Allgem. Chemie, 333, 128 (1964). The aminated product is unknown and is a new product. The product obtained in its crude state contained 24% phosphorus. The theoretical value is 33% if the reaction proceeds as follows.
H.sub.2 N-NH.sub.2.HCl + 2PCl.sub.5 → Cl.sub.3 P=N--N=PCl.sub.3 .sup.HN.sbsp.3 (H.sub.2 N).sub.3 P=N--N=P(NH.sub.2).sub.3
a chlorine residue which seems to persist indicates the probability of this material being a salt, probably a hydrochloride salt.
This white powder is very soluble in water and appears to form a complex with silver nitrate. Its aqueous solution is slightly alkaline. The only other solvent found to date is ethylene glycol. The material does not melt up to 350°C. but some change occurs, since a crystalline substance was noticed on the walls of the melting point tube above the bath level.
A slurry of 34.3 g (0.5 m) of hydrazine monohydrochloride and 208.5 g (1.0 m) of PCl 5 in 500 ml of benzene was stirred and heated at reflux for 17 hours. After the first half hour of reflux, most of the solids had dissolved, and the surface of the yellow solution was covered with small bubbles like a foam. Hydrogen chloride gas was detected at the end of the drying tube atop the condenser. The reaction mixture was cooled, and the dissolved hydrogen chloride and most of the solvent were removed under vacuum leaving a white solid which is Cl 3 P=N--N=PCl 3 .
The solid was slurried with 500 ml of chloroform, and 1200 ml of liquid ammonia was added cautiously with stirring. The ammonia was contained by a Dry Ice condenser for at least 6 hours; then, it was allowed to evaporate overnight. The resultant white solid was allowed to settle. A portion of the supernatant liquid left no residue upon evaporation indicating the insolubility of the product in chloroform.
Two hundred and nineteen grams (3 m) of diethylamine was added to the slurry which was heated to reflux and kept there for 23 hours for the purpose of converting the by-product ammonium chloride to soluble diethylamine hydrochloride and ammonia. The resulting slurry was filtered, and the white filter cake was washed with 750 ml of chloroform in 250 ml portions. Air drying followed by vacuum drying at room temperature yielded 121.1 g of product. The infrared spectrum of this material showed strong --NH absorption, a strong band at 8.1μ and a weaker but broader band at 10.7μ. An aqueous solution of the product was weakly alkaline. The material was insoluble in chloroform, acetone and cold methanol.
______________________________________ % Found______________________________________ H -- N 37.80 P 24.42 Cl 13.73______________________________________
A thermogravimetric analysis revealed that nearly 41% of the material was lost between 25° and 300°C., but from 300°-715°C. only 3% additional weight loss occurred in helium. In air, the weight loss was similar, but from 650°-900°C. another 14% was lost.
Treatment of Fabrics
A solution containing the desired weight percent of the product in sufficient water to just saturate the cloth was poured on a weighed piece of cloth lying flat in a plastic bag. The solution was worked over the surface of the cloth, until it was uniformly wet. After standing for about fifteen minutes, the cloth was placed in an oven at the desired temperature and cured. After curing and drying, the cloth was allowed to equilibrate before being weighed.
Cure Conditions
Cure was effected at 140°C. using the one operation to also dry the wet sample. Formaldehyde and magnesium chloride catalyst were included in the treatment in some instances to see if this supplemental treatment made the material more durable to washing.
Flammability Tests
Samples of cloth 10 in. × 31/2 in. were clamped in a metal stand and tested according to AATCC Test Method 34-1969 using a propane torch in place of the special gas mixture. This flammability test is described in J. Amer. Assoc. Text. Chem. and Colorists 2 (3), 49/19 (1970).
Tabulation of Data
The test data are tabulated in the following table. The table is divided into three main sections: Fabric Treatment, Flammability Tests and Miscellaneous Conditions. The following column headings are used. The added notes are for explanation of their meanings where not self explanatory.
______________________________________Column Heading Explanation______________________________________1 Cloth Type2 Reagent *Cl.sub.3 P=N-N=PCl.sub.3 +NH.sub.3 product3 Auxiliary material used to bind to cloth such as formaldehyde and catalyst; TMM = trimethylolmelamine and catalyst4 % Final Add-On weight percent of product added to the cloth after all processes including laundering if indicated in column 95 Distance this represents the length of Burned, in. the sample that was burned out, charred or scorched from the ignited edge6 Time, Sec time from ignition to removal of flame even though self extinguishment had already occurred7 Self answers question -- Did the fire Extinguish self extinguish before burning (SE) the entire sample length Y = yes; N = no8 Cure temperature at which the wet Temperature cloth was dried and cured in a single operation9 Post Treatment indicates treatment of sample after curing but before flammability test L = laundered, detergent wash & dried NL = not laundered______________________________________
MiscellaneousFabric Treatment Flammability Test Conditions % Distance Cure Final Burned, Time Temp PostCloth Type Reagent Auxiliary Add-On in. Sec SE °C Treatment__________________________________________________________________________65/35 * -- 19.0 5 5-30 Y 140 NLpolyester/cotton65/35 * -- 12.15 5 5--30 Y 140 Lpolyester/cotton * -- 13.2 4 5-30 Y 140 NLcotton * -- 5.0 4 5-30 Y 140 Lcotton * CH.sub.2 O, MgCl.sub.2 5.4 10 10 N 140 Lcotton65/35 * CH.sub.2 O, MgCl.sub.2 6.67 6 6-30 Y 140 Lpolyester/cotton100 polyester.sup.1 * -- 27.9 Y 140 NL100 polyester.sup.2 * -- 11.1 Y 140 L100 polyester.sup.2 * CH.sub.2 O, MgCl.sub.2 35.0 melts Y 140 NL100 polyester.sup.2 * CH.sub.2 O, MgCl.sub.2 8.1 melts Y 140 Lcotton * CH.sub.2 Cl.sub.2 10.6 5 30 Y 140 Lcellulose sponge.sup.3 * CH.sub.2 O, MgCl.sub.2 19.5 Y 140 Lwool * -- 3 45 Y 140 L100 polyester.sup.4 * -- 18.0 3 Y 140 NL100 polyester.sup.5 * -- 4.7 N 140 Lcotton.sup.6 * -- 5.8 31/2 30 Y 140 Lcotton.sup.6 * -- 5.8 23/8 30 Y 140 L__________________________________________________________________________*Cl.sub.3 P=N-N=PCl.sub.3 +NH.sub.3 product .sup.1 Melts and shrinks in flame, does not burst into flameSE = Self Extinguishing .sup.2 No flaming when removed from burnerY = Yes .sup.3 Charred and smoked but failed to ignite, some intumescenceNL = Not Laundered .sup.4 Melted, but no drippingN = No .sup.5 Burned with tendency to extinguishL = Laundered .sup.6 Same sample on different end__________________________________________________________________________
Although the invention has been described in terms of specified embodiments which are set forth in considerable detail, it should be understood that this is by way of illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. It is obvious from the data in the table that since the flame-retardant is operable on cotton, polyester and 65/35 polyester cotton, that the flame-retardant will also be operable on 50/50 polyester/cotton, 30 to 70% by weight cotton in a cotton/polyester blend and, in fact, for any blend of cotton and polyester. For example, effectiveness has been shown on cellulose sponge and it would be expected that other types of cellulose such as cellulosic paper would be protected. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | The new product, a Cl 3 P=N--N=PCl 3 + NH 3 reaction product, has been found to be an excellent flameretardant for material made from cellulose such as cotton, paper and sponge; polyester, wool and blends thereof. Conveniently the material can be treated with an aqueous solution containing a sufficient amount of the product and the material dried to make the material self-extinguishing. Then the treated and dried material is cured at a sufficient temperature to bond the product to the material. Alternatively, and usually preferably, the drying and curing can be accomplished as a single operation. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit and priority of European Patent Application Serial No. 1000063.5, filed on Jan. 11, 2010, which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention refers to a method and a system of power management for electronic devices, to extend battery life. The invention also relates to the field of telecommunications, and more specifically, to the field of power control in wireless communicating equipments in which low power constraints are required.
BACKGROUND
[0003] Conventional wireless communicating equipments are powered by rechargeable batteries or primary batteries. The operational life of wireless equipment between battery charges is directly dependent on the charge life battery. In addition, the charge life battery is related to battery size, which is a major factor in determining the equipment's physical and operational characteristics, i.e. size, weight, and operational life span.
[0004] Today, wireless equipments are currently used in some industrial or mass deployment applications, for commercial, maintenance or logistic reasons. In these circumstances, but not exclusively, a recurrent problem is usually encountered by the wireless equipments industry to search for ways to extend the battery life before recharging is required, and consequently lower the power consumption of the wireless equipment.
[0005] In many communication systems, the wireless communication equipment, such as a cellular phone, PDA (personal digital assistant), etc. . . . , are only randomly active. Indeed, this kind of equipment remains idle for significant periods of time when no call is in progress. And during such idle periods the equipment consumes substantially the same amount of power as during active periods. However to ensure that the transceiver of this equipment receives randomly transmitted messages, it must continuously monitor a channel of communication. The equipment may consume significant of power by continuously monitoring the channel for incoming messages. The resulting power drain on the battery reduces the time available for actively handling calls.
[0006] In order to overcome these problems, a system is known in the prior art and relates in the document US 2004/0029620 permitting to save power in a radio receiver. In this system, a control module of a radio equipment like for example a radio receiver or a radio transceiver evaluates whether an element of this radio receiver may be powered down, or when it should be brought back up. This control module comprises means to determine a power cycle time in order to power back or power down at least one element of the radio transceiver. Thus, this control element serves to intelligently manage power consumption on an element-by-element basis.
[0007] However, such a kind of system has some limitations because it does not comprise set up possibilities, and feedback information concerning the communication reliability. These problems and deficiencies are clearly felt in the art and are solved by the present invention in the manner described below.
SUMMARY
[0008] The present invention aims at solving this problem related to the maximization of battery life base on a method which improves power management functionality of a wireless equipment based on an integration in an RF transceiver silicon of a state machine automat which is managing the timing for supplying of the different blocks, associated with a computer processing in order to adjust the timing sequence, regarding the RF characteristics.
[0009] More specifically, the subject-matter of the invention relates to a method of power management of an electronic device comprising the steps of:
[0010] sending periodically at least one signal by the microcontroller to a radio equipment in order to control an incoming radio frequency transmission after an inactivity time of the radio equipment,
[0011] returning in standby mode of the microcontroller,
[0012] initiating by the radio equipment of a power up sequence,
[0013] powering up one by one the different functional blocks of the radio equipment, and
[0014] executing a measurement of a received power of the incoming radio frequency transmission once a RSSI detection functional block is powered,
[0015] determining an appropriate mode, between a stand-by mode and an active mode, relative to power consumption to apply to all the functional blocks of the radio equipment and the microcontroller comparing said measurement to a reference threshold.
[0000] An advantage of the invention is to power up all the functional blocks once by once progressively, in function of the use, instead of starting them at the same time in order to reduce the power consumption, because each of these blocks has different setup times and does not need to be powered on at the same time.
[0016] According to particular embodiments:
[0017] the step of determining the appropriate mode comprises a step of changing the microcontroller mode to the active mode if the measurement is greater than the reference threshold;
[0018] the step of determining the appropriate mode comprises a step of changing the mode of all the functional blocks of the radio equipment to the standby mode if the measurement is smaller than the reference threshold;
[0019] the microcontroller returns to the active mode when it receives a signal from the RSSI detection block;
[0020] the measurement is greater than the reference threshold when an incoming radio frequency is detected;
[0021] the different functional blocks are powered up in the order as following:
a oscillator block, a bias block, a synthesizer block, a receiver chain, and the RSSI detection block;
[0027] the step of initiating comprises the steps of:
starting an oscillation circuit internal to the radio equipment, and creating the oscillation circuit initialisation on an external quartz crystal component in order to generate a clock frequency.
[0030] The invention is also referred to a power management device in a apparatus comprising process means which contains processing algorithms and a radio equipment, the said radio equipment comprising an integrated circuit operating in different frequency range and different functional blocks having the possibility to be powered up separately, and wherein the radio equipment is associated and driven by the microcontroller in order to determine a state mode of power consumption according to the method.
[0031] According to particular embodiments:
[0032] one of the different functional blocks corresponds to an oscillator;
[0033] one of the different functional blocks corresponds to a bias;
[0034] one of the different functional blocks corresponds to a synthesizer;
[0035] the radio equipment is a radio receiver or a radio transceiver;
[0036] the process means are a microcontroller, and
[0037] the process means are a digital block.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:
[0039] FIG. 1 , is illustrating a communication system according to one embodiment of the invention;
[0040] FIG. 2 , is a schematic bloc diagram of a power management system in accordance with the present invention;
[0041] FIG. 3 , is a flow chart illustrating the automatic power up sequences of the state machine automat according to one embodiment of the invention;
[0042] FIG. 4 , is a flow chart illustrating the mechanism of the microcontroller; and
[0043] FIG. 5 , is illustrating one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, preferred embodiments of the invention are described. FIG. 1 illustrating an example of wireless communication equipment 1 in which the invention may be implemented. This wireless communication equipment 1 is a part of a communication system that includes another wireless communication equipments and base stations 2 or access points. This wireless communication equipment 1 may be a cellular telephone, personal computers, hand held or laptop devices.
[0045] Each base stations 2 or access points have a wireless connection or transceiver (e.g., an antenna) and may operate according to various wireless standards to communicate with the wireless communication equipment 1 . The wireless communication equipment comprises notably processing means 3 , a system power management 4 and a battery 5 . The system power management 4 is illustrated in the FIG. 2 . This system power management comprises two main components:
[0046] a radio equipment like for example a radio transceiver or a radio receiver 21 (or radio-frequency Application-Specific Integrated Circuit, ASIC), and
[0047] a microcontroller 20 .
[0048] In manner non-restrictive, in this embodiment, we consider that the radio equipment is radio transceiver. The radio-frequency ASIC consists of two main parts: an analog part 45 and a digital part 14 .
[0049] The analog part 45 comprises:
[0050] a receiver front end block 9 comprises a LNA (low noise amplifier) which allows the first amplification of the received signal and limit the noise adding by the receiver, and a mixer which allows the down conversion to an intermediary frequency of few hundred of khz (kilohertz);
[0051] an oscillator block 8 which allows the generation of a reference frequency for the RF frequency synthesis and for the clock used by the digital part. The oscillator bloc is the active part of the oscillator. The passive part is the Crystal (block 7 );
[0052] a transmitter PA block 12 which allows the amplification of the transmitted signal;
[0053] a synthesiser PLL block 11 which allows the synthesis of the frequency used by the receiver and the transmitter. The PLL bloc is the main part of the PLL. The external loop filter (block 17 ) is also a part of the PLL;
[0054] a bias block 13 which allows the generation of the bias current (reference) for the Asic;
[0055] a sigma delta block 10 is a Sigma Delta ADC (Analog to digital converter) which allows the digitalization of the down converted signal and the rejection of the noise.
[0056] The receiver front end 9 comprises means of connection with the sigma delta block 10 and the synthesiser PLL block 11 . The received signal is amplified and down converted by the front end block. The PLL supply the local oscillator frequency used for the mixer. At the output of the mixer the down converted signal is filtered and digitalized by the sigma delta ADC. The transmitter PA block 12 comprises means of connection with the synthesiser PLL block 11 . The PLL is directly modulated to supply the transmitted signal.
[0057] The oscillator block 8 comprises means of connection with a crystal 7 and the digital part 14 . The oscillator bloc is connected to the crystal because it is the active part of the oscillator—the crystal is the passive part. The output of the oscillator is connected to the PLL (reference frequency of the PLL) and to the digital part (clock). The synthesiser PLL block 11 comprises means of connection with a loop filter 17 . The loop filter is a passive part of the PLL. It is external to the Asic to allow different loop filter for different data rate.
[0058] The radio frequency signal 6 received by the receiver front end block 9 is down-converted at a low frequency to an intermediary frequency, in general few hundred kilohertz. Then this signal is filtered and converted to a digital signal in order to be transmitted to the digital part 14 . This digital part 14 comprises a RSSI (Received Signal Strength Indication) detection functional block 15 and a state machine 16 .
[0059] The RSSI detection functional block 15 is able to establish a measurement of the power present in a received radio signal transmitted by the receiver front end block 9 . This RSSI detection functional block 15 is often done in the intermediate frequency (IF) stage before the IF amplifier. In zero-IF systems, it is done in the baseband signal chain, before the baseband amplifier. RSSI output is often a DC analog level. In this embodiment, the low IF, RSSI is done by the digital part. It can also be sampled by an internal ADC and the resulting codes available directly or via peripheral or internal processor bus. The RSSI is used internally in the wireless communicating equipment 1 to determine when the amount of radio energy in the channel is below a certain threshold.
[0060] The state machine 16 is a logic block. This block is a coded logic which allows to execute automatically the algorithm of the autopower up sequence. The state machine is control by the microcontroller but is independent.
[0061] The microcontroller 20 comprises, notably, the following features:
[0062] a 8-bit processor single;
[0063] discrete input and output bits, allowing control or detection of the logic state of an individual package pin;
[0064] serial input/output such as serial ports (UARTs);
[0065] other serial communications interfaces like I 2 C, Serial Peripheral Interface and Controller Area Network for system interconnect;
[0066] peripherals such as timers, event counters, PWM generators, and watchdog;
[0067] volatile memory (RAM) for data storage;
[0068] ROM, EPROM, EEPROM or Flash memory for program and operating parameter storage;
[0069] a timer 19 ;
[0070] analog-to-digital converters, and
[0071] in-circuit programming and debugging support.
[0000] In another embodiment, the task of the microcontroller can be done by a digital block.
[0072] The timer 19 comprises means of connection with a quartz timing crystal 18 , which has a frequency of 32 kHz. This frequency is used to keep track of time, and to provide a stable clock signal. The microcontroller 20 is linked with the digital part of the radio transceiver 21 with an BUS interface.
[0073] Referring to the FIGS. 3 and 4 , the state machine 16 controls the different steps of the automatic power up sequence. The system power management 5 is structured around several blocks which have different setup times and which do not need to be powered on at the same time, and all together at the same moment. The oscillator 8 set up time is longer than the low noise amplifier (LNA), so the LNA has to be switched on after the oscillator. The LNA is a special type of electronic amplifier or amplifier used in communication systems to amplify very weak signals captured by an antenna.
[0074] The state of machine 16 automatically manages the timing for the supply of different blocks. All blocks; oscillator 8 , bias 13 , synthesiser PLL 11 , Receiver chain 9 and 10 , RSSI 15 ; are started and powered once by once, progressively, depending on the usage. The microcontroller 20 contains processing algorithms, which control parameters in order to adjust the timing sequence, regarding the radio transceiver 21 characteristics.
[0075] In the context of the present invention, the system power management 5 allows the receiver front end block 9 to check the radio frequency medium every 1 second with an average consumption about 10 μA, which is compliant with ten or fifteen years of life duration required by lots of applications. The microcontroller 20 initiates a periodic radio transceiver wake up. After a step in which the microcontroller 20 is in a sleep mode 35 . The microcontroller 20 sends periodically at least one signal to a radio transceiver 21 in order to control an incoming radio frequency transmission after an inactivity time of the radio transceiver 21 .
[0076] The cycle of the periodic activation is controlled by the timer. Indeed, after each cycle the timer is re-initialized in the step 37 . The microcontroller 20 leave the sleep mode 35 , if the time calculated by the timer 19 is greater than a period of wake up previously defined, step 36 . If it is the case, the timer is re-initialized in the step 37 and an interrupt signal is sent to the radio transceiver 21 , step 38 . In the contrary case, the microcontroller 20 stays in a sleep mode configuration, in the step 35 .
[0077] The microcontroller returns in sleep mode, step 39 and wait a interrupt signal of the transceiver, step 40 . The interrupt signal is wait for a certain time. This control is done at the step 41 . Then the radio transceiver 21 turns on the crystal oscillator at step 23 . At the step 22 , the transceiver check the interrupt signal of the microcontroller sent at the step 38 .
[0078] The crystal oscillator need time to start up. The oscillator is considered running if its output signal has a enough level to clocked the state machine. 2 way exists to be sure that the signal is enough: 1/wait a delay 2/pull the level of the output of the crystal oscillator, at the step 24 . The second one is here used because it allows to optimise start up time. Then the bias circuit block is turned on as the synthesiser PLL at respectively step 25 and 26 .
[0079] The step 27 , a lock detector is used internally in the Asic to know when the PLL is locked (or when the expected frequency is available—with a given accuracy). To avoid an infinite loop, in case the PLL never lock, a programming delay “time out” is controlled by the block 28 . If the PLL doesn't locked during the “time out” time, the receiver return to stand by mode 44 . If the PLL locked in the “time out” delay, all the rest of the receiver (Rx) is turn on (front end, filter, ADC, digital part), at the step 29 .
[0080] The radio transceiver performs a RSSI measurement based on the RSSI detection functional block at step 30 , and checks at step 31 the RSSI level value with a threshold. If the RSSI level value is smaller than the threshold the radio transceiver returns in a stand by mode at step 44 , the RSSI measurement, step 30 , and the check with the threshold, step 31 , is repeat during a programming duration. The control of this loop is done at the step 32 , where the time spent since the first measurement is compared with the programming value. If the time is lower, the RSSI, step 30 , is again measured. If not, the transceiver go back to the stand by mode step 35 . Otherwise, the radio transceiver sends an interrupt signal to the microcontroller 20 at step 33 , because a radio frequency signal 6 has been detected by the radio transceiver 21 which needed to stay in a full reception mode at step 34 .
[0081] The measurement performed by the RSSI detection block 15 is greater than the reference threshold when an incoming radio frequency is detected. When the microcontroller 20 received the interrupt signal send by the RSSI functional block at step 40 , it leaves the sleep mode (step 42 ).
[0082] In order to guarantee global low power consumption, the microcontroller 20 must have the capability to pass from the sleep mode to the active mode very quickly, just about few microseconds. This can be obtained with a microcontroller 20 which manages the internal clock based on a synthesiser PLL and a low power 32 kHz oscillator. It is not always necessary because a PLL, a RC or other oscillator can be used, in another embodiment.
[0083] Once the microcontroller 20 is in the active mode, it processes the data received by the receiver front end block 9 , in a step 43 . The microcontroller 20 returns in a sleep mode at the step 35 and a new cycle will start again according to the parameter of wake up period. The state mode of all the functional blocks of the radio transceiver 21 changes to a standby mode if the measurement performed by the RSSI functional block 15 is smaller than the reference threshold.
[0084] The FIG. 5 is illustrating the average consumption of the wireless communicating equipment reached. The period of scanning the reception of a radio frequency signal 6 corresponding to one complete cycle when no radio frequency signal 6 has not been detected is 1 second.
[0085] The average current and so the autonomy of the wireless communication equipment 1 depends on the autopowerup sequence and is determinate based on the values of the different currents:
[0086] I0 stand by current;
[0087] I1 of the oscillator 8 during the period t 1 of activation;
[0088] I2 of the bias 13 during the period t 2 of activation;
[0089] I3 of the synthesiser PLL 11 during the period t 3 of activation, and
[0090] I4 of the receiver chain and RSSI detection functional block 15 during the period t 4 of activation.
[0091] All these values are recorded in the table 1 below:
[0000]
TABLE 1
Time (us)
Current (mA)
Average current
Autonomy
t1
t2
t3
t4
I0
I1
I2
I3
I4
I avg rf
L regul + μ
I tot avg
Year
3000
150
250
500
0.0005
0.1
0.25
11
15
11.1
2.5
13.6
17.1
3000
150
250
500
0.0005
0.1
0.25
11
17
12.1
2.5
14.6
16.0
3000
150
250
500
0.0005
0.1
0.25
11
20
13.6
2.5
16.1
14.5
3000
150
250
500
0.0005
0.1
0.25
11
17
12.1
2.5
14.6
16.0
[0092] The average current is calculated based on:
[0000] I avg =I 0+( I 1· t 1+ I 2 ·t 2+ I 3 ·t 3+ I 4 ·t 4)/ T,
[0000] with T corresponding to the scanning time, and I avg the average current.
[0093] In the table 2 below, the contribution of each phase in regard of the current received corresponds to the followings results:
[0000]
TABLE 2
Phase
0
Stand
1
2
3
4
by
Xtal
Bias
Synth
Rx
total
1 avg
3
0.3
0.0375
2.75
8.5
14.6
%
20.5
2.1
0.3
18.8
58.2
100.0
[0094] The obtained average current I avg with 1 second pulling is roughly 14.6 μA. The system power management 5 can be implemented in wireless communication equipments dedicated for ultra low power applications.
[0095] As a further aspect of the present invention is to be used in applications where the wireless communication equipment with low power constraints are required, specially for battery powered devices, for examples in domains like:
[0096] automatic meters reading systems;
[0097] alarm peripheral;
[0098] home automation remote devices;
[0099] medical and healthcare battery powered devices, and
[0100] active RFID (radio frequency identification) tags.
[0000] The wireless communication system is only an example of suitable communication system and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Neither should the wireless communication system be interpreted as having any dependency or requirement relating to any combination of components illustrated in the exemplary wireless communication system. | A method of power management of an electronic device, the method including the steps of:
sending periodically at least one signal by the microcontroller to a radio equipment in order to control an incoming radio frequency transmission after an inactivity time of the radio equipment, returning in standby mode of the microcontroller, initiating by the radio equipment of a power up sequence, powering up one by one the different functional blocks of the radio equipment, and determining of a measurement of a received power of the incoming radio frequency transmission once a RSSI detection functional block is powered, and determining a state mode of power consumption to apply to all the functional blocks of the radio equipment and the microcontroller functions of the comparison of the measurement to a reference threshold. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to tank gauging systems of the type incorporating a free-float. More particularly, this invention relates to an electrostatically safe float for use in such systems.
2. Description of the Prior Art
One technique prevalent today in the measurement of liquid level within a storage tank includes a guide to be vertically supported within the tank. A donut-shaped float is positioned about the guide and is supported by the liquid surface. As the float rides with the liquid level, its position is sensed by suitable means to indicate the level of the liquid within the tank.
This type of system is generally acceptable in most applications, but presents a potential electrostatic hazard when applied in tanks containing flammable liquids. In storage tanks which are partially open to the surrounding atmosphere, such as cone-roof tanks, the electrostatic hazard is greatly increased.
It is well known in the art that during the process of pumping a liquid into a storage tank, the liquid will become electrostatically charged. The rate of accumulation of this charge is related to the flow rate and conductivity of the liquid. If the rate of accumulation of charge is greater than the rate at which it is neutralized, a net charge will be present on the bulk of the liquid, and consequently on the float. For example, at flow rate in excess of one meter/second, liquids having conductivities less than 50 picosiemens may develop a net charge of 30-40 K volts during the filling operation.
This net charge will be totally neutralized within a predetermined time period, called the Relaxation Time. The Relaxation Time may range from seconds for crude oil, to many minutes for gasoline or jet fuel.
During this time period, if the float comes sufficiently close to or in contact with, the vertically supported guide an electrostatic spark of sufficient energy may be developed in the tank's vapor space to cause an ignition of the flammable vapors.
One prior art solution calls for the float to be continuously tied to electrical ground by a bonding wire. In this manner, the two elements (i.e., the float and the wire) are maintained at the same electrical potential. The drawback of this approach is the maintenance of a reliable bond while allowing the float to ride freely with the liquid surface.
Another prior art solution calls for the use of a radioactive source contained within the float. The source ionizes the vapor space between the float and the guide, causing it to become conductive. This provides a low impedance discharge path between the float and the guide, such that static electric charge generated during the filling operation is neutralized before a sufficient net accumulation of charge to cause a spark is generated. The obvious drawback with this approach is customer acceptance of the radioactive source.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention there is provided a float for use in tank gauging systems having a guide vertically supportable in the tank. In the preferred embodiment, the float includes a body member having an aperture for receiving the guide. The body member acts as a pontoon and rides freely with the liquid surface.
A discharge assembly is bonded to the body member and includes a tubular member positioned about the guide below the liquid surface. The tubular member is chosen to have a radius in relation to the radius of the body member aperture such that the path of least resistance for an electrostatic spark discharge of the float is maintained below the liquid surface.
Therefore, it is an object of the present invention to provide an improved float for use in tank gauging systems. Other objects, aspects and advantages of the invention will be pointed out in, or apparent from the following detailed description of the preferred embodiment, considered together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a tank gauging system embodying the present invention,
FIG. 2 illustrates, in a cut-away perspective view, the float of the present invention,
FIG. 3 illustrates the relationship between the two radii, R1 and R2, associated with the float structure of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings, the present invention will now be discussed in detail.
FIG. 1 illustrates a tank gauging system 10 embodying the present invention. A storage tank 12 contains a liquid volume 14, such as gasoline, the level of which is to be measured and a vapor space 16. A guide 18 is tautly supported in a vertical position by a pulley assembly 20. The tank 12 and the guide 18 are both connected to electrical ground.
A float 22, having an aperture 24 and a magnet 26, is positioned about the guide 18 for unrestrained vertical movement with the liquid surface. As the float rides with the liquid surface, the position of the magnet 26 is sensed in a suitable manner by top works assembly 28 producing a direct measure of liquid level. An example of such a sensing system is disclosed in copending U.S. application Ser. No. 904,692, now U.S. Pat. No. 4,158,964, assigned to the assignee of this application.
An inlet assembly 30, including a pump 32, an inlet pipe 34 and a filter 36, is provided near the bottom of the tank 12 to facilitate the filling operation. Typically, the tank is filled by a variable-speed pumping operation which forces the liquid into the tank. As stated previously, a net electrostatic charge may be produced on the bulk of the liquid during the filling operation.
Before discussing the present invention in greater detail, a discussion of the generation and effects of the electrostatic charge will be presented.
It is well known that when two dissimilar materials, at least one of which is a good insulator, are brought into close contact and moved relative to one another, an electrostatic charge is generated. One of the materials will become positively charged, the other negatively charged. This effect is seen during the filling operation of a storage tank. As a liquid of high dielelctric strength (such as flammable liquids) is pumped into the tank at high flow-rates, the liquid will become electrostatically charged.
The major source of the generated electrostatic charge is flow-rate. It is the frictional contact of the liquid with the surface of any filters in the flow-line which is the major electrostatic generator. Other conditions, such as liquid contact with the inner walls of the flow-line, turbulence and the presence of entrained air, water and the like in the liquid enhanced the electrostatic generation.
Counteracting the effect of flow-rate is the neutralization of the charge within the tank as the tank is being filled. Generally, the charge tends to neutralize to the tank walls and the guide, both of which are, as stated previously, at electrical grounds.
The rate at which the charge will be neutralized, the Relaxation Time (T), is inversely related to the conductivity of the liquid. The relationship is defined as follows:
T=EE.sub.o /k;
where, E is the dielectric constant of the liquid (about 2 for hydrocarbons), E o is the dielectric constant of a vacuum, and k is the conductivity of the liquid.
An electrostatic hazard may be defined as any circumstance which will produce a spark of sufficient energy to ignite the vapor space. A float by its presence provides an electrostatic hazard. It provides a place for an electrostatic spark discharge to occur. The large potential difference which exists between the float and the guide during the filling operation generates an electrostatic field in the area between the float and the guide. If the surface of the float is conductive, this electrostatic field will cause the float to be drawn to the guide. As the float comes sufficiently close to, or in contact with, the guide, a gap or path of least resistance and thus a resulting electrostatic spark discharge may be formed in the vapor space. The minimum resistance of the path required to produce a spark depends on the charge mobility in the vicinity of the float, the electrostatic potential and the dielectric constant of the vapor space.
In order for the generated spark to produce ignition two factors must be present. First, the vapor/air mixture of the vapor space must be in the explosive range, called the stoichiometric range; and second, the spark must contain sufficient energy.
The vapor/air mixture of the vapor space depends on various factors, such as the type of tank and the tank temperature. If the concentration of flammable vapors is too high, ignition cannot occur due to a lack of sufficient oxygen. If the concentration is too low there is not enough fuel for ignition. Between these extremes there is a range of concentrations, with one concentration being the easiest to ignite. This is approximately at the stoichiometric mixture of the vapor and air. Above the upper explosive limit the vapor concentration is such that ignition will not occur, no matter how much energy is available. At the opposite extreme is the lower explosive limit below which ignition will also not occur. As the vapor concentration deviates from the stoichiometric mixture, more energy is required for ignition until one of the limits is reached after which no amount of energy will cause ignition. Typically, for hydrocarbons, the stoichiometric range is 1.5 to 11% concentration of vapors by volume.
For hydrocarbons, the amount of energy required in a spark to cause an ignition is typically 0.25 millijoules. This amount of energy can be easily stored in a body having sufficient capacity. For example, assuming a static electric potential of 1,600 volts, which is relatively small for a static charge, the capacity required to store 0.25 millijoules of energy is only 200 picofarads.
FIG. 2 illustrates a perspective view of the float 22 having a discharge means positioned below the surface of the liquid such that any spark which may be developed will occur below the liquid surface, rather than in the vapor space. That is, the float of the present invention has a geometry which assures that the discharge path for a spark is maintained below the liquid surface. In this manner, due to the lack of sufficient oxygen, ignition will not result.
The float 22 includes a body member 38, and a discharge assembly 40, as well as the magnet 26. Preferably, the float is fabricated of a non-conductive material to greatly reduce the charge mobility on the surface of the float and thus to greatly reduce the effects of the electrostatic field generated in the vicinity of the aperture 24.
The body member 38, having the aperture 24, acts as a pontoon to maintain the float stable as it rides on the liquid surface. The body member 38 includes a core 42 fabricated of a foamed urethane surrounded by a dense shell 44. The shell 44 is formed of a mixture of epoxy resin with miniature glass balloons.
The discharge assembly is connected to the body member 38 to be positioned below the liquid surface, and includes support members 46, an annular support ring 48 and a tubular member 50. The support members 46 are bonded to the body member 38 by suitable means, such as the bonding holes 52, and are provided to maintain the annular support ring 48 in fixed position.
The support ring 48 is provided to protect the magnet 26 and to maintain the tubular member 50 is fixed concentric position with the body member 38. Preferably, the support members are formed of nylon, and the support ring is formed of the same material as the shell 44.
The tubular means 50 is positioned below the liquid surface and acts as the main discharge means for the float during normal operation. The radius (R1) of the tubular member 50 is chosen in relation to the radius (R2) of the aperture 24 such that the path of least resistance for an electrostatic spark discharge is maintained below the liquid surface for all orientations of the float in the plane of FIG. 1.
FIG. 3 illustrates the relationship between the radii R1 and R2. An electrostatically charged member 54, having a geometric characteristic similar to a half-section of the float 22, is shown positioned relative to an electrically grounded wire 56. The member 54 has a surface 58 a distance R2 from the wire, and a surface 60 a distance R1 from the wire. In this manner, two possible discharge paths are developed, path R1 and path R2.
As is well known in the art, an electrostatic charge will discharge along the path of least resistance, or in the present example, along path R1 or R2 depending upon their relative resistances.
The resistance of paths R1 and R2 depend upon the resistivity of the liquid 14 and the vapor 16, respectively. For example, the resistivity of a typical hydrocarbon is 150 Kvolts/ inch and the resistivity of the vapor space 16 will be in the order of 30 Kvolts/inch. Thus, the vapor to liquid resistivity factor (k) is 5. Therefore, if the radius R2 is 5 times larger than the radius R1 the resistance of the discharge paths below and above the liquid surface will be equal. Obviously, this is not acceptable for it produces an equal probability that a spark will occur above the surface of the liquid rather than below the liquid surface.
To maintain the path of least resistance below the liquid surface, it has been found that a safety factor (SF) of 3 or 4 is acceptable. Thus, for a radius R2 of 3 inches, and a safety factor of 3, then the radius R1 is: ##EQU1##
The length of the member 50 is chosen to assure that as the float rotates in the plane of FIG. 1, the path of least resistance remains below the liquid surface. That is, again referring to FIG. 3, as the member 54 rotates in the plane of the FIG., the path (R1) defined by the surface 60 continuously presents the path of least resistance to the charge on the member 54. Preferably, the tubular member 50 has a length of 6 inches for the example cited above.
The inner surface of the member 50 is bevelled at both ends to assure unrestrained movement of the float, and preferably is made of nylon.
Also, a secondary discharge means is provided in the event the float 22 becomes free of the guide 18. The body member 38 is provided with a circumferential lip 62 below the liquid surface. The length of the lip 62 is chosen such that if the float becomes free of the guide, the lip 62 will provide the path of least resistance below the surface of the liquid if the float comes in contact with, or sufficiently close to, the walls of the tank 10.
While only a single embodiment of the invention has been illustrated and described in detail, the invention is not to be considered limited to the precise construction shown. Various adaptations, modifications and uses of the invention may occur to those skilled in the art to which the invention pertains and the intention is to cover all such adaptations, modifications and uses which fall within the spirit and scope of the appended claims. | A float is disclosed for use in tank gauging systems of the type having a vertically supported guide. The float includes a donut-shaped body member adapted to be positioned about the guide to ride freely with the liquid surface. A discharged tube is positioned concentrically with the body member by a number of support members. The discharge tube is positioned below the liquid surface and acts as a discharge electrode to maintain the path of least resistance for an electrostatic discharge of the float below the liquid surface. | 6 |
TECHNICAL FIELD
The present invention relates to the field tree stands utilized by hunters and sportsmen; and particularly to a portable tree stand for use with non-vertical trees whereby the standing and seating platforms may remain parallel and may be adjustable.
BACKGROUND OF THE INVENTION
The use of tree stands by sportsmen is well known in the prior art prior art tree stands have basically consisted of familiar, expected, and obvious structural configurations designed to fulfill a particular need or requirement. Very few prior art tree stands have addressed the issues surrounding the fact that tree stands are generally not installed on perfectly vertical trees. Such installations of conventional tree stands in non-vertical trees illustrate the myriad of issues that the prior art has left unsolved. A majority of these issues are very dangerous given that most tree stands are used during hunting.
The portable tree stand of the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus developed for offering a lightweight portable tree stand that securely attaches to virtually any tree in a quick and easy fashion, while providing improved safety via adjustable seating and standing platforms. While some of the prior art devices attempted to improve the state of the art, none have achieved the beneficial attributes of the present invention. With these capabilities taken into consideration, the instant invention addresses many of the shortcomings of the prior art and offers significant benefits heretofore unavailable. Further, none of the known prior art, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF INVENTION
In its most general configuration, the present invention advances the state of the art with a variety of new capabilities and overcomes many of the shortcomings of prior devices in new and novel ways. In its most general sense, the present invention overcomes the shortcomings and limitations of the prior art in any of a number of generally effective configurations. The instant invention demonstrates such capabilities and overcomes many of the shortcomings of prior methods in new and novel ways.
In one of the simplest configurations, the portable tree stand of the present invention is designed to be releasably secured to a non-vertical tree. It includes a standing platform, a seating platform, a mounting structure, and a seat support post that maintains a predetermined angular relationship between the standing platform and the seating platform.
The standing platform has a standing platform deck, at least one standing platform support, a support post receiver, and at least one platform retainer releasably secured to the standing platform. The seating platform has a seating platform deck, a seating support assembly, and a support post mount. The mounting structure has a mounting chain and an attachment member to releasably secure the platform retainer and the mounting chain to the mounting structure. The seating platform assembly and standing platform are rotably connected to the mounting structure. Additionally, the attachment member is connected to the mounting structure and includes a chain tightening assembly attached to the mounting chain and a mounting chain receiver slot for releasably receiving the mounting chain encircling the tree. The mounting chain and chain tightening assembly may impart a tensile load on the mounting chain to grip the tree. Lastly, the seat support post has a proximal end and a distal end, wherein the seat support post is rotably connected to the support post mount substantially near the distal end and the proximal end is adjustably received by the support post receiver.
The unique construction and assembly of these components enable the standing platform deck and the seating platform deck to remain in a predetermined angular relationship despite a non-orthogonal relationship between the mounting structure and the standing platform deck or the seating platform deck. The configuration of the seat support post relative to the seating platform and the standing platform creates a parallelogram support that may act to keep the seating platform and the standing platform in any predetermined angular relationship. For example, if the seat support post were adjusted to give a slightly upwards tilt to the seating platform relative to the standing platform, a subsequent adjustment of the platform retainer would change the angulation of the seating platform and the standing platform relative to the tree or ground, but the slight upward tilt of the seating platform relative to the standing platform would be maintained. Additionally, the seat support post may be formed to have a plurality of adjustment receivers designed to cooperate with an adjustment pin. This configuration permits a user to quickly and easily adjust the position of the seating platform.
The seat support post may be formed to be telescoping, or have at least one hinged joint, to facilitate compact storage of the apparatus. The standing platform supports may be bent, or formed, to allow for more compact storage when folded. The standing platform supports of the present embodiment are simply bolted to the mounting structure proximal end, thereby ensuring a reliable connection that is easy to rotate.
The seating platform includes the seating platform deck, the seating platform assembly, and the support post mount. The seating platform deck may be constructed and configured in much the same way as the standing platform deck. The seating support assembly may include at least one receiver attached to the seating platform deck and at least one mount rotably attached to the mounting structure. The at least one receiver and the at least one mount are formed to cooperate with each other such that the seating platform deck and the at least one receiver may slide away from the mounting structure on the at least one mount.
One knowledgeable in the field of tree stands will recognize the functional significance of this novel feature, as tree stands are very rarely installed on perfectly vertical trees. Conventional tree stands have often not facilitated installation on the forward leaning side of a tree thereby greatly limiting the utility, as, for instance, a forward leaning tree greatly reduces the user's seating area. The user would have to lean forward to accommodate the sloping tree, thereby causing great discomfort, and potential safety issues, during the long-hours spent in the tree stand. Fortunately, the sliding seating platform deck of the present invention alleviates such problems. As previously mentioned, the seating platform deck and the at least one receiver may slide away from the mounting structure on the at least one mount, thereby moving the user's seating position away from the tree and permitting the user to sit upright.
A further embodiment incorporates at least one adjustable standing platform support. The at least one adjustable standing platform support allows the standing platform deck to move away from the mounting structure. This feature is particularly useful in the situation of a forward leaning tree, as described above, where the seating platform deck has been moved away from the mounting structure thereby reducing the amount of foot room on the standing platform. Such an adjustable standing platform support permits the user to adjust the standing platform deck in proportion to the seating platform deck, thereby maintaining the same amount of foot room regardless of the adjustments that must be made to accommodate mounting the apparatus in non-vertical trees. The at least one adjustable platform support may include a first member that is slideably received onto a second member connected to the support structure.
The receiver and the mount may be configured in any manner that permits the seating platform deck to be relocated away from the mounting structure. The mount may be bent, or formed, to allow for more compact storage when folded. The mounts may be simply bolted to the mounting structure distal end thereby ensuring a reliable connection that is easy to rotate.
The mounting structure is connected to the at least one standing platform support and to the at least one seating support mount. The mounting structure may include at least one primary support and at least one secondary support, which may easily cooperate with each other to allow adjustability in the distance between the seating platform and the standing platform. A support interconnector may be added to increase the rigidity of the apparatus, as well as serve as a mounting point for the seat support mounts. Additionally, the mounting structure may include a mounting plate, most commonly attached to each of the primary supports, to increase the rigidity of the apparatus and provide a location for engaging a tree screw that may be secured to the tree.
The mounting structure also includes a mounting chain, ultimately secured to the attachment member. The attachment member is rigidly attached to the mounting structure, and in one embodiment, to each of the primary supports. The attachment member serves as a convenient and flexible location to releasably secure the mounting chain and the at least one platform retainer. The attachment member is formed with a mounting chain receiver slot, sized and configured to cooperate with the mounting chain. The receiver slot permits one of the numerous chain links to slide into the receiver thereby blocking entry of an adjacent chain link, so that the user may easily wrap the mounting chain around the tree and engage the receiver slot. The chain tightening assembly may then be used to impart a tensile load on the mounting chain to lock the apparatus to the tree.
The chain tightening assembly may include a mounting bracket, a threaded rod, a rod limiter, a coupling having a plurality of gripping studs, and a chain interface. The mounting bracket acts to rotably join the other components of the chain tightening assembly to the attachment member. The coupling is threadedly engaged with the threaded rod and the plurality of gripping studs permit a user to apply torque on the coupling thereby imparting more tensile force on the mounting chain through the threaded rod and the chain interface. The coupling is sized such that it is retained by the mounting bracket, and not capable of passing through the hole formed in the mounting bracket for the threaded rod. Additionally, the threaded rod has a rod limiter so that the threaded rod is incapable of passing through the coupling. Therefore, as the user applies force to the plurality of gripping studs the coupling rotates, thereby causing the threads of the coupling to travel the threads of the threaded rod, moving the threaded rod and tightening the mounting chain. The chain tightening assembly of the present invention may be used to impart at least hundreds of pounds of tensile force on the chain, thereby ensuring a solid grip on the tree. The mounting chain may be joined to the threaded rod via the chain interface, which may be a rigid connection, such as a simple weld. The mounting bracket rotates, to allow the chain tightening assembly to rotate and accommodate trees of varying diameters. This rotation allows the first end of the mounting chain to remain coaxial with the threaded rod no matter what the diameter of the tree, thereby transferring the tensile load to the mounting chain in the most effective manner.
Overall, the instant invention advances the art by allowing, among other features, sliding adjustment of both the seating platform and standing platform, thus allowing the tree stand to be easily and safely used in trees that may be substantially vertical, or in trees with an angular lean.
BRIEF DESCRIPTION OF THE DRAWINGS
Without limiting the scope of the present invention as claimed below and referring now to the drawings and figures:
FIG. 1 is a side elevation view of a portable tree stand constructed according to the present invention;
FIG. 2 is a front elevation view of a portable tree stand constructed according to the present invention;
FIG. 3 is a top plan view of a portable tree stand constructed according to the present invention;
FIG. 4 is a top plan view of a portable tree stand, with the standing platform deck and the seating platform deck removed for clarity, constructed according to the present invention;
FIG. 5 is an elevated perspective view of the mounting structure constructed according to the present invention;
FIG. 6 is a side elevation view of a portable tree stand constructed according to the present invention;
FIG. 7 is a side elevation view of a portable tree stand constructed according to the present invention in a collapsed, or folded, configuration;
FIG. 8 is a side elevation view of a portable tree stand, mounted to a backward leaning tree, constructed according to the present invention;
FIG. 9 is a side elevation view of a portable tree stand, mounted to a forward leaning tree, constructed according to the present invention;
FIG. 10 is a side elevation view of a portable tree stand, mounted to a forward leaning tree, constructed according to the present invention;
FIG. 11 is a side elevation view of a portable tree stand, mounted to a forward leaning tree, constructed according to the present invention; and
FIG. 12 is an elevated perspective view of the mounting structure constructed according to the present invention.
Also, in the various figures and drawings, the following reference symbols and letters are used to identify the various elements described herein below in connection with the several figures and illustrations: T, R, and M.
DETAILED DESCRIPTION OF THE INVENTION
The portable tree stand of the instant invention enables a significant advance in the state of the art. The preferred embodiments of the apparatus accomplish this by new and novel arrangements of elements and methods that are configured in unique and novel ways and which demonstrate previously unavailable but preferred and desirable capabilities. The detailed description set forth below in connection with the drawings is intended merely as a description of the presently preferred embodiments of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the designs, functions, means, and methods of implementing the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and features may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
The portable tree stand 50 of the present invention is designed to be releasably secured to a non-vertical tree and includes a standing platform 100 , a seating platform 200 , a mounting structure 300 , and a seat support post 400 that maintains a predetermined angular relationship between the standing platform 100 and the seating platform 200 , as seen in FIG. 1 .
The standing platform 100 has a standing platform deck 110 , at least one standing platform support 120 , a support post receiver 112 , and at least one platform retainer 130 having a proximal end 132 and a distal end 134 wherein the proximal end 132 is releasably secured to the standing platform 100 , as illustrated best in FIG. 6 . The seating platform 200 has a seating platform deck 210 , a seating support assembly 220 , and a support post mount 230 , as seen in FIG. 2 . The mounting structure 300 has a proximal end 302 , a distal end 304 , a mounting chain 310 having a first end 312 and a second end 314 , and an attachment member 360 to releasably secure the at least one platform retainer 130 distal end 134 and the mounting chain 310 to the mounting structure 300 , seen best in FIG. 2 and FIG. 5 . The seating platform assembly 200 is rotably connected substantially near the distal end 304 of the mounting structure 300 and the at least one standing platform support 120 is rotably connected substantially near the proximal end 302 of the mounting structure 300 . Additionally, the attachment member 360 is connected between the proximal end 302 and the distal end 304 and includes a chain tightening assembly 364 attached to the mounting chain 310 at the first end 312 and further includes a mounting chain receiver slot 362 for releasably receiving the mounting chain 310 upon encircling the tree T. The chain tightening assembly 364 may impart a tensile load on the mounting chain 310 thereby gripping the tree T. Lastly, the seat support post 400 has a proximal end 402 and a distal end 404 , wherein the seat support post 400 is rotably connected to the support post mount 230 substantially near the distal end 404 and the proximal end 402 is adjustably received by the support post receiver 112 . The unique construction and assembly of these components enable the standing platform deck 110 and the seating platform deck 210 to remain in a predetermined angular relationship despite a non-orthogonal relationship between the mounting structure 300 and the standing platform deck 110 or the seating platform deck 210 .
Now, referring back to the standing platform 100 , it may be constructed of any number of to materials and configured in a number of ways. In one particular embodiment, the standing platform deck 110 is constructed of weather-resistant plywood, or similar oriented strand board type material. Alternatively, one with skill in the art can appreciate that the standing platform deck 110 may be constructed of expanded metal grating and composite decking type products.
Similarly, the standing platform support 120 may be constructed of any number of materials and configured in a number of ways. For example, in the embodiments illustrated in FIG. 1 through FIG. 11 the standing platform support 120 consists of two support members each rotably attached to the mounting structure proximal end 302 . In this particular embodiment the standing platform supports 120 are constructed of bent ¾″ electrical metallic tubing (EMT). Such EMT based construction facilitates the lightweight corrosion-resistant construction and low cost of the present invention. Alternatively, one with skill in the art can appreciate that the standing platform supports 120 may be constructed of any shape tubing, whether it is metallic, plastic, or composite. The standing platform supports 120 may be bent, or formed, as seen in FIG. 7 , to allow for more compact storage when folded. The standing platform supports 120 of the present embodiment are simply bolted to the mounting structure proximal end 302 thereby ensuring a reliable connection that is easy to rotate.
The at least one platform retainer 130 acts to transfer a portion of the load on the standing platform 100 to the mounting structure 300 . The embodiments illustrated in FIG. 1 through FIG. 11 illustrate the at least one platform retainer 130 as a chain, however one with skill in the art can appreciate that alternative devices, such as cable, may be used. Chain is the preferred material because is provides for easy adjustability. For instance, the chain may be easily attached to the attachment member 360 by a chain retainer 372 , often a thumb-screw or wing nut assembly, which simply passes through a link in the chain, as seen in FIG. 6 . Therefore, a user may easily adjust the angle of the standing platform 100 while always having a safe and secure attachment. The chain preferably has elastomeric coated links to reduce the likelihood of noise and to reduce the possibility of corrosion.
Now moving on to the seating platform 200 , it consists of the seating platform deck 210 , the seating platform assembly 220 , and the support post mount 230 , as seen in FIG. 2 . The seating platform deck 210 may be constructed and configured in much the same way as the previously discussed standing platform deck 110 . The seating support assembly 220 may include at least one receiver 222 attached to the seating platform deck 210 and at least one mount 224 rotably attached to the mounting structure 300 . The at least one receiver 222 and the at least one mount 224 are formed to cooperate with each other such that the seating platform deck 210 and the at least one receiver 222 may slide away from the mounting structure 300 on the at least one mount 224 , as seen in FIG. 4 . The direction of motion M of the seating platform deck 210 is illustrated well in FIG. 8 .
The functional significance of this novel feature is illustrated in FIG. 8 through FIG. 11 . As one knowledgeable in the field of tree stands will recognize, tree stands are very rarely installed on perfectly vertical trees. The apparatus 50 is shown installed on a rearward leaning (relative to the stand) tree in FIG. 8 . Alternatively, the apparatus 50 is shown installed on a forward leaning (relative to the stand) tree in FIG. 9 through FIG. 11 . Conventional tree stands have often not facilitated installation on a forward leaning tree thereby greatly limiting their utility. For instance, the forward leaning tree of FIG. 9 greatly reduces the user's seating area. The user would have to lean forward to accommodate the sloping tree, thereby causing great discomfort, and potential safety issues, during the long-hours spent in the tree stand. Fortunately, the sliding seating platform deck 210 of the present invention alleviates such problems, as illustrated in FIG. 10 . As previously mentioned, the seating platform deck 210 and the at least one receiver 222 may slide away from the mounting structure 300 on the at least one mount 224 , thereby moving the user's seating position away from the tree and permitting the user to sit upright, as seen in FIG. 8 . The travel length of the seating platform deck 210 may be limited in a number of ways. In one embodiment this safety feature incorporates a translation limiter 226 in the form of at least one wire secured at one end to the mounting structure 300 and secured at the opposing end to the seating platform deck 210 or the at least one receiver 222 . Alternative embodiments of the translation limiter 226 may feature structures built into the receiver 222 or the mount 224 to limit the travel. Additionally, the at least one receiver 222 and the at least one mount 224 may be releasably fixed with respect to one another with at least one locking device 228 , seen in FIG. 6 . The at least one locking device 228 may include simple thumb screws that pass through the at least one receiver 222 and engage the at least one mount 224 .
A further embodiment incorporates at least one adjustable standing platform support 122 , as seen in FIG. 11 . The at least one adjustable standing platform support 122 allows the standing platform deck 110 to move away from the mounting structure 300 . This feature is particularly useful in the situation described above, and illustrated in FIG. 10 , where the seating platform deck 210 has been moved away from the mounting structure 300 , thereby reducing the amount of foot room on the standing platform 100 . Referring again to FIG. 11 , the adjustable standing platform support 122 permits the user to adjust the standing platform deck 110 in proportion to the seating platform deck 200 , thereby maintaining the same amount of foot room regardless of the adjustments that must be made to accommodate mounting the apparatus 50 in non-vertical trees. As seen in FIG. 11 , the at least one adjustable platform support 122 may include a first member 124 that is slideably received onto a second member 126 that is connected to the support structure 300 . This standing platform 100 embodiment may incorporate the same translation limiters 226 and materials of construction discussed above regarding the seating platform 200 .
As with the standing platform support 122 , the receiver 222 and the mount 224 may be constructed of EMT. Such construction is lightweight, corrosion-resistant, and offers low material and fabrication costs. However, one with skill in the art can appreciate that the receiver 222 and the mount 224 may be constructed of any shape member or tubing, whether it is metallic, plastic, or composite. Additionally, the receiver 222 and the mount 224 are not limited to the telescoping arrangement illustrated in the figures, they may be configured in any manner that permits the seating platform deck to be relocated away from the mounting structure 300 . The mount 224 may be bent, or formed, as seen in FIG. 7 , to allow for more compact storage when folded. Additionally, the mounts 224 of the present embodiment are simply bolted to the mounting structure distal end 304 thereby ensuring a reliable connection that is easy to rotate.
Next, the mounting structure 300 , best illustrated in FIG. 5 and FIG. 12 , is connected at the proximal end 302 to the at least one standing platform support 120 , and is connected at the distal end 304 to the at least one seating support mount 224 , as seen in FIG. 2 . The mounting structure 300 may include at least one primary support 330 and at least one secondary support 340 . The embodiment illustrated in FIG. 5 and FIG. 12 shows the at least one primary support 330 and the at least one secondary support 340 configured in complementary shapes and sizes so that they may easily cooperate with each other thereby introducing adjustability in the distance between the seating platform 200 and the standing platform 100 . In one embodiment the secondary supports 340 slide into the primary supports 330 , each made of tube steel, thereby offering low material and fabrication costs. One with skill in the art can appreciate that the primary and secondary supports 330 , 340 may be constructed of any shape member or tubing, whether it is metallic, plastic, or composite. Additionally, the primary and secondary supports 330 , 340 are not limited to the telescoping arrangement illustrated in the figures. They may be configured in any manner that permits the seating platform 200 to be adjusted nearer to, or farther away from, the standing platform 100 . The apparatus 50 may include a plurality of locking devices 380 to releasably fix the relationship between the at least one primary support 330 and the at least one secondary support 340 . The plurality of locking devices 380 may include setscrews or wing nuts that extend through the primary support 330 to engage the secondary support 340 , or may consist of pins that extend through cooperating recesses formed in the primary support 330 and the secondary support 340 , as seen in FIG. 6 .
A support interconnector 342 , as seen in FIG. 5 , may be added to increase the rigidity of the apparatus 50 , as well as serve as a mounting point for the seat support mounts 224 . The support interconnector 342 may be formed of a threaded rod extending through each of the secondary supports 340 . Additionally, the mounting structure 300 may include a mounting plate 350 , most commonly attached to each of the primary supports 330 , to increase the rigidity of the apparatus 50 and provide a location for engaging a tree screw 320 that may be secured to the tree.
The mounting structure 300 also includes a mounting chain 310 having a first end 312 and a second end 314 . The mounting chain 310 is ultimately secured to the attachment member 360 . The attachment member 360 is rigidly attached to the mounting structure 300 , and more particularly in one embodiment, to each of the primary supports 330 , as seen in FIG. 5 . This rigid connection may be made using virtually any mechanical joining means, however the connection is welded in a preferred embodiment. The attachment member 360 serves as a convenient and flexible location to releasably secure the mounting chain 310 and the at least one platform retainer 130 . The attachment member 360 is formed with a mounting chain receiver slot 362 sized and configured to cooperate with the mounting chain 310 . The receiver slot 362 permits one of the numerous chain links to slide into the receiver thereby blocking entry of an adjacent chain link. As such, the user may easily wrap the mounting chain 310 around the tree and engage the receiver slot 362 . The chain tightening assembly 364 may then be used to impart a tensile load on the mounting chain 310 , thereby locking the apparatus 50 to the tree.
The chain tightening assembly 364 may include a mounting bracket 365 , a threaded rod 366 , a rod limiter 367 , a coupling 368 having a plurality of gripping studs 369 , and a chain 20 interface 370 , as seen in FIG. 5 and FIG. 12 . The mounting bracket 365 acts to rotably join the other components of the chain tightening assembly 364 to the attachment member 360 . The mounting bracket 365 may be formed to receive the treaded rod 366 . The coupling 368 is threadedly engaged with the threaded rod 366 and the plurality of gripping studs 369 permit a user to apply more torque on the coupling 368 thereby imparting more tensile force on the mounting chain 310 through the threaded rod 366 and the chain interface 370 . The coupling 368 is sized such that it is retained by the mounting bracket 365 , and not capable of passing through the hole formed in the mounting bracket 365 for the threaded rod 366 . Additionally, the threaded rod 365 has a rod limiter 367 so that the threaded rod 366 is incapable of passing through the coupling 368 . Therefore, as the user applies force to the plurality of gripping studs 369 the coupling 368 rotates thereby causing the threads of the coupling to travel the threads of the threaded rod 366 , moving the threaded rod 366 and tightening the mounting chain 310 . The chain tightening assembly 364 of the present invention may be used to impart at least hundreds of pounds of tensile force on the chain, thereby ensuring a solid grip on the tree. The mounting chain 310 may be joined to the threaded rod 366 via the chain interface 370 , which may be a rigid connection, such as a simple weld, such that the use of a turning coupling 368 on a threaded rod 366 , as seen in FIGS. 5 , 6 , and 8 through 12 , tends to minimize any turning effect on the threaded rod 366 . The rotable mounting bracket 365 rotates, as indicated by rotation indicator R in FIG. 5 and FIG. 12 , to allow the chain tightening assembly 364 to rotate and accommodate trees of varying diameters. This rotation allows the first end 312 of the mounting chain 310 to remain coaxial with the threaded rod 366 no matter what the diameter of the tree, thereby transferring the tensile load to the mounting chain 310 in the most effective manner.
The attachment member 360 and the mounting bracket 365 are constructed with common angle iron in the illustrated embodiment. Such construction is extremely strong, lightweight, and offers low material and fabrication costs. However, one with skill in the art can appreciate that the attachment member 360 and the mounting bracket 365 may be constructed of structural members of virtually any shape, whether it is metallic, plastic, or composite.
Lastly, the seat support post 400 may be constructed of EMT, preferably ¾″ or 1″, or any shape tubing, whether it is metallic, plastic, or composite. Additionally, the seat support post 400 may be formed to have a plurality of adjustment receivers 410 designed to cooperate with an adjustment pin 420 . This configuration permits a user to quickly and easily adjust the position of the seating platform 200 . The configuration of the seat support post 400 relative to the seating platform 200 and the standing platform 100 , creates a parallelogram support that may act to keep the seating platform 200 and the standing platform 100 in any predetermined angular relationship. For example, if the seat support post 400 were adjusted to give a slightly upwards tilt to the seating platform 200 relative to the standing platform 100 , a subsequent adjustment of the platform retainer 130 would change the angulation of the seating platform 200 and the standing platform 100 relative to the tree or ground, but the slight upward tilt of the seating platform 200 relative to the standing platform 100 would be maintained. Additionally, the seat support post 400 may be formed to be telescoping, or have at least one hinged joint, to facilitate compact storage of the apparatus 50 .
Numerous alterations, modifications, and variations of the preferred embodiments disclosed herein will be apparent to those skilled in the art and they are all anticipated and contemplated to be within the spirit and scope of the instant invention. For example, although specific embodiments have been described in detail, those with skill in the art will understand that the preceding embodiments and variations can be modified to incorporate various types of substitute and or additional or alternative materials, relative arrangement of elements, and dimensional configurations. Accordingly, even though only few variations of the present invention are described herein, it is to be understood that the practice of such additional modifications and variations and the equivalents thereof, are within the spirit and scope of the invention as defined in the following claims. The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or acts for performing the functions in combination with other claimed elements as specifically claimed. | A portable tree stand for use with non-vertical trees provides standing and seating platforms that may remain parallel and may be adjustable. Adjustments include a slidable seat platform and a slidable standing platform that may be extended to allow adequate seating and standing space to compensate for tree trunks that diverge from the vertical. Additionally, the distance, or height, between the standing platform and the seating platform maybe varied. A threaded chain tensioner tightens a chain around the tree helping hold the stand to the tree, and optionally a tree screw secures attachment to the tree trunk. An adjustable seat support post establishes a parallelogram relationship between the seat platform and the standing platform such that an angular relationship, which may be parallel or non-parallel, may be maintained between the seat platform and the standing platform. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to mine brattice installations and more particularly, it concerns an improved system and method for mounting a malleable sheet metal barrier on a jack post supported peripheral framework in an underground mine tunnel.
In commonly assigned U.S. Pat. No. 3,972,272, issued Aug. 3, 1967 to James Allen Bagby, there is disclosed a mine brattice structure in which a gas impervious barrier of malleable sheet metal, such as aluminum, is affixed to a yieldable peripheral framework in turn supported by shear pin retained, telescopic jack posts spaced from each other in the general plane of the brattice. An essentially air-tight seal between the sheet metal barrier and the wall surfaces defining the interior tunnel periphery in which the brattice is placed is achieved by bending, hammering or otherwise deforming the edges of the malleable sheet metal into engagement with the interior tunnel surfaces.
In the installation of such brattices, the jack posts are first placed between the mine tunnel floor and roof to be appropriately spaced across the width of the tunnel. Once the jack posts are installed, a framework of slotted beams are bolted to each other and to the jack posts so as to conform roughly with the inner periphery of the tunnel. The air impervious sheet metal barrier is then mounted to the framework and deformed into sealing engagement with the tunnel surfaces to complete the brattice installation.
Because the intended function of the brattice is to provide a barrier against air or gas flow in mine ventilating systems, the pressures to which the brattice is subjected can be substantial and require that the sheet metal be attached to the jack post supported framework securely. In light of this, threaded bolts and nuts have been preferred to achieve the needed mounting strength for the sheet metal barrier and also to minimize leakage of air or gas.
While both sides of the brattice are most generally accessible, considerable time has been required for the installation of such brattices particularly in the bolting attachment of the sheet metal barrier to the framework. Not only has this operation required two people, one on each side of the brattice being installed, but the difficulty of coordination between the two people particularly during the final stages of installation has been found tedious and time consuming.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention, a sheet metal mounting system and method is provided by which brattices of the type referred to may be installed very effectively by one or more persons working on only one side of the brattice and in substantially less time that was required heretofore. Although the jack post supported, slotted beam framework is again employed, the sheet metal is erected by pressing it over piercing pins, pre-mounted at appropriate locations on the slotted beam framework, and then drawn tight against the framework by positive fastening devices. The piercing pins are preferably in the nature of threaded bolts projecting from one side of the framework so that once the sheet metal is pierced and temporarily supported by the bolts, it may be anchored permanently in place simply and effectively by drawing a multi-apertured washer and nut tight on the threaded bolt shank projecting through the pierced sheet metal.
A primary object of the present invention is, therefore, the provision of an improved system and method for mounting a malleable sheet metal barrier on a jack post supported framework in the installation of underground mine brattices and by which such installation is simplified and expedited. Other objects and further scope of applicability of the present invention will become apparent from the detailed description to follow taken in conjunction with the accompanying drawings in which like parts are designated by like reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cut away perspective view of a mine brattice in which the system and method of the present invention is applicable;
FIG. 2 is an exploded fragmentary cross-sectional view illustrating the various components of the mining system of the present invention; and
FIG. 3 is a similar partial cross-section with the system components permanently in place.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 of the drawings, a mine brattice in which the present invention is particularly suited for use, is generally designated by the reference numeral 10 and shown in a mine tunnel represented in phantom lines to include a floor 12, a roof 14, and side edges or ribs 16. As is well known, the installed brattice functions to block the passage of air and other gases through the tunnel section in which it is placed and to this end, includes a gas impervious sheet metal barrier 18 supported from a peripheral framework of slotted, plate-like beams 20 and 22 bolted or otherwise yieldably connected to each other for relative sliding and pivotal movement under forces resulting from dimensional changes in the mine tunnel. The framework of beams 20 and 22 is supported by suitable means such as U-bolts to a plurality of vertical jack posts 24 spaced horizontally from each other in the general plane of the brattice 10.
It will be appreciated from the illustration in FIG. 1 and from the full disclosure of the aforementioned U.S. Pat. No. 3,972,272 that the brattice 10 is installed by first placing the jack posts 24 between the floor 12 and roof 14 of the mine tunnel, securing the framework of slotted beams 20 and 22 to the jack posts 24 in a manner to generally complement the interior peripheral configuration of the mine tunnel, and then by placement of the sheet metal barrier 18 to the jack supported framework. A highly effective seal may be provided between the sheet metal barrier 18 and the interior periphery of the mine tunnel by bending or otherwise deforming the edges of the sheet metal into sealing engagement with the interior tunnel surfaces. The installation of the sheet metal barrier 18 in this manner is facilitated by the malleable characteristics of such metals as aluminum and further by the use of multi-apertured washer plates 26 tending to retain the edges of the sheet metal barrier in place.
Each of the jack posts 24 are formed of telescopically interconnected upper and lower sections 28 and 30, respectively, which in practice may be appropriately sized sections of conventional pipe. The top of the upper pipe section 28 and the bottom of the lower pipe section 30 are fitted with anchorage plates 32 from which a pointed dowel-like pin 34 may project to assure a firm anchorage in the floor and roof of the tunnel in which the brattice is to be installed.
The jack posts 24 are placed using a hydraulic or mechanical lifting jack (not shown) which operates to lift the upper section 28 relative to the lower section and serves to compress the upper and lower sections 28 and 30 firmly against the roof 14 and floor 12, respectively. The extended relationship of the upper and lower sections 28 and 30 is then maintained by a system of shear pins 36.
As described in the aforementioned U.S. Pat. No. 3,972,272, the sheet metal barrier 18 may be formed in two or more sheet sections and is preferably bolted to the framework of slotted beams 20 and 22 using multi-apertured washer plates 38 at least about the peripheral edges of the brattice. By selection of the appropriate aperture in each washer plate 38, the portion of the sheet metal outside the framework of the beams 20 and 22 is supported by projection of the washer plate to the inner surface of the tunnel.
In accordance with the present invention, prior to installing the sheet metal barrier 18, a plurality of threaded bolts 40 are first mounted on the slotted beams 20 and 22 is selected positions by inserting each bolt 40 through a head washer 42, the slot 44 of the beams 20 or 22, and fixing it in place with a bolt mounting nut 46 drawn against a nut washer 48 and the side of the beam opposite the bolt head 50. The threaded shank 52 of each bolt so fixed in place projects from one side of the framework of beams 20 and 22 as a piercing pin in the manner shown in FIGS. 2 and 3 of the drawings. Also, it is to be noted that the bolt mounting nut 46 defines a stepped enlargement at the base of each projecting bolt shank 52 or piercing pin.
With the bolts 40 fixed in place and projecting as piercing pins from a common side of the slotted beams 20 and 22, the sheet metal barrier 18 is installed by pressing the sheet metal against the projecting ends of the bolt shanks 52 sufficiently so that the bolt shanks pierce the sheet metal. This piercing application of the sheet metal to the bolts shanks may be effected in practice using a conventional wrench socket and hammer or by using one of the mounting plates 38 and a hammer. In this respect it is to be noted that the sheet metal used for the barrier 18 is untempered aluminum having a thickness of from 0.17 to 0.19 inches. The bolts 40 are preferably conventional one quarter inch machine bolts having a threaded shank of between 1.5 and 2.5 inches in length. In light of the shank diameter of the bolts and the guage of non-tempered aluminum used for the barrier 18, it will be appreciated that the pressing force needed for the bolts to pierce the aluminum is readily developed using such techniques.
After being pierced by the bolt shank 52 in the aforementioned manner, the washer plate 38 is applied and drawn against the sheet metal 18 by a barrier retaining nut 54 and washer 56. The final position of the various mounting components as well as the sheet metal 18 is as illustrated in FIG. 3 of the drawings. From the illustration in FIG. 3, it will be noted that the apertures 58 in the mounting plate 38 are in a size larger than the outside diameter of the bolt mounting nuts 46 by an amount such that during the final threading of the barrier retaining nuts 54, the sheet metal 18 is forced against the bolt retaining nut 46 deforming the pierced portion of the sheet metal 18 surrounding the bolt shank 52 into the mounting plate aperture 58 wherein it is seized between the outside of the bolt mounting nut 46 and the interior of the mounting plate aperture 58. In this way, a very firm, gas-tight mounting of the sheet metal 18 is accomplished.
From the foregoing it will be appreciated that the sheet metal mounting system and method of the present invention enables complete placement of the brattice by one person and without requiring access to both sides of the brattice at least during the final stage of installation. This latter feature is particularly important in underground mine environments where access to both sides of an installed brattice is often not conveniently available. Prior to placement of the sheet metal barrier 18, of course, access may be had to opposite sides of the jack posts 24 and of the framework of beams 20 and 22 supported thereon due to the open character of the framework at that stage of brattice installation.
In light of the foregoing, it may be seen that as a result of the present invention, a highly improved system and method for mounting the sheet metal barrier of brattices of the type described and by which the stated objective among others are completely fulfilled. It is also contemplated that modifications and/or changes may be made in the embodiment of the invention described and illustrated herein. Accordingly, it is expressly intended that the foregoing description and accompanying drawings are illustrative only, not limiting, and that the true spirit and scope of the present invention will be determined by reference to the appended claims. | A sheet metal attachment system and method for the installation of underground mine brattices of the type in which a gas impervious barrier of malleable sheet metal is retained on a peripheral framework of slotted beams. The fastening system involves pre-mounting a plurality of bolts projecting from one face of the framework as piercing pins so that the sheet metal may be initially applied by forcing it over the pins. The pierced sheet metal is then drawn against the framework by a multi-apertured washer plate and barrier mounting nut threaded onto the bolts. | 8 |
FIELD OF INVENTION
The present invention relates to novel methanofullerene derivatives, negative-type photoresist compositions prepared therefrom and methods of using them. The derivatives, their photoresist compositions and the methods are ideal for fine pattern processing using, for example, ultraviolet radiation, extreme ultraviolet radiation, beyond extreme ultraviolet radiation, X-rays and charged particle rays.
BACKGROUND
As is well known, the manufacturing process of various kinds of electronic or semiconductor devices such as ICs, LSIs and the like involves a fine patterning of a resist layer on the surface of a substrate material such as a semiconductor silicon wafer. This fine patterning process has traditionally been conducted by the photolithographic method in which the substrate surface is uniformly coated with a positive or negative tone photoresist composition to form a thin layer of the photoresist composition and selectively irradiating with actinic rays (such as ultraviolet light) through a photomask followed by a development treatment to selectively dissolve away the photoresist layer in the areas exposed or unexposed, respectively, to the actinic rays leaving a patterned resist layer on the substrate surface. The thus obtained patterned resist layer is utilized as a mask in the subsequent treatment on the substrate surface such as etching. The fabrication of structures with dimensions of the order of nanometers is an area of considerable interest since it enables the realization of electronic and optical devices which exploit novel phenomena such as quantum confinement effects and also allows greater component packing density. As a result, the resist layer is required to have an ever increasing fineness which can by accomplished only by using actinic rays having a shorter wavelength than the conventional ultraviolet light. Accordingly, it is now the case that, in place of the conventional ultraviolet light, electron beams (e-beams), excimer laser beams, EUV, BEUV and X-rays are used as the short wavelength actinic rays. Needless to say the minimum size obtainable is primarily determined by the performance of the resist material and the wavelength of the actinic rays. Various materials have been proposed as suitable resist materials. In the case of negative tone resists based on polymer crosslinking, there is an inherent resolution limit of about 10 nm, which is the approximate radius of a single polymer molecule.
It is also known to apply a technique called “chemical amplification” to the polymeric resist materials. A chemically amplified resist material is generally a multi-component formulation in which there is a main polymeric component, such as a novolac resin which contributes towards properties such as resistance of the material to etching and its mechanical stability and one or more additional components which impart desired properties to the resist and a sensitizer. By definition, the chemical amplification occurs through a catalytic process involving the sensitizer which results in a single irradiation event causing exposure of multiple resist molecules. In a typical example the resist comprises a polymer and a photoacid generator (PAG) as sensitizer. The PAG releases a proton in the presence of radiation (light or e-beam). This proton then reacts with the polymer to cause it to lose a functional group. In the process, a second proton is generated which can then react with a further molecule. The speed of the reaction can be controlled, for example, by heating the resist film to drive the reaction. After heating, the reacted polymer molecules are free to react with remaining components of the formulation, as would be suitable for a negative-tone resist. In this way the sensitivity of the material to actinic radiation is greatly increased, as small numbers of irradiation events give rise to a large number of exposure events.
In such chemical amplification schemes, irradiation results in cross-linking of the exposed resist material; thereby creating a negative tone resist. The polymeric resist material may be self cross-linking or a cross linking molecule may be included. Chemical amplification of polymeric-based resists is disclosed in U.S. Pat. Nos. 5,968,712, 5,529,885, 5,981,139 and 6,607,870.
Various methanofullerene derivatives have been shown to be useful e-beam resist materials by the present inventors, Appl. Phys. Lett. Volume 72, page 1302 (1998), Appl. Phys. Lett. Volume 312, page 469 (1999), Mat. Res. Soc. Symp. Proc. volume 546, page 219 (1999) and U.S. Pat. No. 6,117,617.
As can be seen there is an ongoing desire to obtain finer and finer resolution of photoresists that will allow for the manufacture of smaller and smaller semiconductor devices in order to meet the requirements of current and further needs. It is also desirable to create materials which can be used in conjunction with these photoresists which will be more robust to the processes used to create current semiconductor devices, such as, for example, etching resistance.
DESCRIPTION OF THE FIGURES
FIG. 1 : shows an SEM showing the resolution obtained from example 1.
FIG. 2 : shows an SEM showing the resolution obtained from example 2.
FIG. 3 : shows an SEM showing the resolution obtained from example 3.
FIG. 4 : shows an SEM showing the resolution obtained from example 4.
FIG. 5 : shows an SEM showing the resolution obtained from example 5.
FIG. 6 : shows an SEM showing the resolution obtained from example 6.
FIG. 7 : shows an SEM showing the resolution obtained from example 7.
FIG. 8 : shows an SEM showing the resolution obtained from example 8.
FIG. 9 : shows an SEM showing the resolution obtained from example 9.
FIG. 10 : shows an SEM showing the resolution obtained from example 10.
SUMMARY OF THE DISCLOSURE
In a first embodiment, a methanofullerene comprising the general formula:
is disclosed wherein C2x represents a fullerene with x at least 10, y is 1-6, n is 0-1, alkyl is a branched or unbranched, substituted or unsubstituted divalent alkyl chain of 1-16 carbons with or without one or more heteroatoms substituted into the chain, aryl is a substituted or unsubstituted divalent phenyl group, heteroaromatic group, or fused aromatic or fused heteroaromatic group, and R is H or an acid labile group. An example of a disclosed methanofullerene comprises the general formula:
In a second embodiment, the methanofullerene of the above embodiment includes divalent alkyl groups comprising a substituted or unsubstituted methylene, ethylene or 1,3-propylene group, and the divalent aryl group comprises a substituted or unsubstituted phenylene group.
In a third embodiment, the methanofullerene of all the above embodiments includes R as either H or an acid labile alkoxycarbonyl group.
In a fourth embodiment, the methanofullerene of the above embodiments includes divalent alkyl group wherein the heteroatoms are one or more of oxygen, nitrogen, sulfur, or oxides of sulfur and/or the alkyl chains may be substituted with fluorine atoms.
In a fifth embodiment, a negative-tone photoresist composition is disclosed comprising at least one of any of the methanofullerenes of the above embodiments, at least one photo acid generator, at least one crosslinker, and at least one solvent, wherein the crosslinker crosslinks at least with the methanofullerene when processed.
In a sixth embodiment, the negative-tone photoresist composition of the above embodiments is disclosed wherein the at least one photoacid generator comprises an onium salt compound, a sulfone imide compound, a halogen-containing compound, a sulfone compound, a sulfonate ester compound, a quinine-diazide compound, or a diazomethane compound.
In a seventh embodiment, the negative-tone photoresist composition of any of the above embodiments is disclosed contain a novolac, a poly-hydroxystyrene, a polyacrylate, or a maleic anhydride ester-acid polymer crosslinking additive.
In an eighth embodiment, the negative-tone photoresist composition of any of the above embodiments is disclosed wherein the at least one crosslinker comprises an acid sensitive monomer or polymer.
In a ninth embodiment, the negative-tone photoresist composition of any of the above embodiments is disclosed wherein at least one methanofullerene comprising the general formula is also included:
wherein x is at least 10, y is 1-6, a is 1-10 and R is H or an acid labile group and the —CH 2 —CH 2 — group may be substituted with fluorine atoms. An example of a disclosed methanofullerene comprises the general formula:
In other embodiments, the above methanofullerenes contain only partially blocked hydroxy groups. In these cases the R groups of the above structures are different and one of the R groups in the molecule is an H while the other R group in the molecule is an acid labile group, as described above. To obtain these molecules, the acid labile group is only partially hydrolyzed. The amount of H groups in these hybrid methanofullerenes ranges between about 1% and about 90%.
In a further embodiment, a process for using any of the above mentioned negative-tone compositions is disclosed including the steps of obtaining a substrate, applying any one of the photoresist compositions of the above embodiments to a desired wet thickness, optionally heating the coated substrate to remove a majority of the solvent to obtain a desired thickness, imagewise exposing the coating to actinic radiation, removing the unexposed areas of the coating, and optionally heating the remaining coating.
In still a further embodiment, the process of the above embodiment is disclosed including a further step of either heating the imagewise exposed coating prior to removing the unexposed areas of the coating or exposing the coating to infrared exposure.
In still a further embodiment, the process of the above embodiment is disclosed wherein the unexposed areas are removed by treating with an organic solvent composition.
In still a further embodiment, the process of the above embodiment is disclosed wherein the actinic radiation is ultraviolet, extreme ultraviolet, beyond extreme ultraviolet, charged particle beam or electron beam.
In all the above embodiments, the fullerene may be substituted with more than one type of methanofullerene.
In still further embodiments, disclosed and claimed herein are negative working photosensitive compositions which contain crosslinking groups which are protected by acid labile protecting groups.
DETAILED DESCRIPTION
As used herein, the conjunction “and” is intended to be inclusive and the conjunction “or” is not intended to be exclusive unless otherwise indicated. For example, the phrase “or, alternatively” is intended to be exclusive.
As used herein, the terms “having”, “containing”, “including”, “comprising” and the like are open ended terms that indicate the presence of stated elements or features, but do not preclude additional elements or features. The articles “a”, “an” and “the” are intended to include the plural as well as the singular, unless the context clearly indicates otherwise.
As used herein, the terms “dry”, “dried” and “dried coating” means having less than 8% residual solvent.
The methanofullerene of the current application for patent is of general formulation:
x is at least 10, such as, for example, 10, 25, 30, 35, 38, 39, 41, 42, 45 and 48 wherein the example fullerene core is C 20 , C 50 , C 60 , C 70 , C 76 , C 78 , C 82 , C 84 , C 90 and C 96 . y is between about 1 to about 6 representing the number of methano substituents on the fullerene. As is well known in the industry, manufacture of such materials often results in mixtures of the number of substitutions such that a useful material may have, for example, y=2.35 or 5.1 representing an average of a mixture of substitutions. Thus y is not meant to be an absolute number of substituents but an average thereof. An example of a disclosed methanofullerene comprises the general formula:
The alkyl group can be a branched or unbranched divalent alkyl chain of 1-16 carbons with or without heteroatoms substituted into the chain, such as, for example, —CH 2 —, —CH 2 CH 2 —, —CH(CH 3 )CH 2 —, —CH 2 CH 2 CH 2 —, —CH 2 CH 2 CH 2 CH 2 —, butylene isomers, and the higher analogs up to and including hexadecylene, as well as their isomers. As used herein alkyl also includes any unsaturations in the chain such an olefin group, such as for example, —CH═CH—, or an alkynyl group. As mentioned the alkyl group may have heteroatoms substituted into the chain as part or the chain, such as O, N, S, S═O or SO 2 and the like, such as, for example, —(CH 2 CH 2 —O) z — wherein z is between about 1 and about 16, or —(CH 2 CH 2 NH) w — wherein w is between about 1 and about 16, and the like. Also included are branched alkyl groups that contain heteroatoms in the ring, such as, for example —(CH 2 CH 2 NR″) v — wherein R″ can be a branched or unbranched divalent alkyl chain of 1-16 carbons with or without heteroatoms substituted into the R″ chain.
Aryl is a substituted or unsubstituted divalent aromatic group, such aromatic groups include, for example the phenylenes (—C 6 H 4 —), the fused divalent aromatic group, such as, for example, the naphthylenes (—C 10 H 6 —), the anthacenylenes (—C 14 H 8 —) and the like, as well as the heteroaromatic groups, such as, for example, the nitrogen heterocycles: pyridines, quinolines, pyrroles, indoles, pyrazoles, the triazines, and other nitrogen-containing aromatic heterocycles well known in the arts, as well as the oxygen heterocycles: furans, oxazoles and other oxygen-containing aromatic heterocycles, as well the sulfur containing aromatic heterocycles, such as, for example, thiophenes.
R may be H or D or an acid labile group, including, for example, substituted methyl groups, 1-substituted ethyl groups, 1-substituted alkyl groups, silyl groups, germyl groups, alkoxycarbonyl group, acyl groups and cyclic acid-dissociable groups. The substituted methyl groups include, for example, the methoxymethyl group, methylthiomethyl group, ethoxy methyl group, ethylthiomethyl group, methoxyethoxy methyl group, benzyloxymethyl group, benzylthiomethyl group, phenacyl group, bromophenacyl group, methoxyphenacyl group, methylthiophenacyl group, α-methylphenacyl group, cyclopropylmethyl group, benzyl group, diphenyl methyl group, triphenylmethyl group, bromobenzyl group, nitrobenzyl group, methoxybenzyl group, methylthiobenzyl group, ethoxy benzyl group, ethylthiobenzyl group, piperonyl group, methoxycarbonylmethyl group, ethoxy carbonylmethyl group, N-propoxy carbonylmethyl group, isopropoxy carbonylmethyl group, N-butoxycarbonylmethyl group and t-butoxycarbonylmethyl group. The 1-substituted ethyl groups include, for example. 1-methoxyethyl group, 1-methylthioethyl group, 1,1-dimethoxyethyl group, 1-ethoxy ethyl group, 1-ethylthioethyl group, 1,1-diethoxy ethyl group, 1-phenoxyethyl group, 1-phenylthioethyl group, 1,1-diphenoxyethyl group, 1-benzyloxyethyl group, 1-benzylthioethyl group, 1-cyclopropylethyl group, 1-phenylethyl group, 1,1-diphenyl ethyl group, 1-methoxycarbonylethyl group, 1-ethoxy carbonylethyl group, 1-N-propoxy carbonylethyl group, 1-isopropoxy carbonylethyl group, 1-N-butoxycarbonylethyl group and the 1-t-butoxycarbonylethyl group. The 1-substituted alkyl group include the isopropyl group, sec-butyl group, t-butyl group, 1,1-dimethylpropyl group, 1-methylbutyl group and 1,1-dimethylbutyl group.
The silyl acid labile groups include, for example, the trimethyl silyl group, ethyldimethylsilyl group, methyldiethylsilyl group, triethylsilyl group, isopropyldimethylsilyl group, methyldiisopropylsilyl group, triisopropylsilyl group, t-butyldimethylsilyl group, methyldi-t-butylsilyl group, tri-t-butylsilyl group, phenyldimethylsilyl group, methyldiphenyl silyl group and triphenylsilyl group. The germyl groups include, for example, the trimethyl germyl group, ethyldimethylgermyl group, methyldiethylgermyl group, triethylgermyl group, isopropyldimethylgermyl group, methyldiisopropylgermyl group, triisopropylgermyl group, t-butyldimethylgermyl group, methyldi-t-butylgermyl group, tri-t-butylgermyl group, phenyldimethylgermyl group, methyldiphenyl germyl group and triphenylgermyl group.
The alkoxycarbonyl acid labile groups include the methoxycarbonyl group, ethoxy carbonyl group, isopropoxy carbonyl group and t-butoxycarbonyl group. The acyl acid labile groups include, for example, the acetyl group, propionyl group, butyryl group, heptanoyl group, hexanoyl group, valeryl group, pivaloyl group, isovaleryl group, lauroyl group, myristoyl group, palmitoyl group, stearoyl group, oxaryl group, malonyl group, succinyl group, glutaryl group, adipoyl group, piperoyl group, suberoyl group, azelaoyl group, sebacoyl group, acrylyl group, propioloyl group, methacryloyl group, crotonoyl group, oleoyl group, maleoyl group, fumaroyl group, mesaconoyl group, camphoroyl group, benzoyl group, phthaloyl group, isophthaloyl group, terephthaloyl group, naphthoyl group, toluoyl group, hydroatropoyl group, atropoyl group, cinnamoyl group, furoyl group, thenoyl group, nicotinoyl group, isonicotinoyl group, p-toluene sulfonyl group and the mesyl group.
Cyclic acid groups include, for example, the cyclopropyl group, cyclopentyl group, cyclohexyl group, cyclohexanyl group, 4-methoxycyclohexyl group, tetrahydropyranyl group, tetrahydrofuranyl group, tetrahydrothiopyranyl group, tetrahydrothiofuranyl group, 3-bromo tetrahydropyranyl group, 4-methoxy tetrahydropyranyl group, 4-methoxy tetrahydrothiopyranyl group and 3-tetrahydrothiophene-1,1-dioxy group.
In the above structure n may be 0 or 1. In the case where n=1, the methanofullerene contains a benzyl alcohol which will crosslink with the crosslinkers when processed. Additionally, in a further embodiment, when the benzyl alcohol is protected with the acid labile groups of the current disclosure, a reactive benzyl alcohol will be obtained when deprotected and, as above, will crosslink with the crosslinkers when processed.
The fullerenes may also be substituted with other groups that introduce certain desired characteristics to the fullerene such as, for example, solubility in certain solvents or compatibility with certain components of the formulation. The fullerenes can be prepared by any of a number of methods, such as, for example, the procedure as shown in the examples below.
The photo acid generators (PAGs) suitable for the negative-tone photoresist of the current disclosure include onium salt compounds, sulfone imide compounds, halogen-containing compounds, sulfone compounds, ester sulfonate compounds, quinone diazide compounds, and diazomethane compounds. Specific examples of these acid generators are indicated below.
Examples of onium salt compounds include sulfonium salts, iodonium salts, phosphonium salts, diazonium salts and pyridinium salts. Specific examples of onium salt compounds include diphenyl(4-phenylthiophenyl)sulphonium hexafluoroantimonate, 4,4′-bis[diphenylsulfoniolphenylsulphide bis hexafluoroantimonate and combinations there of, triphenylsulfonium nonafluorobutanesulfonate, triphenylsulfonium trifluoromethanesulfonate, triphenylsulfonium pyrenesulfonate, triphenylsulfonium dodecylbenzenesulfonate, triphenylsulfonium p-toluene sulfonate, triphenylsulfonium benzenesulfonate, triphenylsulfonium 10-camphor-sulfonate, triphenylsulfonium octanesulfonate, triphenylsulfonium 2-trifluoromethyl benzenesulfonate, triphenylsulfonium hexafluoroantimonate, triarylsulfonium hexafluoroantimonates, the triarylsulfonium hexafluorophosphates, the triarylsulfonium tetrafluoroborates as well as other tetrafluoroborates, triphenylsulfonium napthalenesulfonate, tri(4-hydroxyphenyl)sulfonium nonafluorobutanesulfonate, tri(4-hydroxyphenyl)sulfoniumtrifluoromethanesulfonate, tri(4-hydroxyphenyl)sulfonium pyrenesulfonate, tri(4-hydroxyphenyl)sulfoniumdodecylbenzenesulfonate, tri(4-hydroxyphenyl)sulfonium p-toluene sulfonate, tri(4-hydroxyphenyl)sulfonium benzenesulfonate, tri(4-hydroxyphenyl)sulfonium10-camphor-sulfonate, tri(4-hydroxyphenyl)sulfonium octanesulfonate, tri(4-hydroxyphenyl)sulfonium 2-trifluoromethylbenzenesulfonate, tri(4-hydroxyphenyl)sulfonium hexafluoroantimonate, tri(4-hydroxyphenyl)sulfonium napthalenesulfonate, diphenyliodonium nonafluorobutanesulfonate, diphenyliodonium trifluoromethanesulfonate, diphenyliodonium pyrenesulfonate, diphenyliodonium dodecylbenzenesulfonate, diphenyliodonium p-toluene sulfonate, diphenyliodonium benzenesulfonate, diphenyliodonium 10-camphor-sulfonate, diphenyliodonium octanesulfonate, diphenyliodonium 2-trifluoromethylbenzenesulfonate, bis(4-t-butylphenyl)iodonium nonafluorobutanesulfonate, bis(4-t-butylphenyl)iodonium trifluoromethanesulfonate, bis(4-t-butylphenyl)iodonium pyrenesulfonate, bis(4-t-butylphenyl)iodonium dodecylbenzenesulfonate, bis(4-t-butylphenyl)iodonium p-toluene sulfonate, bis(4-t-butylphenyl)iodonium benzenesulfonate, bis(4-t-butylphenyl)iodonium 10-camphor-sulfonate, bis(4-t-butylphenyl)iodonium octanesulfonate, bis(4-t-butylphenyl)iodonium 2-trifluoromethylbenzenesulfonate, 4-hydroxy-1-naphthyl tetrahydrothiophenium trifluoromethanesulfonate and 4,7-dihydroxy-1-naphthyl tetrahydrothiophenium trifluoromethanesulfonate.
Specific examples of a sulfone imide compound include N-(trifluoromethylsulfonyloxy)succinimide, N-(trifluoromethylsulfonyloxy)phthalimide, N-(trifluoromethylsulfonyloxy)diphenylmaleimide, N-(trifluoromethylsulfonyloxy)bicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(trifluoromethylsulfonyloxy)-7-oxabicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(trifluoromethylsulfonyloxy)bicyclo[2.2.1]heptane-5,6-oxy-2,3-dicarboxyimide, N-(trifluoromethylsulfonyloxy)naphthylimide, N-(10-camphor-sulfonyloxy)succinimide, N-(10-camphor-sulfonyloxy)phthalimide, N-(10-camphor-sulfonyloxy)diphenyl maleimide, N-(10-camphor-sulfonyloxy)bicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(10-camphor-sulfonyloxy)-7-oxabicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(10-camphor-sulfonyloxy)bicyclo[2.2.1]heptane-5,6-oxy-2,3-dicarboxyimide, N-(10-camphor-sulfonyloxy)naphthylimide, N-(p-toluene sulfonyloxy)succinimide, N-(p-toluene sulfonyloxy)phthalimide, N-(p-toluene sulfonyloxy)diphenyl maleimide, N-(p-toluene sulfonyloxy)bicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(p-toluene sulfonyloxy)-7-oxabicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(p-toluene sulfonyloxy)bicyclo[2.2.1]heptane-5,6-oxy-2,3-dicarboxyimide, N-(p-toluene sulfonyloxy)naphthylimide, N-(2-trifluoromethylbenzenesulfonyloxy)succinimide, N-(2-trifluoromethylbenzenesulfonyloxy)phthalimide, N-(2-trifluoromethylbenzenesulfonyloxy)diphenyl maleimide, N-(2-trifluoromethylbenzenesulfonyloxy)bicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(2-trifluoromethylbenzenesulfonyloxy)-7-oxabicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(2-trifluoromethylbenzenesulfonyloxy)bicyclo[2.2.1]heptane-5,6-oxy-2,3-dicarboxyimide, N-(2-trifluoromethylbenzenesulfonyloxy)naphthylimide, N-(4-fluorobenzenesulfonyloxy)succinimide, N-(4-fluorobenzenesulfonyloxy)phthalimide, N-(4-fluorobenzenesulfonyloxy)diphenyl maleimide, N-(4-fluorobenzenesulfonyloxy)bicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(4-fluorobenzenesulfonyloxy)-7-oxabicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(4-fluorobenzenesulfonyloxy)bicyclo[2.2.1]heptane-5,6-oxy-2,3-dicarboxyimide, N-(4-fluorobenzenesulfonyloxy)naphthylimide, N-(nonafluorobutylsulfonyloxy)succinimide, N-(nonafluorobutylsulfonyloxy)phthalimide, N-(nonafluorobutylsulfonyloxy)diphenyl maleimide, N-(nonafluorobutylsulfonyloxy)bicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(nonafluorobutylsulfonyloxy)-7-oxabicyclo[2.2.1]hepto-5-ene-2,3-dicarboxyimide, N-(nonafluorobutylsulfonyloxy)bicyclo[2.2.1]heptane-5,6-oxy-2,3-dicarboxyimide and N-(nonafluorobutylsulfonyloxy)naphthylimide.
Examples of halogen-containing compounds include, for example, haloalkyl group-containing hydrocarbon compounds and haloalkyl group-containing heterocyclic compounds. Specific examples of halogen-containing compounds include (poly)trichloromethyl-s-triadine derivatives such as phenyl-bis(trichloromethyl)-s-triadine, 4-methoxyphenyl-bis(trichloromethyl)-s-triadine and 1-naphthyl-bis(trichloromethyl)-s-triadine, and 1,1-bis(4-chlorophenyl)-2,2,2-trichloroethane.
Examples of sulfone compounds include, for example, β-ketosulfone and β-sulfonylsulfone, and the α-diazo compounds thereof. Specific examples of the sulfone compounds include phenacyl phenylsulfone, mesitylphenacyl sulfone, bis(phenylsulfonyl)methane, 1,1-bis(phenylsulfonyl)cyclobutane, 1,1-bis(phenylsulfonyl)cyclopentane, 1,1-bis(phenylsulfonyl)cyclo hexane, and 4-trisphenacyl sulfone.
Examples of sulfonate ester compounds include alkylsulfonate esters, haloalkyl sulfonate esters, aryl sulfonate esters sand imino sulfonates. Specific examples of sulfonate ester compounds include benzoin tosylate, pyrogallol tristrifluoromethanesulfonate, pyrogallol trisnonafluorobutanesulfonate, pyrogallol methanesulfonate triester, nitrobenzyl-9,10-diethoxy anthracene-2-sulfonate, α-methylol benzoin tosylate, α-methylol benzoin octanesulfonate, α-methylol benzoin trifluoromethanesulfonate and α-methylol benzoin dodecylsulfonate.
Examples of quinine diazide compounds include compounds containing a 1,2-quinone diazide sulfonyl group such as the 1,2-benzoquinone diazide-4-sulfonyl group, 1,2-naphthoquinone diazide-4-sulfonyl group, 1,2-naphtho quinine diazide-5-sulfonyl group and 1,2-naphthoquinone diazide-6-sulfonyl group. Specific examples of quinone diazide compounds include 1,2-quinone diazidesulfonate esters of (poly)hydroxyphenylaryl ketones such as 2,3,4-trihydroxybenzophenone, 2,4,6-trihydroxybenzophenone, 2,3,4,4′-tetrahydroxybenzophenone, 2,2′,3,4-tetrahydroxybenzophenone, 3′-methoxy-2,3,4,4′-tetrahydroxybenzophenone, 2,2′,4,4′-tetrahydroxybenzophenone, 2,2′3,4,4′-pentahydroxybenzophenone, 2,2′3,4,6′-pentahydroxybenzophenone, 2,3,3′4,4′,5′-hexahydroxybenzophenone, 2,3′4,4′,5′,6-hexahydroxybenzophenone; 1,2-quinone diazide sulfonate esters of bis[(poly)hydroxyphenyl]alkanes such as bis(4-hydroxyphenyl)methane, bis(2,4-dihydroxyphenyl)methane, bis(2,3,4-trihydroxyphenyl)methane, 2,2-bis(4-hydroxyphenyl)propane, 2,2-bis(2,4-dihydroxyphenyl)propane and 2,2-bis(2,3,4-trihydroxyphenyl)propane; 1,2-quinone diazide sulfonate esters of (poly)hydroxytriphenylalkanes such as 4,4′-dihydroxytriphenylmethane, 4,4′,4″-trihydroxytriphenylmethane, 2,2′,5,5′-tetramethyl-2″,4,4′-trihydroxytriphenylmethane, 3,3′,5,5′-tetramethyl-2″,4,4′-trihydroxytriphenylmethane, 4,4′,5,5′-tetramethyl-2,2′,2″-trihydroxytriphenylmethane, 2,2′,5,5′-tetramethyl-4,4′,4″-trihydroxytriphenylmethane, 1,1,1-tris(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 1,1-bis(4-hydroxyphenyl)-1-[4-{1-(4-hydroxyphenyl)-1-methylethyl}phenyl]ethane, 1,1,3-tris(2,5-dimethyl-4-hydroxyphenyl)propane, 1,1,3-tris(2,5-dimethyl-4-hydroxyphenyl)butane and 1,3,3-tris(2,5-dimethyl-4-hydroxyphenyl)butane; and 1,2-quinone diazide sulfonate esters of (poly)hydroxyphenylflavans such as 2,4,4-trimethyl-2′,4′,7-trihydroxy-2-phenylflavan and 2,4,4-trimethyl-2′,4′,5′,6′,7-pentahydroxy-2-phenylflavan.
Specific examples of diazomethane compounds include bis(trifluoromethylsulfonyl)diazomethane, bis(cyclohexylsulfonyl)diazomethane, bis(phenylsulfonyl)diazomethane, bis(p-toluene sulfonyl)diazomethane, methylsulfonyl-p-toluene sulfonyldiazomethane, 1-cyclohexylsulfonyl-1-(1,1-dimethylethylsulfonyl)diazomethane and bis(1,1-dimethylethylsulfonyl)diazomethane.
The compositions of the current disclosure may contain one or more of the above mentioned photoacid generators.
Crosslinkers suitable for the current disclosure constitute compounds able to cross-link with the methanofullerene during the process such that when the methanofullerene is substituted with a phenol or similar group, such as, for example, an alkyl —OH group, or when the methanofullerene is deprotected to provide for a phenol or similar group, the crosslinker will react with the —OH group situated on the phenol or similar group. Not to be held to theory, it is believed that the acid that is generated by exposure to the actinic radiation not only reacts with the acid-labile group of the methanofullerene but aids in the reaction of the crosslinker with itself and with the methanofullerene. Examples of crosslinkers include compounds comprising at least one type of substituted group that possess a cross-linking reactivity with the phenol or similar group of the methanofullerene. Specific examples of this crosslinking group include the glycidyl ether group, glycidyl ester group, glycidyl amino group, methoxymethyl group, ethoxy methyl group, benzyloxymethyl group, dimethylamino methyl group, diethylamino methyl group, dimethylol amino methyl group, diethylol amino methyl group, morpholino methyl group, acetoxymethyl group, benzyloxy methyl group, formyl group, acetyl group, vinyl group and isopropenyl group.
Examples of compounds having the aforementioned cross-linking substituted group include, for example, bisphenol A-based epoxy compounds, bisphenol F-based epoxy compounds, bisphenol S-based epoxy compounds, novolac resin-based epoxy compound, resol resin-based epoxy compounds, poly(hydroxystyrene)-based epoxy compounds, methylol group-containing melamine compounds, methylol group-containing benzoguanamine compounds, methylol group-containing urea compounds, methylol group-containing phenol compounds, alkoxyalkyl group-containing melamine compounds, alkoxyalkyl group-containing benzoguanamine compounds, alkoxyalkyl group-containing urea compounds, alkoxyalkyl group-containing phenol compounds, carboxymethyl group-containing melamine resins, carboxy methyl group-containing benzoguanamine resins, carboxymethyl group-containing urea resins, carboxymethyl group-containing phenol resins, carboxymethyl group-containing melamine compounds, carboxymethyl group-containing benzoguanamine compounds, carboxymethyl group-containing urea compounds, and carboxymethyl group-containing phenol compounds, methylol group-containing phenol compounds, methoxymethyl group-containing melamine compounds, methoxymethyl group-containing phenol compounds, methoxymethyl group-containing glycol-uril compounds, methoxymethyl group-containing urea compounds and acetoxymethyl group-containing phenol compounds. The methoxymethyl group-containing melamine compounds are commercially available as, for example, CYMEL300, CYMEL301, CYMEL303, CYMEL305 (manufactured by Mitsui Cyanamid), the methoxymethyl group-containing glycol-uril compounds are commercially available as, for example, CYMEL117 4 (manufactured by Mitsui Cyanamid), and the methoxymethyl group-containing urea compounds are commercially available as, for example, MX290 (manufactured by Sanwa Chemicals).
Examples of suitable solvents for the current disclosure include ethers, esters, etheresters, ketones and ketoneesters and, more specifically, ethylene glycol monoalkyl ethers, diethylene glycol dialkyl ethers, propylene glycol monoalkyl ethers, propylene glycol dialkyl ethers, acetate esters, hydroxyacetate esters, lactate esters, ethylene glycol monoalkylether acetates, propylene glycol monoalkylether acetates, alkoxyacetate esters, (non-)cyclic ketones, acetoacetate esters, pyruvate esters and propionate esters. Specific examples of these solvents include ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monopropyl ether, ethylene glycol monobutyl ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, diethylene glycol dipropyl ether, diethylene glycol dibutyl ether, methylcellosolve acetate, ethyl cellosolve acetate, propylene glycol monomethyletheracetate, propylene glycol monoethyletheracetate, propylene glycol monopropyletheracetate, isopropenyl acetate, isopropenyl propionate, methylethyl ketone, cyclohexanone, 2-heptanone, 3-heptanone, 4-heptanone, 2-hydroxypropionate ethyl, 2-hydroxy-2-methylpropionate ethyl, ethoxy acetate ethyl, hydroxyacetate ethyl, 2-hydroxy-3-methyl methylbutyrate, 3-methoxybutylacetate, 3-methyl-3-methoxybutylacetate, 3-methyl-3-methoxybutyl propionate, 3-methyl-3-methoxybutyl butylate, ethyl acetate, propyl acetate, butyl acetate, methyl acetoacetate, ethyl acetoacetate, methyl 3-methoxypropionate, ethyl 3-methoxy propionate, 3-ethoxy propionate methyl and 3-ethoxy propionate ethyl. The aforementioned solvents may be used independently or as a mixture of two or more types. Furthermore, at least one type of high boiling point solvent such as benzylethyl ether, dihexyl ether, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, acetonylacetone, isoholon, caproic acid, capric acid, 1-octanol, 1-nonanol, benzyl alcohol, benzyl acetate, ethyl benzoate, diethyl oxalate, diethyl maleate, γ-butyrolactone, ethylene carbonate, propylene carbonate and phenylcellosolve acetate may be added to the aforementioned solvent.
Various additives may be added to the photoresist formulations to provide certain desirable characteristic of the photoresist such as, for example, acid diffusion control agents to retard acid from migrating into unexposed areas of the coating, surfactants to improve coating of substrates, adhesion promoters to improve adhesion of the coating to the substrate and sensitizers to improve the photosensitivity of the photoresist coating during photoexposure, and antifoaming agents and air release agents, as well as other materials well know in the coatings industry.
In other embodiments other methanofullerenes are added to provide various desired properties such as improved sensitivity to the actinic radiation or for improvements in line edge roughness. Examples of such methanofullerenes include:
wherein x, y and R are described about and R can include a carboxylic acid derivative which together with the —(CH 2 CH 2 —O) a provides for a carboxylic ester structure. The —(CH 2 CH 2 —O) group may be substituted with fluorine atoms. A can be from about 1 to about 10. An more specific example of a disclosed methanofullerene comprises the general formula:
The components of the compositions of the current disclosure are included in ranges as follows based on weight/weight: methanofullerenes from about 1% to about 65%, crosslinker from about 10% to about 80%, photoacid generator from about 0.5% to about 50%. The percent solids of the composition may range from about 0.001%-about 25%.
In other embodiments, the above methanofullerenes contain only partially blocked hydroxy groups. In these cases the R groups of the above structures are different and one of the R groups in the molecule is an H while the other R group in the molecule is an acid labile group, as described above. To obtain these molecules, the acid labile group is only partially hydrolyzed. The amount of H groups in these hybrid methanofullerenes ranges between about 1% and about 90%.
The photoresist compositions can be coated onto substrate such as a silicon wafer or a wafer coated with silicon dioxide, aluminium, aluminum oxide, copper, nickel, any of a number of semiconductor materials or nitrides or other substrates well known the semiconductor industry, or a substrate having thereon an organic film, such as, for example, a bottom layer anti-reflective film or the like. The photoresist compositions are applied by such processes as spin coating, curtain coating, slot coating, dip coating, roller coating, blade coating and the like. After coating, the solvent is removed to a level wherein the coating can be properly exposed. In some cases a residual of 5% solvent may remain in the coating while in other cases less than 1% is required. Drying can be accomplished by hot plate heating, convection heating, infrared heating and the like. The coating is imagewise exposed through a mark containing a desired pattern.
Radiation suitable for the described photoresist compositions include, for example, ultraviolet rays (UV), such as the bright line spectrum of a mercury lamp (254 nm), a KrF excimer laser (248 nm), and an ArF excimer laser (193 nm), extreme ultraviolet (EUV) such as 13.5 nm from plasma discharge and synchrotron light sources, beyond extreme ultraviolet (BEUV) such as 6.7 nm exposure, X-ray such as synchrotron radiation. Ion beam lithography and charged particle rays such as electron beams may also be used.
Following exposure, the exposed coated substrate may optionally be post exposure baked to enhance the reaction of the photoacid generator, such as, for example, heating from about 30 to about 200° C. for about 10 to about 600 seconds. This may be accomplished by hot plate heating, convection heating, infrared heating and the like. The heating may also be performed by a laser heating processes such as, for example, a CO 2 laser pulse heating for about 2 to about 5 milliseconds. Both heating processes may be combined in tandem.
A flood exposure process may be applied after the pattern exposure to aid in further cure. Results have indicated that flood exposure reduces or eliminates pattern collapse after development of the negative-tone resists as well as reduction in line edge roughness. For example, a 532 nm continuous wave laser exposes the previously exposed resist for 1-2 sec followed by wet development. The flood process may or may not be followed by a heating step.
The unexposed areas are next moved using a developer. Such developers include organic solvents as well as aqueous solution such as aqueous alkali solution. When an organic solvent is used to remove the unexposed areas generally the solvent is less aggressive than the solvent that was used in preparing the photoresist composition. Examples of aqueous alkali development solution include, for example, at least one type of alkaline compound such alkali metal hydroxides, ammonia water, alkylamines, alkanolamines, heterocyclicamines, tetraalkyl ammonium hydroxides, cholines, and 1,8-diazabicyclo[5.4.0]-7-undecan,1,5-diazabicyclo[4.3.0]-5-nonene at a concentration of about 1 to about 10% by weight, such as, for example, about 2 to about 5% by weight. Water-soluble organic solvents such as methanol and ethanol and surfactants may also be added in suitable amounts to the alkaline aqueous solution, depending on the desired development characteristics and process parameters.
After development a final baking step may be included to further enhance the curing of the now exposed and developed pattern. The heating process may be, for example, from about 30 to about 600° C. for about 10 to about 120 seconds and may be accomplished by hot plate heating, convection heating, infrared heating and the like.
Negative working photosensitive compositions of the current disclosure contain crosslinking material which are protected by acid labile protecting groups. Such crosslinkers include monomer, oligomer and polymers. Such polymers include, for example, phenolic resins, cresol-formaldehyde resins, carboxylic acid containing resins, and hydroxy group containing resins. The reactive portions of these resins are protected by the acid labile protecting groups that are listed above. The composition contain photoacid generators, as listed above, the protected crosslinking materials and other materials which crosslink with the crosslinkers when the reactive portions of the crosslinkers are deprotected. Other materials may also be present in the composition which are generally present in photosensitive coatings, such as, for example, wetting agents, leveling agents, colorants, photosensitizing agents, and the like. Thus the components of the composition are admixed in a solvent and coated onto a substrate and dried to a suitable dryness. The coating is exposed to actinic radiation to convert a portion of the photoacid generator to acid and the acid reacts to deprotect the protected crosslinking materials. The crosslinking materials, by themselves or with the aid of the photogenerated acid, crosslinks the composition. The unexposed areas can now be removed with a developer leaving behind an image.
It has also been found that inclusion of the protected materials in photoresists enhances the contrast of the photoimage as acids that may migrate to areas which have not been exposed to actinic radiation are captured by the protected materials.
EXAMPLES
Synthesis Example A
Methanofullerene I: [3-(4-t-butoxycarbonyl)phenyl-1-propyl malonate]-methano-[60]fullerene
Synthesis of 3-(4-t-butoxycarbonyl)phenyl-1-propanol (1)
To a 250 mL round bottom flask was added 3-(4-hydroxyphenyl)-1-propanol (10 g, 65.7 mmol), dichloromethane (75 mL) and di-tert-butyldicarbonate (14.36 g, 65.7 mmol). The mixture was stirred under nitrogen and cooled to 0° C. in an ice bath. Potassium carbonate (24.37 g, 176 mmol) and 18-crown-6 (0.90 g, 3.4 mmol) dissolved in dichloromethane were added. The resulting mixture was stirred and warmed to room temperature overnight. The crude reaction mixture was filtered through a silica gel and rinsed with ethyl acetate. The resulting solvent was evaporated and the residue was purified via flash column chromatography on silica gel with ethyl acetate: hexane (40%) as eluant. The third fraction was combined and the solvent removed to give 15.7 g (yield: 95%) of 1 as a yellow oil. The product was characterized by 1 H NMR and MS.
Synthesis of 3-(4-t-butoxycarbonyl)phenyl-1-propyl malonate (2)
Dichloromethane (275 mL) was added to 1 (13.71 g, 54.4 mmol) in a 500 mL round bottom flask. To this was added, with stirring, pyridine (5.72 g, 72.35 mmol, 1.33 equiv) and the solution was cooled to 0° C. in an ice bath under nitrogen. Malonyl dichloride (2.65 mL, 27.2 mmol, in dichloromethane solution) was dropwise added. The initially clear solution became dark red upon complete addition of the malonyl dichloride. The mixture was stirred and warm up to room temperature overnight, upon which time it have become dark blue/green in color. The mixture was filtered through silica gel with ethyl acetate. The filtrate was evaporated and the residue was purified via flash column chromatography on silica gel using ethyl acetate as eluant. The fractions were collected and removed solvent to give 2 as yellow oil (9.56 g, 61% yield). The product was characterized by 1 H and MS.
Synthesis of [3-(4-t-butoxycarbonyl)phenyl-1-propyl malonate]-methano-[60]fullerene(3)
In a round bottom flask, [60]fullerene(1 equivalent), 9,10-dimethylancethracene(22 equivalent) and toluene were added. The resulting solution was stirred under N 2 for one hour to completely dissolve the fullerene. Carbon tetrabromide (22 equivalent) and 2 (22 equiv) were added to the solution. 1,8-Diazabicyclo[5.4.0]undec-7-ene (108 equivalent) was added dropwise and the resulting mixture was stirred at room temperature overnight and the initial purple solution had become a dark red color. The crude mixture was poured though silica gel with toluene to remove unreacted [60]fullerene, and then rinsed with dichloromethane: ethyl acetate:methanol (2:2:1) to remove the red/brown band containing the crude products. The solvents were evaporated and the resulting residue 3 (dark red/brown oil) was obtained and characterized by 1 H NMR and MALDI MS. Major components in 3 is multi-adducts fullerenes (n=4 to 6).
Synthesis Example B
Methanofullerene II: (3-phenol-1-propyl malonate)-methano-[60]fullerene
Synthesis of (3-phenol-1-propyl malonate)-methano[60]fullerene (4)
In a 50 mL round bottom flask, 3 was dissolved in dichloromethane (10 mL) and stirred under nitrogen. Triflic acid (0.1 mol %) was added and stirred for 4 hours. The solvent was removed under vacuum and the resulting residue 4 was obtained and characterized by 1 H NMR and MALDI MS.
Synthesis of ((3-phenol-1-propyl)-(3-(4-t-butoxycarbonyl)-phenyl-1-propyl)malonate)methano-[60]fullerene
In a 50 mL round bottom flask, 3 was dissolved in dichloromethane (10 mL) and stirred under nitrogen. Triflic acid (0.1 mol %) was added and stirred for 0.5 hours to partially hydrolyze the 4-t-butoxycarbonyl groups. The solvent was removed under vacuum and the resulting residue 4 was obtained and characterized by 1 H NMR and MALDI MS.
Composition Example 1
Into 100 mL of propylene glycol monomethyl ether (PGME) was added 0.25 g of methanofullerene I, 0.50 g of poly[(o-cresyl glycidyl ether)-co-formaldehyde] and 0.25 g of triphenylsulfonium hexafluoroantimonate and stirred for 1 hr at room temperature. The composition was applied to a silicon wafer and spin coated at 500 rpm for 5 sec followed by 2000 rpm for 60 sec. The coated wafer was then heated on a hot plate at 75° C. for 5 min to give a film of approximately 25 nm. The wafer was imagewise exposed to synchrotron based EUV light at 13-14 nm wavelength at 31.2 mJ/cm 2 and post exposure baked at 90° C. for 3 min. The unexposed areas were removed by puddle development in a 50:50 blend of monochlorobenzene and isopropyl alcohol for 20 sec followed by an isopropyl alcohol rinse. FIG. 1 shows the resulting 22 nm lines and spaces for example 1.
Composition Example 2
Example 1 was repeated but 150 mL of PGME was used to reduce the solids content. The resulting film thickness was 18 nm and the exposure was 21.2 mJ/cm 2 . FIG. 2 shows the resulting 18 nm lines and spaces for example 2.
Composition Example 3
Example 1 was repeated using methanofullerene II in place of methanofullerene I. A 48 mJ/cm 2 exposure dosage was used. FIG. 3 shows the resulting 25 nm lines and spaces for example 3.
Composition Example 4
Example 1 was repeated using an E-beam exposure in place of 13-14 nm exposure. Area dose testing established a sensitivity of 90 μC/cm2 at 30 keV. For high resolution patterning a line dose of 575 pC/cm was applied at a nominal half-pitch of 50 nm, given lines of ˜20 nm with ˜30 nm spaces. FIG. 4 shows the resulting lines and spaces for example 4.
Composition Example 5
Example 3 was repeated using an E-beam exposure of 90 μC/cm 2 at 30 keV in place of 13-14 nm exposure. For high resolution patterning a line dose of 575 pC/cm was applied at a nominal half-pitch of 50 nm, given lines of ˜20 nm with ˜30 nm spaces FIG. 5 shows the resulting lines and spaces for the example 5.
Composition Example 6
The formulation of Example 1 was repeated using 0.125 g of methanofullerene I and 0.125 g of a methanofullerene having tetraethylene glycol esters capped with acetic acid to provide acetate esters. The composition was applied to a silicon wafer and spin coated at 500 rpm for 5 sec followed by 2000 rpm for 60 sec. The coated wafer was then heated on a hot plate at 75° C. for 5 min to give a film of approximately 25 nm. The wafer was imagewise exposed to 40 μC/cm 2 of E-beam radiation and post exposure baked at 90° C. for 3 min. For high resolution patterning a line dose of 600 pC/cm was applied at a nominal half-pitch of 50 nm, given lines of ˜20 nm with ˜30 nm spaces. The unexposed areas were removed by puddle development in a 50:50 blend of monochlorobenzene and isopropyl alcohol for 20 sec followed by an isopropyl alcohol rinse. FIG. 6 shows the resulting lines and spaces for example 6.
Composition Example 7
Into 100 mL of propylene glycol monomethyl ether (PGME) was added 0.50 g of polyhydroxystyrene, 1.00 g of poly[(o-cresyl glycidyl ether)-co-formaldehyde] and 0.50 g of triphenylsulfonium hexafluoroantimonate and stirred for 1 hr at room temperature. The composition was applied to a silicon wafer and spin coated at 500 rpm for 5 sec followed by 2000 rpm for 60 sec. The coated wafer was then heated on a hot plate at 70° C. for 5 min to give a film of approximately 80 nm. The wafer was imagewise exposed to 30 keV E-beam and post exposure baked at 90° C. for 2 min. The unexposed areas were removed by puddle development in a 50:50 blend of monochlorobenzene and isopropyl alcohol for 20 sec followed by an isopropyl alcohol rinse. A line dose of 118 pC/cm was applied, given an isolated line of ˜20 nm. FIG. 7 shows the resulting line for example 7.
Composition Example 8
Example 7 was repeated using 0.5% polyhydroxystyrene which was 95.5% protected with t-BOC in place of the polyhydroxystyrene. A line dose of 118 pC/cm was applied, giving an isolated line of ˜22 nm. FIG. 8 shows the resulting line for example 8.
Composition Example 9
Into 100 mL of ethyl lactate was added 0.25 g of polyhydroxystyrene, 0.50 g of poly[(o-cresyl glycidyl ether)-co-formaldehyde] and 0.25 g of triphenylsulfonium hexafluoroantimonate and stirred for 1 hr at room temperature. The composition was applied to a silicon wafer and spin coated at 500 rpm for 5 sec followed by 1200 rpm for 80 sec. The coated wafer was then heated on a hot plate at 70° C. for 5 min to give a film of approximately 30 nm. The wafer was imagewise exposed to 30 keV E-beam and post exposure baked at 110° C. for 2 min. The unexposed areas were removed by puddle development in a 50:50 blend of monochlorobenzene and isopropyl alcohol for 20 sec followed by an isopropyl alcohol rinse. A line dose of 88 pC/cm was applied at a nominal half-pitch of 25 nm, given lines of ˜20 nm with ˜30 nm spaces. FIG. 9 shows the resulting lines and spaces for the example 9.
Composition Example 10
Example 9 was repeated using 0.25% polyhydroxystyrene which was 95.5% protected with t-BOC in place of the polyhydroxystyrene. A line dose of 117 pC/cm was applied at a nominal half-pitch of 25 nm, giving lines of ˜20 nm with ˜30 nm spaces. FIG. 10 shows the resulting lines and spaces for the example 10. | The present disclosure relates to novel methanofullerene derivatives, negative-type photoresist compositions prepared therefrom and methods of using them. The derivatives, their photoresist compositions and the methods are ideal for fine pattern processing using, for example, ultraviolet radiation, beyond extreme ultraviolet radiation, extreme ultraviolet radiation, X-rays and charged particle rays. Negative photosensitive compositions are also disclosed. | 0 |
FIELD OF THE INVENTION
[0001] The invention relates generally to techniques for retrieving information over the Internet or other communication networks, and more particularly to retrieval techniques which are configured to protect the privacy of an associated retrieving user.
BACKGROUND OF THE INVENTION
[0002] Privacy is an important aspect of digital commerce. However, privacy requirements are often difficult to satisfy when combined with other important properties, such as fair and correct charging for information downloaded or otherwise retrieved over the Internet or other type of network. In order for a merchant to be able to charge a customer or other user correctly for such retrieved information, it generally must know that the user has obtained information exactly corresponding to a particular requested payment. However, in many situations a user may prefer that no one, not even the merchant, know exactly what information he or she is buying. Existing techniques for private information retrieval have been unable to provide an adequate solution to this problem in an efficient manner. Moreover, such techniques have generally been unable to hide from the merchant the particular purchase price associated with a given retrieved information item. This type of approach fails to provide adequate protection of user privacy in that the type of information purchased can often be inferred from the purchase price.
[0003] A wide variety of cryptographic techniques are also known in the art. Such techniques include public key cryptography and digital signatures. One well-known type of public key cryptography is based on ElGamal encryption using discrete logarithms, and is described in T. ElGamal, “A Public Key Cryptosystem and a Signature Scheme Based on Discrete Logarithms,” IEEE Transactions on Information Theory, Vol. 31, pp. 469-472, 1985, which is incorporated by reference herein. A well-known type of digital signature referred to as a Schnorr signature is described in C. P. Schnorr, “Efficient Signature Generation for Smart Cards,” Journal of Cryptology 4, pp. 161-174, 1981, which is incorporated by reference herein. It is also known that a signed ElGamal encryption of a message can be generated as an ElGamal ciphertext together with a Schnorr signature of that ciphertext, with the public signature key given by the ElGamal ciphertext. This signed ElGamal encryption is described in greater detail in M. Jakobsson, “A Practical Mix,” turocrypt ′98, LNCS 1403, pp. 448-461, 1998, and in U.S. Pat. No. 6,049,613 issued Apr. 11, 2000 and entitled “Method and Apparatus for Encrypting, Decrypting and Providing Privacy for Data Values,” both of which are incorporated by reference herein.
[0004] Although these and other cryptographic techniques are known in the art, such techniques have not heretofore been applied to private information retrieval in a manner which solves the above-noted problem of preventing a merchant from determining the particular information items purchased by a given user.
SUMMARY OF THE INVENTION
[0005] The invention solves the above-noted problem of the prior art by providing techniques for tagged private information retrieval. In accordance with one aspect of the invention, purchase of information items from a merchant over the Internet or other network is implemented so as to ensure that the merchant is unable to identify the particular information item(s) purchased by a user.
[0006] An illustrative embodiment of the invention is configured such that a user when considering purchase of a given information item is permitted to access a corresponding signed ciphertext of that item. The signed ciphertext in the illustrative embodiment includes a first ciphertext portion in the form of a symmetric key encrypted using a public key associated with the merchant, a second ciphertext portion corresponding to the information item encrypted using the symmetric key, an unencrypted description of the information item, and a tag which includes a signature. The user requests purchase of the information item by sending a blinded version of the first ciphertext portion to a payment server along with an appropriate payment. The payment server decrypts the blinded version of the first ciphertext portion and returns the resulting symmetric key to the user. The user then utilizes the symmetric key to decrypt the second ciphertext portion so as to obtain the desired information item.
[0007] In accordance with another aspect of the invention, the decrypting operation performed by the payment server may be implemented in at least part of a set of multiple rounds, with the user providing the payment server with a blinded ciphertext and receiving in response a corresponding decryption result for each of the rounds. For example, the decrypting operation may be implemented in j rounds, such that for each of the first j−1 of the rounds the user provides a blinded ciphertext to the payment server and receives in response a corresponding decryption result. A plaintext generated by the payment server after the jth round and supplied to the user may then provide a decryption key or other information that is utilized by the user in conjunction with accessing the given information item. Alternatively, a plaintext generated after one of the first j−1 rounds may provide the decryption key or other information that is utilized by the user in conjunction with accessing the given information item. The payment server is unable to determine which of these arrangements is being utilized at any given time, since it is decrypting blinded ciphertext.
[0008] The invention provides a number of advantages over the conventional techniques described previously. For example, the tagged private information retrieval of the invention can ensure that no one other than the user is able to determine what particular information item has been purchased, and that no electronic or paper “trail” is created. In addition, if a given purchased information item does not correspond to its associated description, the user may show a transcript of the decryption process to the merchant or a designated third party in order to complain, and potentially get a refund. The invention thus allows complaints to be made in case a merchant advertises one type of information item but actually sells another type of information item to the customer. The tagged private information retrieval of the invention can also be configured such that the payment server knows only the total amount charged but does not know whether this charge corresponds to one sale at the total amount, or to multiple sales at lesser amounts. Advantageously, the invention hides from the payment server and merchant the price paid by the user for particular information items. The payment server and merchant will only know that the user paid the appropriate amount for the information items.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 shows an illustrative embodiment of an information retrieval system configured to provide tagged private information retrieval in accordance with the invention.
[0010] [0010]FIG. 2 is a block diagram of one possible implementation of a given one of the elements of the system of FIG. 1.
[0011] [0011]FIG. 3 is a flow diagram of an example tagged private information retrieval process in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The present invention will be illustrated below in conjunction with an exemplary system in which the tagged private information retrieval techniques of the invention are implemented over the Internet or other type of network or communication channel. It should be understood, however, that the invention is more generally applicable to any type of electronic system or device application in which it is desirable to provide privacy for information retrieval. For example, although well-suited for use with computer communications over the Internet or other computer networks, the invention can also be applied to numerous other information retrieval applications, including applications involving information retrieval over wireless networks using wireless devices such as mobile telephones or personal digital assistants (PDAs).
[0013] [0013]FIG. 1 shows an exemplary system 100 in which tagged private information retrieval techniques are implemented in accordance with the invention. In the system 100 , a merchant 102 communicates over one or more communication channels 104 with a customer 106 . A set of elements including a private database 110 , a public database 112 , and a payment server 114 is associated with the merchant 102 . The one or more communication channels 104 in this illustrative embodiment comprise a network 120 . A user device 122 is associated with the customer 106 . The customer 106 is more generally referred to herein as a user. The term “user” as used herein should be understood to include the customer 106 or a processing device such as user device 122 associated with that customer. Operations referred to herein as being performed by or in conjunction with a user may therefore be performed by or in conjunction with user device 122 .
[0014] Although the payment server 114 is associated with the merchant 102 in the system 100 , this is not a requirement of the invention, and the payment server 114 may be a third party entity separate from the merchant 102 in other embodiments of the invention.
[0015] The network 120 may be a local area network, a metropolitan area network, a wide area network, a global data communications network such as the Internet, a private “intranet” network or any other suitable data communication medium, as well as portions or combinations of such networks or other communication media. For example, elements 112 and 122 may be connected by one network, while elements 114 and 112 are connected by another network. Numerous other interconnection arrangements may also be used.
[0016] The user device 122 may be a desktop or portable personal computer, a mobile telephone, PDA, a television set-top box or any other type of device capable of retrieving information over network 120 .
[0017] It should be understood that although only a single merchant 102 and customer 106 are shown in the FIG. 1 embodiment, the invention is more generally applicable to any number, type and arrangement of different merchants and users.
[0018] The private database 110 associated with the merchant 102 includes a number of entries each corresponding to a particular retrievable information item m i , i=1, 2, . . . N. These are plaintext information items, i.e., are in an unencrypted form. The information itself may be audio, video, image, data or any other type of information as well as combinations thereof. The term “retrievable information item” as used herein is thus intended to include any type of information in any form retrievable over a network or other communication channel.
[0019] The public database 112 in the illustrative embodiment includes for each information item m i a corresponding entry which comprises a signed ElGamal ciphertext of the form (c 1t , C 2t , desc t , tag t ). Each of the elements of the ith signed ElGamal ciphertext entry will be described in detail below.
[0020] Element c 1t is an ElGamal encryption of a random symmetric key k l , where k t is an element of a strong cyclic group G of prime order q with generator g, and may be generated using techniques that are well known in the art. The ElGamal encryption c 1t , of the key k l is generated as follows:
c 1t =( y r k t ,g r )= E {y} ( k t ),
[0021] for r chosen uniformly at random from Z q , where Z q is the field of integers modulo q, and where y is the public key of the merchant 102 . As will be apparent to those skilled in the art, k l is an element of the group G generated by g, and may otherwise be converted into a format required for the second encryption operation described below, using well-known techniques. Associated with the public key y is a secret key x that is used for decryption of the encrypted key k t , as will be described below. This secret key x is known to the payment server 114 associated with merchant 102 but unknown to the customer 106 .
[0022] Element C 2t is an encryption of the corresponding information item m i , and is generated using the key k t , that is,
c 2t =E {k t 1 } ( m i ),
[0023] This encryption may be performed using a symmetric cipher, such as the Rijndael cipher recently selected for use as the Advanced Encryption Standard (AES). Additional details regarding the Rijndael cipher can be found at, e.g., http://www.esat.kuleuven.ac.be/˜rijmen/rijndael/, and http://csrc.nist.gov/encryption/aes. Other types of known encryption techniques may also be used. In addition, the encryption used to generate c 2t may be based on an appropriate function of the key k t , rather than the key itself, as will be apparent to those skilled in the art.
[0024] The element desc t is a description of the corresponding information item m i . This description will generally contain information about the retrievable information item, such as an abstract if the item is an article, or a thumbnail sketch if the item is an image or video. The description desc t will also preferably contain pricing information, which may be in the form of a sales contract or other type of pricing policy specifying the charge given different constraints, such as previous purchases, subscription information, etc.
[0025] The element tag t in the illustrative embodiment is a Schnorr signature on (c 1t , c 2t , desc t ) generated using g r , i.e., the second portion of the ElGamal encryption c 1t described above, as a public key and r as a secret key. Note that r is a temporary secret key and is used for this particular element tag t only. Additional details regarding Schnorr signatures can be found in the above-cited reference C. P. Schnorr, “Efficient Signature Generation for Smart Cards,” Journal of Cryptology 4, pp. 161-174, 1981 .
[0026] [0026]FIG. 2 shows one possible implementation of a given one of the processing elements of system 100 . The implementation in FIG. 2 may represent one or more of the elements 110 , 112 and 114 associated with the merchant 102 , or the user device 122 associated with customer 106 , as well as portions of these elements. In this example implementation, the element of system 100 includes a processor 200 , an electronic memory 220 , a disk-based memory 240 , and a network interface 260 , all of which communicate over a bus 270 . One or more of the processing elements of system 100 may thus be implemented as a personal computer, a mainframe computer, a computer workstation, a smart card in conjunction with a card reader, or any other type of digital data processor as well as various portions or combinations thereof. The processor 200 may represent a microprocessor, a central processing unit, a digital signal processor, an application-specific integrated circuit (ASIC), or other suitable processing circuitry. It should be emphasized that the implementation shown in FIG. 2 is simplified for clarity of illustration, and may include additional elements not shown in the figure. In addition, other arrangements of processing elements may be used to implement one or more of the elements of the system 100 .
[0027] The elements 102 and 106 of system 100 execute software programs in accordance with the invention in order to provide tagged private information retrieval in a manner to be described in detail below. The invention may be embodied in whole or in part in one or more software programs stored in one or more of the element memories, or in one or more programs stored on other machine-readable media associated with the elements of the system 100 .
[0028] [0028]FIG. 3 is a flow diagram illustrating an example tagged information retrieval process implemented in the system 100 of FIG. 1 in accordance with the invention. It is initially assumed for this example that the cost of each retrievable information item m i is the same, i.e., a fixed charge c, although this is not a requirement of the invention, and embodiments in which this assumption does not apply will be described in more detail below.
[0029] In step 300 of FIG. 3, a user selects an entry of interest from the public database 112 . As noted above, the complete signed ElGamal ciphertext entry in public database 112 for information item m t is of the form (c 1t , c 2t , desc t , tag t ). The user corresponds in this example to customer 106 , and establishes a connection with the public database 112 via user device 122 and network 120 in a conventional manner, e.g., in accordance with the well-known Internet protocol. The selection in step 300 may be made through interaction with one or more web pages associated with public database 112 , using a browser or other similar program implemented on the user device 122 . It is assumed for illustration purposes only that the user in step 300 selects from the public database 112 a single entry corresponding to information item m i .
[0030] Verification and decryption of the signed ElGamal ciphertext may be performed by the user in the manner indicated in step 302 - 312 of FIG. 3. In step 302 , the user checks that tag t is a proper Schnorr signature on (c 1t , c 2t , desc t ). In step 304 , the user removes or “peels off” the portion (desc t , tag t ) from the signed ElGamal ciphertext. The user then blinds c 1t and submits the resulting blinded ciphertext c 1t ′ to the payment server 114 for decryption, along with an appropriate payment for the information item m i , as indicated in step 306 .
[0031] In the illustrative embodiment, in which an ElGamal ciphertext is signed using a Schnorr signature, the blinding may be implemented as follows. As previously noted, the ElGamal ciphertext c 1t of the symmetric key k t is given by (y r k t , g r ) for random rεZ q , where Z q is the field of integers modulo q. The user blinds this ElGamal ciphertext c 1t by picking a random uεG and a random s εZ q , where as previously noted G is a strong cyclic group of prime order q with generator g, and then generating the blinded ciphertext c 1t ′ as (y r+s uk t , g r+s ). The invention can also be implemented using other types of blinding.
[0032] The payment server in step 308 records the purchase, decrypts the blinded ciphertext c 1t ′ using the secret key x in order to obtain a blinded key k t ′ and sends the blinded key k t ′, to the user. The user in step 310 receives the blinded key k t ′ from the payment server, and unblinds it by multiplication with u −1 to obtain the key k t . The user in step 312 utilizes the key k t to decrypt the ciphertext c 2t , thereby obtaining the desired information item m i .
[0033] The above-described blinding is an important feature of the invention, since it allows the sale of the information item m i in a private manner, i.e., without anyone other than the user, i.e., customer 106 , learning what information was sold, and without the possibility of any electronic or paper “trail” being created. More particularly, the payment server 114 and the merchant 102 do not know and cannot determine what retrievable information item the user has purchased. The invention thus provides strong protection of user privacy for purchase of retrievable information items over the Internet or other type of network.
[0034] If the information item m i generated in step 312 does not correspond to desc t , the user may show a transcript of the above decryption process to the merchant or a designated third party in order to complain, and potentially get a refund. This is another important feature of the invention, as it allows complaints to be made in case a merchant advertises one type of information but attempts selling another piece of information.
[0035] As noted previously, the user does not know the secret decryption key x corresponding to the public encryption key y. The payment server 114 associated with the merchant 102 therefore performs the decryption of the blinded ciphertext c 1t ′ as indicated in step 308 . The payment server receives the blinded ciphertext c, 1t ′ along with a request for the information item m i and an appropriate payment as indicated in step 306 . The payment server will thus charge the user for the information item m i in return for providing the blinded key k t ′ obtained by decryption of the blinded ciphertext c 1t ′. It is also possible for the payment server to include, along with its transmission of the blinded key k t ′ to the user, a proof of correct decryption, as will be readily apparent to those skilled in the art. Such a proof allows the user to check decrypted information received from the payment server for correctness, and can facilitate generation of a complaint if the result of the decryption of the ciphertext C 2t is not what was described in desc t .
[0036] Although illustrated in the case of a single selected retrievable information item m i , it will be apparent to those skilled in the art that the process of FIG. 3 can be extended in a straightforward manner to operate with multiple selected retrievable information items. For example, steps 302 - 312 can be repeated serially or in parallel in order to allow the process to accommodate multiple selected items.
[0037] As noted above, it is possible for the merchant 102 to impose different prices or pricing policies for different retrievable information items. The present invention permits such an arrangement without allowing the identity of the purchased items to be inferred from the purchase price.
[0038] One example of an embodiment of the invention which allows different prices for different information items is as follows. As described previously, the embodiment illustrated in conjunction with FIG. 3 uses a particular public key y which corresponds to a fixed charge c. In order to charge an amount j*c, the merchant may instead use a public key y j for which the secret key is given by x j =x j mod q. For example, the public key y j may be as follows:
y j =g {x j } mod p.
[0039] The decryption performed by the payment server in step 308 of FIG. 3 can then be done in one round using the key x j , or in j rounds using the key x for each round. If the latter approach is utilized, the user may reblind the partial decryption result for each round, and may also substitute that result with another ciphertext key to be decrypted. The payment server will never know which of these occurred, since both would be blinded. Therefore, the payment server knows the total amount charged (j*c) but does not know whether this corresponds to one sale at the total amount, or to j sales of c each, or to something in between. This is yet another important feature of the present invention, since it hides from the payment server and merchant the price paid by the user for particular information items. It should also be noted that if an anonymous payment scheme is used, and the payments are independent, then the payment server will also not know whether it is interacting with one user or more than one user at any given time, and thus cannot separate the processing operations for different users.
[0040] As another example of an embodiment of the invention which allows different prices for different information items, the merchant 102 may establish different public keys for different prices. In such an embodiment, the merchant may establish one public key y 1 for one price, and another public key y 2 for a second price. Since the payment server 114 with necessity will know what secret key it uses for decryption, it will also know what the charge should be. If subscriptions are used to determine charges, the user may present subscription information instead of or along with his or her payment.
[0041] The present invention in the illustrative embodiments described herein preferably uses ElGamal encrypted ciphertext signed using Schnorr signatures. However, other types of encryption and signature techniques could also be used. Examples of such techniques are described in A. J. Menezes et al., “Handbook of Applied Cryptography,” CRC Press, 1997, which is incorporated by reference herein.
[0042] It should be understood that the above-described embodiments of the invention are illustrative only. For example, the invention can be applied to any type of information retrieval system and corresponding arrangement of user or merchant devices, and different encryption and signature techniques may be used. Furthermore, the particular process utilized in a given embodiment may vary depending upon factors such as the pricing policies used, the number of items selected, the use of subscriptions or anonymous pricing policies, etc. These and numerous other alternative embodiments within the scope of the following claims will be apparent to those skilled in the art. | Purchase of information items from a merchant over the Internet or other network is implemented so as to ensure that the merchant is unable to identify the particular information item(s) purchased by a user. The user when considering purchase of a given information item is permitted to access a corresponding signed ciphertext of that item. The signed ciphertext in an illustrative embodiment includes a first ciphertext portion in the form of a symmetric key encrypted using a public key associated with the merchant, a second ciphertext portion corresponding to the information item encrypted using the symmetric key, an unencrypted description of the information item, and a tag corresponding to a signature. The user requests purchase of the information item by sending a blinded version of the first ciphertext portion to a payment server along with an appropriate payment. The payment server decrypts the blinded version of the first ciphertext portion and returns the resulting symmetric key to the user. The user then utilizes the symmetric key to decrypt the second ciphertext portion so as to obtain the desired information item. The decrypting operation performed by the payment server may be implemented using at least part of a set of multiple rounds, with the user providing a blinded ciphertext and receiving a corresponding decryption result for each of the rounds. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 07/958,926 filed Oct. 9, 1992, entitled NEEDLE CURVING APPARATUS, now abandoned, the disclosure of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to needle forming devices. More particularly, the invention relates to a multistation needle forming device for flat pressing, curving and side pressing one needle blank, or a multiplicity of needle blanks, to form curved rectangular bodied needles. The device is capable of transferring the blanks from one die station directly to the next die station.
2. Description of the Related Art
The production of needles involves many processes and different types of machinery in order to prepare quality needles from raw stock. These varying processes and machinery become more critical in the preparation of surgical needles where the environment of intended use is in humans or animals. Some of the processes involved in the production of surgical grade needles include: straightening spooled wire stock, cutting needle blanks from raw stock, tapering or grinding points on one end of the blank, providing a bore for receiving suture thread at the other end of the blank, imparting flat surfaces on opposite sides of the blank by flat pressing a portion of the needle blank to facilitate grasping by surgical instrumentation and curving the needle where curved needles are desired. Additional processing may be done to impart flat surfaces substantially perpendicular to the flat pressed portions of the needle blank by side pressing a portion of the needle blank to further facilitate grasping by surgical instrumentation and insertion into humans or animals.
Conventional needle processing is, in large part, a labor intensive operation requiring highly skilled workmen. Generally, extreme care must be taken to ensure that only the intended working of the needle is performed and the other parts of the needle remain undisturbed.
Curved rectangular bodied needles have advantages over other needle configurations in many surgical procedures for a variety of reasons including, uniformity of entry depth for multiple sutures and proper "bite" of tissue surrounding the incision or wound. When providing curved rectangular bodied needles for surgical procedures it is desirable for the needles to have a specified rectangular cross-section and a specified curvature, i.e., a predetermined radius of curvature. The desired cross-section and radius of curvature for the finished needle varies with specific applications.
Known methods of forming curved rectangular bodied needles require several separate and distinct operations on various machinery. The needle blank must first be flat pressed to impart initial flat surfaces along barrel portions of the needle blanks located between a tapered point end of the blank and a drilled end. After flat pressing, the needle blank can then be taken from the flat press dies to a curving machine to impart the proper curvature to the needle blank. Care must be taken when removing the blanks from the flat press dies and positioning the needle blank in the curving machinery to avoid disturbing the flat surfaces imparted by the flat pressing operation.
After curving, the flat pressed and curved needle blanks can then be taken from the curving anvil to a side press station to impart flat surfaces substantially perpendicular to the flat pressed sides to give the final rectangular cross sectional profile to the needle barrel. Again care must be taken during removal of the needle blanks from the curving anvil and during side pressing so as to avoid disturbing the previously imparted flat pressed and curved portions of the needle blank.
Known flat pressing techniques create the flat edges on the needle barrel by pressing the barrel portion of the needle blank between a pair of opposing needle dies having the desired length and width characteristics. Typically, the needle blanks are inserted into a lower die and compressed between the dies to impart the flat surfaces on opposed sides of the needle barrels . The flat pressed blanks can then be removed from the dies and taken to the curving machinery. After removal of the needle blanks, the dies can also be inspected to ensure no needle blanks remain stuck to one of the dies.
Known needle curving techniques create the curve by bending the needle blank around an anvil structure having a desired curvature. To attain the desired needle configuration, the anvil structure provides a shaping surface for deforming the needle. Typically, the needle is positioned for curving by manually placing the needle for engagement with the anvil structure and holding it in place by a holding device. The needle is subsequently bent by manipulating the holding device so the needle curvature is formed about the shaping surface of the anvil structure. Needles improperly positioned on the anvil may result in a deformation of the previously imparted flat press sides and may have to be reprocessed or discarded.
When needles are made of steel or similar resilient materials, the anvil or mandrel used should have a smaller radius than the radius desired in the final needle. This configuration allows for some springback after the bending operation and ensures that the desired radius of curvature is attained. A disclosure of such features may be found in, for example, U.S. Pat. No. 4,534,771 to McGregor et al.
After flat pressing and curving the needle blank it may be desirable to side press the barrel portion of the needle blank to obtain a rectangular cross-section in the needle barrel. As with the above flat press process, known side pressing techniques require inserting the blank between a pair of dies to compress and impart flat sides to the needle blank. Needles improperly positioned within the dies may become deformed and also have to be discarded or reprocessed.
One disadvantage to conventional needle forming techniques is that typically only one needle processing operation at a time, such as, for example, flat pressing between a pair of dies, curving around an anvil structure or side pressing between another set of dies, can be performed on a single piece of machinery. A further disadvantage is the long processing time and high costs required in forming and transporting the needles between the various machinery. Lastly, a still further disadvantage is the need to readjust several pieces of machinery to process needles of varying lengths and diameters thereby further increasing production time and costs.
Therefore, a need exists for a single needle forming apparatus that is capable of flat pressing, curving, and side pressing a multiplicity of needle blanks or a single needle blank by transporting the needle blanks directly between the various die sets of the same apparatus. It is also desirable to provide a needle forming device which cooperates with a needle feeding fixture for sequentially loading and positioning one or more needles at a first processing station so as to increase the production rate of the needle manufacturing process by maintaining a continuous flow of needle blanks through the device.
SUMMARY OF THE INVENTION
An apparatus is disclosed for forming at least one curved, flat sided surgical needle which comprises frame means, flat press means associated with the frame means for imparting first flat surfaces to opposite sides of at least a portion of at least one needle blank and curving means associated with the frame means for imparting an arcuate profile to at least a portion of the at least one needle blank. The apparatus for forming at least one curved, flat sided surgical needle preferably comprises a frame portion, flat press means mounted on the frame portion for imparting first flat surfaces to opposite sides of at least a portion of at least one needle blank and curving means mounted on the frame portion for imparting an arcuate profile to at least a portion of the at least one needle blank.
The flat press means comprises upper die means and lower die means, the lower die means being adapted to support at least one surgical needle blank and the upper die means being engagable against the lower die means to impart first flat surfaces to opposite sides of the at least one needle blank positioned therebetween. The lower die means is in the form of a plate member reciprocally movable between a first position remote from the upper die means to a second position adjacent the upper die means.
The upper die means and the lower die means include needle die portions having lead in tapers dimensioned and configured for flat pressing only a center portion of the needle blank, the lead in tapers providing a clearance to prevent flat pressing of a tapered end and a drilled end portion of the needle blank. The lead in tapers in the upper and lower die means are approximately 3° to 15° and more approximately 5°. The lower die means includes at least one longitudinal die channel or groove to support the at least one needle blank. The plate member is reciprocally movable between the second position adjacent the upper die means to a third position adjacent the curving means to directly transfer the at least one needle blank between the plate member and the curving means.
The curving means preferably comprises mandrel means for imparting an arcuate profile to at least a portion of the at least one needle blank and reciprocating means for biasing and reciprocally moving the at least one needle blank against the mandrel means. The mandrel means comprises a rotatable shaft having at least a portion configured to impart the arcuate profile to the at least one needle blank. The apparatus, wherein the portion of the shaft comprises a curvature having a predetermined radius in the range of between about 0.05 inches and about 3.00 inches.
The reciprocating means cooperates with the mandrel means to accept a needle blank therebetween from the flat press means and preferably comprises at least one pair of rotatable members positioned in adjacency and belt means positioned about the at least one pair of rotatable members for biasing and reciprocally moving the at least one needle blank against the mandrel means. The reciprocating means further comprises belt drive means for selectively moving the belt means and tensioning means for applying tension to the belt means.
The tensioning means preferably comprises at least one tensioning roller biased toward the belt means. The belt means comprises an elastic belt and is fabricated from a material selected from the group of materials consisting of Neoprene, Nylon, Polyurethane or Kevlar. Biasing means is provided for applying a continuous force to at least one of the pair of rotatable members such that a friction fit is maintained between the curving means, the at least one pair of rotatable members and the at least one needle blank when the curving means is engaged with the reciprocating means.
According to the invention, side press means is mounted on the frame portion for imparting second flat surfaces to opposite sides of the needle blank, wherein the second flat surfaces are imparted substantially perpendicular to the first flat surfaces. The side press means includes side die means for supporting the needle blank and clamp means for pressing the side die means about the needle blank. The side die means has a plurality of adjacent plate members, each the adjacent plate member having at least one die slot or groove coacting with a corresponding die slot in said next adjacent plate member to support a needle blank therebetween. The corresponding die slots cooperate to form side press dies, the dies having lead in tapers of approximately 34° to approximately 15° and preferably about 5°.
The side die means is rotatable from a first position adjacent the curving means for direct receipt of the needle blanks therefrom to a second position adjacent the clamp means for side pressing the needle blank therebetween. The side die means is also rotatable from the second position adjacent the clamp means to a third position removed from the clamp means. Means in the form of air jet means is provided to urge the needle blanks free from the side die means to remove the needle blanks from the side die means when the side die means is in the third position. The removal means comprises
Detection means is provided for sensing the presence of the at least one needle blank in the lower die means. Detachable feed means for supplying a plurality of needle blanks to the lower die means is also provided. The feed means includes a feed block having a plurality of V-shaped hoppers. Each hopper has cascade means at a base thereof for supplying the needle blanks one at a time into each of a plurality of lower die slots in the lower die means.
Also, the preferred apparatus for forming at least one curved, rectangular sided surgical needle comprises a frame assembly. A flat press means is affixed to the frame assembly for imparting first flat surfaces to first opposing sides of at least a portion of at least one needle blank. A curving means is affixed to the frame assembly for imparting an arcuate profile to at least a portion of the needle blank. A side press means is affixed to the frame assembly for imparting second flat surfaces to second opposing sides of the needle blank. The second flat surfaces are imparted substantially perpendicular to the first flat surfaces.
There is also disclosed a method of forming a curved rectangular bodied needle from a substantially round-elongated needle blank. The method comprises the steps of flat pressing opposite sides of the needle blanks between a pair of flat press dies. The needle blanks are drawn from at least one of the flat press dies onto a rotatable mandrel curving the needle blanks between the rotatable mandrel and a reciprocable belt. The needle blanks are rotated adjacent side press dies and the needle blanks are deposited therebetween. Opposite sides of the needle blanks are side pressed between the side press dies. The side pressing acts on sides of the needle blanks substantially perpendicular to the flat pressed sides.
The flat pressing steps comprise positioning the needle blanks on a lower flat press die member. Then the lower die member is advanced adjacent an upper flat press die member. The needle blanks are compressed between the upper flat press die member and the lower flat press die member. The lower flat press die member is advanced adjacent the reciprocable belt.
The curving steps comprise drawing the needle blanks off at least one of the flat press dies between said mandrel and the belt by advancement of the belt and pressing the belt against the needle blanks and reciprocating the belt to form the needle blanks about the rotatable mandrel.
The side pressing steps comprise capturing the needle blanks between a plurality of adjacent die plates rotating said die plates between a pair of clamp members and clamping the die plates about the needle blanks by squeezing the clamp members against the die plates.
Also there is disclosed a needle having a tapered distal portion, a rectangular central portion and a bored proximal portion formed on to the apparatus. The tapered distal portion has a generally circular cross-section, the rectangular central portion is generally square and the bored proximal portion has a generally circular cross-section.
Finally, there is disclosed a needle having a tapered distal portion, a rectangular central portion and a bored proximal portion formed according to the method. The tapered distal portion has a generally circular cross-section, the rectangular central portion is generally square and the bored proximal portion has a generally circular cross-section.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described hereinbelow with reference to the drawings wherein;
FIG. 1 is a perspective view of the needle forming apparatus of the present invention;
FIG. 2 is a side elevation view of the apparatus of FIG. 1;
FIG. 3 is an enlarged elevation view of the three needle forming stations of the apparatus of FIG. 1;
FIG. 4 is a partial cross-sectional view taken along the lines 4--4 of FIG. 3;
FIG. 5 is a perspective view of the lower die plate of the apparatus of FIG. 1;
FIG. 6 is a cross-sectional view of the lower die plate of FIG. 5;
FIG. 7 is an enlarged partial side elevational view of the needle curving station shown in FIG. 2;
FIG. 8 is an enlarged partial side elevational view of the needle curving station illustrating a needle blank drawn between the curving belt and the curving mandrel;
FIG. 9 is an enlarged partial side elevational view illustrating the needle being curved about the mandrel;
FIG. 10 is an enlarged partial side elevational view showing the needle being rotated for acceptance by the side die plates;
FIG. 11 is an enlarged partial end elevational view taken along the lines 11--11 of FIG. 3;
FIG. 12 is an enlarged partial cross-sectional view taken along the lines 12--12 of FIG. 3 and illustrating needle blanks being fed from the feed hopper to the lower die plate;
FIG. 13 is an enlarged partial cross-sectional view taken along the lines 13--13 of FIG. 3 illustrating the needle blanks being flat pressed between the upper die plate and the lower die plate;
FIG. 14 is an enlarged partial cross-sectional view taken along the lines 14--14 of FIG. 3 illustrating the needle blanks being curved about the mandrel by the curving belt;
FIG. 15 is an enlarged partial cross-sectional view taken along the lines 15--15 in FIG. 3 illustrating the needle blanks positioned between the side press die plates;
FIG. 16 is an enlarged partial cross-sectional view similar to FIG. 15, illustrating the needle blanks being side pressed between the side press dies; and
FIG. 17 is a perspective view of a needle formed by the needle forming apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Generally, the needle forming apparatus of the present invention is utilized to flat press, curve or bend and side press a multiplicity of needle blanks to produce curved, rectangular bodied needles. However, pressing and curving of a single needle blank is also contemplated. As used herein, the term needle blank refers to a surgical needle in various stages of fabrication.
Needle forming apparatus 10 is illustrated in FIGS. 1 and 2 and generally includes a support stand 12, a flat press station 14, a curving station 16, a side press station 18, and a computer controller 20, all of which are, preferably, connected to support stand 12. Referring to FIGS. 1 and 2, support stand 12 generally includes a base frame 22 having a shelf 24 and a back plate 26. Preferably, curving station 16 and side press station 18 are mounted with respect to back plate 26. Support stand 12 further includes an inclined shelf 28 extending between one end of support stand 12 and flat press station 14. As shown in FIGS. 1 and 2, a computer control station 20 may be mounted on back plate 26 or supported separately by legs 23.
Referring now to FIGS. 2-4, flat press station 14 includes an upper die plate 32 which is affixed to and suspended beneath a flat press ram 34. Flat press ram 34 is slidably mounted on support members 36 and is movable in a vertical direction by means of a hydraulic cylinder 38. The direction of movement of flat press ram 34 and the force applied thereto by hydraulic cylinder 38 are controlled and can be adjusted by computer control station 20. Preferably, flat press ram 34, and thus upper die plate 32 which is affixed thereto, has a vertical range of travel of approximately 2.0 inches. Additionally, hydraulic cylinder 38 can supply a pressure of approximately 10,000 psi to upper die plate 32.
Flat press station 14 further includes a movable lower die plate 30. Lower die plate 30 is slidably supported and reciprocal along inclined shelf 28. A worm screw motor 44 connected to lower die plate 30 by worm screw shaft 46 is provided to reciprocate lower die plate 32 between a first position remote from upper die plate 32 to a second position adjacent to and beneath upper die plate 32. Additionally, lower die plate 30 is reciprocally movable between the first and second positions and a third position adjacent to curving station 16. The direction and speed of motor 44 and thus lower die plate 30 are controlled by computer control station 20.
Referring now to FIGS. 5 and 6, lower die plate 30 further includes a plurality of needle die slots or grooves 40 which are configured, dimensioned and adapted to retain and position a single or several needle blanks on lower die plate 30 for flat pressing between lower die plate 30 and upper die plate 32. As shown in FIG. 6, lower die plate 30 and specifically needle grooves 40 are formed with lead in tapers O formed between surfaces 42 and 48 on lower die plate 30. Taper O provide clearance for a drilled or bored end portion of the needle and a tapered or pointed end portion of the needle blank to prevent damage to the end portions of the needle blank during pressing between upper die plate 32 and lower die plate 30. Preferably, lead in tapers O are on the order of 3° to 15° or more preferably on the order of approximately 5°. Grooves 40 are preferably 0.5 inches long to accommodate needle blanks ranging in length from 0.300 to 1.5 inches and are further dimensional to hold needle blanks ranging from 0.008 to 0.032 inches in diameter. Upper die plate 32 may also include similar die slots or grooves and lead in tapers to help protect the tapered end and drilled end portions of the needle blanks.
Referring again to FIG. 1, flat press station 14 may further include a camera or other sensing eye 48 positioned adjacent lower die plate 30 and remote from upper die plate 32. Eye 48 is provided to count the number of needle blanks in grooves 40 before and after flat pressing to assure that no needle blanks remain lodged against upper die plate 32 after flat pressing has been completed. Upper die plate 32 and lower die plate 30 may be coated with various materials to help prevent needle blanks from adhering thereto. Upper die plate 32 and lower die plate 30 are preferably fabricated from a material having a hardness which is at least substantially equal to the hardness of the needle blank material. Typically die plates 30 and 32 have a Rockwell hardness value of between 40C to about 70C. Die plates 30 and 32 are preferably adapted to press three needle blanks at a time although other amounts of needle blanks may be pressed by changing the number of grooves 40 in the die members.
While it is possible to feed needle blanks into needle grooves 40 by hand, needle forming apparatus 10 preferably includes a needle hopper 50 which can retain a supply of needle blanks and feed them one at a time into each needle groove 40. Referring now to FIGS. 4 and 12, needle hopper 50 generally includes a face plate 52, preferably formed of a clear plastic, affixed to a front section of needle hopper 50. Needle hopper 50 is further provided with 3 V-shaped hopper sections 54 which funnel down to three curved or cascade style feed grooves 56. Hopper sections 54 function to supply feed grooves 56 with a continuous supply of needle blanks. As seen in FIGS. 4 and 12, feed grooves 56 are oriented and positioned to deposit one needle at a time into lower die plate needle grooves 40 when lower die plate 30 is slid beneath needle hopper 50. As shown in FIG. 4, flow control knobs 58 are provided at the base of each hopper section 54 to prevent or allow needle blanks to flow from hopper sections 54 to curved feed grooves 56. It has been found that by using V-shaped hopper sections 54 and curved or cascade path feed grooves 56 reliable and consistent feeding of needle blanks to lower die plate grooves 40 can be maintained. Occasionally, needle blanks may become wedged against one another or hopper 50 as they flow down V-shaped hopper sections 54 and through feed grooves 56. To help prevent wedging of any needle blanks in hopper 50, needle forming apparatus 10 may further be provided with a vibrator 60 which gently vibrates needle hopper 50 by means of bar 61 to ensure that needles to not become stuck or wedged together and to ensure that the needle blanks will flow freely into and through curved feed grooves 56.
As noted above, lower die plate 30 is reciprocal between a position adjacent flat press station 14 and a position adjacent curving station 16 to transfer needle blanks therebetween. Referring now to FIG. 7, needle curving station 16 of the present invention preferably includes a rotatable curving mandrel 62 and right and left needle curving jaws, 64 and 66, respectively. Jaws 64 and 66 are preferably pivotally mounted to a curving ram 70 by means of pivot pins 92 and 93. As shown in FIG. 3, curving ram 70 is reciprocally movable in a vertical direction by means of a hydraulic curving cylinder 68. A curving belt 72 is provided to draw needle blanks out of needle die grooves 40 when lower die plate 30 is positioned adjacent curving mandrel 62. Belt 72 surrounds jaws 64 and 66 at one end and a pulley 76 at the other end as shown in FIG. 3. A motor 74 is provided to turn pulley 76 by means of a motor belt 80 and a motor belt pulley 78. Motor 74 may be actuable in clockwise and counterclockwise directions to reciprocate belt 72 about the ends of jaws 66 and 64.
A pair of ram rollers 82 and 83 of FIG. 7 are rotatably affixed to curving ram 70 to guide and tension belt 72. A pair of jaw rollers 84 and 85 are affixed to jaws 64 and 66, respectively to guide belt 72 around jaws 64 and 66 and to aid in reciprocating and biasing belt 72 against the needle blanks. Belt 72 is positioned around jaw rollers 84 and 85 on jaw 64 and ram rollers 82 and 83 on ram 70. As shown in FIG. 7, jaws 64 and 66 are biased together by a spring 86. As shown in FIGS. 7 and 9, jaws 64 and 66 are movable between an initial position where rollers 84 and 85 are adjacent each other and above mandrel 62 to a curving position. In the curving position, ram 70 is biased downward by hydraulic cylinder 68 of FIG. 3. This forces jaws 64 and 66 open and apart from each other causing jaws 64 and 66 and belt 72 to surround mandrel 62 thereby holding a needle blank therebetween.
Mandrel 62 is preferably an elongated shaft or rod positioned transversely with respect to lower die plate 30. Mandrel 62 has a solid cross-section and is fabricated from a material having a hardness which is at least substantially equal to the hardness of the needle blank material. Typically, mandrel 62 has a rockwell hardness value of between about (55C) and about (57C). This hardness discourages unwanted shaping or marring of the needle blank and/or mandrel 62. In addition, mandrel 62 may be coated with an elastomer material to help prevent unwanted marring of the needle blank and/or mandrel 62 during the current process.
Preferably, mandrel has a circular cross-section to impart an arcuate profile to the needle blank resulting in a curved surgical needle having a predetermined radius of curvature of between about (0.5") and about (3.0"). However, surgical needles requiring different arcuate profiles require various shaped mandrels, such as elliptical, triangular, rectangular, or pear-shaped mandrels which impart a predetermined curvature to the needle blanks. The diameter of the preferred circular mandrel is dependent on numerous factors including the length of the needle blank desired radius of curvature, and the spring back characteristics of the needle material, i.e., the tendency of the needle material to return to its original shape after being deformed. To illustrate, larger diameter mandrels produce a larger radius of curvature and smaller diameter mandrels produce a smaller radius of curvature. Further, in instances where the needle blank is fabricated from a material having spring back tendencies, the mandrel diameter should be smaller than the desired radius of curvature. Thus, the needle will spring back to the desired radius of curved after bending. The apparatus of the present invention is configured to accommodate mandrels with various diameters necessary for curving surgical needles of various sizes.
As shown in FIG. 3, an adjustment knob 88 is provided to adjust the tension of belt 72 around jaws 64 and 66. Specifically as jaws 64 and 66 are moved up and down by ram 70, belt 72 may stretch or otherwise become elongated. Belt tension adjustment knob 88 allows for vertical adjustment of pulley 76 to compensate for elongation of belt 72. Further, a jaw stop adjustment knob 90 is also provided to limit the vertical downward movement of ram 70 and thus of jaws 64 and 66 about curving mandrel 62. The motions of the belts, jaws and hydraulic cylinders are controlled by computer station 20.
As can be seen in FIGS. 7-10, needle curving station 16 is adapted to receive needle blanks directly from lower die plate 30. This is done by reciprocating lower die plate 30 to a position adjacent mandrel 62 and belt 72 and rotating belt 72 to draw the needle blanks between mandrel 62 and the belt 72. In this manner a needle blank is transported from lower die plate 30 of flat press station 14 directly to curving mandrel 62 of curving station 16 without ever having to remove the needle blanks from the needle forming apparatus 10 or subject the needle blanks to transportation mechanisms other than the die plates.
Referring now to FIGS. 3 and 11, needle side press station 18 includes a plurality of side press die plates adapted to receive needle blanks from curving station 16 and hold them for side pressing within side press station 18. As shown in FIGS. 4 and 11, side press station 18 is provided with a pair of end side press die plates 94 and 95 having die grooves 98 on an inner surface only thereof and two center side press die plates 96 and 97, each having die grooves 98 on both exterior faces. Side press die plates 94, 95, 96 and 97 are mounted with respect to an indexing shaft 100 which is adapted to rotate die plates 94, 95, 96 and 97 between a first position adjacent curving station 16 to a second position for side pressing. Indexing shaft 100 is rotated by a stepper type motor 102 via a drive wheel 104 and a drive belt 114. Drive belt 114 surrounds drive wheel 104 at one end and a drive pulley 116 at another end. Pulley 116 is connected to stepper motor 102 for rotation therewith. A cam rod 106 extends outward from drive wheel 104 and engages a groove 112 in a side press die carriage 110. Indexing shaft 100 may also include means to bring die plates 94, 95, 96 and 97 together to hold needle blanks therebetween and to separate the die plates to accept and release needle blanks.
Referring now to FIGS. 3, 4, 15 and 16, it can be seen that side press station 18 further includes a pair of side die rams 120 and 121 which are pivotally supported by pivot pins 122 and 123. A pair of toggle links 124 and 125 are pivotally affixed at one end of side die rams 120 and 121. Toggle links 124 and 125 overlap at one end thereof and are connected to a drive shaft 126. Drive shaft 126 is reciprocally movable by means of a hydraulic cylinder 128 (FIG. 3). By advancing drive shaft 126 toggle links 124 and 125 force side die rams 120 and 121 outward to pivot die rams 120 and 121 around pivot pins 122 and 123. This forces the opposite ends of the die rams to compress inwardly. The ends of side die rams 120 and 121 opposite toggle links 124 and 125 are provided with inwardly directed ends 127 and 129. As shown specifically in FIG. 4, inward movement of inwardly directed ends 127 and 129 of side die rams 120 and 121 compresses side die plates 94, 95, 96 and 97 about needle blanks positioned within needle die grooves 98.
Die plates 94, 95, 96 and 97 are rotatable with respect to side press die carriage 110 to rotate from a first position (where die grooves 98 are adjacent needle curving station 16) to a second position (where die plates 94 and 95 are positioned between side die rams 120 and 121 for side pressing therebetween). After side pressing, side press die plates 94, 95, 96 and 97 are movable between the second position and a third position adjacent a needle receptacle 134 (FIG. 3). Side press die plates 94, 95, 96 and 97 may each be provided with blow holes 130 which are communicable between an outside surface of the die plates and needle die grooves 98. When carriage 110 is rotated to position the die plates in the third position, blow holes 130 align with an air manifold 132. Means are provided for forcing a flow of air through manifold 132 and thus through blow holes 130 to eject needle blanks from die grooves 98 after die plates 95, 96, 97 and 98 separate. Preferably side press station 18 simultaneously presses three needle blanks. However, other amounts of needle blanks may be pressed by increasing or decreasing the number of side plates and thus the number of needle die grooves 98.
Turning now to the operation of needle forming apparatus 10, a plurality of needle blanks are initially placed within hopper sections 54. As shown in FIGS. 1, 4 and 10, upon opening flow knobs 58, needle blanks flow from the hopper sections 54 through needle grooves 56 which deposit a single needle blank in each of lower die plate needle grooves 40. At this stage lower die plate 30 retracts to a position adjacent the eye 48 which views the number of needle blanks positioned within the needle grooves. Computer 20 counts the number of needle blanks viewed and stores the number of in memory. After counting the number of needles blanks present in lower die plate 30, lower die plate 30 is advanced to a position adjacent to and directly beneath upper die plate 32. Upper die plate 32 is then forced downward by means of flat press ram 34 and hydraulic cylinder 38 to compress the needle blanks between the upper and lower die plates 32 and 30, respectively.
As noted above, needle grooves 40 are provided with lead in tapers 42 which prevent drilled end portions and tapered end portions of the needle blanks from being flat pressed between upper die plate 32 and lower die plate 30. After the needle blanks are flat pressed between lower die plates 30 and upper die plate 32, lower die plate 30 is again retracted adjacent eye 48 which views the needle blanks. This allows the computer to recount the number of needle blanks present in lower die plate needle grooves 40 and compare the result to the number of needle blanks originally viewed to insure that no needle blanks remain lodged against upper die plate 32.
Referring now specifically to FIGS. 2, 7 and 8, it can be seen that after flat pressing the needle blanks, lower die plate 30 advances beneath and past upper die plate 32 in the direction of arrow A to a position adjacent belt 72 and mandrel 62 as best shown in FIG. 7. At this point belt 72 is rotated slightly in the direction of arrows B (FIG. 8) to draw the needle blanks out of needle grooves 40 and to position the needle blanks between belt 72 and mandrel 62.
The curving sequence of curving station 16 will now be described specifically with reference to FIGS. 8 and 9. Once needle blanks have been drawn between mandrel 62 and belt 72, and lower die plate 30 has been retracted in the direction of arrow C, ram 70 is forced downward in the direction of arrow D by hydraulic cylinder 38 (FIG. 3) to force open jaws 64 and 66 (arrows E) against the tension of spring 86. The downward motion of ram 70 causes belt 72 to move down and around the needle blanks and mandrel 62 as shown in FIG. 9. At this point belt 72 is reciprocated back and forth through a slight motion by means of motor 74 to curve needle blank about mandrel 62. Rollers 82, 83, 84 and 85 insure belt 72 rotates needle blanks smoothly about curving mandrel 62. Belt 72 and jaws 64 and 66, as tensioned by spring 86, are sufficiently resilient to insure that the needle blanks are merely curved about mandrel 62 and not compressed or flat pressed to any significant extent. This insures that a drilled end portion and a tapered end portion of the needle blanks are not deformed during the curving process between belt 72 and mandrel 62.
Referring now to FIGS. 10 and 11 it can be seen that as belt 72 is further rotated, the needle blanks are rotated about mandrel 62. This positions the needle blanks for deposit in needle die grooves 98 of side press die plates 94, 95, 96 and 97. As noted above, side press die plates 94, 95, 96 and 97 are rotatable to a first position adjacent to curving station 16. At this point the plates are expanded slightly to make room for the needle blanks within needle grooves 98. Belt 72 rotates the needle blanks into die grooves 98. Die plates 94, 95, 96 and 97 are then compressed slightly to hold the needle blanks within die grooves 98. In this manner, needle blanks are transported from a needle hopper 50 through flat press and curving stations 14 and 16, respectively, to side press station 18. This occurs without having to remove the needle blanks from needle forming apparatus 10. As noted above, this direct handling of the needle blank between flat press station 14, curving station 16 and side press station 18 insures consistent and reliable forming of needle blanks.
Referring now to FIG. 4, side press die plates 94, 95, 96 and 97 are now pivoted to a position between side rams 120 and 121. Actuation of hydraulic cylinder 128 drives die shaft 126 upwardly forcing toggle links 124 and 125 to pivot side press die rams 120 and 121 about pivot pins 122 and 123 thereby forcing ends 127 and 129 of side press dies 120 and 121, respectively, against side press die plates 94 and 95 compressing plates 96 and 97 together to side press needles captured in needle die grooves 98. As noted above with respect to flat press die plate 30, side press die plates 94, 95, 96 and 97 may also be provided with lead in tapers similar to tapers O to insure that the drilled end portions and tapered end portions are not deformed during the side press operation. As also noted above, these lead in tapers O may be approximately on the order of between 3 and 15 degrees and preferably on the order of approximately 5 degrees. Hydraulic cylinder 38 can compress side press rams 120 and 121 with a force of approximately 10,000 to 15,000 psi and preferably approximately 12,500 psi. The motions of the side press operations are controlled by computer station 20 which also coordinates the motions of all three needle forming stations 14, 16 and 18.
After the needle blanks are side pressed between die plates 94, 95, 96 and 97 by side die rams 120 and 121, side press die carriage 110 can be rotated to the third position thereby positioning blow holes 130 on plates 94, 95, 96 and 97 adjacent air manifold 132. Die plates 94, 95, 96 and 97 are separated slightly and air is injected through manifold 132, and thus through blow holes 130, to force the needle blanks out of die grooves 98 into needle blank receptacle 134. Needle blank receptacle 134 is preferably formed of a foam, e.g., Neoprene material to insure that needle blanks deposited therein are not deformed during ejection of the needles from die grooves 98.
The needle forming apparatus 10 of the present invention is particularly adapted to transport a plurality of tapered and drilled needle blanks from an initial position within hoppers 54 through flat press station 14, curving station 16 and side press station 18 and into receptacle 134 without having to remove or touch the needle blanks. And more particularly, needle forming apparatus 10 moves the needle blanks directly from one die set to another without any intervening transport mechanisms.
The continuous and direct flow of needle blanks from one set of dies to the next is best illustrated in FIGS. 12 through 16. As shown in FIG. 12, needle blanks work their way down through grooves 56 in hopper 50 and single needle blanks are deposited in each of lower die plate grooves 40. Lower die plate 30 is then positioned beneath upper die plate 32 which flat presses opposite sides of the needle blanks as shown in FIG. 13. As noted above, the needle blanks are then advanced to a position adjacent curving station 16 by lower die plate 30 wherein belt 72 draws the needles out of grooves 40 in die plate 30 and reciprocally curves them about mandrel 62 as shown in FIG. 14. After curving about mandrel 62, the needles are then rotated beneath mandrel 62 and deposited between side press die plates 94, 95, 96 and 97 as shown in FIG. 15. The needle blanks are then compressed between die plates 94, 95, 96 and 97 by means of ends 127 and 129 of rams 120 and 121 as shown in FIG. 16. After side pressing, the resulting needle blanks are curved and have a rectangular cross section thus forming curved rectangular bodied needles. And by side pressing and flat pressing the needle blanks to the same extent, a needle having a square cross-section may be obtained. An illustration of a curved rectangular bodied needle 200 formed by the needle forming apparatus 10 is best illustrated in FIG. 17.
It will be understood that various modifications can be made to the embodiments of the present invention herein disclosed without departing from the spirit and scope thereof. For example, various sizes of the instrument are contemplated, as well as various types of construction materials. Also, various modifications may be made in the configuration of the parts. Therefore, the above description should not be construed as limiting the invention but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision other modifications within the scope and spirit of the present invention as defined by the claims appended hereto. | An apparatus for forming at least one curved, rectangular bodied surgical needle which comprises frame means, flat press means associated with said frame means for imparting first flat surfaces to opposite sides of at least a portion of at least one needle blank, curving means associated with said frame means for imparting an arcuate profile to at least a portion of the at least one needle blank and side press means mounted on said frame portion for imparting second flat surfaces to opposite sides of the needle blank, wherein said second flat surfaces are imparted substantially perpendicular to said first flat surfaces. There is also disclosed a method of forming a curved rectangular bodied needle from a substantially round-elongated needle blank comprising the steps of flat pressing opposite sides of the needle blanks between a pair of flat press dies, drawing the needle blanks from at least one of said flat press dies onto a rotatable mandrel, curving the needle blanks between said rotatable mandrel and a reciprocable belt, rotating the needle blanks adjacent side press dies and depositing the needle blanks therebetween and side pressing opposite sides of the needle blanks between said side press dies, on sides of the needle blanks substantially perpendicular to the flat pressed sides. A surgical needle is also disclosed having a tapered distal portion, a rectangular central portion and a bored proximal portion formed according to the apparatus and method described above. The tapered distal portion of the needle has a generally circular cross-section, the rectangular central portion is generally square and the bored proximal portion also has a generally circular cross-section. | 1 |
This application is a division, of now abandoned application Ser. No. 770,776, filed Aug. 29, 1985.
BACKGROUND OF THE INVENTION
The present invention relates to a method of forming a pressure-contact typ semiconductor device.
FIG. 1 is a sectional view showing a conventional pressure-contact type semiconductor device disclosed in Japanese Published Patent specification No. Sho. 46-35213.
In FIG. 1, the reference numeral 1 designates a diode element in which an anode is formed on one main surface and a cathode is formed on the other main surface. The numeral 2 designates an anode conductor, and the numeral 3 designates a cathode conductor. The anode conductor is formed of a copper post in which a recess portion 2a for containing the diode element 1 is formed at one end and a mounting bolt 2b is provided at the center of the other end, and a mounting bolt 2b is provided at the center of the other end. The anode of the diode element 1 is pressure contacted with the bottom surface of the recess portion 2a. The cathode conductor 3 is made of a copper material, and has a plate-shaped portion pressure contacted with the cathode of the diode element 1, and a cathode leading rod at the central part of the plate-shaped portion. The numeral 4 designates an insulating washer. The numeral 5 designates a metal washer. The numerals 6a, 6b and 6c designate leaf springs. The numeral 7 designates a metal cylindrical body. The numeral 8 designates projections provided at the cylindrical body 7. The projections 8 are formed to be engaged with the outer peripheral edge of the upper surface of the upper stage 6c of the leaf springs 6a, 6b and 6c of compressed state at a plurality of positions in a circumferential direction of the side wall of the cylindrical body 7. These projections 8 have a function for pressure contacting the cathode conductor 3 with the cathode of the diode element 1 by the spring pressures of the leaf springs 6a, 6b and 6c of compressed state and for pressure contacting the anode of the diode element 1 with the recess portion 2a of the anode conductor 2.
FIG. 2 is a sectional view of the essential portion for describing one method of forming a projection for engaging the leaf springs of compressed state with the side wall of the metal cylinder of the conventional example.
In FIG. 2, the same reference numerals are used to designate the same or corresponding parts or elements as those shown in FIG. 1.
The leaf springs 6a, 6b and 6c are first pressed in a compressed state by a tubular pressing jig 50. The outer diameter of the tubular body of the jig 50 is smaller than that of the leaf spring 6c as shown in FIG. 1. Further, the inner diameter of the tubular body is larger than the outer diameter of the cathode leading rod. Then, a plurality of positions (the portions corresponding to the outer peripheral edges of the leaf spring 6c) on the periphery of the side wall of the cylindrical body 7 are broken by the ends of bites 51, thereby forming the projections 8 engaged with the outer peripheral edge of the upper surface of the leaf spring 6c.
The projections 8 of the conventional example are formed as described above. Thus, if the distance (designated by h) between the lower surfaces of the bites 51 and the outer peripheral edge of the upper surface of the leaf spring 6c of the leaf springs 6a, 6b and 6c of compressed state becomes close to 0, the ends of the bites 51 damage the leaf spring 6c when the ends of the bites 51 break the side wall of the cylindrical body 7. If the distance h is increased in order to prevent the damage of the leaf spring 6c, the leaf spring 6c might not be engaged with the projections 8 when the jig 50 is removed after the projections 8 are formed. Therefore, it is not easy to form the projections 8 so that the spring pressures of the leaf springs 6a, 6b and 6c become a predetermined value.
Furthermore, when the projections 8 are formed by breaking the side wall of the cylindrical body 7 by the ends of the bites 51, small broken pieces might be generated from the forming portions of the projections 8 of the side wall of the cylindrical body 7. These broken pieces fall down on the portion between the metal washer 5 of the insulating washer 4 and the cathode leading rod of the cathode conductor 3, as exemplified by the reference character A in FIG. 2, when the leaf spring 6c is engaged with the projections 8 by removing the jig 50, and cause a short-circuit between the anode and the cathode of the diode element 1, thereby lowering the electric characteristics.
SUMMARY OF THE INVENTION
The present invention is directed to solve the problems pointed out above, and has for its object to provide a pressure-contact type semiconductor device in which projections are provided on part of the entire periphery, or on a plurality of portions of part of the side wall, of a metal cylindrical body by pressing from the outside toward the inside, thereby readily setting the spring pressures of the leaf springs to a predetermined value.
Other objects and advantages of the present invention will become apparent from the detailed description given hereinafter; it should be understood, however, that the detailed description and specific embodiment are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an example of a prior art pressure-contact type semiconductor device;
FIG. 2 is a cross-sectional view of the essential portion for explaining the method of production of the projections engaged with the leaf springs of compressed state at the side wall of the cylindrical body of the prior art example;
FIG. 3 is a cross-sectional view of a pressure-contact type semiconductor device formed according to one embodiment of the present invention; and
FIG. 4 is a partial cross-sectional view for explaining the method of producing the projections engaged with the leaf springs of compressed state at the side wall of the cylindrical body illustrated in this embodiment of FIG. 3.
The same reference numerals designate the same or corresponding parts or elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, the same reference numerals designate the same or corresponding parts or elements as those shown in FIGS. 1 and 2. The reference numeral 18 designates a projection formed at a metal cylindrical body 7. The projection 18 is formed by pressing from the outside toward the inside at the portion over the entire periphery of the side wall of the cylindrical body 7 corresponding to the outer peripheral edge of the upper surface of the leaf spring 6c of leaf springs 6a, 6b and 6c of compressed state. Then, the projection 7 is formed to engage with the outer peripheral edge of the upper surface of the leaf spring 6c of the leaf springs 6a, 6b and 6c in their compressed state.
In the embodiment described above, a diode element 1 is a semiconductor element in which a first main electrode is formed on one main surface and a second main electrode of opposite polarity to the first main electrode is formed on the other main surface. In other words, an anode is formed on one main surface, and a cathode is formed on the other main surface. The first and second main electrode conductors are anode conductor 2 and cathode conductor 3, respectively. The leaf springs 6a, 6b and 6c form a cylindrical elastic body.
FIG. 4 is a partial cross-sectional view for explaining the method of forming the projection 18 in the embodiment of FIG. 3.
In FIG. 4, the same reference numerals as those shown in FIGS. 1 to 3 designate the same or equivalent members or elements. The reference numeral 52 designates a projection forming jig, and this jig 52 has an inner peripheral surface of the same inner diameter as the outer diameter of the cylindrical body 7 and split structures of cylindrical shape divided into three sections in the peripheral direction. The projection 52a is provided on the inner peripheral surface of the jig, and the projection 18 is formed by pressing the jig to the inside of the side wall of the cylindrical body 7.
When the projection 18 is formed at the cylindrical body 7 by using the projection forming jig 52, the leaf springs 6a, 6b and 6c are first pressed by the jig 50 into a compressed state having a predetermined spring pressure. Then, the projection forming jig 52 is disposed outside the cylindrical body 7 so that the lower end of the projection 52a and the outer peripheral edge of the upper surface of the leaf spring 6c are located in the same plane. Then, when the jig 52 is pressed so that its inner peripheral surface is contacted with the outer peripheral surface of the cylindrical body 7, the portion of the side wall of the cylindrical body 7 to be contacted with the projection 52a of the jig 52 is pressed inward, thereby forming the projection 18 to be engaged with the outer peripheral edge of the upper surface of the leaf spring 6c.
Since the projection 18 is formed in this manner as described above, the deflecting sizes of the leaf springs 6a, 6b and 6c do not alter when the jig 50 is removed after the projection 18 is formed, and the spring pressures of the leaf springs 6a, 6b and 6c can be readily set to a predetermined value. In addition, since small broken pieces (shown by A in FIG. 1) are not produced as in the case of the prior art example when the projection 18 is formed, a short-circuit between the anode and the cathode of the diode element 1 and the resultant decrease in the electric characteristics do not occur.
In the embodiment shown in FIG. 3, the metal washer 5 is used. However, the washer 5 may be omitted if the insulating washer 4 has a strength capable of resisting the spring pressures of the leaf springs 6a, 6b and 6c of their compressed state.
Further, in the embodiments described above, the recess portion 2a is formed on the main surface of the anode conductor 2. However, it is not always necessary to form the recess portion 2a, and the recess portion 2a may be omitted.
In the embodiments described above, the leaf springs 6a, 6b and 6c are used. However, it is not always necessary to use the leaf springs. Alternatively they may be coiled springs or other cylindrical elastic members.
In the embodiments described above, the projection 18 is formed on the portion over the entire periphery of the side wall of the cylindrical body 7. However, the present invention is not limited to the particular embodiments. For example, the projections may be formed at a plurality of positions at intervals in the peripheral direction of the side wall of the cylindrical body 7.
Moreover, in the embodiments described above, the present invention has been described with respect to the case of the diode element 1. However, the present invention is not limited to the particular embodiments. For example, the present invention may be applied to the case of a semiconductor element in which a first main electrode is formed on one main surface and a second main electrode of the opposite polarity to the first electrode is formed on the other main surface. | A method of manufacturing the present invention relates to a semiconductor device by providing a projection formed by pressing the side wall portion of a metal cylindrical body from the outside toward the inside of the cylindrical body and engaging the outer peripheral edge of the upper surface of the cylindrical elastic member contained in the cylindrical body with the projection. | 7 |
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
The present invention relates to solid propellant grains or the like and more particularly to a process for preparing propellant grains comprising thermoplastic binders and suspended solid particulates.
Conventional solid composite propellants have binders which utilize cross-linked elastomers in which prepolymers are cross-linked by chemical curing agents. As outlined in U.S. Pat. No. 4,361,526, there are important disadvantages to cross-linked elastomers. Cross-linked elastomers must be cast within a short time after addition of the curing agent, which time period is known as the "pot life". Disposal of a cast cross-linked propellant composition is difficult, except by burning, which poses environmental problems.
As an alternative to cross-linked elastomer binders, U.S. Pat. No. 4,361,526 proposes to use a thermoplastic elastomeric binder which is a block copolymer of a diene and styrene, the styrene blocks providing a meltable crystalline structure and the diene blocks imparting rubbery or elastomeric properties to the copolymer. In order to prepare a propellant composition using the copolymer, the copolymer is dissolved in an organic solvent, such as toluene, and the solids and other propellant ingredients are added. The solvent is then evaporated, leaving a rubbery solid which may be divided into pellets suitable for casting or other processing.
A disadvantage of formulating a propellant using a thermoplastic elastomeric binder which must be dissolved in a solvent is that the propellant grain cannot be cast in a conventional manner, e.g., into a rocket motor casing. Further, solvent-based processing presents problems with respect to removal and recovery of the solvent. Organic solvents, such as toluene., present certain hazards to the immediate work area and to the larger environment, necessitating various precautions to be taken with regard to processing such propellant formulations.
It has also been proposed to produce thermoplastic elastomeric propellants in which the solid particulates and thermoplastic elastomer are fused in a high-shear mixer and the fused mixture poured or extruded into a casing or mold. There are important disadvantages with such techniques. Because of the high-solids loading of propellant formulations, viscosities tend to be quite high, making mixing difficult, and, in many cases, impossible on a large scale. Localized overheating in high-shear apparatus can cause ignition and catastrophic combustion of these high-energy formulations.
As an alternative to high-shear mixing and/or extrusion, U.S. Pat. No. 4,764,316 proposes to dry blend thermoplastic elastomer particles and energetic particles, pack the blended particles into a mold or casing, then fuse the particulates and thermoplastic elastomer together. A disadvantage of this method is the possibility of voids in the fused propellant.
There exists a need for improved processes for producing propellant grains with thermoplastic elastomer binders.
Accordingly, it is an object of the present invention to provide a castable, thermoplastic composite rocket propellant.
It is another object of this invention to provide a process for producing a thermoplastic composite rocket propellant.
Other objects and advantages of the present invention will become apparent to those persons skilled in the art from a reading of the following description of the invention.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a castable, thermoplastic composite rocket propellant comprising about 3 to 10 wt % of a thermoplastic elastomer, about 3 to 20 wt % of a plasticizer, balance energetic particulates.
Also provided is a process for producing a thermoplastic composite rocket propellant which comprises melt blending a thermoplastic elastomer and about 100 to 300 phr (parts by weight per 100 parts by weight of rubber (elastomer)) plasticizer, adding energetic particulates to the melt, with mixing, and casting the mixture in a suitable mold.
DETAILED DESCRIPTION OF THE INVENTION
A wide variety of thermoplastic elastomers may be used in the present invention, provided they have suitable properties, including the following: melting temperature of about 50° to 125° C., preferably about 75° to 125° C.; viscosity at or below 125° C. of 400 Poise or less; stable at 125° C. for at least 12 hours, preferably about 20 hours at the melting temperature; a glass transition temperature of -4° C. or below, preferably -20° C. or below, more preferably -40° C. or below; and compatibility with the energetic particles.
Suitable thermoplastic elastomers include styrene-diene block copolymers, such a styrene-butadiene, styrene-isoprene, styrene-ethylene/butylene block copolymers having star or radial, triblock (e.g., styrene-butadiene-styrene), multiblock or graft configurations, nonstyrenic block copolymers such as polyester-polyether, polyamide-polyether or segmented polyurethanes, ionomers, polyolefin thermoplastic elastomers, 1,2-syndiotactic polybutadiene and ethylene-vinyl acetate/ethylene-acrylic acid copolymers.
Particularly suitable for use in the present invention are the triblock and star-configured (radial) styrene-butadiene block copolymers. The polystyrene and polybutadiene segments of these polymers are thermodynamically incompatible and form separate microdomains, both in the elastomeric state and in the melt. Since both blocks are separated into two phases, two glass transitions are observed, one for each phase. The block copolymer is elastomeric in the region between the two glass transition temperatures. The triblock copolymers are preferable to radial copolymers because they require less plasticizer to achieve the desired low melt viscosity. This is because the molecular weight of radial copolymers is about double that of the triblock copolymers. In general, for use in the present invention molecular weights in the approximate range of 50,000 to 250,000 are desired.
The styrene-butadiene block copolymers are available commercially from a number of manufacturers, in a variety of molecular weights and relative concentrations of the styrene/butadiene segments. Examples of commercial materials are the radial copolymer available from Cosden Oil and Chemical Co., Dallas, Tex., under the tradename Finaprene and the triblock copolymer available from Shell Oil Co., Houston, Tex., under the tradename Kraton.
Plasticizers for use in the present invention should be compatible with the thermoplastic elastomer (TPE) and the energetic particulates, should have a low pour point, low viscosity and low volatility with good thermal stability at 125° C. The styrenic TPEs may be plasticized with nonpolar plasticizers such as mineral oils, while the nonstyrenic TPEs may be plasticized with polar plasticizers. Suitable nonpolar plasticizers include Tufflo 6016, a paraffinic oil available from Lyondell Petrochemical Co., Houston, Tex., and Oronite, a polyisobutene, available from Amoco Chemicals Corp., Chicago, Ill. The quantity of plasticizer employed with the TPE is sufficient to provide a P l /P o (Plasticizer/Polymer) ratio of about 1:1 to 3:1, or about 100 to 300 phr (parts by weight per 100 parts by weight of rubber or elastomer).
Energetic particulates are selected from energetic materials that are commonly used in propellant formulations. Particulate aluminum, beryllium or boron are common fuel materials. Common oxidizers include ammonium perchlorate (AP), potassium perchlorate (KP),ammonium nitrate (AN), cyclotrimethylene trinitramine (RDX), and cyclotetramethylene tetranitramine (HMX), as well as mixtures thereof. In general, the propellant formulations of the present invention comprise about 80 to 92 wt % energetic solids, with the balance of the grain consisting essentially of the binder system.
The propellant formulation optionally includes minor amounts of additional components, such as processing aids, burn rate modifiers (up to about 1 wt %), bonding agents (about 0.3 to 0.5 wt %), such as aminopropyl triethoxysilane (available from Union Carbide under the tradename A-1100) or neoalky 1 tri(N-ethylamino ethylamino) titanate, etc. which are known in the art. The formulation may further comprise up to about 3 wt % of a resin or polymer modifier such as Endex 160, an alpha-methylstyrene resin, available from Hercules, Inc., which acts to sharpen the melting point of the binder system of TPE and plasticizer.
The thermoplastic elastomer and the plasticizer are mixed, using a high-shear mixer, at a temperature above the melting temperature of the polymer. The solids and optional components of the propellant formulation are then mixed into the melt using a low-shear mixer. Because of the relatively low viscosities of the molten polymer/plasticizer mixture, no solvents are required for blending or other processing, such as casting or extrusion.
An example of a propellant formulation embodying the present invention is as follows with the percentages given by weight:
______________________________________Finaprene 416 (binder) 3.28Tufflo 6016 (plasticizer) 9.01Endex 160 (polymer modifier) 1.31Ammonium Perchlorate (oxidizer) 68.0Aluminum (fuel) 18.0A-1100 (bonding agent) 0.4______________________________________
The binder consisting of the Finaprene 416, Tufflo 6016 and Endex 160 was melted and blended in an internal mixer at a suitable temperature. The ammonium perchlorate and aluminum were then mixed into the binder in increments. The A-1100 bonding agent was added with mixing, and the homogeneous mixture cast at 125° C. into a rocket motor case and allowed to cool.
The resulting propellant had a tensile strength of 104 psi, elongation at break of 26%, with a modulus E 0 of 555 psi at 25° C. The onset of softening occurred at 58° C. (by TMA); creep was minimal below 40° C. End of mix viscosity was 57 kpoise at 125° C. The propellant had a burn rate of 0.60 in/sec at 1000 psi chamber pressure and a burn rate exponent of 0.48.
Such a propellant has 86 wt % solids for high performance, yet the binder-plasticizer combination is sufficiently fluid for processing.
Various modifications may be made to the invention as described without departing from the spirit of the invention or the scope of the appended claims. | A castable, thermoplastic composite rocket propellant comprising about 3 to 10 wt % of a thermoplastic elastomer, about 3 to 20 wt % of a plasticizer, balance energetic particulates is provided.
Also provided is a process for producing a thermoplastic composite rocket propellant which comprises melt blending a thermoplastic elastomer and about 100 to 300 phr (parts by weight per 100 parts by weight of rubber (elastomer)) plasticizer, adding energetic particulates to the melt, with mixing, and casting the mixture in a suitable mold. | 2 |
This application claims the benefit of U.S. Provisional Patent Application No. 61/766,144 filed Feb. 19, 2013, the entire disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The invention is directed to the production of gears and in particular to the generation of straight bevel gears utilizing rotary disc cutters.
BACKGROUND OF THE INVENTION
It is known to produce straight bevel gears, as well as skew bevel gears, face couplings and splined parts, by providing a pair of inclined rotary cutting tools whose rotating cutting blades effectively interlock to simultaneously cut the same tooth space on a workpiece. Examples of this type of machining can be seen, for example, in U.S. Pat. No. 2,586,451 to Wildhaber; U.S. Pat. Nos. 2,567,273 and 2,775,921 to Carlsen; U.S. Pat. No. 2,947,062 to Spear or in the company brochure “Number 102 Straight Bevel Coniflex® Generator” published by The Gleason Works.
Straight bevel gears may be formed by a non-generating process where the inclined tools are plunged into the workpiece to form a tooth slot with the profile surface of the tooth being of the same form as that of the blade cutting edge. Alternatively, tooth surfaces may be generated wherein the inclined tools are carried on a machine cradle which rolls the tools together with the workpiece via a generating roll motion to form a generated profile surface on the workpiece. In either instance, the tools may also include cutting edges that are disposed at a slight angle (e.g. 3°) to the plane of cutter rotation. Such an angled cutting edge, in conjunction with the inclination of the tools, removes more material at the ends of a tooth slot thereby resulting in lengthwise curvature of the tooth surface (i.e. lengthwise ease-off) for tooth bearing localization.
Bevel and hypoid gears can be cut in a single indexing process (face milling) or in a continuous indexing process (face hobbing). A basic cutting setup in the generating or cradle plane will put the center of the cutter head in a position which is away from the generating gear center (cradle axis) by the amount known as the radial distance. The silhouette of the cutter blades represents one tooth of the generating gear while the cutter rotates. Common face cutters for bevel gear cutting have several blade groups with each group having between one and four blades. Most common are alternating (completing) cutters with one outside and one inside blade. Peripheral cutter heads for the manufacture of straight bevel gears according to the above-described interlocking cutters method use only one kind of blades (e.g. outside blades) which have been used on conventional mechanical machines in the past.
On modern CNC machines, such as those machines known as 6-axis or free-form machines and disclosed by, among others, U.S. Pat. No. 6,715,566 the disclosure of which is hereby incorporated by reference, only one cutter from the above-discussed interlocking pair of cutters is used to cut a first tooth flank in a lower cutting position and, with the same cutter, also cut a second tooth flank in an upper cutting position in a single indexing process as disclosed in, for example, U.S. Pat. No. 7,364,391 the disclosure of which is hereby incorporated by reference. The cutting of the first flank faces the problem that material has to be removed not only on the cutting edge but also on the clearance edge of the blade. The result is high part temperature, poor cutting performance and low tool life. In a combined process, of vector feed and rolling, the clearance side of the blades during the first slot cutting can be moved away from the material which protects the clearance side of the cutting edge. However, a vector feed in straight bevel gear cutting has to use a very steep angle (only few degrees away from the blades center line) which makes the blade tip subject of severe chip removing loads. This leads to early failure of the blade tips and therefore results in low tool life.
Similar conditions occur if in a face cutting process only one kind of blades is used (e.g. inside blades only or full profile blades). The cutting blades will only be optimal on one side for high amounts of chip removal, which increases part temperature and reduces tool life.
SUMMARY OF THE INVENTION
The invention is directed to generating cutting processes for producing bevel gears and employing a single rotary disc cutter wherein a portion of the generating cutting process effectively includes a reduction of the workpiece roll angle during generating thereby reducing or eliminating cutting action on the clearance side of the rotary disc cutter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a conventional interlocking cutter arrangement. The upper cutter has cutting edges exposed on the top and the cutter axes are inclined such that the cutting edges represent the pressure angle of a generating rack profile.
FIG. 2 shows four views onto the cross-section in the middle of the face width of a straight bevel pinion with a peripheral cutter engaged. Only the lower cutter of FIG. 1 is shown which has a horizontal orientation of the cutter axis.
FIG. 3 shows four views onto the cross-section in the middle of the face width of a straight bevel pinion with a peripheral cutter engaged. Only the upper cutter of FIG. 1 is shown which has a horizontal orientation of the cutter axis.
FIG. 4 shows three views onto the cross-section in the middle of the face width of a straight bevel pinion with a peripheral cutter starting to engage in position 1 , the cutter being 50% engaged in position 2 and the cutter being fully engaged in position 3 . In spite of the rolling process, shown in FIGS. 2 and 3 , the cutter is fed into the material along a linear path under a predetermined vector direction.
FIG. 5 shows four views onto the cross-section in the middle of the face width of a straight bevel pinion with a peripheral cutter engaged in a lower position as in FIG. 2 . The work roll angle from the start work roll (position 1 ) to the position 3 has been reduced, the amount of reduction being proportional to the amount of work roll from the start.
FIG. 6 shows four graphics which accomplish in a reverse rolling mode (second pass of a double roll) the generation of the correct involute profile. After the sequence in FIG. 5 , the flank profile is not the desired correct involute, which is caused by the work roll reduction.
FIG. 7 shows a cross section of the virtual cylindrical gear, which represents the straight bevel gear in its mean section. The cutter blade represents one side of the generating rack which follows the path marked with s Pitch (or s 1 ) during the generation of the involute profile.
FIG. 8 shows the work and the cutter from FIG. 7 rotated in clockwise direction by an angle α in order to receive a horizontal cutter axis. FIG. 8 shows a number of radii and angles which are used in a set of proposed formulas to calculate the clearance side interference.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The terms “invention,” “the invention,” and “the present invention” used in this specification are intended to refer broadly to all of the subject matter of this specification and any patent claims below. Statements containing these terms should not be understood to limit the subject matter described herein or to limit the meaning or scope of any patent claims below. Furthermore, this specification does not seek to describe or limit the subject matter covered by any claims in any particular part, paragraph, statement or drawing of the application. The subject matter should be understood by reference to the entire specification, all drawings and any claim below. The invention is capable of other constructions and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting.
The details of the invention will now be discussed with reference to the accompanying drawings which illustrate the invention by way of example only. In the drawings, similar features or components will be referred to by like reference numbers.
The use of “including”, “having” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The use of letters to identify elements of a method or process is simply for identification and is not meant to indicate that the elements should be performed in a particular order. Although references may be made below to directions such as upper, lower, upward, downward, rearward, bottom, top, front, rear, etc., in describing the drawings, there references are made relative to the drawings (as normally viewed) for convenience. These directions are not intended to be taken literally or limit the present invention in any form. In addition, terms such as “first”, “second”, “third”, etc., are used to herein for purposes of description and are not intended to indicate or imply importance or significance.
FIG. 1 illustrates a conventional arrangement of a pair of inclined rotary disc cutters 2 , 4 (commonly referred to as upper and lower cutters, respectively) having cutting blades 6 for cutting a tooth slot in a workpiece 8 . Upper cutter 2 is rotatable about axis 12 and lower cutter 4 is rotatable about axis 10 . In a generating process on a conventional mechanical cradle-style machine, the inclined cutters 2 , 4 are usually fed into the workpiece to a predetermined depth and a generating roll of the machine cradle (not shown) is commenced in a synchronized manner with rotation of the workpiece 8 to generate tooth profile surfaces 14 , 16 .
The cutters of FIG. 1 comprise an interlocking cutter arrangement of rotary disc cutters. The upper cutter 2 has cutting edges 7 exposed on the top. The cutter axis 12 is inclined such that the cutting edges 7 represent the pressure angle of a generating rack profile. The blade edges 9 on the lower side of the upper cutter 2 are clearance edges, which are not sharp with respect to chip removal and therefore are not suited for participating in the cutting process. The lower cutter 4 has cutting edges 11 exposed to the bottom. The cutter axis 10 is also inclined by the same angle than the upper cutter 2 but in the negative direction. The blade edges 13 on the upper side of the lower cutter 4 are clearance edges, which are not sharp with respect to chip removal and therefore are not suited for participating in the cutting process. Since both cutters 2 , 4 are oriented so as to provide an interlocking arrangement, every blade of the upper cutter 2 (with a cutting edge 7 on top) is followed by a blade from the lower cutter 4 (with a cutting edge 11 on the bottom). This type of blade interaction makes provides a completing process, with alternating blades which together cut both sides 14 , 16 of one tooth slot in the workpiece 8 . During the generating rolling process, the two cutters 2 , 4 are kept in their orientation to each other, while they swing around the generating gear axis which is the same as the cradle axis of an older cradle style mechanical machine. It should be understood that for the present invention, the center of roll position is the position where the cutters are symmetrically located within the tooth slot such as shown in FIG. 1 .
The inventors have developed of a process that reduces or eliminates the clearance side cutting action on rotary disc cutters such as those shown at 2 or 4 in FIG. 1 if single rotary disc cutters are used such as in the previously mentioned U.S. Pat. No. 7,364,391 for example. In the case of interlocking cutters as in FIG. 1 , two separate cutters, one with cutting edges on the bottom side, the second with cutting edges on the top side are working simultaneously to remove chips from a tooth slot similar to alternating cutters.
However, If only one cutter is used in order to rough out a tooth slot and finish roll (i.e. generate) a first tooth flank, then a clearance side cutting action like that shown in FIG. 2 , or a severe tip cutting action as shown in FIG. 4 , occurs during the roughing portion of the cycle.
FIG. 2 shows four two dimensional views onto the cross section in the middle of the face width of a straight bevel pinion 20 with a peripheral cutter 22 engaged. Only one cutter (e.g. same as the lower cutter 4 of the two cutters in FIG. 1 ) is shown having a now horizontal orientation of the cutter axis. This is the orientation in a free form machine (e.g. previously discussed U.S. Pat. No. 6,712,566 and U.S. Pat. No. 7,364,391) with horizontal cutter axis and horizontal work axis, which presents the axes configuration required to achieve a rolling process between tool and work with the same relative orientation between tool and work as it is in the mechanical machine with interlocking cutters. A free form machine with a single cutter spindle does not possess the ability to work with a pair of interlocking cutters. The problem therefore is the fact that one single cutter with only sharp cutting edges on one side 24 (i.e. the right side in FIG. 2 ) has to rough out a tooth slot (cutting on both sides of the blades) and to finish cut (e.g. via a generating roll) a first tooth flank. This requires a form cutting action on the clearance side 26 of the blades. FIG. 2 shows how the left side of the blades after the start work roll position (position 1 ) to the end work roll position (position 4 ) is continuously participating on the chip removing process. The cutting edges on the right side of the blades are formed sharp by a side rake angle of, for example, 4° to 12°. The left side of the blades is therefore dull due to a −4° to −12° side rake angle. The left sides of the blades are not well suited for chip removal which leads to poor cutting performance with high part temperature and low tool life. The original (i.e. theoretical) work roll rotation angle is equal the generating gear rotation angle times the ratio of roll (number of teeth on the generating gear/number of teeth on the workpiece).
FIG. 3 shows four two dimensional views onto the cross section in the middle of the face width of a straight bevel pinion 20 with a peripheral cutter 28 engaged (e.g. same as the upper cutter 2 of the two cutters in FIG. 1 ) is shown but now with a horizontal orientation of the cutter axis. This can be the same cutter (i.e. cutter 22 ) that was used to cut in the lower position in FIG. 2 , which can be repositioned by a free form machine in order to also cut and form the second flank. The problem of cutting action on the clearance side of cutting blades as noted in the lower cutting position does not occur in the upper position shown in FIG. 3 . Since the slot roughing has already been performed in the lower cutting position, the process in the upper position is limited to finish rolling of the second flank. It is understood that the upper and lower positions could be exchanged. In such a case the lower position would be limited to finish rolling.
FIG. 4 shows three two dimensional views onto the cross section in the middle of the face width of a straight bevel pinion 30 with a peripheral disc cutter 32 starting to engage in the position 1 , the cutter being 50% engaged in position 2 and the cutter being fully engaged in position 3 . In spite of the rolling process, shown in FIGS. 2 and 3 , the cutter is fed into the material along a linear path under a predetermined vector direction. The vector direction is chosen to take chip load away from the dull clearance side blade edge and move this chip load to the sharp cutting edge. The plunging process shown in FIG. 4 is only suitable for the slot roughing. After plunging, a rolling and flank forming with the same cutter occurs in both the lower and the upper position. The vector feed plunging can move some chip load away from the clearance edge, however, it also directs a higher amount of chip load to the blade tips. Vector plunge roughing compared to a “roll only” process leads to a high blade tip wear and still is not capable of eliminating all cutting action on the clearance side blade edge.
The inventors discovered that in case of a “roll only” process (no rough plunging but slot roughing by rolling) the clearance side cutting action can be eliminated by reducing the amount of the work roll (rotation) angle. The work roll angle reduction is preferably achieved by reducing the rate of workpiece rotation (reduced with respect to an original theoretical amount) from the start roll position to and end roll position preferably not beyond the center roll position. A work roll reduction past the center roll position will cause an undercutting of the involute flank function, which makes it difficult in a second roll pass (double roll) to clean up the involute flank surface with a moderate set over. Optimal results can be achieved by utilizing a reduced work rotation rate (i.e. reduced with respect to an original theoretical work rotation rate) from the start roll position to the center roll position, preferably a position Δφi before the center roll position. The reduced work rotation rate is preferably constant from start roll to center roll positions, but may be varied in this interval. After the work roll reduction end position, the original, not reduced, rate of work rotation is preferably used. Most preferably, Δφi is a number between 0° and (end roll position—center roll position)/2.
The reduced work roll rate results in a form cut clearance side as shown in FIG. 5 which provides enough clearance to prevent any clearance side cutting action. The amount of work roll rate reduction is preferably calculated such that enough material on the form cut clearance side is still present in order to form the second flank with a correct slot width in a second (upper) cutting step as shown in FIG. 3 .
FIG. 5 shows four two dimensional views onto the cross section in the middle of the face width of a straight bevel pinion 34 with a peripheral cutter 36 engaged in a lower position such as in FIG. 2 . The difference between FIG. 5 and FIG. 2 is a reduction 38 of the work roll angle 40 from the start work roll (position 1 ) to position 3 , the amount of reduction preferably being proportional to the amount of work roll from the start although disproportional amounts of work roll reduction are likewise contemplated. For example, in FIG. 5 , a work roll reduction rate of −0.25 degrees per 15 degrees of roll motion is shown although the invention is not limited thereto. Thus, at position 3 , a work roll reduction angle of −0.75 degree has been achieved for a work roll angle of 45 degrees. At position 3 (which is near to the center roll position) the work roll reduction ends, which means that between position 3 and position 4 the change in work roll is exactly the value calculated (i.e. the original or theoretical amount) from the generating gear (cradle) rotation times the ratio of roll.
Rolling beyond the center roll position (from position 3 to position 4 ) while continuing with a reduced rate of work rotation will likely lead to an undercut of the root area and thus should be avoided. The work roll reduction between position 1 and position 4 rotates the left side 41 of the tooth slot away from the clearance side 42 of the blade 36 , such that the clearance side has no cutting contact during the entire roll of the first flank. The work roll reduction angle 38 has to be large enough to prevent cutting on the clearance side 42 of the blade 36 . However, a work roll reduction angle 38 that is too large will open the slot beyond the possibility to form a correct involute and achieve the proper slot width (no clean up in the following step).
After the rough rolling (where the blades have reached the root of the first flank) a set-over of the cutter versus the flank is performed in order to provide stock for a finish roll from root to top, as shown in FIG. 6 .
FIG. 6 shows four two dimensional graphics which accomplish in a reverse rolling mode (second pass of a double roll) the generation of the correct involute profile. After the sequence in FIG. 5 , the flank profile resulting from the work roll reduction 38 is not the desired correct involute. A set-over (which is a small clockwise work rotation Δε) towards the generated flank occurs which is followed by the reverse rolling (position 5 to position 8 ) which forms the correct profile from the bottom to the top. The set-over amount is between zero and a small amount (e.g. about 10% of the entire work roll reduction angle) to assure surface cleanup. Alternatively, the set-over amount may be a fixed amount (i.e. thickness) of stock material additionally removed from the tooth surface, such as, for example, 0.1 mm.
It should be understood that the “positions” shown in the Figures are for illustrative and explanatory purposes and the invention is not be limited to the number or location of the positions shown.
FIG. 7 shows a cross section of a virtual cylindrical gear 50 which represents a straight bevel gear in its mean section. The cutter disc 52 represents one side of the generating rack 54 (shown in the center of roll position) which follows the path marked with S Pitch (or S 1 ) during the generation of the involute profile. In the example of FIG. 7 , the cutter disc 52 has cutting edges 56 which are perpendicular to the axis of cutter rotation. Since the angle of the generating rack flanks is α, and the generating rack is horizontal, the cutter axis has to be inclined by α in order to simulate one flank of the generating rack. The distances S 1 and S Pitch in FIG. 7 are preferably identical.
FIG. 8 shows the work and the cutter from FIG. 7 rotated in clockwise direction by an angle α in order to receive a horizontal cutter axis. FIG. 8 shows a number of radii and angles which are used in a set of preferred equations to calculate the clearance side interference. The angle φ Int indicates the angle of interference between the work material on the clearance side (as cut correctly by the tip of the blade). φ Int is calculated from the work roll rotation (of the first cut point cut with the clearance side tip) and the location of the blades clearance point at the outside diameter in the center roll position. The interference angle is used for a work roll reduction between the left blade position and the right blade position in FIG. 8 .
FIG. 8 shows one possibility for calculating the interference angle φ Int . The interference angle is the angular amount of material on top of the clearance side of the tooth slot which leads to interference with the clearance side of the blade. FIG. 7 and FIG. 8 represent the virtual cylindrical gear of a straight bevel pinion or gear which is calculated from the critical cross section (along the face width). The critical cross section is in mid face or at the heel. The shown calculation is based on the cross section in mid face. The virtual cylindrical gear approximates the profile relationships of the real straight bevel gear and it allows an observation of the profiles in a two-dimensional plane. This calculation is accepted as precise for profile observations and is known such as from, E. Buckingham, Analytical Mechanics of Gears , McGraw-Hill Book Company Inc., 1949, pp. 324-328. Referring to the angles marked in FIG. 8 , the following formulae can be applied:
Given:
d 0 . . . mean pitch diameter γ . . . pitch angle h K . . . addendum of real bevel gear h F . . . dedendum of real bevel gear R Pitch . . . pitch radius at mid face R Top . . . Outside radius at midface R Root . . . Root radius at midface α . . . pressure angle of straight bevel gear Δq . . . generating roll from start roll to center roll RA . . . Ratio of roll between generating gear and work gear
R Pitch =d 0 /(2 cos γ) (1)
R Top =R Pitch +h K (2)
R Root =R Pitch −h F (3)
from the relationship in FIG. 8 :
R Top ·cos(φ 2 −α)= R Root ·cos(φ 1 −α) (4)
φ 1 =α+P W /(2 R Root )[rad] (5)
Equation (5) into (4) delivers:
φ 2 =arccos( R Root cos(φ 1 −α)/ R Top )+α (6)
from geometrical relationship in FIG. 8 :
S 1 =R Top sin(φ 2 −α)− R Root sin(φ 1 −α) (7)
The gearing law leads to the shifting of a trapezoidal generating rack tangential to the pitch circle of a gear blank (see FIG. 7 ) in order to generate an involute tooth profile. The work gear rotation is equal to s/d 0 [rad] in order to achieve rolling without slippage between the pitch circle of the work gear and the pitch line of the generating rack. A rotation of the work and the cutter disc, drawn in FIG. 7 , in clockwise direction by an angle α, results in the cutter-work relationship in FIG. 8 .
S 1 is in the direction of generating gear shift. S 1 relates to φ WorkRoll from start roll to center roll since it is equal S Pitch .
work roll angle from start roll to center roll:
φ WorkRoll =S 1 /R Pitch (generating law) [rad] (8)
φ 3 =φ 2 −φ WorkRoll (9)
φ 4 =α CL −(φ 1 −α) (10)
φ 5 =φ 1 +φ 4 ( R Top −R Root )/ R Root (11)
Interference angle from relationship in FIG. 8 , using (6) and (11):
φ Int =φ 2 −φ WorkRoll −φ 5 (12)
Interference angle per φ WorkRoll from start roll to center roll results in a sliding factor:
f Slide =φ Int /φ WorkRoll (13)
The sliding factor can be used to calculate modification of work roll angle depending on theoretical work roll angle:
Δφ= f Slide ·φ WorkRoll (14)
The sliding factor can also be used to calculate a ratio of roll which will include the new sliding rotation in the work gear:
φ WorkRoll =Δq·RA (15)
φ WorkRoll *=Δq·RA (1= f Slide ) (16)
RA*=RA (1+ f Slide ) (17)
In summary, it is possible to superimpose Δφ to the work roll angles as the process progresses, or to use RA* from start roll to center roll. The calculated angle Δφ will eliminate the severe interference but will not create any clearance between the blades' clearance side and the blank material. In order to eliminate any clearance cutting edge contact by an additional amount, Δφ 0 has to be added to Δφ. Preferred values for Δφ 0 are 5% to 15% of Δφ(Δφ·0.05<Δφ 0 <Δφ·0.15)
Δφ Total =Δφ+Δφ 0 (18)
The gear, shown in FIGS. 7 and 8 is the virtual cylindrical gear of an observed straight bevel gear. The virtual cylindrical gear shows in a two-dimensional representation the same geometrical properties as the real straight bevel gear would show in a profile section (which of course would be a three-dimensional representation). The two-dimensional virtual cylindrical gear profile allows the application of trigonometric expressions in order to make the interference problem on the clearance side of the cutter blades visible and to allow a corrective angle (i.e. a corrective ratio of roll) to be determined.
Rotary disc cutters for the cutting of straight bevel gears generally use a dish angle. In case of a dish angle, the cutting edges are not perpendicular to the cutter axis. The cutter representation in FIGS. 7 and 8 have been drawn without a dish angle. Since the presence of a dish angle changes the pressure angle α used in FIGS. 7 and 8 , the graphic would be automatically adjusted to any dish angle introduction. This means also, that the formulas (1) through (16) apply for all dish angles, including 0°.
The calculation shown to determine a corrective work roll reduction is only one possible way to quantify a reduction angle which prevents clearance side interference. More complex calculations (e.g. the generation of the entire clearance side slot surface as it would be generated by the blades' clearance edges and the comparison of this surface with the clearance side of the slot as it is formed by the entire clearance side of the blades ( FIG. 2 , position 4 )) may deliver more accurate results. However, the more precise calculation will not lead to an improved overall result, since a certain percentage of Δφ (mentioned as Δφ 0 above) has to be added in order to achieve clearance without any unwanted contact.
The inventive method may also be applied to bevel gear cutting processes with face cutter heads in those cases where only one kind of blades is used for slot roughing and finishing of one flank.
Although the invention has been explained and illustrated with respect to a reduction of the workpiece roll angle during generation of a tooth slot, it follows that the invention may also be achieved by an increase in the amount of roll movement of the rotary disc cutter (increased with respect to an original theoretical amount) during a portion of the generation of a tooth slot.
While the invention has been described with reference to preferred embodiments it is to be understood that the invention is not limited to the particulars thereof. The present invention is intended to include modifications which would be apparent to those skilled in the art to which the subject matter pertains without deviating from the spirit and scope of the appended claims. | Generating cutting processes for producing bevel gears and employing a single rotary disc cutter ( 36 ) wherein a portion of the generating cutting process effectively includes a reduction ( 38 ) of the workpiece roll angle ( 40 ) during generating thereby reducing or eliminating cutting action on the clearance side ( 42 ) of the rotary disc cutter. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Continuation Application of U.S. application Ser. No. 13/583,498 filled Sep. 7, 2012, which claims priority from PCT Application No. PCT/KR2012/006764 filed Aug. 24, 2012, which claims priority to Korean Patent Application No. 10-2011-0085481, filed Aug. 26, 2011, No. 10-2011-0117253, filed Nov. 11, 2011 and No. 10-2011-0117254, filed Nov. 11, 2011, the entireties of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] This embodiment relates to a lighting device.
[0004] 2. Background Art
[0005] A light emitting diode (LED) is a semiconductor element for converting electric energy into light. As compared with existing light sources such as a fluorescent lamp and an incandescent electric lamp and so on, the LED has advantages of low power consumption, a semi-permanent span of life, a rapid response speed, safety and an environment-friendliness. For this reason, many researches are devoted to substitution of the existing light sources with the LED. The LED is now increasingly used as a light source for lighting devices, for example, various lamps used interiorly and exteriorly, a liquid crystal display device, an electric sign and a street lamp and the like.
Technical Problem
[0006] The objective of the present invention is to provide a lighting device including a light source and a circuitry which are separable from each other.
[0007] The objective of the present invention is to provide a lighting device of which the lifespan does not depend on the circuitry.
[0008] The objective of the present invention is to provide a lighting device of any damaged one out of the light source and circuitry can be freely replaced.
[0009] The objective of the present invention is to provide a lighting device of which the light source and circuitry can be independently produced and sold.
[0010] The objective of the present invention is to provide a lighting device capable both of remarkably reducing defects caused by the destruction of a tap when a bolt is fastened to conventional power supply unit (PSU) housings of MR, PAR and a general bulb product and of remarkably reducing defects caused by crack.
[0011] The objective of the present invention is to provide a lighting device capable of both reducing a manufacturing cost and an assembly lead time by removing parts.
[0012] The objective of the present invention is to provide a lighting device capable of maintaining security for the design structure of the PSU housing because the PSU housing is fastened within a heat sink by a hook and is difficult to analyze.
[0013] The objective of the present invention is to provide a lighting device which includes an inlet for injecting molding liquid to an inner case and causes the molding liquid to be injected into only heat generating parts, so that a manufacturing cost is reduced.
[0014] While in the past a rubber cover is inevitably added in order to prevent water from leaking at the time of injecting the molding liquid, the objective of the present invention is to provide a lighting device which cures the molding liquid by using the rubber cover as JIG and removes the rubber cover, so that a manufacturing cost is reduced by removing parts.
Technical Solution
[0015] One embodiment is a lighting device. The lighting device includes: a light source including: a member which includes a first placement portion and a second placement portion; a light source module which is disposed in the first placement portion; and a first terminal which is disposed in the second placement portion and is electrically connected to the light source module; and a heat sink including: a first receiver in which the second placement portion of the member is disposed; a second receiver in which a circuitry is disposed; and a second terminal which is disposed corresponding to the first terminal of the light source.
[0016] The second placement portion of the member has a screw thread. The heat sink has a screw groove corresponding to the screw thread.
[0017] The member has a catching projection. The heat sink has a catching groove which is coupled to the catching projection.
[0018] The catching projection is disposed on the second placement portion of the member. The catching groove has an “L”-shape.
[0019] The second placement portion of the light source includes an insulating portion surrounding the first terminal. The insulating portion prevents electrical short-cut between the first terminal and the member.
[0020] The heat sink includes an insulating portion surrounding the second terminal. The insulating portion prevents electrical short-cut between the second terminal and the heat sink.
[0021] The light source module includes a substrate and a light emitting device disposed on the substrate. The member has a cavity in which the substrate is disposed.
[0022] The lighting device further includes a cover which is disposed over the light source module and is coupled to the member.
[0023] The member further includes a guide disposed between the cover and the heat sink.
[0024] The first terminal and the second terminal include a circular first electrode and a second electrode surrounding the first electrode, respectively.
[0025] Another embodiment is a lighting device. The lighting device includes: a light source module; a heat sink in which the light source module is disposed and which has a receiver and an insertion recess disposed in the inner surface thereof defining the receiver; an inner case which is disposed in the receiver of the heat sink and has a hook coupled to the insertion recess; and a circuitry which is disposed within the inner case and supplies electric power to the light source module.
[0026] The hook is disposed on both sides of the outer surface of the inner case respectively.
[0027] The inner case has an opening. The hook extends toward the opening and projects in such a manner that the end of the hook is inclined.
[0028] The inner case includes: a cylindrical receiver; a connection portion disposed under the receiver in such a manner as to have a diameter less than that of the receiver; and a level-difference portion connecting the receiver with the connection portion.
[0029] The inner case has a guide projection disposed on the outer surface of the receiver in the longitudinal direction of the receiver. The heat sink has a guide groove disposed at a position corresponding to the position of the guide projection.
[0030] The inner case has a guide groove disposed on the outer surface of the receiver in the longitudinal direction of the receiver. The heat sink has a guide projection disposed at a position corresponding to the position of the guide groove.
[0031] Further another embodiment is a lighting device. The lighting device includes: a light source module; a heat sink in which the light source module is disposed and which has a receiver; an inner case which is disposed in the receiver of the heat sink and has at least one inlet for injecting molding liquid; and a circuitry which is disposed within the inner case and supplies electric power to the light source module.
[0032] The inner case includes: a cylindrical receiver; a connection portion disposed under the receiver in such a manner as to have a diameter less than that of the receiver; and an inclined portion connecting the receiver with the connection portion and having an inlet is disposed therein.
[0033] The inlet is sealed with silicone or resin material.
[0034] The heat sink has an insertion recess. The inner case has a hook coupled to the insertion recess.
Advantageous Effects
[0035] In a lighting device according to the embodiment, a light source and a circuitry of the lighting device can be separated from each other.
[0036] In the lighting device according to the embodiment, the lifespan of the lighting device does not depend on the circuitry.
[0037] In the lighting device according to the embodiment, any damaged one out of the light source and circuitry can be freely replaced.
[0038] In the lighting device according to the embodiment, the light source and circuitry can be independently produced and sold.
[0039] In the lighting device according to the embodiment, it is possible both to remarkably reduce defects caused by the destruction of a tap when a bolt is fastened to conventional PSU housings of MR, PAR and a general bulb product and to remarkably reduce defects caused by crack.
[0040] In the lighting device according to the embodiment, it is possible to reduce a manufacturing cost and an assembly lead time by removing parts.
[0041] In the lighting device according to the embodiment, it is possible to maintain security for the design structure of the PSU housing because the PSU housing is fastened within a heat sink by a hook and is difficult to analyze.
[0042] In the lighting device according to the embodiment, an inlet for injecting molding liquid into an inner case is formed and causes the molding liquid to be injected into only heat generating parts, so that a manufacturing cost is reduced.
[0043] While in the past a rubber cover is inevitably added in order to prevent water from leaking at the time of injecting the molding liquid, the lighting device according to the embodiment cures the molding liquid by using the rubber cover as JIG and removes the rubber cover, so that a manufacturing cost is reduced by removing parts.
DESCRIPTION OF DRAWINGS
[0044] FIG. 1 is a perspective view of a lighting device according to a first embodiment;
[0045] FIG. 2 is an exploded perspective view of the lighting device shown in FIG. 1 ;
[0046] FIG. 3 is a perspective view showing that a light source and a circuitry of the lighting device shown in FIG. 1 are separated from each other;
[0047] FIG. 4 is a bottom perspective view of a heat sink shown in FIG. 2 ;
[0048] FIG. 5 is a view showing modified examples of a first terminal and a second terminal, each of which is shown in FIGS. 2 and 3 respectively;
[0049] FIG. 6 is a perspective view showing a modified example of the lighting device shown in FIG. 2 ;
[0050] FIG. 7 is a view showing another modified example of the lighting device shown in FIG. 2 ;
[0051] FIG. 8 is a view showing further another modified example of the lighting device shown in FIG. 2 ;
[0052] FIG. 9 is an exploded perspective view of a lighting device according to a second embodiment;
[0053] FIG. 10 is an inner cross sectional view of a lighting device according to a third embodiment;
[0054] FIG. 11 is a perspective view showing only an inner case shown in FIG. 9 ;
[0055] FIG. 12 is a perspective view showing a first modified example of the inner case shown in FIG. 11 ;
[0056] FIG. 13 is a perspective view showing a second modified example of the inner case shown in FIG. 11 ;
[0057] FIG. 14 is an inner cross sectional view of the lighting device according to the second embodiment shown in FIG. 9 ;
[0058] FIG. 15 is a perspective view of the inner case shown in FIG. 9 which is turned upside down;
[0059] FIG. 16 is a cross sectional view showing that molding liquid is injected into heat generating parts of the circuitry through an inlet of the inner case; and
[0060] FIG. 17 is a perspective view of a rubber cover used to inject the molding liquid through the inlet of the inner case.
DETAILED DESCRIPTION
[0061] A thickness or size of each layer is magnified, omitted or schematically shown for the purpose of convenience and clearness of description. The size of each component does not necessarily mean its actual size.
[0062] In description of embodiments of the present invention, when it is mentioned that an element is formed “on” or “under” another element, it means that the mention includes a case where two elements are formed directly contacting with each other or are formed such that at least one separate element is interposed between the two elements. The “on” and “under” will be described to include the upward and downward directions based on one element.
[0063] A lighting device according to various embodiments will be described with reference to the accompanying drawings.
First Embodiment
[0064] FIG. 1 is a perspective view of a lighting device according to a first embodiment. FIG. 2 is an exploded perspective view of the lighting device shown in FIG. 1 . FIG. 3 is a perspective view showing that a light source and a circuitry of the lighting device shown in FIG. 1 are separated from each other. FIG. 4 is a bottom perspective view of a heat sink shown in FIG. 2 .
[0065] Referring to FIGS. 1 to 4 , the lighting device according to the first embodiment may include a cover 100 , a light source 200 , a heat sink 300 , a circuitry 400 , an inner case 500 and a socket 600 . Hereafter, the components will be described in detail respectively.
[0066] The cover 100 has a bulb shape or a hemispherical shape. The cover 100 has an empty space and a partial opening.
[0067] The cover 100 is coupled to the light source 200 . Specifically, the cover 100 may be coupled to a member 250 of the light source 200 . The cover 100 may be coupled to the member 250 by using an adhesive or various methods, for example, bolt-fastening, rotary coupling, hook coupling and the like. In the bolt-fastening method, the cover 100 and the member 250 are coupled to each other by using a bolt. In the rotary coupling method, the screw thread of the cover 100 is coupled to the screw groove of the member 250 . That is, the cover 100 and the member 250 are coupled to each other by the rotation of the cover 100 . In the hook coupling method, the cover 100 and the member 250 are coupled to each other by inserting and fixing the hook (for example, a protrusion, a projection and the like) of the cover 100 into the groove of the member 250 .
[0068] The cover 100 is optically coupled to the light source 200 . Specifically, the cover 100 may diffuse, scatter or excite light emitted from the light source 200 . Here, the inner/outer surface or the inside of the cover 100 may include a fluorescent material so as to excite the light emitted from the light source 200 .
[0069] The inner surface of the cover 100 may be coated with an opalescent pigment. Here, the opalescent pigment may include a diffusing agent diffusing the light. The roughness of the inner surface of the cover 100 may be larger than that of the outer surface of the cover 100 . This intends to sufficiently scatter and diffuse the light emitted from the light source 200 .
[0070] The cover 100 may be formed of glass, plastic, polypropylene (PP), polyethylene (PE), polycarbonate (PC) and the like. Here, the polycarbonate (PC) has excellent light resistance, thermal resistance and rigidity.
[0071] The cover 100 may be formed of a transparent material causing the light source 200 to be visible to the outside or may be formed of an opaque material causing the light source 200 not to be visible to the outside.
[0072] The cover 100 may be formed by a blow molding process.
[0073] The light source 200 may include at least one light source module 210 and the member 250 .
[0074] The light source module 210 is disposed on the member 250 in such a manner as to emit light to the inner surface of the cover 100 . The member 250 may be coupled to the heat sink 300 . The member 250 coupled to the heat sink 300 is able to electrically connect the light source module 210 with the circuitry 400 . Hereafter, the light source module 210 and the circuitry 400 will be described in detail.
[0075] The light source module 210 includes a substrate 211 and at least one light emitting device 215 . The light emitting device 215 is disposed on one side of the substrate 211 . As shown in the drawing, the two light source modules 210 may be provided. Otherwise, one or more than three light source modules 210 may be provided.
[0076] The substrate 211 may be disposed on the member 250 .
[0077] The substrate 211 may have a quadrangular plate shape. However, the substrate 211 may have various shapes without being limited to this. For example, the substrate 211 may have a circular plate shape or a polygonal plate shape. The substrate 211 may be formed by printing a circuit pattern on an insulator. For example, the substrate 211 may include a common printed circuit board (PCB), a metal core PCB, a flexible PCB, a ceramic PCB and the like. Also, the substrate 211 may include a chips on board (COB) allowing an unpackaged LED chip to be directly bonded to a printed circuit board. The substrate 211 may be formed of a material capable of efficiently reflecting light. The surface of the substrate 211 may have a color such as white, silver and the like capable of efficiently reflecting light.
[0078] The surface of the substrate 211 may be coated with a material capable of efficiently reflecting light. The surface of the substrate 211 may be coated with a color capable of efficiently reflecting light, for example, white, silver and the like.
[0079] The light emitting device 215 may be a light emitting diode chip emitting red, green and blue light or a light emitting diode chip emitting UV. Here, the light emitting diode chip may have a lateral type or vertical type and may emit blue, red, yellow or green light.
[0080] The light emitting device 215 may have a fluorescent material. The fluorescent material may include at least any one selected from a group consisting of a garnet material (YAG, TAG), a silicate material, a nitride material and an oxynitride material. Otherwise, the fluorescent material may include at least any one selected from a group consisting of a yellow fluorescent material, a green fluorescent material and a red fluorescent material.
[0081] The member 250 may include a first placement portion 251 , a guide 253 and a second placement portion 255 . Here, the first placement portion 251 may be the top surface of the member 250 . The second placement portion 255 may be the bottom surface of the member 250 . The first placement portion 251 and the second placement portion 255 may be separated by the guide 253 .
[0082] The light source module 210 is disposed in the first placement portion 251 . Specifically, the substrate 211 of the light source module 210 may be disposed in the first placement portion 251 . The first placement portion 251 may have a cavity 251 - 1 into which the substrate 211 may be inserted. The depth of the cavity 251 - 1 may be the same as the thickness of the substrate 211 . A plurality of the cavities 251 - 1 may be provided according to the number of the substrates 211 .
[0083] As shown in FIG. 3 , a first terminal 270 is disposed in the second placement portion 255 . The first terminal 270 is a conductor through which electricity flows.
[0084] The first terminal 270 may include a positive (+) electrode and a negative (−) electrode. Here, the positive (+) electrode and the negative (−) electrode are disposed apart from each other. The positive (+) electrode is connected to the positive (+) electrode of a second terminal 330 . The negative (−) electrode is connected to the negative (−) electrode of the second terminal 330 .
[0085] The first terminal 270 is electrically connected to the light source module 210 disposed in the first placement portion 251 . The first terminal 270 may be electrically connected to the light source module 210 by using a wire. That is, one end of a wire may be connected to the first terminal 270 . The other end of the wire may be connected to the substrate 211 of the light source module 210 .
[0086] The first terminal 270 may be electrically connected to the light source module 210 by the first terminal 270 itself, That is, one end of the first terminal 270 may be connected to the substrate 211 of the light source module 210 . The other end of the first terminal 270 may be disposed in the second placement portion 255 .
[0087] The first terminal 270 directly contacts with the second terminal 330 of the heat sink 300 . Due to the direct contact between the first terminal 270 and the second terminal 330 , the first terminal 270 and the second terminal 330 may be electrically connected to each other.
[0088] The guide 253 is disposed between the cover 100 and the heat sink 300 . The upper portion of the guide 253 is coupled to the cover 100 . The lower portion of the guide 253 is coupled to heat radiating fins 370 of the heat sink 300 . The first placement portion 251 and the second placement portion 255 may be separated by the guide 253 .
[0089] The second placement portion 255 may be received in a first receiver 310 of the heat sink 300 . When the second placement portion 255 is received in the first receiver 310 , the first terminal 270 mechanically contacts with the second terminal 330 , and then the first terminal 270 and the second terminal 330 can be electrically connected to each other.
[0090] The member 250 may be formed of a material having thermal conductivity. This intends that the member 250 rapidly receives heat generated from the light source module 210 and protects the light source module 210 from the heat. The member 250 may be formed of, for example, Al, Ni, Cu, Mg, Ag, Sn and the like and an alloy including the metallic materials. The member 250 may be also formed of thermally conductive plastic. The thermally conductive plastic is lighter than a metallic material and has a unidirectional thermal conductivity.
[0091] The member 250 may include an insulating portion 290 . When the member 250 is made of a metallic material through which electricity flows, since the first terminal 270 is also a conductor, electrical short-cut may occur between the member 250 and the first terminal 270 . The insulating portion 290 prevents the electrical short-cut. The insulating portion 290 may be disposed in the second placement portion 255 of the member 250 in such a manner as to surround the first terminal 270 .
[0092] The heat sink 300 receives the heat from the light source 200 and the circuitry 400 and radiates the heat. The heat sink 300 may be formed of Al, Ni, Cu, Mg, Ag, Sn and the like and an alloy including the metallic materials. The heat sink 300 may be also formed of thermally conductive plastic. The thermally conductive plastic is lighter than a metallic material and has a unidirectional thermal conductivity.
[0093] The heat sink 300 may have the first receiver 310 and a second receiver 350 .
[0094] The first receiver 310 may be formed by the heat radiating fins 370 and one side of the heat sink 300 . Specifically, the first receiver 310 may be determined by one side 311 of the heat sink 300 and one side 371 of the heat radiating fin 370 . Here, the one side 311 of the heat sink 300 and the one side 371 of the heat radiating fin 370 may be inclined with respect to each other or may be substantially perpendicular to each other.
[0095] The first receiver 310 receives the second placement portion 255 of the member 250 . In this case, since the second placement portion 255 directly contacts with the one side 311 of the first receiver 310 and the one side 371 of the heat radiating fin 370 , the heat from the member 250 may be directly transferred to the heat sink 300 and the heat radiating fins 370 .
[0096] The second terminal 330 is disposed in the first receiver 310 . The second terminal 330 is disposed on the one side 311 of the heat sink 300 . The second terminal 330 is a conductor and directly contacts with the first terminal 270 of the member 250 . Therefore, the second terminal 330 is electrically connected to the first terminal 270 .
[0097] Like the first terminal 270 , the second terminal 330 may include a positive (+) electrode and a negative (−) electrode. The positive (+) electrode and the negative (−) electrode are disposed apart from each other. The positive (+) electrode is connected to the positive (+) electrode of the first terminal 270 . The negative (−) electrode is connected to the negative (−) electrode of the first terminal 270 .
[0098] The second receiver 350 is disposed corresponding to the first receiver 310 of the heat sink 300 . The first receiver 310 is disposed on the second receiver 350 . Contrarily, the second receiver 350 is disposed under the first receiver 310 .
[0099] The second receiver 350 may be a cavity formed in the other side of the heat sink 300 . The second receiver 350 has a predetermined depth in the direction of the first receiver 310 . The depth of the second receiver 350 may be greater than that of the first receiver 310 . The depth of the second receiver 350 may be changed according to the size of the circuitry 400 .
[0100] The second receiver 350 receives the circuitry 400 and the inner case 500 . Specifically, the inner case 500 receives the circuitry 400 , and then the second receiver 350 receives the inner case 500 .
[0101] The heat sink 300 may have the heat radiating fins 370 . The heat radiating fins 370 may extend from or may be connected to the outer surface of the heat sink 300 . The heat radiating fins 370 increase the heat radiating area of the heat sink 300 , thereby improving heat radiation efficiency.
[0102] The one side 371 of the heat radiating fin 370 , together with the one side 311 of the heat sink 300 can determine the first receiver 310 .
[0103] The guide 253 of the member 250 is disposed on the heat radiating fins 370 . The heat radiating fins 370 are able to directly receive heat from the guide 253 .
[0104] The heat sink 300 may include an insulating portion 390 . When the heat sink 300 is made of a metallic material through which electricity flows, since the second terminal 330 is also a conductor, electrical short-cut may occur between the heat sink 300 and the second terminal 330 . The insulating portion 390 prevents the electrical short-cut. The insulating portion 390 may be disposed on the one side 311 of the heat sink 300 in such a manner as to surround the second terminal 330 .
[0105] The circuitry 400 receives external electric power, and then converts the received electric power in accordance with the light source module 210 of the light source 200 . The circuitry 400 supplies the converted electric power to the light source 200 .
[0106] The circuitry 400 is received in the heat sink 300 . Specifically, the circuitry 400 is received in the inner case 500 , and then, together with the inner case 500 , is received in the second receiver 350 of the heat sink 300 .
[0107] The circuitry 400 may include a circuit board 410 and a plurality of parts 430 mounted on the circuit board 410 .
[0108] The circuit board 410 may have a quadrangular plate shape. However, the circuit board 410 may have various shapes without being limited to this. For example, the circuit board 410 may have an elliptical plate shape or a circular plate shape. The circuit board 410 may be formed by printing a circuit pattern on an insulator. The circuit board 410 may include a metal core PCB, a flexible PCB, a ceramic PCB and the like.
[0109] The circuit board 410 is electrically connected to the second terminal 330 of the heat sink 300 . The circuit board 410 may be electrically connected to the second terminal 330 by using a wire. That is, one end of a wire may be connected to the second terminal 330 . The other end of the wire may be connected to the circuit board 410 .
[0110] The circuit board 410 may be electrically connected to the second terminal 330 by the second terminal 330 itself. That is, one end of the second terminal 330 may be directly connected to the circuit board 410 . The other end of the second terminal 330 may be, as shown in FIG. 2 , disposed on the one side 311 of the heat sink 300 .
[0111] The plurality of parts 430 may include, for example, a Converter converting AC power supply supplied by an external power supply into DC power supply, a driving chip controlling the driving of the light source module 210 , and an electrostatic discharge (ESD) protective device for protecting the light source module 210 .
[0112] The inner case 500 receives the circuitry 400 thereinside. The inner case 500 may have a receiver 510 for receiving the circuitry 400 . The receiver 510 may have a cylindrical shape. The shape of the receiver 510 may be changed according to the shape of the second receiver 350 of the heat sink 300 .
[0113] The inner case 500 is received in the heat sink 300 . The receiver 510 of the inner case 500 is received in the second receiver 350 of the heat sink 300 .
[0114] The inner case 500 is coupled to the socket 600 . The inner case 500 may include a connection portion 530 which is coupled to the socket 600 . The connection portion 530 may have a screw thread corresponding to the screw groove of the socket 600 . The diameter of the connection portion 530 may be less than that of the receiver 510 .
[0115] The inner case 500 is a nonconductor. Therefore, the inner case 500 prevents electrical short-cut between the circuitry 400 and the heat sink 300 . The inner case 500 may be made of a plastic or resin material.
[0116] The socket 600 is coupled to the inner case 500 . Specifically, the socket 600 is coupled to the connection portion 530 of the inner case 500 .
[0117] The socket 600 may have the same structure as that of a conventional incandescent bulb. The circuitry 400 is electrically connected to the socket 600 . The circuitry 400 may be electrically connected to the socket 600 by using a wire. Therefore, when external electric power is applied to the socket 600 , the external electric power may be transmitted to the circuitry 400 .
[0118] The socket 600 may have a screw groove corresponding to the screw thread of the connection portion 530 .
[0119] FIG. 5 is a view showing modified examples of the first terminal and the second terminal, each of which is shown in FIGS. 2 and 3 respectively.
[0120] Terminals 270 ′ and 330 ′ shown in FIG. 5 are modified examples of the second terminal 330 shown in FIG. 2 and the first terminal 270 shown in FIG. 3 .
[0121] Referring to FIG. 5 , each of the first and the second terminals 270 ′ and 330 ′ may include a circular negative (−) electrode and a positive (+) electrode surrounding the negative (−) electrode. Contrarily, each of the first and the second terminals 270 ′ and 330 ′ may include a circular positive (+) electrode and a negative (−) electrode surrounding the positive (+) electrode.
[0122] Though not shown separately in the drawing, the second terminal 330 shown in FIG. 2 and the first terminal 270 shown in FIG. 3 may have a shape which is inserted and fitted like a battery or may have a protruding shape which can be pushed inwardly.
[0123] FIG. 6 is a perspective view showing a modified example of the lighting device shown in FIG. 2 .
[0124] In description of the lighting device according to the modified example shown in FIG. 6 , only differences between the lighting device shown in FIG. 6 and the lighting device shown in FIGS. 1 to 4 will be described.
[0125] A light source 200 ′ has a screw thread 255 a′. Specifically, the screw thread 255 a′ may be disposed on a second placement portion 255 ′ of a member 250 ′. More specifically, the screw thread 255 a′ may be disposed on the lateral surface of the second placement portion 255 ′.
[0126] The light source 200 ′ includes the first terminal 270 ′ shown in FIG. 5 .
[0127] A heat sink 300 ′ has a first receiver 310 ′. The first receiver 310 ′ may be a cavity which is determined by the lateral surface 313 ′ and bottom surface 311 ′ of the heat sink 300 ′.
[0128] The heat sink 300 ′ has a screw groove 313 a′. The screw groove 313 a′ is coupled to the screw thread 255 a′ of the light source 200 ′. The screw groove 313 a′ may be disposed on the lateral surface 313 ′ of the first receiver 310 ′.
[0129] The heat sink 300 ′ includes the second terminal 330 ′ shown in FIG. 5 . The second terminal 330 ′ may be disposed on the bottom surface 311 ′ of the heat sink 300 ′.
[0130] In the lighting device shown in FIG. 6 , the light source 200 ′ and the heat sink 300 ′ can be easily coupled to or separated from each other by rotating them through the use of the screw thread 255 a′ and the screw groove 313 a′. Also, since the lighting device shown in FIG. 6 includes the first and the second terminals 270 ′ and 330 ′ shown in FIG. 5 , the light source 200 ′ and the heat sink 300 ′ can be easily electrically connected to each other without distinguishing between the positive (+) electrode and the negative (−) electrode.
[0131] FIG. 7 is a view showing another modified example of the lighting device shown in FIG. 2 .
[0132] In description of the lighting device according to the another modified example shown in FIG. 7 , only differences between the lighting device shown in FIG. 7 and the lighting device shown in FIGS. 1 to 4 will be described.
[0133] A light source 200 ″ has a catching projection 253 a″. The catching projection 253 a″ may be disposed on a guide 253 ″ of a member 250 ″. Specifically, the catching projection 253 a″ may project from the guide 253 ″ toward a heat sink 300 ″.
[0134] The second placement portion 255 ″ of the light source 200 ″ includes the first terminal 270 ′ shown in FIG. 5 . However, the first terminal 270 ′ may be the first terminal 270 shown in FIG. 3 without being limited to this.
[0135] The heat sink 300 ″ has a tap 320 ″. A first receiver 310 ″ may be determined by the tap 320 ″ and one side 311 ″ of the heat sink 300 ″.
[0136] The tap 320 ″ has a catching groove 320 a″. The catching projection 253 a″ of the light source 200 ″ is inserted into the catching groove 320 a″.
[0137] The number of the catching grooves 320 a″ may correspond to the number of the catching projections 253 a″.
[0138] The heat sink 300 ″ includes the second terminal 330 ′ shown in FIG. 5 . However, the second terminal 330 ′ may be the second terminal 330 shown in FIG. 2 without being limited to this.
[0139] In the lighting device shown in FIG. 7 , the light source 200 ″ and the heat sink 300 ″ can be easily coupled to or separated from each other by using the catching projection 253 a″ and the catching groove 320 a″. Also, since the lighting device shown in FIG. 7 includes the first and the second terminals 270 ′ and 330 ′ shown in FIG. 5 , the light source 200 ″ and the heat sink 300 ″ can be easily electrically connected to each other without distinguishing between the positive (+) electrode and the negative (−) electrode.
[0140] FIG. 8 is a view showing further another modified example of the lighting device shown in FIG. 2 .
[0141] In description of the lighting device according to the further another modified example shown in FIG. 8 , only differences between the lighting device shown in FIG. 8 and the lighting device shown in FIG. 7 will be described.
[0142] A light source 200 ′″ has a catching projection 255 a′″. The catching projection 255 a′″ may be disposed on a second placement portion 255 ′″ of a member 250 ′. Specifically, the catching projection 255 a′″ may project from the lateral surface of the second placement portion 255 ′. Also, the catching projection 255 a′″ may project from the second placement portion 255 ′″ perpendicularly to a direction in which the light source 200 ′″ is coupled to a heat sink 300 ′″.
[0143] The light source 200 ′ includes the first terminal 270 ′ shown in FIG. 5 . However, the first terminal 270 ′ may be the first terminal 270 shown in FIG. 3 without being limited to this.
[0144] The heat sink 300 ′″ has a catching groove 320 a′″. The catching projection 255 a′″ is inserted into the catching groove 320 a′″. The catching groove 320 a″ may be bent in the form of “L”. As the catching projection 255 a′″ moves along the “L”-shaped catching groove 320 a′″, the light source 200 ′″ may be coupled to the heat sink 300 ′″.
[0145] The number of the catching grooves 320 a′″ may correspond to the number of the catching projections 255 a′″.
[0146] The heat sink 300 ′″ includes the second terminal 330 ′ shown in FIG. 5 . However, the second terminal 330 ′ may be the second terminal 330 shown in FIG. 2 without being limited to this.
[0147] In the lighting device shown in FIG. 8 , the light source 200 ′″ and the heat sink 300 ′″ can be easily coupled to or separated from each other by using the catching projection 255 a″ and the catching groove 320 a′″. Also, since the lighting device shown in FIG. 8 includes the first and the second terminals 270 ′ and 330 ′ shown in FIG. 5 , the light source 200 ′″ and the heat sink 300 ′ can be easily electrically connected to each other without distinguishing between the positive (+) electrode and the negative (−) electrode.
Second Embodiment
[0148] FIG. 9 is an exploded perspective view of a lighting device according to a second embodiment.
[0149] Referring to FIG. 9 , the lighting device according to the second embodiment may include a cover 110 , a light source module 130 , a heat sink 140 , a circuitry 150 , an inner case 160 and a socket 170 . In the lighting device according to the second embodiment, the heat sink 140 and the inner case 160 are coupled to each other by a hook coupling method.
[0150] The cover 110 is the same as the cover 100 shown in FIG. 1 except for the fact that the cover 110 is directly coupled to the heat sink 140 . Therefore, the detailed descriptions of the same parts as those of the aforementioned embodiment will be omitted.
[0151] The light source module 130 is the same as the light source module 210 shown in FIG. 1 except for the fact that the light source module 130 is disposed on the heat sink 140 . Specifically, the light source module 130 includes a substrate 131 and a light emitting device 132 . The substrate 131 is the same as the substrate 211 shown in FIG. 1 . The light emitting device 132 is the same as the light emitting device 215 shown in FIG. 1 .
[0152] The heat sink 140 may be formed of Al, Ni, Cu, Mg, Ag, Sn and the like and an alloy including the metallic materials. The heat sink 140 may be also formed of thermally conductive plastic. The thermally conductive plastic is lighter than a metallic material and has a unidirectional thermal conductivity.
[0153] The heat sink 140 is able to improve heat radiation efficiency by coming in surface contact with the light source module 130 . Here, the heat sink 140 and the light source module 130 may be coupled to each other to come in surface contact with each other by using a structure like a screw, or may be coupled to each other by using an adhesive.
[0154] The heat sink 140 has a flat portion 141 including a first base 141 a and a second base 141 b. Here, a level difference is formed between the first base 141 a and the second base 141 b. Each of the first base 141 a and the second base 141 b has a flat plate shape. The second base 141 b has a seating portion 142 formed therein. The light source module 130 is installed in the seating portion 142 . A guide 143 is formed on the upper circumference of the heat sink 140 . A recess (not shown) into which the cover 110 is inserted is formed between the guide 143 and the first base 141 a.
[0155] A plurality of heat radiating fins 144 are formed on the outer surface of the heat sink 140 . The heat radiating fins 144 may extend from or may be connected to the outer surface of the heat sink 140 . The heat radiating fins 144 increase the heat radiating area of the total heat sink 140 , thereby improving heat radiation efficiency.
[0156] The lower inside of the heat sink 140 has a receiver for receiving the inner case 160 . The receiver may be a predetermined space. The receiver may be a recess or a groove which has a predetermined depth.
[0157] An insertion recess (not shown, see reference numeral 147 of FIG. 10 ) is formed within a receiver of the inner case 160 , that is, in the inner surface defining the receiver of the inner case 160 . A hook (see reference numeral 164 of FIG. 11 ) of the inner case 160 is inserted into the insertion recess, so that the inner case 160 is fixed to the heat sink 140 .
[0158] The inner case 160 is disposed within the lower portion of the heat sink 140 and is coupled to the socket 170 . The circuitry 150 is received in the inner case 160 . The circuitry 150 controls the power of the light source module 130 through the electrode terminal of the light source module 130 .
[0159] As shown in FIG. 11 , the inner case 160 includes the receiver 161 , a connection portion 162 and a level-difference portion 163 . The receiver 161 has a cylindrical shape. The connection portion 162 is formed under the receiver 161 in such a manner as to have a diameter less than that of the receiver 161 . The level-difference portion 163 connects the receiver 161 with the connection portion 162 .
[0160] The inner case 160 may include the hook 164 . Specifically, the hook 164 may be formed on both sides of the outer surface of the receiver 161 . When the inner case 160 is disposed within the lower portion of the heat sink 140 , the hook 164 is coupled to the insertion recess (see reference numeral 147 of FIG. 10 ) formed within the heat sink 140 .
[0161] The inner case 160 may be variously changed as shown in FIGS. 11 to 13 . Detailed descriptions of the modified examples of the inner case 160 will be provided in FIGS. 11 to 13 .
[0162] The inner case 160 may be formed of a nonconductor in order to prevent electrical short-cut between the circuitry 150 and the heat sink 140 . The inner case 160 may be made of a plastic or resin material.
[0163] The circuitry 150 receives electric power from the socket 170 coupled to the lower portion of the inner case 160 and supplies the electric power to the light source module 130 .
[0164] The circuitry 150 converts the received electric power in accordance with the driving voltage of the light emitting module 130 , and then supplies the converted electric power to the light source 130 . For this purpose, the circuitry 150 includes a Converter 153 which is disposed on a substrate 151 and converts AC power supply supplied through the socket 170 into DC power supply, a driving chip which controls the driving of the light source module 130 , and an electrostatic discharge (ESD) protective device for protecting the light source module 130 .
[0165] The socket 170 is coupled to the inner case 160 and supplies electric power to the circuitry 150 . The socket 170 functions to support the lighting device. Like a socket of an incandescent bulb, a screw thread and a screw groove are formed on the outer surface of the socket 170 . The socket 170 is coupled to the inner case 160 , and then is electrically connected to the circuitry 150 . Here, the socket 170 may be connected to the circuitry 150 through a wire or may be directly connected to the circuitry 150 .
[0166] In the lighting device according to the second embodiment, the hook 164 formed on both sides of the outer surface of the inner case 160 is coupled to the insertion recess formed within the heat sink 140 . Accordingly, it is possible to overcome defects caused by the destruction of a tap when a bolt is fastened to conventional power supply unit (PSU) housings of MR and PAR products and to overcome defects caused by crack. Here, the PSU is designated to include the heat sink 140 and the inner case 160 receiving the circuitry 150 therewithin.
Third Embodiment
[0167] FIG. 10 is an inner cross sectional view of a lighting device according to a third embodiment.
[0168] Like the lighting device according to the second embodiment shown in FIG. 9 , in the lighting device according to the third embodiment shown in FIG. 10 , when the inner case 160 is inserted into the inside of the lower portion of the heat sink 140 , the hook 164 of the inner case 160 is coupled to the insertion recess 147 formed within the heat sink 140 . However, the lighting device according to the third embodiment shown in FIG. 10 is different from the lighting device according to the second embodiment shown in FIG. 9 in that the light source module 130 is disposed within the upper portion of the heat sink 140 , and a lens 120 is disposed on the light source module 130 .
[0169] Here, an undescribed reference numeral 144 represents a heat radiating fin formed on the outer surface of the heat sink 140 . An undescribed reference numeral 150 represents a circuitry received in the inner case 160 .
Inner Case 160
[0170] FIG. 11 is a perspective view showing only an inner case shown in FIG. 9 .
[0171] Referring to FIG. 11 , the inner case 160 includes the receiver 161 , the connection portion 162 and the level-difference portion 163 . The receiver 161 has a cylindrical shape. The connection portion 162 is formed under the receiver 161 in such a manner as to have a diameter less than that of the receiver 161 . The level-difference portion 163 connects the receiver 161 with the connection portion 162 .
[0172] Here, the hook 164 is integrally formed on both sides of the outer surface of the receiver 161 . Specifically, the hook 164 may be disposed on the lower portion of the outer surface of the receiver 161 . However, the hook 164 may be disposed on the upper or central portion of the outer surface of the receiver 161 without being limited to this.
[0173] The hook 164 may be disposed in an opening 165 formed in the outer surface of the inner case 160 . Specifically, the hook 164 may extend toward the opening 165 of the inner case 160 . The hook 164 may project in such a manner that the end of the hook 164 is inclined.
[0174] When the inner case 160 is disposed within the lower portion of the heat sink 140 , the hook 164 is coupled to the insertion recess formed within the heat sink 140 . Therefore, the inner case 160 can be fixed to the heat sink 140 by the coupling of the hook 164 and the insertion recess.
[0175] The hook 164 formed on both sides of the outer surface of the inner case 160 is coupled to the insertion recess formed within the heat sink 140 . Accordingly, it is possible to overcome defects caused by the destruction of a tap when a bolt is fastened to conventional power supply unit (PSU) housings of MR, PAR and a general bulb product and to overcome defects caused by crack.
First Modified Example of Inner Case
[0176] FIG. 12 is a perspective view showing a first modified example of the inner case shown in FIG. 11 .
[0177] Referring to FIG. 12 , like the inner case 160 shown in FIG. 11 , an inner case 160 ′ includes the receiver 161 , the connection portion 162 and the level-difference portion 163 . Here, the inner case 160 ′ shown in FIG. 12 further includes a guide projection 167 .
[0178] The guide projection 167 may project from the outer surface of the receiver 161 and may be formed in the longitudinal direction of the receiver 161 .
[0179] The guide projection 167 may have a hemispherical shape. However, the guide projection 167 may have a polygonal shape including a triangular shape, a quadrangular shape and the like.
[0180] The guide projection 167 may be inserted into a guide groove (not shown) formed within the heat sink (see reference numeral 140 of FIG. 9 ) in a sliding manner. Here, the guide groove (not shown) of the heat sink 140 is formed at a position corresponding to the position of the guide projection 167 of the inner case 160 ′. The guide groove (not shown) of the heat sink 140 may have a shape corresponding to the shape of the guide projection 167 of the inner case 160 ′. As such, the guide projection 167 may function to indicate a direction in which the inner case 160 ′ and the heat sink 140 are coupled to each other and where the inner case 160 ′ and the heat sink 140 are coupled to each other.
[0181] When the guide projection 167 formed on the outer surface of the inner case 160 ′ is inserted in a sliding manner into the guide groove (not shown) formed within the heat sink 140 , the hook 164 formed on both sides of the outer surface of the inner case 160 ′ is automatically coupled to the insertion recess formed within the heat sink 140 . Accordingly, it is possible to overcome defects caused by the destruction of a tap when a bolt is fastened to conventional power supply unit (PSU) housings of MR, PAR and a general bulb product and to overcome defects caused by crack.
Second Modified Example of Inner Case
[0182] FIG. 13 is a perspective view showing a second modified example of the inner case shown in FIG. 11 .
[0183] Referring to FIG. 13 , like the inner case 160 shown in FIG. 11 , an inner case 160 ″ includes the receiver 161 , the connection portion 162 and the level-difference portion 163 . Here, the inner case 160 ″ shown in FIG. 13 further includes a guide groove 167 ′.
[0184] The guide groove 167 ′ may be formed toward the inside of the receiver 161 in the longitudinal direction of the receiver 161 .
[0185] The guide groove 167 ′ may have a hemispherical shape. However, the guide projection 167 may have a polygonal shape including a triangular shape, a quadrangular shape and the like.
[0186] The guide groove 167 ′ may be inserted into a guide projection (not shown) formed within the heat sink (see reference numeral 140 of FIG. 9 ) in a sliding manner. Here, the guide projection (not shown) of the heat sink 140 is formed at a position corresponding to the position of the guide groove 167 ′ of the inner case 160 ″. The guide projection (not shown) of the heat sink 140 may have a shape corresponding to the shape of the guide groove 167 ′ of the inner case 160 ″. As such, the guide groove 167 ′ may function to indicate a direction in which the inner case 160 ″ and the heat sink 140 are coupled to each other and where the inner case 160 ″ and the heat sink 140 are coupled to each other.
[0187] When the guide groove 167 ′ formed on the outer surface of the inner case 160 ″ is inserted in a sliding manner into the guide projection (not shown) formed within the heat sink 140 , the hook 164 formed on both sides of the outer surface of the inner case 160 ″ is automatically coupled to the insertion recess formed within the heat sink 140 . Accordingly, it is possible to overcome defects caused by the destruction of a tap when a bolt is fastened to conventional power supply unit (PSU) housings of MR and PAR products and to overcome defects caused by crack.
[0188] FIG. 14 is an inner cross sectional view of the lighting device according to the second embodiment shown in FIG. 9 . FIG. 15 is a perspective view of the inner case shown in FIG. 9 which is turned upside down.
[0189] Referring to FIGS. 9 , 14 to 15 , the inner case 160 includes an inlet 166 . The inlet 166 is a hole for injecting molding liquid to heat generating parts received within the inner case 160 . The inlet 166 may be formed in the level-difference portion 163 .
[0190] The circuitry 150 is received within the inner case 160 . Molding liquid 210 is cured and then disposed around the Converter 153 of the circuitry 150 . Since the Converter 153 generates heat from the operation thereof, the molding liquid 210 surrounds the Converter 153 for the purpose of protecting other circuits from the generated heat and radiating the heat.
[0191] The Converter 153 may be an AC-DC converter which changes a value of alternating current voltage or a value of alternating current.
[0192] The molding liquid 210 is injected only around the internal heat generating parts, i.e., the Converter 153 through the inlet 166 formed in the inner case 160 , and then is cured. Through this, a manufacturing cost can be reduced by reducing the amount of the molding liquid used.
[0193] More specifically, in the past, the molding liquid 210 was filled in the entire inside of the inner case 160 through the opening of the inner case 160 . As a result, a molding process was also performed on portions requiring no molding liquid. However, in the embodiment, after a rubber cover 200 is coupled to the opening of the inner case 160 , the molding liquid 210 is injected into only the Converter 153 through the inlet 166 and is cured, so that the amount of the molding liquid used can be reduced.
[0194] FIG. 16 is a cross sectional view showing that the molding liquid is injected into the heat generating parts of the circuitry through the inlet of the inner case. FIG. 17 is a perspective view of the rubber cover used to inject the molding liquid through the inlet of the inner case.
[0195] The inner case 160 includes the receiver 161 , the connection portion 162 and the level-difference portion 163 . Here, the level-difference portion 163 is an inclined portion. The inlet 166 is formed in the inclined portion 163 .
[0196] The inlet 166 is formed in the inclined portion 163 of the inner case 160 so as to surround only the Converter 153 by the molding liquid 210 . Further, for the sake of preventing the leakage of the molding liquid 210 being injected, the rubber cover 200 is provided in the opening of the receiver 161 of the inner case 160 in the form of JIG. After the molding liquid 210 is injected into the inner case 160 and is cured, the rubber cover 200 is removed.
[0197] The rubber cover 200 includes a flat portion 201 and a border wall 203 . The flat portion 201 has a flat circular shape. The border wall 203 projects from the outer circumference of the flat portion 201 and is coupled to the outer surface of the receiver 161 . A recess 202 is formed in the flat portion 201 . When the rubber cover 200 is coupled to the opening of the receiver 161 , the projecting portion of the circuitry 150 is inserted into the recess 202 .
[0198] A method for injecting the molding liquid 210 into the inside of the inner case 160 by using the rubber cover 200 and the inner case 160 having the inlet 166 formed therein will be described.
[0199] First, the rubber cover 200 is coupled to the opening of the receiver 161 of the inner case 160 . Then, the inner case 160 is installed such that the inlet 166 faces upward (see FIG. 16 ). Here, the heat generating parts received within the inner case 160 , i.e., the Converter 153 is, as shown in FIG. 16 , positioned in the lower portion of the inner case 160 .
[0200] Then, the molding liquid 210 is injected through the inlet 166 of the inner case 160 . Here, the molding liquid 210 is injected in such a manner as to sufficiently cover only the heat generating parts including the Converter 153 , which are received within the inner case 160 .
[0201] Lastly, the molding liquid 210 is cured and then the rubber cover 200 is removed.
[0202] In the foregoing molding method, after the molding liquid 200 injected through the inlet 166 is cured, the inlet 166 may be sealed by being molded with silicone or resin material.
[0203] As such, in the lighting device according to the second embodiment, the inlet 166 used to inject the molding liquid 210 into the inner case 160 is formed and the molding liquid is injected into only the heat generating parts. Through this, a manufacturing cost can be reduced. Also, the rubber cover 200 is provided in the form of JIG and removed after the molding liquid is cured. As a result, a manufacturing cost can be reduced by removing the parts.
[0204] Although embodiments of the present invention were described above, these are just examples and do not limit the present invention. Further, the present invention may be changed and modified in various ways, without departing from the essential features of the present invention, by those skilled in the art. For example, the components described in detail in the embodiments of the present invention may be modified. Further, differences due to the modification and application should be construed as being included in the scope and spirit of the present invention, which is described in the accompanying claims. | A lighting device may be provided that comprises: a cover; a member comprising a first placement portion, a second placement portion and a guide disposed between the first placement portion and the second placement portion; a light source module disposed on the first placement portion; a heat sink comprising a first receiver and a second receiver, the first receiver being defined by a flat surface and a plurality of heat radiating fins extending from an edge portion of the flat surface; and a circuitry disposed in the second receiver; wherein the second placement portion is disposed in the first receiver, wherein a first portion of the guide is couple to the cover and a second portion of the guide is couple to the heat radiating fins of the heat sink, and wherein the guide is spaced apart from the flat surface, the guide contacts the heat radiating fins, and the guide is disposed on the heat radiating fins. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/524,712 filed Nov. 24, 2003 which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to a method and system for viewing imagery and, in particular, relates to a method and system for transforming digital images created by a first sensor such that the transformed images appear as if they were created by a second sensor which has different characteristics than those of the first sensor.
[0004] 2. Discussion of Background
[0005] Over the past two or three decades, screen-film mammography (SFM) has greatly aided the detection of early breast cancers. Annual screening of women age 40 and older has lowered breast cancer deaths by as much as 30 percent. Nonetheless, as many as one in five cancers still are overlooked because the mammographic changes may be very subtle. Full-field digital mammography (FFDM) may help locate some of these cancers. In contrast to conventional film mammography, which uses radiographic film to acquire, store and display an image, FFDM conveniently offers a means of separating these functions. Further, FFDM has a number of attributes that may help a small breast tumor stand out from surrounding normal tissue: the efficient absorption of incident x-ray photons, a linear response over a broad range of radiation intensity, and comparatively little system “noise” (extraneous information).
[0006] In SFM, x-ray energy is converted to light which exposes a film. Conventional SFM uses low energy x-rays that pass through a compressed breast during a mammographic examination. The exiting x-rays are absorbed by film which is then developed and subsequently reviewed by the radiologist. This traditional process is analogous to personal photographic cameras and photographic film where light is focused on the film and developed to produce a negative which can be printed as a picture.
[0007] FFDM systems, on the other hand, directly create digital mammograms. With FFDM, low energy x-rays pass through the breast as in conventional mammograms but are recorded by means of an electronic digital detector instead of film. This electronic image can either be displayed on a video monitor similar to a television or printed onto film. Again, this is similar to digital cameras that produce a digital picture that can be displayed on a computer screen or printed on paper. The radiologist can manipulate the digital mammogram electronically to magnify an area, change contrast, or alter the brightness. Like SFM, FFDM uses x-rays to produce images of breast tissue. The difference is that with FFDM, an electronic x-ray detector replaces the film cassette and converts the x-ray photons to light, which in turn passes to a device that converts the light to a digitized signal for display on a monitor. A monitor in the examination room allows the mammographic technologist to view the mammogram in several seconds instead of developing films and waiting ten minutes to see an image. The radiologist can alter the orientation, magnification, brightness and contrast of the images as desired.
[0008] Typically, when radiologists interpret mammograms- usually four films for a patient, two views of each breast - the images from the current exam are compared to the images from the prior exam, usually created two or three years earlier. The issue becomes how to conveniently display and compare the film images with FFDM images. One obvious problem is that films must be displayed on a light box while FFDM images must be displayed on a monitor, thereby requiring two disparate types of equipment. One solution is to create digital images of the films with a digitizer, then display the resultant images on a monitor with the FFDM images. However, without additional processing, the displayed images are not well-suited for comparison. The digitized film images and FFDM will generally have markedly different intensity value distributions and physical dimensions. Alternatively, a digital image may be printed on film and subsequently viewed on a lightbox. Although this would allow comparison of images from both sensors to be compared on a lightbox, it involves the time and expense of printing additional film. Furthermore, the printed film image is not likely to have similar visual characteristics as the original SFM images.
[0009] Therefore, a need exists for a method and system for viewing images created by different types of sensors such that the visual qualities of the viewed images are similar. This is important so that when the images from the two different types of sensors are viewed for comparison purposes on one or more monitors, the images have similar visual characteristics.
SUMMARY OF THE INVENTION
[0010] When images from two different types of sensors are viewed for comparison purposes, it is beneficial to modify the images such that both images have similar visual characteristics Therefore, the present invention allows for the viewing of images created by different types of sensors to have similar visual qualities when viewed together. An image is obtained by a first sensor. The image is modified so that the resulting image has characteristics similar to those achieved as if the image had been obtained by a second type of sensor. An object of interest may be selected from the image. A current image is also obtained by the second sensor. The modified image and the current image are then displayed. Multiple images may be transformed, displayed, and compared to other images. Additionally, computer-aided detection marks can be displayed on the current image from the second sensor as well as the composite image.
[0011] Accordingly, it is an object of the present invention to transform images created by a first sensor such that the transformed images appear as if they were created by a second sensor having different characteristics than first sensor.
[0012] It is another object of the present invention to facilitate viewing and comparison of images created by the first and second sensor types.
[0013] It is yet another object of the present invention to facilitate viewing and comparison of mammographic images created by screen-film mammography with those created by full-field digital mammography.
[0014] Other objects and advantages of the present invention will be apparent in light of the following description of the invention embodied herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals, and in which:
[0016] FIG. 1 is a block diagram illustrating the transformation process according to an embodiment of the present invention;
[0017] FIG. 2 illustrates the transformation curve from a full-field digital mammography sensor to a film digitizer according to an embodiment of the present invention;
[0018] FIG. 3 illustrates the mapping from a film digitizer to a full-field digital mammography sensor according to an embodiment of the present invention;
[0019] FIG. 4 illustrates the effects of inverting the transformation from a film digitizer to a full-field digital mammography sensor with the full-field digital mammography to film digitizer mapping according to an embodiment of the present invention;
[0020] FIG. 5 illustrates the effects of inverting the transformation from a full-field digital mammography sensor to film digitizer with the film digitizer to full-field digital mammography mapping according to an embodiment of the present invention;
[0021] FIG. 6 illustrates a breast mask before and after smoothing according to an embodiment of the present invention;
[0022] FIG. 7 illustrates the margin dimming of the re-sampled image according to an embodiment of the present invention;
[0023] FIG. 8 is a comparison between a fabricated full-field digital mammography and an actual full-field digital mammography according to an embodiment of the present invention; and
[0024] FIG. 9 is an example of a display of current full-field digital mammography images and prior digitized images according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration, and not by way of limitation, specific preferred embodiments in which the invention may be practiced. 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 spirit and scope of the present invention.
[0026] An overview of the method is shown in FIG. 1 . The primary objective is to transform an input image acquired with a first sensor such that the transformed output image has the characteristics of an image acquired with a second sensor. First, the input image from Sensor 1 , 25 , is resampled in step 100 to provide the desired inter-pixel spacing (IPS) in the output image, 250 . The object mask, 50 , is a binary image derived from the input image, 25 , having ON pixels at locations determined to contain an object of interest. The object mask is smoothed and resampled in Step 125 . Then in step 150 , pixel values from areas located within the object of interest are selected from the resampled input image. In step 175 , the selected pixel values are transformed according to the lookup table (LUT), 75 . The transformed pixel values are then superimposed on a typical Sensor 2 background in step 200 , providing the output image, 250 .
[0027] In one embodiment, the present invention describes the viewing of mammographic images. Therefore, during the description, the first sensor would represent a film digitizer and the second sensor would represent an FFDM device. The film digitizer can be, for example, a Howtek Fulcrum and 861 series film digitizers, a VIDAR DiagnosticPro and SIERRA plus film digitizers, Kodak LS 40 and LS 70 film digitizers, or any other similar type film digitizer. The FFDM device can be, for example, a General Electric Senographe FFDM device, Fischer Imaging Corporation SenoScan device, Hologic, Inc. Lorad® Digital Breast Imaging device, Siemens Mammomat Novation DR device or any other similar type FFDM device. In this situation, the invention provides a method for transforming digitized film images such that they appear as if they were created by an FFDM device.
Film Digitizer to FFDM Lookup Table
[0028] A lookup table 75 converts the digitized film intensity values to FFDM intensity values. The lookup table, 76 , is obtained from the characteristic curves of the film digitizer and FFDM system. The characteristic curve of the film digitizer defines the mapping from optical density to digital image gray level values. For an FFDM system, the characteristic curve defines the mapping from exposure to digital image gray level values. Characteristic curves can be empirically derived using calibrated step wedge targets with knowledge of the sensor type.
[0029] A method for obtaining a look up table to map FFDM values to film digitizer values is described in U.S. patent application Ser. No. 10/682,687, entitled “Methods for sensor independence in computer-aided detection systems,” filed on Oct. 9, 2003. FIG. 2 ( a ) plots an FFDM device to film digitizer look up table. However, the desired mapping of the present invention is from a film digitizer to an FFDM device. Therefore, the LUT obtained for mapping FFDM device values to film digitizer values must be inverted.
[0030] FIG. 2 ( b ) shows details of the LUT for FFDM intensity values between 10,000 and 15,000. This plot shows that at certain input intensities, a plurality of FFDM intensities are mapped to individual film digitizer intensities. This result is a consequence of FFDM intensities being represented with fourteen bits while film digitizer intensities are represented by twelve bits—corresponding to four times as many available FFDM intensities as film digitizer intensities. Also, there are gaps in the FFDM-to-film digitizer LUT such that no FFDM intensity is mapped to certain film digitizer intensities, as shown in FIG. 2 ( c ). In this figure, circles indicate the points of the transformation. Note that for each single step increase in sensor 2 intensity value, the value of sensor 1 decreases by two steps. For these reasons, inversion of the FFDM to film digitizer LUT is not well-defined.
[0031] The algorithm for the FFDM-to-film digitizer LUT inversion works as follows. Each film digitizer intensity is mapped to the rounded average of the FFDM intensities that are mapped to it. If there are no FFDM intensities mapped to a film digitizer intensity, then the next lower intensity that has FFDM intensities mapped to it is used. The next lower intensity was used rather than the next higher intensity to avoid mapping film digitizer intensities 4093 and 4094 to the same FFDM intensity as 4095, which has 335 FFDM intensities mapped to it.
[0032] The minimum film digitizer intensity, 0, is treated as a special case and is mapped to the maximum FFDM intensity,16383. This is because no FFDM intensities are mapped to film digitizer 0, and there are no lower film digitizer intensities. The inverted LUT, for mapping film digitizer values to FFDM values is shown in FIG. 3 .
[0033] FIG. 4 ( a ) shows the effects of transforming film digitizer values to FFDM values with the LUT of FIG. 3 , then back to film digitizer values with the LUT of FIG. 2 ( a ). FIG. 4 ( b ) shows details of the transformation for original sensor 1 intensity values from 3612 to 3634. FIG. 5 shows the effects of transforming the FFDM values to film digitizer values with the LUT of FIG. 2 ( a ), and then back to film digitizer values with the LUT of FIG. 3 .
[0034] If the LUTs were both truly invertible, then the transformations in FIGS. 4 ( a ) and 5 would be straight lines. The inversion limitations are more evident in FIG. 5 because the FFDM-to-film digitizer LUT is less invertible than the film digitizer-to-FFDM LUT. Given the characteristics of the sensors, the resultant film digitizer-to-FFDM LUT is optimal.
Transformation Procedure
[0035] The inputs to the transformation procedure are the full-resolution digitized film image and object mask. Referring to FIG. 1 , the input image is re-sampled in step 100 . The up and down sampling factors are chosen such that the resultant IPS becomes substantially equivalent to the IPS of the FFDM sensor, in this case, 94.1 microns. Using replication up-sampling by 5 and average down-sampling by 11, the IPS of the re-sampled image becomes ({fraction (11/5)}) ths of the IPS in the input image. For a film digitizer with an IPS of 43.5 microns, the resultant IPS becomes 95.7 microns. If memory constraints are an issue, the re-sampled image may be computed without explicit up-sampling and sub-sampling.
[0036] In a mammographic application, the object mask corresponds to a breast mask, wherein ON pixels of the breast mask denote image pixels representing breast tissue. In step 125 , the breast mask is smoothed and re-sampled. In the smoothing process, the edges of the mask that have sufficient ON pixels are first padded. Then, the mask is convolved with an averaging kernel. The averaged mask is unpadded and re-thresholded, producing an intermediate mask. The intermediate mask is ANDed with the original breast mask, producing a first smoothed mask.
[0037] The original IPS for the digital representation of the breast mask is converted to the IPS of the FFDM sensor by re-sampling. The first smoothed breast mask is re-sampled from an IPS of 696 microns to an IPS of 95.7 microns using up- and down-sampling factors of 80 and 11. The re-sampled mask is then smoothed again using the method described above. FIGS. 6 ( a ) and 6 ( b ) show examples of both the original and smoothed breast masks.
[0038] Before transforming the film digitizer pixel intensities with the LUT, the margin of the breast image is dimmed. The margin of the breast image is defined as the area between the edge of the re-sampled breast mask and the edge of an eroded version of the re-sampled breast mask. The dimming is accomplished by weighting the intensity of each pixel in the margin of the breast image by the factor (1−d 2 /d eroded 2 ), where d is the minimum distance from the pixel to the eroded perimeter, and d eroded is the distance the mask was eroded. FIG. 7 ( a ) is an input image and FIG. 7 ( b ) shows the effects of dimming the margin.
[0039] Next the pixel intensities of the re-sampled and dimmed image are transformed with the film digitizer-to-FFDM LUT. The resultant image is shown in FIG. 7 ( c ). Then the breast area is cropped from the transformed image and superimposed on a properly sized FFDM-style background, yielding the raw pseudo-FFDM image. FIG. 8 compares a pseudo-FFDM image, FIG. 8 ( a ), to an actual FFDM image, FIG. 8 ( b ). For presentation purposes only, both these images are displayed after transformation with the FFDM-to-film digitizer LUT.
EXAMPLE
[0040] The method and system described transforms digitized film images to be visually compatible and consistent with FFDM digital images in terms of pixel spacing, gray levels, and overall appearance. An example of the results produced are shown in FIG. 9 . The upper portion of the figure shows a set of transformed digitized film images, representative of a prior mammographic exam with a film-based mammography system. The lower portion of the figure shows a set of FFDM images, representing a current mammographic exam with an FFDM system. The system allows a radiologist to compare prior film exams to a current digital exam without the need for a light box. Furthermore, the image characteristics of the breast tissue in the prior exam are similar to those of the current exam. Additionally, the background image characteristics are also similar for the prior and current exams.
Use with Computer-Aided Detection System
[0041] In one embodiment of the present invention, computer-aided detection (CAD) results are displayed on the images from the current digital exam only, as shown in FIG. 9 . In another embodiment, the CAD results are displayed on both the prior and current images.
[0042] It is noted that terms like “preferably,” “commonly,” and “typically” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention.
[0043] For the purposes of describing and defining the present invention it is noted that the term “substantially” is utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The term “substantially” is also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.
[0044] Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention. | A method and system of viewing images created by different types of sensors such that the visual qualities of the viewed images are similar is disclosed. An image is obtained by a first sensor. The image is modified so that the modified image has characteristics similar to those achieved as if the image had been obtained by a second type of sensor. An object of interest may be selected from the image. A current image is obtained by the second sensor. The modified image and the current image are then displayed. Multiple images may be transformed, displayed, and compared to other images. Computer-aided detection marks can be displayed on the current image from the second sensor as well as the modified image. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of smoke-wetting implements and more specifically to the field of hookahs.
BACKGROUND
[0002] Of the many proud traditions of Ottoman culture, few have achieved the world-wide fame of hookah smoking. Once confined to the Middle East and Near East regions, the hookah's notoriety was invigorated by Napoleon's invasion of Egypt and the stream of curious Westerners which followed thereafter. Painters, such as Eugene Delacroix and Jean-Leon Gerome, when depicting Oriental styles typically included a hookah as a symbol of the depicted culture. The hookah was elevated from a regional curiosity to a universal symbol of sophistication.
[0003] The hookah, which has maintained a constant popularity in the Middle East, presently enjoys in American culture a unique, niched function. Hookah smoking combines community and relaxation into a single event. Rarely does one witness a group smokers crowded about a single cigarette, cigar, or pipe. Though hookahs are often designed with a single smoke outlet; the presence of multiple hoses, each capable of simultaneous use, emanating from a single smoking instrument is unique to the hookah. Multiple hose hookahs form the centerpieces of hookah clubs in which hookah smokers gather to unwind and converse with other community members. A hookah combines fashion, art, and function into a single device.
[0004] A basic hookah includes a base, a stem, at least one hose with a mouthpiece, and a bowl. The hookah bowl holds the hookah tobacco, frequently “massell.” Massell is a mixture of tobacco, molasses, and often a flavor or fruit extract, The molasses and fruit extract add a substantial amount of moisture to the massell that is missing in conventional tobacco. This added moisture makes massell more sensitive to the elements relative to conventional tobacco;
[0005] prolonged exposure to air evaporates much of the moisture of massell and reduces its flavor. When properly protected, massell allows a smoker a more recreational, flavored smoke than the tobacco of cigars, cigarettes, pipes, and the like. An experienced hookah smoker will know to loosely distribute massell into a pile within the hookah bowl to allow heat to evenly circulate through the pile.
[0006] The heat that ignites the massell derives from coals positioned above the hookah bowl. The coals and massell preferably never contact one to the other. A common method of placing coals proximate to the massell involves spreading a foil upon the top of a hookah bowl, punching holes in the foil, and then placing the coals onto the foil. The heat from the lighted coals travels through the holes in the foil to ignite portions of the massell. Particulates from the massell travel in the smoke created by the ignition down through the hookah bowl into the hookah pipe.
[0007] The hookah stem is the body of a hookah and is usually fabricated from brass, tin, or stainless steel. The stem transports the massell smoke from the bowl to the hookah base, which is a cavern containing water. The base of the hookah is typically fabricated of glass or plastic and tends to be the most expressive portion of the hookah, ranging from translucent to wildly-colored. Within the cavern of the hookah base, the massell smoke is cooled by the water within. The cooled massell smoke then returns to the stem, though not through the same entrance by which the massell smoke enters the base. From the stem, the massell smoke travels through the hose and out of the mouthpiece.
[0008] There are presently two prominent versions of hookah structures: the Lebanese style and the Egyptian style. Although the aficionado will explain that there are many differences between the two styles, the practical layman would quickly note the obvious difference: the connection point between the stem and the hookah bowl. The Egyptian style hookah pipe tapers upward into what is generally referred to as a male connection. The Egyptian style hookah bowl includes a female connection which receives the pipe's male connection. In the Lebanese style hookah the bowl has the tapered male connection and the pipe has the female connection to accept the Lebanese style hookah bowl. In both styles, to allow a more airtight connection a collar is generally added to fit around the male connection.
[0009] As hookah use increases in prominence, the need to make hookah smoking more amenable to a larger market increases in importance. Unlike cigarettes, pipes, cigars, and many other portable smoking instruments, a hookah lacks a means for effective movement of the combustion unit while in use. A pipe user may grasp the handle of the pipe and the cigarette and cigar holder positions her fingers distant from the burning tip, but a hookah bowl generally lacks an extremity and instead relies upon the use of heat-dissipating construction materials or users knowledgeable enough to utilize heat shielding (e.g., gloves). Furthermore, pipes, cigars, and cigarettes employ a unitary construction that permits motion to be reliably translated throughout the body of the device. Hookahs may include multiple components fastened with crude attachment implement, (e.g. tape or cloths).
[0010] Therefore, there is a need for a hookah bowl that accommodates a hookah stem portion and permits simple affixation, transport, and removal of the hookah bowl during combustion.
SUMMARY
[0011] The present invention is directed to a hookah bowl system and hookah bowl. The hookah bowl includes a bowl body with a floor and a raised peripheral wall that circumscribes the floor. The body includes a base aperture with a sidewall that mates with a hookah stem connection. A dry smoke aperture in the floor permits communication into the base aperture. The centrally affixed upon the floor is a bowl spire that extends above the raised peripheral wall. A preferred height of the spire is greater than twice the height of the raised peripheral wall. The spire permits a user to grasp the bowl from above, but away from, the raised peripheral wall for simple attachment of the bowl upon a hookah stem. The spire positioning further simplifies removal as a user may use radial force, rather than longitudinal force away from the hookah stem, to remove the hookah bowl.
[0012] The system of the present invention includes the bowl with a longitudinally movable perforated coal plate a means for fixing the position of the coal plate upon the spire. Means of fixing the position of the coal plate include a removable barrier, fixed barrier, a raised peripheral wall diameter less than or equal to the diameter of the coal plate, a spire girth adapted to provide a close fit between the spire and coal plate, and other mechanisms described herein.
[0013] Therefore, it is an aspect of the present invention to provide a hookah bowl and system that provides a user with an advantageous means of attachment and removal.
[0014] Therefore, it is an aspect of the present invention to provide a hookah bowl and system that provides a rotatable coal plate.
[0015] Therefore, it is an aspect of the present invention to provide a hookah bowl and system that accommodates a transversely-stabilized coal plate.
[0016] Therefore, it is an aspect of the present invention to provide a hookah bowl and system that provides effective transportation of a hookah bowl during combustion.
[0017] Therefore, it is an aspect of the present invention to provide a hookah bowl and system that allows removal and affixation of a hookah bowl without contacting the peripheral wall.
[0018] Therefore, it is an aspect of the present invention to provide a hookah bowl and system to that allows selective positioning of a coal plate upon a hookah bowl.
[0019] Therefore, it is an aspect of the present invention to provide a hookah bowl and system that allows selective positioning of a coal plate upon a hookah bowl irrespective of bowl dimensions.
[0020] These aspects of the invention are not meant to be exclusive. Furthermore, some features may apply to certain versions of the invention, but not others. Other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of the system of the present invention,
[0022] FIG. 2 is a perspective view of the system of the present invention.
[0023] FIG. 3 is a perspective view of the system of the present invention.
[0024] FIG. 4 is a cutaway view of the bowl of the present invention.
[0025] FIG. 5 is a perspective view of the system of the present invention.
[0026] FIG. 6 is a perspective view of the bowl of the present invention.
[0027] FIG. 7 is a perspective view of the system of the present invention.
DETAILED DESCRIPTION
[0028] Referring first to FIG. 1 , a basic embodiment of a system 100 of the present invention is shown. The system 100 includes a hookah bowl 102 and a coal plate 120 . The hookah bowl 102 includes a bowl body 104 with a floor 106 and a raised peripheral wall 108 that circumscribes the floor 106 . A bay 130 is formed in the open space bounded by the wall 108 and the floor 106 . Within the floor 106 are one or more dry smoke apertures 112 . Centrally positioned within the bay 130 and upon the floor is a spire 110 that extends above the raised peripheral wall 108 . Preferred heights for the spire include heights 1 . 25 times the height of the wall 108 and greater. Although the spire 110 may include multiple dimensions and configurations, a preferred spire configuration is disclosed in FIG. 1 .
[0029] The spire 110 may assumes functions, including stability, heat dissipation, and placement. A spire increases the stability of the coal plate as a coal plate generally lacks support as it is placed upon the hookah bowl. The spire running through the body of the coal plate, irrespective of whether a close fit (i.e., minimum clearance fit) is achieved, provides a central barrier that prevents significant lateral motion of the coal plate. To assist with heat dissipation, the spire may include a solid interior to permit a greater volume of mass. The spire, or a portion thereof, may be constructed of a material different from that of the bowl. A preferred bowl and spire construction material includes ceramic or clay. A solid interior spire construction further permits greater latitudinal force to be applied to the spire in placement and removal of the bowl. As a spire apex 114 increases in height, the girth g of the spire 110 should increase accordingly. The girth g of the spire 110 may be generally uniform, or may be variable along the height thereof. A preferred embodiment of the bowl 102 includes a spire 110 with a girth g that gradually diminishes downwardly from the apex of the spire.
[0030] The perforated coal plate 120 of the system 100 of the present invention serves to support combustible materials, e.g. coals, and preferably includes dimensions that are substantially planar in height and mimic the shape of the bowl 102 otherwise. Shapes of the coal plate 110 and bowl 102 may include rectangular, circular, polygonal, and other shapes—as viewed from above. The coal plate 120 includes perforations 122 that permit heat from the combustible materials to traverse the body of the coal plate 120 into the howl. The coal plate 120 includes a central plate aperture 124 with a plate aperture diameter d 2 .
[0031] A preferred system 100 of the present invention includes a peripheral support means of positioning the coal plate 120 about the hookah bowl 102 . The peripheral wall 108 is located a distance of diameter d 1 from a central point occupied by the spire 110 . The peripheral wall diameter d 1 need not be constant, and indeed, preferably slopes gradually inward with respect to the floor 106 . The wall diameter d 1 is less than or equal to the coal plate diameter d 3 at the point of contact. As shown by FIGS. 2 and 3 , the coal plate 120 slides down the spire 110 through the central aperture 124 . As the coal plate 120 longitudinally traverses the spire 110 the central aperture 124 is sized is accommodate the entirety of the spire 110 positioned above the plane of the apex of the wall 108 . The coal plate 120 rests upon the wall 108 for support. The coal plate 120 may rest upon the wall in multiple ways, including use of indentures in the wall and plate wherein the interlocking effect is mutually supporting, but the preferred means of wall support of the coal plate includes a wall that with a substantially uniform height and a coal plate with a substantially planar periphery along portions that would contact the wall. A coal plate planar periphery mated with a substantially uniform wall height permits the coal plate to rotate on the wall about the spire. The radial motion of the coal plate allows a user to selectively burn tobacco within the tobacco bowl with reference to the placement of coal upon the coal plate. Coals, and other combustible materials, are not always uniformly dispersed about a coal plate. Non-uniform coal distribution may lead to non-uniform tobacco burn and the ability to rotate the coal allows a user to select portions of tobacco to burn, while the central placement of the spire ensures that tobacco will be placed in a non-central location within the hookah bowl.
[0032] The extents, or other portions, of the bowl wall 108 and coal plate 120 need not be dimensioned for wall support. Another means of positioning the coal plate 120 upon the spire 110 includes correlating the spire girth g and central aperture diameter d 2 to form a close fit arrangement at a position predefined for effective burning of tobacco within the tobacco bowl 102 . Effective burning of tobacco occurs when a commercial coal array when placed upon the coal plate can burn commercial tobacco positioned upon the floor of the hookah bowl. A preferred arrangement includes a position proximate to the height of the peripheral wall 108 .
[0033] The close fit occurs at the point where g approaches d 2 in magnitude. In discussing the spire, but applicable to all such mentions of diameter, girth, and the like, it is important to note that the dimensions of the present invention are not limited to circular and quasi-circular shapes and may include any shape suitable to achieve any aspect of the present invention. For example, a rectangular central aperture 124 and rectangular cross-sectioned spire 110 may be desirable. The preferred spire 110 is symmetrical by cross-section to permit radial motion by the coal plate. The close fit between the spire 110 and the coal plate 108 may occur above the peripheral wall 108 apex or below the peripheral wall 108 apex.
[0034] As FIG. 4 shows, the tobacco burned within the bay 130 passes through one or more dry smoke apertures 112 to a base aperture 118 formed by a base sidewall 116 . The base sidewall 116 may be dimensioned to connect to a hookah stem through either direct connect or some other medium, including a grommet or other compressible device.
[0035] As FIG. 5 shows, the system 100 or the present invention may include a barrier 140 detachable from the spire 110 . The detachable barrier 140 includes a barrier diameter d 5 and a barrier aperture 142 with a harrier aperture diameter d 4 . The barrier aperture 142 accepts the spire along portions of the spire amenable to effective combustion of tobacco. It is preferred that the barrier 140 include an elastic construction to ensure sealed contact with the spire 110 . To promote aspects of rotatability of the coal plate 120 about the spire 110 , a washer may be placed above the harrier 140 upon which the coal plate 120 may sit. The barrier diameter d 4 is dimensioned such that the central aperture 124 cannot pass through the barrier. The barrier 140 includes a diameter d 5 that is greater than the girth g of the spire 110 at portions contiguous, i.e. immediately below and above (when applicable), to the barrier in its position on the spire. A second barrier 140 may be included for placement about the top surface of the coal plate 120 to prevent longitudinal movement of the coal plate 120 during turbulent uses of a hookah, e.g. smoking while walking. The preferred second barrier 140 includes a weighted ring or an elastic ring.
[0036] Turning now to FIG. 6 , the bowl 102 of the present invention may include barriers 140 fixed along the spire 110 . The fixed barriers 140 are permanently attached to the spire 110 and serve to block the longitudinal motion of the coal plate (not shown) along the spire 110 . A spire 110 may include a single fixed barrier 140 or multiple fixed barriers 140 . If a fixed barrier 140 is present, it is preferred that at least one fixed barrier be positioned in an inferior position, i.e. a lower position adapted to position a coal plate above the bay 130 in a location suitable for effective burning of tobacco within the bay 130 . The fixed barrier 140 includes a contact surface 146 , which is the surface of the barrier 140 that naturally contacts the coal plate 120 . The contact surface 146 may include any configuration, but it is preferred that the barrier 140 posses a substantially planar contact surface 146 to allow a coal plate with a substantially planer lower surface to rotate about the spire. The inferior fixed barrier blocks downward movement of the coal plate proximate to the bay and permits a coal plate of dimensions less than those of the peripheral wall 108 to be used effectively with the bowl. A superior fixed barrier, when present, blocks upward movement of the coal plate at any position deemed pertinent. A natural position for the superior barrier is proximate to the spire apex 114 . Use of two fixed barriers permits a coal plate to be permanently positioned on the spire with a fixed path of travel between the two barriers rather than permitting a user to selectively remove the coal plate from the spire.
[0037] A user of the bowl of the present invention can position the bowl on a hookah stem (not shown) by grasping and moving the bowl by the spire toward a hookah stem connection. The bowl may be guided solely by the spire and downwardly positioned on to the hookah stem attachment with the spire. Downward force originating from a hand through the spire may attach the bowl without resorting to hand pressure upon the wall of the bowl. Radial force may be more effectively utilized in affixing the bowl upon the hookah connection. The spire acts as a lever and permits a user to position and remove the bowl with slower, more deliberate motions, contrasting with a forceful downward positioning of a bowl which may often dislocate the contents of the tobacco bowl. Additionally, the bowl may be removed from the stem connection by radial force from a hand acting upon the spire.
[0038] As FIG. 7 shows the coal plate 120 may include a raised periphery 150 that prevents combustible material from leaving the upper surface of the coal plate 120 . The raised periphery 150 may be integrally formed into the coal plate, or the coal plate 120 may include a surface indenture or track 152 about a perimeter that accepts a separable raised peripheral fence 150 .
[0039] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | The present invention is directed to a hookah bowl with a central spire and a hookah bowl system with the hookah bowl and a coal plate. The coal plate fits about the spire and may be retained upon the hookah bowl via multiple means. The spire assists transportation, attachment, use, and removal of the hookah bowl. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 08/992,045, filed by Anderson et al on Dec. 17, 1997, and to issue as U.S. Pat. No. 5,817,740, being itself a continuation-in-part of application Ser. No. 08/799,514, filed Feb. 12, 1997, and now abandoned.
FIELD OF THE INVENTION
This invention concerns improvements in low pill copolyester, as described hereinafter, and is more particularly concerned with a new copolyester composition that provides staple fiber that is capable of forming yarns, fabrics and garments that have a combination of excellent pilling performance, particularly in the presence of humidity/moisture, aesthetics and tactility ("hand"), especially such staple fiber of non-round cross-sections as multi-grooved scalloped-oval cross-sections that retain such cross-section so their fabrics have outstanding qualities of moisture-management, dryness and comfort as well as exhibiting minimal pills (particularly in the presence of moisture), and downstream products thereof, intermediates therefor and processes for obtaining or processing any of these.
BACKGROUND OF INVENTION
This invention is an improvement in, and, largely, a selection from the range of low pill copolyester described and claimed by Anderson et al. in U.S. Pat. No. 5,817,740 (DP-6585-A) and corresponding WO 98/36027, which are expressly incorporated herein by reference. The extensive background in polyester staple fibers and previous efforts to improve their pilling performance has been described therein, including the following prior publications, U.S. Pat. Nos. 2,071,251 (Carothers) 2,465,319 (Whinfield and Dickson), 4,110,316 (Edging and Lee), 4,113,704 (MacLean and Estes), 4,146,729 (Goodley and Shiffler), 4,945,151 (Goodley and Taylor), 3,104,450 (Christens et al), 3,335,211 (Mead et al), 3,018,272 (Griffing and Remington), 5,559,205 and 5,607,765 (Hansen et al.), 3,576,773 (Vaginay), and 5,300,626 and 5,478,909 (Jehl et al.), Ludewig in "Polyester Fibres, Chemistry and Technology", published in German in 1964 and in English in 1971 by John Wiley and Sons, Ltd., Oxford et al in WO 92/13120, and Duncan in U.S. SIR H1275. Also specific non-round cross-sections referred to herein as multi-grooved cross-sections have been disclosed in U.S. Pat. Nos. 5,591,523, 5,626,961 and 5,736,243 (Aneja) and in U.S. application Ser. No. 08/778,462 (DP-6550, Roop), now allowed, and earlier cross-sections, referred to as scalloped-oval, in 3,914,488 (Gorrafa), 4,634,625 (Franklin) and 4,707,407 (Clark et al.). These prior publications are expressly incorporated herein by reference and are discussed in much more detail in U.S. Pat. No. 5,817,740 and WO 98/36027, referred to hereinabove.
Aforesaid U.S. Pat. No. 5,817,740 describes and claims a basic-dyeable, ethylene terephthalate copolyester polymer that contains 0.5 to 3 mol % of a sodium sulfonate salt of a glycollate of isophthalic acid, and that has been polymerized in the presence of a trifunctional or tetrafunctional silicate ortho ester in amount 0.05 to 0.5% by weight, and that contains titanium dioxide in amount 0.1 to 2% by weight, said copolyester being of relative viscosity about 8 to 12 LRV and about 1 to 3 delta RV, as defined, especially in the form of staple fiber that provides fabrics of acceptable hand and of improved pill rating as compared with fabrics of commercially-available fibers of scalloped-oval cross-section known as Type 702W, as described therein (as Comparison B therein), and compared also hereinafter. The relative viscosities (LRV, delta RV and NRV) and how they are measured are described in the aforesaid U.S. patent, and an understanding of them is important for understanding the present invention, as will be apparent hereinafter. The silicate ester acts as a chain-branching agent during polymerization but may be hydrolyzed downstream, i.e., later.
As in the aforesaid patent, terms such as "filament" and "fiber" are often used generically.
The objective of the present invention is to provide copolyester polymer and fiber of still further improved pill rating and/or other advantages as compared with what was specifically disclosed in aforesaid U.S. Pat. No. 5,817,740 and WO 98/36027.
We had noted that pilling in 100% polyester garments had been much worse in specific areas of garments, such as the neck, collar, armpits, and upper thigh (groin), and also after undergoing laundering. But we had not understood the effect of moisture on measurements of pilling, for instance when making RTPT pill ratings following ASTM D-3512-82. This will be discussed hereinafter. Another matter that we had not sufficiently understood was the hydrolysis of the polymer in fiber form, especially during downstream processing, or its effect upon NRV.
SUMMARY OF THE INVENTION
According to one aspect of the invention, there is provided a basic-dyeable ethylene terephthalate copolyester polymer that contains 0.5 to 3 mol % of a sodium sulfonate salt of a glycollate of isophthalic acid, and that has been polymerized in the presence of a trifunctional or tetrafunctional silicate ortho ester in amount (TES %) at least 0.05% by weight, said copolyester being of LRV relative viscosity about 8 to about 12 and about 1 to 3 delta RV, as defined, wherein said amount (TES %) corresponds to the Non-Acid Relative Viscosity (NRV) of the polymer as defined by the polygon ABCDEFGA in FIG. 1 of the accompanying Drawings.
Preferably said amount (TES %) corresponds to the (NRV) as defined by the triangle JKLJ in FIG. 1 of the accompanying Drawings.
An important aspect of the invention is the provision of such polymer in the form of fibers. We have found that such new selected copolyester polymer compositions can be spun and drawn and converted into staple fiber that can provide knit fabrics of 100% polyester that have an excellent pill rating, even when tested in presence of moisture. We have also found that such fabrics can be made to have a hand that is acceptable for previously unattainable end-uses, hand being rather subjective.
According to another aspect of the invention, therefore, there is provided basic-dyeable ethylene terephthalate copolyester staple fiber of denier per filament about 0.5 to about 5 (about 0.6 to about 6 dtex) and cut length about 20 mm to about 10 cm, such as is capable of providing knitted fabrics of 100% polyester fiber of RTPT pill rating as defined herein of at least 2.5, preferably at least 3, after a period of 30 minutes and sometimes more. Such pill ratings as defined herein have not previously been obtained by a practicable process for knitted fabrics of 100% polyester fiber. As indicated, we have made such fabrics with a good hand.
We have found, according to the invention, that some of such new selected copolyester polymers can be formed into staple fiber of non-round cross-section, especially multi-grooved and scalloped-oval cross-sections that have excellent cross-sectional shape retention, for instance an excellent multi-grooved configuration that can provide excellent comfort properties, such as moisture-management and dryness in fabrics, as well as excellent pilling performance and tactile aesthetics.
According to another aspect of the invention, therefore, there is provided basic-dyeable ethylene terephthalate copolyester staple fiber of multi-grooved peripheral cross-section of aspect ratio about 1.3:1 to about 3:1 and groove ratio as defined about 0.50:1 to about 0.95:1. Groove ratio is described by Aneja in U.S. Pat. No. 5,626,961 (DP-6365-A) and by Roop in application Ser. No. 08/778,462 (DP-6550) filed Jan. 3, 1997, and now allowed, and is hereby defined as the ratio of the separation distance (such as d 1 ) between grooves on either side of the major axis of the cross-section to the width (such as b 1 ) of a bulge measured across the major axis as described therein.
As indicated, the silicate ester chain-brancher in the polymer can be hydrolyzed. This tends to happen over time when the polymer in the form of fiber is exposed to moisture, for instance in the atmosphere, and especially during aqueous treatments at elevated temperatures, such as dyeing of fabrics and garments. As the chain-brancher links are hydrolyzed, the NRV tends to decrease significantly more than the LRV. Consequently, the NRV of polymer and fiber that have been spun having viscosities according to the invention as described already and that can be processed to have highly desirable performance properties as have already been described may well decrease below the ranges already described (with reference to polygon ABCDEFGA and triangle JKLJ) although, when spun, that polymer provided the basis for making fibers, fabrics and garments of such highly desirable performance properties because that polymer, as-spun, was within the ranges described (with reference to polygon ABCDEFGA, and preferably triangle JKLJ). So another aspect of the invention is fiber having a (TES wt %) amount that may not always correspond to the NRV, as described for the amounts (TES %) in relation to such polygon or triangle.
According to another aspect of the invention, therefore, there is provided a basic-dyeable ethylene terephthalate copolyester polymer that is in the form of fiber and that contains 0.5 to 3 mol % of a sodium sulfonate salt of a glycollate of isophthalic acid, and that has been polymerized in the presence of a trifunctional or tetrafunctional silicate ortho ester in amount (TES %) at least 0.05% by weight, said fiber being of LRV relative viscosity about 8 to about 12, as defined, and having a (TES wt %) amount that corresponds to the Non-Acid Relative Viscosity (NRV) of the fiber as defined by the pentagon MNOPQM in FIG. 2 of the accompanying Drawings.
Preferably said (TES %) amount corresponds to the NRV as defined by the quadrilateral RSTUR in FIG. 2 of the accompanying Drawings.
We use herein the expression "(TES wt %) amount" to indicate such amounts in fiber that are relevant to the pentagon and quadrilateral in FIG. 2 in contrast to the expression "amount (TES %)" (which is also by weight) that is relevant to the polygon and triangle in FIG. 1.
Preferably, also provided are staple fiber of denier, cut length, and providing RTPT pill ratings as hereinabove and also preferably of cross-section as hereinabove.
Also provided, according to the invention, are downstream products of such fibers, including yarns, fabrics and garments and intermediate products, such as continuous filaments, tows and slivers, (including blends with other fibers, especially with cotton or wool, being natural fibers), and processes for obtaining and for processing any of them. Preferred such processes are as follows, it being understood that the term "monomer" is used for convenience, as oligomer may be formed in a vessel before entering a polymerization vessel.
Accordingly, there is provided a continuous process for preparing such new basic-dyeable ethylene terephthalate copolyester polymer comprising (1) forming a monomer by a transesterification reaction between ethylene glycol and dimethyl terephthalate in a mole ratio of about 1.5-2.5:1 while introducing into the reaction a trifunctional or tetrafunctional silicate ortho ester and the sodium salt of dimethyl5-sulfoisophthalate mixed in with at least some of said ethylene glycol, preferably at a temperature of about 100-150° C., (2) passing the resulting monomer, preferably at a temperature of about 200-240° C., via transfer piping while introducing therein a slurry of finely divided titanium dioxide in some of said ethylene glycol to a polymerization vessel, and (3) effecting polymerization of said monomer in a series of polymerization vessels while reducing the pressure to remove byproduct ethylene glycol and increasing the temperature, and preferably sequentially reducing the pressure to about 1 to 7 mm Hg.
There is also provided a continuous process for preparing such new basic-dyeable ethylene terephthalate copolyester polymer comprising (1) forming a monomer by a transesterification reaction between ethylene glycol and dimethyl terephthalate in a mole ratio of about 1.5-2.5:1 while continuously introducing into the reaction the sodium salt of dimethyl 5-sulfoisophthalate mixed in with said ethylene glycol, preferably at a temperature of about 100-150° C., (2) passing the resulting monomer, preferably at a temperature of about 200-240° C., via transfer piping while introducing therein a slurry of finely divided titanium dioxide in additional ethylene glycol and the ethylene glycollate form of the silicate ortho ester mixed in with additional ethylene glycol to a polymerization vessel, and (3) effecting polymerization of said monomer in a series of polymerization vessels while reducing the pressure to remove byproduct ethylene glycol and increasing the temperature, and preferably sequentially reducing the pressure to about 1 to 7 mm Hg.
There is further provided a continuous process for preparing such new basic-dyeable ethylene terephthalate copolyester polymer comprising (1) forming a monomer by an esterification reaction between ethylene glycol and terephthalic acid in a mole ratio of about 1.5-2.5:1, (2) passing the resulting monomer, preferably at a temperature of about 200-240° C., while introducing therein ethylene glycollates of the sodium salt of 5-sulfoisophthalic acid and of a trifunctional or tetrafunctional silicate ortho ester in additional ethylene glycol and a slurry of finely divided titanium dioxide in additional ethylene glycol to a polymerization vessel, and (3) effecting polymerization of said monomer in a series of polymerization vessels while reducing the pressure to remove byproduct ethylene glycol and increasing the temperature, and preferably sequentially reducing the pressure to about 1 to 7 mm Hg.
Preferably such new copolyester polymer is melt-spun into filaments at a withdrawal speed of about 1200 to 1800 ypm (1100-1650 m/min), and drawn preferably about 2×-3.5×, preferably at a temperature of about 80-100° C., crimped and then relaxed, preferably at a temperature of about 100-175° C., and, if desired being annealed at a temperature of about 150-230° C. before being crimped and relaxed. The resulting filaments (including staple fiber) are preferably of 0.5 to 5 dpf (about 0.5 to 6 dtex).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot of NRV vs. amount (TES %) as described herein in more detail.
FIG. 2 is a plot of NRV vs. (TES wt %) amount as described herein in more detail.
FIG. 3 gives plots of RTPT pill ratings measured after time intervals as described hereinafter in more detail.
DETAILED DESCRIPTION OF THE EMBODIMENTS
As indicated in the Background, the art contains much description relevant to the manufacture of polyester polymer compositions, their melt-spinning (extrusion) into filaments, processing of the filaments, including conversion to staple fiber, processing of staple fiber into spun yarn, processing of spun yarn into fabrics, and the treatment of fabrics, such as dyeing and finishing, and the testing of such fabrics and garments for their performance and of precursor filaments and staple, so it would be redundant to repeat such disclosure that is already available in the art; the disclosures in the art referred to herein, and in art cited therein are incorporated herein specifically by reference.
Useful staple fiber for conversion into spun yarn and for use in fabrics thereof is generally of dpf about 0.5 to 5 (0.5 to 6 dtex) and of cut length about 20 mm to about 10 cm. The new copolyester may, however, be used for other applications, which may require different shaped articles and/or other parameters.
A copolyester having ethylene terephthalate repeat units and containing also a sodium sulfonate salt of a glycollate of isophthalic acid has been used to improve dyeability for many years, as indicated in references such as we have mentioned hereinabove. Suitable amounts of such metal salt comonomer are generally 0.5 to 3 mol %, as disclosed in the art. The improved dyeability of the new polyesters according to the present invention is an important advantage, and overcomes one of the "complaints" about homopolyester PET fiber, but is not by itself a novel feature. Much of the disclosure hereinafter is directed to an ethylene terephthalate copolyester composition that has been found especially useful and advantageous, namely the sodium salt of dimethyl 5-sulfoisophthalate modified with tetraethyl orthosilicate, as these comonomers have been available and have given such excellent and surprising results according to the invention. However, variations may be used, as disclosed in the art.
Likewise, the use of oxysilicon compounds, such as tetraethyl orthosilicate, to improve pilling performance of polyester fibers was suggested generally and specifically in the prior art, such as mentioned hereinbefore, so is not by itself a novel feature.
No combination, however, of all claimed features of the present invention has been specifically taught, and, importantly, pilling has remained a serious problem for the polyester fiber industry despite the many suggestions published in the art.
As indicated already, the viscosities (LRV, NRV and delta RV) are fully defined in the aforesaid U.S. Pat. No. 5,817,740 and WO 98/36027, and as will be understood, depending on the processing of the fibers and fabrics containing the polymers, hydrolysis is likely to take place so the NRV will decrease as a result and the delta RV may disappear, but traces of the silicate will remain and we have found that pilling performance of fabrics made from fibers spun from filaments having viscosities as claimed has been excellent and these attributes will reveal use of the present invention upstream.
The invention for the polymer that is made and spun into fibers may be represented by a basic-dyeable ethylene terephthalate copolyester polymer that (1) contains a sodium sulfonate salt of a glycollate of isophthalic acid, (2) generally contains a delusterant, preferably titanium dioxide, as described in aforesaid U.S. Pat. No. 5,817,740 and WO 98/36027, and (3) that has been polymerized to an NRV range in the presence of a trifunctional or tetrafunctional silicate orthoester, in amount by weight, i.e., "Amount (TES %)" as defined essentially within the polygon ABCDEFGA in FIG. 1 of the accompanying Drawings, and preferably as defined essentially within the triangle JKLJ therein.
The points plotted on FIG. 1 of the accompanying Drawings have the following coordinates for NRV and for amount (TES %):
______________________________________POINT NRV Amount (TES %)______________________________________A 10.5 0.05 B 10.5 0.258 C 15.0 0.325 D 15.0 0.240 E 14.0 0.240 F 12.5 0.176 G 11.2 0.05 J 10.8 0.247 K 14.1 0.295 L 10.8 0.116______________________________________
The equations for the lines that join adjacent points and define the polygon and the triangle are as follows:
______________________________________LINE EQUATION______________________________________AB NRV = 10.5 BC (TES %) = 0.100 + 0.015 NRV CD NRV = 15.0 DE (TES %) = 0.240 EF (TES %) = -0.362 + 0.043 NRV FG (TES %) = -1.025 + 0.096 NRV GA (TES %) = 0.05 LJ NRV = 10.8 JK (TES %) = 0.085 + 0.015 NRV KL (TES %) = -0.467 + 0.054 NRV______________________________________
The lines DE, EF and PG are mathematical approximations to represent a curve, and the line KL could also have been represented instead by a curve but, for simplicity is shown linearly between K and L, it being understandable that no precise boundaries are being defined, but that problems tend to increase as shown in FIG. 1 as the amount (TES %) in relationship to the NRV is further removed from within the preferred zone that is shown. Thus, as the NRV (of the polymer spun) drops, fiber formation problems tend to increase. As the amount (TES %) is increased, mill processability problems tend to increase. As the amount (TES %) is decreased and as the viscosity is increased, pilling problems tend to increase. But it is possible, as shown in Example 1 and FIG. 1, to use an amount (TES %) and a polymer NRV so as to spin filaments and process them in the mill to produce 100% polyester knitted fabrics whose pill performance is excellent and unprecedented as shown in FIG. 3.
The invention for the polymer that has been spun into fibers and that may have been hydrolyzed to a significant extent so as to lower the NRV may be represented by a basic-dyeable ethylene terephthalate copolyester polymer that (1) contains a sodium sulfonate salt of a glycollate of isophthalic acid, (2) generally contains a delusterant, preferably titanium dioxide, as described in aforesaid U.S. Pat. No. 5,817,740 and WO 98/36027, and that has been polymerized in the presence of a trifunctional or tetrafunctional silicate orthoester, and wherein the NRV and (TES wt %) amount are as defined essentially within the pentagon MNOPQM in FIG. 2 of the accompanying Drawings, and preferably as defined essentially within the quadrilateral RSTUR therein.
The points plotted on FIG. 2 of the accompanying Drawings have the following coordinates for NRV and for (TES wt %) amount, and the lines that join adjacent points have equations given as follows:
______________________________________POINT NRV (TES WT %) AMOUNT______________________________________ M 8.9 0.31 N 11.3 0.31 O 11.3 0.24 P 10.8 0.05 Q 8.9 0.05 R 9.2 0.10 S 9.2 0.29 T 10.2 0.29 U 9.7 0.10______________________________________LINE EQUATION______________________________________QM NRV = 8.9 MN (TES wt %) = 0.31 NO NRV = 11.3 OP (TES wt %) = 0.40 NRV -4.28 PQ (TES wt %) = 0.05 RS NRV = 9.2 ST (TES wt %) = 0.29 TU (TES wt %) = 0.38 NRV -3.57 UR (TES wt %) = 0.10______________________________________
FIG. 3 provides plots of RTPT pill ratings measured as described hereinafter (both without and with added moisture) over a period of time for fabrics made from fiber and polymer described in Example 1 of the invention herein and, for comparison, from Type 702W fiber which has a somewhat similar cross-section. The improvement obtainable by the invention in this regard is very striking. The RTPT Pill Ratings measured as described hereinafter are shown in FIG. 3 as follows:
1. Solid shapes indicate measurements without added moisture, whereas open shapes indicate measurements in the presence of added moisture as described;
2. Triangles were ratings made on knitted fabrics as described hereinafter in Example I according to the invention;
3. Squares were ratings made on knitted fabrics as described hereinafter for Type 702W commercially-available fiber;
Despite the abundance of prior literature, no one previously has disclosed how to provide knit fabrics of 100% polyester staple fiber from an ethylene terephthalate polymer that could give a pill rating after 30 or 60 minutes as high as 4 or 5, using both RTPT pilling test procedures as described hereinafter, unlike what we have shown in FIG. 3.
The invention is further illustrated in the following Examples; all parts, percentages and proportions are by weight unless indicated otherwise, polymer weight recipes generally being calculated with regard to the weight of the polymer in the filaments. The yarn properties are measured in conventional units, denier being a metric unit, and so the tensile properties are given as measured in gpd, but conversions into SI units are also given in parentheses (g/dtex), and the Crimps per Inch, CPI, have similarly been converted, and are likewise shown in parentheses (CPcm).
The test procedures were as described in aforesaid U.S. Pat. No. 5,817,740, with some refinement however of the pilling test procedure, more rigorous testing conditions having proved desirable because of commercial needs as the presence of moisture has been found to affect the results. The testing (following ASTM D-3512-82) described in the aforesaid U.S. Patent used dehumidified air at a pressure of 3 psi (about 21 kPa). The ratings described herein were all carried out with air at 2.5 psi (about 17.5 kPa), which we have found to be more rigorous. In addition to ratings that were measured using dehumidified air as for the measurements in the aforesaid U.S. Patent, however, other measurements were made in the presence of moisture added by squirting water twice (applying a total of about 1.04 grams of water) into the tester every 30 minutes. As will be understood, therefore, the RTPT ratings are only truly comparable when all the fabrics are tested under the same conditions, so the RTPT ratings herein should not be compared with those in the U.S Patent, and the RTPT ratings herein are given both for testing without added water and in the presence of added moisture, as described above. The procedure for preliminary treatment of the knit fabrics was also changed from that described in aforesaid U.S. Pat. No. 5,817,740 and was as follows. The knit fabric is scoured by first being put into a 69 gallon (260 liter) Klauder, Weldon, Giles Model 25 PPW Beck Dye Machine with paddle agitator filled with tap water. It is then heated over a period of 5-10 minutes to 120° F. (49° C.) while being stirred. When that temperature is reached, the following reagents are added: Klenzol 201 at 2% OWF, Soda Ash at 2% OWF, Lana-Foam at 2% OWF, OWF being by weight calculated on the weight of fiber. The temperature is then raised to 220° F. (104° C.) at 15 psi (1 kg/cm 2 ) and held for 20 min. The solution is drained and the fabric is rinsed, dried in a home laundry type dryer (Kenmore) for 10 min at about 150° F. (65° C.) and pressed with a dry iron (heated to permanent press setting) to simulate calendering. The resulting "finished" fabrics are evaluated for aesthetics, "hand", and cover, as well as for pilling by the procedure that has just been described. The following pilling test procedure should, therefore, be used to measure a pill rating as defined herein. Staple fiber of cut length 1.5 inches (38 mm) is converted into yarn of 30/1 cc, which is knit on a 48-feed single jersey, 22-cut machine. The knit fabric is "finished" by the procedure that has just been described. The resulting "finished" fabric is evaluated for pilling following the procedure set out in the Random Tumble Pilling Tester Method ASTM D3512-82 and as described above, using dehumidified air at a pressure of 2.5 psi (about 17.5 kPa), in the presence of moisture added by squirting water twice (applying a total of about 1.04 grams of water) into the tester every 30 minutes. Such ratings are made on a scale of 1 to 5 by comparison with standard samples, 5 being the best, i.e., showing no pilling, whereas 1 is the worst, and the RTPT Pill Rating is an average of 10 tests, i.e., on 10 samples from the same fabric.
The amounts (TES %) given in the following Examples and herein were generally measured on filaments as spun (i.e., soon after spinning and before drawing). Viscosity measurements herein were also generally measured on as-spun filaments. As indicated, however in more detail hereinabove, and especially in Example II, the LRV remains relatively constant while the NRV tends to decrease and measurements have sometimes been made (where specifically indicated, as in Example II) on the fibers in fabrics that have been made and processed ("finished") essentially as has just been described.
EXAMPLE I
An ethylene terephthalate copolyester polymer was made with approx. 2 mol % of sodium dimethyl 5-sulfoisophthalate and 0.27 weight % of tetraethyl orthosilicate, amount (TES %), and containing 0.3 weight % of titanium dioxide and to have relative viscosities (after spinning) of 9.1 LRV and of 12.4 NRV, so 3.3 ΔRV, as follows. Ethylene glycol (EG), containing transesterification and condensation catalysts and, in approximate amounts by weight with respect to the weight of DMT added at this stage, 3.4 wt. % sodium dimethyl 5-sulfoisophthalate, 0.40 wt. % of tetraethyl orthosilicate, and 80 ppm of tetraisopropyl titanate, was preheated to 149° C. and metered into a transesterification reactor at a location above where dimethyl terephthalate (DMT) was also metered into the reactor at a temperature of approximately 175° C. The molar ratio of EG:DMT metered into the reactor was about 2.25:1. Temperature was controlled by a Dowtherm-heated calandria at about 236° C. at the base of the reactor. Low boiling materials (mainly methanol and water) were taken overhead in vapor form and condensed, and part was recycled (refluxed) to the top of the reactor. Monomer product was removed at the base of the calandria and was pumped via a monomer transferline to the first of three polymerization vessels. A slurry containing titanium dioxide and a recipe of whitening agents in additional EG was injected into the monomer transferline prior to entering the first vessel of these polymerization vessels. Phosphoric acid in additional EG was metered into this first polymerization vessel to deactivate the transesterification catalyst. The pressure in the first polymerization vessel was controlled at 100 mm Hg, and the temperature of the resulting prepolymer was controlled at 232° C. Prepolymer was transferred to the second polymerization vessel. Pressure in this second polymerization vessel was controlled at 35 mm Hg. Prepolymer of higher viscosity was removed from this vessel at a temperature of 261° C., and was transferred to the third polymerization vessel. Pressure in this third vessel was controlled to give the goal LRV and NRV (9.1 and 12.4, after spinning, respectively) and was usually in the range of 1.5 to 4 mm Hg. The temperature of polymer leaving this third vessel was controlled at approximately 269° C.
Filaments of approximately 3 dpf (3.3 dtex) were melt-spun at 272° C. from this copolyester by being extruded through a spinneret containing 1,506 capillaries at a rate of 92.4 lbs (41.9 Kg) per hour per position on 13 positions of a conventional spinning machine. The capillary orifice shape was three diamonds joined together as described by Aneja in U.S. Pat. No. 5,736,243 (DP-6400) so as to make filaments of 4-grooved scalloped-oval cross-section similar to that described therein. The filaments were spun at a withdrawal speed of 1500 ypm (about 1370 m/min), quenched as described by Anderson et al in U.S. Pat. No. 5,219,582, and collected in a can as a tow bundle of approximately 63,252 denier (about 70,280 dtex). The as-spun properties are given in Table I.
28 cans of this tow were combined to give a tow of 548,184 filaments and 1.65 million denier (1.83 million dtex), which was drawn at a draw ratio of 2.5× in hot spray water at a temperature of 85° C., then passed through a stuffer box crimper, and was then relaxed at a temperature of 123° C. to give a final tow of denier 778,421 (864,912 dtex), i.e., of filaments of about 1.42 dpf (1.6 dtex). The resulting (drawn) properties are also given in Table I.
The tows were cut to staple of length 1.5 inches (38 mm) after applying a conventional finish to give a level of about 0.22% finish on fiber, and the staple was converted to yarn (22/1 cc) and knit as described on a 48-feed single jersey, 22-cut machine to knit fabric that was "finished" so its pilling and other fabric characteristics could be evaluated as described. Fabrics had excellent pill performance (triangles in FIG. 3) both when tested without added moisture and when tested in the presence of added moisture which was not only surprising but an astonishingly high rating for a 100% polyester knit fabric, especially as the fabric also showed excellent aesthetics, hand (tactility), body and cover. Measurements on fiber from the "finished" fabric gave an NRVof 9.6 and a (TES wt %) amount of 0.28%.
TABLE I______________________________________ TENA- MODU- CITY LUS AS- FILA- gpd E.sub.B gpd DHS CPI GROOVE PECT MENTS (g/dtex) % (g/dtex) % (CPcm) RATIO RATIO______________________________________As-spun 0.84 289 19 (17) (0.76) Drawn 2.47 19 38 (35) 0.3 12 (5) 0.91:1 1.6:1 (2.25)______________________________________
EXAMPLE II
Copolyester was prepared and spun into filaments, collected, combined and drawn, essentially as described in Example I except that the amount (TES %) was about 0.22 weight % and the viscosities were 9.3 LRV and 12.2 NRV, so 2.9 ΔRV, as spun, and the final tows were of denier 789,384 (877,093 dtex), i.e., the filaments were of about 1.44 dpf (1.6 dtex). The properties are given in Table II.
TABLE II______________________________________ TENA- MODU- CITY LUS AS- FILA- gpd E.sub.B gpd DHS CPI GROOVE PECT MENTS (g/dtex) % (g/dtex) % (CPcm) RATIO RATIO______________________________________As-spun 1.0 234 19 (17) (0.90) Drawn 2.1 17 40 (36) 1.5 16 (6) 0.78:1 1.6:1 (1.9)______________________________________
The tows were cut to staple of length 1.5 inches (38 mm) after applying a conventional finish to give a level of about 0.26% finish on fiber, and the staple was converted to yarn (30/1 cc) and knit as described on a 48-feed single jersey, 22-cut machine to knit fabric that was "finished" so its pilling and other fabric characteristics could be evaluated as described. Fabrics had excellent pill resistance both when tested without added moisture and when tested in the presence of added moisture. To indicate how the NRV decreases more than the LRV, the filament viscosities after drawing were NRV=11.2, LRV=9.2, whereas viscosities in the "finished" fabric were NRV=9.6, LRV=8.6, and the (TES wt %) amount was 0.24%.
EXAMPLE III
Copolyester was prepared essentially as described in Example I except that the amount (TES %) was 0.19% by weight, and the viscosities were 9.9 LRV and 12.8 NRV, and so 2.9 ΔRV, and filaments of similar dpf and cross-section were spun, drawn and relaxed essentially as described in Example 1, and the properties of the spun and drawn filaments are in Table III. The tows of drawn filaments were processed essentially as described in Example 1, and the fabrics were also evaluated and had excellent aesthetics, as did those of Example 1, and their pilling performance was also far superior to that of prior Type 702W polyester fabrics, but slightly worse than that of Example 1. Measurements on fiber from "finished" fabric gave an NRV of 11.0 and a (TES wt %) amount of 0.26%.
TABLE III______________________________________ TENA- MODU- CITY LUS AS- FILA- gpd E.sub.B gpd DHS CPI GROOVE PECT MENTS (g/dtex) % (g/dtex) % (CPcm) RATIO RATIO______________________________________As-spun .96 211 18 (16) (.87) Drawn 2.1 17 41 (37) 0.9 13 (5) 0.85:1 1.6:1 (1.9)______________________________________
EXAMPLE IV
Copolyester was prepared essentially as described in Example 1 except that the amount (TES %) was 0.244% by weight, and the viscosities were 10.3 LRV and 14.0 NRV, and so 3.7 ΔRV, and filaments of similar dpf and cross-section were spun, drawn and relaxed essentially as described in Example 1, and the properties of the spun and drawn filaments are in Table IV. The tows of drawn filaments were processed essentially as described in Example 1, and the fabrics were also evaluated and had excellent aesthetics as did those of Example 1, and their pilling performance was also far superior to prior polyester fabrics, but inferior to that of Example I. Measurements on fiber from "finished" fabric gave an NRV of 11.0 and a (TES wt %) amount of 0.29%.
TABLE IV______________________________________ TENA- MODU- CITY LUS AS- FILA- gpd E.sub.B gpd DHS CPI GROOVE PECT MENTS (g/dtex) % (g/dtex) % (CPcm) RATIO RATIO______________________________________As-spun 1.0 200 21 (19) (0.9) Drawn 2.5 17 38 (35) 1.1 13 (5) 0.80:1 1.6:1 (2.2)______________________________________
Comparative Data
Comparative data are summarized in Table V hereinafter. In Table V, the performance experiences of Examples I and II (using polymer of NRV and amount (TES %) inside the preferred triangle JKLJ of FIG. 1 and providing fiber of (TES wt %) amount inside the preferred quadrilateral RSTUR of FIG. 2) are summarized together, and the performance experiences of Examples III and IV are summarized together (using polymer of NRV and amount (TES %) in the less preferred area of the invention shown outside triangle JKLJ but within polygon ABCDEFGA of FIG. 1 and providing fiber of (TES wt %) amount outside preferred quadrilateral RSTUR but within pentagon MNOPQM of FIG. 2), such performance experiences including filament spinning and mill/yarn process as well as RTPT Pill Ratings after 30 minutes of the resulting 100% polyester knit fabrics when tested without moisture and with added moisture as described previously. As can be seen from Table V, these performance experiences were surprisingly good for the Examples of the invention in all these performance respects in contrast to experience with prior art Type 702W and also when using polymer of different compositions of NRV and amount (TES %) outside polygon ABCDEFGA in FIG. 1. These different polymer compositions are referred to in Table V as Comparisons X, Y and Z, and also in Table VI, which gives properties of the filaments used in these Comparisons X, Y and Z, and for Type 702 W. Each of these Comparisons X, Y and Z were spun into filaments and then processed into fabrics essentially as described in Example I.
Comparison X
The filaments for Comparison X were spun from copolyester made essentially as described for Example I, but with a higher amount (TES %) of 0.322%, which is above Line BC of FIG. 1 herein, as the NRV was 12.3. These values for Comparison X are plotted on FIG. 1 as "C x ", which is outside polygon ABCDEFGA in FIG. 1, and estimated values are plotted on FIG. 2, and are estimated to be outside pentagon MNOPQM. The fibers obtained from Comparison X showed considerable amounts of "fly" waste (fiber and finish particles) during mill processing steps of carding, roving and spinning. Such "fly" waste is undesirable due to reduced productivity and especially inferior yarn quality (poor uniformity). The fabric had quite good pilling performance, however.
Comparison Y
The filaments for Comparison Y were spun from copolyester made essentially as described for Example 1 but of lower viscosity and amount (TES %), i.e., having 10.4 NRV (i.e., outside Figure ABCDEFGA, being below 10.5 NRV), and amount (TES %) of 0.086% (from approx. 0.16 wt. % of tetraethyl orthosilicate, with respect to the weight of the DMT, and the molar ratio of EG:DMT metered into the reactor was about 2.05:1). The values for Comparison Y are plotted on FIGS. 1 and 2 as "C y ", the NRV having decreased to 10.0 NRV, and the (TES wt %) amount being 0.09, measured on fiber in the "finished" fabric.
The fibers for Comparison Y are less desirable (although the fabric also had quite good pilling performance) because they could not be made efficiently owing to high levels of spinning breaks during melt spinning. In addition the fibers had very poor shape definition, as can be seen from the Groove Ratio in Table VI. As indicated, however, when filaments are made and processed into fabrics, the pilling performance is greatly improved over Type 702W.
Comparison Z
The filaments for Comparison Z were spun from copolyester made essentially as described for Example 1 but of relatively high viscosity, having 13.2 NRV, and relatively low amount (TES %) of 0.157 weight % (using, with respect to the weight of the DMT, approx. 0.22 wt. % of tetraethyl orthosilicate, and approximately 62 ppm of tetraisopropyl titanate (TPT), and a molar ratio of EG:DMT metered into the reactor of about 2.00:1). These values for Comparison Z are plotted on FIG. 1 as "C z ", and are below line EF. Estimated values are plotted for C z on FIG. 2 and are estimated to be outside pentagon MNOPQM.
The fibers for Comparison Z were spun efficiently and processed efficiently in the mill, but the resulting fabric showed inferior pill performance after 30 minutes, as can be seen from Table V.
Type 702W
In addition, fabrics were made and tested from commercially-available fibers, sold by DuPont as Type 702W. The copolyester was made with 2 mole % of sodium dimethyl 5-sulfoisophthalate and had an LRV of 13.8. No tetraethyl silicate was used. The filaments were spun essentially as described in Example 1, except as follows. The extrusion was through 1,054 capillaries at a rate of 64.7 lbs (29.4 Kg) per hour per position on 16 positions of a commercial spinning machine. The resulting tow was of 16,864 filaments and of 50,592 denier (56,200 dtex). 33 cans of such tow were combined to a total of 556,512 filaments, 1.7 million denier (1.9 million dtex). After drawing, the drawn filaments were relaxed at 123° C. to give a final denier of about 800,000 (900,000 dtex) and average dpf 1.4 (about 1.6 dtex, as for Example 1). The cut fibers were formed into yarns of 22/1 cc, and processed then essentially as described for Example I. The pill rating was only 1, the decreases in RTPT ratings when tested over a period of up to 2 hours being shown in FIG. 3, but the performance experience in spinning and in mill and yarn processing has been good and the fabric has good hand and cover, demonstrating the need for a fiber with comparable aesthetics and performance in spinning and mill yarn processing, but improved pilling performance.
The numerics in Table VI need little or no explanation beyond what is described in the art already referred to. A groove ratio of 1.0:1 would indicate the absence of any real groove in the sense that d 1 would be less than b 1 , as described by Aneja in U.S. Pat. No. 5,626,961, for example, but only a discontinuity in the periphery of the filament. Where "NONE" is recorded for Comparison Y, there was not even any such discontinuity, i.e., the drawn filaments were of smooth oval peripheral cross-section.
TABLE V______________________________________ Processing RTPT Pill Rating (30 min) Fiber Mill/Yarn Without Added Spinning Processing Moisture Moisture______________________________________Examples I and II Good Good >3.5 >3.5 Examples III and IV Good Good >3.0 >2.5 Comparison X Good Poor >3.5 >3 Comparison Y Poor Good >3.5 >2.5 Comparison Z Good Good 1-3 1-2 (Type 702W) Good Good 1 1______________________________________
TABLE VI______________________________________Properties of Filaments Used TENA- MODU- CITY LUS AS- FILA- gpd E.sub.B gpd DHS CPI GROOVE PECT MENTS (g/dtex) % (g/dtex) % (CPcm) RATIO RATIO______________________________________X - 1.1 220 16 (14) as-spun (1.0) X - 2.0 21 34 (31) 1.5 0.84:1 1.4:1 drawn (1.8) Y - 1.0 271 18 (16) as-spun (0.9) Y - 2.2 20 40 (36) 1 13 (5) None 1.5:1 drawn (2.0) Z - 1.0 212 11 (10) as spun (0.9) Z - 1.8 22 40 (36) 12 (5) 0.84:1 1.43:1 drawn (1.6) 702W - 1.3 239 18 (16) as spun (1.2) 702W - 3.4 37 34 (31) 4.1 12 (5) 0.68:1 1.7:1 drawn (3.1)______________________________________ | New copolyester composition that provides excellent filament spinning and mill/yarn processing of staple fiber into fabrics having combination of excellent pilling performance as well as aesthetics and tactility ("hand"). Preferred fibers have non-round cross-sections, especially multi-grooved and scalloped-oval cross-sections that provide fabrics having outstanding comfort qualities of moisture-management, dryness and comfort, as well as minimal pilling. | 8 |
TECHNICAL FIELD
The present invention relates to a magneto-rheological (“MR”) fluid damper, and more particularly, to a linear-acting fluid damper suitable for vibration damping in a vehicle suspension.
BACKGROUND OF THE INVENTION
Magneto-rheological fluids are materials that respond to an applied magnetic field with a change in rheological behavior (i.e., change in formation and material flow characteristics). The flow characteristics of these MR fluids change several orders of magnitude within milliseconds when subjected to a suitable magnetic field. In particular, magnetic particles noncolloidally suspended in fluid align in chainlike structures parallel to the applied magnetic field, thus increasing the viscous characteristics, or apparent viscosity, of the MR fluid.
Devices, such as controllable dampers and struts, benefit from the controllable viscosity of MR fluid. For example, linearly acting MR fluid dampers are used in vehicle suspension systems as vibration dampers. At low levels of vehicle vibration, the MR fluid damper lightly damps the vibration, providing a more comfortable ride, by applying a low magnetic field or no magnetic field all to the MR fluid. At high levels of vehicle vibration, the amounts of damping can be selectively increased by increasing the density of the magnetic field and by applying control integration into vehicle suspension systems that sense and respond to vehicle load, road surface condition, and driver preference by adjusting a suspension performance accordingly.
Generally, current linearly acting MR fluid dampers are based on a monotube design with a coil positioned in a piston of the damper. In the monotube design, the piston moves within the fixed length cylindrical reservoir in response to force from a piston rod that extends outside of the cylinder. The monotube approach simplifies sealing of the MR fluid within the monotube reservoir; however, monotube dampers may experience reliability problems arising from the electrical wiring leading to the coil, etc., necessary for generating a magnetic field in or around parts of the piston. Typically, the electrical wiring passes up through a passage in the piston rod to a coil in the piston. Elaborate assembly procedures are required to seal this passage. Even if adequately sealed, the electrical wiring may flex with the movement of the piston, sometimes resulting in breakage of the wires.
In some dampers, it is known to reduce failure from wire flexing by holding the coil stationary with respect to a portion of the reservoir of (e.g., either the inner or outer tube). In particular, in U.S. Pat. No. 5,277,281, a reduced diameter piston moves within a reduced diameter inner tube. A coil, separate from the piston, acts as a valve control for a flow passage between the inner and outer tubes, rather than a coil integral to the piston controlling flow past the piston. Although wire flexing is reduced, the reduced piston diameter correspondingly reduces damping. Also, leaks due to introducing wiring into the reservoir are not avoided.
Consequently, a significant need exists for an MR fluid damper that is more reliable and inexpensive to manufacture while being tolerant of side loads on the damping components and furthermore, reduces the likelihood of pressure leaks from the MR fluid reservoir.
SUMMARY OF THE INVENTION
The present invention provides an MR fluid damper that is of a simpler construction then known dampers and can be manufactured for less cost. However, the MR fluid damper design of the, present invention provides an improved, more reliable performance and substantially increases the reliability of the electrical connection to the coil. One aspect of the invention provides an improved magneto-rheological (“MR”) fluid damper including a damper cylinder containing a volume of MR fluid. The cylinder includes an inner surface. A piston assembly is disposed in the cylinder and has an outer surface slidably contacting with the cylinder inner surface. The piston assembly includes a flow gap formed therein and an external coil surrounding a portion of the cylinder, the external coil capable of generating a magnetic field across at least a portion of the flow gap. A pair of ferromagnetic rings are provided, one of which is positioned above and the other of which is positioned below the external coil for directing the magnetic field or flux through the flow gap.
Other aspects of the invention provide a damper wherein the piston assembly includes a first portion having a first diameter and a second portion having a second diameter, the first diameter being less than the second diameter, the second portion including the outer surface in contact with the cylinder inner surface. The MR damper flow gap can be formed along the first portion of the piston assembly. The second portion of the piston assembly can include a plurality of openings. The MR damper can further include a piston rod, a major portion of which is disposed in the cylinder and wherein the piston assembly is secured to an inner end of the piston rod. The piston assembly can be secured to the rod by a pin. The pin can secure the first portion of the piston assembly to the inner end of the piston rod. The outer surface of the second portion of the piston assembly may include a wear resistant coating. The wear resistant coating can include a nickel plating. The wear resistant coating can include an iron alloy including from about 27-50% cobalt and alternately, about 2% vanadium. The wear resistant coating can be sprayed onto the outer surface of the second portion of the piston assembly. The outer surface may be turned and roller burnished. The MR damper may further include a first pair of retaining members positioned in grooves formed in the piston rod at positions above and below the piston assembly and a Belleville spring positioned between one of the first pair of retaining members and the piston assembly to secure the piston assembly to the piston rod. The retaining members may be retaining rings. The extending end of the piston rod opposite the inner end is secured to a housing of the damper by a threaded member. The extending end of the piston rod opposite the inner end may be secured to a housing of the damper by a second pair of retaining members positioned on the inside and the outside of the housing and a Belleville spring can be positioned between one of the pair of retaining members and the housing to secure the piston rod to the housing. The piston rod can be a solid rod. The cylinder can be made of a material that saturates at about 0.5 to about 2 Tesla. The MR damper can further include a gas cup slidingly contained within the cylinder, the gas cup defining a gas chamber containing a gas in one portion of the cylinder, the gas cup configured to seal the MR fluid from the gas chamber. The ferromagnetic rings may include a pair of inner bearings for allowing the ferromagnetic rings and the coil positioned therebetween to slidingly contact the cylinder. The vertical span of the coil and ring assembly may be a length at least equal to a vertical span of the piston.
The foregoing and other features and advantages of the invention will become further apparent from the following detailed description of the presently preferred embodiments, read in conjunction with the accompanying drawings. The detailed description and drawings are merely illustrative of the invention rather than limiting, the scope of the invention being defined by the appended claims and equivalents thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of one embodiment of a magneto-rheological damper in accordance with the present invention; and
FIG. 2 is a sectional view of another embodiment of a magneto-rheological damper in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For purposes of this description, words such as “upper”, “lower”, “right”, “left” are applied in conjunction with the drawing for purposes of clarity. As is well known, dampers may be oriented in substantially in any orientation, so these directional words cannot be used to imply the particular absolute directions for damper consistent with the invention.
Referring to the drawings, illustrated in FIG. 1 is a linearly acting magneto-rheological (MR) fluid damper, in particular, a strut generally illustrated at 10 . In general, the strut is designed for operation as a load bearing and shock-absorbing device within the vehicle suspension system. The strut 10 can be connected between the sprung (body) and unsprung (wheel assembly) masses (not shown) as is known in the art. The strut 10 may include housing 12 including a housing tube or cylinder 14 with an open end 16 and a closed end 18 . The closed end 18 includes an opening 20 . A mounting bracket 22 adjacent the closed end 18 is secured to cylinder 14 by any suitable means such as welding. The mounting bracket 22 has suitable openings 24 for connection to the unsprung mass of the vehicle at a location such as the steering knuckle (not illustrated).
A piston assembly 28 is connected to a piston rod 30 and is positioned within the housing tube 14 . Any suitable means may be used to fix the assembly 28 to the rod 30 . In the illustrated embodiment, the piston 28 is connected to the rod by pinning the piston to the rod with a transverse cross-dowel or pin 90 or the like. The piston rod 30 extends through and is attached to the housing 12 at the opening 20 . In the illustrated embodiment, the rod 30 is secured to the housing portion 18 by way of a threaded nut 92 . The piston assembly 28 is slidingly received within a damper body tube 32 that includes a first end 34 at an outboard position adapted to be connected to the sprung mass of the vehicle and includes a second end 36 at an inboard position. A rod guide 38 supports the second end 36 of the damper body tube 32 about the piston rod 30 . An opening 40 in the rod guide 38 allows the damper body tube 32 to move longitudinally inboard and outboard with respect to the housing 12 . The damper body tube 32 thus forms a fluid-tight cylindrical reservoir 41 .
The piston assembly 28 includes a solid piston core or stepped cylinder 42 containing ferromagnetic material, such as soft steel or sintered iron. The piston core 42 preferably includes a narrowed portion 44 and an extended portion 46 . An annular flow gap 43 is formed about the narrow portion 44 , between piston portion 44 and cylinder 32 . A plurality of openings or orifices 56 are formed through extended portion 46 to permit fluid to pass from a compression chamber 52 and an extension chamber 54 of reservoir 41 .
A non-magnetic cap (not shown) may be provided the piston 42 at the end near the narrow portion 44 as is known in the art to reduce flux leakage to the damper tube 14 . Any magnetic flux leakage from the rod 30 to the tube 14 that may occur only improves performance by increasing flux density in the flow gap 43 . The outer surface of the extended portion or outer step portion 46 of the piston 42 can be coated with a thin wear resistant coating such as electroless nickel plating. The coating may be a thicker coating such as a thermal spray coating, provided such coating is hard enough to withstand the wear and has “soft” magnetic properties to minimize residual magnetization. One of such coatings could be a 27-50% Co, 2% V, Fe bal. Alloy that is sprayed on the surface, turned and roller burnished to increase the hardness and improve the surface finish. An outer surface of the piston portion thus prepared bears on inner surface 58 of tube 32 .
The cylinder 32 can be made from medium or low carbon steel and allowed to saturate at a value of about 2 Tesla. In the alternate, a material may be chosen to saturate at a lower flux density from about 0.8 to about 1.5 Tesla thereby decreasing the amount of flux “lost to the tube” and further improving magnetic performance. The optimum saturation value should be such that the portion of tube 36 in contact with the piston 42 is nearing saturation. The magnetic field energy that is dissipated through other portions of the damper body tube 36 is referred to as “lost to the tube” since it does not interact with MR fluid contained between shear surfaces of the piston assembly 28 and damper body tube 32 .
The MR fluid may be any conventional fluid including magnetic particles such as iron or iron alloys which can be controllably suspended within the fluid by controlling a magnetic field, thereby varying the flow characteristics of the MR fluid through flow gap 43 defined in piston portion 46 . Varying the magnetic field thereby controls the flow characteristics of the MR fluid to achieve a desired damping effect between the sprung and unsprung masses of the vehicle for a given application.
Fundamentally, during damping, MR fluid present in one of the chambers 52 , 54 of the damper body tube 32 flows through flow gap 43 from, for example, extension chamber 54 to compression chamber 52 , as the tube 32 moves outboard with respect to the housing 12 .
A gas cup 62 may also be carried in the damper body tube 32 between the piston assembly 28 and the first (outboard) end 34 . The gas cup 62 slides along the inner surface 58 of damper body tube 32 , separating out a compensation chamber 64 from compression chamber 52 . While the extension chamber 54 and compression chamber 52 carry a supply of MR fluid, the compensation chamber 64 may carry a compressible nitrogen gas supply. During extension and compression directed travel of the damper body tube 32 relative to the piston assembly 28 , a decreasing or an increasing volume of the piston rod 30 is contained within the damper body tube 32 depending on the strut position of the strut 10 . In order to compensate for this varying volumetric amount of the piston rod 30 within the fluid filled chambers 52 , 54 , the gas cup 62 slides, compressing or expanding the compensation chamber 64 .
An external coil 70 generates the magnetic field across the flow gap 43 to the piston assembly 28 . The external coil 70 encompasses a portion of the damper body tube 32 corresponding to, and stationary with respect to, the piston assembly 28 . To concentrate the magnetic field, the external coil 70 is longitudinally placed between a pair of ferromagnetic rings 72 , 74 , forming an external coil assembly 76 .
The external coil assembly 76 is advantageously contained within an external coil crimp casing 78 that provides structural support when the open end 16 of the housing 12 is deformed around the external coil assembly 76 to form an attachment. Any suitable method of fixing the coil assembly 76 may be used to attach the assembly 76 in place about the tube 32 .
An internal surface of the external coil assembly 76 laterally supports the damper body tube 32 . In particular, the assembly 76 includes a pair of plain bearings 84 , 86 that are pressed into the external coil assembly 76 and bear against the damper body tube 32 . The bearings 84 , 86 concentrically support the damper body tube 32 with respect to the external coil assembly 76 . This provides a fluid-tight chamber 88 between the bearings 84 and 86 , which is filled with a lubricating oil. The fluid tight chamber 88 and bearings 84 , 86 can be protected by scraper seals (not shown) on each axial end of the assembly 76 and are in contact with the damper body tube 32 .
An advantage of placing the external coil 70 outside of the cylindrical reservoir 41 is that electrical wiring (not shown) to the external coil 70 is readily installed through the housing tube 14 . In addition, the electrical wiring is secured to the housing 12 so that wire flexure and failure is reduced or prevented.
Referring to FIG. 2, an alternate means of securing the rod and piston is illustrated with the same elements as shown in the above illustration being referred to with the same reference characters. This embodiment uses a number of retaining rings and Belleville springs or washers to retain the rod 30 to the housing 14 and the piston assembly 28 to the rod 30 .
In particular, the piston assembly 28 is secured to the free end or upper end 110 of the rod 30 . A first retaining ring or circlip 112 is positioned in a groove of the rod 30 . The piston assembly 28 is slid onto the end 110 of the rod 30 . A Belleville spring or washer 114 is positioned upon the end of the assembly 28 adjacent the upper end 110 . A second retaining ring 116 is positioned in a groove of the rod 30 to trap the Belleville spring 114 between the assembly 28 and the ring 116 . It will be understood that the spring or washer 114 will be provided with a pre-load or bias to secure the assembly 28 to the rod 30 and prevent movement or misalignment of the assembly with respect to the bore 58 of the tube 32 .
The rod 30 may be held to the housing 14 at a lower end 102 of the rod. A first (lower) retaining ring or circlip 104 is held in a groove of the rod outside the lower end 18 of the housing 14 . A second (lower) retaining ring 106 is held in a groove of the rod 30 just inside the lower end 18 . Between the second ring 104 and the lower end 18 of the housing 14 a Belleville spring 108 is positioned to bias the first ring 104 against the lower end 18 and secure the rod 30 thereto in a similar preload manner as above. It will be understood that maintaining the rod 30 in a secure fashion with respect to the housing 14 helps to align the piston assembly 28 concentrically within the cylinder 32 .
The use of an external coil improves the reliability of the electrical connection thereto and allows higher flux densities to be generated, improving performance of the damper. The stepped piston assembly includes both a flow gap and a bearing surface, lowering complexity and cost of the assembly. Since the bearing surface is magnetic, (previously provided by a stainless steel plate or the like) stainless steel (non-ferrous) components are eliminated from the MR damper.
While the embodiments of the invention disclosed herein are presently considered to be preferred, various changes and modifications can be made without departing from the spirit and scope of the invention. The scope of the invention is indicated in the appended claims, and all changes that come within the meaning and range of equivalents are intended to be embraced therein. | An improved magneto-rheological (“MR”) fluid damper includes a damper cylinder containing a volume of MR fluid. The cylinder includes an inner surface. A piston assembly is disposed in the cylinder and has an outer surface in slidable contact with the cylinder inner surface. The piston assembly includes a flow gap formed thereabout and an external coil surrounding a portion of the cylinder, the external coil capable of generating a magnetic field across at least a portion of the flow gap. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to certain novel 2,3,6-substituted 5,6,7,8-tetrahydro-pyrido[4,3-d]pyrimidin-4 (3H)-ones which have demonstrated activity as angiotensin II (AII) antagonists and are therefore useful in alleviating angiotensin induced hypertension and for treating congestive heart failure.
SUMMARY OF THE INVENTION
According to the present invention, there are provided novel compounds of Formula I which have angiotensin II-antagonizing properties and are useful as antihypertensives: ##STR2## wherein:
R is ##STR3##
X is straight or branched alkyl of 3 to 5 carbon atoms;
R 6 is ##STR4##
The present invention also provides novel intermediate compounds, methods for making the novel pyrimidin-4 (3H)-one angiotensin II antagonizing compounds, methods of using the novel pyrimidin-4 (3H)-one angiotensin II antagonizing compounds to treat hypertension, congestive heart failure and to antagonize the effects of angiotensin II. ##STR5##
DETAILED DESCRIPTION OF THE INVENTION
The novel compounds of the present invention are prepared according to the following reaction schemes.
As illustrated in Scheme I, to prepare compounds for which R 6 is hereinbefore defined, 3-carbethoxy-4-piperidone hydrochloride 1, is acylated with benzylchloroformate, trimethylacetyl chloride or acetic anhydride in the presence of aqueous sodium carbonate to afford 2. In the case of 2-hydroxyisobutyric acid, acylation is accomplished in aqueous sodium carbonate using 1,1'-carbonyldiimidazole. Reaction of the acylated 1,3-dicarboxylate 2 with amidine 3 where x is hereinbefore defined in the presence of an alkoxide yields the appropriate 2-substituted-3,5,7,8-tetrahydro-4-oxo-pyrido[4,3-d]pyrimidine-6(4H)-carboxylate 4. The coupling of the pyrimidine intermediate 4 to the biphenyl tetrazole 5, where R is the trityl protected tetrazole is accomplished by dissolving the reactants in a suitable solvent such as N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidinone, methanol, ethanol, t-butanol, tetrahydrofuran, dioxane, acetone or dimethylsulfoxide in the presence of potassium carbonate or other suitable base such as sodium carbonate, cesium carbonate, sodium hydride, potassium hydride, sodium methoxide, sodium ethoxide, sodium t-butoxide, potassium t-butoxide or lithium methoxide for 2-24 hours, at 20° -80° C. to afford the alkylated pyrido[4,3-d]pyrimidin-4(3H)-one 6. Deprotection of the trityl group on 6 is accomplished by treatment with a catalytic amount of hydrochloric acid in acetone or other suitable acid such as sulfuric, trifluoroacetic or hydrogen chloride for 1-24 hours or by heating in tetrahydrofuran-methanol to afford the pyrido[4,3-d]pyrimidin-4(3H)-one 7.
Reactions are performed in a solvent appropriate to the reagents and materials employed and suitable for the transformation being effected. It is understood by those skilled in the art of organic synthesis that the various functionalities present on the molecule must be consistent with the chemical transformations proposed. This may necessitate judgement as to the order of synthetic steps, protecting groups, if required, and deprotection conditions. Substituents on the starting materials may be incompatible with some of the reaction conditions. Such restrictions to the substituents which are compatible with the reaction conditions will be apparent to one skilled in the art.
Pharmaceutically suitable salts include both the metallic (inorganic) salts and organic salts; a list of which is given in Remington's Pharmaceutical Sciences, 17th Edition, pg. 1418 (1985). It is well known to one skilled in the art that an appropriate salt form is chosen based on physical and chemical stability, flowability, hygroscopicity and solubility. Preferred salts of this invention for the reasons cited above include potassium, sodium, calcium, magnesium and ammonium salts.
While the invention has been illustrated using the trityl protecting group on the tetrazole, it will be apparent to those skilled in the art that other nitrogen protecting groups may be utilized. Contemplated equivalent protecting groups include, benzyl, p-nitrobenzyl, propionitre or any other protecting group suitable for protecting the tetrazole nitrogen. Additionally, it will be apparent to those skilled in the art that removal of the various nitrogen protecting groups, other than trityl, may require methods other than dilute acid.
The compounds of this invention and their preparation can be understood further by the following examples, but should not constitute a limitation thereof.
EXAMPLE 1
Methyl valerimidate hydrochloride
A solution of 16.5 g of valeronitrile and 9 ml of anhydrous methanol in 75 ml of isopropyl ether is cooled in ice and 8.02 g of gaseous HCl bubbled into the reaction mixture. The reaction mixture is refrigerated for 70 hours. A crystalline solid forms and is filtered, washed with isopropyl ether and dried under vacuum for 2 hours to afford 15.7 g of the desired product as a white crystalline solid, m.p. 81°-84° C.
EXAMPLE 2
Valeramidine hydrochloride
To 40 ml of anhydrous methyl alcohol is added 11.7 g of methyl valerimidate hydrochloride and the reaction mixture is cooled in ice while excess gaseous ammonia is added over 5 minutes. A colorless precipitate forms and is rapidly dissolved. The cooling bath is removed and the colorless solution kept at room temperature for 22 hours then evaporated. The concentrate is evaporated under high vacuum for 5 hours to afford 10.3 g of the desired product as a colorless oily solid.
EXAMPLE 3
1-(Phenylmethyl)-4-oxo-3-ethyl-1,3-piperidinedicarboxylic acid
To a mixture of 2.0 g of 3-carbethoxy-4-piperidone hydrochloride and 20 ml of 1M sodium carbonate is cooled in an ice bath and rapidly treated with 1.4 ml of benzylchloroformate. Stirring is continued in the cold for one hour. An opaque oil is formed and the reaction mixture is extracted with ether. The organic layer is dried with magnesium sulfate and concentrated to afford 3.0 g of a colorless oil.
EXAMPLE 4
Phenylmethyl 2-butyl-3,5,7,8-tetrahydro-4-oxo-pyrido[4,3-d]pyrimidine-6(4H)-carboxylate
To a mixture of 3.0 g of 1-(phenylmethyl)-4-oxo-3-ethyl-1,3-piperidinedicarboxylic acid and 1.4 g of valeramidine hydrochloride is added 20 ml of dry ethanol followed by 10 ml of 1M sodium methoxide in methanol. The resulting mixture is stirred and heated under reflux for 1.5 hours. The reaction mixture is allowed to cool, filtered and the filtrate evaporated. The concentrate is stirred with 20 ml of ether for 20 minutes and the solid collected. The solid is air dried and then dried under vacuum at 56° C. for 1.5 hours to afford 2.3 g of a slightly tacky solid, m.p. 117°-122° C. The solid is stirred with water for 10 minutes and the solid collected, washed with water and air dried for 2 hours then at 56° C. under high vacuum for 1 hour to afford 1.9 g of colorless solid, m.p. 125°-127° C.
EXAMPLE 5
Phenylmethyl 2-butyl-3,5,7,8-tetrahydro-4-oxo-3-[[2'-[1-(triphenylmethyl)-1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl-pyrido[4,3-d]pyrimidine-6(4H)-carboxylate
To a stirred solution of 100 mg of phenylmethyl 2-butyl-3,5,7,8-tetrahydro-4-oxo-pyrido[4,3-d]-pyrimidine-6(4H)-carboxylate in 2 ml of dry N,N-dimethylformamide at room temperature is added 12 mg of 60% sodium hydride in mineral oil. After stirring at room temperature for 10 minutes, the clear, colorless solution is heated with 162 mg of 5-[4'-(bromomethyl)-[1,1'-biphenyl]-2-yl]-1-(triphenylmethyl)-1H-tetrazole. The resulting light yellow solution is stirred at room temperature for 17 hours and poured into cold water. The solid is collected by filtration washed with water and air dried for 2 hours to afford 0.25 g of product. The product is purified on thick layer silica gel plates by elution with 1:1 hexanes-ethyl acetate to afford 80 mg of the desired product as a colorless foam.
EXAMPLE 6
Phenylmethyl 2-butyl-3,5,7,8-tetrahydro-4-oxo-3-[[2'-[1-(triphenylmethyl)-1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl-pyrido[4,3-d]pyrimidine-6(4H)-carboxylate
To a stirred solution of 100 mg of phenylmethyl 2-butyl-3,5,7,8-tetrahydro-4-oxo-pyrido[4,3-d]-pyrimidine-6(4H)-carboxylate in 1 ml of dry methanol at room temperature is added 0.29 ml of 1M lithium methoxide in methanol. After stirring at room temperature for 1.5 hours the reaction mixture is evaporated and the residue dried under high vacuum for 18 hours. The residue is dissolved in 2 ml of dry tetrahydrofuran solution followed by 162 mg of 5-[4'-(bromomethyl)-[1,1'-biphenyl]-2-yl]-1-(triphenylmethyl)-1H-tetrazole. The resulting solution is stirred and heated under reflux for 48 hours then applied to thick layer silica gel plates. Elution with 1:1 hexanes-ethyl acetate affords 80 mg of the desired product as a colorless foam. The product is dissolved in acetone and while standing for a week crystals form.
EXAMPLE 7
Phenylmethyl 2-butyl-3,5,7,8-tetrahydro-4-oxo-3-[[2'-(1H-tetrazol-5-yl)[1,1' -biphenyl]-4-yl]methyl]pyrido[4,3-d]pyrimidin-6(4H)-carboxylate
A solution of 80 mg of phenylmethyl 2-butyl-3,5,7,8-tetrahydro-3-[[2'-[1-(triphenylmethyl)-1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl-pyrido-[4,3-d]pyrimidine-6(4H)-carboxylate in 2 ml of tetrahydrofuran is stirred at room temperature and treated with 1.0 ml of 3M hydrochloric acid. The resulting solution is stirred at room temperature for 1.5 hours and ice is added. The reaction mixture is made strongly basic with 0.4 ml of 10N sodium hydroxide. The turbid mixture is extracted with ether. The aqueous phase is acidified with hydrochloric acid and a gum separates. The aqueous phase is decanted and the gum washed with additional water. The gum is dissolved with methylene chloride, dried and evaporated to afford 20 mg of a colorless gum. Ether is added to the gum followed by evaporation under vacuum to afford the desired product as a glass.
EXAMPLE 8
Ethyl 1-(2,2-dimethyl-1-oxopropyl)-4-oxo-3-piperidinecarboxylate
To a mixture of 2.0 g of 3-carbethoxy-4-piperidone hydrochloride and 20 ml of 1M sodium carbonate is cooled in an ice bath and rapidly treated with 1.3 ml of trimethylacetyl chloride. Stirring is continued in the cold for 1.5 hours. The reaction mixture is filtered and the collected solid washed with water, air dried and then dried at 56° C. for 1.25 hours under high vacuum to afford 1.4 g of the desired product as a colorless solid, m.p. 46°-50° C.
EXAMPLE 9
2-Butyl-6-(2,2-dimethyl-1-oxopropyl)-5,6,7,8-tetrahydro-pyrido[4,3-d]pyrimidin-4(3H)-one
A mixture of 1.3 g of ethyl 1-(2,2-dimethyl-1-oxopropyl)-4-oxo-3-piperidinecarboxylate and 0.75 g of valeramidine hydrochloride in 10 ml of anhydrous ethyl alcohol is treated with 5.3 ml of a 1M solution of sodium methoxide in methanol. The resulting mixture is stirred and heated at reflux for one hour. The reaction mixture is allowed to cool over 30 minutes then filtered. The filtrate is evaporated to a gummy residue and stirred with 40 ml of ether for 30 minutes, filtered and the cake washed with ether. The cake is dried at 56° C. under vacuum to afford 1.0 g of the desired product as a colorless solid, m.p. 167°-172° C.
EXAMPLE 10
Ethyl 1-acetyl-4-oxo-3-piperidinecarboxylate
To a vigorously stirred, ice-water cooled suspension of 2.0 g of 3-carbethoxy-4-piperidone in 20 ml of aqueous sodium carbonate is added 1 ml of acetic anhydride. The mixture is stirred in the cold for 30 minutes then extracted with ether. The organic layer is dried and evaporated to afford 1.5 g of colorless solid, m.p. 53°-55° C.
EXAMPLE 11
6-Acetyl-2-butyl-5,6,7,8-tetrahydro-pyrido-[4,3-d]pyrimidin-4(3H)-one
A mixture of 1.5 g of ethyl 1-acetyl-4-oxo-3-piperidinecarboxylate and 1.0 g of valeramidine hydrochloride in 15 ml of anhydrous ethyl alcohol is treated with 7.5 ml of a 1M solution of sodium methoxide in methanol. The resulting mixture is stirred and heated at reflux for one hour. The reaction mixture is allowed to cool over 30 minutes then filtered. The filtrate is evaporated to a colorless syrup which is stirred with 50 ml of ether for 2 hours then filtered. The tacky cake is dried under high vacuum at 56° C. to afford 1.7 g of the desired product, m.p. 106°-113° C.
EXAMPLE 12
Ethyl 1-(2-hydroxy-2-methyl-1-oxopropyl)-4-oxo-3-piperidinecarboxylate
A suspension of 2.0 g of 3-carbethoxy-4-piperidone hydrochloride in 20 ml of 1M sodium carbonate is vigorously stirred at room temperature for 10 minutes then filtered. The filter cake is washed with a small amount of water, air dried followed by high vacuum drying at room temperature for 4 hours to afford 0.9 g of colorless solid, m.p. 125°-127° C. (compound A).
To an ice-bath cooled solution of 0.5 g of 2-hydroxy-isobutyric acid in 5 ml of anhydrous tetrahydrofuran is added 0.8 g of 1,1'-carbonyldiimidazole. The cooling bath is removed immediately after adding the 1,1'-carbonyldiimidazole. After stirring for 15 minutes (compound A) is added in one portion with ice-water cooling. The cooling bath is removed and stirring continued for 18 hours. The reaction mixture is poured into ice-water and extracted with ether. The organic layer is dried and evaporated to afford 0.7 g the desired product as a colorless syrup.
EXAMPLE 13
2-Butyl-5,6,7,8-tetrahydro-6-(2-hydroxy-2-methyl-1-oxopropyl)-pyrido[4,3-d]pyrimidin-4(3H)-one
A mixture of 0.7 g of ethyl 1-(2-hydroxy-2-methyl-1-oxopropyl)-4-oxo-3-piperidinecarboxylate and 0.4 g of valeramidine hydrochloride in 8 ml of anhydrous ethyl alcohol is treated with 2.8 ml of a 1M solution of sodium methoxide in methanol. The resulting mixture is stirred and heated at reflux for one hour. The reaction mixture is allowed to cool over 30 minutes then filtered. The filtrate is evaporated to a syrup which is stirred with 50 ml of ether overnight. The ether is decanted to afford a oily solid which is dissolved in acetone and applied to thick layer silica gel plates. The plates are eluted with ethyl acetate and the major zone washed stirred with water and the water decanted. The residue is dried and chromatographed on thick layer silica gel chromatography plates using ethyl acetate as the elution solvent. The major band at Rf=0.2 is isolated by washing with acetone to afford 0.65 g of the desired product as a colorless solid, m.p. 159°-161° C.
EXAMPLE 14
2-Butyl-5,6,7,8-tetrahydro-6-(2-hydroxy-2-methyl-1-oxo-propyl-3-[[2'-[1-(triphenylmethyl)-1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl]-3-piperidinecarboxylate
To a stirred mixture of 85 mg of 2-Butyl-5,6,7,8-tetrahydro-6-(2-hydroxy-2-methyl-1-oxo-propyl)-pyrido[4,3-d]pyrimidin-4(3H)-one in 2 ml of dry N,N-dimethylformamide at room temperature is added 12 mg of 60% sodium hydride in mineral oil. After stirring at room temperature for 10 minutes, the clear colorless solution is heated with 162 mg of 5-[4'-(bromomethyl)[1,1'-biphenyl]-2-yl]-1-(triphenylmethyl)-1H-tetrazole. The resulting light yellow solution is stirred at room temperature for 17 hours and poured into cold water. The resulting solid is collected, washed with water and dried under vacuum at 56° C. for one hour to afford 180 mg of colorless solid. The product is purified on thick-layer silica gel chromatography plates using 1:1 hexanes-ethyl acetate to afford 75 mg of the desired product as a colorless oil.
EXAMPLE 15
2-Butyl-5,6,7,8-tetrahydro-6-(2-hydroxy-2-methyl-1-oxopropyl-3-[[ 2'-[1-(triphenylmethyl)-1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl]-3-piperidinecarboxylate
To a stirred mixture of 255 mg of 2-Butyl-5,6,7,8-tetrahydro-6-(2-hydroxy-2-methyl-1-oxo-propyl)-pyrido[4,3-d]pyrimidin-4(3H)-one in 3 ml of dry methanol at room temperature is added 0.87 ml of 1M lithium methoxide in methanol. After stirring at room temperature for 1.5 hours the reaction mixture is evaporated to a residue which is dried under high vacuum for 18 hours. The residue is dissolved in 10 ml of dry tetrahydrofuran solution followed by the addition of 162 mg of 5-[4'-(bromomethyl)[1,1'-biphenyl]-2-yl]-1-(triphenylmethyl)-1H-tetrazole. The resulting solution is stirred and heated under reflux for 3 days and evaporated to approximately 2 ml and applied to thick layer silica gel plates. Elution with 1:1 acetone-hexanes affords 215 mg of the desired product as a pale yellow glass.
EXAMPLE 16
2-Butyl-5,6,7,8-tetrahydro-6-(2-hydroxy-2-methyl-1-oxopropyl)-3-[[2'-[1-(1H-tetrazol-5-yl)[1,1'-biphenyl]-4-yl]methyl]pyrido[4,3-d]pyrimidin-4(3H)-one
A solution of 75 mg of 2-Butyl-5,6,7,8-tetrahydro-6-(2-hydroxy-2-methyl-1-oxopropyl-3-[[2'-[1-(triphenylmethyl)-1H-tetrazol-5-yl][1,1'-biphenyl]-4-yl]methyl]-3-piperidinecarboxylate in 2 ml of tetrahydrofuran is stirred and 1 ml of 3N hydrochloric acid is added. Stirring is continued for 1 hour and 0.4 ml of 10N sodium hydroxide is added. The reaction mixture is extracted with ether. The aqueous layer is acidified with hydrochloric acid and extracted with methylene chloride. The organic layer is dried, evaporated and further dried under high vacuum to afford 34 mg of the desired compound as a glass.
Utility
The performance of the novel compounds of the present invention are shown in the following In Vitro test. The results of this test for representative compounds of the present invention are shown in Table I.
Angiotensin II Antagonists In Vitro Tests
Receptor Binding Assay:
Binding of [ 125 I] (Sar 1 ,Ile 8 ) AngII
The binding of [ 125 I] (Sar 1 ,Ile 8 ) AngII to microsomal membranes is initiated by the addition of reconstituted membranes (1:10 vols.) in freshly made 50.0 mMTris.HCl buffer, pH 7.4 containing 0.25% heat inactivated bovine serum albumin (BSA):80 ul membrane protein (10 to 20 ug/assay) to wells already containing 100 ul of incubation buffer (as described above) and 20 ul [ 125 I] (Sar 1 ,Ile 8 ) AngII (Specific Activity, 2200 Ci/mmole). Non-specific binding is measured in the presence of 1.0 uM unlabeled (Sar 1 ,Ile 8 ) AngII, added in 20 ul volume. Specific binding for [ 125 I] (Sar 1 ,Ile 8 ) AngII is greater than 90%. In competition studies, experimental compounds are diluted in dimethylsulfoxide (DMSO) and added in 20 ul to wells before the introduction of tissue membranes. This concentration of DMSO is found to have no negative effects on the binding of [ 125 I] (Sar 1 ,Ile 8 ) AngII to the membranes. Assays are performed in triplicate. The wells are left undisturbed for 60 min. at room temperature. Following incubation, all wells are harvested at once with a Brandel® Harvester especially designed for a 96 well plate (Brandel® Biomedical Research & Development Labs. Inc., Gaithersburg, Md., U.S.A.). The filter discs are washed with 10×1.0 ml of cold 0.9% NaCl to remove unbound ligand. Presoaking the filter sheet in 0.1% polyethylenemine in normal saline (PEI/Saline) greatly reduces the radioactivity retained by the filter blanks. This method is routinely used. The filters are removed from the filter grid and counted in a Parkard® Cobra Gamma Counter for 1 min. (Packard Instrument Co., Downers Grove, Ill., U.S.A.). The binding data are analyzed by the non-linear interactive "LUNDON-1" program (LUNDON SOFTWARE Inc., Cleveland, Ohio U.S.A.). Compounds that displace 50% of the labelled angiotensin II at the screening dose of 50 μM are considered active compounds and are then evaluated in concentration-response experiments to determine their IC 50 values. The results are shown in Table I.
TABLE I______________________________________ ##STR6## Angiotension IIEx. ReceptorNo. R.sup.6 X Binding IC.sub.50 (M)______________________________________ 7 ##STR7## (CH.sub.2).sub.3 CH.sub.3 6.6 × 10.sup.-716 ##STR8## (CH.sub.2).sub.3 CH.sub.3 6.0 × 10.sup.-7______________________________________
The enzyme renin acts on a blood plasma α 2 -globulin, angiotensinogen, to produce angiotensin I, which is then converted by angiotensin converting enzyme to AII. The substance AII is a powerful vasopressor agent which is implicated as a causative agent for producing high blood pressure in mammals. Therefore, compounds which inhibit the action of the hormone angiotensin II (AII) are useful in alleviating angiotensin induced hypertension.
The compounds of this invention inhibit the action of AII. By administering a compound of this invention to a rat, and then challenging with angiotensin II, a blockage of the vasopressor response is realized. The results of this test on representative compounds of this invention are shown in Table II.
AII Challenge
Conscious Male Okamoto-Aoki SHR, 16-20 weeks old, weighing approximately 330 g are purchased from Charles River Labs (Wilmington, Mass.). Conscious rats are restrained in a supine position with elastic tape. The area at the base of the tail is locally anesthetized by subcutaneous infiltration with 2% procaine. The ventral caudal artery and vein are isolated, and a cannula made of polyethylene (PE) 10-20 tubing (fused together by heat) is passed into the lower abdominal aorta and vena cava, respectively. The cannula is secured, heparinized (1,000 I.U./ml), sealed and the wound is closed. The animals are placed in plastic restraining cages in an upright position. The cannula is attached to a Statham P23Db pressure transducer, and pulsatile blood pressure is recorded to 10-15 minutes with a Gould Brush recorder. (Chan et al., (Drug Development Res., 18:75-94, 1989).
Angiotensin II (human sequence, Sigma Chem. Co., St. Louis, Mo.) of 0.05 and 0.1 ug/kg i.v. is injected into all rats (predosing response). Then a test compound, vehicle or a known angiotensin II antagonist is administered i.v., i.p. or orally to each set of rats. The two doses of angiotensin II are given to each rat again at 30, 90 and 150 minutes post dosing the compound or vehicle. The vasopressor response of angiotensin II is measured for the increase in systolic blood pressure in mmHg. The percentage of antagonism or blockade of the vasopressor response of angiotensin II by a compound is calculated using the vasopressor response (increase in systolic blood pressure) of angiotensin II of each rat predosing the compound as 100%. A compound is considered active if at 30 mg/kg i.v. it antagonized at least 50% of the response.
TABLE II__________________________________________________________________________% INHIBITION (ANGIOTENSIN BLOCKAGE) OF ANGIOTENSIN II (A11)VASOPRESSOR RESPONSEEx. Dose A11 Dose Min Post Control Response Average %No. (mg/kg) mcg/kg IV Dose Before A11 After A11 Change Change Inhibition__________________________________________________________________________ 0.05 0 190 230 40 37.5 175 210 35 0.1 185 230 45 42.5 180 220 407 15 IV 0.05 30 185 192 7 11 71 160 175 15 0.1 175 190 15 17.5 59 160 180 20 0.05 60 170 200 30 25 33 170 190 20 0.1 175 215 40 38 11 170 206 36 0.05 90 170 200 30 26 31 160 182 22 0.1 170 210 40 42.5 0 155 200 45 15 IV 0.05 120 185 195 10 5 87 185 185 0 0.1 170 176 6 8 81 170 180 10 0.05 180 175 200 25 25 33 135 160 25 0.1 177 215 38 29 32 140 160 20 0.05 0 207 257 50 47 185 225 40 0.1 205 260 55 50 185 230 4516 15 IV 0.05 30 195 210 15 12.5 72 175 185 10 0.1 195 205 10 7.5 85 175 180 5 0.05 60 190 215 25 15 67 185 190 5 0.1 190 220 30 21.5 57 175 188 13 0.05 90 183 225 42 28.5 37 175 190 15 0.1 188 230 42 33.5 33 170 195 25 0.05 120 210 245 35 27.5 39 175 195 20 0.1 200 240 40 32.5 35 175 200 25 0.05 180 175 230 55 42.5 6 165 195 30 0.1 210 260 50 47.5 5 165 210 45__________________________________________________________________________
As can be seen from Tables I and II, the compounds demonstrate excellent Angiotensin II Receptor Binding activity as well as inhibiting the action of AII.
When the compounds are employed for the above utility, they may be combined with one or more pharmaceutically acceptable carriers, for example, solvents, diluents and the like, and may be administered orally in such forms as tablets, capsules, dispersible powders, granules, or suspensions containing, for example, from about 0.05 to 5% of suspending agent, syrups containing, for example, from about 10 to 50% of sugar, and elixirs containing, for example, from about 20 to 50% ethanol, and the like, or parenterally in the form of sterile injectable solutions or suspension containing from about 0.05 to 5% suspending agent in an isotonic medium. Such pharmaceutical preparations may contain, for example, from about 0.05 up to about 90% of the active ingredient in combination with the carrier, more usually between about 5% and 60% by weight.
The effective dosage of active ingredient employed may vary depending on the particular compound employed, the mode of administration and the severity of the condition being treated. However, in general, satisfactory results are obtained when the compounds of the invention are administered at a daily dosage of from about 0.5 to about 500 mg/kg of animal body weight, preferably given in divided doses two to four times a day, or in sustained release form. For most large mammals the total daily dosage is from about 1 to 100 mg, preferably from about 2 to 80 mg. Dosage forms suitable for internal use comprise from about 0.5 to 500 mg of the active compound in intimate admixture with a solid or liquid pharmaceutically acceptable carrier. This dosage regimen may be adjusted to provide the optimal therapeutic response. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation.
These active compounds may be administered orally as well as by intravenous, intramuscular, or subcutaneous routes. Solid carriers include starch, lactose, dicalcium phosphate, microcrystalline cellulose, sucrose and kaolin, while liquid carriers include sterile water, polyethylene glycols, non-ionic surfactants and edible oils such as corn, peanut and sesame oils, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of pharmaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, preserving agents, and antioxidants, for example, vitamin E, ascorbic acid, BHT and BHA.
The preferred pharmaceutical compositions from the standpoint of ease of preparation and administration are solid compositions, particularly tablets and hard-filled or liquid-filled capsules. Oral administration of the compound is preferred.
These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxypropylcellulose. Dispersions can also be prepared in glycerol, liquid polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (e.g., glycerol, propylene glycol and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oils. | The invention provides novel 2,3,6-substituted 5,6,7,8-tetrahydro-pyrido[4,3-d]pyrimidin-4 (3H)-ones of the formula ##STR1## wherein X, R and R 6 are described in the specification which have activity as angiotensin II (AII) antagonists. | 2 |
This application is a continuation of application Ser. No. 07/824,808, filed Jan. 22, 1992, now abandoned.
FIELD OF THE INVENTION
This invention relates to flushing mechanisms for toilets. In particular, the design provides a flushing mechanism activated by closure of a toilet seat cover that is suitable for being retrofit into existing tank-type toilets.
BACKGROUND OF THE ART
Ensuring that the toilet seat is returned to the closed position after use of the toilet is a common problem. The widely used two-part toilet seat includes a seating ring and a cover, both hinged to the bowl. The seating ring, when in a closed position over the rim of the bowl, provides a comfortable seating surface for the user of the toilet. The cover, when in the closed position, covers the closed seating ring. Both the seating ring and the cover, or the cover alone, may swing upward from the closed position to an open position away from the rim of the bowl to rest against a stop, the stop often being on the front of the toilet tank.
It is usually desired that the seating ring and the cover be left in the closed position between uses of the toilet. The closed cover improves the aesthetic qualities of the toilet, limits access to the water in the bowl by, e.g., pets or small children, and prevents objects from inadvertently falling into the open bowl. Closing the cover after use of the toilet also ensures that the seating ring, which is positioned below the cover on the hinge, is in the closed position. This closing of the seating ring also prevents a subsequent unwary user from inadvertently sitting directly on the toilet rim or falling into the bowl.
Despite the advantages of closing the toilet seat after use of the toilet, remembering to close the seat is difficult, and reminders by others, typically are much after the fact. Direct censure of the forgetful users may, further, have the undesirable collateral effects of engendering embarrassment or hostility.
SUMMARY OF THE INVENTION
The present invention provides a mechanism for encouraging the user of a toilet to return the toilet's seat and cover to the closed position after use. In particular, the mechanism is suitable for retrofit into existing tank-type toilets.
Specifically, a magnet is positioned to move with the seat cover to lie adjacent to a magnet sensor in either the open or closed position. The sensor produces a signal indicating the position of the cover and activates a motor after a transition of the cover between the open and closed positions. The motor turns a crank arm attached to the motor shaft and there is a pivot orbiting the motor shaft. The pivot pulls a tensile link to open the flapper valve and allow flushing of the toilet.
It is one object of the invention, therefore, to encourage the closing of the toilet seat cover after use. The magnet and sensor serve in lieu of the conventional flush lever, thus requiring closing of the seat cover to flush the toilet Combining the functions of closing and flushing reduces the effort required to do both, further encouraging such closing.
It is also an object of the invention to provide such a flushing mechanism which may be practically retrofitted into a standard tank-type toilet. The use of the motor driven crank arm permits the apparatus to work with flapper valves typically found in toilets. The single pivot of the crank arm provides a simple and energy efficient activation of the flapper valve permitting the unit to be battery powered, if desired, thus avoiding the need for additional wiring. The motor unit may include a flange to allow it to hang over the lip of the tank and be held by the tank top. This eliminates the need to drill mounting holes or the like in the ceramic tank structure, yet permits sliding adjustment of the motor unit over the flapper valve to fit the particular toilet type.
The motor unit may also incorporate a delay timer for preventing the flushing of the toilet for a predetermined period after first opening of the toilet lid.
It is also another object of the invention to provide a battery powered flushing mechanism that resists rapid repeated flushings of a type that might wear down the battery and would be ineffective as a result of the failure of the tank to completely refill.
Other objects and advantages besides those discussed above will be apparent to those skilled in the art from the description of the preferred embodiment of the invention which follows. Thus, in the description, reference is made to the accompanying drawings, which form a part hereof, and which illustrate one example of the invention. Such example, however, is not exhaustive of the various alternative forms of the invention. Therefore, reference should be made to the claims which follow the description for determining the full scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in elevation of a toilet with a partial cutaway of the tank;
FIG. 2 is an enlarged perspective view of the motor unit of FIG. 1;
FIGS. 3(a)-(c) are schematic representations of the crank arm and flapper valve of FIGS. 1 and 2 in various stages of the flushing cycle;
FIGS. 4(a)-(d) is a graph showing the signal from the magnet sensor and other related signals as the seat cover is moved between the open and closed positions;
FIG. 5 is a schematic of the circuit used to control the motor in response to signals of FIG. 4(a)-(d); and
FIG. 6 is a perspective view of the magnet sensor of FIG. 1 showing the hanger for attaching the sensor unit to the tank wall.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is provided a tank-type toilet 10 suitable for use with the flush mechanism of the present invention. It includes an upstanding water reservoir 12 filled with water 16 to a water height. A conventional float activated inlet valve can be used to refill the tank. The upper portion 18 of the reservoir 12 includes an opening capped by a reservoir cover 20 which rests on a rim 22, the latter being simply the upper end 18 of the walls of the reservoir 12.
The reservoir 12 is positioned at the rear of the toilet 10 and has in its bottom wall an opening 24 communicating with a bowl structure 26 of the toilet 10 so as to pass water 16 from the reservoir 12 through channels internal to the bowl structure in the usual fashion. Bowl rim 28 includes a plurality of ports which communicate the water 16 into the bowl 30 to provide for a flushing of the toilet 10 as is well understood in the art.
The opening 24 between the reservoir 12 and the bowl structure 26 is normally closed by an elastomeric flapper valve 32 hinged about a pivot point 34 (shown in FIG. 3(c)) to move between a closed state, obstructing the opening 24 and preventing water flow therethrough, and an open state removed upward from the opening 24 to allow the flow of water through that opening. As will be described in detail below, typically the flapper valve 32 is somewhat buoyant in the water 16 but held in the closed position when the reservoir 12 is filled with water 16 by the differential force of that water applied solely to its upper surface when the flapper valve 32 rests within the opening 24.
A chain 35 attaches from the top of the flapper valve 32 to a flushing motor assembly 36, the latter which may pull the flapper valve 32 from the closed state to the open state as will be described in more detail below.
A toilet covering assembly 38 comprised of a seating ring 40 and a cover 42, is attached to the rear of the rim 28 by a conventional hinge 44 so as to swing between a generally vertical, open position, resting against the front wall of the rearward positioned reservoir 12, and to a generally horizontal, closed position lying adjacent to the rim 28. In the closed position, the cover 42 lies on top of the seating ring 40. Thus when the cover 42 is closed, the seating ring 40 must also be closed.
The seating ring 40 is generally annular in shape to conform to the annular rim 28 and to provide support for a seated user. The cover 42 is a planar structure following the outline of the seating ring 40 and rim 28 to cover the opening of the bowl 30.
A magnet 46 is preferably attached to the cover 42 so as to lie adjacent to the upper rim 22 of the reservoir 12 when the cover 42 is in the open position. In the alternative, the magnet could be on the seat, (e.g. if no top cover is provided) and the term cover should be broadly construed to include the seating ring in such situations. The magnet 46 is of sufficient strength, and lies close enough to the reservoir 12 when the cover 42 is in the open position, so that a threshold level magnetic field boundary 48 extends into the reservoir 12 in the area of the rim 22. Yet the magnet 42 is not so strong that when the cover 42 is in the closed position, the magnetic field boundary 48 will extend into the reservoir 12.
A magnet sensor 50 is preferably placed within the reservoir 12 and within the area of the magnetic field boundary 48 when the cover 42 is in the open position. It detects the magnetic field of the magnet 46 and then provides a signal when the cover 42 moves from the open to the closed position. A flexible lead 52 connects the magnet sensor 50 to the flushing motor assembly 36 to permit the magnet sensor 50 to be mounted near the front of the reservoir 12 independent of the mounting of the flushing motor assembly 36 near the rear of the reservoir 12.
Referring now to FIGS. 1 and 2, a mounting bracket 54 hooks over the top of the rim 22 of the rear of the reservoir 12 to support a housing 56 of the flushing motor assembly 36 above the water height 14. The mounting bracket 54 includes a flange portion 58 which is captured between the rim 22 and the lower surface of the reservoir cover 20 to hold the mounting bracket 54 firmly in place. Prior to placement of the reservoir cover 20 on the flange portion 58, the mounting bracket 54 is free to slide in a lateral direction 60 to permit adjustment of the position of the flushing motor assembly 36 so the pivot 74 can be at a point substantially vertically aligned with the flapper valve 32 for a variety of reservoir designs. The mounting bracket 54 eliminates the need for modification of the reservoir 12, e.g. drilling holes, and makes the flushing mechanism of the present invention suitable to be retrofit to most ceramic reservoirs 12.
Housing 56 of the flushing motor assembly 36 includes a battery compartment 62 that holds two "D" cell batteries 64. It is covered by a sliding cover 66, the latter which may be removed in the lateral direction 60 to permit replacement of the batteries.
The housing 56 also includes a motor 68 having its shaft 70 extending through the housing 56 toward the center of the reservoir 12 to drive a crank arm 72. The end of the crank arm 72 that is removed from the shaft 70 holds a pivot 74 to which is attached the upper end of chain 35. The crank arm 72 is rotated by the motor 68 in a counterclockwise direction 76 to provide a simple and efficient lifting of the flapper valve 32 without the friction and additional mechanism required of lever type systems. Avoiding the traditional but bulky lever type system for direct activation by a crank arm 72 and the ability to easily reposition the flushing motor assembly 36 along the rim 22 over the flapper valve 36 provides increased flexibility in the flushing mechanism's ability to fit in different toilet types.
Attached to motor shaft 70 inside of housing 56 is vane 78 which rotates with the motor shaft 70 to periodically interrupt internal magnet sensor 80 and thus to provide an indication of the position of motor shaft 70 and crank arm 72. The position of vane 78 is such as to interrupt magnet sensor 80 when the pivot 74 is in its lowermost position.
Also included within the housing 56 of the flushing motor assembly 36 is motor control circuit 82 (see FIG. 5) which controls the motor 68 based on signals from the sensors 50 and 80.
Referring now to FIG. 1 and FIGS. 3(a) through 3(c), prior to the start of a flush, the water 16 is at water height 14 in the reservoir 12 and the flapper 32 closes the opening 24 preventing water from flowing into the bowl structure 26. When the toilet 10 is used, the cover 42 (or the cover 42 and the seating ring 40) are raised so that magnet 46 is adjacent to magnet sensor 50 providing a signal through flexible lead 52 to motor control circuit 82 within the flushing motor assembly 36 indicating that the cover 46 is in the open position.
Upon moving the cover 46 to the closed position, as indicated by arrow 84 in FIG. 1, the motor 68 in the flushing motor assembly 36 rotates the crank arm 72 to raise the pivot point 74 from its lowest point shown in FIG. 3(a) to its highest point shown in FIG. 3(b) thus raising the flapper valve 32 and allowing the flow of water into the bowl structure as indicated by arrows 86.
As shown in FIG. 3(c), the crank arm 72 continues to rotate in a counterclockwise direction 76 until the pivot point 74 is again in its lowermost position. However the natural buoyancy of the flapper valve 32 prevents the flapper valve from falling into the opening 24 until the water 16 has dropped to the bottom of the reservoir 12.
As noted above, the rotation of the crank arm 72 one revolution during the flushing cycle depicted in FIGS. 3(a) through 3(c) is controlled by means of the vane 78 and internal magnet sensor 80. Prior to a flushing, vane 78 interrupts magnet sensor 80 which removes power to the motor 68, by means of the motor control circuit 82 to stop the crank arm 72. Magnet sensor 80 is a normally-closed reed relay which is opened when an internally generated magnetic field is interrupted by vane 78. Movement of the cover 42 to the closed position activates the motor 68 for a brief period to move the crank arm 72 and vane 78 until the vane 78 no longer obstructs the internal magnet sensor 80. At this point, the magnet sensor 80 provides energy to the motor 68 and the crank arm 72 continues to move regardless of signals from the magnet sensor 50 or the position of the cover 42 until the crank arm 72 has completed one full revolution and the vane 78 once again interrupts magnet sensor 80.
Referring now to FIGS. 4 and 5, the control circuit 82 for controlling the motor 68 in response signals from the sensors 80 and 50 employs a transistor 88 placed in series with motor 68 across the batteries 64, to control the motor current. Internal magnet sensor 80 shunts transistor 88 so that motor 68, in fact, may be activated by current flowing through the transistor 88 or through the magnet sensor 80.
The controlling gate of transistor 88 is connected by series connected resistors 90 and 92 to ground. Before the flush is activated, the resistors 90 and 92 ensure that transistor 88 is not conducting current. Referring momentarily to FIG. 3(a), if transistor 88 is not conducting current, and the vane 78 is interrupting the magnet sensor 80, the motor 68 will be turned off. This condition occurs when the pivot point 74 of the crank arm 72 is in its lowermost position.
The junction 94 between resistors 90 and 92 is connected to one side of capacitor 96. The other side of capacitor 96 connects to a junction 98 between resistors 100 and 102. The other end of resistor 100 connects to ground and the other end of resistor 102 connects through magnet sensor 50 to the positive side of the batteries 64. Magnet sensor 50 is also a normally closed relay which is opened when magnet 46 approaches the magnet sensor 50 with the opening of the seat cover 42 so that the magnetic field at the sensor 50 exceeds the threshold field strength.
Referring to FIG. 4(a), the voltage at the junction 104 between resistor 102 and magnet sensor 50, if resistor 102 were disconnected from junction 98 would rise to approximately the voltage on the battery 64 when the seat cover 42 is closed, and the reed switch of magnet sensor 50 is closed, and drops to approximately zero volts when the seat cover 42 is opened, and the reed switch of magnet sensor 50 is opened. With the next closing of the seat cover 42, at flush initiating point 106, the voltage again rises to approximately that of the battery 64.
With the connection of resistor 102 to junction 98, the voltage at junction 98 generally follows that indicated above with respect to junction 104 when the seat cover 42 is closed, however, when the seat cover 42 is open, the voltage at junction 98 decays exponentially according to the RC time constant determined by capacitor 96 and resistor 100. In the preferred embodiment, this time constant is approximately 1/2 second. When the seat cover is closed at the flush initiation point 106, the voltage at junction 98 rises abruptly to approximately the voltage of the battery 64.
Referring now to FIG. 4(c), when the voltage at junction 98 rises at the flush initiation point 106, the voltage at junction 94 experiences a positive going pulse 113. This pulse 113, in turn, activates transistor 88 providing a current pulse 108 to motor 68 allowing motor 68 to move shaft 70 sufficiently so as to remove the vane 78 from the magnet sensor 80 and thus to begin the flush cycle as previously described.
Referring again to FIG. 4(b), if the seat cover 42 were to be opened at premature point 110, such as might be caused by a rapid movement of the seat cover 42 up and down to activate the flushing mechanism, the failure of capacitor 96 to have completely discharged results in the production of a voltage pulse 112 (shown in FIG. 4(c)) of much lower amplitude than the voltage pulse 113 produced at the flush initiation point 106. This pulse 112 will, in general, be of too low an amplitude and too little duration to activate the transistor 88 thus preventing flushing rapid movements of the seat cover 42 such as might be caused by accidental jarring of the seat cover 42 or intentional misuse. Thus, capacitor 96 provides an effective delay timer to prevent flushing for a predetermined period, dictated by the RC time constant of resistor 100 and capacitor 96, after the seat cover 42 is first opened.
Referring now to FIG. 6, the magnet sensor 50 is generally positioned within the reservoir 12 and is held on the rim 22 by a wire hanger 114 captured between the rim 22 and the reservoir cover 20 in much the same manner as the flange 58 associated with the flushing motor assembly 36. As held by the hanger 114, the magnet sensor 50 may slide in the lateral direction 60 to allow essentially independent positioning of the sensor 50 from that of the flushing motor assembly 36 and so as to permit the sensor to be movable along the wall of the reservoir 12 to within the magnet field boundary 48 for optimum sensitivity.
The above description has been that of a preferred embodiment of the present invention. It will occur to those who practice the art that many modifications may be made without departing from the spirit and scope of the invention. In order to apprise the public of the various embodiments that may fall within the scope of the invention, the following claims are made. | A flushing mechanism for a toilet triggers a flush in response to the closing of the toilet seat cover. A magnet is attached to the seat cover and detected by a sensor. The sensor activates a battery powered motor having a crank arm which directly raises a flapper valve by means of a tensile link. The sensor and motor unit are suspended out of sight in the tank of the toilet by flanges fitting between the tank rim and the tank top. The flanges allow adjustment of the motor and sensor to a variety of preexisting tank type toilets for effective retrofitting. A delay timer prevents repeated energy wasting flushing of the toilet. | 4 |
RELATED APPLICATION
[0001] This divisional application claims priority to and the benefit of U.S. application Ser. No. 10/403,466, filed on Mar. 31, 2003, which, in turn, claims priority to and the benefit of United Kingdom patent application number 0207643.8, filed on Apr. 2, 2002, which applications are herein incorporated by reference in their entirety.
BACKGROUND
[0002] The present invention relates generally to building components and, more particularly, but not exclusively, to building components for roofing, in the form of inflatable cushions.
[0003] Inflatable cushions comprise two or more layers of a plastic foil material such as ETFE (ethylene tetra flouro ethylene) inflated with low pressure air. The ETFE foil cushion is restrained in a perimeter frame usually manufactured from extruded aluminium, which in turn is fixed to a support structure. As the ETFE foil cushion is inflated, the ETFE is put under tension and forms a tight drum like skin. ETFE foil cushions are sold under a number of trade names, for example “Texlon.”
[0004] ETFE cushions of this kind are fixed to a support structure to form a cladding and are used to enclose atria or other enclosed spaces to provide a transparent or translucent roof or façade to the enclosure, as an alternative to and in a similar way to glass. A number of buildings have been built using this technology most notably the Eden project in Cornwall, England.
[0005] Whenever a space is enclosed by a cladding system due consideration needs to be given to the effects of a fire should it break out in the building. In these circumstances, smoke and other products of combustion must be ventilated from the enclosure to prevent injury to the occupants and property. In some specialist buildings, other noxious fumes may also need to be ventilated from the enclosure to prevent injury to the occupants and property. In some specialist buildings, other noxious fumes may also need to be ventilated to atmosphere.
[0006] To ventilate noxious fumes to atmosphere, two methods are primarily utilized. Firstly, the smoke, and/or fumes can be extracted by a mechanical extraction system usually consisting of fire-rated duct work and extraction fans. Alternatively, the smoke and/or fumes can be extracted by opening part of the roof or building façade and allowing the smoke to ventilate to atmosphere through the action of convection and/or wind.
[0007] ETFE foil cushions can be used to ventilate smoke and/or fumes to the atmosphere in much the same ways as other cladding systems in that they can be fixed to a frame which opens automatically through a mechanical device in the event of fire. In addition, ETFE is a thermo-plastic material and therefore has the innate property of failing if the temperature reaches approximately 200° C., as the material loses its tensile properties as its temperature increases. When the cushion fails, it allows smoke and/or fumes to ventilate naturally to the atmosphere.
[0008] The above methods suffer from a number of draw backs. The mechanical extraction approach is expensive and requires fire-rated machinery, regular maintenance and testing. Natural extraction requires expensive opening frames, which are complex to render, weather and watertight. They do not look the same as the adjacent cladding as they require a secondary opening frame, and mechanical operating parts which themselves require regular maintenance and testing. The failure of the ETFE due to high temperature does not occur if the building fire is located some way away from the ETFE, as the ETFE is not sufficiently heated by smoke and/or fumes to fail.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide an economical, visually unobtrusive, method of causing ETFE foil cladding systems to fail on demand in order to allow natural smoke ventilation from a building enclosure.
[0010] It is a further object of the invention to allow the system to fail on demand in order to shed high loads such as snow or water ponding.
[0011] Thus, according to one aspect, the present invention provides a building component in the form of an inflatable cushion comprising two or more sheets of plastics foil and a relatively rigid frame surrounding and supporting the foil sheets, the building component further incorporating a release mechanism in or adjacent to the frame arranged to release the foil sheets from the frame.
[0012] Preferably, the sheets are made from ethylene tetrafluoro ethylene (ETFE). Preferably, the sheets define a space between them which is inflated with air and the frame restrains the sheets about their perimeters, thereby forming the cushion. The release mechanism may extend the entire periphery of the cushion. Alternatively, it may extend only part of the way around, for example, in the case of a polygonal cushion, it may extend around all sides except one. In the case of a rectangular cushion, therefore, it might extend around three sides.
[0013] Preferably, the cushion has a bead formed around its periphery, and the bead is located within the frame. The bead may be a rope encapsulated by the sheet material. The bead may be held by a keder edge within the frame.
[0014] The frame may be manufactured from extruded aluminium which, in turn, may be fixed to a support structure. The frame preferably incorporates a device which releases the ETFE foil cushion from the frame in the event of fire so allowing the smoke to ventilate to atmosphere.
[0015] For releasing the ETFE foil cushion from the frame two exemplary means may be employed, namely, mechanically releasing the cushion or cutting it free.
[0016] In the case of mechanical release, this may be achieved by either extracting the rope from the bead which restrains the ETFE foil cushion in the frame, or by hinging a part of the frame so that it releases the keder edge. Preferably, therefore, the release mechanism comprises a device which removes the rope from the bead on demand, releasing the ETFE foil cushion from the frame. Suitable means for removing the rope include, by way of example, a mechanical winch, or ram, block and tackle. This can be done via a turning wheel. Alternatively, the release mechanism may comprise a hinged member engaging the cushion, the hinged member being movable on demand to a position in which it does not engage the cushion, thereby releasing the cushion from the frame.
[0017] In the case of cutting the cushion free, preferably, the frame incorporates a cutting device which either physically cuts or melts the ETFE foil along the edge of the cushion. Preferably, therefore, the release mechanism comprises an electrical resistance cable which causes the edge of the cushion to melt on demand, releasing the ETFE foil cushion from the frame. Alternatively, the release mechanism may comprise a cutting blade adjacent to the perimeter frame, and a means for moving the cutting blade so that on demand, the blade moves, cutting the ETFE foil cushion, thereby releasing the ETFE foil cushion from the frame. The cutting blade can be situated either above or below the inflated cushion. Suitable means for moving the blade include a mechanical winch, ram or block and tackle.
[0018] Whichever mechanism is used for releasing the ETFE foil cushion from the frame, on release from the frame, the ETFE cushion moves away from the frame so allowing the products of combustion or other noxious fumes to ventilate to atmosphere. On operation of the release mechanism on one or more sides, the ETFE foil cushion may form a cylindrical or spherical shape due to retention of pressurised air in the cushion; flap or fall away from one or more sides of the frame; or flap or fall away from all sides of the frame. In any event, the removal of the cushion from all or part of the frame will allow smoke or noxious fumes to ventilate from the building. It will also allow any excessive water or snow loads to be released.
[0019] A better understanding of the objects, advantages, features, properties and relationships of the invention will be obtained from the following detailed description and accompanying drawings which set forth illustrative embodiments which are indicative of the various ways in which the principles of the system and method may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a better understanding of the invention, reference may be had to preferred embodiments shown in the following drawings in which:
[0021] FIG. 1 is a plan of an exemplary ETFE cushion constructed in accordance with the present invention;
[0022] FIG. 2 is a cross section through the assembly of FIG. 1 ;
[0023] FIG. 3 is a detailed cross section of the perimeter cushion frame showing one embodiment of an exemplary release mechanism;
[0024] FIG. 4 is a detailed cross section of an alternative perimeter cushion frame showing a variant of the first embodiment of release mechanism;
[0025] FIG. 5 is a detailed cross section of the perimeter cushion frame showing a second embodiment of an exemplary release mechanism;
[0026] FIG. 6 is a detailed cross section of the perimeter cushion frame showing a third embodiment of an exemplary release mechanism;
[0027] FIG. 7 is a detailed cross section of a perimeter cushion frame showing a fourth embodiment of an exemplary release mechanism; and
[0028] FIG. 8 is an elevation of FIG. 7 .
DETAILED DESCRIPTION
[0029] Turning now to the figures, where like reference numerals refer to like elements, FIGS. 1 and 2 show an exemplary ETFE cushion constructed in accordance with the invention. The cushion 11 comprises three rectangular ETFE foil sheets 12 , 13 , 14 , a support frame 15 and a plenum 16 . The frame 15 is located about the perimeter of the sheets 12 , 13 , 14 and incorporates a release mechanism. The space between the sheets 12 , 13 , 14 is inflated with air via the plenum 16 .
[0030] FIG. 3 shows a first embodiment of an exemplary release mechanism. The overall arrangement comprises a cushion 21 , a support frame 22 and a building structure 23 . The cushion 21 has a bead 24 at its perimeter made from a rope 25 encapsulated by an extended portion of the sheets 26 , 27 , 28 . Between the bead 24 and the inflated part of the cushion 21 , there is an edge support 29 . The bead 24 is captured within a keder edge 31 , made from aluminium.
[0031] The frame 22 comprises a housing 32 and a cap 33 . The keder edge 31 is clipped into the housing 32 and the cap 33 is bolted into the housing 32 to form a weather-tight seal. The housing 32 is itself bolted to the structure 23 .
[0032] The edge support 29 includes a cable 34 , preferably electrically resistant, extending around the perimeter of the cushion 21 , or at least around three sides. When required, current may be passed through the cable 34 for the purpose of raising its temperature to a level where the ETFE foil 26 , 27 , 28 or the support 29 fails and the cushion 21 is freed from the frame 22 .
[0033] A further exemplary release mechanism is shown in FIG. 4 which is similar to that of FIG. 3 , but in this case, the bead 44 of the cushion 41 is located in a compressible gasket 42 made, for example, of EPDM which is itself swaged into a retaining channel 43 forming part of the frame 45 . Again, there is a resistance cable 46 in contact with the foil of the cushion 41 which causes the foil to fail when current is passed through the cable 46 .
[0034] A still further exemplary release mechanism is shown in FIG. 5 . Again, the cushion 51 is located within the frame 52 by means of a peripheral bead 53 including a rope 54 , the bead being captured by a keder edge 55 which is clipped into the frame housing 56 . However, in this embodiment, there need not be a resistance cable. Instead, the rope 54 may be wound round a pulley 57 and connected to a winch (not shown). Thus, when required, the rope 54 is drawn by a winch, and the bead 53 collapses. As a result, the cushion 51 is released.
[0035] Yet another exemplary release mechanism is shown in FIG. 6 . In this case, the cushion 61 is located within the frame 62 by means of a peripheral bead 63 captured by a keder edge 54 clipped into the frame housing 65 . However, in this embodiment, a blade 66 may be provided on a carriage 67 which is arranged to be rotatable and to travel along a track 68 around at least three sides of the periphery of the cushion 61 , when required, cutting through the cushion foils to free the cushion 61 . Although the blade 66 is shown located below the cushion it could equally well be above. In the illustrated example, the blade 66 is shown in its deployed position, cutting through the foils. It is to be understood that in its normal position, the blade 66 would not make contact with the foils. When required, the blade 66 would be swung into the deployed position and moved along the cushion 61 . There may be a separate blade 66 for each side of the cushion 61 .
[0036] Still further examples of a release mechanism are illustrated in FIGS. 7 and 8 . In this case the cushion 71 is located within the frame 72 by means of a peripheral bead 73 captured by a keder edge 74 clipped into the frame housing 75 . However, in this embodiment, the foils, between the bead 73 and the inflated part of the cushion 71 are supported on and held along each edge by a hinged member 76 forming part of the housing 75 . Each hinged member 76 is pivoted about an axle 77 . Each hinged member 76 is held in its normal position, engaging the foils, by a series of levers 78 which are pivotally connected to the frame 72 by pins 79 . The levers 78 are connected together by connecting rods 81 and one lever is connected to a pneumatic or hydraulic ram 82 . When it is desired to release the cushion 71 , the ram 82 associated with each side is operated. This draws the levers 78 towards the ram 82 , rotating them clockwise about the pins 79 to the positions shown in broken lines. This in turn allows the hinged member 79 to pivot downwards about the axle 77 to the positions shown in broken lines, so releasing the cushion 71 from the housing 75 .
[0037] From the foregoing, it will be understood, when the cushion is released, smoke can be ventilated and/or any accumulated excess snow or water loads can be released.
[0038] While various embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. For example, it is to be appreciated that the arrangements shown in FIGS. 6 and 7 could be combined, to allow the cushion to be released downwards to the blade. It will also be appreciated that, as with the earlier embodiments, the release mechanism illustrated in FIGS. 7 and 8 can act on three sides or all four sides of the cushion. Accordingly, it will be understood that the particular arrangements and procedures disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any equivalents thereof. | A building component for forming a roof. The component includes an ETFE foil cushion comprising sheets of ETFE foil which are held in a frame about their periphery, and which are inflated. The frame includes a release mechanism for releasing the cushion from the frame, for example, in the event of a fire. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 08/984,956, filed on Dec. 4, 1997 abandoned and a further continuation-in-part of application Ser. No. 09/184,606, filed Nov. 2, 1998 abandoned.
FIELD OF THE INVENTION
The present invention relates to the functionality of a system periodically changing in time and, more specifically, to a method and apparatus for establishing a performance scale for determining functionality of the system on the performance scale.
DESCRIPTION OF PRIOR ART
For the cardiocirculatory system functionality is usually inferred by relating maximal or minimal values of the periodically changing hemodynamic parameters during one cycle to an empirically derived surrogate range of normalcy. The empiricism associated with the surrogate range of normalcy provides for ambiguous patient diagnosis. Absent is a cardiocirculatory performance scale descriptive of the functionality of the cardiocirculatory system to measure objectively and quantitatively human performance.
Disclosed in U.S. Pat. No. 5,370,122 is a method to establish the synergy of several hemodynamic parameters from which to deduce functionality. Also, U.S. Pat. No. 5,810,011 discloses a method to measure the synergy of several different parameters to deduce functionality for display in a single reference frame. Both disclosures fail to describe functionality with specificity on a performance scale.
It is therefore an object of the present invention to provide a cardiocirculatory performance scale for hemodynamic parameters to measure human performance on said scale and to display functionality in a performance diagram.
It is a further objective of the present invention to identify basal units on the performance scale for hemodynamic parameters to allow measurements of hemodynamic parameters in basal units for display in a performance diagram.
It is still another object of the present invention to determine zones of criticalities for sustenance of life, myocardial impairment, myocardial fitness, dysfunctions from the human performance scale for diagnosis of cardiocirculatory compliance and failure, for improvement and/or deterioration of cardiocirculatory status, and for design and monitoring therapeutic interventions.
SUMMARY OF THE PRESENT INVENTION
According to the present invention, there is provided a diagnostic device and method for diagnosis of the functionality of the cardiocirculatory system of an individual, measured on a performance scale, and displayed in a performance diagram said scale and performance diagram to be used for diagnosis of myocardial fitness, myocardial impairment, dysfunctions, critical illness, cardiocirculatory compliance, cardiocirculatory failure, improvement and/or deterioration of cardiocirculatory status, and outcome. The device includes the combination of sensors responsive to physiological parameters of an individual changing in time, collectively referred to as A, at an initial time t 1 , denoted, A 1 and at a subsequent time t 2 , denoted A 2 , means to transmit A to a computer for computing the magnitudes of A at various times, the difference of the magnitudes of A at various times, the ratio of the change of A at various times in relation to the magnitude of A at an initial time, and the time trend of the computed parameters. The computer further includes sensors responsive to pre-selected magnitudes of A which are fractions or multiples determined from a standard signal A under standard conditions to serve as basal unit, on a cardiocirculatory performance scale and to establish zones of criticalities. Still further, the computer includes means for comparing the measured signal A with its standard to produce a signal A* which expresses signal A in basal units for display on the cardiocirculatory performance scale for determining functionality, said functionality comprising myocardial fitness, myocardial impairment, dysfunctions, critical illness, cardiocirculatory compliance, cardiocirculatory failure, improvement and/or deterioration of cardiocirculatory status, and, outcome, where said diagnosis is derived by reference to the zones of criticalities and the time trend of the computed parameters. The device further provides means for selecting therapeutic interventions, depending on the attainment of zones of criticalities, displays and monitors for recording improvement or deterioration by departing or approaching the zones of criticalities, recording means, audible and visible warning means activated upon the establishment of pre-selected values to warn of criticalities, and modems for transmission to a central storage facility.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood when the following detailed description is read in conjunction with the accompanying drawings in which:
FIG. 1 illustrates the time sequence of physiological parameters A, said parameters A to include electrocardiographic signals, ECG, arterial pressure, left ventricular pressure, atrial pressure, jugular pressure, carotid pressure, radial pressure, pulmonary artery pressure, right ventricular pressure, and ventricular volume, collectively referred to as signals A, in the instant invention during the time of one heart beat;
FIG. 2 illustrates a performance diagram used to determine functionality of the cardiocirculatory system and to diagnose myocardial impairment, myocardial fitness, dysfunctions, critical illness, cardiocirculatory compliance, cardiocirculatory failure, improvement and/or deterioration of cardiocirculatory be status, and outcome;
FIG. 3 shows a block diagram of the apparatus to practice the instant invention;
FIG. 4 illustrates the utility of the present invention to determine cardiocirculatory functionality and to diagnose myocardial impairment, myocardial fitness, dysfunctions, critical illness, cardiocirculatory compliance, cardiocirculatory failure, improvement and/or deterioration of cardiocirculatory status, and outcome of a patient;
FIG. 5 demonstrates the utility of the present invention to diagnose cardiocirculatory fitness;
FIG. 6 illustrates the utility of the relation of separation of subsequent measurements to assure accurate trend determination for improvement and/or deterioration diagnosis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there are displayed electromechanical physiological signals A as a function of time. The magnitudes of the electromechanical signals at a specific time describe the state of the system at that time but not functionality. Sustenance of life, for example, reflects functionality. For life to be sustained a minimal difference of A at two different times is needed. To determine functionality of the cardiocirculatory system the difference of A at two different times, AA, is derived as
AA=A 1 −A 2 (1)
Expanding the right side of equation (1) by the ratio of A 1 /A 1 yields AA = ( A 1 - A 2 ) × A 1 A 1 = EF ( A ) × A 1 ( 2 )
where EF(A) is the ejection fraction of A, describing the efficiency of the cardiocirculatory system.
EF( A )=( A 1 −A 2 )/ A 1 (3)
Physiological parameters change with body surface area, BSA, and age. Further, the instantaneous demand placed upon the cardiocirculatory system is not only met by the magnitude of AA but also by the adjustment of the time of one heart beat, RR, (R to R interval in the electrocardiogram) during which AA is expended.
To standardize with respect to BSA and to convert a per-beat event into a per-unit time event equations (1) and (2) are divided by BSA and RR to yield the functionality equations
AA*=A 1 *−A 2 * (4)
AA * =EF( A )× A 1 * (5)
where AA*=AA /(BSA×RR) A 1 *=A 1 /(BSA×RR) and A 2 *=A 2 /(BSA×RR)
To establish a cardiocirculatory performance scale, valid for all subjects, a basal AA*, denoted AA* basal , is required, which has assigned a basal unit, 1 BU. AA* basal =1 BU. In general, basal units are derived as a fraction of a constant property. For example, the original basal unit of measuring a length is one meter, which is derived as a fraction of the constant property of the earth circumference around the equator. Hemodynamic parameters change with age due to physiological processes. Such physiological process include growth during childhood which is completed approximately at age of 20 years and aging which commences approximately at age of 30 years. The hemodynamic parameters of the age group of 20 to 30 years, measured at rest in supine position is a constant property for all subjects unaffected by growth and aging. Therefore, they have utility for use as basal units for adults on the cardiocirculatory performance scale.
To determine the basal value, AA* basal , needed to sustain life, hemodynamic values for subjects of the age group of 20 to 30 years measured in supine position under resting conditions are inserted into equation (4). To convert electromechanical physiological parameters AA, measured in conventional units into the same parameters measured in basal units AA is divided by BSA, RR, and AA* basal , according to AA * ( BU ) = AA (conventional units) BSA ( m 2 ) × RR ( sec ) × AA basel * ( conventional units ) ( 6 )
Further, a basal value of EF(A), denoted EF(A) basal , is derived from equation (3) by insertion of hemodynamic parameters for subjects of the 20 to 30 years age group. Subsequent substitution of EF(A)basal into equation (5) yields A 1 * basal as AA* basal /EF (A) basal or 1/ EF(A) basal Additionally, A 2 * basal is derived from equation (4) as A 2 * basal =A 1 * basal −AA* basal =A 1 * basal −1.
Referring now to FIG. 2, there is shown a performance diagram, according to the teachings of the instant invention. A computer computes AA*, A 1 *, A 2 *, and EF(A) from the functionality equations (3), (4), and (5) and plots AA*, A 1 *, and A 2 * on a lower scale versus time and EF(A) on an upper scale also versus time. The upper plot shows the efficiency with which A 1 * of the lower plot is converted to AA*, according to equation (5). The lower plot illustrates the manner in which a specific AA* is derived in a transition from A 1 * to A 2 *, according to equation (4).
Basal values, EF(A) basal , A 1 * basal , AA* basal , and A 2 * basal are added to the performance diagram of FIG. 2 as horizontal lines. The basal lines serve to delineate zones of criticalities. With reference to the basal lines a performance diagram determines cardiocirculatory status as:
1. compliant, when all parameters fall into a zone, where they equal or exceed basal values,
2. failing (without immediate danger of death), when at least one parameter EF(A), A 1 *, or A 2 * falls into a zone so as to not equal or exceed basal values,
3. critical illness (failure with immediate danger of death) when AA* falls into a zone, given by AA*<AA* basal . Critical illness may occur as a result of inefficient operation (myocardial impairment), when EF(A) is sufficiently small to cause AA*<AA* basal or as a result of circulatory dysfunction, when A 1 * is sufficiently small to cause AA*<AA* basal , according to equation 5,
4. deterioration of cardiocirculatory status, when the trend of two successive measurements of at least one parameter departs from the basal value,
5. improvement of cardiocirculatory status, when the trend of two successive measurements of all parameters returns to basal value.
All values EF(A), A 1
*, AA*, A 2 * are expressed in BUs for use in the performance diagram. Basal values, according to the instant invention, serve to define the zones of critical illness, myocardial impairment, myocardial fitness, dysfunctions, cardiocirculatory compliance, cardiocirculatory failure, improvement, and/or deterioration of cardiocirculatory status. Expressing these parameters in terms of BUs permits a quantitative determination of the intensity of myocardial impairment, myocardial fitness, dysfunctions, and critical illness. By measuring performance on the cardiocirculatory performance scale the instant invention teaches the assessment of general age related diseases and the specific dysfunctions which may occur at any age.
The performance diagram, measured at rest, permits the determination of improvement and/or deterioration and, thus, outcome from trend measurements. Trends departing from the basal lines indicate deterioration and trends approaching basal values indicate improvement. The performance diagram, established from measurements not measured at rest, reflects the stress of physical activities. The concomitant changes of EF(A), A 1 *, AA*, and A 2 * of the compliant cardiocirculatory system of an exercising subject are a measure of physical fitness.
To establish a trend for determination of progress and/or regress successive measurements must be truly different from each other. All measurements are afflicted with an unavoidable error. The true value of the measurement is never known only that it falls within the error range. For two measurements to be truly different the error ranges cannot overlap otherwise both measurements may fall into the overlap region where they would not be different from each other.
The embodiment, as shown in FIG. 3 illustrates the teachings of the instant invention. Accordingly, sensors 2 are placed on a subject 1 to detect signals representative of physiological signals A to include but not limited to mechanical signals, ventricular volumes, atrial volumes, cross-sectional ventricular areas, cross-sectional atrial areas, ventricular pressures, arterial pressures, central venous pressure, jugular pressure, radial pressure, pulmonary artery pressure, carotid pressure, atrial pressure, echocardiographic signals, ultra-sound signals, bioimpedance signals, electrical signals, electrocardiographic signals, magnetic signals, chemical signals, arterial oxygen concentration, venous oxygen concentration, oxygen consumption, temperature signals, time signals, heart rate, and combinations thereof which are transmitted on multi-line wire 3 to computer 4 . Such sensors 2 may include catheters, electrodes, electrocardiographs, bioimpedance measuring equipment magnetic resonance measuring equipment, ultra-sound equipment, pressure transducers, pressure cuffs, temperature sensors, chemical sensors, time sensors, and echocardiographic sensors. Additional input representative of patient information including weight, height, body surface area, pre-selected time intervals, and pre-selected basal electromechanical physiological parameters values. is provided from a keyboard 5 to computer 4 on line 6 . Computer 4 is programmed to process the incoming signals on line 6 to establish a basal value for AA* basal as basal unit for the cardiocirculatory functionality scale and to establish basal values EF(A)basal, A 1 * basal , and A 2 * basal for further establishing zones of criticality. Computer 4 is also programmed to process the it incoming signals on line 3 , to determine their magnitudes and to convert them into multiples of the basal unit for use on the cardiocirculatory performance scale. Further, computer 4 generates a performance diagram, establishes zones of criticality and determines myocardial impairment, myocardial fitness, dysfunctions, and critical illness by reference to the zones of criticality. Additionally, computer 4 determines suitable values of EF(A), AA*, A 1 *, and A 2 * to establish a trend for diagnosis of improvement and/or deterioration of the cardiocirculatory system. All parameters, representative of said functionality, are transmitted by line 8 to a monitor 9 which is comprised of a display 10 , audible and visual alarms 11 to warn of emergencies if preset values of the parameters are attained, and indicators 12 to display diagnosis of myocardial impairment, myocardial fitness dysfunctions, critical illness, compliance, failure, improvement, deterioration, outcome, and physical fitness from the attainment of specific magnitudes of the electromechanical physiological variables, measured on the cardiocirculatory performance scale by reference to the zones of criticalities. The signals displayed by display 10 and the audio and visual alarms 11 and the signals displayed by indicator 12 are transmitted on line 14 to a printer 13 for producing hard copies and on line 16 to a modem 15 for in transmission to central storage and retrieval. A memory 17 in the computer 4 serves as storage of all information and data.
Referring now to FIG. 4, there is shown a performance diagram generated by computer 4 of FIG. 3 from data published by it Bonignore et.al. in an article entitled, Obstructive sleep apneas, in Respiratory Critical Care Medicine 1994;149:155-159, prior to, during and after termination of a sleep apnea. Here the physiological parameter AA* is the pulmonary artery pulse pressure, PP*, A 1 * is the systolic pulmonary artery pressure SBP*, and A 2 * is the diastolic pulmonary artery pressure, DBP* all measured in basal units and displayed versus time at successive heart beats, according to the instant invention, said performance diagram showing a compliant system, C, alternating with a failing system and more specifically showing a myocardially impaired system, M, a dysfunctional system, D, and a critically ill system, I, during the apneic period. According to the instant invention, an alarm is triggered upon the attainment of the danger zones of myocardial impairment and dysfunctions. A different sound may be triggered upon the attainment of the zone of critical illness, thus, providing an instant warning of imminent death.
Referring now to FIG. 5, there is shown a performance diagram generated by computer 4 of FIG. 3 from data published by R. A. Wolthuis et. al. in an article entitled, The response of healthy men to treadmill exercise, Circulation 1977;55:153-157. Here the electromechanical parameter AA* is the arterial pulse pressure, A 1 * is the systolic arterial blood pressure, and A 2 * is the diastolic arterial blood pressure. The performance diagram of FIG. 5 examines subjects of the three age groups of 26 years, 47 years and 60 years performing a graduated exercise test, GXT. According to the instant invention, the performance diagram reveals diminishing efficiency of the cardiocirculatory system with increasing age. It permits assessment of cardiocirculatory performance, design and monitoring of rehabilitation and conditioning exercise programs.
Referring now to FIG. 6, there is shown the relationship of separation for two measurements from each other which is a requirement for accurate trend determination from which to diagnose improvement and/or deterioration. All measurements are afflicted with errors. The true value of a measurement is never known, only that it lies within the error range of the measurement. Placing two measurements m 1 and m 2 and their respective error ranges±e m 1 and±e m 2 on a number line reveals the two measurements to be truly different when the error ranges of both measurements do not overlap. Otherwise both measurements m 1 and m 2 may fall into the overlapping region where they would not be different from each other. The condition for two measurements to be different can be expressed by the relationship age of separation
| m 1 −m 2 |>e m 1 +e m 2 (7)
where |m 1 −m 2 | is the absolute value of the difference of ml and m 2 . Computer 4 in FIG. 3 selects measurements for trend determination to diagnose cardiocirculatory compliance and failure from all measurements satisfying the relationship of separation.
In other embodiments of the present invention other physiological parameters including but not limited to mechanical signals, ventricular volumes, atrial volumes, cross-sectional ventricular areas, cross-sectional-atrial areas, ventricular pressures, arterial pressures, central venous pressure, jugular pressure, radial pressure, pulmonary artery pressure, carotid pressure, atrial pressure, echocardiographic signals, ultra-sound signals, bioimpedance signals, electrical signals, electrocardiographic signals, magnetic signals, chemical signals, arterial oxygen concentration, venous oxygen concentration, oxygen consumption, temperature signals, time signals, heart rate, and combinations thereof, including but not limited to ventricular, atrial, aortic energies, and work, together with other constant physiological parameters to serve as basal units, said parameters to be used to determine functionality from which to select therapeutic interventions and to monitor improvement and/or deterioration, and to evaluate drugs.
While the present invention has been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same functions of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims. | A diagnostic and monitoring device is disclosed to determine functionality of the cardiocirculatory system, to generate a cardiocirculatory performance scale for display in a performance diagram, and to measure cardiocirculatory functionality on the performance scale. The diagnostic and monitoring device further identifies zones of criticalities on the performance scale used as reference to diagnose myocardial fitness, myocardial impairment, dysfunctions, critical illness, improvement and/or deterioration of cardiocirculatory status, and outcome. The method and device have utility to design and monitor therapies for differential treatment of myocardial impairment, dysfunctions, rehabilitation, and conditioning exercises, to evaluate the efficacy of drugs, and to predict outcome of interventions. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None
BACKGROUND OF THE INVENTION
[0003] In the transfer of liquids from a source to a desired receptacle at a more or less remote location, unusual challenges are presented when the liquid to be transferred is not of uniform composition, has insoluble contaminants or is comprised of suspended solids that tend to settle out of solution. The situation is exacerbated when pump cycles are discontinuous and the pump is idle long enough to allow sediment to clog pump internal moving parts. In most applications, it is impractical to flush the transfer lines and pump components between pump cycles. Similar problems arise even when solids are comminuted or when viscosity is great enough to cause stress on moving pump components. One particularly vexing problem is the tendency for some solutions of otherwise perfectly soluble chemicals to precipitate crystals which clog outlets and interfere with the operation of ball values, spring leaded check valves, and the like.
[0004] The type of pump selected for a particular application is dictated by the nature of the application. Selection must take into account both the mechanism propelling liquid, but also the design of the valves creating the unidirectional flow.
[0005] For example, the bellows-type component of the instant pump is an excellent source of measurement and propulsion, but if conventional duckbill valves are employed, especially in vertical orientation, the cavities surrounding the duckbill quickly plug, and the valve will not open.
[0006] In general, conventional valves of the paddle, vane, or flexible vane type are not suitable for transferring liquids having high sediment content. Between pump cycles, sediment accumulates on the floor of the valve impeding flow in subsequent cycles. Even the flexible vane embodiment, while avoiding complete plugging because of flexing over sediment deposits, nevertheless will give inaccurate delivery volumes if relying on lapsed time records, and would require real time volumetric determinations.
[0007] U.S. Pat. No. 4,445,823 discloses a transfer system for manure and other barn waste (one of the applications to which the present invention is particularly well suited). It describes a powered shaft upon which is mounted a hollow piston urged up and down in a collection hopper to effect agitation and create a pumping action. Although much of the transfer flow is affected by gravity, agitation is beneficial in that it largely prevents a heavy scum from forming on the surface of the liquid, and also prevents stagnation in the upper levels of the hopper.
[0008] Another approach to pumping heterogeneous liquids is disclosed in U.S. Pat. No. 4,773,834, and consists of a screw-like transfer of materials in a feedstock through a progressive cavity pump. The screw has helical continuous depressions sealed by a pliant filler contained within a rigid housing. Material is moved by rotating the screw in an upwardly direction to physically translate the material from the entry to the exit point. This device is suitable for conveying both mixed content liquids as well as dry solids. A still further approach is disclosed in U.S. Pat. No. 7,553,124 for a centrifugal pump having one or two recessed impellers; or one or two-disk type impellers, or a combination of one recessed and one disk-type. The pump is designed for high viscosity liquids, slurries, and liquids with solids. One advantage is a lack of dead space in the pump chamber. U.S. Pat. No. 7,321,753 describes an interesting secondary pumping device in which a bladder is contained within a housing chamber in which both contain liquids. When the housing reservoir is filled, the bladder is squeezed thereby expelling the liquid contained therein.
[0009] There are many patents disclosing liquid transfer systems, i.e., for example, U.S. Pat. Nos. 8,186,817 and 6,733,252. Such patents disclose functional sites and conduit strategies, as well as transfer stations, but provide few details of the pumping equipment specifications.
SUMMARY OF THE INVENTION
[0010] In accordance with the present invention, a pump assembly is provided that contains no structural components capable of retaining significant quantities of sediment which restrict or impede free flow of a liquid containing a high solids content. The pump is intended to deliver from inlet conduit to an outlet conduit from 6 percent to up to 18 percent suspended solids, as well as carrying up to an additional load of 10 percent dissolved solids. The pump is particularly suited for applications requiring intermittent pumping action, but in one embodiment may be applied to substantially continuous flow.
[0011] Pumping action is provided by a flexible bellows-type chamber, preferably pleated or accordion-like, having a liquid communicating port at one end mounted fixedly within a rigid housing, or frame. Flexibility of the chamber is a property of the materials from which it is made, an elastomeric plastic or rubber. The opposite end of the chamber is attached to a plate adapted for slidable movement within the housing. Extension and retraction of the bellows is effected by a reciprocating drive means attached by a rigid piston shaft to the slidable plate, powered to expand or contract the bellows. In one embodiment a double chambered air cylinder contains an air pressure-responsive moveable disk situated perpendicular to the sides of the cylinder in air sealing engagement, thus defining the two chambered cylinder. A piston shaft is attached horizontally, parallel to the sides of the cylinder, to the disk at one end, and attached to the slidable plate of the bellows-type chamber at the opposite end. Application of air pressure to one cylinder chamber or the other, respectively, causes alternately forward or aft reciprocally actuated movement of the piston shaft, thus drawing into or expelling liquid from the bellows chamber. In a second embodiment, reciprocating motion of the bellows to fill or empty the bellows chamber can be attained by employing a reversible electric motor-driven gear assembly and piston shaft similarly configured. For heavy duty applications requiring force to operate the bellows chamber, a non-compressible fluid such as hydraulic fluid can be substituted for air.
[0012] Directionally-committed flow of liquid into and out of the bellows chamber is regulated by two flexible tubular pinch-type valves. The first such valve is connected to a source of liquid feedstock, conveyed by a feed conduit. The exit port of the valve is connected flowably to the communicating port of the bellows chamber. When the valve is open, and the bellows activated for extension, liquid from the feed conduit is drawn into the bellows chamber through the first pinch-type valve. To propel the liquid from the filled bellows chamber into a destination conduit, the first valve operable by pneumatic means, is closed, a second flexible tubular pinch-type valve having substantially the same configuration as the first such valve, also flowably connected to the same communicating port of the bellows chamber, is opened to coincide with activation of the bellows chamber for contraction.
[0013] Pump cycles are timed and coordinated by programmed control means, typically a computer or micro-processor. By such means both operation of pinch-type valves and the reciprocating drive means are tightly controlled and coordinated by virtually instantaneous electronic signals. In actual practice, however, such timing and coordination are not perfectly reliable because the physical components of the pump are not quite as instantly responsive as the electronics would dictate, principally the result of very short delays in opening of the pinch-type valves. Therefore, it was found that physical intervention means is needed to align pump cycles through physical feedback independent of the programmed control means.
[0014] In one embodiment of the intervention means, a pair of limit switches is mounted at the furthest extension and retraction positions of the bellow-type chamber. In the event that the computer has “timed out” a particular phase of the pump cycle, but the limit switch has not been tripped, the cycle is extended momentarily until physical completion of this phase is confirmed by electrical contact in the switch circuit. In this way, the switch signal overrides timing and allows the bellows to complete its cycle then in progress.
[0015] In a second embodiment, a mechanically operated quick pneumatic relief valve having inlet and exhaust ports is mounted to the tubular pinch-type valves. The relief valve connects the actuating pneumatic inlet port thereof to a pneumatic inlet port activating the tubular pinch-type of the operable pneumatic means. The relief valve senses by a pressure drop when the air pressure has been terminated, and allows virtually instantaneous exhaust through the relieve valve exhaust port, thereby resulting in a correspondingly virtually instantaneous opening of the pinch-type valve. Preferably the quick relief valve is a membrane type valve and exhausts back pressure upon cessation of positive pneumatic pressure applied through the inlet port. According to empirical evaluation, limit switch intervention alone relieves about 90 percent of the noted discrepancy in fluid delivery; the relief valve intervention nearly all the discrepancy. It appears to add beneficial performance enhancement to utilize both embodiments simultaneously.
[0016] The pump of the present invention is intended to be used primarily in intermittent pump cycles, and it is a principal object of the invention to provide a pump free from clogging caused by settling of suspended solids between pump cycles. However, the present pump can be adapted for substantially continuous flow by providing two facing pump units configured as summarized above utilizing a single reciprocating mechanical drive. In this embodiment the piston shaft is operable at both ends with each end being attached to the slidable plate of each unit.
[0017] Thus, one bellows-type chamber evacuates liquid on the down stroke while simultaneously filling a second bellows-like chamber on its corresponding up stroke.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of the pump components fully assembled as they appear from the exterior.
[0019] FIGS. 2 and 3 are cross-sectional views of the internal structure of pump parts, and further illustrate partially retracted ( FIG. 2 ) and extended ( FIG. 3 ) positions of the bellows chamber.
[0020] FIGS. 4A and 4B are planar enlargements of the bellows feature in extended and retracted positions, respectively.
[0021] FIGS. 5A and 5B are planar enlargements of the flexible tubular pinch-like valves in open and closed states.
[0022] FIGS. 6A and 6B are cross-sectional views of the quick relief valve in closed and open positions, respectively.
[0023] FIG. 7 is a cross-sectional view of an embodiment of the pump in continuous flow or dual flow configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] The conveyance of liquids containing substantial content of sedimentary suspended solids is daunting because the solids tend to settle out and adhere to internal moving parts of the pump and clog its action. In the present invention, the pump components are characterized in having smooth, even surfaces that prevent adherence or entrainment of sediment, and provides accurate volume control of the liquid being dispensed. FIG. 1 illustrates the gross exterior structures of the instant pump components. In its preferred embodiment, the pump comprises a flexible pleated bellows-type chamber 120 enclosed within a frame or housing 116 , anchored at one end to a mounting plate or the wall of the frame 122 , and at the other end to a plate 106 adapted for slidable reciprocal movement within the housing or frame. The pleated feature of the bellows is important for proper filling and evacuation of the chamber; a straight walled structure crimps and is not suitable. However, note that at its point of furthest extension, the bellows is straight-walled at every pump cycle preventing entrainment of sediment. The bellows-type chamber 120 is connected flowably through a manifold, generally 10 , to two flexible tubular pinch-type valves 30 . The configuration of the manifold 10 is not critical, provided that it connects both the pinch-type valves 30 to the bellows chamber 120 . In FIG. 1 , it is shown in a “T” conformation 124 .
[0025] A reversible or reciprocating drive means 100 , attached to the end plate 106 , passes through the housing or frame 116 . It is preferably a pneumatic or hydraulic device having air or hydraulic fluid entry ports 114 , but may be a motorized gear-driven assembly.
[0026] Finally, the tubular pinch-type valves 30 are provided with physical intervention means, in this embodiment a mechanically operated pneumatic relief valve 50 to ensure rapid release of air pressure within the pinch-type valves 30 .
[0027] This is essential for virtually instantaneous opening of the valves 30 to maintain pumping volume at precise disbursement rates.
[0028] FIGS. 2 and 3 show cross-sectional views of the pump in which the bellows-like chamber is depicted partially retracted and extended respectively. The cross-sectional view particularly reveals the structure of the preferred pneumatic or hydraulic reciprocating drive means, an air cylinder having a pressure responsive moveable disk 112 integral (as shown) to a rigid piston shaft 110 . When air pressure is applied at inlet port 114 , the moveable disk 112 is displaced, moving in retraction mode. Correspondingly, the slidable plate 106 attached to the rigid piston shaft 110 , is displaced a commensurate distance, thereby retracting the bellows-type chamber. The opposite action occurs when pressure is applied at the other inlet on the opposite side of the moveable disk 112 . The moveable disk 112 is displaced outwardly in extension mode of the bellows. It is advantageous that the inner wall of the air cylinder 100 be lubricated or lined with a material having a low frictional coefficient, so that the moveable disk moves bi-directionally with ease; but not so loose fitting as to cause a leak of air or hydraulic fluid from one air chamber to the other during forward and aft movement of piston shaft 110 .
[0029] The flexible bellows like chamber is secured in place at its ends by concentric fastening means 122 such as a pressure seal 125 . The pleated accordion-like structure of the chamber facilitates retraction and extension thereof by having natural fold lines. Referring to FIG. 4A and 4B , the structure of the pleated chamber is shown in greater detail. The pleat has an apex 106 and a sloping portion 104 . When the pleat is compressed the distance between the folds decreases. At full compression the sloping portions 104 merge with liquid therebetween being squeezed into the chamber. Sediment has no structure upon which to be deposited; and plugging is prevented. Thus, there are two points in the pumping cycle, namely, at the point of full extension (a straight wall) and at the point of full retraction when retention of a solids residue is obviated
[0030] FIGS. 5A and 5B are enlarged views of the tubular pinch-type valve in its open and closed positions respectively. The valve comprises a housing in two parts, a body portion 32 , and two end caps 34 , shown threaded 49 , to receive a threaded conduit, a flexible membranous liner 44 , and in this embodiment a series of restraining bolts to hold the pieces together. The membrane liner 44 is shown tethered concentrically at either end at a recess groove in body portion 42 . The wall of the housing has an air inlet port 30 having an aperture 48 at its center, for ingress of pressurized air and also serves as an exhaust port. When air pressure is applied, the flexible membrane stretches inwardly ( FIG. 5B ) until it converges at a center point 32 , thus providing an effective barrier to flow of liquid within the valve. The membrane may vary in thickness 46 from the perimeter to the center to favor convergence at the center. It is significant that when the valve is open during passage of liquid, there is no moving part in the body portion or other obstruction at which sediment can collect and plug or impede flow.
[0031] The electronic control means is capable of instantaneously sending a signal opening one valve and closing the other, and coordinating the pumping action of the bellows-like chamber with valve action. Typically, valve action is mediated by a solenoid valve that gives the pinch-type valves access to air pressure. Conventionally, a vent tube is run from the pinch-type valve to one of the solenoid stations vented to atmosphere, thus relieving pressure within the tubular chamber, and opening the valve. It was discovered empirically that venting by this method is too slow, so there is delay (however momentary) in opening a valve. This means that on the inlet side, the pump “times out” before the bellows is completely filled; and on the outlet side, the bellows is pumping against a closed circuit. The result is starving the flow of liquid to its destination. The computer notes a liquid volume greater than has actually been delivered.
[0032] It was found that a quick relief valve mounted on the pinch-type valve solves this problem in addition to inclusion of limit switches as described above. FIG. 6A and 6B illustrate the quick relief valve of the preferred embodiment, although many other valve configurations may be available commercially and more or less be substituted for this particular one. FIG. 6A and 6B illustrate a quick release valve (generally 50 ) having essentially two chambers separated by a moveable membrane 57 . FIG. 6A shows the valve in closed position. The valve is contained within a housing 52 . A source of pressurized air is connected flowably to an entry port 60 and flows through an aperture 55 into a left chamber. Air is then directed through a duckbill valve 54 into an upper chamber, which vents through an upper port 53 to a right upper chamber. The entry port 60 circular conduit passing through the center, the top portion (above the moveable membrane 57 ) serving as an exhaust port. An exit port 56 is flowably connected directly to the inlet port 30 at its aperture 48 . While a short conduit separating the quick relief valve from its corresponding pinch-type valve is shown in FIGS. 2 and 3 , to emphasize the flow pattern, it is desirable to mount the quick relief valve directly on the body of the pinch-type valve to minimize the distance exhaust air must flow to open the valve.
[0033] In operation, the quick relief valve receives and transmits pressurized air to a pinch-type valve, thereby closing it. The air pressure also deflects the flexible moveable membrane 57 to form a sealing engagement of the membrane against the upper portion of the entry port 60 , thereby blocking escape of air to the exhaust portion of the conduit. When air pressure ceases, the back pressure of air already contained in the pinch-type valve closes it, deflects the membrane downward to allow air to escape through the exhaust portion of the entry port 60 . Thus, the opening of the valve is physically and functionally defined independently of computer timing instructions. This has a profound and somewhat surprising effect on normalizing flow volume between pump cycles. In combination especially with the limit switch feature, it virtually eliminates all aberrant flow.
[0034] Although the pump of the present invention is primarily intended for discontinuous intermittent pumping cycles, the pump can be configured to deliver substantially continuous flow by combining two such units into a solitary device, as shown in FIG. 7 . The two units face each other in presenting the bellow-type chamber apparatus, and share a common reciprocating drive means. All parts are identical and conform to drawing previously presented herein. The difference is that the drive means is adapted to bi-directional movement by extending the rigid piston shaft 102 so that it engages and is attached to the slidable plate of the bellows-like chamber of both units. In addition to providing substantially continuous pumping of identical feedstocks into a common transfer conduit, this device has the following additional advantages: (1) it allows two different feed stocks to be combined; (2) while the length of the pump stroke is fixed, the diameter is not, and therefore different proportions of two different feed stocks can be admixed; and (3) using the same integrated reciprocating drive means for two different pumps allows diversion of the two exit streams to different destinations. | A pump for transferring liquids containing suspended solids comprises a bellows-type chamber retractable and extendable by a reciprocating drive means. The pump is fed by feed stock inflow controlled by a flexible tubular pinch-type valve, and propelled out of the chamber through a substantially identical pinch-type valve. Programmed control means is inadequate to properly regulate volume of flow, and independently interventional means are disclosed to correct aberrant pump cycles. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a mobile communication device with a positioning capability. In particular, the present invention relates to a mobile communication device (e.g., a cellular telephone) that is also capable of receiving a global positioning system (GPS) signal, and which shares an oscillator between the communication and positioning functions.
[0003] 2. Description of the Related Art
[0004] The utility of a mobile communication device (e.g., a cellular telephone) is enhanced if it is provided the additional capability of receiving and processing global positioning system (GPS) signals that can be used to determine the position of the mobile communication device.
[0005] To provide for both positioning and communication functions, it is possible to share a local oscillator between the receiver and transmitter of the communication circuit and the GPS signal receiver. While sharing a local oscillator can reduce the cost and bulkiness of such a mobile communication device, there are some practical problems to be overcome to achieve high performance. For example, in cellular communications, when a mobile communication device leaves the service area of a base station and enters into the service area of another base station, a “hand-off” procedure takes place in which the mobile communication device tunes into the operating frequency or channel of the new base station. During the hand-off, it is often necessary to adjust the offset (i.e., deviation from the base station's “nominal center frequency”), as each base station may have a different offset. In degraded signal conditions, continuous tracking of a carrier may also require an offset frequency adjustment. However, if such an adjustment is made during the acquisition of a GPS signal, both the mixing frequency and the sampling frequency of the GPS receiver—used in down-converting and digitizing the GPS signal, respectively—are affected. The received signal may yield an erroneous result, or even a failure to detect the GPS signal. In fact, in one system, a 0.05 parts-per-million (ppm) adjustment has the effect of a 79 Hz shift in the carrier frequency in the received GPS signal.
[0006] One approach avoids the corruption of the GPS signal by locking the communication circuit out from accessing the oscillator for frequency adjustment so long as a GPS signal acquisition is in process. However, such an approach is undesirable because it prevents the mobile communication device from establishing contact with one or more base stations while a GPS signal is being acquired, which may lead to temporary loss of communication service. Also, such an approach complicates the control software in the mobile communication device, thereby deterring manufacturers from incorporating positioning capability in their mobile communication devices.
[0007] In GPS signal detection, one source of uncertainty in the carrier modulation frequency in the received signal is the “clock Doppler,” which results from the unknown syntony between the clock on the signal source (e.g., a GPS satellite) and the receiver's own clock. Precise knowledge of the local oscillator's frequency can reduce the frequency search space (“Doppler range”) for the GPS signal. At any given time, the actual frequency of a local oscillator depends on a number of variables, such as manufacturing variations, temperature, aging and operating voltage. Oscillators used in signal sources (e.g., GPS satellites) are typically well-characterized and are tuned to the specified frequency with high accuracy. Because of their cost, high power requirements, and bulkiness, however, such oscillators are unsuited for use in a mobile communication device. To more accurately determine the operating frequency of a local oscillator, the prior art typically requires a more costly oscillator then conventionally found in a mobile communication device. Others require a complex calibration procedure to tune the oscillator to a precision carrier frequency. The latter approach is disclosed, for example, in U.S. Pat. No. 5,874,914 to Krasner, entitled “GPS Receiver utilizing a Communication Link.” Neither approach is satisfactory from a cost and performance standpoint.
SUMMARY
[0008] According to one embodiment of the present invention, provided in a mobile communication device, is a method for compensating for a frequency adjustment in an oscillator shared between a communication circuit and a positioning signal receiver. In one embodiment, the method includes (a) at a first point in time, beginning receiving and storing into a storage device the positioning signal; (b) at a second time point, adjusting a frequency of the oscillator by a given amount; (c) recording the frequency adjustment; (d) at a third time point, completing receiving and storing of the positioning signal from the positioning signal receiver; and (e) processing the positioning signal, taking into consideration the frequency adjustment. In one implementation, the second time point is recorded as the time at which the frequency adjustment of the oscillator is made. Having the knowledge of the time at which the frequency adjustment is made, the processing searches for a frequency shift in the received positioning signal between the second time and the third time. In another implementation, the amount by which the frequency of the oscillator is adjusted is recorded, and the processing searches for a time point at which the frequency adjustment of the oscillator is made. In one implementation, the processing integrates a correlation function.
[0009] The present invention is applicable to GPS processing using aiding data, such as satellite ephemeris data. The present invention is particularly applicable to cellular communication in which an oscillator adjustment may be made when the mobile receiver moves between service areas of base stations.
[0010] Thus, accurate processing of the positioning data is ascertained without preventing the communication circuit from accessing the shared oscillator while positioning data is being acquired.
[0011] According to another aspect of the present invention, a mobile communication device determines an operating frequency of an oscillator based on a reference signal from a reliable time base. In one embodiment, a beginning time point of the reference signal is received by the mobile communication device. When the beginning time point of the reference signal is detected, a counter is enabled to count a number of cycles in a clock signal derived from the oscillator. The ending time point of the reference signal is then detected. Upon detecting the ending time point of the reference signal, the counter is stopped to prevent the counter from further counting. Finally, the frequency of the oscillator is determined based on the count in the counter and an expected time that elapsed between the beginning time point and the ending time point.
[0012] The present invention can use reference signals having a known duration in time, or having recurring events in the reference signal that recurs at a fixed frequency. In some implementation, the frequency of the oscillator so derived can be further adjusted, taking into account the processing times in the mobile communication device for detecting the beginning time point and the ending time point.
[0013] Using the method of the present invention, the operating frequency of a local oscillator can be determined to the accuracy of the oscillator of the base station oscillator, without incurring the expense or inconvenient bulkiness of the more costly, higher precision oscillator typically found in base stations or less mobile equipment. In a GPS signal receiver, by removing the uncertainty in oscillator frequency, the Doppler range over which the positioning signal receiver software searches can be further limited.
[0014] The present invention is better understood upon consideration of the detailed description below and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 shows a block diagram of mobile communication device 100 to which a method of the present invention is applicable.
[0016] [0016]FIG. 2 shows a flow chart of method 200 that compensates for the frequency adjustment in shared local oscillator 108 , in accordance with one embodiment of the present invention.
[0017] [0017]FIG. 3 shows a block diagram of mobile communication device 100 to which a method of the present invention is also applicable.
[0018] [0018]FIG. 4 illustrates method 400 for measuring the operating frequency of shared local oscillator 103 , in accordance with one embodiment of the present invention.
[0019] To facilitate comparison between figures and to simplify the detailed description below, like reference numerals are used for like elements in the figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention provides a method that compensates the frequency adjustment effects in the positioning signal detection process. According to another aspect of the present invention, a method for accurately determining the frequency of a local oscillator is provided.
[0021] [0021]FIG. 1 shows a block diagram of mobile communication device 100 to which a method of the present invention is applicable. Mobile communication device 100 can be, for example, a cellular telephone handset. As shown in FIG. 1, mobile communication device 100 includes communication receiver 101 , communication transmitter 102 , positioning signal receiver 103 , analog baseband circuit 106 , digital baseband circuit 107 , shared local oscillator 108 and synthesizer 109 . In mobile communication device 100 , shared local oscillator 108 is the frequency source for communication receiver 101 , communication transmitter 102 , and positioning signal receiver 103 . Shared local oscillator 108 can be implemented, for example, by a voltage-controlled oscillator. Antenna 104 serves both communication receiver 101 and communication receiver 102 , and antenna 105 serves positioning signal receiver 103 .
[0022] A communication signal coupled by antenna 104 into communication receiver 101 is band-pass filtered, amplified and then down-converted by mixing with a signal from synthesizer 109 to a baseband signal; (The signal from synthesizer 109 has the expected carrier modulation frequency.) The baseband signal so obtained is low-pass filtered and sampled for digital processing in digital baseband circuit 107 . A communication signal to be transmitted is provided as a digital signal from digital baseband circuit 107 . The digital signal is converted into analog form, filtered and modulated by mixing with a carrier frequency provided by synthesizer 109 . The modulated signal is amplified and transmitted through antenna 104 . The positioning signal received at positioning signal receiver 103 is processed in substantially the same manner as described for the communication signal, except that the expected modulation carrier frequency, rather than generated by a synthesizer (e.g., synthesizer 109 ), is provided by a PLL, which multiplies the frequency of shared local oscillator 108 by a factor of 100 or more.
[0023] Analog baseband circuit 106 's functions include enabling communication transmitter 102 to transmit a communication signal, providing a frequency adjustment to shared local oscillator 108 , and changing the frequency in synthesizer 109 . As mobile communication device 100 switches between base stations, analog baseband circuit 106 directs synthesizer 109 to switch between the channels of the base stations. As explained above, switching between base stations or tracking a carrier signal during degraded signal conditions may necessitate a frequency adjustment to shared local oscillator 108 . In addition, as shown in FIG. 1, analog baseband circuit 106 may include a codec and interfaces to a microphone and a speaker for processing voice communication. The codec quantizes a voice signal from the microphone into digital samples to be processed by digital baseband circuit 107 and reconstructs an analog audio or voice signal from digital samples provided by digital baseband circuit 107 . The analog audio signal is replayed at the speaker.
[0024] Digital baseband circuit 107 includes receiver interface (RXIF) 111 and transmitter interface (TXIF) 112 to communication receiver 101 and communication transmitter 102 , respectively. The output signal of shared local oscillator 108 provides a reference signal for clock generation circuit 113 to provide the internal clock signals distributed within digital baseband circuit 107 and analog baseband circuit 106 (e.g., to drive sampling of a voice codec). The internal clock signals generate from timing generation circuit 114 timing strobes used both internally in digital baseband circuit 107 and analog baseband circuit 106 . Various serial communication and input/output (I/O) ports 115 are provided in digital baseband circuit 107 for communication with peripheral devices, positioning signal receiver 103 and analog baseband circuit 106 .
[0025] Digital baseband circuit 107 , which can be implemented as an application specific integrated circuit (ASIC), includes central processing unit (CPU) subsystem 131 , which performs and controls the communication functions of mobile communication device 100 . Such communication functions include executing the communication protocol stack, peripheral hardware control, man-machine interface (e.g., keypad and graphical user interfaces), and any application software. As shown in FIG. 1, in this embodiment, external memory modules 127 , 128 and 129 are coupled to digital baseband circuit 107 through external memory interface (EMIF) 126 . External memory modules 127 , 128 and 129 are used in this embodiment to provide data memory, program memory and positioning data memory for CPU subsystem 131 . (Positioning data memory stores samples of a positioning signal and data used in positioning signal detection.) In other embodiments, data memory, program memory and positioning data memory can be provided by built-in memory modules in digital baseband circuit 107 . Alternatively, positioning data memory 129 and data memory 128 can reside in the same physical memory module. As shown in FIG. 1, CPU subsystem 131 communicates with RXIF 111 , TXIF 112 , clock generation circuit 113 , timing generation circuit 114 and communication and I/O ports 115 over a direct memory access (DMA) and traffic control circuit 116 .
[0026] As shown in FIG. 1, CPU subsystem 131 includes CPU 130 , random access memory (RAM) 123 , read-only memory (ROM) 124 and cache memory 131 . CPU 130 communicates with RAM 123 , ROM 124 and cache memory 131 over a processor bus. Bridge 122 allows data to flow between the processor bus and DMA and traffic control circuit 116 . As known to those skilled in the art, software executed by CPU 130 can be stored in a non-volatile fashion in ROM 124 and also in external program memory 128 . RAM 123 and cache memory 131 provide the memory needs of CPU 130 during its operation.
[0027] In the embodiment shown in FIG. 1, digital signal processor (DSP) subsystem 132 is provided in digital baseband circuit 107 . DSP subsystem 132 can be used to execute computationally intensive tasks, such as encoding and decoding voice samples, and executing the tasks of the physical layer in communication with a station. DSP subsystem 130 can be implemented, for example, substantially the same organization as CPU subsystem 131 , and provided similar access to external memory modules 127 , 128 and 129 through EMIF 126 .
[0028] The positioning signal receiver software, which detects GPS signals from multiple GPS satellites to determine the location of mobile communication device 100 , may be run on either CPU subsystem 131 or DSP subsystem 132 . In this embodiment, the digitized samples of the received GPS signal are stored in memory. The stored GPS signal samples are then later retrieved and processed to search for the GPS satellite, the code phase and frequency shift (“Doppler”) that would provide the received signal. In one embodiment, positioning receiver software searches for a peak in the modulus of a complex correlation integral under hypothesized code phase, Doppler and integration time values. One example of such positioning receiver software is disclosed in co-pending patent application (“Copending Application”), Ser. No. ______, entitled “Method for Optimal Search Scheduling in Satellite Acquisition” by J. Stone et al., filed on or about the same day as the present application, Attorney Docket number M-12558 US, assigned to Enuvis, Inc., which is also the Assignee of the present application. The disclosure of the Copending Application is hereby incorporated by reference in its entirety.
[0029] If the mobile communication device, in response to communication with a base station, adjusts the frequency of shared local oscillator 108 while the GPS signal is being captured, a discontinuity appears as a step shift in carrier frequency in the digitized GPS signal. The present invention compensates for this carrier frequency shift in the complex correlation integral.
[0030] [0030]FIG. 2 shows a flow chart of a method that compensates for the frequency adjustment in shared local oscillator 108 , in accordance with the present invention. As shown in FIG. 2, at step 201 , the data processing portion of the positioning signal receiver software (PRXPF) receives a request for the user's position (e.g., the user selecting a “get position” command from a menu), or from an external source (e.g., a protocol request in a message relayed from the base station). At step 202 , PRXPF retrieves aiding data (e.g., GPS ephemeris, approximate location, and time) from local storage or memory, or from an external source (e.g., by protocol messages to a server sent over a radio communication link to a base station). At step 203 , the control portion of the positioning signal receiver software (PRXCF) initializes positioning signal receiver 103 to begin storing samples between time to t 0 time t 2 . Time may be measured, for example, in mobile communication device 100 's local time base or relative to a timing event in the communication link between mobile communication device 100 and a base station (e.g., a frame boundary in the radio communication interface to a base station). At time to, the contribution to the residual carrier frequency due to shared local oscillator 108 should ideally be zero.
[0031] Suppose at time t 1 (t 0 <t 1 <t 2 ), mobile communication device 100 adjusts the frequency of shared local oscillator 108 by an amount such that the residual carrier frequency in the positioning signal samples changes by Δf 1 . Thus, at step 204 , a record is made in mobile communication device 100 , noting the time of the frequency adjustment and the amount of the frequency adjustment. At time t 2 (step 205 ), PRXCF turns off positioning signal receiver 103 . At step 206 , using the knowledge of the time and amount of the frequency adjustment, PRXPF performs the complex correlation integration using different hypotheses of a frequency offset due to shared local oscillator 108 , according to whether the integration time limits are with the [t 0 , t 1 ] interval or [t 2 , t 3 ] interval. That is:
f vco (t)=0, for t 0 <t<t 1
f vco (t)=Δf 1 , for t 0 <t<t 1
[0032] At step 207 , using the compensated integration of step 206 , PRXPF executes the remainder of PRXPF to obtain the pseudo-range and, consequently, the position of mobile communication device 100 .
[0033] For any reason, if either the frequency adjustment time t 1 or the amount of frequency adjustment cannot be ascertained, the frequency adjustment time t 1 or the amount of frequency shift due to shared local oscillator 108 (i.e., Δf 1 ) are considered additional search parameters. For example, if the frequency adjustment time t 1 is known, but the frequency adjustment amount is not known, multiple hypothetical values for Δf 1 can be used to search for Δf 1 . Alternatively, if the frequency adjustment time t 1 is not known, but the frequency shift due to shared local oscillator 108 is known, multiple hypothetical values for t 1 can be used to search for time t 1 . Of course, if neither the frequency adjustment time t 1 nor the frequency shift due to shared local oscillator 108 is known, both the time and frequency parameter spaces have to be searched. In any case, the frequency adjustment software in the mobile communication device notifies the PRXPF that such an adjustment has occurred, and provides as much information related to the adjustment as is available.
[0034] [0034]FIG. 3 shows a block diagram of mobile communication device 300 , to which is a method of the present invention is also applicable. Unlike mobile communication device 100 of FIG. 1, mobile communication device 300 uses a CPU or DSP 151 which resides outside of digital baseband circuit 107 . Other than where the positioning signal receiver software and data reside and execute, the operation of mobile communication device 300 and mobile communication device 100 with respect to location determination and compensation for frequency adjustment in shared local oscillator 108 are substantially identical.
[0035] According to another aspect of the present invention, the frequency of a local oscillator (e.g., shared local oscillator 108 or the higher frequency output signal of a phase-locked loop) can be determined using the oscillator of a base station. The present invention uses a timing signal of known duration, or having events of known recurring frequency, as a reference or “stop watch” signal to measure the actual local oscillator frequency. For example, in a CDMA network, a “short code” of 26 ⅔ millisecond duration is broadcast on a pilot channel. The frequency of the short code rollover at 37.5 Hz can be used for synchronization. Alternatively, a “long code” broadcast on a CDMA network can also be used to synchronize a 10 MHz source. Each code has a starting point and an ending point indicated by a predetermined pattern. Similarly, in a GSM network, the Broadcast Control Channel (BCCH) transmitted by the base station includes a Synchronization Channel (SCH) having counts indicating the positions of the current frame within a multi-frame, super-frame and hyper-frame structures. The multi-frame, super-frame and hyper-frame structures have respective durations of 0.235 seconds, 6.12 seconds and approximately 3 hours and 29 minutes. Thus, in a GSM network, the starting points of successive mult-frames can be used as fixed time intervals. Other intervals inherent in the GSM air-interface frame structure can also be used as fixed time intervals. In addition, a counter is provided in the hardware that is clocked by a clock signal generated from shared local oscillator 108 . In one embodiment, a nominally 200 MHz signal from a PLL in positioning signal receiver 103 is used to clock the counter.
[0036] [0036]FIG. 4 illustrates method 400 for measuring the operating frequency of shared local oscillator 103 , in accordance with the present invention. As shown in FIG. 4, step 401 detects a starting point in the selected reference signal from the base station. At step 402 , when the starting point in the reference signal is detected, the counter is reset to enable count, incrementing one for each cycle of its input clock signal. In one embodiment, detecting the starting point and starting the counter can be accomplished by software running in CPU subsystem 130 . In other embodiments, these functions can be carried out in hardware. At step 403 , when the ending point of the reference signal is detected, the counting is disabled. At that time, the count in the counter represents the number of clock cycles elapsed between the starting and ending point of the referenced signal (i.e., the fixed time interval). The frequency of shared local oscillator 108 is thus simply this fixed time interval divided by the count in the counter. An adjustment to the count may be desirable to account for the latencies in signal detection and the counter operations for higher accuracy.
[0037] In one embodiment, shared local oscillator 108 can operate between 10-25 MHz. A PLL in positioning signal receiver 103 multiplies the oscillator frequency to 200 MHz. Theoretically, the uncertainty in this 200 MHz signal under method 400 in that embodiment is estimated to be 10 Hz. However, nondeterministic latencies (e.g., due to the tasks in CPU subsystem 130 ) brings the uncertainty up to about 100 Hz.
[0038] Using the method of the present invention, the operating frequency of shared local oscillator 108 can be determined to the accuracy of the oscillator of the base station oscillator, without incurring the expense or inconvenient bulkiness of the more costly higher precision oscillator typically found in base stations. By removing the uncertainty in oscillator frequency, the Doppler range over which the positioning signal receiver software searches can be further limited.
[0039] The above detailed description is provided to illustrate specific embodiments of the present invention and is not intended to be limiting. Numerous variations and modifications within the scope of the present invention are possible. For example, the detailed description above describes a system in which the positioning signal receiver stores the sampled received signal and later retrieves the stored data for processing. Another embodiment which processes the sampled data as they are sampled is within the scope of the present invention. The present invention is set forth in the following claims. | In a mobile communication device, a method for compensating for a frequency adjustment in an oscillator shared between a communication circuit and a positioning signal receiver is provided. In one embodiment, the method begins to receive and store a positioning signal at a first time point. When, at a second time point, the operating frequency of the shared oscillator is adjusted, the frequency adjustment is recorded. After the positioning signal is completely received and stored, the processing of the positioning signal takes into consideration the frequency adjustment. In that embodiment, the processing hypothesizes a frequency shift in the received positioning signal. According to another aspect of the present invention, a method for determining the operating frequency of an oscillator detects a beginning time point of a reference signal received by the mobile communication device and enables a counter to count in step with a clock signal derived from the oscillator. When an ending time point of the reference signal is received by the mobile communication device, the count is stopped, and the frequency of the oscillator is determined based on the count in the counter and an expected time that elapsed between the beginning time point and the ending time point. | 6 |
FIELD OF THE INVENTION
This invention relates generally to building hardware and more specifically to apparatus for eliminating squeaks in flooring.
BACKGROUND OF THE INVENTION
In the construction of buildings, floors are frequently installed by supporting a deck atop a series of floor joists, which in turn are supported by an underlying foundation. The deck is usually fabricated from wood and fastened to the underlying joist by means of nails. The wooden deck may take the form of large sheets of plywood or similar material or maybe configured as a plurality of relatively narrow boards. In either instance, problems of squeaking can arise when the floor deck, for reasons of warpage, shrinkage or the like separates from the underlying joist. If this happens, the flooring "floats" above the joist and is compressed thereagainst when weight is placed on it. This compression gives a spongy feel to the floor and further more may cause squeaking particularly if the boards rub against the nail or one another. In time, repeated flexing of the deck causes further loosening of other nails and can result in still greater squeaking.
Various steps have heretofore been taken in an attempt to stop squeaking floors. The simplest approach is to drive new nails into the joist thereby fastening the squeaking board snugly thereagainst. This is impractical in situations where carpeting or tile covers the floor and is aesthetically unattractive since the exposed nail heads mar the surface of a finished floor. Furthermore, this solution does not always work, particularly if the nails is originally loosened because of a weakness or drying out in the underlying joist. In some instances, squeaks can be halted by injecting a lubricant such as graphite or talcum powder into spaces between the boards to permit them to slide without squeaking. This approach, when in works at all, cures the symptoms, but not the cause of the squeaking and does nothing to prevent a spongy floor feel or creation of new squeaks. In other instances, shims are placed between the joist and the floor to fill in the space and prevent compression of the overlying floor boards. While this approach works, it is frequently impractical insofar as access to the space between the floor and the joist is frequently limited and accordingly it is difficult to properly place the shim members.
It will be appreciated that there is a need for a means for drawing a floor deck into contact with a subjacent joist so as to eliminate squeaks and/or prevent the spongy feel associated with loose floor boards. The present invention provides such floor tightening means and furthermore is easy to use, does not mar the top surface of the floor and does not require removal of floor covering. As will be described in greater detail hereinbelow, the present invention provides a floor squeak eliminator which is affixed to the bottom surface of the floor proximate a joist and which attaches the joist and is operative to pull the floor into registry therewith.
It has previously been known to anchor items to joists; however, use of a floor joist as an anchor point for the elimination of floor squeaks has not been heretofore accomplished. U.S. Pat. No. 4,226,058 shows an anchor bolt for roof mounting of air conditioners and similar equipment, which bolt is configured to wrap around a subjacent joist to provide a base for anchoring of the equipment. This bolt however can not operate to eliminate floor squeaks and furthermore must be used in conjunction with a hole drilled through the overlying deck and hence cannot be modified to function in a manner similar to the present invention.
BRIEF DESCRIPTION OF THE INVENTION
There is disclosed herein a squeak eliminator for drawing a floor into contact with a subjacent joist. The squeak eliminator is comprised of a floor plate assembly including a generally planar member having means for affixing said planar member to the underside of the floor and further including a generally elongated member retained by said planar member and projecting approximately perpendicular therefrom. The squeak eliminator further comprises a generally hook-shaped joist strap having a first end configured to be hooked about, and retainably engaged by, a floor joist and a second end having an opening configured to have a portion of the length of the elongated member pass therethrough. The squeak eliminator still further includes attachment means operative in conjunction with the joist strap and the elongated member to retain the joist strap and the elongated member in fixed relationship and to bias the planar member and joist strap toward one another so that the floor is urged into contact with the joist thereby eliminating the squeak.
In particular embodiments, the affixing means for the floor plate may comprise a plurality of screws and the elongated member may be a carriage bolt retained by, and projecting from the plate. The joist strap may include a hook-shaped first end configured to engage the joist from the floor and may further include a second end which is generally planar and configured to be disposed parallel to the floor when the first end is engaged with the joist. The attachment means may include a threaded fastener such as a nut engagable with a threaded portion of the elongated member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a squeak eliminator of the present invention shown in use;
FIG. 2 is a top plan view of the planar member of the floor plate assembly of the present invention;
FIG. 3 is a perspective view of one configuration of joist strap of the present invention; and,
FIG. 4 is a perspective view of another embodiment of joist strap of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is shown one embodiment of a squeak eliminator structured in accord with the present invention, as disposed in use. Shown in FIG. 1 is a portion of a floor which includes a deck 10 and a pair of subjacent floor joists 12,14. The floor deck 10 is supported in direct contact with the first joist 12 and affixed thereto by a nail 16, shown here in phantom outline. A second portion of the floor deck 10 is attached to the second joist 14 by means of another nail 16 also shown in phantom outline. It will be noted that the floor deck 10 does not rest in contact with the second joist 14 but rather, there is a gap therebetween. It is this gap that will produce a squeak and/or a spongy feel to the floor. When weight is placed on the floor deck 10 in the region of the second joist 14, the weight will drive the deck 10 against the upper surface of the joist 14 and the floor may squeak either as a result of wood rubbing the nail 16 or wood rubbing other pieces of wood.
The squeak eliminator, as illustrated in FIG. 1 includes a floor plate assembly generally comprised of a planar member 18 having a carriage bolt 20, or other such generally elongated member retained thereby and projecting therefrom. The planar member 18 is affixed to the underside of the floor deck 10 by means of screws 22, although obviously other affixing means such as nails or adhesives may be similarly employed. The squeak eliminator further includes a joist strap 24 which has a first hook shaped end configured to fit about the joist 14, distal the floor deck 10. The joist strap 24 further includes a second end which has an opening therethrough configured to receive the carriage bolt 20 or other elongated member. The squeak eliminator still further includes a nut 26 or similar attachment means which functions to join the joist strap 24 to the elongated member 20 of the floor plate assembly and to draw the planar member 18 of the floor plate assembly and the joist together so as to tighten the floor against the joist. It will also be noted from the FIG. 1 illustration that a washer in 28 is interposed between the nut 26 and the second end of the joist strap 24. This washer facilitates tightening of the nut.
Referring now to FIG. 2, there is shown a top plan view of one embodiment of planar member 18 of the floor plate assembly. In the illustrated embodiment, the planar member 18 includes four holes 30 therethrough. Each hole is configured to allow the shaft of a wood screw to pass therethrough but is made small enough so as to retain the head of the screw. In this manner, the holes 30 may be used in conjunction with the screws to mount the planar member 18 onto the bottom surface of the floor. It is to be understood of course that the planar member may take other shapes and that a greater or lesser number of holes may be included and that the planar member 30 may be affixed to the floor by nails, adhesive or other such means.
The central portion of the planar member 18 includes a depressed region 32 configured to receive the head of a carriage bolt. This depressed portion also includes a generally square opening 34 therein. As is generally known to those of skill in the mechanical arts, carriage bolts have a generally cylindrical shaft with at least a portion thereof threaded and the a top most portion of the shaft proximate the bolt head is configured to be of square cross section. The square opening 34 in the planar member 18 is sized to engage and retain the square portion of the carriage bolt shaft so as to lock the bolts from turning. The planar member 18 is thus configured to retain the carriage bolt so that the bolt projects therefrom in and approximately perpendicular relationship. As utilized herein, the term "approximately perpendicular" refers to the fact that the bolt projects away from the planar member at an angle greater than 45°. This accounts for the fact that the planar member 18 may be placed at various distances from the joist and the carriage bolt 20 will accordingly contact the joist strap at angles which may not precisely equal 90°.
Referring now to FIG. 3, there is shown one embodiment of joist strap 24 structured in accord with the principles of the present invention. As will be noted from the drawing, the joist strap 24 includes a first end 36 having a generally hooklike shape and configured to engage a portion of a standard floor joist. It is to be appreciated that this hook portion maybe made in various sizes to accommodate different joist thicknesses or it may be made in one size which is large enough to fit most standardly available joists. The joist strap 24 further includes a second end 38 which, when the joist strap 24 is properly affixed to a joist, will lie in a plane generally parallel to the plane of the floor. The second end 38 includes an opening 40 therethrough configured to receive a portion of the carriage bolt or other elongated member depending from the floor plate assembly.
Referring now to FIG. 4 there is shown yet another embodiment of joist strap 42 having a generally U-shaped hook portion 44. The joist strap 42 of FIG. 4 further includes two second end portions 38, generally similar to those previously described. A joist strap of this type allows for engagement with two floor plate assemblies, one of which is disposed on either side of the joist and may be particularly advantageous when relatively large downward force need be applied to the floor to eliminate a squeak. The FIG. 4 joist strap exhibits still another feature of the present invention. It will be noted that the holes 46 in the second end portions 38 of the strap 42 are configured as slotted holes. This provides for easier placement of the carriage bolt with relation to the joist strap 42. Obviously, the slotted holes of this type may be similarly employed in connection with the joist strap 24 illustrated in FIG. 3. Furthermore, the holes may be oversized or slotted in the other direction to accommodate further variation in placement.
The squeak eliminator of the present invention may be fabricated from a variety of materials although for ease of fabrication and economy it will generally be preferred that the various components will be fabricated from a metallic material, particularly a ferrous material. Dimensions of the various components of the squeak eliminator will depend upon the particular size of the joist although it has been found in general that the opening of the hook portion of the joist strap should be approximately 1.5 inches and it has generally been found practical and advantageous to fabricate the joist strap to be approximately 4 inches in height from the base of the hook to the flat surface of the second end. It has been found that a joist hook having a width of approximately 1.0 inches will provide sufficient strength in most instances. The joist strap may be readily manufactured by a stamping process utilizing mild steel stock 0.12 inch in thickness.
The planar member of the floor plate assembly may be similarly fabricated by stamping from 0.12 inch steel stock and will generally be fabricated as a two inch square item having a central indented portion approximately 0.62 inches in diameter and 0.12 inches in depth. The square opening in the indented portion is preferably 0.26 inches long and accommodates a standard 1/4--20×6 carriage bolt. The screw holes in the plate are preferably 7/32 inches in diameter and accommodate a No. 105/8 inch wood screw.
Other variations of the present invention are possible and contemplated within the scope hereof. For example, the joist strap and planar member of the floor plate assembly may be joined together by an elongated member passing therethrough which includes a turn buckle type arrangement along the length thereof for drawing the two members together. The joist strap may also be fabricated of a design other than that precisely illustrated. For example, the joist strap may be fabricated from stock having a round cross-section and rather than having a slot or hole drilled therethrough may include an eye portion formed by bending. These and other variations are all contemplated within the scope of the disclosure herein.
In light of the foregoing, it should be apparent that many variations and modifications of the present invention are possible. For that reason, the foregoing drawings, description and discussion are merely meant to illustrate particular embodiments of the present invention and are not meant to be limitations upon the practice thereof. It is the following claims, including all equivalents, which define the scope of the invention. | A floor squeak eliminator includes a plate assembly affixable to the underside of the floor and including a downwardly projecting threaded member. The squeak eliminator also includes a joist strap having a first end configured to engage the bottom side of a floor joist and second end configured to engage a portion of the threaded member. A nut or similar item engages the threads and draws the floor plate and joist strap together bringing the floor into contact with the subjacent joist. | 4 |
TECHNICAL FIELD
This invention relates to cover doors for automotive air bag restraint systems and, more particularly, to an arrangement for providing the cover door with a predetermined opening characteristic upon inflation of an air bag located behind the cover door.
BACKGROUND OF THE INVENTION
Air bag restraint systems are used in vehicles such as automobiles to help reduce the extent of personal injuries incurred in vehicular accidents. Air bags are designed to inflate during a collision to restrain movement of the driver and/or other occupants to help avoid injurious contact with interior portions of the automobile. They are typically stowed behind a cover door in one or more interior trim structures, such as the steering wheel cover, door panel, or dashboard. The cover door is attached to, or formed as part of, the interior trim structure in such a manner as to inhibit access through the door opening from outside the door (e.g., by an occupant of the vehicle), and to open under the force of an expanding air bag to permit the air bag to expand out through the opening and into the interior of the vehicle.
Common deployment locations within an automobile for air bag restraint systems include, for the driver, the center hub of the steering wheel and, for a front seat passenger, either the top (horizontal) or rear-facing (vertical) surface of the dashboard. Other deployment locations include door panels, seats, and headliners. Cover doors for air bag deployment openings that are located in a generally horizontal opening in the dashboard are referred to as top mount cover doors and cover doors for deployment openings located in a generally vertical opening in the dashboard are referred to as mid-mount doors. Examples of top mount air bag cover doors are disclosed in U.S. Pat. Nos. 4,893,833 to A. J. DiSalvo et al., 4,964,653 to K. L. Parker, and 5,154,444 to E. S. Nelson. Examples of mid-mount doors are disclosed in U.S. Pat. Nos. 3,708,179 to R. E. Hulten and 4,895,389 to W. D. Pack, Jr. PG,4
As shown in the patents to DiSalvo et al. and Parker, top mount cover doors are commonly designed to pivot along a front edge of the door so that the door swings upwardly and toward the automobile's windshield. As the air bag inflates it moves upwards through the door opening and rearwardly towards the front passenger seat. A duality of problems can arise from this arrangement. First, the forceful opening of the air bag cover door by the inflating air bag causes the door to swing open with sufficient force and speed that the cover door can contact and even break the automobile's windshield. Second, since the deployment opening is located in a generally horizontal orientation, the air bag must first move upwards as it exits through the door opening, even though the desired direction of inflation is rearward toward the front passenger seat.
Cover doors for front passenger restraint systems are typically secured along an edge of the cover door, either by a releasable fastener or otherwise. It is known to use hook and loop tape as a releasable fastener to maintain the cover door closed until deployment of the underlying air bag. See, e.g., U.S. Pat. No. 5,161,819 issued Nov. 10, 1992 to R. D. Rhodes, Jr. Although suitable for maintaining a tamper-resistant closure of the cover door, the arrangement disclosed in that patent only restricts the opening of the door initially--it does not limit the speed of the cover door as it swings open. Rather, once the hook and loop tape separates, the door is free to swing open with as much force as is imparted to it by the expanding air bag.
SUMMARY OF THE INVENTION
The present invention provides an air bag cover door assembly that opens upon inflation of an underlying air bag in a desirable and predetermined manner. The assembly includes an interior trim structure having an air bag deployment opening and an air bag cover door in the opening that is pivotally attached to the interior trim structure along a first edge of the cover door. The cover door has opposed second and third edges that extend away from the first edge and that are releasably attached to the interior trim structure proximate the first edge. The cover door can be held closed at a section of the cover door located remotely from the first edge in a conventional manner.
The cover door can be releasably fastened to the interior trim product using any of a number of fastening schemes, including hook and loop tape, pin and knob fasteners, releasable adhesives, or mechanical interlocks. The releasable fastener provides resistance to complete opening of the cover door, giving the cover door a predetermined opening characteristic in which preparation of a portion of the cover door from the interior trim structure is hindered. Consequently, when the cover door opens, it initially hinges about a line extending generally between the releasable fasteners at the second and third edges. As the air bag continues to expand through the deployment opening, the fasteners separate with some of the force imparted by the expanding air bag to the cover door being used to provide the force needed for this separation. As a result, the speed (and, thus, momentum) of the cover door is reduced as it swings open. This arrangement is particularly advantageous when utilized in a top mount location of a vehicle dashboard because it helps direct the air bag rearwardly toward the front passenger seat and it limits the speed of the cover door to reduce and/or eliminate the incidence of windshield breakage. Other predetermined opening characteristics can be provided by changing, for example, the location of the fasteners and/or the separation force of the fasteners.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred exemplary embodiment of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements, and:
FIG. 1 is a perspective view of an automobile dashboard incorporating a preferred embodiment of the air bag cover door assembly of the invention;
FIG. 2 is a cross-sectional view taken along the 2--2 line of FIG. 1;
FIG. 2A is an enlarged fragmentary perspective view showing a hook and loop fastener used in connection with the embodiment of FIG. 2;
FIG. 3 is a top view of the cover door assembly of FIG. 1 with the air bag cover door removed;
FIG. 4 is a perspective view showing the initial opening of the air bag cover door of FIG. 1;
FIG. 5 is a cross-sectional view taken along the 5--5 line of FIG. 4;
FIG. 6 is a perspective view showing the air bag cover door of FIG. 1 near its fully opened position;
FIG. 7 is a cross-sectional view taken along the 7--7 line of FIG. 6; and
FIG. 8 is an enlarged, cross-sectional view showing a mechanical interlock that can be used as a releasable fastener with the embodiment of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an air bag cover door assembly 10 for an automobile air bag restraint system is shown. Cover door assembly 10 includes a closure panel or cover door 12 that fits within an air bag deployment opening 14 that is located in a top (horizontal) surface 16a of an automobile dashboard or instrument panel 16. Deployment opening 14 has a rectangular shape and cover door 12 has a corresponding shape that closely conforms to the rectangular shape of opening 14. In particular, cover door 12 has a front edge 12a located proximate a front windshield 18, a rear edge 12b located proximate rear surface 16b of dashboard 16, and a pair of opposed side edges 12c and 12d that extend between front edge 12a and rear edge 12b. As will be described in greater detail below, cover door 12 is pivotally mounted along its front edge 12a so that expansion of an underlying air bag causes cover door 12 to swing upwardly about front edge 12a to permit deployment of the air bag through opening 14.
As will be appreciated from the preceding paragraph, the adjectives used to indicate spatial relationships (e.g., top, horizontal, rear, front) indicate spatial relationships as they exist when the components of cover door assembly 10 are located in their intended orientation with the automobile. Thus, for example, rear edge 12b is so named because it is the edge of cover door 12 that is closest to the rear of the automobile when cover door 12 is installed in the automobile in its intended orientation. This convention is utilized throughout the specification and claims. Also, although cover door assembly 10 is shown being located in a top mount position, it will of course be appreciated that the deployment opening could be located on rear surface 16b of dashboard 16 or at another location, depending upon the desired location of the air bag unit. Moreover, other tear seam configurations could be used, such as an H-shaped tear seam, which could be formed from two U-shaped doors.
In accordance with the present invention, cover door 12 is releasably fastened to a substructure of dashboard 16 in such a manner as to provide a predetermined opening characteristic; specifically, an opening characteristic in which separation of the front section of the cover door (i.e., the section of cover door 12 proximate edge 12a) from the substructure is hindered. This resistance to separation can be provided by a releasable fastener, such as hook and loop tape, connecting the cover door and substructure along sides 12c and 12d proximate side 12a. This results in some of the force imparted by the expanding air bag to the cover door being used to overcome the resistance of the cover door from further pivoting once it has partially opened, thereby reducing the speed (and, thus, momentum) of the cover door as it swings upwardly and towards the windshield. This construction also helps direct the air bag rearwardly toward the front passenger seat, rather than upwardly toward the roof. This feature of the invention is described in greater detail below.
Referring now to FIGS. 2 and 3, the details of construction and operation of cover door assembly 10 will now be described. As shown in FIG. 2, cover door assembly 10 includes cover door 12, hook and loop fastener 20, a hinge or tether 22, and a substructure, such as a recessed rim 24 of a pad retainer 26 of dashboard 16. Below cover door 12 is an air bag unit 28, comprising an uninflated air bag 30 and a gas generator 32 located in a casing 34 that is mounted underneath dashboard 16 in a conventional manner. Gas generator 32 has a plurality of openings 32a through which a suitable gas is expelled to inflate air bag 30. Vehicle impact is detected by an impact sensor 36 which signals a controller 38 to initiate gas generation, as is well known to those skilled in the art. Air bag 30 is connected about generator 32 to casing 34 so that the gas flows from generator 32 into the interior 30a of air bag 30, resulting in expansion of air bag 30. Casing 34 includes rigid sidewalls which insure that expansion of air bag 30 will be through opening 14 rather than into other areas underlying dashboard 16. Cover door 12 is secured within opening 14 at rear edge 12b by a releasable fastener 40 that separates under the pressure exerted by the expanding air bag. Preferably, fastener comprises a hook and loop tape closure arrangement (one half of which is shown in FIG. 3) constructed according to the teachings of U.S. Pat. No. 5,161,819, issued Nov. 10, 1992 to R. D. Rhodes, Jr., the disclosure of which is hereby incorporated by reference. Any other suitable arrangement for securing cover door 12 in a closed position can be used without departing from the scope of the present invention.
Cover door 12 is a composite article having a vinyl outer skin 42, a rigid insert 44, and an intermediate foam layer 46. Outer skin 42 and insert 44 are typically pre-formed and can thereafter be made integral with foam layer 46 in various ways that are known to those skilled in the art. In the illustrated embodiment, outer skin 42 has edge portions 42a that are formed over peripheral edges 44a of insert 44 with foam layer 46 located therebetween. Outer skin 42 can be a polyvinyl chloride, such as plastisol or drysol, a thermoplastic urethane, or an acrylonitrile-butadiene-styrene (ABS) resin and can be formed by processes such as those disclosed in U.S. Pat. Nos. 4,664,864, issued May 12, 1987 to J. M. Wersoskey, and 4,784,911, issued Nov. 15, 1988 to J. C. Gembinski et al. Insert 44 can be preformed as described, for example, in U.S. Pat. No. 4,734,230, issued Mar. 29, 1988 to R. D. Rhodes, Jr. et al. The preformed outer skin 42 and insert 44 can then be placed on opposing inner surfaces of a mold and bonded together by the formation of foam layer 46 therebetween. Such a process is described in U.S. Pat. No. 4,743,188, issued May 10, 1988 to J. D. Gray et al. The disclosures of the patents referenced in this paragraph are hereby incorporated by reference.
Dashboard 16 has a construction that is similar to cover door 12. It has an outer skin 48 surrounding a foam layer 50. Outer skin 48 is attached at its lower surface 48a to pad retainer 26 which provides structural integrity to dashboard 16. Cover door 12 and dashboard 16 are matched in terms of color, aesthetic detailing, and resiliency so as to minimize the effect of cover door 12 on the aesthetic quality of the automobile's interior.
Cover door 12 is secured within opening 14 to hinge 22 and recessed rim 24. As best seen in FIG. 3, rim 24 partially circumscribes deployment opening 14. It includes a rear section 24b extending along rear edge 14b of opening 14 and opposed side sections 24c and 24d that extend along respective edges 14c and 14d of opening 14. Hinge 22 is a co-planar extension of pad retainer 26 that is located along front edge 14a of opening 14. It includes a plurality of spaced apertures 52 by which it is secured to cover door 12 using rivets 54.
Fastener 20 comprises two complementary components--hook tape 20a and loop tape 20b. Hook tape 20a is adhered or otherwise secured to section 24d of rim 24 at a location proximate front edge 14a of opening 14. Similarly, loop tape 20b is adhered or otherwise secured to the surface of insert 44 along a portion of edge 12d of cover door 12 so as to mate with hook tape 20a. A second fastener 56 releasably fastens cover door 12 to pad retainer 26 along a portion of side 12c of cover door 12 that is proximate front edge 12a of cover door 12. Fastener 56 comprises hook tape 56a attached to section 24c of rim 24 and loop tape 56b (not shown) attached to insert 44 along edge 12c of cover door 12. Hook and loop tape fasteners 20 and 56 can be, for example, that sold under the trademark Velcro by Velcro U.S.A., Inc. of Manchester, N. H. If desired, an adhesive can be added between the hook tape and loop tape of fasteners 20 and 56 to further strengthen the adhesion of these tapes together.
It will of course be appreciated that other means of providing a predetermined opening characteristic could be utilized. For example, hinge 22 could be constructed so as to resist pivoting of cover door 12 to thereby direct the air bag rearwardly and slow the speed of the cover door. As another example, cover door 12 could include a metal retainer that is hinged or preweakened along a plurality of spaced lines running across the cover door parallel to front edge 12a so that cover door 12 "rolls" or "curls" as it is forced open upon deployment of the air bag.
Referring now to FIGS. 4-7, the opening characteristic of cover door 12 will be described. As shown in FIGS. 4 and 5, expansion of air bag 30 (not shown) initially causes fastener 40 to separate and rear edge 12b of cover door 12 to pivot upwardly about a line 58 extending generally between the rear-most edges of fasteners 20 and 56. This helps direct the expanding air bag rearward towards the front passenger seat. As the force of the expanding air bag increases, fasteners 20 and 56 begin to separate at their rear-most edges. This separation of cover door 12 from rim 24 is achieved using some of the force imparted to cover door 12 from the expanding air bag, resulting in the speed at which cover door 12 swings open being less than it would be otherwise. As shown in FIGS. 6 and 7, progression of the separation of fasteners 20 and 56 is forwardly toward edge 12a of cover door 12. The air bag continues to expand through opening 14 until fully deployed, by which time cover door 12 has fully opened with fasteners 20 and 56 having completely separated.
As will be appreciated, the opening resistance provided by fasteners 20 and 56 not only helps direct the air bag toward the front passenger seat, but also limits the speed of cover door 12 so as to reduce and/or eliminate the incidence of windshield breakage. The hinging of cover door 12 along line 58 may also help limit the speed of cover door 12. The stiffness of cover door 12 is selected in relation to the holding force of fasteners 20 and 56 such that the cover door initially hinges along line 58. Cover door 12 (e.g., insert 44) can be preweakened along line 58 if desired to aid in this intermediate hinging action.
As will be appreciated by the foregoing discussion of the operation of cover door assembly 10, fasteners 20 and 56 together comprise a means for limiting the speed of cover door 12 as it opens in response to air bag 30 being deployed through opening 14. It will of course be appreciated that other means could be used for limiting the speed of the cover door as it is forced open by expansion of air bag 30. For example, other tear apart fastening arrangements could be used, such as tear apart fasteners using a pin and knob interface, or an adhesive that bonds cover door 12 to instrument panel 16 along all or part of sides 12c and 12d and that is selected so that the force exerted by the expanding air bag is sufficient to overcome the adhesive bond. Optionally, a mechanical interlock 60 such as that shown in FIG. 8 could be used. Mechanical interlock 60 includes a metal channel 62 that is secured to instrument panel 16 and that runs along one of the side edges of cover door 12. A metal tab 64 having an expanded head portion 66 is secured to cover door 12 along the same side edge. Head portion 66 runs along and is captured within channel 62 by a pair of ears 68 that extend along the length of channel 62. Upward force on cover door 12 by an inflating air bag causes ears 68 to be pressed outwardly as head portion 66 is pulled out of channel 62. Other such variations will become apparent to those skilled in the art.
Of course, the substructure to which cover door 12 is connected need not necessarily be a part of dashboard 16. Rather, it could be a part of air bag unit 28. For example, rim 24 and/or hinge 22 could be formed as part of casing 34 so that the dashboard does not form a part of the air bag cover door assembly. Optionally, the cover door, or portions thereof, could be formed as a unitary part of the dashboard, as in U.S. Ser. No. 07/985,916, assigned to the assignee of this application and hereby incorporated by reference. For example, a pair of doors that open along an "H" shaped line could be used, with outer skin 42 of cover door 12 and outer skin 48 of dashboard 16 being formed as a unitary article. In this embodiment, a predetermined door opening characteristic can be implemented by providing a tear seam only running along the common boundary of the two doors. Then, upon deployment of the air bag, the outer skin will separate readily along this tear seam, but the necessary tearing of the outer skin along the opposing sides of the two doors will be through the full thickness and strength of the outer skin and will operate to limit the speed of the doors as they open.
It will thus be apparent that there has been provided in accordance with the present invention an air bag cover door assembly which achieves the aims and advantages specified herein. It will of course be understood that the foregoing description is of a preferred exemplary embodiment of the invention and that the invention is not limited to the specific embodiment shown. Various changes and modifications will become apparent to those skilled in the art. For example, rather than fasteners 20 and 56 providing opening resistance at the front section of cover door 12, the opening resistance could be distributed only at the initial opening of the cover door (i.e., near its rear edge) or throughout the opening of the cover door, depending upon the opening characteristic desired for a particular application. All such variations and modifications are intended to come within the scope of the appended claims. | An air bag cover door assembly utilizes a releasable fastener along each side of the air bag cover door to provide a predetermined opening characteristic for the cover door. The fasteners can be hook and loop tape, mechanical interlocks, adhesive strips, etc., with one half of each fastener secured to the inside surface of the cover door and the other half secured to a substructure, such as a dashboard pad retainer, in mating engagement with the first half. The fasteners are located along the sides of the cover door proximate the hinging axis of the cover door so that expansion of the air bag causes the cover door to initially hinge along a line extending between the engaged fasteners and then causes the fasteners to separate, allowing the cover door to swing open fully about its hinging axis. This reduces the speed of the cover door as it fully opens, thereby directing the air bag rearwardly toward the occupant and reducing the possibility of windshield breakage when the cover door assembly is used in a passenger side, top mount position of an automobile. | 1 |
REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the filing date of EP Patent Application Serial No. EP 11 164 940.6 filed 5 May 2011 and U.S. Provisional Patent Application Ser. No. 61/482,909 filed 5 May 2011, the disclosure of both application are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to the supply of power to field devices. In particular, the present invention relates to a charging-current regulating device for regulating an input current of a field device and for regulating a charging current for charging an energy storage device for the field device, to a field device with a charging-current regulating device, and to a method for regulating a charging current for charging an energy storage device for a field device.
BACKGROUND
Field devices are, for example, used in measuring and automation engineering. In order to be prepared independently of an electricity supply by way of an electricity grid or for the case of a power outage, field devices may comprise an energy storage device that makes it possible to operate the field device independently of an electricity supply by way of an electricity grid. The term “energy storage device” may, for example, refer to rechargeable batteries.
In particular, the term “energy storage device” may refer to rechargeable batteries which during operation of the field device are charged by way of an electricity grid.
SUMMARY OF THE INVENTION
In field devices the input current load is limited, for example, by protective circuits for measures relating to electromagnetic compatibility, or by reverse-polarity protection circuits (hereinafter referred to as “input protection circuits”).
Stated are a charging-current regulating device for charging an energy storage device for a field device and for regulating a charging current for the energy storage device, a field device with a charging-current regulating device, as well as a method for regulating a charging current according to the characteristics of the independent claims. Developments of the invention are set out in the subordinate claims and in the following description.
Many of the characteristics described below with reference to the charging-current regulating device may also be implemented as method-related steps and vice versa.
According to a first aspect of the invention, a charging-current regulating device for charging an energy storage device for a field device and for regulating a charging current for the energy storage device is stated, which charging-current regulating device comprises a control unit, a regulating unit and a switching regulator.
In switching regulators for charging circuits for charging rechargeable batteries the input current depends on the input voltage and on the output power. With an increase in the input voltage and with a constant output power of a switching regulator, the input current that is used to charge the energy storage device drops without regulation.
With the drop in the input current of the switching regulator the entire current draw of the field device, which comprises the switching regulator and the charging circuit for the energy storage device, drops so that any input protection circuit in this case is no longer used to capacity. Accordingly, the output power of the switching regulator, on which output power the charging time of the energy storage device depends, can be increased, which results in turn in an increased current draw of the field device so that the input protection circuit of the field device is used to capacity.
In this manner the charging process of the energy storage device, for example of rechargeable batteries, may be accelerated, and at the same time overloading input protection circuits of the field device may be prevented.
The components in the input protection circuit may be designed for the maximum load case. With a specified output power of a switching regulator for a charging circuit this is the case with a low input voltage, because in turn a high input current is necessary in order to attain the specified output power. In contrast to this, the input current of a switching regulator for loading rechargeable batteries drops with an increase in the input voltage and with the output power remaining constant.
In the high input voltage range, which is tantamount to a low input current with a specified output power, an input protection circuit is not used to maximum capacity, and consequently a rechargeable energy storage device that is to be charged, for example rechargeable batteries, may not be charged at the fastest possible rate.
The control unit is used to specify a command variable for the regulating unit. The command variable may, for example, be a maximum-permissible input current for an input protection circuit of the field device. The control unit may be configured manually or in an automated manner in that the command variable is adjusted, for example depending on external parameters, for example an ambient temperature of the field device.
The regulating unit may be designed to regulate the input current of the switching regulator for charging the energy storage device in that from the regulating unit a control variable is transmitted to the switching regulator.
However, the regulating unit can also be designed to transmit a control variable to an electrical consumer of the field device so that the electrical consumer reduces its current draw, and consequently, in turn, the input current of the field device is reduced so that an input protection circuit of the field device is not overloaded, or with the input current remaining constant the charging current may be increased.
The switching regulator may specify an input voltage and an input current for a charging circuit that carries out a charging process of the energy storage device of the field device.
The input current of the electrical consumer and the input current of the switching regulator for charging the energy storage device specify the entire input current of the field device, which input current flows through the input protection circuit of the field device.
Thus the input current of the field device may be regulated in that the regulating unit adjusts the input current of the switching regulator or the input current of the electrical consumer.
By way of the control unit for the regulating unit it may be possible to specify whether and in what manner the input current of the electrical consumer and/or the input current of the switching regulator for charging the energy storage device are/is to be adjusted.
According to a further aspect of the invention, a charging-current regulating device for charging an energy storage device for a field device and for regulating a charging current for the energy storage device without in this process a limiting value relating to an input current of the field device being exceeded is stated. In this arrangement, the charging-current regulating device may comprise a current sensing resistor or a corresponding device, an operational amplifier or a corresponding device and a switching regulator or a corresponding device.
The input current of the field device can flow through the current sensing resistor, and consequently a corresponding voltage drops at the current sensing resistor. The voltage that drops at the current sensing resistor may be used as the input voltage for the operational amplifier. Furthermore, an output value of the operational amplifier can be fed to the switching regulator so that a pick-up current or an output current of the switching regulator can be altered. In this arrangement the switching regulator is controlled by the operational amplifier in such a manner that the pick-up current or the output current of the switching regulator is altered in such a manner that the input current of the field device, which input current flows through the current sensing resistor, does not exceed the limiting value of the input current of the field device.
The input current of the field device or the pick-up current or the output current of the switching regulator represent the variable to be controlled, and thus the controlled variable.
The operational amplifier in conjunction with the current sensing resistor represents a regulator or a regulating unit. The command variable of the regulator is the limiting value of the input current of the field device.
The actual value of the input current of the field device is determined indirectly by way of a dropping voltage on the current sensing resistor, wherein the voltage dropping at the current sensing resistor is caused by the input current of the field device, which input current flows through the current sensing resistor.
From a comparison of the setpoint value of the input current of the field device with the actual value of the input current of the field device, on the operational amplifier an output signal is caused that can serve as a control variable for the current draw of the switching regulator so that from an adjustment of the pick-up current or of the output current of the switching regulator an adjustment of the input current of the field device results.
An output value of the operational amplifier can of course also be fed to an electrical consumer of a field device so that an input current of the electrical consumer is regulated, and consequently the input current of the field device is also adjusted.
A control unit can be connected to the operational amplifier in such a manner that a setpoint value relating to the input current of the field device is specified.
According to a further embodiment of the invention, the operational amplifier is switched as a differential amplifier so that a voltage differential present at two inputs of the operational amplifier is output, weighted by an amplification factor, at an output of the operational amplifier.
The difference between a setpoint value relating to the input current of the field device and the actually measured value of the input current of the field device thus causes the output value of the operational amplifier, which output value serves as the control variable for the current draw of the switching regulator and/or of the electrical consumer of the field device.
According to a further embodiment of the invention, the current sensing resistor is an ohmic resistor.
A charging-current regulating device as described above and below is particularly suitable for use in field devices that are operated with direct current and in a direct voltage range of, in particular, 12 volts, 24 volts or 32 volts.
Of course, operation at any other voltage values and current values may also be possible.
According to a further aspect of the invention, a field device is stated that comprises a charging-current regulating device as described above and below.
According to a further embodiment of the invention, the field device furthermore comprises an input protection circuit, an energy storage device, at least one electrical consumer and a charging circuit.
In this arrangement the input protection circuit represents a limiting factor for an input current load of the field device. In other words, an excessive input current load can result in damage to the input protection circuit.
The energy storage device is designed to supply the electrical consumer with electrical power.
The charging circuit is designed to supply the energy storage device with energy in such a manner that the energy storage device stores the supplied energy, wherein the charging-current regulating device regulates the charging current supplied to the charging circuit.
The input protection circuit can, for example, comprise measures relating to electromagnetic compatibility or measures relating to reverse polarity protection.
Any component can be used as an energy storage device, which component is suitable to store electrical power, in particular in chemical form. In this arrangement, the energy storage device is used to provide energy in order to operate the field device away from access to an electrical grid or in the case of a power outage.
The at least one electrical consumer of the field device can, for example, be a measuring device or an evaluation device for data acquired by a measuring device.
For example, the measuring device can be a fill level sensor, a pressure sensor or a flow sensor. Of course, for example, sensors for any physical size can be in a field device as described above and below.
However, the electrical consumer can also be an evaluation unit that receives a number of acquired values with at least one measured value, and can further process them, for example for transmission to a further evaluation unit, but can also prepare them for subsequent processing.
Of course, the field device as described above and below can also comprise a multitude of electrical consumers, for example a multitude of sensors and/or, for example, a multitude of evaluation units.
The charging circuit is designed to be supplied with energy by the switching regulator of the charging-current regulating device in such a manner that the energy storage device connected to the charging circuit is charged.
In this arrangement the charging-current regulating device regulates the charging current of the charging circuit and the current draw of the at least one electrical consumer so that a maximum-permissible load of the input protection circuit is not exceeded, while the energy storage device is nevertheless charged as quickly as possible.
A charging-current regulating device as described above and below enables the energy storage device to be charged as quickly as possible because the charging current can be regulated depending on the current consumed by the at least one electrical consumer so that at all times the maximum current supply capacity of the field device can be utilized, taking into account the maximum load of the input protection circuit.
According to a further embodiment of the invention, the energy storage device is a unit of rechargeable batteries.
In this arrangement, the unit of rechargeable batteries can comprise at least one rechargeable battery, but also a multitude of rechargeable batteries.
According to a further embodiment of the invention, the electrical consumer of the field device is a fill-level measuring device.
According to a further embodiment of the invention, the electrical consumer of the field device is a flow measuring device.
According to a further embodiment of the invention, the electrical consumer of the field device is a pressure measuring device.
Of course, apart from the measuring devices, the field device as described above and below can also comprise an associated evaluation unit. Furthermore, a field device as described above and below can comprise a multitude of measuring devices, also for various physical sizes.
The evaluation units can obtain the measured values from the measuring devices by way of wireless or wire-bound transmission of data. Of course, the evaluation devices can transmit processed data from the measured values also wirelessly or in a wire-bound manner to further evaluation units.
According to a further embodiment of the invention, the current draw of the electrical consumer can be altered in such a manner that the charging current for the energy storage unit and thus the input current of the field device can follow a specifiable value.
For example, the current draw of the electrical consumer can be regulated depending on the ambient temperature, the input voltage or other external physical values as well as depending on the charge state of the energy storage device.
Regulating the current draw of the electrical consumer can, for example, take place in that a control unit undertakes prioritization of the charging process of the energy storage device by way of the regulating unit.
According to a further embodiment of the invention, the specifiable value relating to the charging current of the energy storage device can be kept constant.
Thereby the current draw of the electrical consumer is also to be kept constant by the regulating unit to the extent that the sum of the charging current and of the current draw of the electrical consumer corresponds to the maximum input current of the field device by way of the input protection circuit.
Of course, both the charging current for the energy storage device and the current draw of the electrical consumer can be regulated in such a manner that the sum of the charging current and of the current draw of the electrical consumer corresponds only to part of the maximum input current of the field device. In order to determine the maximum input current, which can, of course, also vary over time, the control unit can use external parameters, for example the ambient temperature, for regulating the charging current and the current draw of the electrical consumer.
In particular, it may be possible for the maximum load of the input protection circuit to vary with an input current, and for the pick-up of the charging current to be regulated in such a manner that the size of the charging current value follows a varying value of the input current.
According to a further aspect of the invention, a method for regulating a charging current is stated, which method in a first step acquires an input current of a field device, and in a second step regulates a charging current so that the sum of the charging current and of the current draw of an electrical consumer does not exceed a specifiable value relating to the input current.
According to a further embodiment, the method, furthermore, comprises the step of regulating the current draw of an electrical consumer.
Of course, both the charging current and the current draw of the electrical consumer can be regulated individually and/or jointly.
A charging-current regulating device, as described above and below, for charging an energy storage device for a field device measures the input current of the field device and regulates, for example on a clocked charging circuit, the charging current for the energy storage device in accordance with the input current measured. With a constant output power of the charging circuit and a rising input voltage on the charging circuit, a dropping charging current would result, which would lead to a dropping input current of the field device. The charging-current regulating device recognizes the dropping of the input current of the field device and regulates the charging circuit for the energy storage device in such a manner that the charging current and thus the input current of the field device rise. Thus an input protection circuit of the field device can, for example, be subjected to a constant input current, or can also be utilized to its maximum.
The charging-current regulating device as described above and below may also be utilized to dimension input protection circuits for smaller input currents, because the charging-current regulating device can be designed not only to increase the charging current, but also to limit it to a specifiable maximum value. Quick charging of the energy storage device of the field device is nevertheless possible, because the charging-current regulating device as described above and below is suitable for using any current differential between the actual current draw of an electrical consumer of the field device and the maximum-possible input current of the field device as a charging current for the energy storage device.
Below, exemplary embodiments of the invention are described with reference to the figures.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a field device with a charging-current regulating device according to an exemplary embodiment of the present invention.
FIG. 2 shows a field device with a charging-current regulating device according to a further exemplary embodiment of the present invention.
FIG. 3 shows a flow chart of a regulating method according to an exemplary embodiment of the present invention.
FIG. 4 a shows a field device with an electrical consumer according to a further exemplary embodiment of the present invention.
FIG. 4 b shows a field device with an electrical consumer according to a further exemplary embodiment of the present invention.
FIG. 4 c shows a field device with a further electrical consumer according to an exemplary embodiment of the present invention.
FIG. 5 shows a flow chart of a method for charging-current regulating according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
The illustrations in the figures are diagrammatical and not to scale.
If in the following description of the figures identical reference characters are used, they relate to identical or similar elements.
FIG. 1 shows a field device 10 according to an exemplary embodiment of the invention. The field device 10 comprises a charging-current regulating device 100 , an input protection circuit 101 , an energy storage device 105 and an electrical consumer 106 .
The charging-current regulating device 100 comprises a regulating unit 102 , a control unit 103 and a switching regulator 104 .
The field device 10 is supplied with the voltage U E and the current I E by way of the input protection circuit 101 . The regulating unit 102 receives from the control unit 103 a command variable, namely the setpoint value of the input current I E , and can, by way of a control variable, act on the switching regulator 104 or the electrical consumer 106 in such a manner that either the switching regulator 104 alters a pick-up current I L or an output current I A , or the electrical consumer 106 alters a current draw I V . The output current I A of the switching regulator 104 corresponds to the charging current for the energy storage device 105 .
The regulating unit 102 can be designed in such a manner that it outputs a control variable to the switching regulator 104 and/or to the electrical consumer 106 . The dashed line from the regulating unit 102 to the electrical consumer 106 shows that this control variable is optional. The current draw I V can be regulated as an alternative or in addition to the pick-up current I L or the output current I A of the switching regulator 104 .
FIG. 1 shows that the sum of the currents I V and I L essentially corresponds to the input current I E . Any differences can be caused by the current draw of the components.
FIG. 2 shows a field device 10 according to a further exemplary embodiment of the invention. The field device 10 comprises an input protection circuit 101 , a switching regulator 104 , an energy storage device 105 and an electrical consumer 106 .
In FIG. 2 the regulating unit 102 is implemented by means of the current sensing resistor R 201 and the operational amplifier 202 .
The input current I E is fed through the input protection circuit and the current sensing resistor 201 , wherein as a result of the through-flowing input current I E the voltage U R at the current sensing resistor 201 drops. The operational amplifier 202 can be operated with the voltage U R as an input voltage and is connected to the switching regulator 104 in such a manner that an output signal of the operational amplifier 202 is fed to the switching regulator 104 in such a manner that the switching regulator 104 can adjust the pick-up current I L or the output current I A depending on the output signal of the operational amplifier 202 in such a manner that the input current I E also changes.
The following correlation applies to the input current I E : with a rising input current I E , for example as a result of a rising charging current I L , the voltage U R on the current sensing resistor R 201 rises, and thus the output signal of the operational amplifier 202 , which signal is fed to the switching regulator 104 , rises. The higher output signal of the operational amplifier 202 has the effect, in the switching regulator 104 , of the pick-up current I L or the output current I A dropping, which results in a drop of the input current I E so that the voltage U R on the current sensing resistor R 201 also drops, which in turn results in an adjustment of the output signal of the operational amplifier 202 .
Of course, the operational amplifier 202 can be switched in such a manner that an output signal of the operational amplifier 202 either behaves so as to be proportional, or so as to be inversely proportional, to the voltage U R . In other words, this means that the output signal of the operational amplifier 202 in the first case also rises with a rising voltage U R (which at the same time means that a dropping voltage U R causes a dropping output signal) and in the second case drops as the voltage U R rises (which at the same time means that a dropping voltage U R causes a rising output signal).
The switching regulator 104 can be designed in such a manner that it adjusts a pick-up current I L as described above and below.
Of course, a setpoint value relating to the input current I E can be specified to the operational amplifier 202 , wherein the setpoint value relating to the input current I E is set indirectly, by way of specifying a reference voltage with which the voltage U R is compared. Specifying the setpoint value can take place by way of a control unit.
Of course, the operational amplifier 202 can also convey its output signal to the electrical consumer 106 , wherein the electrical consumer 106 can be designed in such a manner that this output signal of the operational amplifier 202 can be used as a control variable for adjusting the method of operation of the electrical consumer and thus for adjusting the current consumption and the current draw I V .
Adjusting the method of operation of the electrical consumer as described above and below can, in particular, take place in that a data acquisition rate relating to the measured values is changed, or, optionally, in that energy-intensive calculation and evaluation operations are carried out.
In particular, the current draw of the electrical consumer as described above and below can be reduced if the data acquisition rate is reduced, and/or if energy-intensive calculation and evaluation operations are not carried out, or are carried out only to a reduced extent.
Reducing the data acquisition rate can take place in a stepped or in a stepless manner.
FIG. 3 shows a flow chart of a regulating method 300 according to an exemplary embodiment of the invention.
The current of the power supply P I is measured by means of a current measuring device 301 ; it is used as an input value relating to current regulating 303 . A voltage value, measured by means of the voltmeter 302 , is used as an input value relating to voltage regulation 304 . By way of the power supply regulated in this manner the energy storage device 105 is charged.
FIG. 4 a shows a field device 401 according to an exemplary embodiment of the invention.
The field device 401 comprises an input protection circuit 101 , a charging-current regulating device 100 , a charging circuit 420 , and an energy storage device 105 . Furthermore, the field device 401 comprises a fill level sensor 404 and an evaluation unit 410 . Of course, the field device 401 can also comprise a multitude of fill level sensors 404 and a multitude of evaluation units 410 .
The charging-current regulating device 100 regulates the charging current for charging the energy storage device 105 so that the sum of the charging current and a current draw of the fill level sensors 404 and of the evaluation units 410 does not exceed the maximum-permissible value of an input current of the field device.
The field device 401 can also be locally spaced apart from the fill level sensors 404 , wherein the fill level sensors 404 can transmit the measured values in a wireless or wire-bound manner to the evaluation units 410 .
FIG. 4 b shows a field device 402 according to a further exemplary embodiment of the invention. The field device 402 comprises an input protection circuit 101 , a charging-current regulating device 100 , a charging circuit 420 , an energy storage device 105 , a pressure sensor 405 and an evaluation unit 410 .
Like the field device 401 , the field device 402 also can comprise a multitude of pressure sensors 405 and a multitude of evaluation units 410 .
In all the field devices 10 , 401 , 402 , 403 as described above and below, the charging-current regulating device 100 can, of course, be used to regulate both the charging current for the energy storage device 105 and the current draw of the electrical consumer, for example of the sensors 404 , 405 , 406 and of the evaluation unit 410 .
FIG. 4 c shows a field device 403 according to a further exemplary embodiment of the invention.
The field device 403 comprises an input protection circuit 101 , a charging-current regulating device 100 , an energy storage device 105 , a charging circuit 420 , a flow sensor 406 , and an evaluation unit 410 .
The charging circuit 420 as described above and below, together with the switching regulator 104 , is used to supply the energy storage device 105 with charging current.
Of course, a field device as described above and below, can also comprise different sensors, for example a pressure sensor, a flow sensor and a fill level sensor. The measured values of the sensors can be acquired, processed and forwarded either by one evaluation unit 410 or by several evaluation units 410 .
FIG. 5 shows a method 500 for regulating a charging current according to an exemplary embodiment of the invention.
In a first step 501 acquiring an input current I E takes place. This is followed in a second step 502 by regulating a charging current I L wherein the sum of the charging current I L and of a current draw I V of an electrical consumer essentially corresponds to the input current I E of a field device, and the input current I E of a field device does not exceed a specifiable limiting value. In a third step 503 regulating the current draw I V of an electrical consumer takes place so that the input current I E of a field device does not exceed a maximum value.
In addition, it should be pointed out that “comprising” does not exclude other elements or steps, and “a” or “one” does not exclude a plural number. Furthermore, it should be pointed out that characteristics or steps which have been described with reference to one of the above exemplary embodiments can also be used in combination with other characteristics or steps of other exemplary embodiments described above. Reference characters in the claims are not to be interpreted as limitations. | Stated is a charging-current regulating device for charging an energy storage device for a field device, and for regulating a charging current for the energy storage device, wherein regulating the charging current for the energy storage device takes place in such a manner that a limiting value relating to an input current of the field device is not exceeded. Regulating the charging current may take place in such a manner that energy storage takes place as quickly as possible and without overloading an input protection circuit of the field device. | 7 |
BACKGROUND OF THE INVENTION
[0001] The subject invention is directed to a convertible waterproof and airtight cable splice enclosure assembly. Assemblies of the type under consideration are particularly suited for enclosing and housing fiber optic cables such as loose buffer and unitube type cables and will be described with particular reference thereto. However, the apparatus could equally well be used with other types of cables or wires such as, for example, hybrid cables including copper wire, twisted pair wire or co-axial cables.
[0002] Many different types of fiber optic cable enclosures are known in the prior art. These prior enclosures are satisfactory to a greater or lesser degree but often have-certain defects which make them inconvenient to use or prevent them from being readily adaptable to changing environments and conditions. One example of a optical fiber splice case that presents a significant improvement over the earlier devices found in the prior art is taught in U.S. Pat. No. 6,215,939, the teachings of which are incorporated herein by reference. In addition to providing improvements over the various prior art devices, the subject optical fiber splice case presents further significant new advances over the earlier apparatus as well.
[0003] Service providers (i.e. communication companies) are providing fiber optic links directly to a home, business, apartment, and even the farm. In order for service providers to keep their infrastructure costs low, a terminal enclosure must be provided to allow for ease of initial installation into service, and time savings for adding (linking) individual subscribers. Adding an individual subscriber is commonly referred to as providing a drop. Adding a drop in existing enclosure designs requires splicing on the fiber tray. This is achieved by removing an enclosure from its location and taking it into a temperature controlled environment. Highly skilled personnel then reenter the enclosure and use laser splicing equipment to add the new service (drop). While performing these tasks, any signals passing through the enclosure have the potential to be disturbed. This operation also requires the critical seals of the enclosure to be effected each time new service is added.
SUMMARY OF THE INVENTION
[0004] In accordance with one aspect of the invention, there is provided a convertible fiber splice enclosure including at least one enclosure base having a first cover member selectively sealingly engaged with at least one side of the at least one enclosure base. The at least one enclosure base includes a first bulkhead having a first plurality of spaced apart selectively removable webs defining a first set of ports therein for selectively receiving first incoming feed cables therethrough. The enclosure also includes a second bulkhead opposed to the first bulkhead. The second bulkhead has a second plurality of spaced apart selectively removable webs defining a second set of ports therein for selectively receiving second incoming feed cables therethrough.
[0005] In accordance with another aspect of the invention, there is provided an optical fiber splice case including at least one enclosure base having at least one cover member selectively sealingly engaged with at least one side of the at least one enclosure base. The at least one enclosure base includes at least one bulkhead member having a selective number of optical fiber ports therethrough.
[0006] In accordance with still another aspect of the invention, a convertible fiber splice enclosure is provided having a first enclosure base coupled to a second enclosure base. The enclosure further includes a first cover member selectively sealingly engaged with an exterior side of one of the first enclosure base and the second enclosure base. A second cover member is selectively sealingly engaged with an exterior side of another of the first enclosure base and the second enclosure base. At least one of the first and the second cover members includes selectively blocked ports for receiving connector housings therethrough.
[0007] In accordance with yet another aspect of the invention, an optical fiber splice case is provided including at least one enclosure base. The at least one enclosure base further includes at least one cover member having a plurality of fiber adapter ports adapted to sealingly receive fiber adapters. Each of the fiber adapters includes a fiber connector. The fiber connector and the splicing tray include a fiber jumper therebetween.
[0008] In accordance with still a further aspect of the invention, a method is provided for connecting fibers to a plurality of associated end users including the steps of, providing at least one fiber splice case having at least one hingedly retained cover member for accessing a splicing chamber and at least one bulkhead, providing the at least one bulkhead with a plurality of optical fiber ports, pivoting the at least one cover member and installing a feeder cable through the at least one bulkhead in the splicing chamber, feeding a selected number of drop wires through the fiber ports, and replacing the at least one cover member.
[0009] In accordance with yet a further aspect of the invention, a method is provided for connecting an optical fiber to a plurality of end users including the steps of, providing at least one optical fiber enclosure base having at least one hingedly retained cover member for accessing a chamber and at least one end plate, providing the at least one cover member with a plurality of fiber adapters, pivoting the at least one cover member and installing a feeder cable through at least one bulkhead in the chamber, the fiber adapters include connector couplers, connecting the fiber connectors on one side of the at least one cover with the splicing tray via a plurality of fiber jumpers, installing a plurality of dust covers on the other side of the at least one cover to the fiber adapters, replacing the at least one cover member, removing a selected number of dust covers from selected fiber adapters to expose a selected number of connector couplers, and attaching a selected number of drop wires to the selected connector couplers.
[0010] In accordance with still a further aspect to the invention an optical splice case is provided including a convertible fiber splice enclosure having at least one enclosure base and a first cover member selectively sealingly engaged with at least one side of the at least one enclosure base. The enclosure base includes a first bulkhead having a first plurality of spaced apart selectively removable webs defining a first set of ports therein. The enclosure base further includes a second bulkhead opposed to the first bulkhead and having a second plurality of spaced apart selectively removable webs defining a second set of ports therein. A plurality of selectively blocked ports is disposed on the first cover for receiving adapter housings for connecting to outgoing fiber cables.
[0011] Other advantages and benefits of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention may take physical form in certain parts and arrangement of parts, embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
[0013] FIG. 1 shows a perspective view of a first embodiment of a housing assembly intended for use with fiber optic cable;
[0014] FIG. 2 is a perspective view of the housing assembly of FIG. 1 with a cover in the open position;
[0015] FIG. 3 a is a perspective view of the cover member;
[0016] FIG. 3 b is an enlarged elevational view of the retention bolts securing a cover to the base in the retained position;
[0017] FIG. 3 c is an enlarged elevational view of the retention bolts securing a cover to the base in the secured position;
[0018] FIG. 4 is a perspective view of a housing assembly according to a second version of the first embodiment of the present invention;
[0019] FIG. 5 is an enlarged perspective view of the restraint bracket;
[0020] FIG. 6 is an enlarged perspective view of the restraint bracket;
[0021] FIG. 7 is an enlarged top perspective view illustrating the end plate;
[0022] FIG. 8 is an enlarged bottom perspective view illustrating the end plate;
[0023] FIG. 9 is an enlarged front perspective view illustrating the bulkhead of an enclosure base;
[0024] FIG. 10 is a bottom perspective view of the cover member according to the first embodiment of the housing assembly;
[0025] FIG. 11 shows a perspective view of a second embodiment of a housing assembly intended for use with fiber optic cable;
[0026] FIG. 12 is an exploded view of the subject convertible housing assembly illustrating interchangeable cover members;
[0027] FIG. 13 shows a perspective view of the second embodiment of a housing assembly intended for use with fiber optic cable;
[0028] FIG. 14 is an enlarged perspective partial view of the housing assembly of FIG. 13 ;
[0029] FIG. 15 shows a cover member in the opened position according to the second embodiment;
[0030] FIG. 16 is an enlarged inside perspective view of a plurality of connector housings according to the second embodiment;
[0031] FIG. 17 is a perspective view of the cover member of the housing assembly of FIG. 15 illustrating a pair of hinge legs and holes adapted to receive the enclosure base;
[0032] FIG. 18 shows an exploded assembly of two enclosure bases in a relative position just prior to joining according to a third embodiment of the present invention;
[0033] FIG. 19 is a perspective view of a first version of an assembly housing according to the third embodiment of the invention;
[0034] FIG. 20 is a perspective view of a second version of the assembly housing according to the third embodiment;
[0035] FIG. 21 is a perspective view of a third version of the assembly housing according to the third embodiment;
[0036] FIG. 22 is a top perspective view of the assembly housing of FIG. 21 ; and,
[0037] FIG. 23 is an enlarged perspective view of a shroud adapted to be used with non-hardened connectors.
DETAILED DESCRIPTION
[0038] Referring now to the drawings wherein the showings are for the purposes of illustrating embodiments of the invention only and not for purposes of limiting same, the overall construction of the subject fiber (i.e. optical) splice case, housing or enclosure assembly 10 , according to a first embodiment, can best be understood by reference to FIGS. 1-10 . As illustrated therein, the splice case assembly housing 10 comprises an enclosure base or splice case 12 , an enclosure cover member 14 , and an end plate 16 . The assembly housing 10 encloses a splice chamber or splice tray support area 20 and a drop chamber or a fiber jumper storage compartment 23 as shown. The housing assembly 10 formed by the cover member 14 , enclosure base 12 , and the end plate 16 are joined together in a sealed clamping relationship to define a somewhat flat truncated oval-shaped splice case volume area therein.
[0039] Although the housing body components and the end plates could be formed from a variety of different materials using different manufacturing techniques, in the subject embodiment, they are preferably injection molded from a suitable plastic, containing fibers for reinforcement. For example, fiber glass filled and reinforced polypropylene.
[0040] The enclosure base 12 includes a pair of bulkheads 26 , 28 at opposing ends. The bulkheads 26 , 28 include breakout webs 30 which can be selectively punched out from the bulkhead in order to create an opening or port 32 therethrough. The housing assembly 10 can be configured for butt or in-line configurations. For butt configurations, the closure cover 14 can be sealed against the enclosure base 12 without having an end plate 16 installed. For in-line configurations, the enclosure base 12 is adapted to receive end plates 16 at opposing ends which can be sealingly engaged with the cover member 14 . The housing assembly 10 , specifically the bulkheads 26 , 28 of the enclosure base 12 are adapted to selectively receive a grommet 40 whereby incoming feed or feeder cables 42 and outgoing drop wires 44 can extend selectively through the same port or opening 32 through the bulkheads 26 , 28 , or can extend through another opening through the bulkhead ( FIG. 4 ).
[0041] Referring now to FIG. 2 , the enclosure base 12 can include a splice tray 50 therein. The cover member 14 can be pivoted relative to the enclosure base 12 whereby access to the splice tray 50 is facilitated. It is to be appreciated that the cover member 14 can be hinged and pivoted either to the left or to the right. Referring to FIG. 3 , the cover member 14 can be secured to the enclosure base 12 with self-retaining mounting bolts 54 . Retaining sleeves 56 allow the bolts 54 to be retained in bolt mounts 58 along an outer edge 60 of the cover 14 while moving in a position to enable the cover 14 to pivot about the enclosure 12 . In FIG. 3 , the cover member 14 is shown including bolts 54 for engaging with the enclosure base 12 . The cover member 14 can also include a pair of hinge legs 62 (i.e. a pair on each side) which allow for the cover member 14 to remain attached to the enclosure base 12 after the mounting bolts 54 are disengaged from the enclosure base 12 . It is to be appreciated that each pair of hinge legs 62 enable cover 14 to selectively pivot to one side or the other when bolts 54 are disengaged from base 12 . Hinge legs 62 allow cover 14 to remain attached to base 12 after bolts 54 are disengaged from base 12 .
[0042] Referring now to FIGS. 5 and 6 , the housing assembly 10 can include a pair of restraint brackets 70 for anchoring the feed cables 42 . The restraint brackets 70 can include a self-tapping screw 72 for mounting to the enclosure base 12 . The restraint brackets 70 also include support ribs 74 that can engage splice trays 50 to increase stability.
[0043] Referring again to FIGS. 2 and 4 , the selective openings 32 through the bulkheads 26 , 28 are adapted to receive grommets 40 . The grommets 40 can be used for sealing incoming cables 42 or gel sealant can be wrapped around the incoming cables 42 . The grommets 40 can include a plurality of openings therethrough capable of accommodating a selected combination of incoming feed cables 42 and outgoing drop wires 44 . As shown in FIG. 7 , the end plate 16 can be mounted with mounting bolts 76 to the enclosure base 12 . The end plates 16 include sealing beads 78 to imbed into a gasket on the interior of the cover surface thereby sealingly engaging the grommets 40 . The enclosure base 12 also can include a tray support or storage bracket 80 . The storage bracket includes a retention post. The storage bracket 80 can pivot around the retention post 82 to allow fiber to be captured below the storage bracket 80 .
[0044] Referring now to FIG. 4 , an in-line configuration of the housing assembly 10 is shown. The in-line configuration includes incoming feed cables 42 and outgoing fiber drops 44 passing through both bulkheads 26 , 28 of the enclosure base 12 . It is to be appreciated that end plates 16 , best shown in FIGS. 7 and 8 , can be installed at each end of the enclosure base 12 over the respective bulkheads 26 , 28 .
[0045] Referring to FIG. 9 , bulkhead 26 is there displayed. A perimeter rib surface 90 seals against the cover to eliminate the end plate in a butt application. If access is desired through one or both ends of the enclosure base 12 , break out walls or webs 30 are selectively removed from the bulkhead 26 . A V-groove 94 around the perimeter of the break out web 30 creates a thin section conducive for breaking out the wall of the web 30 . Ribbed walls 96 around the break out web 30 reinforce the structure so that it does not break when the wall 30 is removed. It is to be appreciated that break out webs 30 can be left in place until needed.
[0046] The enclosure base 12 includes fastener holes 100 around a perimeter 102 for the cover member 14 attachment. The perimeter 102 also includes fastener holes 103 for stacking a pair of enclosure bases together, to be described hereinafter. The enclosure base 12 also includes flanges proximal to opposing bulkheads 26 , 28 for receiving the end plates 16 . The installation of the end plates 16 provides the continuation of a perimeter sealing ring when break out walls or webs 30 are removed. The enclosure base 12 also includes the perimeter sealing ring or rib 90 .which compresses against a cover member gasket 106 which can be mounted on the inside of the cover member 14 to form a seal therearound. Referring to FIG. 10 , the cover member 14 can include the cover member gasket 106 on the inside of the cover member 14 .
[0047] The enclosure base 12 can also provide for a base window or opening which can be either molded solid or selectively opened. In the opened arrangement, the base window can provide access between adjacent enclosure bases in an enclosure stack assembly, to be described hereinafter.
[0048] Referring again to FIGS. 2, 5 , and 6 , it is to be appreciated that the restraint brackets 70 include a slotted hole 120 for attachment to the enclosure base 12 . The restraint brackets 70 also include bracket legs 122 which can be bent outward to compensate for cable diameter ranges and can retain feeder cables 42 thereon. The restraint brackets 70 also include a plurality of slots 124 for retaining a strap that secures fiber splice trays 50 in the enclosure base 12 . The restraint brackets 70 provide support rib or protrusion member 74 that engages a corresponding groove 134 on splice trays 50 thereby increasing their stability within the-housing assembly 10 . The restraint brackets 70 include a pair of caps 136 for retaining a strength member of the feed cables 42 .
[0049] Referring now to FIGS. 11-17 , a second embodiment of a housing assembly is illustrated. As illustrated therein, a splice case housing assembly 210 adapted for hardened connectors can be configured for butt or in-line configurations. For butt configurations, a closure cover or cover member 214 is arranged to seal against the enclosure base 12 without having an end plate 16 installed. The housing assembly 210 can be reconfigured into an in-line enclosure by adding an end plate 16 to an opposing end of the enclosure base 12 and breaking out a selected number of webs 30 at the respective bulkhead. As will be described in more detail hereinafter, after initial installation of the feed fibers 42 and subsequent splicing to a back side of a hardened connector, the housing assembly 210 does not need to be reopened to provide service to a customer. This feature allows a lesser-trained installer to make the connection to the customer, thus reducing the future installation costs of the service provider.
[0050] The cover member 214 can include selectively blocked ports or molded over holes 220 adapted to receive connector (adapter) housings or fiber adapters 222 . Incoming feed cables 42 can pass through the bulkhead of the enclosure base 12 . The connector housings 222 can be covered with protective caps or dust covers 224 until a connection is desired. The protective caps 224 can be factory or field installed. As shown in FIGS. 13 and 14 , the connector housings 222 include couplers 223 which are adapted to matingly receive hardened connectors 226 , 227 . The hardened connectors 227 include a fiber drop wire 250 extending therefrom. Fiber jumpers 240 , including connectors 226 , can be connected to the back side of the connector housings 222 and routed onto the splice tray for connection to the feed cables 42 . As shown in FIGS. 15 and 16 , a threaded nut 242 can be provided for securing the connector housing 222 to the cover member 214 . It is to be appreciated that the fiber jumpers 240 , along with the connectors 226 mounted in connector couplers or feed thru adapter modules 223 , allow a signal to flow from the fiber jumper 240 out to the external fiber drop cable 250 .
[0051] As shown in FIG. 17 , the cover member 214 to be used with hardened connectors 226 , 227 can include a plurality of holes 220 which can be initially molded over, thereby eliminating the need to supply a connector housing 222 therein. As connectors are needed, the molded over holes 220 can be opened and a connector housing 222 received therein. The holes 220 include flat sides 252 which prevent rotation of the connector housing 222 during installation. The holes 220 can also include a recessed ring 254 for retention of an o-ring (not shown) thereby creating a seal between the connector housing 222 and the cover member 214 . The cover member 214 includes a pair of hinge legs 260 at opposing ends of one side, or both sides (not shown), and a plurality of mounting bolts 54 for engaging with the enclosure base 12 . The cover member 214 can also include a cover gasket (not shown) mounted to the inside surface of the cover member.
[0052] In order to connect the housing assembly 210 to an individual end user, an operator removes one or more of the dust covers 224 from the fiber adapters 222 to expose the fiber connector coupler 223 . The operator attaches the drop wire 250 including the hardened connector 227 thereon which has been prefitted with an internally threaded cap 272 . It is to be appreciated that the steps to connect an individual end user takes only a matter of minutes and does not disturb the integrity of the enclosure seals. The ease of connection allows an operator with less technical capability to add service (drops) to a plurality of customers in an extremely efficient manner without affecting signals passing through to other customers.
[0053] Referring now to FIGS. 18-23 , a third embodiment of a splice case housing assembly 300 is illustrated. As illustrated therein, a stacked design is provided which allows for two independent chambers to keep the feed side of the closure protected and/or secured from the installer adding drop fibers to the splice case housing assembly. The stacked design also provides for a secondary chamber which increases the drop capacity of the housing assembly. It is to be appreciated that either cover member 14 , 214 , described in the first and second embodiments, can be used on either side of the housing assembly 300 which allows the unit to be configured for non-hardened or hardened connectors. Each cover member 14 , 214 can have distinctive securing means thereby restricting access to one side of the housing assembly 300 if desired.
[0054] Referring now to FIG. 18 , a pair of enclosure bases 12 can be assembled together to form a housing assembly with two independent chambers. A base window 304 can be removed to allow for passing of fibers between the opposing chambers. Window gasket 306 can be captured between the enclosure bases 12 to seal the base window 304 openings. Fasteners 307 , 308 can be used to secure the enclosure bases 12 together.
[0055] Referring now to FIG. 19 , a first version of the housing assembly 300 according to the third embodiment is shown. The housing assembly 300 includes independent chambers whereby one chamber accommodates incoming feed cables and a standard cover member 14 . The other chamber comprises a drop chamber whereby a cover 214 including hardened connectors is provided.
[0056] FIG. 20 illustrates a second version whereby the housing assembly 301 includes a pair of cover members 214 in which both plates accommodate hardened connectors. By providing hardened connectors on both cover members 214 , an increase in drop capacity is provided. The enclosure bases 12 can be elongate defining a longitudinal axis 309 therethrough. A first set of bulkhead ports can be adapted to receive an associated first cable into the enclosure along a first insertion axis 310 . A second set of bulkhead ports can be adapted to receive an associated second cable into the enclosure along a second insertion axis. The first insertion axis and the second insertion axis can be generally parallel to and offset from the longitudinal axis 309 defined by the enclosure base 12 .
[0057] As best shown in FIG. 20 , it is to be appreciated that each cover 214 can be adapted to receive cables into the enclosure along third and fourth insertion axes 312 , 313 , respectively. The third insertion axis forms an angle 314 less than 90 degrees relative to the longitudinal axis 309 defined by its associated enclosure base. As shown, the angle is about 45 degrees. Similarly, the fourth insertion axis forms an angle 315 less than 90 degrees relative to the longitudinal axis 309 defined by its associated enclosure base. Also as shown, the angle is about 45 degrees. It is to be appreciated that the third insertion axis 312 is generally parallel to the fourth insertion axis 313 . The adapter housings can generally be arranged in rows and/or columns relative to the longitudinal axis 309 .
[0058] Referring now to FIGS. 21-23 , a splice case housing assembly 302 including a pair of enclosure bases 12 is illustrated and is adapted for non-hardened connectors. This embodiment allows for standard drop wire to be used for the outgoing drops. Also, this embodiment allows for a higher quantity of drop wire to exit the drop chamber versus the hardened connector version. In particular, the housing assembly 302 includes standard cover members 14 mounted on opposing sides of the pair of enclosure bases. Two independent chambers are formed, namely a drop chamber and a feed chamber. Incoming feed cables can be supplied through one of the enclosure bases. The incoming feed fibers can be spliced to fiber jumpers on the splice tray (not illustrated). Once spliced, the fiber jumpers can be routed through the base window into the drop chamber and connected to the back of the bulkhead plate. A shroud 320 , including a bulkhead plate 322 , is provided, thereby creating an area to splice fiber jumpers 323 to the outgoing fiber drops. The outgoing fiber drops are routed through apertures in the grommet and extend through the bulkhead of one of the enclosure bases 12 .
[0059] As shown in FIG. 22 , the shroud 320 covers the base window on the drop chamber side, thereby preventing tampering with a feed signal connection.
[0060] Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended that the invention be construed as including all such modifications and alterations as fall within the scope of the appended claims or the equivalents thereof. | An optical fiber splice case particularly adapted for providing fiber optic links directly to a home, business, et al. is provided wherein at least one enclosure base has at least one cover member selectively sealingly engaged with at least one side of the at least one enclosure base. The at least one enclosure base includes at least one bulkhead having a selective plurality of optical fiber ports therethrough. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/703,556, filed Sep. 20, 2013, entitled “Insurance Claim Capitation and Predictive Payment Modeling,” hereby incorporated by reference as to its entirety.
BACKGROUND
Automotive insurance claims are typically handled as follows. An insured makes a claim, the vehicle is inspected, and it is determined whether the vehicle is repairable or a total loss. If the vehicle is repairable, either an insurance adjuster or a repair facility determines an estimated cost for repairing the vehicle, based on the damage sustained to the vehicle. Thus, depending upon the vehicle and the type of damage, the estimated cost for various claims may take on a wide range of values.
Unfortunately, the estimation process itself is time-consuming, expensive, and often inaccurate. Estimation of repair value typically is performed by someone highly trained in the particulars of vehicle repair, and given the high work load and time involved in estimation, these persons are relatively expensive to maintain. And, because the estimation is just that—an estimation—the estimate is often later adjusted after the repair is completed to reflect actual repair costs. This can be inefficient for both the insurer and the repair facility and can sometimes result in lengthy negotiations between the parties. This, itself, can also be time-consuming and expensive, and can induce friction in the relationship between the insurance company and the repair facility.
SUMMARY
A claim-based capitation model is proposed for handling vehicle repair insurance claims. Rather than determining a detailed estimate of the expected actual cost of repair, the estimate may be determined using a simpler model. For example, the insurance company and a repair facility may agree to following a predictive payment model in which the insurance company pays a fixed predicted amount of money for each repair claim, regardless of the amount of repair work that will be needed. By the law of large numbers, it may be expected that an appropriately-determined fixed amount may, in the long term, result in a fair payment for both parties. Moreover, by potentially eliminating the detailed cost estimate and the post-repair negotiations, such a model may have the effect of reducing overall costs to both parties. For instance, repair shops may need fewer qualified estimation and negotiation resources, and insurance companies may also need fewer oversight and negotiation resources.
In a variation of the above model, the payment amount may not be entirely fixed across all vehicle claims, however the payment amount may be based on a pricing process that may be much simpler than the traditional estimation process. The pricing process may not even be based on an actual inspection of the vehicle. Rather, the amount to be paid to a repair shop for a given claim may be determined (e.g., predicted) based on a predictive and/or heuristic model. For instance, the amount to be paid may be determined based at least in part on one or more loss attributes of the claim, where each loss attribute may itself be associated with a particular fixed amount of money. Such loss attributes may include, for example, make, model, and/or year of the vehicle; type of damage or event (e.g., front-end collision, rear bumper damage, etc.), origin of manufacture of the vehicle (e.g., domestic, European, Asian, etc.); place of occurrence of the event; date of occurrence of the event; point of impact to the vehicle; volume and/or frequency of the particular claim type; and/or insurance coverage of the insured. These are merely examples, and so additional and/or alternative loss attributes may be used. As another example, the payment amount may be established by first classifying a claim into a range of payments that are applicable based on conditions to be assessed by the repair facility and validated by the insurance company. For example, a claim of front end damage may be classified in a range of $X to $Y, where the actual amount in that range ultimately depends upon whether the radiator must be replaced.
According to further aspects, the determined payment (e.g., the fixed payment or the loss-attribute-determined payment) may be paid to the repair facility up front. For example, the determined payment for a given claim may be paid to the repair facility before the repair has begun, before the vehicle has been received by the repair facility, or at any time during the claim. In further aspects, the payment may be provided even before the claim has been made by the insured. This may occur in a bulk process, for instance, where a repair facility is pre-paid for X number of repair claims per time period (e.g., per month, per quarter, or per year). If the repair shop is able to be paid earlier in the claims process, then the repair shop may be able to benefit from this such as by having the ability to invest the money in the business at an earlier stage. This may benefit both the repair facility and the insurance company in the long run, as it may allow the repair facility to make better business decisions, follow up with long-term planning with greater financial stability, and generally result in a potentially more cost-efficient repair business. Other potential benefits to the repair facility by receiving forecasted demand and prepayment for at least some types of repairs may ability to manage staff hiring and/or training, improved capacity to manage the parts supply chain, and/or improved capacity to manage parts costs.
These features are merely examples, and these and other features and details will be discussed below in the Detailed Description section of this paper. It is also noted that, while vehicle insurance claims are discussed in the various examples herein, the capitation models discussed herein may also be applied to other types of insurance claims, such as but not limited to homeowner insurance claims, renter's insurance claims, boat insurance claims, aircraft insurance claims, and personal property insurance claims in general.
BRIEF DESCRIPTION OF THE DRAWINGS
Some features herein are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements.
FIG. 1 is a block diagram of an example insurance claim environment that may be used in accordance with aspects as described herein.
FIG. 2 is a block diagram of an example computing device that may be used to embody or otherwise implement any of the elements and functions discussed herein.
FIG. 3 is a flow chart of an example process that may be performed in accordance with one or more aspects as described herein.
FIG. 4 is a flow chart of another example process that may be performed in accordance with one or more aspects as described herein.
FIG. 5 is a flow chart of still another example process that may be performed in accordance with one or more aspects as described herein.
DETAILED DESCRIPTION
FIG. 1 is a block diagram of an example insurance claim environment that may be used in accordance with aspects as described herein. The environment in this example includes an insurance company and one or more repair facilities. While only a single repair facility is shown in FIG. 1 , it will be understood that there may be multiple different repair facilities in the environment, and each may be configured such as in the manner of the shown repair facility. Each repair facility may be, for example, an automobile repair garage that is dedicated for that purpose or that is included as part of a larger business such as a car dealer, a tire dealer, a gas station, a store, or the like.
The insurance company may have or otherwise control one or more computing and data storage resources for performing various functions related to insurance claims processing. In this example, the insurance company may have or otherwise control at least a claim processing system 101 , a maintenance system 102 , a data storage system 103 , and an accounting system 107 . It will be understood that the insurance company is likely to have other types of systems as well. The repair facility may have or otherwise control a repair tracking system 104 , a data storage system 105 , and an accounting system 108 . Any of the systems of the insurance company and the repair facility may communicate with each other by sending information (e.g., electronically and/or physically) back and forth via a network 106 .
The various systems 101 , 102 , 104 , 107 , and 108 may include or otherwise be embodied as one or more computing devices, such as one or more servers, personal computers, tablet computer, and the like, and/or one or more humans performing various tasks. Moreover, while each of the elements 101 - 108 are shown in FIG. 1 as separate elements, these elements may be physically and/or logically combined in any combination or subcombination, and/or further physically and/or logically sub-divided. For example, a single computing device may act as both the maintenance system 102 and the claim processing system 101 , and/or as portions of one or both. The term “computing device” is broadly used herein to include both a single device (e.g., a single server) as well as multiple devices that work together (e.g., a plurality of servers and/or personal computers).
Claim processing system 101 may be responsible for processing incoming claims (e.g., in the form of data), and for making a determination as to how to process those claims. Information that may be used by claim processing system 101 may include the incoming claim information, information retrieved from data storage 103 , information received from maintenance system 102 , and/or information received from repair tracking system 104 .
Maintenance system 102 may be responsible for maintaining the information (e.g., data) stored by data storage 103 , including updating the information as needed. Maintenance system 102 may maintain the information stored by data storage 103 on the basis of received external data, data stored in data storage 103 , and/or information received from claim processing system 101 .
Network 106 may be any one or more networks, and may include one or more network types. Non-limiting examples of networks from which network 106 may be comprised may include the Internet, an intranet, a local area network, a wide-area network, a wired network (e.g., a landline telephone network, and Ethernet network, etc.), a wireless network (e.g., an IEEE 802.11 compliant network, a BLUETOOTH network, a cellular network, etc.), and an optical network. Network 106 may additionally or alternatively include one or more non-electronic networks for transferring information in physical form, such as a mail courier (e.g., the U.S. Postal Service, UPS, Federal Express, etc.).
Repair tracking system 104 may be responsible for keeping track of expected, current, and/or completed repairs performed by the repair facility. Information that may be tracked may include, for instance, information about the claim with which the repair is associated, the date and/or timeframe of the repair, the amount paid (or to be paid) by the insurance company for the repair, the estimated cost for the repair, the actual cost incurred for performing the repair, information about the vehicle customer, information about the vehicle, and/or any other information as desired. Such information may be stored in data storage 105 .
Data storage 103 and 105 may be physically separate from the other elements 101 , 102 , 104 , 107 , and/or 108 . For instance, data storage 103 and/or 105 may be embodied as racks of tape storage drives and/or hard drives. Alternatively, one or more of data storage 103 and/or 105 may be partially or fully integrated with one or more of the other elements 101 , 102 , 104 , 107 , and/or 108 . For instance, data storage 103 and/or 105 may be embodied as hard drives, memory, and/or other computer-readable storage media that are at least partially part of one or more of the computing devices of any of elements 101 , 102 , 104 , 107 , and/or 108 . Moreover, data storage 103 and data storage 105 may each include one or more computer-readable data storage devices, which may in turn include one or more computer-readable storage media. In addition, each of data storage 103 and data storage 105 may include or be interfaced by a database system that can be queried to update and/or retrieve data to/from data storage 103 and/or 105 .
The accounting systems 107 and 108 may each be responsible for maintaining an accounting of payments made by the insurance company versus payments owed to the repair facility. The accounting systems 107 and 108 may be separate systems and/or they may be part of claim processing system 101 and/or repair tracking system 104 . Moreover, the accounting system(s) 107 and/or 108 may be maintained by a third party if desired, such as by a bank or other financial institution.
FIG. 2 illustrates an example of general hardware and/or software elements that can be used to partially or fully embody any of the various devices and functions discussed herein, such as any of those elements discussed herein with regard to FIG. 1 . A computing device 200 (also often referred to as a computer) may include one or more processors 201 , which may execute instructions of a computer program to perform any of the features described herein. The instructions may be stored in any type of tangible and/or non-transitory computer-readable data storage device 202 (which may include one or more computer-readable storage media, such as a memory or hard drive) to configure the operation of the processor 201 . For example, instructions may be stored in a read-only memory (ROM), a random access memory (RAM), a removable media such as a Universal Serial Bus (USB) drive, compact disk (CD) or digital versatile disk (DVD), a floppy disk drive, an attached (or internal) hard drive, and/or any other desired data storage medium. The computing device 200 may include or be coupled to one or more output devices, such as a display device 205 (e.g., an external television, or a computer monitor), and may include one or more output device controllers, such as a video processor. The display device 205 may be physically separate from the computing device 200 , or it may be integrated with the remainder of the computing device 200 . There may also be one or more user input devices, such as a remote control, camera, keyboard, mouse, touch screen, microphone, etc. The computing device 200 may also include a communication interface 204 , which may include one or more input and/or output circuits (e.g., in the form of a network card) to communicate with an external device or network (e.g., network 106 ). The communication interface 204 may include one or more wired interfaces, wireless interfaces, or a combination of the two.
FIG. 3 is a flow chart of an example process in accordance with one or more aspects as described herein. The various steps in the flow chart may be performed by one or more devices and/or humans, such as any of the elements of FIG. 1 . While certain steps may be described below as being performed by a specific element, it will be understood that this is merely an example, and that each step may be performed by alternative elements. Moreover, while the steps are shown in a particular order and divided into specific steps, it will be understood that the order may be modified, and that one or more of the steps may be combined and that one or more of the steps may be further sub-divided into further steps.
At step 301 , the insurance company may receive an incoming new or revised claim. This may occur by, for instance, receiving and/or generating data representing characteristics of the claim, such as a description of the claim, an identification of the property (e.g., vehicle) affected by the claim, an identification of the insured, and identification of the type and/or extent of damage to the property, and identification of the timeframe (e.g., time, date, etc.) at which the damage occurred and/or when the claim is made, and/or any other information as desired. The data may be generated by and/or provided to, for instance, claim processing system 101 .
At step 302 , the claim may be validated, such as by physical inspection of the property (e.g., vehicle) to confirm the claimed damage, the existence of the property, and/or other issues that may be associated with a claim. Validating a claim may additionally or alternatively include, for instance, receiving one or more of the following inputs from the insured customer, an agent or another representative of the insurance company, and/or the repair facility: images of damage, descriptions of damage guided by a form or system, or free-form descriptions of damage. Any of those inputs may be analyzed by a system (such as claim processing system 101 ), such as according to a predictive payment model, to validate the claim, classify the nature of the claim or damage or repair needed, and/or establish a preliminary or final payment amount or range.
Validation may also involve determining whether the property can reasonably and/or cost-effectively be repaired (e.g., whether the property is repairable), or whether the property is considered “totaled” and no repair is to be made under the insurance contract. If it is determined that the property is repairable, then the process may move to step 303 . Step 302 may be performed prior to sending the property to the repair facility (and by a party other than the repair facility such as an insurance adjuster), or it may be performed by the repair facility itself during, for instance, step 305 .
At step 303 , the payment amount to be made to the repair facility for the claim may be determined by, for instance, claim processing system 101 , in accordance with a predetermined model. As previously discussed, the determination may be of a fixed amount defined by the model that does not vary from claim to claim (or at least from automotive repair claim to automotive repair claim). Thus, for example, a claim for a side-view mirror replacement may result in the same determined payment amount as a claim for a bumper replacement and re-painting and as a claim for body work performed on a vehicle. The determined payment amount may thus already be predetermined at the time that step 303 is performed, and data representing the predetermined payment amount may be stored in a data storage device, such as data storage 103 and/or as part of claim processing system 101 .
Alternatively, the payment amount may be determined according to a particular model, referred to herein by way of example as a predictive payment model. The predictive payment model may be predetermined and/or dynamic, and may be stored as data and/or computer-executable instructions in a computer-readable storage medium such as data storage 103 , and may be executed or otherwise implemented by one or more computers such as claim processing system 101 .
The predictive payment model may include a payment schedule, in which the determined payment amount may vary depending at least upon the particular characteristics of the claim. In this case, the payment amount may be determined based at least on information (e.g., the payment schedule) stored in data storage 103 and/or information provided by maintenance system 102 . For instance, the payment schedule stored in data storage 103 may associate each of a plurality of predetermined loss attributes with an effect on the determined cost. In this case, determination of the payment amount may include determining which of the loss attributes apply to the present claim. For example, if two of the predetermined loss attributes are (1) European car and (2) American car, and the claim is for damage to an American car, then the loss attribute “American car” may apply to that claim.
One or more of the loss attributes may be associated in data storage 103 (e.g., via a database) with a particular cost, and so the final determined payment amount may be based at least on a sum of those particular costs for the appropriate loss attributes of a claim. One or more of the loss attributes may additionally or alternatively be associated in data storage 103 with a particular multiplier, and so the final determined payment amount may additionally or alternatively be based at least on one or more costs being multiplied by one of the multipliers.
For example, assume that at least the following predetermined attributes are stored in data storage 103 and associated with the following costs and/or multipliers, as shown below in the example payment schedule of Table 1.
TABLE 1
Example Payment Schedule
Loss Attribute
Associated Cost
Associated Multiplier
European car
M1
American car
M2
side view mirror
C1
front bumper
C2
frontal collision
M4
. . .
. . .
. . .
If the claim is for an American car that needs a new front bumper and a side view mirror, then in this simplified example, the payment amount P for the claim may be based at least on the following calculation: M2*(C1+C2). Of course, the payment amount may depend upon other factors and other loss attributes. Moreover, the particular calculation is only an example, and loss attributes may affect the determined payment in other ways. Moreover, the multipliers do not need to necessarily affect all associated costs, and so the stored data of data storage 103 may further associate each multiplier with a list or class of loss attributes to be multiplied with. In general, one may consider each loss attribute to be associated with at least one value that may contribute to the final determined payment amount, and one may envision many possible ways in which the loss attribute values may be combined to determine the payment amount.
At step 304 , the determined payment amount is actually paid to the repair shop. Payment may be performed physically (e.g., via physical currency) and/or electronically (e.g., via transfer to a bank account, and/or via recording the payment amount to an account of the repair shop). It is note that payment does not actually need to occur between steps 303 and 305 , and may occur at any time. In this example, the payment may be made at any time once the payment amount for the claim has been determined. For example, payment may be made periodically for a batch of claims, rather than on a claim-by-claim basis.
At step 305 , the repair shop may perform the needed repair on the vehicle and/or other property covered by the claim. If the vehicle has not already been transported to the repair shop at an earlier step (such as during validation at step 302 ), then the vehicle may be transported to the repair shop. Once the repair is complete, the vehicle may be returned to the vehicle owner.
At step 306 , the repair shop may maintain repair data, such as via repair tracking system 104 (and which may be stored by data storage 105 ). The repair data may include any information about the claim and/or about the repair made. For instance, the repair data may include information about the claim with which the repair is associated, the date and/or timeframe of the repair, the amount paid (or to be paid) by the insurance company for the repair, the estimated cost for the repair, the actual cost incurred for performing the repair, information about the vehicle customer, information about the vehicle, information detailing what was involved in the repair (e.g., parts and/or labor), and/or any other information as desired. This information may be provided to the insurance company (e.g., to claim processing system 101 ) on a continuous or intermittent (e.g., periodic) basis. During step 306 , the repair facility and/or the insurance company may also update their accounting systems 107 and/or 108 to reflect that a claim has been completed to repair.
As will be described further below, the insurance company may use the repair and/or accounting data to update the information stored in data storage 103 and/or to update the algorithms used to determine the payment amount in future claims.
In addition, as part of step 306 and/or at any other time, the quality of repairs that have been made (or that are in process) may be managed by various means such as spot inspections by the insurance company or a third party or through customer satisfaction surveys. Another possibility may be to require that the repair facility provide a warranty of each repair. The characteristics of the warranty program and process may be agreed to by the repair facility and insurance company and covered by the agreed payment amounts. The warranty program may be underwritten by a third party and adjudicated by the insurance company, or it may be adjudicated by the warranty company or another party agreed to by the insurance company, repair facility, and warranty company.
FIG. 4 is a flow chart of another example process in accordance with one or more aspects as described herein. The various steps in the flow chart may be performed by one or more devices and/or humans, such as any of the elements of FIG. 1 . While certain steps may be described below as being performed by a specific element, it will be understood that this is merely an example, and that each step may be performed by alternative elements. Moreover, while the steps are shown in a particular order and divided into specific steps, it will be understood that the order may be modified, and that one or more of the steps may be combined and that one or more of the steps may be further sub-divided into further steps.
At step 401 , rather than paying a specific amount for a claim (or in bulk for a group of claims) after the incoming claims have been received, the process may involve partial or full pre-payment of predicted payment amounts for one or more future expected claims. The total payment amount in step 401 may be determined according to the predictive payment model in any of the ways discussed previously with regard to step 303 , except in this case the payment amount may be determined based on predicted hypothetical future claims.
At step 402 , the insurance company may receive an incoming new or revised claim. As previously described with regard to step 301 , receipt of an incoming claim may occur by, for instance, receiving and/or generating data representing one or more characteristics of the claim. Again, the claim data may be generated by and/or provided to, for instance, claim processing system 101 .
At step 403 , the claim may be validated, such as by physical inspection of the property (e.g., vehicle) to confirm the claimed damage, the existence of the property, and/or other issues that may be associated with a claim. Validation has already been described in connection with step 302 , and may also be performed in the same manner here. Moreover, step 403 may be performed prior to sending the property to the repair facility (and by a party other than the repair facility such as an insurance adjuster), or it may be performed by the repair facility itself during, for instance, step 404 .
At step 404 , the repair shop may perform the needed repair on the vehicle and/or other property covered by the claim. If the vehicle has not already been transported to the repair shop at an earlier step (such as during validation at step 403 ), then the vehicle may be transported to the repair shop. Once the repair is complete, the vehicle may be returned to the vehicle owner.
At step 405 , the repair shop may maintain the previously-described repair data, such as via repair tracking system 104 (and which may be stored by data storage 105 ). As previously described, the repair data may include any information about the claim and/or about the repair made. This information may be provided to the insurance company (e.g., to claim processing system 101 ) on a continuous or intermittent (e.g., periodic) basis.
During step 405 , the repair facility and/or the insurance company may also update their accounting systems 107 and/or 108 to reflect that a claim has been completed to repair. Where pre-payment has been made, such as in step 401 , this may involve tracking how many claims have been completed versus how many have been pre-paid. If the pre-paid amount is deemed to be insufficient (e.g., if all predicted claims have been completed or are otherwise in process), then the insurance company may again perform step 401 to make an additional pre-payment for still further future claims.
As shown in FIG. 4 , the claim process may repeated as desired, such as for the duration that the pre-payment amount from step 401 is sufficient to cover repair of the claims. Moreover, as will be described further below, the insurance company may use the repair and/or accounting data to update the information stored in data storage 103 and/or to update the algorithms used to determine the payment amount for future batches of predicted claims.
FIG. 5 is a flow chart of still another example process that may be performed in accordance with one or more aspects as described herein. The various steps in the flow chart may be performed by one or more devices and/or humans, such as any of the elements of FIG. 1 . While certain steps may be described below as being performed by a specific element, it will be understood that this is merely an example, and that each step may be performed by alternative elements. Moreover, while the steps are shown in a particular order and divided into specific steps, it will be understood that the order may be modified, and that one or more of the steps may be combined and that one or more of the steps may be further sub-divided into further steps.
As previously explained, the insurance company may use the repair and/or accounting data to update the information stored in data storage 103 and/or to update the algorithms used to determine the payment amount for future submitted claims (in the case of payment after claim submission such as in FIG. 3 ) and/or for future expected hypothetical claims (in the case of pre-payment such as in FIG. 4 ). An example of how this may be accomplished is described in connection with FIG. 5 .
At step 501 , the insurance company may receive the repair and/or accounting data provided by the repair facility during, for instance, steps 306 and/or 405 . The data may be received at any system of the insurance company, such as claim processing system 101 , maintenance system 102 , and/or accounting system 107 .
At step 502 , the insurance company may further receive or otherwise obtain any other data, which may be external data (e.g., from a third party separate from the insurance company) and/or internal data (e.g., data generated by or previously obtained by the insurance company). This additional data may include, for instance, information about claims by other insurance companies, news items, insurance statistics, profit margins, and/or vehicle sensor data (e.g., accelerometer, Global Positioning System, speed, etc.) that was collected during the incident leading to the claim. Any of such data may influence the predictive payment model and/or be used as inputs to the predictive payment model. Steps 501 and 502 may be performed at any time and in any particular order (even simultaneously and/or on a continuous or intermittent basis). These steps are shown in a particular order only as an example.
At step 503 , the insurance company may determine whether and/or how to revise the predictive payment model stored in data storage 103 . Such a determination may be performed by, for instance, maintenance system 102 . The determination may be made based on one or more factors. For instance, it may be determined that the insurance company is less profitable than expected, or that the insurance company may even be losing money, based on the current predictive payment model. Additionally or alternatively, it may be determined (such as based on the external data) that the costs of parts for repairs are rising. In response to determinations such as these, maintenance system 102 may determine that the predictive payment model should be revised accordingly (so that, for instance, the average payments to repair facilities are higher). Of course, the opposite may be true—if the insurance company determines that the predictive payment model could be adjusted so that payments to the repair facilities are, on average, lower, then the predictive payment model could be revised accordingly as well.
At step 504 , the predictive payment model as stored in data storage 103 may be revised in the determined manner, such as by maintenance system 102 . As future claims and/or payments are made, the revised predictive payment model may be used going forward. The process of FIG. 5 may be repeated as desired on an ongoing basis. For instance, the process of FIG. 5 may be continuously performed and/or on an intermittent (e.g., periodic) basis, such as monthly, quarterly, or annually.
The various features described above are merely non-limiting examples, and can be rearranged, combined, subdivided, omitted, and/or altered in any desired manner. | A claim-based capitation model is proposed for handling vehicle repair insurance claims. Rather than determining a detailed estimate of the expected actual cost of repair, the estimate may be determined using a simpler model. For example, the insurance company and a repair facility may agree to following a predictive payment model in which the insurance company pays a fixed predicted capitated amount of money for each repair claim, regardless of the amount of repair work that will be needed. Alternatively, the insurance company may pre-pay a fixed capitated amount for a predicted number of future insurance claims. | 6 |
RELATED APPLICATIONS
This application is a Continuation-in-Part of patent application Ser. No. 451,694 filed Mar. 15, 1974 and herewith abandoned.
FIELD OF THE INVENTION
This invention relates to the novel homocysteine thiolactone of nicotinamide and its salts and more particularly to its synthesis, utility and modes for its useful administration.
THE INVENTION
The compound: homocysteine thiolactone of nicotinamide having the formula: ##STR2## and its pharmacologically acceptable salts have useful pharmacological activity related to liver function and indicated therapeutic activity in lowering cholesterol, free fatty acid, and triglyceride, plasma levels and in improving BSP bile clearance in conditions where such effects are indicated.
DETAILED DESCRIPTION OF THE INVENTION
The invention above will be more fully described by the appended examples and by references to the drawing where:
FIG. 1 shows the effect of the compound of the invention on lipid metabolism (FFA and triglycerides) in fasted rats.
FIG. 2 shows the effect of the compound of this invention on BSP handling in liver damaged rats.
FIG. 3 shows the effect of the compound of this invention upon the cumulative bile excretion of BSP in liver - damaged rats.
The compound is prepared by reacting nicotinyl chloride hydrochloride or nicotinic acid esters with homocysteine thiolactone hydrochloride in an anhydrous organic solvent inert to the reactants. Preferably the reaction is carried out in the presence of halacid acceptors. Dioxane, tetrahydrofurance, (THF), N,N-dimethyl formamide (DMF). DMF is preferred. The solvent medium may include an anhydrous proton or haloacid acceptor. Among such anhydrous acceptors are triethylamine, other trialkylamines, pyridine etc. Triethylamine or pyridine are preferred.
The reaction proceeds at temperatures between 25° and 125° C. Preferably the reaction provides a purer product in best yield at temperatures in the range 90° ± 10° C.
The product is purified by recrystallization from ethyl acetate. The chromatographically pure produce melts in the range 150° - 152° C.
The compound, homo-cysteine thiolactone nicotinamide, may be prepared into non-toxic pharmaceutically acceptable salts with organic acids such as acetic, citric, tartaric, salicylic, maleic etc. or with inorganic acids such as hydrochloric and hydrobromic acid, sulfuric acid, nitric acid, and phosphoric acid.
This compound (and its salts) has been found to be active pharmacologically by reducing cholesterol, free-fatty acid and triglyceride levels in the plasma after administration. This pharamacological activity is associated with the function of the compounds in the liver and the compound has been noted to counteract abnormalities resulting from experimentally-induced liver malfunction, thus indicating therapeutic activity.
The exact mode or situ of such activity in the organism is as yet unclear but the activity is unmistakable. An additional factor of utility of the compounds for therapy is its low toxicity, high therapeutic index.
The appended examples indicate a useful simple and preferred synthesis of the novel compound, its pharmacological activity and its therapeutic activity. The synthetic methods and the modes of administration are merely exemplary. All art-recognized equivalent methods and materials are intended.
EXAMPLE 1
Homocysteine thiolactone of nicotinamide: (ST-22) ##STR3##
Suspend 1 mole of nicotinic acid chloride hydrochloride in N-N-dimethylformamide; slowly and under stirring add 3.3 moles of anhydrous triethylamine and homocysteine thiolactone hydrochloride previously dissolved in N-N-dimethylformamide. The reaction vessel is equipped with a stirrer and a reflux condenser. The reaction mixture is maintained for 4 hours at 90° C. with stirring. The reaction product is filtered. The N-N-dimethylformamide solution is evaporated to dryness and then the residue is recrystallized from ethyl acetate.
The melting point of the chromatographically pure product obtained is 150° - 152° C.
EXAMPLE 2
The compound of Example 1 (ST-22) has an LD 50 of 4500 mgm/kg per os and 2400 mgm/kg e.p. in rats.
EXAMPLE 3
Pharmacological Activity
The pharmacological activity of the compound ST-22 was assessed by using the methods described in the following articles.
A -- The antilipolytic activity in the fasting state was studied in accordance with
(1) Carlson L. A. and E. R. Nye, Acute Effect of Nicotinic Acid In the Rat. Plasma and liver lipids and blood glucose. Acta. Med. Scand., 179, 453, 1966.
(2) Dalton C., C. Van Trabert and J. X. Dwyer, Relationship of Nicotinamide and Nicotinic acid to Hypolipidemia, Biochemical Pharmacology, 19, 2609, 1970.
(3) Bizzi A. and S. Garattini, Drugs Lowering Plasma Free Fatty Acids: Similarities and Dissimilarities with the Nicotinic acid Effect, p. 207; K. F. Gey and L. A. Carlson Edrs., Hans Huber Publisher, Bern Stuttgard Vienna, 1971.
B -- The antilipolytic activity in the case of Nor-Adrenaline stimulated lipolysis in rats was investigated in accordance with
1. S. Garattini and A. Bizzi, Inhibiteurs de la mobilization des acides gras libres, Actualite Pharmacologiques XXII Serie, 169, 1969.
C -- The hypolipidaemic activity was studied in accordance with
1. Assous E., Pouget M., Nadand J. ecc., Etude d'un novel hypolipidemiant -- le bis (hydroxy-ethyl-thio) 1-10 decane, Therapie, 27, 395, 1972.
D -- The activity in experimental liver injury was studied according to
(1) Schwarzmann W., Les hepatites toxiques experimentales, Revue Int. d'Hepatol., 5, 387, 1957.
2. Stern P. H., T. Fuzukuwa, T. M. Brody, Rat liver and plasma lipids after CC14 administration, J. Lipid Res., 6, 278, 1965.
The new compound of Example 1 (ST-22) exhibited the following pharmacological activity in the above detailed tests:
(1) Antilipolytic action: threshold dose 39/mg/kg os. 156 mg/kg os reduced the plasma levels of F.F.A. by 70%, triglycerides by 60% in the 17-hour fasted rats (FIG. 1) and reduced the lipolytic activity of subcutaneously injected Nor-adrenaline by 75% in rats.
(2) Hypolipidaemic action: 156 mg/kg os for 15 days had an inhibitory effect against the increase in plasma total lipids, cholesterol and β-lipoproteins induced by an atherogenic diet in rats.
(3) Action on experimental liver injury: does of 156 mg/kg os or 78 mg/kg os or subcutaneously reduced changes in the biochemical pattern (plasma GPT, GOT, LDH, total lipids, triglycerides, cholesterol and glycogen) induced by carbontetrachloride intoxication, and increased plasma clearance and biliary-excretion of Bromsulphonphtalein (FIGS. 2 and 3).
The high therapeutic index of the compound was noted. (ST-22) homo-cysteine thiolactone nicotinamide clearly reduces hyperlipidaemic levels resulting from stimulated lipod mobilization and liver injury induced by chlorinated hydrocarbons and is useful in therapy where such activity is indicated as in altered, lipid metabolism rates or liver injury.
EXAMPLE 4
The various experimental animals used in the above tests were carefully observed and no untoward or unusual toxic syndromes were noted in other than the LD 50 test. It was noted however, that ST-22 demonstrated a slow-acting hypotensive effect which differed from the rapid vaso-dilation hypotensive effects noted with nicotinic acid.
The invention includes within its scope pharmaceutical preparations containing, as an active ingredient, the therapeutically active compound (ST-22) homocysteine thiolactone nicotinamide or the non-toxic acid addition salts thereof, in association with a pharmacologically acceptable carrier. Other therapeutic and compatible materials may be included in the preparation. The preparations may take any of the forms customarily employed for administration of therapeutically active substances, but the preferred types are those suitable for oral administration and especially tablets, pills and capsules including the substance. The tablets and pills may be formulated in the usual manner with one or more pharmacologically acceptable diluents or excipients, for example lactose or starch, and include materials of a lubricating nature, for example calcium stearate. Capsules made of absorbable material, such as gelatin, may contain the active substance alone or in admixture with a solid or liquid diluent. Liquid preparations may be in the form of suspensions, emulsions, syrups or elixirs of the active substance in water or other liquid media commonly used for making orally acceptable pharmaceutical formulations, such as liquid paraffin, or a syrup or elixir base. The active substance may also be provided when indicated, in a form suitable for parenteral administration, i.e.e as a solution suspension or emulsion in sterile water or an organic liquid usually employed for injectable preparations, for example a vegetable oil such as olive oil, or a sterile solution in an organic solvent.
The following Examples illustrates the preparation of a pharmaceutical composition according to the invention.
EXAMPLE 5
25 g of ST-22
25 g of Avicel PH 101 (microcrystalline cellulose) and
25 g of Aerosil (highly purified silicon dioxide)
are mixed together and gelatin capsules are filled each with the mixture so that each capsule contains 10 mg of active substance ST-22.
EXAMPLE 6
800 g of lactose and 200 g of maize starch are mixed with 200 ml of 5% maize starch in water. The mixture is granulated, dried at 55° C. and sieved through a no. IV sieve (Sieve opening 0.7 mm).
1000 g of the granulate are mixed with 100 g of ST-22 and gelatin capsules are filled each with the mixture so that each capsule contains 10 mg of the active substance ST-22. | A novel cysteine thiolactone of nicotinamide is disclosed having the formula: ##STR1## The compounds, homo-cysteine thiolactone of nicotinamide, and its pharmacologically acceptable salts have the useful pharmacological activity of lowering cholesterol, free fatty acid and triglyceride plasma level in the case of altered lipid metabolism and improving BSP clearance ratio in cases of liver injury.
A synthesis of the compound from nicotinoyl chloride, hydrochloride or nicotinic acid esters is described as well as modes for the administration of the compound. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed in general to magnetic resonance tomography as employed in medicine for examining patients. The present invention is specifically directed to a method for manufacturing a carrier tube for the body coil of an MRI apparatus.
[0003] 2. Description of the Prior Art
[0004] MRT is based on the physical phenomenon of nuclear magnetic resonance and has been successfully utilized as an imaging method in medicine and in biophysics for more than 15 years. In this examination modality, the subject is disposed in a strong, constant magnetic field. The nuclear spins of the atoms in the subject that were previously irregularly oriented are aligned as a result. Radio-frequency energy can then excite these “ordered” nuclear spins to a specific oscillation. This oscillation generates the actual measured signal in MRT that is picked up with suitable reception coils. The examination subject can be spatially encoded in all three spatial directions by utilizing non-uniform magnetic fields generated by gradient coils. The method allows a free selection of the slice to be images, allowing tomograms of the human body to be acquired in all directions. As a tomographic imaging method in medical diagnostics, MRT is distinguished first and foremost by a versatile contrast capability as a “non-invasive” examination modality. MRT currently employs applications with high gradient power that enable an excellent image quality with measuring times on the order of magnitude of seconds and minutes.
[0005] The constant technological improvement of the components of MRT devices and the introduction of fast imaging sequences have created an increasing number of medical application in medicine. Real-time imaging for supporting minimally invasive surgery, functional imaging in neurology and perfusion measurement in cardiology are a few examples.
[0006] [0006]FIG. 9 shows a schematic section through a conventional MRT apparatus. The section shows further components of the interior that is surrounded by the basic field magnet 1 . The basic field magnet 1 contains superconducting magnet coils that are situated in liquid helium and is surrounded by a magnet envelope 12 in the form of a two-shell vessel. The cryo-head 15 that is attached to the magnet envelope 12 at the outside is responsible for keeping the temperature constant. The gradient coil 2 is concentrically suspended via carrying elements 7 in the interior surrounded by the magnet envelope 12 (also called magnet vessel). A carrying tube with the radio-frequency antenna applied thereon is likewise concentrically introduced in the interior of the gradient coil 2 . The carrying tube and RF antenna are referred to below as an RF resonator or as a “body coil” 13 . The gradient coil 2 and the body coil 13 thus represent two cylinders inserted into one another with a radial spacing therebetween—in the form of an air gap—amounting only to about 3 cm. The RF antenna converts RF pulses emitted by a power transmitter into a magnetic alternating field for exciting the atomic nuclei of the patient 18 , and subsequently converts the alternating field emanating from the precessing nuclear moment into a voltage supplied to the reception branch. The upper part of the body coil 13 is mechanically connected to the magnet envelope 12 via a cladding 29 that is funnel-shaped. Tongues 30 (see FIG. 10) are mounted at the lower part of the body coil 13 , the body coil 13 being mechanically connected via these tongues 30 to the lower part of the magnet envelope 12 via a cladding 29 as well as with carrying elements 7 . The tongues 30 as well as the body coil 13 are mechanically connected to bed rails 33 . Under certain circumstances, the tongues 30 are considered as belonging to the body coil 13 . The patient 18 on a patient bed 19 is moved into the opening in the interior of the system via glide rails 17 . The patient bed is disposed on a vertically adjustable carrying frame 16 .
[0007] The gradient coil 2 is likewise composed of a carrying tube 6 having an exterior on which three windings (coils) are disposed that each generate a gradient that is proportional to the current supplied to the coil. The three gradients are perpendicular to one another. A radio-frequency shield (RF shield) 20 that shields the coils from the radio-frequency field of the RF antenna is applied on the inside of the carrying tube 6 . As shown in FIG. 11, the gradient coil 2 has an x-coil 3 , a y-coil 4 and a z-coil 5 that are respectively wound around the carrying tube 6 and thus respectively generate gradient fields in the directions of the Cartesian coordinates x, y and z. Each of these coils is equipped with its own power supply in order to generate independent current pulses with the correct amplitude and at the correct time in conformity with the sequence programmed in the pulse sequence controller. The required currents lie at approximately 250 A. Since the gradient switching times should be as short as possible, current rise rates on the order of magnitude of 250 kA/s are required. In an extremely strong magnetic field as is generated by the basic field magnet 1 (typically between 0.22 and 1.5 Tesla), such switching events involve strong mechanical oscillations due to the Lorentz forces that thereby occur, these mechanical oscillations leading to considerable noise.
[0008] The following demands are made of the body coil 13 of an MRT apparatus:
[0009] For space reasons, a tube wall thickness of only up to 10 mm can be accepted. The material of the body coil should comprise an optimally low power absorption of RF power, i.e. must be electrically non-conductive. The body coil must be MR-compatible, i.e. non-imaging in the sense of magnetic resonance (for example, it dare not contain any water). Since the body coil is supposed to carry the patient bed with patient, the body coil must comprise high mechanical shape stability. In order to shield the noise generated mainly by the gradient coil as well as possible, to body coil should be optimally long without comprising interruptions. For design-oriented reasons, however, the funnel-shaped widened portion (cladding 29 ) of the patient tunnel should also begin as far inside as possible, which leads to a very short body coil and does not meet the noise-related demands.
[0010] In conventional solutions, short cylindrical Gfk tubes of epoxy resin are employed for the body coil, the functional elements of the RF antenna being applied thereon in the form of planar copper conductors. For manufacturing such tubes, a rotating arbor is wrapped with resin-saturated fiberglass rovings and is cured (possibly upon application of heat). This solution involves compromises that have a significant disadvantage with respect to one of the two aspects of noise or design: Although the body coil is short, the funnel-shaped widened portion is not a part of the body coil but is composed of a separate plastic part (cladding 29 ). This is inadequate for meeting the noise-reducing demands since it lacks the necessary mass and rigidity. Second, the interface between the body coil and the funnel-shaped cladding represents an acoustic weak point.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to optimize the noise and design properties as well as the electromechanical stability of a magnetic resonance tomography apparatus.
[0012] This object is inventively achieved in a magnetic resonance tomography apparatus having a basic field magnet surrounded by a magnet envelope that surrounds and limits an interior space, with a gradient coil system disposed in this interior space, and a body coil having an RF antenna and a carrying tube disposed in the gradient coil system as an inner encapsulation cylinder, and wherein the magnet envelope and the gradient coil system are optically as well as acoustically closed by the body coil and a diaphragm at the end faces and in the interior. The body coil is inventively manufactured by a vacuum casting process or a vacuum die-casting process.
[0013] A body coil manufactured in this way yields a great number of advantages.
[0014] First, the casting technique allows significantly more degrees of freedom as to the shaping.
[0015] In order to meet optimum noise-related requirements, for example, the body coil can be cast such that has an overall length that is greater than the gradient coil lying behind it.
[0016] In order to also meet optimum design requirements, the body coil can be cast such that it is widened with a funnel-shape at one end or at both end faces. This is possible only to a limited extent and with considerable outlay given the conventionally employed winding technique.
[0017] When tongues and/or bed rails are provided in the lower region of the body coil, these can be inventively cast with the body coil to form a unit, which leads to a considerably better overall mechanical stability.
[0018] Functional elements, which are conventionally glued onto the wound body coil, can likewise be cast with the body coil to form a stable unit as a result of manufacturing the body coil with vacuum casting or vacuum die-casting methods.
[0019] The functioning of the RF antenna or the shielding thereof with the RF shield can be greatly improved by manufacturing the body coil with vacuum casting or vacuum die-casting methods because functional elements of the RF antenna of the body coil can be cast with the body coil on an arbitrary radius. Capacitances of the RF antenna likewise can be cast in as fixed components or overlapping structures and thus are optimally protected against external arcing or other disturbing effects.
[0020] Cooling elements also can be cast into the body coil by manufacturing the body coil with vacuum casting or vacuum die-casting methods, these cooling elements having a far greater efficiency than cooling elements that are applied onto the surface of the body coil.
[0021] Material having a low dielectric constant can be locally introduced into the mold in carrying tube regions with a high electrical field intensity when manufacturing the body coil with vacuum casting or vacuum die-casting methods and can be subsequently cast with the tube. As a result dielectric losses are kept small and the capacitive coupling of the RF field to the patient is improved.
[0022] Mechanically weak regions of the surface of the body coil can be reinforced by introducing a reinforcement into the mold before the casting.
[0023] Rovings and/or woven mats and/or pre-pregs are inventively employed for reinforcement.
[0024] The casting material can be suitably optimized by adding fillers.
DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 schematically illustrates a section through a magnetic resonance tomography (MRT) apparatus having a body coil constructed in accordance with the principles of the present invention.
[0026] [0026]FIG. 2 is a more detailed schematic section through the body coil constructed in accordance with the invention, engaged in the gradient coil.
[0027] [0027]FIG. 3 is a section taken along line III-III of FIG. 2, illustrating the contour that can be achieved on the body coil constructed in accordance with the present invention, compared to a conventional contour.
[0028] [0028]FIG. 4 is a plan view of a conventional body coil and support therefor.
[0029] [0029]FIG. 5 is a section taken along line V-V of FIG. 4, showing the conventional attachment of the body coil to the support.
[0030] [0030]FIG. 6 is a section taken along line VI-VI of FIG. 4, showing the interior structure of a conventional support for the body coil.
[0031] [0031]FIG. 7 is a plan view of a body coil and a support therefor constructed in accordance with the present invention.
[0032] [0032]FIG. 8 is a section taken along line VIII-VIII of FIG. 7.
[0033] [0033]FIG. 9 schematically illustrates a section through a magnetic resonance tomography apparatus having a conventionally constructed body coil.
[0034] [0034]FIG. 10 is a perspective view of a conventionally constructed body coil with tongues attached thereto.
[0035] [0035]FIG. 11 is a perspective view of a conventional gradient coil having three gradient windings, and an RF shielding coil.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] [0036]FIG. 1 is a schematic section through an MRT apparatus having a body coil 28 that was inventively manufactured with vacuum casting or vacuum die-casting technology. The manufacturing technology allows a lengthening of the body coil 28 beyond the gradient coil lying behind it while allowing a one-sided funnel-shaped widening of the upper part. The tongues 30 with the stabilizing bed rails 33 are likewise cast into the body coil 28 . The cladding 29 in the upper part of the MRT apparatus is correspondingly shortened. All further components of the MRT apparatus as already described in connection with FIG. 5 remain unmodified.
[0037] [0037]FIG. 2 shows a detailed schematic section through the inventive body coil 28 engaged into the gradient coil 2 . Mechanical weak points 31 are reinforced by introducing mechanically stabilizing elements into the corresponding regions of the mold. Stabilizing, all around stiffeners 23 and bearings 22 , which were glued or otherwise applied on the body coil 13 after the winding of the body coil 13 according to conventional technology, are firmly cast with the body coil 23 by means of vacuum casting or vacuum die-casting technology.
[0038] [0038]FIG. 3 is a sectional view taken along line III-III of FIG. 2 showing, with the solid line 35 , the shape of the exterior contour that can be obtained by manufacturing the body coil 28 by means of vacuum casting or vacuum die-casting. Virtually any desired contour can be obtained, in contrast to the conventional contour 34 , indicated in FIG. 3 with a dashed line, which was dictated, and could not be deviated from, by the conventional winding technique used to manufacture the conventional body coil 13 .
[0039] Differences between the conventional wound technique and the inventive vacuum or vacuum die-casting technology are further illustrated on the basis of FIGS. 4 - 6 , which represent a conventional support element for the RF resonator (body coil) 13 , and FIGS. 7 and 8 which represent a component made according to the invention.
[0040] [0040]FIG. 4 is a plan view of a mechanical component 24 . Conventionally, this is an injection-molded part that serves the purpose of supporting or suspending the RF resonator 13 . To this end, a brass bushing with an interior thread 25 is centrally cast in the component 24 . According to the conventional method as shown in FIG. 5, which is a section along line V-V in FIG. 5, the injection-molded part 24 is glued to the RF resonator 13 . In order to create a better connection between injection molded part 24 and RF resonator 13 , undercuts 27 that have smaller diameters 26 at the side adjacent the RF resonator 13 , are concentrically provided around the bushing 25 . These are shown in section in FIG. 6, which is taken along line VI-VI on FIG. 5. During gluing, the adhesive penetrates through the smaller openings 26 and fills a part of the larger-volume undercuts 27 , resulting in a kind of “solder flow effect” after the drying of the adhesive that sets a firmer connection between the injection molded part 24 and the RF resonator 13 than would be the case given a purely planar connection between the two parts.
[0041] Such undercuts 26 , 27 are no longer needed in the MR apparatus manufactured a method according to the present invention (FIG. 7) since a gluing is also no longer required. The support 22 is created in the mold and the threaded bushing 25 is secured to the mold with fixing aids (for example, screws). After casting, the support 22 with the threaded bushing 25 therein is a fixed component of the body coil 28 and forms a compact unit together with it (FIG. 9, which is a section along line VIII-VIII of FIG. 7).
[0042] In accordance with the present invention the body coil is manufactured with a vacuum casting or vacuum die-casting technology. Epoxy resin as well as other resins or other castable materials can be employed as the casting material. The casting properties of the particular material that is used can be optimized by adding fillers (for example, quartz powder). The mechanical strength can be increased by introducing rovings and/or woven mats and/or pre-pregs (pre-impregnated materials) into the mold. Pre-pregs are pre-treated (with resin), woven fiberglass, aramid or carbon fiber mats that are cured under high temperature after the desired shaping or, respectively, positioning.
[0043] As mold is inventively employed that is composed of an arbor at the inside and a casing at the outside. The two end faces are closed by flanges. Functional elements (to be described in detail below) are introduced into the mold with fixing aids (for example, of Gfk material) and are placed at the desired location or integrated into the arbor or casing from the very outset.
[0044] When a vacuum casting technology is employed, the mold is evacuated before the casting. An overflow reservoir is located at the highest point of the mold. Given, for example, a vertically placed mold, the evacuation ensues at the lower flange, and the upper flange contains the overflow reservoir. The upper side can alternatively be open if it has a planar upper edge. In this case, a flange with an overflow reservoir is not necessary. A closed upper side with an overflow reservoir, however, allows an arbitrary, non-planar terminating edge to be formed. For example, such a non-planar edge is needed when tongues 30 are also to be integrated into the body coil 28 (see FIG. 1) in the casting process.
[0045] This inventive manufacturing of the body coil of an MRT apparatus yields a number of advantages, which are as follows.
[0046] In contrast to the conventional winding technique, the casting technique makes it possible to lengthen the body coil beyond the gradient coil and to design the extension with a funnel-like widening. It is also likewise possible to accept the tongues 30 into the mold of the body coil 28 , even at both sides under certain circumstances. Such a modified body coil 28 is shown hatched in FIG. 1. The funnel-shaped widening at the one end and in the upper region of the body coil satisfies the aforementioned design demands. The overall length projects beyond both end faces of the gradient coil and insures a best-possible noise shielding. The tongues 30 that accept the patient bed 19 are correspondingly shortened and are an integral component of the body coil 13 .
[0047] The casting technique allows significantly more degrees of freedom in the shaping. In contrast to the conventional wound tube, exactly identical wall thicknesses are obtained (when desired) without requiring mechanical post-processing. Moreover, deviations from windable shapes are possible such as, for example, variable outside diameters, arbitrary outside contours (see FIG. 3) or (funnel-shaped) widened portions of the diameter (see the front region of the body coil 13 in FIGS. 1 and 2). Local weak points 31 can be reinforced in a simple way by strengthening the wall thickness (for example, with reinforcing fibers by means of rovings, woven mats or pre-pregs). The mechanical properties of the corresponding weak point 31 (for example, sagging under load) can be significantly improved by an optimum alignment of the reinforcing fibers as well as by selecting the appropriate mesh width without being restricted to a specific winding angle.
[0048] As a result of the vacuum casting or vacuum die-casting technique, functional elements (mechanical components such as bushings) of the tube, or in the antenna (copper strips or rods, PC boards with conductive structures, etc.) can be introduced in defined fashion on an arbitrary radius within the wall. Particularly given application of the RF antenna onto the surface of the tube, the subsequent gluing as is currently implemented is eliminated. Since the properties of the antenna can be highly dependent on, among other things, the radial spacing from the patient as well as from the surrounding RF shield, an optimization in terms of the emission and shielding of the RF field can ensue by means of suitable placement of the antenna within the body coil 28 .
[0049] Capacitances of the RF antenna can be cast as fixed components (for example, discrete capacitors) or overlapping structures (of, for example, copper) and are thus optimally protected against external arcing or other disturbing effects (such as, for example, corona discharges).
[0050] Under certain circumstances, it is meaningful or necessary to design the electrical properties of the body coil 28 differently in regions thereof. For example, dielectric losses can be kept low or the capacitive coupling of the RF field to the patient can be improved by locally introducing material having a low dielectric constant (for example, hard foam with large closed pores) into the regions that experience high electrical fields. Such a procedure can be implemented in a simple way with the inventive manufacturing method without weakening the (outer) layers that are important for the mechanical properties.
[0051] Cooling elements can be integrated in a simple way with the vacuum or vacuum die-casting technique. Thus, for example, plastic conduits for air cooling or cooling conduits for cooling with MR-neutral liquids as well as copper tubes for water cooling can be cast in a simple way. Integrated cooling elements have a far higher efficiency than cooling elements that are applied onto the outer surface of the body coil 28 , also is currently done.
[0052] The vacuum or vacuum die-casting technique also enables the integration of further function elements such as bed rails 33 , appliques 23 , fastening or, support elements 22 , etc. Such components were hitherto glued onto the body coil. Compared to gluing, casting these components into the cast part simplifies the manufacturing and assembly process and increases the mechanical strength. To this end, the components are secured to the casing or arbor with adhesive tape or screwed connections during the setup. It is likewise also possible to incorporate the corresponding components into the mold topology (casing or arbor).
[0053] The vacuum or vacuum die-casting technique for manufacturing the body coil 28 ultimately leads to an inventively modified MRT apparatus as shown in FIG. 1. A noise reduction is achieved by means of such an inventive redesign of the body coil 28 . Overall, the manufacturing and assembly process is simplified taking the acoustic and design boundary conditions into consideration.
[0054] Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art. | A magnetic resonance tomography apparatus has a basic field magnet that is surrounded by a magnet envelope. This basic field magnet surrounds and limits an interior space with a gradient coil system disposed in this interior space and a body coil having an RF antenna and a carrying tube disposed in said gradient coil system as an inner encapsulation cylinder. The magnet envelope and the gradient coil system are both optically as well as acoustically closed by the body coil and a cladding at the end faces and in the interior. The body coil is manufactured by a vacuum casting or vacuum die-casting process. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a monitoring device for drive equipment for elevators. In particular, the present invention relates to a device that monitors the standstill mode of the drive after shutdown thereof.
In drive equipment for elevators with a feed and control of three-phase or direct current electric motors, the requirement to be fulfilled for the case of shutdown of the drive and monitoring of the standstill of the same is that there should be measures defined by static means. These measures are described in, for example, European Standard EN 81-1 of 1998 under 12.7. Requirements with respect to fault examination and safety devices are described in, for example, European Standard EN 81-1 of 1998 under 14.1.
An example of a monitoring device for a drive control for elevators is disclosed in European patent document EP 0 903 314 A1. This monitoring device essentially consists of a safety sensor and motor circuit and/or brake circuit and the monitoring is carried out by means of electronic components.
In particular, a monitoring device 101 with a motor-and-brake circuit 103 is connected to a drive motor 105 and a brake 106 as shown in FIG. 3 of the EP 0 903 314 A1 document, which corresponds with FIG. 6 of the present application. Schematically illustrated in addition is a safety circuit 104 with a signal source 110 as well as a safety sensor system 102 with a connection 120 to the motor-and-brake circuit 103 .
The motor-and-brake circuit 103 basically consists of a frequency changer power unit 150 , a VVVF drive/control unit 151 (wherein VVVF signifies variable voltage and variable frequency), an intelligent protection system 152 and a brake control 153 .
The frequency changer power unit 150 contains all electronic power components in order to transform the mains voltage into an intermediate circuit direct voltage and from that into the three-phase current for the drive motor 105 . The VVVF drive/control unit 151 is the combination of the components for drive regulation and elevator control. The VVVF drive/control unit 151 controls the frequency changer power unit 150 and is on the other hand addressed by the intelligent protection system 152 as an interface. The intelligent protection system 152 is the safety module of the electronic drive. It consists of an electronic safety circuit and monitors all functions relevant to safety.
Moreover, FIG. 4 of the EP 0 903 314 A1 document, which corresponds to FIG. 7 of the present application, shows a motor control. The interface between the VVVF drive/control unit 151 and the intelligent protection system 152 is very simple without electromechanical relays. The energy flow, which forms the three-phase current, to the drive motor 105 can be blocked and applied through two switching elements, namely an input direct current rectifier 155 and an IGBT alternating current rectifier 156 , by the intelligent protection system 152 via the VVVF drive/control unit 151 . The input direct current rectifier 155 is fed by three phases L 1 , L 2 , L 3 of alternating current electrical power and consists of a half thyristor bridge with a direct current rectifier control 157 . The input direct current rectifier 155 can be switched on and off by the direct current rectifier control 157 . When it is switched off, a small current flows through a charging resistor R C . Control signals T 1 to T 6 of a pulse width modulation PWM for drive control of the IGBT's of the alternating current rectifier 156 are checked and gated as a block by the intelligent protection system 152 via a logical linking in the VVVF drive/control unit 151 .
Measurement signals of the motor current iU, iV, and iW are prepared by the VVVF drive/control unit 151 and passed on to the intelligent protection system 152 . The monitoring function is roughly subdivided into the sequences “start”,“run” and “stop” of the drive for an elevator. The “stop” sequence follows an intermediate circuit voltage test of interest here. In that case, according to the frequency changer power unit 150 shown in FIG. 7 an intermediate circuit capacitor C, controlled by the components TB and RB of the VVVF drive/control unit 151 , is discharged to such an extent that the intelligent protection system 152 can establish on the basis of an intermediate circuit voltage UZK whether the input direct current rectifier 155 is switched off. The drive is thereafter freed for a specific time minutes or hours) for a fresh start. If this time is exceeded, a new intermediate circuit voltage test has to be performed.
In this intermediate circuit voltage test a discharging of the capacitor C by way of TB and RB is necessary for the purpose of establishing whether the input direct current rectifier 155 is switched off. The capacitor has to be changed again later for the normal operation of the elevator. According to this state of the art circuit, an additional circuit connected downstream of the input direct current rectifier 155 is thus required by reason of the intermediate circuit lowering needed for the test.
SUMMARY OF THE INVENTION
The present invention has an object of creating a monitoring device by which it can be ascertained, without a large additional circuit, whether switching-off of the drive equipment for an elevator definitely has taken place.
In particular, according to the present invention, the ascertaining of a definite switching-off of the drive equipment is performed by a control on the input side externally of the frequency changer power unit. The input side circuit ascertains the presence or the absence of monitoring signals, which are derived from the multi-phase mains voltage, at the input of the frequency changer power unit or the static transformer. Upon ascertaining the presence of such a signal, the input side control can interrupt the energy flow to the frequency changer power unit by generating one or more switching-off signals to a switching device.
As the control device for monitoring a definite switching-off of the drive equipment is arranged at the input of the frequency changer power unit and not, as in the prior art monitoring devices, between the direct current rectifier and the alternating current rectifier, a measuring of the intermediate circuit direct voltage is superfluous. Thus, a charging and discharging of a capacitor is, according to the invention, redundant. Moreover, the device of the present invention is, due to the arrangement at the input of the frequency changer power unit, usable in a more flexible manner than the device for measuring the intermediate circuit direct voltage according to the prior art.
Further, according to the present invention preferably all three phases of the mains voltage can be individually monitored and selectively switched off. The check for an energy-free circuit can thereby be made without energy having to be applied for that purpose.
According to one embodiment, the switching device at the input of the frequency changer power unit comprises three single-phase relays with respective relay answering-back to the control at the input side.
According to a further embodiment the switching device at the input of the frequency changer power unit comprises three intrinsically safe semiconductor relays with signaling outputs for answering-back to the control at the input side.
According to another embodiment the switching device at the input of the frequency changer power unit is integrated with and the frequency changer power unit at the input is constructed as an active B 6 bridge. A sensor provided in each branch of the bridge reports the signal state in the respective bridge branch to the control at the input side. In that case, the sensor provided in each branch of the bridge is preferably a current sensor, which is, for example, a Hall sensor or a current measuring coil.
The control, to which the measured signal states are delivered, at the input side is preferably the elevator control.
DESCRIPTION OF THE DRAWINGS
The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
FIG. 1 is a block diagram of drive equipment for an elevator with a monitoring device according to the present invention;
FIG. 2 is schematic diagram of a control at the output side of the drive equipment shown in FIG. 1;
FIG. 3 is a schematic diagram of a first embodiment of the monitoring device according to the present invention;
FIG. 4 is a schematic diagram of a second preferred embodiment of the monitoring device according to the present invention;
FIG. 5 is a schematic diagram of a third preferred embodiment of the monitoring device according to the present invention;
FIG. 6 is a schematic illustration of a prior art motor-and-brake circuit switching circuit; and
FIG. 7 is a detailed schematic of the prior art motor control with a monitoring device shown in FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a block circuit diagram of drive equipment for an elevator with a monitoring device according to the present invention. A three-phase mains alternating current source (not shown) applies voltages L 1 , L 2 and L 3 to inputs of a switching device 1 that can switch on or off the energy flow to a downstream intermediate circuit 2 , 3 , which converts the three-phase mains voltages L 1 , L 2 and L 3 into an intermediate circuit direct voltage. The intermediate circuit 2 , 3 consists of a frequency changer power unit or a static transformer 2 and an intermediate circuit capacitor 3 . When the energy flow is switched on, the energy flows into the frequency changer power unit 2 and from the intermediate circuit capacitor 3 onward to an alternating current rectifier or frequency transformer 4 or a similar circuit for converting the intermediate circuit direct voltage into three-phase current U, V and W for a drive motor 5 . The devices 2 , 3 and 4 form a power supply unit having an input connected to the mains voltage source through the switching device I and an output connected to the drive motor 5 .
Moreover, there are shown in FIG. 1 an input side control 6 connected at the input side of the power supply apparatus and, independently thereof, an output side control or VVVF control 8 connected at the output side of the power supply apparatus.
According to FIG. 1, monitoring signals 60 which indicate the presence or the absence of the mains voltages L 1 , L 2 and L 3 , at the input of the frequency changer power unit 2 , are in accordance with the invention fed to the input side control 6 . The control 6 is arranged externally of the frequency changer power unit 2 and which in the case of the presence of the signal 60 can issue a switching-off signal 70 to the switching device 1 so as to cause a switching-off of the mains voltages L 1 , L 2 and L 3 . The checking for a presence or an absence of mains voltages L 1 , L 2 and L 3 can be undertaken separately for all three phases, so that a selective switching-off is possible. The possibility of an energy-free circuit can thereby be investigated without energy for that purpose having to be made available. The feed of the signals 60 to the control 6 can be made by the switching device 1 (arrow with solid line) or by the frequency changer power unit 2 (dotted line), as will be more clear in the following descriptions of the first preferred embodiment and the second preferred embodiment or the third preferred embodiment.
The input side control 6 is connected with the output side control 8 . The output side control 8 , which is shown in FIG. 2, by way of example is a VVVF control known from the above-described prior art, such that an explanatory description is omitted here. The control 8 controls or regulates the frequency transformer 4 being connected to a plurality of solid state switches 41 through 46 .
In FIG. 3, there is shown the frequency changer power unit 2 as a plurality of direct current rectifier diodes 21 to 26 in a bridge circuit (a B 6 bridge). As a first preferred embodiment, the switching device 1 has single-phase relays 11 , 12 and 13 with respective relay answering-back 61 , 62 and 63 to generate the monitoring signals 60 to the input side control 6 , wherein the drive control of the single-phase relays 11 , 12 and 13 is performed by relay coils 71 , 72 and 73 responding to the switching-off signals.
In FIG. 4, there is shown the frequency changer power unit 2 also with direct current rectifier diodes 21 to 26 in a bridge circuit (B 6 bridge). As a second preferred embodiment, a switching device 1 ′ with intrinsically safe semiconductor relays 14 , 15 and 16 has fault reporting outputs 64 , 65 and 66 for answering-back to the input side control 6 with the monitoring signals 60 , wherein the drive control of the semiconductor relays 14 , 15 and 16 is shown by switching-off signal lines 74 , 75 and 76 .
In FIG. 5 there is shown a frequency changer power unit 2 ′ with the direct current rectifier diodes 21 to 23 and a plurality of controlled direct current rectifiers 27 to 29 in a bridge circuit (B 6 bridge). In a departure from the circuits shown in the FIGS. 3 and 4, the direct current rectifiers 24 , 25 and 26 are replaced by the controlled direct current rectifiers 27 , 28 and 29 . The controlled direct current rectifiers 27 , 28 and 29 form a switching device 1 ″ and are controlled respectively by switching-off signal lines 77 , 78 and 79 from the input side control 6 . Provided in each bridge branch of the frequency changer power unit 2 ′ are sensors 67 , 68 and 69 , which sensors are constructed in such a manner that they generate the monitoring signals 60 to the input side control 6 as a respective signal state of the bridge branch in which they are provided. The sensors 67 , 68 and 69 are, in that case, preferably current sensors such as, for example, Hall sensors or current measuring coils.
A monitoring according to the invention in all preferred embodiments takes place, in particular, in the closed or switched-on state of the switching devices 1 , 1 ′ or 1 ″ whereby the prior art problem of a continual charging and discharging of the intermediate circuit of the static transformer is eliminated. The direct current rectifiers of the static transformers 2 and 2 ′ operate in a bridge circuit B 6 bridge, as shown in the FIGS. 3 to 5 . If a bridge branch is now switched off, a B 4 bridge is still available for the direct current rectification. The B 4 bridge has sufficiently strong output power to maintain the intermediate circuit 2 , 3 for permanent drive. The three bridge branches, and thus the drive equipment, are successively switched off in each standstill phase of the elevator. The switching-off of each branch can and must be separately monitored. The switching device 1 , 1 ′ or 1 ″ is checked after each travel of the elevator car for the functional capability of an all-pole switching-off according to the standard EN 81-1 of 1998 under 12.7 mentioned above.
The monitoring signals 60 generated to the input side control 6 are processed in the control, wherein the demands on fault examination and on safety devices according to the standard EN 81-1 of 1998 under 14.1 mentioned above are obviously taken into consideration.
For example, in the case of a fault in one of the three bridge branches, the other branches are activated and switched off. A new starting-up of the elevator is prevented. A defective branch also leads to no energy flow. The circuit remains inactive and no energy is applied to the drive or motor 5 .
If a fault happens simultaneously in two of the three bridge branches, the energy flow by way of the frequency transformer 4 can still be interrupted by reporting to the output side control (VVVF) 8 , so that no energy is applied to the drive or the motor 5 .
If a fault simultaneously happens with exactly two of the six switches, then an energy flow does indeed arise, but this does not lead to a three-phase field in the drive and thus to any risk, as in this case the brake can keep the drive at standstill.
There is thus disclosed in the foregoing a development of a monitoring device for the drive equipment for elevators, which exhibits, in particular, the advantage that a charging or discharging of an intermediate circuit is eliminated and that a selective switching-off is possible.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | A definite switching-off of drive equipment for elevators is accomplished with a control at an input side external of a frequency changer power unit that ascertains the presence or the absence of monitoring signals which are derived from the mains voltage at the input of the frequency changer power unit. Upon ascertaining the presence of one or more such signals when the drive is at standstill, the input side control interrupts the energy flow to the frequency changer power unit by generating a switching-off signal to a switching device to disconnect the mains voltage. | 1 |
This is a continuation-in-part application of U.S. patent application Ser. No. 11/380,123 filed on Apr. 25, 2006 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mechanical seal, and, particularly, to a mechanical seal with a retainer holding two compression rings by engaging blocks and engaging with two rotating seal rings by a plurality of slide legs.
2. Description of the Related Art
Referring initially to FIG. 1 , a conventional rotary machine such as a pump system has a shaft 9 , which may be used to stir liquids contained in a housing such as a liquid tank. In rotating operation, the rotary machine functions as a stirring apparatus of the housing for example. The rotary machine generally includes a mechanical seal for keeping the stirred liquids within the housing.
Typically, the mechanical seal includes a gland 7 and a rotating assembly 8 . The gland 7 permits extension of the shaft 9 and mounts the shaft 9 on equipments such as the said housing. The rotating assembly 8 is securely mounted on and rotated with the shaft 9 while being received in the gland 7 . The gland 7 includes a shaft bore 70 , a fluid inlet 71 , and a fluid outlet 72 . The shaft bore 70 longitudinally extends through the body of the gland 7 for the rotating assembly 8 and shaft 9 to pass through. The fluid inlet 71 and fluid outlet 72 both communicate the outside of the gland 7 and the shaft bore 70 for gas or a coolant to be guided into and out of the shaft bore 70 through the fluid inlet 71 and the fluid outlet 72 . Besides, two stationary seal rings 73 are oppositely received in the shaft bore 70 at two ends thereof, and longitudinally sandwiched between the gland 7 and rotating assembly 8 , with both of the stationary seal rings 73 being able to move longitudinally.
The rotating assembly 8 includes a retainer 81 , a pair of compression rings 82 , a pair of O-rings 83 , a pair of rotating seal rings 84 and a shaft sleeve 85 . The retainer 81 , the compression rings 82 , the O-rings 83 and the rotating seal rings 84 are mounted and assembled on an outer periphery of the shaft sleeve 85 . There are a series of spring members 810 provided on each of two longitudinally opposite sides of the retainer 81 for bias forces of the spring members 810 to oppositely push the two compression rings 82 outwards relative to the retainer 81 . Besides, a plurality of pins 811 are also sandwiched between the retainer 81 and the compression rings 82 for preventing the compression rings 82 from revolving about the shaft 9 . Two side surfaces of each compression rings 82 are respectively in contact with the corresponding spring members 810 and the corresponding rotating seal ring 84 . The O-rings 83 are disposed between the compression rings 82 and the rotating seal rings 84 for providing sealing effects therebetween. Each of the rotating seal rings 84 closely abuts one of the stationary seal rings 73 . Furthermore, the shaft sleeve 85 is mounted on the shaft 9 and rotated therewith.
When the shaft 9 rotates, the stationary seal rings 73 in the shaft bore 70 of the gland 7 elastically abut against the rotating seal rings 84 of the rotating assembly 8 . In long-term use, there are abrasions occurring between the stationary seal rings 73 and the rotating seal rings 84 of the rotating assembly 8 . The bias forces of the spring members 810 ensure no gap existing between the stationary seal rings 73 and the rotating seal rings 84 by successively pushing the rotating seal rings 84 through the corresponding compression rings 82 . Consequently, the bias forces of the spring members 810 can reduce the possibilities of liquid leakage in the interior of the mechanical seal.
The conventional mechanical seal has several drawbacks in manufacture. In the installing process, the spring members 810 must be disposed between each side of the retainer 81 and the corresponding rotating seal rings 84 without any positioning member before the whole rotating assembly 8 is completely fixed on the shaft 9 . The primary problem in such a structure is the difficulty in assembling or maintaining due to the fact that the spring members 810 may be easily fallen off from the retainer 81 . Disadvantageously, this may result in a low efficiency in assembly of the above-mentioned elements of the mechanical seal. Moreover, convenience in assembly is especially important for repair or replacement of the rotating seal rings 84 due to the said abrasions thereof.
Another problem naturally occurring during use of such a mechanical seal is due to the fact that liquids contained in the housing may permeate through a clearance existing between the compression ring 82 and the rotating seal rings 84 . With the structure shown in FIG. 1 , because the spring members 810 for pushing the rotating seal rings 84 at two sides of the retainer 81 are isolated, there is no assistant effect provided by the spring members 810 to prevent the compression rings 82 from revolving about the shaft 9 . In this circumstance, the liquid pressure can press the O-ring 83 and the compression ring 82 to be moved backward to the retainer 81 , and thus can further compress the spring members 810 to be retracted. Consequently, the rotating seal rings 84 cannot exactly abut against the corresponding stationary seal rings 73 . Disadvantageously, the possibility of leakage in such a mechanical seal is increased.
Another conventional mechanical seal in U.S. Pat. No. 5,375,853 and titled “SECONDARY CONTAINMENT SEAL” discloses a retainer with a cylindrical outer circumferential and an inner wall, and an annular disk element with several apertures is arranged along a central portion of the inner wall. Therefore, a plurality of springs can be inserted in the apertures and sandwiched between a pair of discs disposed on two sides of the annular disk element, with the said springs oppositely pushing two rotating seal rings to respectively abut two stationary seal rings through the said pair of discs. However, in order to retain the discs and rotating seal rings within the retainer, there should be an internal groove adjacent to each end of the retainer for receiving a snap ring with a radially extending wall. As a result, the invention disclosed in the said cited patent provides a complex structure and an assembly process that are still inconvenient for processing the repair or replacement of the rotating seal rings. Furthermore, in operation, the retainer of this cited structure has to suffer a large torque and a revolving movement of the discs. Besides, still another conventional mechanical seal disclosed by U.S. Pat. No. 3,888,495, titled “DUAL-COOLED SLIDE RING SEAL,” provides a structure similar to the last cited patent and also has the same problem of inconvenience in assembly.
Another US patent titled “SELF-CONTAINED ROTARY MECHANICAL SEALS” and U.S. Pat. No. 4,213,618 shows another conventional mechanical seal mounted on a shaft for rotating therewith and including a lug holder, a plurality of lugs, a plurality of belleville washers, a contact washer, and a carbon seal washer. The lug holder is radially fixed around the shaft, with the lugs extending from the lug holder and parallel to the shaft. The belleville washers are radially surrounded by the lugs and axially compressed between the lug holder and the contact washer to create a spring force urging the carbon seal washer forwards into abutting against a seal seat. Regarding to this conventional invention, what is characterized is that a plurality of tines extending from the lugs in a direction perpendicular to the lugs and concentric to the shaft is provided while several shoulders radially extend from the carbon seal washer. Besides, the shoulders are dimensioned for engagement with the lugs and tines. In detail, a distance of a gap between two adjacent tines of two different lugs is not smaller than a length of the shoulder, so that the shoulder can pass through the gap and received between the said two different lugs. Although convenience in assembly for mechanical seal is improved by this conventional invention, the belleville washers and contact washer are still easy to fall out of the space defined by the lugs once the carbon seal washer is removed. And this is inconvenient for repair or replacement of the carbon seal washer as well. Furthermore, because the carbon seal washer directly abuts against the tines, the shoulders may be easily damaged due to axially pushing force of the belleville washers. Hence, there is a need for a further improvement over the conventional mechanical seal.
SUMMARY OF THE INVENTION
The primary objective of this invention is to provide a mechanical seal with a retainer and two compression rings for easily maintaining a plurality of spring members between the two compression rings and in a plurality of spring holes of the retainer while two rotating seal rings are axially released from the retainer, with the retainer further providing a plurality of engaging blocks for retaining the compression rings and spring members in the retainer. And, the mechanical seal is used as a dual cartridge seal with two-way-pushing spring members to provide a balanced structure. As a result, the release of the rotating seal rings are completed without disengagement between the spring members, retainer, and compression rings, and only stationary seal rings and rotating seal rings have to be routinely replaced.
The secondary objective of this invention is to provide the mechanical seal, which has a shaft sleeve with a positioning flange disposed at an outer periphery thereof to limit an axial movement of an O-ring or one of the rotating seal rings. Accordingly, the positioning flange of the shaft sleeve can enhance the sealing effect of the rotating assembly.
Another objective of this invention is to provide the mechanical seal with a reduced area of the said interface. Accordingly, the mechanical seal is suitable for use in viscous liquid stir.
Further another objective of this invention is to provide the mechanical seal with a stirring unit that forms an end of the shaft sleeve and faces the said interface. Consequently, suspended impurities in the liquid are unable to accumulate in the said interface.
The mechanical seal in accordance with an aspect of the present invention includes an gland for being mounted on a housing, a rotating assembly for being passed through by a shaft, and two stationary seal rings separately installed on the gland, with the rotating assembly being arranged between the gland and the stationary seal rings. An inner wall of the gland defines a shaft bore for the rotating assembly as well as the shaft to pass through. And the rotating assembly comprises a retainer, a first compression ring, a second compression ring, a plurality of spring members, a first rotating seal ring, a second rotating seal ring, an a shaft sleeve. The retainer has a primary ring, a plurality of first slide legs, and a plurality of second slide legs. The primary ring is coaxial with the shaft bore and defines a first axial surface and a second axial surface at two axial ends thereof, and a plurality of spring holes communicate the said first and second axial surfaces. The first slide legs are formed on the first axial surface and axially extend outwards while an free end of each first slide leg has a first engaging block protruding to an axial line of the shaft bore. The second slide legs are formed on the second axial surface and axially extend outwards while an free end of each second slide leg has a second engaging block protruding to the said axial line. The first compression ring is coaxial with the shaft bore and formed with at least one cutaway portion at an outer periphery thereof. And the first compression ring is movably positioned between the first axial surface and the first engaging block in axial direction and is radially surrounded by the first slide legs. The second compression ring is also coaxial with the shaft bore and formed with at least one cutaway portion at an outer periphery thereof. And the second compression ring is movably positioned between the second axial surface and the second engaging block in axial direction and is radially surrounded by the second slide legs. The spring members are separately received in the spring holes and oppositely abut against the first and second compression rings with two ends. The first rotating seal ring has one end being abutted by the first compression ring, and a plurality of first notches are formed in a outer periphery of the first rotating seal ring. And an amount of the first notches is not less than an amount of the first slide legs for each first slide leg to be received in and engaged with one of the first notches. The second rotating seal ring has one end being abutted by the second compression ring, and a plurality of second notches are formed in a outer periphery of the second rotating seal ring. And an amount of the second notches is not less than an amount of the second slide legs for each second slide leg to be received in and engaged with one of the second notches. The shaft sleeve for mounted on the shaft sequentially passes through one of the stationary seal rings, the first rotating seal ring, first compression ring, primary ring of the retainer, second compression ring, second rotating seal ring, and the other stationary seal ring. The spring members oppositely push the first and second rotating seal rings through the first and second compression rings. And thus the first and second rotating seal rings respectively abut against the two stationary seal rings to form an interface between the first rotating seal ring and one of the stationary seal rings and another interface between the second rotating seal ring and the other stationary seal ring. A smallest distance form the axial line of the shaft bore to each cutaway portion is not larger than a distance from the said axial line to each first or second engaging block, and radiuses of the outer peripheries of the two compression rings out of the at least one cutaway portion are larger than the said distance between the said axial line and each first or second engaging block, but are not larger than a smallest distance form the said axial line to each slide leg excluded the engaging blocks. The at least one cutaway portion of the first compression ring is mis-aligned with each first slide leg for the first compression ring to be limited between the first engaging blocks and the first axial surface, and the at least one cutaway portion of the second compression ring is mis-aligned with each second slide leg for the second compression ring to be limited between the second engaging blocks and the second axial surface.
In a separate aspect of the present invention, an end of the shaft sleeve adjacent to the first rotating seal ring forms at least one helical groove facing the said interface between the first rotating seal ring and the corresponding stationary seal ring, with a circular extending direction of each helical groove or helical blade being opposite to a rotating direction of the shaft.
In a further separate aspect of the present invention, at least one untaken notch is inclined relative to the first or second slide leg when the number of the notches of the first or second rotating seal ring is larger than the number of the first or second slide leg.
Further scope of the applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinafter and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a cross-sectional view of a conventional mechanical seal in accordance with the prior art;
FIG. 2 is an exploded, perspective view of a rotating assembly and a fluid guiding member of a mechanical seal in accordance with a first embodiment of the present invention;
FIG. 3 is an assembled, cross-sectional view of the mechanical seal in accordance with the first embodiment of the present invention;
FIG. 4 is a cross-sectional view, taken along line 4 - 4 in FIG. 3 , of a gland of the mechanical seal in accordance with the first embodiment of the present invention;
FIG. 5 is a partial, perspective view of a primary ring, slide legs, and compression rings before a fore-step in assembly is processed;
FIG. 6 is a partial, cross-sectional view of the primary ring, slide legs, and compression rings before the fore-step in assembly is processed;
FIG. 7 is a partial, perspective view of the primary ring, slide legs, and compression rings after a later step in assembly is processed;
FIG. 8 is a partial, cross-sectional view of the primary ring, slide legs, and compression rings after the later step in assembly is processed;
FIG. 9 is an exploded, perspective view of a rotating assembly and a fluid guiding member of a mechanical seal in accordance with a second embodiment of the present invention;
FIG. 10 is an assembled, cross-sectional view of the mechanical seal in accordance with the second embodiment of the present invention;
FIG. 11 a is a partial, perspective view of a blade-formed stirring unit of the mechanical seal in accordance with the second embodiment of the present invention;
FIG. 11 b is a partial, perspective view of a groove-formed stirring unit of the mechanical seal in accordance with the second embodiment of the present invention;
FIG. 12 is a perspective view of a blade-formed helical guiding unit of the mechanical seal in accordance with the second embodiment of the present invention;
FIG. 13 is an assembled, cross-sectional view of a mechanical seal in accordance with a third embodiment of the present invention; and
FIG. 14 is a perspective view of a fluid guiding member of the mechanical seal in accordance with the third embodiment of the present invention.
In the various figures of the drawings, the same numerals designate the same or similar parts. Furthermore, when the term “first”, “second”, “inner”, “outer” “axial”, “radial” and similar terms are used hereinafter, it should be understood that these terms are reference only to the structure shown in the drawings as it would appear to a person viewing the drawings and are utilized only to facilitate describing the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 2 through 4 , views of a mechanical seal in accordance with a first embodiment of the present invention are shown, which includes a gland designated numeral 1 , a rotating assembly designated numeral 2 and a fluid guiding member designated numeral 3 . In the illustrated embodiment, the mechanical seal is installed between a rotary machine and a housing such as a liquid tank or the like for mechanically linking them.
Still referring to FIG. 3 , construction of the gland 1 shall be described in detail. In the first embodiment, the gland 1 is firmly mounted on the housing and includes a shaft bore 10 , a fluid inlet 11 , and a fluid outlet 12 . The shaft bore 10 , through which the rotating assembly 2 and a shaft 9 extends, is penetratingly arranged along an axial direction of the gland 1 and defined by an inner wall of the gland 1 . The fluid inlet 11 and fluid outlet 12 both communicate the outside of the gland 1 and the shaft bore 10 , so that a fluid such as gas or a coolant can be guided into and out of the shaft bore 10 through the fluid inlet 11 and the fluid outlet 12 . Preferably, the said fluid inlet 11 and fluid outlet 12 radially extend in the same axial level relative to the shaft bore 10 . In operation, the fluid provides a heat exchange function, such as heat dissipation or heat absorption, to maintain a suitable operational temperature of the gland 1 and the rotating assembly 2 . Besides, two stationary seal rings 13 are received in the shaft bore 10 at two opposite ends thereof, and axially compressed between the gland 1 and rotating assembly 2 , with both of the stationary seal rings 13 being able to move along an axial direction of the gland 1 .
Referring again to FIGS. 2 and 3 , the construction of the rotating assembly 2 is described in detail as the following. In the first embodiment, the rotating assembly 2 is connected with the shaft 9 and includes a retainer 21 , a pair of compression rings 22 , a shaft sleeve 23 , a first rotating seal ring 24 , a second rotating seal ring 25 and a collar 26 . Extending through the retainer 21 are a series of spring holes to receive spring members identified as “a”. The compression rings 22 are located at either side of the retainer 21 and are in contact with ends of the spring members “a” received in the spring holes. In assembling, each of the compression rings 22 pushes the corresponding rotating seal ring 24 or 25 by spring forces of the spring members “a”. The retainer 21 , the compression rings 22 , the first rotating seal ring 24 and the second rotating seal ring 25 are assembled on the shaft sleeve 23 . The collar 26 securely connects with the shaft sleeve 23 on the shaft 9 such that the rotating assembly 2 may rotate with the shaft 9 .
Preferably, the rotating seal rings 24 , 25 may be made of wear resisting silicon carbide, carbon steel for example, and closely abut against the stationary seal rings 13 mounted in the gland 1 . Besides, the first rotating seal ring 24 is at a side of the mechanical seal facing the inner of the housing, and the second rotating seal ring 25 is at another side of the mechanical seal adjacent to the atmospheric side. Constructions of the retainer 21 , the compression rings 22 , the shaft sleeve 23 , the first rotating seal ring 24 and the second rotating seal ring 25 will be further described in greater detail below.
The construction of the fluid guiding member 3 shall be described in detail, still referring to FIGS. 2 through 4 . In the first embodiment, the fluid guiding member 3 is mounted on the inner wall of the gland 1 , adjacent to at least one of the fluid inlet and outlet 11 , 12 , and provided with an axial hole 30 , a stepped portion 31 and a channel 32 . Preferably, the fluid guiding member 3 is in a ring shape and coaxial with the shaft bore 10 of the gland 1 . A diameter of the axial hole 30 allows the passage of any section of the rotating assembly 2 passed through by the shaft 9 , as best shown in FIG. 3 . An O-ring identified as “b 1 ” rests on a side of the stepped portion 31 to seal a clearance existing between the inner wall of the gland 1 and the fluid guiding member 3 such that any possible leakage of liquid is prevented. The channel 32 is radially extended, connects an outer periphery and an inner periphery of the fluid guiding member 3 , and aligns with both of the fluid inlet 11 and fluid outlet 12 . Preferably, each of two opposite edges defining the channel 32 provides a guiding surface 321 , and the two guiding surfaces 321 are adjacent to and obliquely face the fluid inlet 11 and fluid outlet 12 as best shown in FIG. 4 . Therefore, each of the guiding surface 321 guides the incoming fluid from a direction along the fluid inlet 11 into a peripheral direction of the shaft bore 10 , or guides the outgoing fluid from the peripheral direction of the shaft bore 10 into a direction along the fluid outlet 12 .
Preferably, the retainer 21 is a monolithic one-piece member provided with a primary ring 211 , a plurality of first slide legs 212 , and a plurality of second slide legs 213 . The primary ring 211 is coaxial with the shaft bore 10 and has a first axial surface 214 , a second axial surface 215 , and the series of spring holes, which are previously described and used for receiving the spring members “a”, identified as “ 216 .” The first and second axial surfaces 214 , 215 respectively form two axial ends of the primary ring 210 while the spring holes 215 communicate the two axial surfaces 213 , 214 . Furthermore, in assembly, the primary ring 210 radially surrounds the shaft sleeve 23 . The first slide legs 211 are formed on the first axial surface 214 and axially extend outwards, and an free end of each first slide leg 211 has a first engaging block 217 protruding to an axial line of the shaft bore 1 of the gland 1 . Similarly, The second slide legs 213 are formed on the second axial surface 215 and axially extend outwards, and an free end of each second slide leg 213 has a second engaging block 218 protruding to the axial line of the shaft bore 1 . Preferably, the first and second engaging blocks 217 , 218 are formed on inner surfaces of the first and second slide legs 212 , 213 , which directly face the axial line of the shaft bore 1 .
Particularly referring to the FIGS. 2 and 5 through 8 , a structure of each compression ring 22 and a relationship between the retainer 21 and the compression rings 22 are illustrated as the following. Each of the compression rings 22 is formed with at least one cutaway portion 221 at an outer periphery thereof. Besides, both of the compression rings 22 are also coaxial with the shaft bore 1 . In order to clearly describe the precise relationship between the retainer 21 and the compression rings 22 , the compression ring 22 faced by the first axial surface 214 of the retainer 21 is renamed and designated as “first compression ring 22 a ,” and the compression ring 22 faced by the second axial surface 215 of the retainer 21 is renamed and designated as “second compression ring 22 b .” The first compression ring 22 a is movably positioned between the first axial surface 214 and the first engaging blocks 217 in axial direction, and radially surrounded by the first slide legs 212 . Similarly, The second compression ring 22 b is movably positioned between the second axial surface 215 and the second engaging blocks 218 in axial direction, and radially surrounded by the second slide legs 213 .
Specifically, please refer to FIGS. 5 and 6 , which show schematic, partial views of the retainer 21 and the first and second compression rings 22 a , 22 b before the two compression rings 22 a , 22 b being assembled into the retainer 21 . The two compression rings 22 a , 22 b with the at least one cutaway portion 221 are characterized in that a smallest distance D 1 form the axial line of the shaft bore 1 to each cutaway portion 221 is not larger than a distance D 2 from the said axial line to each first or second engaging block 217 or 218 . Besides, if there are plural cutaway portions 221 utilized in the compression rings 22 a , 22 b , each of the plural cutaway portions 221 corresponds to one of the slide legs 212 , 213 . Therefore, regarding to a fore-step in assembly, taking the first engaging block 217 and the first compression ring 22 a for example, the at least one cutaway portion 221 initially aligns with at least one of the first slide legs 212 for the first compression rings 22 a to be pressed into a space between the first engaging blocks 217 and the first axial surface 214 of the retainer 21 . Please be noted that the pressing of the first compression ring 22 a can be completed with the first compression ring 22 a being parallel to the first axial surface 214 when the numbers of the first slide legs 212 and the at least one cutaway portion 221 are the same. Alternatively, the insertion of the first compression ring 22 a is completed with the first compression ring 22 a being inclined relative to the first axial surface 214 for passing the first engaging blocks 217 . The insertion of the second compression ring 22 b is complete in the same way to place the second compression ring 22 b in a space between the second engaging blocks 218 and the second axial surface 215 of the retainer 21 .
Please further refer to FIGS. 7 and 8 , which show schematic, partial views of the retainer 21 and the first and second compression rings 22 a , 22 b after the said fore-step in assembly is finished. The two compression rings 22 a , 22 b with the at least one cutaway portion 221 are further characterized in that radiuses R of the outer peripheries of the two compression rings 22 a , 22 b out of the at least one cutaway portion 221 are larger than the said distance D 2 but not larger than a smallest distance D 3 form the axial line of the shaft bore 1 to each slide leg 212 or 213 excluded the engaging blocks 217 or 218 . Therefore, regarding to a later step in assembly, taking the first slide leg 212 and the first compression ring 22 a for example, the first compression ring 22 a is turned about the said axial line for the at least one cutaway portion 221 of the first compression ring 22 a to be mis-aligned with each first slide leg 212 . And thus the first compression ring 22 a is exactly limited in the space between the first engaging blocks 217 and the first axial surface 214 . Alternatively, the second compression ring 22 b is also turned for being exactly limited in the space between the second engaging blocks 218 and the second axial surface 215 of the retainer 21 . Therefore, an assembly of the retainer 21 and compression rings 22 a , 22 b can be easily completed by the following steps: firstly pressing or inserting the first compression ring 22 a into the space between the first engaging blocks 217 and the first axial surface 214 through the said fore-step; turning the first compression ring 22 a about the said axial line to complete the misalignment between the at least one cutaway portion 221 of the first compression ring 22 a and each first slide leg 212 through the later step; placing the spring members “a” into the spring holes 216 of the retainer 21 ; pressing or inserting the second compression ring 22 b into the space between the second engaging blocks 218 and the second axial surface 215 through the said fore-step; and turning the second compression ring 22 b about the said axial line to complete the misalignment between the at least one cutaway portion 221 of the second compression ring 22 b and each second slide leg 213 through the later step at last. As a result, the spring members “a” can be always maintained between the two compression rings 22 a , 22 b and in the spring holes 216 .
Referring again to FIGS. 2 and 3 , the shaft sleeve 23 is a monolithic body and includes a shaft-assembling hole 230 , a positioning flange 231 , and an annular groove 232 . The shaft-assembling hole 230 is penetratingly arranged along an axial direction of the shaft sleeve 23 and coaxial with the gland 1 for the shaft 9 to extend through. The positioning flange 231 is disposed at an outer periphery of the shaft sleeve 23 , and used to limit an axial movement of an O-ring identified as “b 2 ” rested on the outer periphery of the shaft sleeve 23 , as best shown in FIG. 3 , so as to provide a greater sealing effect. Alternatively, the positioning flange 231 can also be used to limit an axial movement of the first rotating seal ring. In rotating operation, the O-ring “b 2 ” functions to prevent any possible leakage of liquids contained in the housing via a clearance existing between the shaft sleeve 23 and the first rotating seal ring 24 . Provided on an inner periphery of the shaft sleeve 23 is the annular groove 232 in which receives another O-ring identified as “b 3 ”. Similarly, the O-ring “b 3 ” functions to prevent any possible leakage of liquids contained in the housing via a clearance existing between the shaft sleeve 23 and the shaft 9 . Besides, the retainer 21 is firmly mounted around the shaft sleeve 23 , preferably, by means of screw connection as shown in FIGS. 2 and 3 .
Still referring to FIGS. 2 and 3 , the first rotating seal ring 24 is provided with an axial hole 240 , a first stepped portion 241 , a second stepped portion 242 and a plurality of notches 243 , and is abutted by the first compression ring 22 a and pushed by the spring members “a” through the first compression ring 22 a . The axial hole 240 connects between two opposite sides of the first rotating seal ring 24 . In assembling, the axial hole 240 permits the shaft sleeve 23 to extend through. The first stepped portion 241 and the second stepped portion 242 are formed on an inner periphery of the first rotating seal ring 24 . Formed between the first stepped portion 241 and the positioning flange 231 is a space to receive the O-ring “b 2 ”. Formed on an outer periphery of the first rotating seal ring 24 are the notches 243 arranged on an annular flange (unlabeled), extending in a direction parallel to the first slide legs 212 , and preferably being spaced out evenly. The number of the notches 243 is not less than that of the first slide legs 212 for the first slide legs 212 to be received in and engage with the notches 243 .
Still referring to FIGS. 2 and 3 , the second rotating seal ring 25 is provided with an axial hole 250 , a stepped portion 251 and a plurality of notches 252 , and is arranged to face the second axial surface 215 and pushed by the spring members “a” through the second compression ring 22 a . The axial hole 250 connects between two opposite sides of the second rotating seal ring 25 . In assembling, the axial hole 250 also permits the shaft sleeve 23 to extend through. The stepped portion 251 is formed on an inner periphery of the second rotating seal ring 25 . An O-ring identified as “b 4 ” is received in the stepped portion 251 . Formed on an outer periphery of the second rotating seal ring 25 are the notches 252 , which are also arranged on an annular flange (unlabeled). The number of the notches 252 is not less than that of the second slide legs 213 for the slide legs 211 to be received in and engage with the notches 252 .
Accordingly, the first rotating seal ring 24 , the retainer 21 and the second rotating seal ring 25 are mounted on the shaft sleeve 23 in order. And the repair or replacement of the rotating seal rings 24 , 25 can surely be simply completed by axially taking off the rotating seal rings 24 , 25 from the retainer 21 without a disengagement between the spring members “a,” retainer 21 , and compression rings 22 . Please be noted that, when the number of the notches 243 or 252 is larger than that of the slide legs 212 or 213 , those of the notches 243 or 252 that are untaken by the slide legs 212 , 213 function as an impeller to drive the fluid in the gland 1 when the shaft 9 is rotated. Moreover, the first and second rotating seal rings 24 , 25 are oppositely pushed by the spring members “a” to closely abut against the two stationary seal rings 13 . Furthermore, a limiting member 14 may firmly engaged on the inner wall of the gland 1 , adjacent to the stationary seal ring 13 abutted by the first rotating seal ring 24 , and radially protruding inwards, so as to prevent failure of sealing due to a large axial movement of the said stationary seal ring 13 . And the limiting member 14 is preferably formed in a ring shape and coaxial with the shaft bore 10 of the gland 1 , with a plurality of through holes 141 extending between two axial faces of the limiting member 14 .
Now further referring to FIGS. 9 and 10 , views of a mechanical seal in accordance with a second embodiment of the present invention are shown. Differences between the mechanical seals of the first and second embodiments are that a stirring unit 233 forms an end of the shaft sleeve 23 and an auxiliary guiding unit 219 is formed on an outer periphery of the primary ring 211 . Regarding the stirring unit 233 , the end of the shaft sleeve 23 provides the stirring unit 233 is adjacent to the first rotating seal ring 24 and also facing the inner of the housing. Particularly, the stirring unit 233 radially faces the said interface between the first rotating seal ring 24 and the corresponding stationary seal ring 13 outwards. Specifically, please further referring to FIGS. 11 a and 11 b , the stirring unit 233 can be formed by at least one helical groove 233 a , or by at least one helical blade 233 b . Preferably, form a middle part of the shaft sleeve 23 to the said end thereof, a circular extending direction of each helical groove 233 a or helical blade 233 b is opposite to a rotating direction of the shaft 9 . Thereby, when the shaft 9 turns, the stirring unit 233 can drive the liquid received and stirred in the housing to flow beside the said interface, so as to prevent suspended impurities in the liquid from accumulating in the said interface.
Regarding the auxiliary guiding unit 219 , referring to FIG. 12 , the auxiliary guiding unit 219 is preferably provided with at least one radially outwards formed helical blade 219 a . Therefore, the auxiliary guiding unit 219 can assist the flowing of the fluid received in the shaft bore 10 .
Moreover, please refer to FIG. 9 again. In order to further enhancing efficiency in driving of the fluid, those untaken ones of the notches 243 or 252 can be inclined relative to the slide legs 212 or 213 .
Now, please refer to FIGS. 13 and 14 . Views of a mechanical seal in accordance with a third embodiment of the present invention are shown. Differences between the mechanical seals of the second and third embodiments are that the fluid inlet 11 and fluid outlet 12 radially extend in different axial levels relative to the shaft bore 10 . Besides, the said fluid guiding member 3 is arranged adjacent to the fluid outlet 12 , with the channel 32 aligning with the fluid outlet 12 . Furthermore, another fluid guiding member 3 ′ is also mounted on the inner wall of the gland 1 but adjacent to the fluid inlet 11 . The fluid guiding member 3 ′ is in a tube shape that is coaxial with the shaft bore 1 and has a first axial end providing a plurality of radial grooves 33 and a second axial end providing a radial extended annular protrusion 34 . Particularly, an inner opening of each radial groove 33 faces first rotating seal ring 24 , preferably the interface between the first rotating seal ring 24 and the stationary seal ring 13 , inwards. The annular protrusion 34 connects with the inner wall of the gland 1 by an outer periphery thereof, and provides a curved surface 341 smoothly linking a surface of the fluid inlet 11 and an outer periphery of the fluid guiding member 3 ′ out of the annular protrusion 34 . Accordingly, the fluid guiding member 3 ′ smoothly guides the fluid inputted from the fluid inlet 11 to pass through the radial grooves 33 and directly cooling down or heating up the first rotating seal ring 24 and stationary seal ring 13 close to the said interface.
As has been discussed above, base on the design of the retainer 21 and the compression rings 22 , assembly and repair of the mechanical seal of the present invention without a disengagement of the spring members “a” is easy to be completed, which is absolutely unachievable for those sited prior arts.
Although the invention has been described in detail with reference to its presently preferred embodiment, it will be understood by one of ordinary skill in the art that various modifications can be made without departing from the spirit and the scope of the invention, as set forth in the appended claims. | A rotating assembly of a mechanical seal includes a retainer, a pair of compression rings, a shaft sleeve, a first rotating seal ring and a second rotating seal ring. The retainer includes a plurality of spring members and a plurality of slide legs longitudinally extended in opposite directions to define limiting spaces where the compression rings are correspondingly restricted. The compression rings are located at opposite sides of the retainer between which the spring members are arranged. In assembling, the retainer, the compression rings, the first rotating seal ring and the second rotating seal ring are assembled on the shaft sleeve. Spring forces of the spring members can actuate the compression rings to push the first rotating seal ring and the second rotating seal ring in the opposite directions. | 5 |
BACKGROUND OF THE INVENTION
[0001] The present invention is generally directed to a tackling practice device. More particularly, the present invention is directed to an anthropomorphic tackling dummy having a channel for positioning the tackling dummy in multiple positions rotationally relative to one another.
[0002] Tackling and blocking are some of the most important skills in football. A successful tackle can prevent a player on an opposing football team in possession of the football from scoring a touchdown. A successful block can prevent a member of an opposing team from being able to reach and tackle a quarterback while still in possession of the football prior to a throw. Tackling practice devices are well-known in the art and are designed to be used for the purpose of allowing a football athlete to practice both tackling and blocking techniques. A conventional tackling practice device, such as those described in U.S. Pat. Nos. 1,962,088 and 2,237,600, generally includes a frame having a padded surface on an upright portion.
[0003] Conventional tackling devices, such as those described above, have certain disadvantages. For example, the padded surface may be nothing more than a padded rectangular block that fails to simulate an anthropomorphic shape. Even if the padded surface is in an anthropomorphic shape, the padded surface cannot be adjusted to simulate the stance of an opposing player in anything other than a frontal configuration.
[0004] Various attempts have been made to overcome the problems associated with conventional tackling machines. For example, U.S. Pat. No. 2,620,188 discloses a resilient bag support having a frame with two skids, an upright structure and a pad resiliently mounted on a coil spring. While this tackling machine may simulate the actual reaction a player encounters when contacting an opponent in an actual game, the bag is non-anthropomorphic. The generally cylindrical shape of the bag does little to simulate the actual body of an opponent. In another example, U.S. Pat. No. 3,216,724 discloses a football practice apparatus. This apparatus only includes padded dummies in a fixed orientation suitable only for simulating an opponent in a frontal configuration. In an additional example, U.S. Pat. No. 5,090,696 discloses a pop-up tackling practice machine. While this apparatus includes a padded dummy simulating an anthropomorphic shape, the dummy is in a fixed orientation suitable only for simulating an opponent in a frontal configuration.
[0005] Accordingly, there is a need for a tackling apparatus having a dummy simulating an anthropomorphic shape. There is a further need for a tackling apparatus having a dummy that is adjustable into both frontal and sideways configurations. The present invention fulfills these needs and provides other related advantages.
SUMMARY OF THE INVENTION
[0006] The tackling dummy of the present invention includes a slide having a ground-engaging skid and an upwardly extending frame configured for slide-fit engagement with a channel extending upwardly into an anthropomorphic body having a front side and a relatively narrower profile side. The channel is configured to position the anthropomorphic body into one of two primary configurations relative to the slide. These configurations are rotationally spaced about the longitudinal axis of the channel approximately 90° from one another. Preferably, the anthropomorphic body includes a pad comprising foam, rubber or gel similar to that of football pads or other football gear. It is also preferable that the anthropomorphic body be angled between 45° and 90° when engaged to the frame.
[0007] The frame is a substantially rectangular member comprising a lower portion connected to the slide, an angled intermediate portion and an upwardly extending top section for receiving the channel. In one embodiment, the channel is X-shaped and preferably configured for slide-fit engagement with the frame.
[0008] Furthermore, the tackling dummy of the present invention may further include a strap extending from the lower side of the anthropomorphic body. The strap restricts vertical travel of the anthropomorphic body while engaged with the frame. The strap effectively prevents detachment of the anthropomorphic body from the frame during use. Accordingly, it is preferable that the strap be adjustable. A clip selectively connected to the strap secures the anthropomorphic body to the frame when the anthropomorphic body is in use. Detachment of the clip enables the anthropomorphic body to be removed and reconfigured on the upwardly extending frame of the slide. Preferably, the anthropomorphic body comprises plastic, metal or a polymeric composite.
[0009] Other features and advantages of the present invention will become apparent from the following more detailed description, when taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings illustrate the invention. In such drawings:
[0011] FIG. 1 is a side elevation view of a tackling dummy embodying the present invention, illustrating using the dummy for tackling practice;
[0012] FIG. 2 is a perspective view of the tackling dummy of FIG. 1 , illustrating the dummy in a sideways configuration;
[0013] FIG. 3 is another perspective view of the tackling dummy of FIG. 1 , illustrating an internal dummy positioning mechanism;
[0014] FIG. 4 is an exploded perspective view of the tackling dummy of FIG. 2 ;
[0015] FIG. 5 is a partially exploded perspective view of the tackling dummy of FIG. 1 , illustrating the dummy in a frontal configuration; and
[0016] FIG. 6 is a perspective view of the tackling dummy of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] As shown in the figures for purpose of illustration, the present invention resides in a tackling machine having a dummy in an anthropomorphic shape and adjustable between a front and profile configuration.
[0018] With reference to FIG. 1 , the tackling dummy 10 includes a generally rectangular sled or frame 12 and an upright dummy support 14 upon which a dummy 16 is removably mounted. The frame 12 includes a pair of tubular side members 18 , 20 , a tubular rear end member 22 , a tubular front end member 24 and a tubular lateral support member 26 . The lateral support member 26 is connected to the frame 12 between the side members 18 , 20 , toward the front end member 24 .
[0019] The upright dummy support 14 has a narrow generally rectangular member with a corresponding rectangular cross-section. The upright dummy support 14 is made of a suitably resilient material (e.g., metal, plastic, composite material, or the like) for simulating the actual reaction a player encounters when contacting an opponent in an actual game. The upright dummy support 14 resists impact and returns energy from the impact back to the player. The upright dummy support 14 is preferably connected to the frame 12 and the lateral support 26 . The upright dummy support 14 extends away from the frame 12 , bending between forty-five to ninety degrees relative to a horizontal surface 28 ( FIG. 1 ) upon which the frame 12 rests. The tubular members 18 , 20 , 22 , 24 of the frame 12 may be made of a single tube bent into the configuration best shown in FIGS. 2-6 and may be made of a suitable material such as metal, plastic, a composite material or the like. The lateral support member 26 may be suitably attached to the frame 12 by various mechanisms including, but not limited to, mechanical fasteners (e.g., bolts, screws or the like), welding or a combination thereof. Alternatively, the side members 18 , 20 may angle upward toward the rear end member 22 of the frame 12 by the rear end member 22 relative to the horizontal surface 28 upon which the frame 12 rests. The upturned end is designed to prevent the tackling dummy 10 from plowing into the ground when the frame 12 is moved by a player during tackling practice.
[0020] The dummy 16 is an anthropomorphic padded frame 30 . The padding material may include foam, rubber, gel and other materials designed to simulate the feel of a human body. The anthropomorphic padded frame 30 is designed to resemble the torso of a human, including a lower body portion 32 , an upper body portion 34 and two laterally extending arm/shoulder portions 36 . The padded frame 30 includes a generally cylindrical internal recess (not shown) on a lower end thereof into which an interconnecting mechanism 38 may be inserted and secured therein. The interconnecting mechanism 38 is designed to allow the dummy 16 to be removably mounted to the upright dummy support 14 in both frontal ( FIG. 6 ) and sideways ( FIG. 2 ) configurations. The dummy 16 is slidably received by the interconnecting mechanism 38 and thereafter received by the upright dummy support 14 by sliding a free end 40 of the interconnecting mechanism 38 thereover. A strap 52 , as best shown in FIGS. 3-4 , is connected to the base of the interconnecting mechanism 38 to prevent inadvertent detachment of the interconnecting mechanism 38 from the upright dummy support 14 during use of the tackling dummy 10 . A looped end 54 of the strap 52 is connected to a retaining ring 56 . The retaining ring 56 is mounted to the bottom of the upright dummy support 14 via a connector 58 . When the connector 58 is engaged to the retaining ring 56 and the looped end 54 of the strap 52 ( FIG. 3 ), the vertical travel distance of the interconnecting mechanism 38 along the free end 40 of the upright dummy support 14 is accordingly restricted to prevent detachment of the interconnecting mechanism 38 from the upright dummy support 14 . The connector 58 is disengaged from the retaining ring 56 when the interconnecting mechanism 38 is to be removed from the upright dummy support 14 , as illustrated in exploded form in FIG. 4 .
[0021] The interconnecting mechanism 38 comprises a receptacle 42 including two intersecting generally rectangular channels 44 that fit into an X-shaped recess formed in the dummy 16 . The channels 44 are connected to an annular plate 46 having an X-shaped aperture (not shown) through which the free end 40 of the upright dummy support 14 can be inserted. A front side 48 of the dummy 16 is aligned with one channel 44 of the X-shaped recess and a pair of profile sides 50 of the dummy 16 are aligned with the other channel 44 of the X-shaped recess. In this manner, the dummy 16 can be lowered onto the free end 40 of the upright dummy support 14 . Accordingly, the free end 40 enters a selected rectangular channel 44 such that the dummy 16 can be positioned in either a sideways configuration ( FIG. 2 ) or a frontal configuration ( FIG. 5 ). The recess may also come in a variety of other cross-sectional shapes (e.g., ovoid, rectangular, square or the like) or a combination of such shapes with the cross-section of the free end 40 shaped accordingly.
[0022] A fitted detachable jersey may also be attached to the dummy 16 to simulate the team colors of an opposing team.
[0023] Although an embodiment has been described in detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims. | The tackling dummy includes a slide having a ground-engaging skid and an upward extending frame configured to receive a channel formed in an anthropomorphic body having a front side and a relatively narrower profile side. The channel extends upwardly into the anthropomorphic body from a lower side thereof and engages the upwardly extending frame for positioning the anthropomorphic body in one of two primary configurations relative to the slide. These configurations are rotationally spaced about the longitudinal axis of the channel approximately 90° from one another. | 0 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/435,633, filed on Dec. 19, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention pertains to systems used to complete subsurface wells, and particularly to systems designed to reduce the number of trips required in and out of the well to complete the well.
[0004] 2. Related Art
[0005] Oil and gas wells are very expensive to drill and complete. A major cost factor is the expense of having a rig at the well site. Significant savings can be realized if the time a rig is needed is minimized.
[0006] One way to minimize rig expense is to provide a system that combines various completion operations. Once such a system is placed in the well, the rig can be removed and alternative, cheaper means can be used to operate the completion system. For example, a tubing conveyed perforating assembly may be used in combination with a sand control assembly, or a sand control assembly may be run in with production tubing. Combining originally separate systems reduces the number of required runs.
[0007] However, existing combinations still require more than one trip to achieve commonly desired completion objectives. Also, one or more capabilities may be compromised in existing tools. The present invention addresses those issues.
SUMMARY
[0008] The present invention provides for a completion system that can be deployed in a single downhole trip, yet still achieve desired completion objectives.
[0009] Advantages and other features of the invention will become apparent from the following description, drawings, and claims.
DESCRIPTION OF FIGURES
[0010] [0010]FIG. 1 is a schematic view, with partial cut-away, of a true rigless one-trip system according to an embodiment of the invention.
[0011] FIGS. 2 A- 2 L are schematic views, with partial cut-away, of the one-trip system of FIG. 1, showing various operational configurations.
DETAILED DESCRIPTION
[0012] Referring to FIG. 1, a true rigless one-trip system 10 has, in accordance with an embodiment of the invention, an upper completion assembly 12 and a lower completion assembly 14 .
[0013] Lower completion assembly 14 comprises a selective nipple 16 , a shroud 18 , an inner string 20 , a no-go nipple 22 , a firing head 24 , a safety spacer 26 , and a perforating gun 28 . Lower completion 14 may also include a pupjoint 30 . Pupjoints 30 are generally short sections of tubing used to join elements and to attain a desired spacing between those elements.
[0014] Selective nipple 16 has a profile that selectively accepts and releasably secures a device having a mating profile while rejecting (i.e., allows to pass) those devices having non-conforming profiles. Selective nipple 16 is used to properly position a device in a wellbore.
[0015] Shroud 18 is a pipe that is joined to the lower end of selective nipple 16 , but does not engage or otherwise interfere with the profile of selective nipple 16 . Shroud 18 initially serves to house and protect inner string 20 , which is initially disposed in the tubular interior of shroud 18 , and serves as a structural element from which other elements can attach.
[0016] Inner string 20 comprises a sand exclusion device or sand screen 32 and a lock 34 . Inner string 20 may also include pupjoints 30 or blank pipe (not shown) for spacing, and may optionally include a lower sliding sleeve 36 . Though generally referred to herein as sand screen 32 , sand exclusion devices 32 include, but are not limited to, wire-wrapped perforated or slotted base pipes, mesh-enclosed perforated or slotted base pipes, and expandable screens such as bi-stable expandable elements. Sand screen 32 has a mating profile to engage the profile of selective nipple 16 and is initially disposed in lower completion assembly 14 with the matching profiles engaged and locked. Lock 34 prevents the unintended release of sand screen 32 from selective nipple 16 .
[0017] No-go nipple 22 attaches to and extends from the lower end of shroud 18 . It has an interior profile like that of selective nipple 16 such that a mating profile such as the profile of sand screen 32 can be secured therein. However, whereas selective nipple 16 will, when lock 34 is not engaged and when sufficient downward force is applied, allow a mating profile to move downward in the wellbore past the profile, no-go nipple 22 will not allow such a mating profile to pass. Thus, no-go nipple 22 establishes a lower limit to which a mating profile such as that of sand screen 32 can travel.
[0018] Firing head 24 attaches to the lower end of no-go nipple 22 . Firing head 24 can be, for example, hydraulically or mechanically actuated and has an automatic gun release to automatically detach spacer 26 and gun 28 upon detonation of gun 28 . Spacer 26 connects at its upper end to the lower end of firing head 24 , and at its lower end to the upper end of gun 28 . It is notable that gun 28 is not attached to inner string 20 , and particularly not attached to sand screen 32 . Gun 28 can be, among other choices, a conventional perforating gun or a tubing conveyed perforator.
[0019] Upper completion assembly 12 comprises some combination of the following elements. Not all elements will necessarily be present in every possible embodiment because the particular requirements of a particular well may not dictate it. Generally, upper completion 12 comprises all or some of the following structural elements. At or near the earth's surface, a valve 38 is located. Valve 38 is sometimes referred to as a Christmas tree. Immediately below valve 38 and sealingly set in production casing 40 is a tubing hanger 42 . Production casing 40 is a type of pipe that is generally cemented in place in the wellbore and, though an integral part of the well completion, is not for our purposes considered part of upper completion 12 . Production casing 40 extends from the earth's surface down into the wellbore past the formation that is the zone of interest
[0020] Upper completion 12 further comprises production tubing 44 , sealingly hung from tubing hanger 42 . For safety, a surface-controlled subsurface safety valve 46 is placed inline with production tubing 44 . If artificial lift is needed, gas lift mandrels 48 with dummy valves can be included and are shown in FIG. 1 some distance below safety valve 46 . Other forms of artificial lift can be used such as electrical submersible pumps. Upper sliding sleeves 50 may optionally be included as part of upper completion 12 . A production packer 52 attaches inline with production tubing 44 and a gravel pack extension 54 having a gravel packing sliding sleeve 56 may optionally be attached below packer 52 . The lowermost element of upper completion 12 connects to the upper end of selective nipple 16 .
[0021] In operation, one-trip system 10 is run into the well, as shown in FIG. 2A. Guns 28 are positioned adjacent the formation that is the zone of interest. Multiple guns 28 can be simultaneously run if there are multiple zones of interest. Once one-trip system 10 is in place, the rig can be removed from the well site. The remainder of the completion operations do not require the use of a rig, but instead use a continuous medium such as coiled tubing 58 , wireline, or slickline, for example, for mechanical manipulation or fluid transport from the earth's surface.
[0022] To secure one-trip system 10 in place in the wellbore, packer 52 is actuated and tested for integrity (FIG. 2B). Packer 52 may be actuated by various means, such as hydraulically or mechanically, depending on the packer type. Gun 28 is then fired to perforate production casing 40 . Upon firing, gun 28 and spacer 26 disconnect from lower completion assembly 14 and drop to the bottom of the well (FIG. 2C). The well can be perforated in an overbalanced, balanced, or underbalanced condition. Various means can be used to fire gun 28 (e.g., hydraulic, mechanical, or electrical). If necessary, sand screen 32 may be open at its bottom end to allow passage of actuating devices.
[0023] Well fluids can be controlled in different ways. The fluids can be forced back into the formation, or, if available, upper sliding sleeve 50 can be opened to allow circulation using the upper well annulus (FIGS. 2D and 2E). Coiled tubing 58 is then run into the well to engage sand screen 32 . Lock 34 is unlocked and sufficient downward force is applied to the coiled tubing 58 to displace sand screen 32 from selective nipple 16 (FIG. 2F). Sand screen 32 is moved until adjacent the perforations made by guns 28 (FIG. 2G). In that position the profile of sand screen 32 mates with the profile of no-go nipple 22 . Lock 34 is re-engaged to lock sand screen 32 in place and the coiled tubing 58 is pulled out of the hole (FIG. 2H).
[0024] To perform the gravel pack operation, various options are available. In one option, a plug 60 is placed in selective nipple 16 and gravel pack sliding sleeve 56 is opened (FIG. 21). The sand control treatment fluid (“gravel”) can be pumped into the well using either the coiled tubing 58 or production tubing 44 . The gravel will exit through ports in extension 54 revealed by the opened sleeve 56 . Gravel travels down the annulus and fills the voids around sand screen 32 (FIG. 2J). When the gravel is packed (“screenout”), usually indicated by a sharp rise in pressure, pumping operations can be halted and the coiled tubing 58 can be used to remove any excess sand. As the coiled tubing 58 is pulled out of the hole, plug 60 is removed, gravel pack sliding sleeve 56 is closed (FIG. 2K), and the well is ready to be placed on production (FIG. 2L).
[0025] In another option not requiring plug 60 but using lower sliding sleeve 36 , gravel is pumped through coiled tubing 58 to pack the space between shroud 18 and sand screen 32 , up to the level of lower sleeve 36 . Lower sliding sleeve 36 is opened using coiled tubing 58 and gravel is further pumped using either coiled tubing 58 or production tubing 44 . Gravel flows through ports exposed by lower sleeve 36 into the well annulus, packing the annulus in the region of shroud 18 . As before, once screenout occurs, pumping operations can be halted and the coiled tubing 58 can be used to remove any excess sand. As the coiled tubing 58 is pulled out of the hole, lower sliding sleeve 36 is closed, and the well is ready to be placed online. If artificial lift is necessary, gas lift mandrels 48 (or other lift means) can easily be actuated. Upper sleeve 56 can be opened to allow annular production, if desired.
[0026] The operational steps described above vary slightly if sand exclusion device 32 is an expandable screen. Also, the lower portion of the well (“rathole”) needs to be extended slightly to accommodate sand accumulation during gravel pack operations. To operate with expandable screen 32 , one-trip system 10 is run in place, the rig is removed, packer 52 is set, and gun 28 is fired and dropped, all as before. Then, gravel or fracturing fluid is pumped through coiled tubing 58 or production tubing 44 through the open gravel pack sleeve 56 until screenout occurs. Coiled tubing 58 then latches onto expandable screen 32 , dislodges it from selective nipple 16 , and moves it downward until it locks into place in no-go nipple 22 . Coiled tubing 58 then engages an expander tool (not shown) and forces the expander tool downward, expanding expandable screen 32 radially outward so that expandable screen 32 is pressed against casing 40 . Upon reaching the bottom of expandable screen 32 , the expander tool can be disengaged from coiled tubing 58 and left in the lower end of expandable screen 32 . As coiled tubing 58 is retrieved from the well it can close sleeve 56 . Coiled tubing 58 can also open optional valves such as the valves in gas lift mandrel 48 to aid production.
[0027] Though the embodiments described refer to sand control techniques, one-trip system 10 may also be used similarly for fracturing operations in which high pressure fluid is injected into the desired subsurface formation and proppants are used to keep the fractures open.
[0028] In the preceding description, directional terms, such as “upper,” “lower,” “vertical,” “horizontal,” etc., may have been used for reasons of convenience to describe the one-trip system 10 and its associated components. However, such orientations are not needed to practice the invention, and thus, other orientations are possible in other embodiments of the invention.
[0029] Although only a few example embodiments of the present invention are described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | The present invention provides for a completion system that can be deployed in a single downhole trip, yet still achieve desired completion objectives. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a flat cathode-ray tube used for such devices as the picture tube and the image display unit for video equipment.
2. Description of Related Art
FIG. 1 is a schematic plan sectional view showing a configuration of a conventional flat cathode-ray tube. In FIG. 1, numeral 7 designates a flat metal housing including a front metal case 7a and a rear metal case 7b. The front side of the front metal case 7a is open, and has a screen glass 4 formed with a phosphor layer 5 sealed from the front side thereof through crystallized frit glass (or a low-melting-point glass, hereinafter referred to as "the frit glass") 15. The front metal case 7a and the screen glass 4 are sealed by glass fusion in some applications. The metal case 7 has built therein an electron beam forming unit as a kind of electron gun including a cathode 1 making up an electron beam source, electron beam extraction means 2 for extracting an electron beam from the cathode 1 and electron beam control means 3 for controlling the passage of the electron beams extracted by the electron beam extraction means 2 with a plurality of electrode plates.
The cathode 1 and the electron beam extraction means 2 are fixed in that order inside of the rear metal case 7b. The electron beam control means 3 has springs 12, 12 mounted at the ends thereof and is suspended thereby, which springs 12, 12 are detachably supported on stud pins 11, 11 of ceramics erected from the side inner wall of the front metal case 7a.
The metal case 7 includes a front metal case 7a with electron beam control means 3 mounted thereon and a rear metal case 7b fixed with a cathode 1 and electron beam extraction means 2 coupled and sealed in opposed relationship to each other. Further, an exhaust pipe 13 for exhausting the interior of the metal case 7 to an ultrahigh vacuum state (10 -5 Pa or less) is arranged on the rear metal case 7b.
Explanation will be made about the operation of the flat cathode-ray tube configured as described above. Upon application of a predetermined voltage to the electron beam extraction means 2 with the cathode 1 maintained at a predetermined potential, an electron beam is extracted from the cathode 1. The passage of the electron beam is controlled by applying a control signal to the electron beam control means 3. When the electron beam is thus correctly impinged on the phosphor layer 5, an image is reproduced. In recent years, as described above, the trend is toward a metal, instead of glass, case employed in order to alleviate the increased weight with the increase in size.
In this flat cathode-ray tube, in order to couple strongly the screen glass 4 and the front metal case 7a to each other through frit glass 15, as shown in FIG. 2, a Cr oxide film (Cr 2 O 3 ) 20 of a few μm thick is required to be formed as a preliminary treatment of the metal material (front metal case 7a). FIG. 3 is an enlarged sectional view showing the coupling portion between the front metal case 7a formed with the Cr oxide film 20 and the screen glass 4 through the frit glass 15.
The oxide film such as Cr oxide film 20, is formed in various ways. Considering the film minuteness and adherence to metal, the wet-hydrogen environment high-temperature oxidation method is considered superior in general. A stainless steel material (SUS430), for example, is known to be formed with a 3-μm oxide film after the process of 1000° C.×about 6 hours. Coupling between the oxide film formed on the metal surface and the frit glass, however, is not considered to have a sufficient coupling strength against the vacuum stress, and this coupling strength is insufficient as a structure of a vacuum case.
It is obvious, on the other hand, that the heating of a metal for long time at high temperatures is a cause of thermal deformation and has an adverse effect on the mechanical properties thereof. As it is known, an early roughening of crystalline particle of some materials leads to brittleness. Also, the heating reduces the flatness of the coupling surface, thereby uniform coupling being made difficult. The problem is therefore that dimensional variations are likely to occur after coupling.
SUMMARY OF THE INVENTION
The invention has been made in order to obviate the above-mentioned problems, and the object thereof is to provide a flat cathode-ray tube by forming a ceramics film or a glass film on the metal surface by thermal spraying in advance and coupling the metal with the glass, thereby realizing a light-weight metal case with high reliability.
A flat cathode-ray tube according to the invention is characterized in that a ceramics film is formed by thermal spraying an oxide family ceramics, or ZrO 2 --Y 2 O 3 , for instance, at the coupling between a metal case and screen glass. A multiplicity of pores generated at the time of thermal spray and existing in the ceramics film absorbs and alleviates the difference in linear expansion coefficient between the oxide family ceramics and the metal case, so that the oxide family ceramics and the metal case are coupled in high coupling strength. Also, the metal case, which is not exposed to high temperatures during the thermal spraying unlike at the time of forming the Cr oxide film in the prior art, is subjected to a lesser thermal deformation.
The feature of the flat cathode-ray tube according to the invention lies in that a ceramics film is formed by thermal spraying an oxide family ceramics at the coupling between a metal case and screen glass, and also the ceramics film is coupled with the screen glass through crystallized frit glass. The coupling strength between the ceramics film and the crystallized frit glass is higher than that between the Cr oxide film and the crystallized frit glass in the prior art. In this way, the coupling strength between the ceramics film and the crystallized frit glass is high, and as described above, that between the ceramics film and the metal case is also high, so that the metal case can be coupled more strongly with the screen glass than in the prior art.
Another feature of the flat cathode-ray tube according to the invention is that a ceramics film is formed by thermal spraying an oxide family ceramics at the coupling portion between the metal case and the screen glass, and also the ceramics film and the screen glass are welded by fusion of glass. As described above, the coupling strength between the ceramics film and the metal case is high and the ceramics film is strongly coupled with the screen glass by glass fusion, thereby so that the metal case can be coupled more strongly with the screen glass than in the prior art.
Still another feature of the flat cathode-ray tube according to the invention resides in that a glass film is formed by thermal spraying inorganic oxide family glass such as SiO 2 --PbO family glass at the coupled portion between a metal case and a screen glass. The thermal spraying of glass having a linear expansion coefficient substantially identical to that of the screen glass permits a coupling strength as high as that obtained when a ceramics film is formed. In this case, too, the high-temperature heat treatment is not necessary and therefore only a small thermal deformation occurs.
A further feature of the flat cathode-ray tube according to the invention is that a glass film is formed by thermal spraying inorganic oxide glass at the coupling of a metal case and in addition the glass film and the screen glass are coupled by crystallized frit glass therebetween. As a result, in addition to the above-mentioned advantages, the coupling strength between the glass film and the crystallized frit glass is higher than that between the Cr oxide film and the crystallized frit glass according to the prior art. Further, since the coupling strength between the glass film and the crystallized frit glass, and also between the glass film and the metal case is so high that the metal case can be coupled with the screen glass more strongly than in the prior art.
A still further feature of the flat cathode-ray tube according to the invention lies in that a glass film is formed by thermal spraying an inorganic oxide family glass at the coupling of a metal case, and also the glass film is coupled with the screen glass by glass fusion. As described above, the coupling strength between the glass film and the metal case is so high and the glass film and the screen glass are coupled to each other so strongly by glass fusion that the metal case and the screen glass can be coupled more strongly than in the prior art.
The above and further objects and features of the invention will more fully be apparent from the following detailed description with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan sectional view showing a configuration of a conventional flat cathode-ray tube.
FIG. 2 is a sectional view showing the front metal case subjected to pretreatment.
FIG. 3 is a sectional view showing the front metal case formed with a Cr oxide film and then coupled with the screen glass through the frit glass.
FIG. 4 is a schematic plan sectional view showing a flat cathode-ray tube according to the invention.
FIG. 5 is an enlarged sectional view showing the coupled portion between the front metal case and the screen glass.
FIG. 6 is a graph showing an example of the in-furnace temperature set at the time of coupling with the frit glass.
FIG. 7 is a schematic diagram showing the manner in which the plasma thermal spraying process is conducted in actual operation.
FIG. 8 is a sectional view showing the coupled portion in enlarged form between the ceramics film and the front metal case.
FIG. 9 is a schematic sectional view showing the coupled portion of a flat cathode-ray tube according to another embodiment of the invention.
FIG. 10 is a graph showing an example of the in-furnace temperature set at the time of glass fusion coupling.
FIG. 11 is a schematic sectional view showing the coupled portion of a flat cathode-ray tube according to still another embodiment of the invention.
FIG. 12 is a schematic sectional view showing the coupled portion of a flat cathode-ray tube according to a further embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will be described in detail below with reference to the drawings showing embodiments.
[Embodiment 1]
FIG. 4 is a schematic plan sectional view showing the configuration of a flat cathode-ray tube according to the invention. In FIG. 4, numeral 7 designates a flat housing-shaped metal case including a front metal case 7a and a rear metal case 7b. The front part of the front metal case 7a is open, and screen glass 4 of silicate family glass is hermetically sealed from the front side thereof through a ceramics film 14 and frit glass (crystallized frit glass) 15. Also, the metal case 7 has built therein an electron beam forming unit as a kind of electron gun including a cathode 1 providing an electron beam source, electron beam extraction means 2 for extracting the electron beam from the said cathode 1 and electron beam control means 3 for controlling the passage of the electron beams extracted by the electron beam extraction means 2 by a plurality of electrode plates.
The cathode 1 and the electron extraction means 2 are securely mounted in that order on the inside of the rear metal case 7b. Also, the electron beam control means 3 has springs 12, 12 mounted at the ends thereof, and is suspended with the springs 12, 12 detachably supported by ceramics stud pins 11, 11 erected from the inner side wall of the front metal case 7a.
The metal case 7 includes the front metal case 7a carrying the electron beam control means 3 coupled in opposed relation to the rear metal case 7b fixedly carrying the cathode 1 and the electron beam extraction means 2. Further, an exhaust pipe 13 for exhausting the interior of the metal case 7 to ultrahigh vacuum state (10 -5 Pa or less) is mounted on the rear metal case 7b.
The operation of the flat cathode-ray tube configured as above will be explained. The cathode 1 is set to a predetermined potential and the electron beam extraction means 2 is supplied with a predetermined voltage thereby to extract electron beams. With a control signal applied to the electron beam control means 3, the passage of the electron beams is controlled to cause the electron beams to impinge accurately on the said phosphor layer 5, thereby reproducing an image.
FIG. 5 is an enlarged view showing the coupled portion between the front metal case 7a and the screen glass 4. The coupling procedure will be described below. First, the coupling surface of the front metal case 7a made of stainless steel (SUS430) processed to predetermined size and shape is toughened by sandblasting using Al 2 O 3 abrasive grains, and further cleansed by degreasing. After that 8% ZrO 2 --Y 2 O 3 powder is thermally sprayed to the thickness of 30 to 50 μm to form a ceramics film 14 at the normal room temperature in the plasma thermal spray apparatus. After coating the frit glass 15 to a predetermined width and thickness, the screen glass 4 is placed thereon and baked at 440° C. for about 40 minutes, thus coupling the front metal case 7a and the screen glass 4.
FIG. 6 is a graph showing an example of the in-furnace temperature set at the time of coupling using the frit glass 15. As shown in FIG. 6, the temperature is increased at the rate of 3.5° C. per minute, and after holding at 470° C. for 60 minutes, decreased to 150° C. at the rate of 2.6° C. per minute, and then at the rate of 2.0° C. per minute. In the case where the in-furnace temperature is set to 470° C., the temperature of the coupling surface of about 440° C. was obtained.
In the ceramics thermal spraying, the plasma thermal spraying process described above is in common practice. FIG. 7 is a schematic diagram showing the manner in which the plasma thermal spraying process is embodied. The plasma thermal spraying is the process in which N 2 , H 2 , or inert gases such as Ne, Ar is ionized by the plasma thermal spray gun 16, the ceramics powder of a material to be coated is fed into a high-temperature high-speed plasma jet issued from the plasma thermal spray gun 16, and the thermally sprayed particles 17 with fusion, injection and acceleration thereof in the jet are thus impinged on the front metal case 7a as the base material, thereby forming a film. The plasma jet is very high in temperature and is suitable for thermal spraying of a high-melting point material such as ceramics. The ceramics particles, after impinging on the base material, are rapidly solidified on being flatly deformed, and are successively accumulated to form a film.
In spite of the fact that the thermal spraying is the process for fusion-depositing a high-melting point material, the temperature increase of the base material is generally known to be comparatively small and to be controlled to about 150° C. Consequently, the likelihood of the base material being deformed by the impingement with the thermally sprayed particles 17 is considered small. In this embodiment, the temperature increase of the front metal case 7a is about 100° C. without any metal deformation and the like. Also, the ceramics film 14 thermally sprayed can be processed to a high dimensional accuracy and a superior surface roughness by grinding.
FIG. 8 is an enlarged sectional view showing the coupled portion between the ceramics film 14 and the front metal case 7a as the base material. This coupling is considered primarily due to the anchoring effect as shown in FIG. 8. A multiplicity of pores generated at the time of thermal spraying and existing in the ceramics film 14 has the ability to absorb and alleviate the difference in linear expansion coefficient between the material thermally sprayed and the base material.
The measurement of the coupling strength of the ceramics film 14 formed by the plasma thermal spraying against the frit glass 15, as compared with other samples, is shown in the table below. The measurement used as samples the stainless steel (SUS430) of 30 mm×30 mm×5 mm thick, the surface of which is subjected to the plasma thermal spraying thereby to form a ceramics film 14 to the thickness of 60 μm, the stainless steel the surface of which is subjected to the wet hydrogen oxidation to form a Cr oxide film 3 μm thick, and a glass plate (#5000). Each sample was heat-treated at 40° C. for an hour to cause natural fusion of frit glass. After thus attaining the diameter of about 25 mm, the coupling strength between the sample plate and the frit glass was measured by the tensile strength test. The data is given as an average value obtained as a result of five tests.
______________________________________Sample Breaking strength Relative strength______________________________________Stainless steel + 61 kg/cm.sup.2 117%ceramics filmStainless steel + 54 kg/cm.sup.2 104%Cr oxide filmGlass plate 52 kg/cm.sup.2 100%______________________________________
The table shows that the coupling strength of the ceramics film 14 against the frit glass is higher than that of the glass or the Cr oxide film which has a proven performance in many fields concerning the coupling with the frit glass. Further, although the metal composition of the metal case in forming a Cr oxide film applied in the prior art is limited to Fe--Cr family, and the like, there is no such a limitation imposed in forming the ceramics film 14 according to the invention.
After a rear metal case 7b is welded by metal to a front metal case 7a with screen glass 4 coupled thereto, vacuum is attained from an exhaust pipe 13 through the heat treatment process at 400° C. for 20 minutes (temperature increased at the rate of 10° C. and decreased at the rate of 10° C. per minute). In the process, no abnormality was observed at the coupling portion between the glass and the metal. Also, after an external atmospheric pressure is applied to the flat cathode-ray tube and the pressure difference of 3 kg is held between the internal and external atmospheres for ten minutes, the case was not damaged nor did the glass/metal coupling exhibit any abnormality. The airtightness check conducted with a He leak detector after the test shows that there is no leak detected that exceeds the apparatus limit.
[Embodiment 2]
FIG. 9 is a schematic sectional view showing the coupled portion between the front metal case 7a and the screen glass 4 of the flat cathode-ray tube according to another embodiment of the invention. According to this embodiment, the front metal case 7a forming the ceramics film 14 and the screen glass 4 are coupled by glass fusion to each other. The remaining component parts are similar to those of FIG. 4. The glass fusion is conducted by heating at 900° C. for 30 minutes and gradually cooling in an N 2 environment furnace using a carbon die for suppressing the setting deformation and positioning the screen glass 4 relative to the front metal case 7a.
FIG. 10 is a graph showing an example of the in-furnace temperature set at the time of glass fusion. As shown in FIG. 10, the temperature is increased at the rate of 20° C. per minute and maintained at 900° C. for 20 minutes, after which it is decreased to 550° C. at the rate of 2.6° C. per minute and subsequently at the rate of 1.7° C. per minute. In this embodiment, as in the above-mentioned embodiments, a satisfactory coupling is obtained.
[Embodiment 3]
FIG. 11 is a schematic sectional view showing the coupled portion between the front metal case 7a and the screen glass 4 of a flat cathode-ray tube according to another embodiment of the invention. According to this embodiment, a glass film 18 is formed on the surface of the front metal case 7a, and further frit glass 15 is formed to couple the front metal case 7a and the screen glass 4. The remaining configuration is similar to that of FIG. 4. In the above-mentioned embodiments a ceramics film 14 is formed by feeding ceramics powder to plasma jet issued from the plasma thermal spray apparatus. According to the invention, glass powder instead of ceramics powder is fed to plasma jet to form a glass film 18 in the thickness of 30 to 50 μm. The SiO 2 --PbO family glass having a linear expansion coefficient of 100×10 -7 /° C. substantially identical to that of the screen glass 4 and a softening point of 660° C. is used as the glass powder.
As in the aforementioned embodiments, the strength and airtightness of the inventional apparatus after rear metal case 7b being welded by metal were tested in vacuum condition, no abnormality was detected for the parts including the glass/metal coupling. The front metal case 7a was used after preheating to 400° C. in order to improve the adhesiveness of the glass film 18, without any deformation observed of the front metal case 7a.
[Embodiment 4]
A satisfactory effect was obtained as in the aforementioned embodiments when the glass film 18 and the screen glass 4 were coupled by glass fusion as shown in FIG. 12.
In the flat cathode-ray tube according to the invention, a sufficient strength, airtightness and dimensional accuracy can be secured with a metal case that can be reduced in weight regardless of the shape and size thereof. As a result, the invention is applicable also to a flat cathode-ray tube such as the High-Vision picture tube requiring a high general assembly accuracy. Further, unlike in the conventional wet hydrogen process, a number of parts can be processed simultaneously and continuously, thereby contributing to a superior mass-productivity.
As this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within metes and bounds of the claims, or equivalence of such metes and bounds thereof are therefore intended to be embraced by the claims. | A flat cathode-ray tube in which a ceramics film or a glass film is formed by thermal spray on the coupled surface of a metal case. This assembly and a glass screen are coupled through crystallized frit glass or by glass fusion. The coupling between the metal case and the glass screen has a coupling strength sufficient to resist the vacuum stress. The metal case, which is not exposed for a long time to high temperatures during thermal spraying, can be made of a metal for realizing a lightweight without any thermal deformation or dimensional variations, thereby attaining satisfactory mechanical properties. | 2 |
RELATED APPLICATIONS
[0001] The present invention claims priority from U.S. Provisional Application Serial No. 60/287,605 filed Apr. 30, 2001, entitled “Method for Efficient Application of a Coating to a Substrate” the entire disclosure of which is hereby incorporated by reference herein.
GOVERNMENT SUPPORT
[0002] This invention was made with government support under the Office of Naval Research—DURIP Grant Nos. N00014-98-1-0355 and N00014-00-1-0147. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The present invention provides a method and an apparatus for efficiently applying a coating to a surface using a directed vapor deposition (DVD) approach, and more particularly the use of improved nozzle devices and related methods.
BACKGROUND OF TIE INVENTION
[0004] The application of a coating to a substrate of a prescribed geometry is required in a variety of engineering applications, including thermal or environmental protection of the substrate, improved wear resistance, altered optical properties or creation of devices on the substrate such as thin film batteries. In all such cases, the ability to deposit compositionally controlled coatings efficiently, uniformly, at a high rate, with high part throughput, and in a cost-effective manner is desired. Some illustrative examples of deposition systems are provided in the following applications and patents and are co-assigned to the present assignee 1) U.S. Pat. No. 5,534,314, filed Aug. 31, 1994, entitled “Directed Vapor Deposition of Electron Beam Evaporant”, 2) U.S. application Ser. No. 09/634,457, filed Aug. 7, 2000, entitled “Apparatus and Method for Intra-layer Modulation of the Material Deposition and Assist Beam and the Multilayer Structure Produced Therefrom”, and 3) PCT International Application No. PCT/IUS01/16693, filed May 23, 2001, entitled “Process and Apparatus for the Plasma Activated Deposition in a Vacuum”. These applications are hereby incorporated by reference herein in their entirety. The present invention discloses, among other things an apparatus and a method for applying a coating(s) on a substrate(s) in an improved and more efficient manner. The present invention method can be applied to coatings of any type onto any substrate geometry. In this document, the application of a thermal barrier coating to a turbine blade is used as a non-limiting example.
[0005] Vapor phase processes are widely used for applying thermal and environmental protection coating systems to components. They are widely used to protect the hot structural components of many gas turbine engines that must operate at temperatures approaching their melting point [1]. As gas inlet temperatures continue to rise, failure by thermally-induced mechanisms has been avoided by making airfoil components with internal cooling conduits, and injecting compressor discharge air to decrease the component temperature [2]. To maximize engine efficiency, however, it is desirable to minimize the use of this air for cooling purposes. Traditionally, this has been accomplished by designing more efficient cooling geometries within the component and by film cooling of the component surface using drilled holes. These approaches have now matured and alternate strategies that exploit the insulating abilities of thermal barrier coatings (TBC's) are being investigated for the thermal protection of engine components.
[0006] The TBC systems currently in use are multilayer systems consisting of an yttria partially-stabilized zirconia (YSZ) top layer that thermally protects the superalloy component, and an underlying MCrAlY (M=Ni, Co) or nickel aluminide bond coat which improves the YSZ adhesion. The YSZ layer has a relatively high thermal expansion coefficient to limit thermally induced strains and a low thermal conductivity resulting in surface temperature reductions of up to 170° C. [3]. This layer is well bonded to a thin (approximately 1 μm) thermally grown (aluminum) oxide (TGO) layer which impedes oxidation and hot corrosion of the underlying component [4]. This TGO layer is formed on the surface of the aluminum-rich alloy layer (bond coat). Either a low pressure plasma spray [5] (LPPS) or pack cementation [6] approach is used to apply the bond coat layer. The high temperature oxidization environment present prior to and during deposition leads to growth of a thin TGO layer at the interface between the TBC and the bond coat layer [7]. The generated YSZ layer consists of a “nontransformable” tetragonal (t′) phase having a complex microstructure consisting of twins and anti-phase boundaries. This microstructure yields a thermomechanically tough coating which has been shown to improve TBC performance by limiting crack propagation in the YSZ layer [8].
[0007] To date, the lowest cost TBC's have been applied using the plasma spray (PS) process, such as an air plasma spray (APS) process. The approach employs a plasma or combustion torch to melt and spray deposit YSZ droplets onto airfoil substrates. These deposits contain disc-like pores in the plane of the coating resulting in a YSZ top layer that has an extremely low thermal conductivity. This is due to the high thermal resistance of the pores oriented normal to the heat flow direction. Unfortunately, these layers also have poor spallation resistance, resulting from a combination of the disc-like coating defects and the large thermal expansion mismatch between the YSZ layer and the bond coat [9]. This lack of reliability limits these coatings to component life extension at current operating temperatures (i.e., they cannot be used to increase engine temperature).
[0008] More recently, TBC's have been produced by electron beam-physical vapor deposition (EB-PVD). Using this technique the YSZ layer has a columnar microstructure with elongated inter-columnar voids aligned perpendicular to the substrate surface. This structure results in a low in-plane stiffness that limits thermomechanical stresses on heating/cooling and improved spallation resistance compared to the LPPS layers [10]. The columns exhibit a tapered shape, growing wider with increased thickness, a faceted surface and a strong {200} crystallographic texture [11]. Failure in these coatings no longer occurs within the YSZ layer but at the TGO/bond coat interface. This failure path appears to result from large stresses within the TGO layer, which increase with oxidation induced layer growth in service [12, 13]. For turbine blade applications, EB-PVD TBC's have the further advantages of limiting the undesirable blocking of air cooling holes during deposition and generating a smoother, more aerodynamic surface [14]. However, EB-PVD coatings have a higher thermal conductivity than their LPPS counterparts [15] and are more costly to apply (due to high equipment costs, deposition efficiencies of about 2-5 percent of the evaporated flux, and relatively slow (approximately 5 micrometers (μm) min −1 ) deposition rates) [16]. To make vapor phase deposited TBC's a viable means for increasing engine performance, improved deposition techniques/strategies are needed.
[0009] The cost of the EB-PVD coatings can be as much as ten times that of PS coatings. The higher equipment costs of EB-PVD are a result of the high vacuum environment that is necessary during deposition (e.g., typically below 10 −6 Torr), high cost of high power electron beam guns, and sophisticated component manipulation needed to achieve acceptable coatings. The operating pressure defines the vacuum pump requirements with lower pressures generally needing more expensive pumps. The low deposition rate and low materials utilization efficiency (MUE) of EB-PVD is related to the distribution of the vapor flux as it leaves the evaporated source. Generally, the vapor flux spreads out from the source with a distribution described by a cos n θ function (where n=2,3,4 or more, and 0 is the angle to the normal axis). The general alignment of the normal axis is referred to herein as the main direction. When relatively long source-to-substrate distances are required (e.g., as in YSZ deposition using EB-PVD where this distance often approaches 50 cm to avoid substrate overheating) deposition efficiency is dramatically decreased to 1-5 percent of the evaporated flux and the deposition rate is proportionally reduced. To overcome the low deposition rate, the evaporation rate from the source materials is raised by increasing the electron beam power. However, this is costly and during YSZ evaporation, increased beam power leads to the production of molten droplets of material rather than atomistic vapor. This produces coating defects, and as a result, other approaches must be used to increase deposition rates. The high cost of deposition also impedes the use of physical vapor deposition methods for the deposition of bond coats.
[0010] The low deposition efficiency results from flux spreading beyond the periphery of the sample. One approach to reduce the spread of the flux exploits entrainment of the vapor in a controllable inert (e.g. helium or argon) carrier gas flow [17]. Such an approach is used in electron beam directed vapor deposition (EB-DVD). In this approach, the combination of a continuously operating 60 kV/10 kW axial e-beam gun (modified to function in a low vacuum environment) and an inert carrier gas jet is used. As shown in FIG. 1, in this system the vaporized material is entrained in the carrier gas jet 5 created using a converging/diverging nozzle 30 configuration and deposited onto the substrate or target 20 at high rate and with a high materials utilization efficiency [18]. Preliminary results have shown that YSZ layers having a columnar structure, a low thermal conductivity, the t′ phase structure and a (200) texture can be produced using this technique [19]. Therefore the use of EB-DVD to produce low cost TBC's appears feasible. However, current versions of the EB-DVD process make inefficient use of the gas jet, which is a significant contribution to the process cost. They are also limited in their ability to spatially manipulate the flux.
[0011] There exists a need in the art for a cost-effective method to apply coatings to surfaces. The present invention addresses this need and provides, among other things, how to further manipulate the spatial distribution of the atomic flux and more efficiently utilize the carrier gas.
SUMMARY OF THE INVENTION
[0012] The present invention provides a method and an apparatus for efficiently applying a coating to a surface using a directed vapor deposition (DVD) approach. While this document may primarily describe the present invention method of applying a thermal barrier coating onto a turbine blade, the present invention method and apparatus has equal or greater utility for the deposition of metal, ceramic, semiconductor or dielectric coatings in a variety of applications including but not limited to fuel cells, thin film batteries, medical product coatings, and energy transmission systems.
[0013] In a first embodiment, the present invention provides a method for applying at least one coating on at least one substrate. The method includes: presenting at least one of the substrates to a chamber, wherein the chamber has an operating pressure ranging from about 0.1 to about 32,350 Pa; presenting at least one evaporant source to the chamber; presenting at least one carrier gas stream to the chamber; impinging at least one the evaporant source with at least one electron beam in the chamber to generate an evaporated vapor flux in a main direction respective for any of the evaporant sources impinged by the electron beam; and deflecting at least one of the generated evaporated vapor flux by at least one of the carrier gas streams. The carrier gas stream is essentially parallel to the main direction and substantially surrounds the evaporated flux, and the evaporated vapor flux at least partially coats at least one of the substrate.
[0014] In a second embodiment, the present invention provides an apparatus for applying at least one coating on at least one substrate. The apparatus includes a chamber, wherein the chamber has an operating pressure ranging from about 0.1 to about 32,350 Pa, wherein at least one of the substrates is presented in the chamber. The apparatus further comprises: at least one evaporant source disposed in the chamber; at least one carrier gas stream provided in the chamber; and at least one electron beam. The electron beam impinges at least one the evaporant source with at least electron beam in the chamber to generate an evaporated vapor flux in a main direction respective for any of the evaporant sources impinged by the electron beam; and deflects at least one of the generated evaporated vapor flux by at least one of the carrier gas stream, wherein the carrier gas stream is essentially parallel to the main direction and substantially surrounds the evaporated flux. The evaporated vapor flux at least partially coats at least one substrate.
[0015] While DVD and its associated converging/diverging nozzle system is generally known by those skilled in the art, the improvements provided by the present invention are attributed to, inter alia, the introduction of a ring nozzle into the DVD technology. Various configurations of the new ring nozzle technology are described herein and shown to convey the advantages that follow. The advantages of the present invention include, but are not limited to: improved use of expensive gases, increased deposition efficiency, improved uniformity in the coating, a means for coating of multiple components with non-planar geometry such as turbine blades/vanes, a means for efficiently heating the parts during coating, and a means for controlling the composition of the coating. These improvements will allow for high rate deposition of multiple components per run leading to a high component throughput while still using a low cost deposition process and producing coatings with the desired properties.
[0016] Moreover, computer modeling reveals that the present invention is novel and has not been taught or suggested in the conventional art. Further yet, the modeling reveals novel, useful, and non-obvious interaction of the ring nozzle gas flow with vapor leaving a crucible source. The result is a dramatically improved method for the efficient application of a coating to a surface.
DESCRIPTION OF THE FIGURES
[0017] The foregoing and other objects, features, and advantages of the present invention, as well as the invention itself, will be more fully understood from the following description of preferred embodiments, when read together with the accompanying drawings, in which:
[0018] [0018]FIG. 1 is an elevational schematic illustration of a converging/diverging nozzle used to create a supersonic carrier gas jet in a EB-DVD deposition approach.
[0019] [0019]FIG. 2 is a schematic illustration of the DVD coating process using a 90 degree configuration (referred to as DVD I herein this document).
[0020] [0020]FIG. 3 is a graphical representation showing the coating uniformity of a thermal barrier coating applied to a 1.0 inch diameter substrate as a function of chamber pressure.
[0021] [0021]FIG. 4 schematically shows a preferred embodiment of a DVD system (referred to as DVD II).
[0022] FIGS. 5 (A)- 5 (D) show direct simulation Monte Carlo (DSMC) simulations, which demonstrate the change in the focus of vapor flux when the helium carrier gas flow rate was increased (FIGS. 5 (A)- 5 (C)), and when an argon carrier gas was used (FIG. 5(D).
[0023] [0023]FIG. 6 graphically shows that the DVD II can operate as an EB-PVD (no gas flow, high vacuum) or DVD coater (gas flow); under DVD conditions, the system deposits up to ten times more vapor.
[0024] FIGS. 7 (A)- 7 (B) and 7 (C)-(D) schematically show nozzle configurations for a DVD system having a present invention ring nozzle configuration and a conventional circular nozzle, respectively.
[0025] [0025]FIG. 8 shows DSMC simulations using the present invention ring nozzle with a chamber pressure of 8 Pa and a gas flow rate of 2.0 standard liters per minute (slm) helium; the ring nozzle effectively focuses the vapor and results in increased deposition efficiency.
[0026] [0026]FIG. 9 shows DSMC simulations using the conventional circular nozzle with a chamber pressure of 8 Pa and a gas flow rate of 2.0 slm helium; the vapor flux is less focused using this nozzle, which results in a lower deposition efficiency (15%) than the ring nozzle.
[0027] [0027]FIG. 10 shows DSMC simulations using the conventional circular nozzle with a chamber pressure of 40 Pa and a gas flow rate of 15.0 μm helium; the vapor flux is well focused due to the high chamber pressure and gas flow rate, however, a wall jet results, which limits the deposition efficiency to approximately 40 percent and leads to a very non-uniform coating thickness.
[0028] [0028]FIG. 11 is a schematic illustration showing a multiple crucible and multiple jet arrangement, in which each source is heated with an electron beam (using either beam scanning or multiple e-beam guns) and the vapor is directed onto a turbine blade or blades at high efficiency and rate.
[0029] [0029]FIG. 12 is a schematic illustration showing a multiple nozzle per crucible configuration in which nozzles can be closely spaced so that one electron beam can be scanned across each source for simultaneous heating, and the orientation of the nozzle openings can be altered to steer the flux onto widely spaced components.
[0030] [0030]FIG. 13 is a schematic illustration of the use of multiple sources to moderately focus a vapor flux, which results in a large uniform vapor flux distribution and allows for the uniform coating of large turbine blades such as those used in industrial power generation turbines.
[0031] [0031]FIG. 14 is a schematic illustration showing the use of a multiple crucible/jet arrangement in which a vapor flux is focused to result in a large uniform vapor flux distribution such that a large number of small turbine blades can be placed into the vapor and be uniformly coated at moderately high efficiency and rate.
[0032] [0032]FIG. 15 is a schematic illustration showing a nozzle configuration consisting of elliptical nozzles, in which the elongated nozzle openings (gaps or channels) are used to focus the vapor flux along one direction, which results in an elliptical vapor flux distribution.
[0033] [0033]FIG. 16 is a schematic illustration showing the use of a two crucible arrangement for alloy deposition using conventional electron beam evaporation.
[0034] [0034]FIG. 17 is a schematic illustration of the present invention showing the use of multiple source evaporation in directed vapor deposition.
[0035] FIGS. 18 (A)- 18 (E) are schematic illustrations showing alternate embodiment of the nozzle ring gaps and source having various shapes and respective alignment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Deposition Efficiency
[0037] Schematically shown in FIG. 2, as well as described by Hass [20], there is provided a DVD apparatus to deposit the YSZ top layer of a TBC in which a carrier gas jet 5 was aligned at a 90 degree angle to the direction of the evaporated vapor flux 15 Also shown is the crucible 10 , nozzle 30 , electron beam system 3 and YSZ source 25 . This arrangement required a relatively high chamber pressure (greater than 26 Pa)/high carrier gas flow rate (greater than 8.0 (measured in standard liters per minute (slm)) combination to redirect the vapor 16 towards the substrate 20 . However, the high pressure/gas flow rate resulted in the formation of a wall jet at the substrate. When strong enough, this wall jet could affect the vapor atom angle of incidence and in some cases turn the vapor away from the substrate. This results in limited deposition efficiency of the process (about 5 to 10 percent for a 2.54 cm diameter substrate located 10 cm from the source). Lower gas flow rates/chamber pressures may not be used in this configuration as this decreases the vapor phase collisions, which occur during vapor transport, and results in the vapor no longer being completely redirected 90 degrees towards the substrate (while below a critical chamber pressure and gas flow rate). This limits the deposition rate of the process.
[0038] Increasing the evaporation rate is not useful in this configuration since a higher evaporation rate requires a higher gas flow rate/chamber pressure to redirect it towards the substrate and therefore the deposition efficiency of the process is decreased as the evaporation rate is increased and little or no increase in the deposition rate is observed. The use of high chamber pressures/gas flow rates has also been found to result in cluster formation in the vapor phase. This leads to very porous (50 percent) coatings, which may be expected to have poor erosion resistance. As shown in FIG. 3, provided is a graphical representation comparing the substrate position with the coating thickness as a function of chamber pressure and gas flow. This approach identifies the coating uniformity of a thermal barrier coating applied to a 1.0 inch diameter substrate as a function of chamber pressure. It should be noted that the higher chamber pressures, Po, lead to increasingly non-uniform thickness distributions. Accordingly, high gas flow rates/chamber pressures result in nonuniformity of the coating thickness. When significant nonuniformity exists, x-y substrate translation is required in order to achieve a uniform coating thickness.
[0039] Turning to FIG. 4, as a first aspect of the present invention, the aforementioned DVD process was reconfigured to the preferred embodiment as schematically shown in FIG. 4, to improve the deposition efficiency, increase the deposition rate and enhance the coating uniformity. In the preferred embodiment, the carrier gas 105 is realigned so that it is substantially in-line with the crucible 110 . In this alignment, the carrier gas flow is placed completely or substantially around the crucible 110 so that the vapor flux 115 no longer has to be turned 90 degrees towards the substrate 120 , but rather can be simply focused onto the substrate located directly above the evaporant source 125 . The carrier gas 105 flows substantially parallel with the normal axis, identified as CL. Additionally, as will be discussed later herein, the nozzle 130 has a nozzle gap or opening 132 , through which the carrier gas 105 flows, is designed such that a more optimal carrier gas speed distribution for focusing the vapor 115 is produced. Also shown is the electron beam gun 103 and vacuum chamber 104 .
[0040] Carrier Gas Costs
[0041] The configuration of the preferred embodiment offers dramatically improved benefits to coating efficiency and cost compared to existing techniques. First, the cost of the DVD process depends in part on the cost of the carrier gas, which is used to focus the vapor. The method by Hass et al. uses a helium/oxygen carrier gas jet mixture. However, deposition efficiency studies have shown that vapor can be focused to the same amount using less gas when argon is used instead of helium as the carrier gas. Typically the carrier gas flow can be cut in half for argon. In addition, helium is 2.5 times more expensive than argon so that argon usage will further reduce the cost of operation for the technology.
[0042] Component Heating
[0043] In addition, TBC's are typically applied at a very high temperature (e.g., 1050° C.). This temperature is achieved by pre-heating the blade before it is entered into the chamber. The radiant heat from the large 2.0-inch diameter source rod is used to maintain the substrate temperature during deposition (blade heating). In the configuration of Hass et al., the substrate is placed along side the source so that little radiant heat is obtained In addition, convective cooling from the carrier gas jet further reduces the substrate temperature. Thus this approach is not conducive to substrate heating and requires more advanced and difficult methods.
[0044] However, by reconfiguring the system in the present invention, such that the blade is placed directly above the source and the carrier gas flow rate may be decreased, the amount for radiant heat from the source is greatly increased and thus blade heating using a standard pre-heating furnace may be realized.
[0045] Moreover, in the existing design of the conventional DVD system, both the vapor and carrier gas flow pass through supersonic shock waves as the gas and vapor move away from the gas flow nozzle. These shock waves affect the density and distribution of the vapor. When a coating surface is then placed such that it intersects the flow, the resulting atomic structure of growing film can be affected by the distance from the gas flow nozzle to the coating surface (relative to the shocks in the flow). In the present invention system, there will still be supersonic shock waves in the carrier gas flows emerging from the ring nozzle. However, since the vapor is no longer incorporated directly into that carrier gas flow, its distribution and density will be less affected by the shocks in the system. As a result, the present invention process will become less critically dependent upon the position of gas flow nozzle and coating surface. Thus, when the geometry of the part being coated dictates a smaller (or larger) source to substrate separation, the present invention system design will be able to more easily accommodate such parts while still producing the desired atomic structure.
[0046] Experimental and simulation results, as discussed hereafter, indicate that the vapor flux can be focused using the present invention configuration to allow for deposition onto a limited area and to improve the process efficiency. The ability to focus the vapor cloud can be seen in FIG. 5. The direct simulation Monte Carlo (DSMC) simulations are shown for several helium and argon flow rates. The DSMC simulation, as captured in FIGS. 5 A- 5 C, show the change in the focus of vapor flux when the helium carrier gas flow rate was increased. Where as shown in FIG. 5D an argon carrier gas was used. It can be observed that the use of an argon carrier gas resulted in the well focused vapor flux required for efficiently coating small components. Also, the focus of the vapor stream can be tailored to the size of the part or area on a part to be coated by altering the gas flow rate. The vapor stream can be altered in a variety of ways including altering the carrier gas flow rate, the ratio of the upstream to downstream pressures and the size of the nozzle opening. Focusing the vapor stream results in a higher deposition efficiency onto small parts than compared to the conventional design.
[0047] Turning to FIG. 6, recent experimental work with the DVD II system has shown that the deposition efficiency is greatest at the highest chamber pressure. These conditions still yield a non-uniform thickness profile and may result in vapor phase clustering. FIG. 6 graphically shows that DVD II system can operate as an EB-PVD (no gas flow, high vacuum) or DVD coater (gas flow). Under EB-PVD conditions, DVD deposits just 2.5% of its vapor onto a 5.08 cm diameter substrate located 16.8 cm from the vapor source. Under DVD conditions, the system deposits up to ten times more vapor. The thickness profile may be improved by translating the component. However, when high pressure/high gas flow rate conditions exist, the vapor distribution is strongly dependent on the geometry of the component. When nonplanar components (i.e. turbine blades) are to be coated, uniform coatings may still be difficult to obtain.
[0048] Applicants set forth herein that in order to achieve a relatively dense, uniform coating, a lower chamber pressure (greater than 13 Pa) is required. In addition, a higher deposition efficiency than the 25-35 percentage reported in FIG. 6 can be obtained.
[0049] In a second aspect of the present invention, to achieve increased efficiency, the nozzle opening or nozzle gap is redesigned so that a more optimal carrier gas speed distribution for focusing the vapor is produced. As shown in FIGS. 7 (A)- 7 (B), this is obtained by using a converging/diverging nozzle 130 with a ring shaped nozzle opening or gap 132 instead of a conventional circular shaped opening 31 , as shown in FIGS. 7 (C)- 7 (D). The present invention design redistributes the carrier gas speed so that higher speeds are achieved away from the axis of symmetry where it is needed most to focus the vapor. Additionally, the area of the nozzle opening or gap 132 for the ring configuration is much smaller than for a circular shaped opening in the conventional design. Therefore higher pressure ratios in the present invention (and in turn carrier gas speeds) can be obtained for the same pumping capacity and gas flow rate setup. The ring shaped opening nozzle allows for a deposition efficiency onto a 5.08 cm wafer of 90 percent even at very low chamber pressures (e.g., 9 Pa). Similar chamber pressures for the conventional circular nozzle yield a deposition efficiency of only 15 percent.
[0050] Turning to FIGS. 8 - 10 , according to the low pressure limits wall jet effects as demonstrated by FIGS. 8 (C) and 9 (C), it is observed from FIGS. 8 (D), 9 (D) and 10 (D) that a more uniform thickness distribution on the substrate is found at lower pressures. FIG. 8 illustrates the DSMC simulations using the present invention ring nozzle (ring-shaped nozzle gap 132 ) with a chamber pressure of 8 Pa and a gas flow rate of 2.0 slm helium showing: vapor flux density (FIG. 8(A)); speed distribution in the x-direction (FIG. 8(B)); speed distribution in the y-direction (FIG. 8(C)); and coating thickness distribution across a substrate (FIG. 8(D)). The ring nozzle effectively focuses the vapor and results in a deposition efficiency of 90 percent when a 2.0 inch diameter substrate is used. It is noted that only a weak wall jet is present in this case and that a relatively uniform coating thickness results.
[0051] [0051]FIG. 9 illustrate DSMC simulations using the conventional circular nozzle with a chamber pressure of 8 Pa and a gas flow rate of 2.0 slm helium showing: vapor flux density (FIG. 9(A)); speed distribution in the x-direction (FIG. 9(B)); speed distribution in the y-direction (FIG. 9(C)); and coating thickness distribution across a substrate (FIG. 9(D)). It is noted that the vapor flux is less focused using this conventional nozzle. This results in a lower deposition efficiency (e.g., 15 percent) than the present invention ring nozzle. It is noted that no wall jet was present and a relatively uniform coating thickness resulted.
[0052] [0052]FIG. 10 illustrates DSMC simulations using the conventional circular nozzle with a chamber pressure of 40 Pa and a gas flow rate of 15.0 μm helium showing: vapor flux density (FIG. 10(A)); speed distribution in the x-direction (FIG. 10(B)); speed distribution in the y-direction (FIG. 10(C)); and coating thickness distribution across a substrate (FIG. 10(D)). The vapor flux was well focused due to the high chamber pressure and gas flow rate, however, a wall jet also resulted limited the deposition efficiency to approximately 40 percent. The wall jet also led to a very non-uniform coating thickness.
[0053] Another advantage of present invention nozzle design is that it may be used with larger source sizes without the need for adding significantly more pumping capacity. The pumping capacity required for DVD is a function of the nozzle opening area. Larger openings require more pumping capacity in order to reach the same chamber pressure than smaller openings. Additionally, as the source size is increased, the nozzle opening size must be increased, and this is true for both configurations. However, the area increase for the present invention ring configuration is much less than for the conventional circular shaped opening. For example, if one assumes that increasing the source size from 0.0127 m to 0.0381 m requires a three fold increase in the nozzle diameter, the increased nozzle opening area can be calculated for both configurations. It is found that the circular opening would have a nine fold increase in area while the ring opening would have only a 2.76 fold increase. Thus, a significant savings in the required pumping capacity and gas flow costs is achieved. The benefit of increasing the source size is that the vapor emitting surface would be increased by nine fold, and in conjunction with the 3 to 4 time improvement in the deposition efficiency, could lead to a deposition rate which is more than 30 times higher than current DVD technology (i.e., greater than 500 μm/min. is then possible based on current deposition rates (of 15 to 20 μm/min.)).
[0054] Multiple Blade Coating
[0055] A third aspect of the present invention method and system, is directed at the capability to “steer” vapor flux from the nozzle by changing the pressure in the nozzle on either side of the vapor source.
[0056] A fourth aspect of the present invention, as shown in FIG. 11, is directed at coating several blades at one time. It is often desirable to coat several blades at one time within the deposition chamber. This embodiment allows for using a number of sources ( 125 ( a ), 125 ( b ), 125 ( c )), carrier gas streams ( 105 ( a ), 105 ( b ), 105 ( c )), and nozzles ( 130 ( a ), 130 ( b ), 130 ( c )) to focus vapor onto individual components. FIG. 11 is a schematic illustration showing a multiple crucible/jet arrangement. In a preferred embodiment, the nozzles include nozzle gaps 132 ( a ), 132 ( b ), 132 ( c ) where carrier gas streams flow therefrom. The nozzle gaps are non-angular 141 ( a ), 141 ( b ), 141 ( c ) having a ring-shape 133 ( a ), 133 ( b ), 133 ( c ). Each source is heated with an electron beam (using either single beam scanning gun or multiple e-beam guns) and the vapor is directed onto a turbine blade at high efficiency and rate. In this case shown, the vapor flux distribution ( 115 ( a ), 115 ( b ), 115 ( c )), is adjusted to the size of the blade or target ( 120 ( a ), 120 ( b ), 120 ( c )). This allows multiple blades or targets to be simultaneously coated at high rate to result in a very high process throughput. Steering of the vapor is accomplished using non-angular symmetric nozzles. In one approach, an additional electron beam 103 is employed for each source 105 . A preferred method is to use the high frequency scanning capability of the electron beam to maintain evaporation from many sources simultaneously.
[0057] Turning to FIG. 12, a fifth aspect of the present invention allows for steering of the vapor using angular symmetric nozzles defined by angular channels 142 ( a ), 142 ( b ), 142 ( c ). In this configuration, multiple sources 125 ( a ), 125 ( b ), 125 ( c ), carrier gas streams 105 ( a ), 105 ( b ), 105 ( c ), and nozzles 130 ( a ), 130 ( b ), 130 ( c ) are employed to steer the vapor flux onto widely spaced individual components. The schematic illustration of this embodiment shows a multiple nozzle per crucible configuration in which nozzles are closely spaced so that one electron beam can be scanned across each source for simultaneous heating. The orientation of the nozzle openings are altered to steer the flux onto widely spaced components (e.g., targets/substrate).
[0058] Turning to FIGS. 13 and 14, in a sixth aspect of the present invention, multiple sources ( 125 ( a ), 125 ( b ), 125 ( c )), carrier gas streams ( 105 ( a ), 105 ( b ), 105 ( c )), and nozzles ( 130 ( a ), 130 ( b ), 130 ( c )) to create one large, uniform vapor cloud in which blades can be placed. Referring to FIG. 13, this embodiment uses multiple sources to moderately focus a vapor flux, which results in a large uniform vapor flux distribution 117 and allows for the uniform coating of large turbine blades such as those used in industrial power generation turbines.
[0059] Turning to FIG. 14, this embodiment uses multiple crucibles and jets arrangement in which a vapor flux is focused to result in a large uniform vapor flux distribution 117 such that a large number of small turbine blades can be placed into the vapor and be uniformly coated at moderately high efficiency and rate. An advantage of this approach is that less carrier gas flow is required while more blades per coating cycle may be coated. The proper approach is dependent on the size of the blades being coated. This approach may be appropriate when blades which are much smaller or larger than the uniform area of a individual jet.
[0060] As discussed above, it is also recognized that nozzle shapes other than ring-shaped may be useful. As shown in FIGS. 15 (A)- 15 (C), in a seventh aspect of the present invention, alternative embodiments utilize elongated elliptical ring gaps 134 and, optionally elongated elliptical source openings 127 , to produce an elliptical vapor flux 116 distribution. This is of interest for non-circular shaped substrates such as turbine blades 120 , in which a higher deposition efficiency can be realized if the shape of the vapor flux distribution is tailored to the size and shape of the part to be coated This approach allows for one to not only apply a coating to the desired area of the part, but also to prevent coating on an area that requires subsequent part manipulation tooling or locations 121 on the part which do not require a turbine blade. The dashed lines shown in FIG. 15(C) indicate a circular vapor flux compared to the desirable elliptical vapor flux 116 distribution of the present invention. The circular case would result in a larger portion of the vapor not being utilized.
[0061] As an eighth aspect of the present invention and as referred to above, the nozzle gaps and source shapes may be of a variety of shapes, alignments, and quantity. For example, FIG. 18(A) schematically shows the plan view of a cross-hatch-shaped nozzle gap 139 in relation to the nozzle 130 and source 125 .
[0062] Next, FIG. 18(B) schematically shows the plan view of an elliptical-shaped nozzle gap 135 in relation to the nozzle 130 and source 125 .
[0063] Next, FIG. 18(C) schematically shows the plan view wherein the ring-shaped nozzle gaps 133 (at least two or more) are concentric or substantially concentric.
[0064] Moreover, as shown in FIGS. 18 (D) and 18 (E), the ring gaps or channels may be partitioned so that a plurality of segments comprise the overall gap or channel. FIGS. 18 (D) and 18 (E) schematically show the plan view of a segmented elliptical 138 and segmented ring gap 136 .
[0065] Composition Control
[0066] Another advantage of using a DVD method is the ability to control the composition of the deposited coating. This can be important as both the insulating top layer and the bond coat layer of a thermal barrier coating are multicomponent coatings. Efforts to deposit multicomponent coatings directly can be challenging because the vapor cloud is not the same composition as the source when the vapor pressures of the components differ by more than a factor of 1000 at the surface temperature of the vapor emitting surface [21]. In such cases, the composition of the resulting coatings can differ greatly from that of the source and varies with deposition time [22].
[0067] In material systems where large vapor pressure differences exist between the precompounded oxide source components (for example Y 2 O 3 —CeO 2 ), multiple source evaporation from individual metal oxide sources is required to deposit a coating with the desired composition. In these cases, reactive deposition from a metal alloy source can sometimes provide an alternative to precompounded oxide evaporation since the vapor pressure differences between metallic alloy components can be significantly different than that of their oxides. For example, there is only a difference of a factor of three in the vapor pressures of Ce and Y at 2500° C. In such cases, multi-component oxide coatings can be produced using a binary alloy which is stoichiometrically evaporated. In principle, this enables one to avoid multiple source evaporation and can expand the range of the complex oxides, which can be deposited using EB-PVD techniques.
[0068] In conventional (high vacuum) EB-PVD processes, vapor phase collisions are rare. When reactive deposition is employed, the vapor components are absorbed onto the substrate before the gas phase reactions occur. Under these conditions, Ritter et al. [23] has shown that the ratio of the number of substrate collisions of the reactive gas to the evaporated material, V a /V b , must be high (i.e greater than 10 2 ) in order to obtain a non-reduced film. Thus, the partial pressure of the reactive gas must increase with the deposition rate to maintain an adequate impingement of oxygen onto the substrate. As a result, the chamber pressure must increase with deposition rate. However, conventional EB guns need to operate in a high vacuum to successfully generate and maintain a high density electron beam, and this constrains the deposition rate of the process. This problem can be partially overcome either by using a high pressure EB-PVD process or employing plasma activation. Increased chamber pressures not only allows for a high oxygen:metal ratio, but also controls vapor phase collisions. At increased pressures, the reaction can occur both during vapor transport and at the substrate. In plasma activation, ionization of the reactive and metal vapor increases the collisional cross section of the reactants to promote vapor phase collisions and reactions without increasing the chamber pressure [22].
[0069] Recently, a high pressure, electron beam directed vapor deposition (DVD) process, has been developed [17]. It combines high rate, low vacuum electron beam evaporation with a rarefied gas jet to entrain the vapor and transport it to a substrate. The approach uses the combination of a continuously operating, high voltage (60 kV) e-beam gun (modified to function in a low vacuum (13.3 to 665 Pa) environment) and a He carrier gas jet. The transonic jet is produced by maintaining a high pressure upstream of the jet nozzle opening that is at least twice that of the downstream chamber pressure. During operation, a source material is vaporized and the carrier gas jet collides (at high velocity) with the vapor, entraining and directing it towards the substrate. Binary collisions in the flow cause the vapor to be scattered toward the substrate where it condenses. By entraining all the vapor in a small (approximately 3 cm) diameter jet a high fraction of the evaporated flux can be deposited and high local deposition rates are achievable, even with moderately low power (10 kW) electron beam guns [18]. By adding oxygen to the gas flow and manipulating the pressures, the flux of reactive gas atoms entering the chamber can be controlled. This allows the metal vapor/carrier gas mean free path to be altered and thus the vapor-oxygen collision frequency can be controlled. The process has been used successfully to create zirconia and yttria-stabilized zirconia coatings from precompounded oxide sources [20].
[0070] A variety of metal sources (such as Zr, Al, Y etc.) can also be evaporated. If oxygen is present in the carrier gas, the evaporated metal atoms have an opportunity to react with the reactive component of the carrier gas flow (either in the vapor phase or at the substrate) to create an oxide coating.
[0071] The present invention process is superior to conventional EB-PVD for reactive deposition (e.g., reactive component of the carrier gas flow) in several ways. First, the low vacuum environment increases the vapor phase collision rate and is likely to promote reactions during vapor transport. The present invention process also allows a sufficient supply of reactive gas for high rate deposition. Second, carrier gas/vapor atom interactions with the electron beam result in higher fractions of ionized species which further increases the reaction probability. Third, the high kinetic energy of the carrier gas and vapor atoms (a result of the supersonic expansion of the carrier gas) may assist reaction barrier activation [18]. These factors of the present invention enhance the reaction probability between the reactants and lead to a more favorable environment for reactive deposition. One objective of the present invention is to provide the utility of the DVD process for creating a simple (single) metal oxide from a metal source. Multicomponent oxides could then be made using a single alloy source provided the vapor pressure constraints above apply.
[0072] On the other hand, for instances where a single alloy is not applied, materials must be evaporated from two or more sources using either a single or multiple electron beam gun arrangement. As shown in FIG. 16, in a conventional EB-PVD configuration, the film composition is strongly dependent on the position of the sources and the substrate position. The compositional uniformity and region of vapor mixing can be maximized when the source spacing, s, is small and the source to substrate distance, h, is large. However, such a configuration is often not advantageous as large source to substrate distances lower the materials utilization efficiency (MUE, the ratio of evaporated atoms which deposit onto the substrate) and the use of a small source size leads to reduced evaporation rates. This is not conducive to high rate deposition and is significantly more costly than single source evaporation [22]. Improved multisource deposition approaches are therefore desired which yield compositionally uniform vapor fluxes and a high process efficiency are therefore desired.
[0073] As a ninth aspect of the present invention, as illustrated in FIG. 17, there is provided an alternative embodiment, wherein vapor phase mixing can be achieved by aligning two (or potentially more) sources 223 , 224 , 225 in line with a carrier gas flow 205 and using electron beam scanning 203 to uniformly heat both (or plurality of) sources. The use of the carrier gas jet in this embodiment not only scatters the vapor flux toward the substrate, leading to a potentially high MUE (and high deposition rates), but also randomizes the vapor trajectory facilitating vapor phase mixing of the two (or plurality of) fluxes 216 . A high MUE would allow for the use of small diameter metal source materials, which could be spaced closely together to further improve the compositional uniformity of the coating, while still achieving a high rate of deposition. The composition of the deposited layer could be systematically controlled by altering the electron beam scan pattern to change the surface temperature (and thus the evaporation rate) of each source material.
[0074] In conclusion, the present invention describes a series of steps, and an apparatus for use therewith for applying a coating to a substrate using an electron beam directed vapor deposition technique, thereby, for example improving upon the method published by Hass et al. [20].
[0075] Some advantages of the present invention process and apparatus, but not limited thereto is that it provides for the materials utilization efficiency of the process to be improved, deposition rate increased, coating uniformity improved, multiple blade coating during each coating cycle, carrier gas flow costs optimized, and blades to be heated to the desired temperature.
[0076] Moreover, this invention allows the ratio of carrier gas flow to vapor molecular concentration to be dramatically reduced while increasing the material utilization efficiency of the technology. Accordingly, this breakthrough has significant positive economic implications for the utility of the process.
[0077] The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting of the invention described herein. Scope of the invention is thus indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced herein.
REFERENCES
[0078] The following references, as cited throughout this document, are hereby incorporated by reference herein in their entirety:
[0079] 1. S. M. Meier and D. K Gupta, Trans. of the ASME, 116, 250 (1994).
[0080] 2. A. J. Glassmnan, Turbine Design and Application, Vol. 3, NASA-SP-290 VOL-3, NASA Lewis Research Center (1975).
[0081] 3. W. J. Brindley and R. A. Miller, Advanced Materials and Processes, 29 (1989).
[0082] 4. R. V. Hillery (ed.), Coatings for High - Temperature structural Materials: Trends and Opportunities, National Academy Press, Washington D.C. (1996).
[0083] 5. C. H. Liebert and R. A. Miller, Ind. Eng. Chem. Prod. Res. Dev., 23, 344 (1984).
[0084] 6. D. Claves and A. Galerie, Journal De Physique IV, C9, 531 (1993)
[0085] 7. O. Unal, J. Am. Ceram. Soc., 77 [4], 984 (1994).
[0086] 8. D. Michel L. Mazerolles and M. Perez Y Jorba, J. of Mat. Sci., 18, 2618 (1983).
[0087] 9. J. T. DeMasi-Marcin, K. D. Sheffler and S. Bose, J. of. Eng. Gas Turbines and Power, 112, 521 (1990).
[0088] 10. T. E. Stranginan, Thin Solid Films, 127, 93 (1985).
[0089] 11. U. Schulz, H. Oettel, and W. Bunk, Z. Metallkd., 87, 6 (1996).
[0090] 12. R. J. Christensen, D. M. Lipkin, D. R. Clarke, and K Murphy, Appl. Phys. Lett., 69 [24], 3754 (1996).
[0091] 13. M. Y. He, A. G. Evans and J. W. Hutchinson, Mat. Sci. Eng., in press (1997)
[0092] 14. K. Fritscher et. al., Advanced Aerospace Materials, H. Buhl (ed.), Springer-Verlag, Berlin, Heidelberg (1992) pp. 84-107.
[0093] 15. D. J. Wortman, B. A. Nagaraj and E. C. Duderstadt, Mat. Sci. Eng., A121, 443 (1989).
[0094] 16. P. Hancock and M. Malik, Materials for Advanced Power Engineer, Part I, D. Coutsouradis et. al. eds., Kluwer Academic Publishers, Netherlands (1994) pp.685-704.
[0095] 17. J. F. Groves and H. N. G. Wadley, Composites B, 28B, 57 (1997).
[0096] 18. J. F. Groves, Ph. D Thesis, University of Virginia (1998).
[0097] 19. D. D. Hass, Ph. D. Thesis, University of Virginia (2001).
[0098] 20. D. D. Hass, P. A. Parrish and H. N. G. Wadley, J. Vac. Sci. Technol., A 16[6] (1998) 339.
[0099] 21. S. Schiller, U. Heisig and S. Panzer, Electron Beam Technology, (1995).
[0100] 22. R. F. Bunshah (ed.), Handbook of Deposition Technologies for Films and Coatings, Noyes Publications, Park Ridge, N.J., (1994) p. 131.
[0101] 23. E. Ritter, J. Vac. Sci. Technol., 3[4] (1966) 225. | A direct vapor deposition (DVD) method and apparatus for applying coating(s) on substrate(s), including: presenting at least one of the substrates to a chamber, presenting at least one evaporant source ( 125 ) in crucible ( 110 ) to the chamber; presenting at least one carrier gas stream ( 105 ) to the chamber using a ring-shaped ( 133 ) converging/diverging nozzle ( 130 ); impinging at least one evaporant source with at least one electron beam in the chamber to generate an evaporated vapor flux in a main direction respective for any of the evaporant sources impinged by the electron beam; and guiding at least one of the generated evaporated vapor flux by at least one carrier gas stream from the ring shaped gap ( 132 ), which is essentially parallel to the main direction and substantially surrounds A the evaporated flux. The evaporated vapor flux at least partially coats at least one of the substrates. | 2 |
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a recovery system and method for detecting and warning a pilot of an unsafe attitude of the aircraft and providing voice instructions to help the pilot recover the aircraft from a presently or potentially dangerous situation.
Many aircraft accidents caused by pilot error involve the pilot's failure to maintain a safe altitude and/or the pilot's spatial disorientation. The pilot may have the aircraft in a nose-high attitude which can produce a stall, or in a nose-low attitude which can put it in a descending spiral. These problems can occur to a VFR (visual flight rules) pilot who inadvertently flies into instrument meteorological conditions (IMC), to and IFR (instrument flight rules) pilot who is out of practice, or to any pilot who suffers hypoxia, fatigue, or another condition that temporarily affects his/her flying ability. To recover the aircraft from a dangerous attitude involves procedures which a disoriented pilot may not have the presence of mind to execute.
In addition, turbulence may cause the aircraft to depart controlled flight, or there may be a partial equipment failure of the vacuum system on the aircraft that powers the instrument panel on which the pilot relies. Navigation during partial panel failure requires additional pilot attention to the aircraft's heading using the demanding technique of “timed turns.” Without a warning system it is difficult for the pilot to identify a partial panel failure because the failure typically takes place gradually as the aircraft's gyros spin down and destabilize.
Another factor affecting aircraft safety is the particular terrain over which the aircraft is flying and obstacles which project up from the ground and thus determine the minimum safe altitude (MSA) for flight.
In the United States the altitude determination problem has been alleviated by the Global Positioning System (GPS), a satellite-based radio navigation system using multiple satellites. By triangulation of signals from three of them, an on-board receiver can pinpoint the aircraft's current position. GPS accuracy has been significantly improved by the introduction of the Wide Area Augmentation System (WAAS), with a margin of error of only a few meters, both horizontally and vertically. WAAS provides ILS-like precision approaches to airports that do not have ILS (Instrument Landing System). Also, WAAS provides information on the status of the GPS system, notifying a pilot in the event that the GPS system becomes unreliable temporarily.
SUMMARY OF THE INVENTION
The present invention is directed to an aircraft pilot assistance system and method that detects an unsafe altitude and a dangerous nose-up or nose-down condition of the aircraft, and provides appropriate voice warnings and directions to help the pilot overcome the problem or problems detected, even if the pilot remains spatially disoriented, fatigued, or otherwise at less than his or her usual flying ability.
The present invention continuously reads the aircraft's altitude, roll rate, and nose-high or nose-low position, and combines these readings to initiate appropriate voice messages to assist the pilot to recover the aircraft to a safe condition. The altitude determination comes from a GPS/WAAS feed to a receiver connected to a computer on-board the aircraft. The nose-high or nose-low condition is determined from GPS signals and from on-board solid state gyros. The roll rate determination is derived from GPS signals and from the solid state gyros and a turn coordinator gyro on the aircraft.
In the event of both an excessive altitude excursion and an excessive roll rate of the aircraft, the system initiates voice messages to the pilot's stereo headset to assist him or her to take the proper corrective action, depending on whether a nose-low or a nose-high condition has been detected. Voice messages pertaining to wing-leveling preferably are sent only to the earpiece on the side of the headset that corresponds to the low-wing side of the aircraft.
The present invention also responds to a partial failure of the aircraft's instrument panel to initiate a series of voice instructions which assist the pilot to perform “timed turns” routine for aircraft safety.
A general object of this invention is to provide a novel and advantageous system and method for assisting a pilot to restore the aircraft form an unsafe condition to a safe attitude and altitude appropriate to the terrain over which the aircraft is flying.
Further objects and advantages of this invention will be apparent from the following detailed description of a presently preferred embodiment thereof, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the major inputs in the present system and method;
FIG. 2 is a flow chart detailing the main features of the correlation algorithm for the present system and method for critical attitude recovery of an aircraft; and
FIG. 3 is a similar flow chart pertaining to a partial failure of one or more vacuum powered instruments on the aircraft's instrument panel.
DETAILED DESCRIPTION OF THE INVENTION
Before explaining the present invention in detail it is to be understood that the invention is not limited in its application to the particular arrangement shown and described since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
As indicated in FIG. 1 , the aircraft 10 carries:
a GPS/WAAS-enabled radio receiver R having a GPS receiver card for receiving GPS signals giving the aircraft's altitude, forward speed and magnetic heading; a vacuum pressure sensor or transducer 11 which senses a failure in the vacuum system that powers the instrument panel readings on which the pilot relies to know the attitude, heading, and other vital information; solid state gyros 12 and a turn coordinator gyro 13 which monitor the aircraft's roll rate; a flight recorder FR which records every 15 seconds on a hard disk the flight path of the aircraft with its heading, speed, location and altitude; and a microprocessor-based computer 15 for collating and processing the information supplied to it from the receiver R, the vacuum pressure sensor 11 , gyros 12 and 13 , and other sources, as explained hereinafter. This computer runs an expert system algorithm, as explained hereinafter.
Stored in the computer 15 is an MSA/approach database 14 which provides information regarding the approaches being flown by the aircraft, the minimum descent altitude, decision altitude, and minimum safe altitude for airways and sectors, taking into account the terrain over which the plane is flying and obstacles on the ground along the flight path that determine the minimum safe altitude. This database is interfaced with the remainder of the system to provide warnings of an unsafe altitude. Within three miles of an airport this feature automatically de-activates to enable the landing approach to be performed without false alarms being triggered.
Computer 15 receives, from a GPS feed 16 , GPS/WAAS navigation signals which tell the instantaneous air speed of the aircraft, its altitude, and its magnetic heading to initiate voice warnings and recovery instructions to the pilot. A large delta in the aircraft's altitude, an excursion to an unsafe altitude, a large delta in the aircraft's heading, an increase or decrease in airspeed, or a combination of two or more of these factors will trigger a scoring system programmed in the computer 15 to indicate an unusual attitude and will instantly analyze this unusual attitude to initiate recovery voice instructions to the pilot. To this end, the computer 15 has an audio output connected to the pilot's stereo headset to deliver voice messages to one or both of the pilot's ears, depending upon the particular warning signal the computer has just received from the GPS feed and the gyros.
In accordance with the minimum safe altitude warning, the present system monitors the current altitude via the GPS feed and compares that to the MSA for the region being flown over. This feature is disabled when the plane arrives within 3 miles of an airport, to enable the approach to be flown without false alarms being triggered.
In accordance with the approach monitoring capability, the present system monitors the aircraft's height above the Minimum Descent Altitude (MDA) or Decision Altitude (DA) and provides voice warnings to the pilot in hundreds of feet, and then in tens of feet, as the aircraft approaches the DA. Additionally, for a non-precision approach this system monitors the distance from the aircraft to the Missed Approach Point (MAP) and warns of reaching the MAP.
FIG. 2 is a flow chart which details the main features of the correlation algorithm which the computer 15 runs. In box 21 , inputs from the aircraft's turn coordinator gyro 13 and its solid state gyros 12 and the GPS feed 16 are correlated to calculate the aircraft's roll rate, or rate of turn, which indicates the stability of flight. The computed roll rate is constantly monitored to a tolerance of 3 degrees per second, and if the roll rate is within this tolerance (box 24 ) no corrective action is suggested.
In box 22 , altitude data are obtained from the GPS feed 16 . If no excessive altitude excursion is in progress (box 25 ) then no alert is indicated. For example, an altitude change greater than 500 feet per minute may be treated as excessive. Conversely, if an excessive altitude excursion is detected in combination with an excessive roll rate, a spatial disorientation event is judged to be in progress.
In box 23 , attitude data is derived from both the GPS feed 16 and the solid state gyros 12 .
In box 26 , a nose-high/nose-low determination is made by use of the attitude data (box 23 ) and the altitude direction of change (box 25 ). If a nose-low condition of the aircraft is determined (box 26 ), the pilot receives appropriate voice notifications and instructions from the computer 15 to assist him or her to restore the aircraft to safe attitude and altitude. Box 27 instructs the pilot (in both ears) to reduce the engine power. Box 28 instructs the pilot (in one ear only) to level the wings, giving voice information to the pilot's ear (left or right) corresponding to the low wing, and then monitors the wings level and gives a voice prompt to the pilot when wings level is achieved. Once the wings are leveled, box 29 instructs the pilot by voice (in both ears) to gently raise the aircraft's nose and add power until a positive climb is established and the aircraft is back at the minimum safe altitude for the area it is flying over.
Conversely, if a nose-high condition of the aircraft is determined (box 26 ), the pilot receives appropriate voice notifications from computer 15 to recover the aircraft from this condition. Box 30 instructs the pilot (in both ears) to increase the engine power. Box 31 instructs the pilot (in both ears) to gently lower the nose of the aircraft and add power until a level attitude is established and the aircraft is back at the minimum safe altitude for the area. Box 32 instructs the pilot (in one ear) to level the wings, speaking into the ear (left or right) corresponding to the low wing, and then monitors the wings level and gives a voice prompt to the pilot when wings level is achieved.
In box C, the turn coordinator gyro 13 is compared to the solid state gyros 12 , and in the event of a significant discrepancy between them (due to an error in the turn coordinator gyro) block 33 announces this to the pilot and instructs him or her to turn off the aircraft's automatic pilot. Such a failure of the turn coordinator gyro, while rare, does occur on occasion and when it does the present system responds in a way to avoid danger to the aircraft.
Another aspect of the present system relates to warning the pilot of a partial failure of the aircraft's instrument panel, with the accompanying loss of the heading and attitude indicators, and directing the pilot in the demanding technique of “timed turns” to respond to this problem.
For this purpose the present system includes a vacuum sensor switch 11 ( FIG. 3 ) operatively connected to the vacuum line to detect a partial failure of one or more vacuum powered instrument panel units (typically, the directional gyro and/or the artificial horizon or attitude indicator). The vacuum sensor triggers a response by computer 15 to cause the GPS signals to be automatically timed to give an approximation of the aircraft's turn rate (block 21 in FIG. 3 ). If the roll rate determined from the timed GPS signals becomes excessive (i.e., past the 2 minute turn standard) a voice warning to this effect is delivered to the pilot (block 34 ) and the pilot is given instructions (block 35 ) for getting the aircraft into a standard turn rate, for notifying the pilot when the standard turn rate is established, and for notifying the pilot when the aircraft passes through the eight cardinal headings.
From the foregoing it will be evident that the system and method of the present invention constitutes an effective and advantageous way of assisting a pilot to recover from a variety of situations that can endanger the aircraft and those on board. | A system and method for assisting a pilot to recover the aircraft from a variety of dangerous situations involving one or more of the following: altitude, airspeed, attitude, roll rate, and a partial equipment failure in the control panel. In accordance with the invention, these factors are sensed automatically, and voice instructions are provided to the pilot to direct him or her to get the aircraft out of the dangerous situation sensed by this system. | 6 |
FIELD OF THE INVENTION
This invention relates to a tool which simplifies the task of removing a cracked or broken windshield in an automobile.
BACKGROUND OF THE INVENTION
A conventional windshield is secured to the frame opening in the vehicle body by means of a peripheral urethane bond. When this bond cures the windshield is firmly sealed in the frame for the life of the automobile. However, due to the impact of stones and metal objects thrown up into the path of travel, windshields can be cracked or broken. Vandalism is also a problem.
A common practice to remove a defective windshield requires the mechanic to position himself in the vehicle with his head and shoulders pressed against the windshield to apply an outward pressure. While maintaining this pressure he must cut the urethane bond at the top and sides and pivot the partially loosened windshield about the bottom so as to cut the bottom bond without damaging any adjacent vehicle components. This procedure is dangerous and can traumatize the mechanic's neck and/or risk cuts.
There is a need for a tool to simplify the operation and substitute mechanical pressure against the windshield for human head and shoulder pressure.
The following prior art reflects the state of the art of which applicant is aware and is included herewith to discharge applicant's acknowledged duty to disclose relevant prior art. It is stipulated, however, that none of these references teach singly nor render obvious when considered in any conceivable combination the nexus of the instant invention as disclosed in greater detail hereinafter and as particularly claimed.
______________________________________PATENT NO. ISSUE DATE INVENTOR______________________________________1,863,897 June 21, 1932 Cloppert2,014,535 September 17, 1935 Maca2,305,995 December 22, 1942 Roberts2,746,767 May 22, 1956 Evans3,116,919 January 7, 1964 Alth3,620,524 November 16, 1971 Czompi3,662,994 May 16, 1972 Johns3,770,259 November 6, 1973 Wagreich3,804,397 April 16, 1974 Neumann4,457,503 July 3, 1984 Connor5,042,772 August 27, 1991 Madjeski5,085,415 February 4, 1992 Shaver5,087,019 February 11, 1992 Peabody, et al.5,135,205 August 4, 1992 Bedard5,479,689 January 2, 1996 Schmit, et al.______________________________________
A number of tool assemblies to aid the mechanic in removing and installing automobile windshields have been invented as typified by U.S. Pat. No. 3,620,524, issued Nov. 16, 1971, to Joseph Czompi; U.S. Pat. No. 5,085,415, issued Feb. 4, 1992, to Craig Shaver; and U.S. Pat. No. 5,479,689, issued Jan. 2, 1996, to David Schmit, et al. The patent to Czompi shows two spaced suction cups connected to an adjustable assembly to support a windshield while it is being installed. Shaver shows a windshield support mounted on the steering wheel to space a portion of the windshield from the frame opening. Schmit, et al. shows a hand-held tool to separate a windshield form the upper frame in order to expose the bottom seal for cutting.
While the above-mentioned patents do teach tools to facilitate the removal and replacement of windshields, the prior art does not teach a windshield removal tool having the flexibility of attachment and precise adjustability to safely push a windshield out of a supporting frame.
The other prior art listed above, but not specifically described further catalog the prior art of which the applicant is aware. These references diverge even more starkly from the references specifically distinguished above.
OBJECTS OF THE INVENTION
The overall object of the invention improves upon the prior art windshield removal tools by providing a telescoping lift acting between the floor and windshield to apply a controlled pushing pressure against the windshield.
It is a specific object of the invention to apply the pressure to the windshield by means of two spaced suction cups which are adjustable with respect to the telescoping lift so as to apply the pressure in the most desirable area. The suction cups and mounting, while attached to the windshield, may be separated from the lift to serve as a carrier to remove the damaged windshield from the vehicle.
It is another object of the invention to provide an adjustment mechanism to extend the telescoping lift in a precise manner so as to maintain the correct pressure against the windshield.
It is yet another object of the invention to provide an adjustable base for the telescoping lift as well as an adjustable support at the top of the lift to enable universal positioning of the suction cups.
Viewed from a first vantage point it is an object of the invention to provide a windshield lift for applying pressure on the inside surface of a windshield comprising a base member, first and second cylindrical members, said first cylindrical member telescopically supported with respect to said second cylindrical member for reciprocating motion to extend and retract said cylindrical members with respect to each other, means on an end of said second cylindrical member remote from said first cylindrical member for pivotally mounting said second cylindrical member on said base member, an end of said first cylindrical member remote from said second cylindrical member supporting a bracket, an elongated support member having first and second ends, said first end being pivotally mounted on said bracket said second end supporting means to frictionally engage said windshield inside surface, and means to extend said cylindrical members.
Viewed from a second vantage point it is an object of the invention to provide a windshield lift for removing a windshield from a vehicle frame by applying pressure to the inside surface comprising a base member for positioning on the floor of a vehicle, a telescoping lift comprising at least two telescoping sections, drive means to reciprocate one of the sections with respect to the other, the fixed section being pivotally mounted on said base member so as to angle the lift in the direction of the windshield, a support bracket mounted on the free end of said movable section, a T-shaped work holder 38 having the stem of the T pivotally and removably mounted on said bracket, and a suction cup mounted on each end of the crossarm of the T-shaped work holder 38.
Viewed from a third vantage point it is an object of the invention to provide a method for the removal of a vehicle windshield from a vehicle frame wherein said windshield is bonded to said frame by means of a peripheral plastic seal, said method comprising the steps of: installing an adjustable lift acting to supply a force against the internal surface of the windshield; gradually increasing the force applied to the windshield until the first sign of stretching of the seal is noticed; cutting the top seal while in a stretched condition; slowly increasing the force on the window stretching to side seals; freeing the side seals; with top and side seals free continue applying force to the windshield pivoting the windshield around its bottom edge; cutting the bottom seal; and removing the windshield.
These and other objects will be made manifest when considering the following detailed specification when taken in conjunction with the appended drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the apparatus of the invention.
FIG. 2 is a front view of the invention.
FIG. 3 is a sectional view of the invention taken along lines 3--3 of FIG. 2.
FIG. 4 is a side view of the invention showing alternate positions of the top portion in phantom.
FIG. 5 is a side view of the top portion of the invention showing alternate positions of the suction device in phantom.
FIG. 6 is a front view similar to FIG. 5.
FIG. 7 is a front view of the invention suction cup arm showing alternate lateral position in phantom.
FIG. 8 is an exploded parts perspective view of the invention.
FIG. 9 is a pictorial view of the invention mounted in operative position.
FIG. 10 is a pictorial view of the suction cup being enabled.
FIG. 11 is a pictorial view showing the windshield bond being cut along the top edge.
FIG. 12 is a pictorial view of the windshield being pushed out after cutting the bond along side edges of the windshield.
FIG. 13 is a pictorial view of the windshield being removed.
FIG. 14 shows a self supporting stand usable with the lift of this invention.
FIG. 15 shows the stand of FIG. 14 supporting a windshield.
FIG. 16 shows a stand supported lift employed to remove a sealed side window of a vehicle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Considering the drawings, wherein like reference numerals denote like parts throughout the various drawing figures, reference numeral 10 is directed to the windshield lift according to the present invention.
Referring now in general to the drawings and in particular to FIGS. 1 through 8, the novel windshield lift 10 of this invention comprises a main cylindrical tube 11 telescopically receiving a slideable cylindrical tube 12. The outside surface of the tube 11 may be provided with a polished surface for decorative purposes, or alternatively, provided with a soft plastic covering to prevent damage to the automobile interior. An extension cylinder 13 is inserted within tube 11 to abut stops 14 internally secured to tube 11. The bottom of extension cylinder 13 projecting below tube 11 is flattened to form a tail piece 15. A base 16 having spaced legs 17 made of plastic material is provided with a channel 18 formed between a pair of upstanding walls 2 to receive the tail piece 15. A headed pin 19 is passed through aligned holes 24 in the tail piece 15 and walls 2 of the base 16 to pivotally support the extension cylinder 13. A nut 20 is secured to pin 19 to hold the extension cylinder 13 in position and to allow for its removal for reasons explained below.
As best seen in FIGS. 1 and 2, extension cylinder 13 is carrying main tube 11 can be rotated clockwise around pin 19 to adjust the lift 10 from a vertical position through a range of almost 90 degrees. It should be understood that extension cylinder 13 can be made in various lengths to adapt the lift 10 for different uses. To change the extension cylinder 13, nut 20 is removed and pin 19 slid out. The extension cylinder 13 is then removed and replaced with one of a different length by inserting it in tube 11 until it strikes stop 14. The lift 10 is then set in channel 18 and the pin 19 inserted and secured by nut 20.
Slideable tube 11 is reciprocated by means of a rack and pinion gear 21, 22 (FIGS. 3 and 8). Rack gear 21 is vertically secured to the internal surface of tube 11 as seen in FIG. 3. Pinion gear 22 is secured on shaft 23 which passes through aligned holes 24 in the main tube 11. Shaft 23 also passes through diametrically opposed longitudinal slots 25 cut into the tube 12. One end of shaft 23 is provided with a crank handle 26 while the other end is positioned by shaft nut 27. Rotation of handle 26 rotates pinion 22 which drives rack gear 21 to extend or retract tube 12 with respect to main tube 11. Tube 12 is maintained in aligned position by shaft 23 passing through longitudinal slots 25. A conventional shaft locking mechanism is provided at 28 to retain the crank handle 26 in a set position. Rotation of threaded nut 29 causes a wedging action against shaft 23.
While a rack and pinion drive is disclosed for explanatory purposes, it should be clearly understood that many other mechanical drives and linkages are available to extend tube 12 with respect to main tube 11. For example, tube 12 may be reciprocated by means of a hydraulic or electric drive, or even a cable and pulley system.
A bracket 30 formed of a back wall 31 joined by two spaced curved side walls 32 is firmly secured to the top end of slidable cylindrical tube 12. A stub tube holder 33 is mounted between the side walls 32 of the bracket 30 for a limited range of angular adjustments. For this purpose a pivot pin 34 is passed through aligned holes 24 in the side walls 32 and holder 33 and permanently staked in position. In this manner holder 33 is permanently secured in bracket 30 while capable of limited angular adjustment. In order to effect this adjustment, a series of paired holes 35 arranged in an arcuate manner around pin 34 as a center are provided in the side walls 32. A hole 36 is drilled through holder 33 to sequentially align with arcuate holes 35 as the holder 33 is rotated around pivot 34. At the desired location of hole registration a pin 37 with a thumb grip is inserted to pass through the holes 24 in the side walls 32 and holder 33 to secure the holder 33 in a set angular position. It should be noted that holder 33 may be positioned so as to extend axially with tube 12, at right angles to tube 12 and a number of angular positions therebetween.
Holder 33 removably supports a generally T-shaped work holder 38. The stem of the T shaped work holder 38 consists of a coupling rod 39 which removably seats in holder 33 and has its other end secured to a tie rod 40. The crossarm 41 of the T is formed as a rod and passes through tie rod 40 and is secured thereto. Each arm of the cross is provided with flattened surfaces 42 on a side.
A suction cup 43 is adjustably secured on each arm of the cross 41 by means of a suction cup holder 44 which comprises a tubular collar 45 telescoped over each arm of the cross. A finger tightening set screw 46 is provided near one end of tube 45 to position it on arm 41. Tightening of screw 46 against flattened surfaces 42 positions tube 45 on arm 41. The other end of tube 45 holds a clamp 47 which is bolted to an end portion of hollow tube 45 by means of bolt and nut 48. Clamp 47 has an opening 49 to securely receive the supporting shaft 50 of suction cup 43. Suction cup 43 is of conventional construction and has a plunger vacuum pump 51 mounted in shaft 50. Manual operation of pump 51 (along arrow H of FIG. 10) draws a vacuum between the suction cup 43 and its attached windshield W. Because of its attachment to tube 45 by bolt and nut 48, clamp 47 with attached suction cup 43 is capable of an arcuate adjustment around bolt 48 acting as a pivot. As shown in FIGS. 5 and 6, suction cup 43 may be pivoted along arcs C and D or arcs E and F as needed.
While suction cups are to be preferred, it should be noted that friction pads and other attachments may be employed instead of suction cups without departing from the scope of the invention.
From FIGS. 4 through 7 it can be seen that the suction cups 43 can be adjustably positioned with respect to the windshield W by means of: (1) rotation around bolt 48 acting as a pivot (as described above), (2) slideable adjustment of hollow tube 45 with respect to crossarm 41 (as along double arrow G in FIG. 7), (3) rotation of rod 39 in holder 33 (as shown in FIG. 4 along arcs A and B) and (4) pivotal adjustment of holder 33 in bracket 30 (as described above).
Operation of the windshield lift 10 shown in FIGS. 1 through 8 will be explained in connection with the pictorial views shown in FIGS. 9 through 13. Referring first to FIG. 9, the lift 10 is positioned in the automobile with the base 16 supported on the floor and the lift 10 itself angled toward the windshield W. The lift 10 along with the work holder 38 and suction cups 43 are shifted and adjusted as explained above until a best fit position is found for the suction cups 43 in relation to the windshield W. The suction cups 43 are then pumped (FIG. 10) one at a time to create a vacuum to securely grip the windshield W. Handle 26 is then cranked around arcuate arrow I extending tube 11 along arrow R and exerting a force on the work holder 38 and suction cups 43 tending to outwardly push the windshield W. Sufficient force must be applied to stress the seal, but not enough to shatter the windshield W. This technique develops with experience.
After the seal is sufficient stressed, the technician goes outside and cuts the top seal with a sharp knife (FIG. 11). It has been discovered that when sufficiently stressed in tension, the seal can be cut more easily than an unstressed seal. After the top seal is cut, the side seals are cut while maintaining pressure on the seals with the crank handle. With the top and side seals cut, the handle 26 is cranked until the windshield W is pivoted out of the frame around the bottom seal which is then cut (FIG. 12) to totally free the windshield W.
As shown in FIG. 13, the final step in the operation is to rotate the windshield W so as to free the T-shaped work holder 38 along with its attached suction cups 43 from stub tube holder 33, leaving the lift body to lean against the dashboard. The work holder 38, along with the attached windshield W can then be carried off. Note the suction cup 43 holds the windshield W sufficiently to allow it to be a handle in carrying the windshield W.
FIG. 14 shows a modification for utilizing the disclosed lift 10 in a free standing mode of operation. Instead of the pivoted base 16 shown in FIG. 1, FIG. 14 shows a free standing base 144 having a cup shaped holder 145 supported by a pair of diverging struts 146 which are securely welded thereto. End portions of the struts 146 are welded to a pair of spaced, parallel feet 147 which engage a supporting surface.
The holder 145 supports the end portion of extension tube 13 including tail piece 15. By removing pin 19 from base 16, the same extension bar 13 can be used in the free standing base 144 by replacing pin 19 with hand screw knob 151. When so mounted, the lift 10 operates as explained in FIGS. 1 through 8.
FIG. 15 shows the standing base 144 of FIG. 14 employed to hold a windshield W for inspection prior to its installation. As explained above, stub tube holder 33 may be adjusted in bracket 30 to be axially aligned. The suction cups 43 will then face upwardly to support the windshield W.
FIG. 16 shows the lift 10 of FIG. 10 arranged to apply pressure against the side window 148 of a van 149. The rigid stand 144 is braced against a curb 150 or similar secure support and the lift 10 angled to secure the suction cups 43 to the side window 148.
While only two applications of the lift 10 equipped with a rigid standing base 144 are shown, the uses are many. For example, the lift 10 may be used to remove the rear windshield W of a truck by bracing the stand against the wheel well.
Moreover, having thus described the invention, it should be apparent that numerous structural modifications and adaptions may be resorted to without departing from the scope and fair meaning of the instant invention as set forth hereinabove and as described hereinbelow by the claims. | A windshield lift acting between the floor of a vehicle and the inside surface of the windshield with the aid of suction cups to apply an outward force to place the seal which bonds the windshield to the vehicle frame under tension. The peripheral seal can then be easily cut with a knife. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to a method for defrosting a refrigeration system, in which a supply arrangement supplies at least one cooling surface with refrigerant and as required a defrosting process is initiated at specific intervals; for implementing the method, the invention also relates to a control unit for a refrigeration system having at least one cooling surface, the unit having an output for switching on and switching off a flow of refrigerant passing through the cooling surface in dependence on the refrigerating chamber temperature.
Such a method and control apparatus are known, for example, from DE 40 06 468 C1. A refrigerator thermostat controls the switching on and off of a compressor (on-off operation). The thermostat switches the compressor off at a lower limit temperature and does not switch it on again until the cooling surface (evaporator) of the refrigerator reaches an upper limit value, which normally lies in the positive temperature range. In this mode of operation a heavy formation of frost or ice is not expected, so that there is no need for enforced defrosting. If, however, the refrigerator is set to a low temperature and, for example, is heavily overburdened as a result of frequent opening of the door or the placing of a large quantity of goods in the refrigerator for cooling, the lower limit temperature is not reached, and the compressor runs continuously for a very long period which leads to the formation of frost and ice on the cooling surface. For that reason a timer is provided, which switches the compressor off after a fixed time and carries out enforced full defrosting. The temperature in the refrigerator rises for a short time during this defrosting. This is tolerated, however, because otherwise with an iced-up evaporator an elevated temperature would occur constantly because of the insulation effect of the iced-up evaporator.
Similar problems arise with other known refrigeration systems too, in which defrosting has to be carried out from time to time because refrigerant is supplied to the cooling surface constantly or at least for relatively long periods of time.
SUMMARY OF THE INVENTION
The invention is based on the problem of being able to carry out de-icing of the cooling surface by defrosting at longer intervals than previously, wherein it is also possible for convenient times for defrosting to be selected.
That problem is solved by the method according to the invention in that partial defrosting is carried out at relatively short intervals and full defrosting is carried out at longer intervals.
Partial defrosting is effected when a layer of frost has formed on the cooling surface. It is caused by the temperature of the cooling surface assuming a value above zero for a short time. The frost layer is not removed in this process. On the contrary, it is converted into a solid layer of ice by fusing of a substantial part of the ice crystals. This layer is a much better conductor of heat than the layer of frost and takes up considerably less volume. This is especially important if the cooling surface has fins between which air flows, the quantity of air being substantially reduced by an increasingly thicker layer of frost but not by this solid ice layer. As operation continues, additional frost forms on the solid ice, and in turn can be converted into solid ice by partial defrosting. The refrigeration system can therefore continue normal operation for a relatively long time before full defrosting has to be carried out.
The efficiency of the refrigeration system is high. Firstly, with partial defrosting the cooling surface is brought only for a short time to a low positive temperature value. Secondly, the layer of ice to be thawed on the cooling surface assists in largely maintaining the desired temperature during the defrosting period.
It has proved beneficial for the shorter intervals to be from one to two hours. In this way the layer of frost has still not achieved a substantial insulating effect before the frost melts partially.
On the other hand, it is advisable for the longer intervals to be eighteen to thirty hours. Experience has shown that only after this time have the several partial defrostings caused the ice layer to build up to such thickness that it must be removed in order to avoid malfunctioning.
For full defrosting it is especially advantageous to select a period in which the refrigeration system is normally least loaded. The increase in the refrigerating chamber temperature tolerated during full defrosting can therefore very quickly be restored to the desired value. In the case of refrigerators in shops and supermarkets, defrosting is expediently carried out at night. At that time no new goods for cooling are being loaded into the refrigerators. The refrigerating chamber does not need to be open for improved accessibility. Even open freezer chests can be covered with insulating panels. Since a twenty-four hour rhythm can be kept to for complete defrosting, it is possible to carry out defrosting every day at the same time. Defrosting at maximum load can therefore be avoided.
The interval between two defrosting processes is expediently dependent on operating parameters of the refrigeration system. The interval between partial or full defrosting processes can thus be fixed in an optimum manner. These operating parameters include those that allow prediction of the thickness of the frost or ice layer, for example, the number of times the door is opened or the increase in the resistance to air during circulation of cooling air.
Operating parameters can also be used to determine the duration of the defrosting period, above all those parameters which enable the end of the defrosting process to be recognized. In particular, the duration of the defrosting processes can be dependent on the temperature of the refrigerating chamber. The end of the defrosting process is distinguished by a slight further temperature rise. In addition, the refrigerating chamber thermostat, normally already present, can be used for that purpose.
An especially simple solution is obtained when defrosting is effected by interrupting the supply of refrigerant to the cooling surface. The latent heat in the goods to be cooled and in the environment then leads to an increase in temperature in the refrigerating chamber, so that partial or full defrosting is carried out. This interruption can be brought about by stopping the supply arrangement, such as a compressor or pump, by actuating a valve, or by other means.
If pulse-width controlled valves are used in the refrigerant circuit it is then advisable to determine the duration of the defrosting processes by extending the "off" time. The switching on and switching off function of such a valve is here used for defrosting purposes.
Another preferred solution consists in monitoring the "on" time of the supply arrangement and when the shorter interval has been exceeded the supply arrangement is stopped until partial defrosting has been achieved.
When using a refrigerant system having several cooling surfaces and continuous supply of refrigerant, a further preferred possibility consists in interrupting the supply to each cooling surface in succession until partial defrosting has been effected. As the individual cooling surfaces are disconnected in succession from the supply of refrigerant, optimum operation is achieved. The refrigerating chamber temperature is only very slightly influenced by the partial defrosting.
In a further embodiment, in a refrigeration system having a secondary circuit with several cooling surfaces, the refrigerant of which is cooled by a primary circuit, provision is made for partial defrosting to be effected by interrupting the secondary refrigerant flow to one or more cooling surfaces. The primary circuit can operate, for example, with ammonia, and the secondary circuit with saline solution.
The problem posed is solved according to the invention using apparatus comprising a first switch-off timer which determines the shorter interval between the start of partial defrosting and the end of the previous defrosting, a second switch-off timer which determines the longer interval between the start of full defrosting and the end of the previous full defrosting, a first switch-on timer which determines the shorter duration of partial defrosting and a second switch-on timer which determines the longer duration of full defrosting. By means of the four timers, the desired partial defrosting and full defrosting can be carried out at the correct time.
It is advisable here to set the two switch-off timers to fixed times. The two switch-on timers on the other hand can respond to operating parameters of the refrigeration system.
BRIEF DESCRIPTION OF THE DRAWING
The invention is explained in greater detail hereinafter with reference to preferred embodiments illustrated in the drawings, in which
FIG. 1 shows diagrammatically a defrostable refrigeration system according to the invention,
FIG. 2 shows another embodiment having primary and secondary circuits,
FIG. 3 shows a third embodiment, suitable for a domestic refrigerator,
FIG. 4 shows the supply temperature of the refrigerant over time,
FIG. 5 shows the exit temperature of the refrigerant over time,
FIG. 6 shows the refrigerating chamber temperature over time,
FIG. 7 shows the on-off state of the refrigerant flow over time,
FIG. 8 shows a cooling surface with an initial formation of frost,
FIG. 9 shows the same cooling surface with an obstructive layer of frost,
FIG. 10 shows the same cooling surface after partial defrosting,
FIG. 11 shows a fin-type cooling surface operating with air circulation, with an initial formation of frost,
FIG. 12 shows the same cooling surface with an obstructive layer of frost,
FIG. 13 shows the same cooling surface after partial defrosting.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a refrigeration system 1 having a compressor 2, which supplies a refrigerant under high pressure at high temperature to a condenser 3. In the condenser 3 the refrigerant is cooled and following this cooling the refrigerant gas is converted into liquid. The condenser 3 feeds three evaporators 4, 5 and 6 connected in parallel, each being arranged in a respective refrigerating chamber 7, 8 and 9. Connection is effected by way of a respective valve 10, 11, 12 and a respective throttle element 13, 14, 15. The latter can be in the form of a capillary tube or expansion valve.
A control unit 16 controls the valves 10 to 12 by way of signal lines 17 in dependence on the refrigerating chamber temperature, for which purpose in each refrigerating chamber 7, 8, 9 there is provided a refrigerating chamber temperature sensor 18 which is connected by way of a signal line 19 to the control unit 16. The compressor 2 is controlled by way of a signal line 20 in dependence on the overall requirement of the refrigeration system. A value a which determines the interval between the preceding defrosting and the following partial defrosting can be fed in through an input 21. A value b, which determines the interval between the preceding full defrosting and the following full defrosting, can be fed in through a second input 22. The duration of partial defrosting and full defrosting is determined in dependence on the temperature of the refrigerating chamber or other operating parameters.
The refrigeration system 23 of FIG. 2 has a primary circuit 24, which is operated with ammonia, and a secondary circuit 25, which is operated with saline solution. The two circuits are connected to one another by way of a heat-exchanger 26. The primary circuit has a compressor 2, a condenser 3 and a throttle element 13, which is connected in series with an evaporator chamber 27 of the heat-exchanger 26. A pump 28 conveys the refrigerant, that is, the saline solution, by way of the secondary exchanger chamber of the heat-exchanger 26 and by way of the valves 29, 20 and 31 controlling the supply of refrigerant to cooling surfaces 32, 33 and 34, each of which is arranged in a respective refrigerating chamber 35, 36, 37. The associated control unit 16 is merely indicated. It controls the valves 29, 30 and 31 and the compressor 2 similarly to the manner of controlling the refrigeration system shown in FIG. 1.
FIG. 3 shows a refrigeration system 38 which is intended for a domestic refrigerator. Again, there is a compressor 2, a condenser 3 and connected thereto by way of a throttling element 13 a cooling surface 39 in the form of an evaporator in a refrigerating chamber 40. A control unit 41 operates similarly in dependence on a refrigerating chamber temperature sensor 42 and controls the compressor 2 by way of a signal line 43. The control unit 41 contains four timers 44, 45, 46 and 47. The first switch-off timer 44 determines the shorter interval a between the start of a partial defrosting and the end of the preceding defrosting, and this can be effected in dependence on the number of operations of a contact 48 operated when the door opens. The second switch-off timer 45 determines the longer interval b between the start of full defrosting and the end of the preceding full defrosting, for example, at twenty-four hours. The first switch-on timer 46 determines the shorter duration c of partial defrosting. The second switch-on timer 47 determines the longer duration d of full defrosting in dependence on the measurement signal of the refrigerating chamber temperature sensor 42. Partial defrosting commences only when the operating time of the compressor 2 exceeds the interval a.
FIGS. 4 to 7 should be considered together. Curve A in FIG. 4 shows the temperature of the refrigerant on admission to the cooling surface, that is, for example, the evaporators 4, 5, 6 or 39 or the heat-exchangers 32, 33 and 34, over the time t. Curve B in FIG. 5 shows the temperature of the refrigerant on leaving the cooling surface over time. Curve C in FIG. 6 shows the refrigerating chamber temperature over time and curve D in FIG. 7 shows the on-off behaviour of refrigerant flow, such as that characteristic of the defrosting according to the invention, over time.
The short intervals 49 in FIG. 7 denote the time of partial defrosting during the period c. The large intervals 50 denote the duration of full defrosting during the period d. The start of partial defrosting lags behind the end of the preceding full defrosting by the interval a. The start of full defrosting lags behind the end of the preceding partial defrosting by the interval b. During period a the valves 10, 11, 12 and 29, 30, 31 are normally in operation. In the intervals 49 and 50 they are closed. Related to the compressor 2 in FIG. 3, the compressor is continuously operative during the intervals a and is switched off during intervals 49 and 50. If, however, because of the refrigerating chamber temperature control the compressor 2 has already been switched off before the interval a has elapsed, the enforced defrosting can be dispensed with.
During partial defrosting, the discharge temperature represented by curve B rises only briefly above zero. This does not significantly influence the refrigerating chamber temperature represented by curve C. During full defrosting, on the other hand, a larger temperature rise in these curves has to be tolerated. It is therefore of great advantage for full defrosting to be carried out only at very long intervals.
FIGS. 8 to 10 show a cooling surface 51 through which refrigerant flows and which is arranged in a refrigerating chamber 52. In FIG. 8 this cooling surface 51 has the beginnings of a frost layer 53, which does not as yet interfere with operation. In FIG. 9, this frost layer 53 has reached a thickness which considerably hinders circulation of air along the cooling surface 51 and thus the exchange of heat. If partial defrosting is now carried out, the frost layer 53 melts partially and a layer of ice 54 is formed, as shown in FIG. 10. Only when that ice layer after several partial defrostings becomes too thick, is a full defrosting to be carried out.
FIGS. 11 to 13 illustrate a cooling surface 55 which is arranged in a refrigerating chamber 56. It has an evaporator coil 57 with numerous cooling fins 58. The refrigerant flows from the inlet 59 to the outlet 60. Air is blown through in counter-current as shown by the arrow 61.
FIG. 11 shows that a layer of frost 62 is starting to form at the lower ends of the fins 58. When this frost layer 62 reaches a thickness such as that shown in FIG. 12, the passage of air is greatly impeded. Partial defrosting is carried out, during which the frost layer melts and changes to a layer of ice 63. There is now again a sufficiently large cross-section for access of air. For the transfer of heat it is largely irrelevant whether the air delivers heat along the surface of the ice layer 63 or to the cooling surface itself. Only when the ice layer has become much thicker is full defrosting required.
The embodiments illustrated can be modified in many respects, without departing from the basic concept of the invention. For example, the intervals a and b can be dependent also on operating parameters of the refrigeration system other than the parameters mentioned. The duration c of partial defrosting can also, for example, be determined by measuring the air resistance in the vicinity of the cooling surface and determining the end of defrosting by a given value being fallen below. In the control unit 41 the four timers 44 to 47 are illustrated as individual blocks. Alternatively, they can be formed by a common computer with a suitable control program.
Defrosting is effected on an increase in temperature to above zero degrees. This can be caused either by an external influence, for example, heat transmission from the environment or heat emission from the goods to be cooled, or by the forced admission of heat to the cooling surfaces, for example, using hot refrigerant or hot saline solution or by electrical heating. | A method for defrosting a refrigeration system makes provision for partial defrosting of the cooling surface to be carried out at relatively short intervals, and for full defrosting to be carried out at longer intervals. To that end an associated control unit has four timers which determine the switching on and switching off times of the defrosting processes. In this manner the interval between successive full defrostings can be considerably increased. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to steam ironing machines and particularly to a steam ironing household appliance.
2. Description of the Prior Art
There are known steam irons which are provided with means capable of delivering a steam flow at a suitable temperature during the ironing of clothes or the like placed on an associated board, the steam flowing out through a plurality of holes provided in the ironing plate. The delivered steam is obviously in direct contact with the cloth to be ironed, which simultaneously is subjected both to the pressing and sliding action exerted by the smooth working surface of the steam iron and to the wetting and heating action exerted by the steam. In a sense, this situation has been recommended since conventional cloth ironing requires wetting of the clothes before the steam iron is pressed over the clothes, so that the ironing operation can be better and easily performed. However, this conventional ironing operation has the disadvantage that, once the clothes are ironed, they generally retain a certain amount of moisture, with the result that after the ironing operation the clothes undergo so-called "recovery", with the result that the ironing does not turn out very well. The clothes partially recover their initial configuration so that the creases and folds that the ironing operation was intended to relieve are reformed, of course to a lesser extent.
It is apparent that in this conventional ironing operation was lacking with regard to drying of the ironed clothes. Therefore, industrial or commercial type ironing machines have been proposed to permit the full drying of the ironed clothes after steam ironing by means of suction removal of the residual moisture. These machines are very heavy and cumbersome since they present a rigid assembly comprising the ironing board and the associated means, such as the base, the steam generator and the aspirator. These machines usually are used in laundries and dry cleaning shops. Conversely, the conventional appliances for household ironing, while being provided with steam capability in addition to the conventional electric ironing capability, cannot perform drying by suction of the residual moisture in the clothes.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a machine, apparatus or the like which combines the features of a household appliance, and which therefore can be easily used in areas of small dimensions, with the advantages of industrial or commercial ironing machines.
This object is achieved by providing a steam ironing machine for clothes, garments, shirts and the like, in the form of a structure including an ironing board directly or indirectly cooperating with means adapted to generate steam to be conveyed to a steam iron. The ironing board is provided with steam means as well as with suction means adapted to remove residual moisture from the ironed clothes. The ironing board is rotatably mounted by hinging means with respect to an appliance support element so as to be movable to two main positions, namely a work position where the board is horizontally disposed and the rest position where the board is vertically disposed. The ironing board rotates from the work position to the rest position with the board tip directed toward and adjacent to the support base. The rotational movement of the ironing board, both in this direction and in a reverse direction, is controlled by shock absorbing means, preferably in the form of gas springs, which enable the operator to carry out this rotational movement with a minimum of effort in both directions and at the same time absorb the stresses deriving from this rotational movement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b respectively are side elevational views of a conventional household ironing board shown in the work position and in the rest position;
FIG. 2 is a side view of the steam ironing appliance of the invention in its rest position;
FIGS. 3a and 3b respectively are a perspective view of a steam iron forming a part of the steam ironing appliance and a side view of the steam ironing appliance in the work position;
FIG. 4 is a top plan view of the steam ironing appliance;
FIG. 5 is a top plan view of the base only;
FIG. 6 is a front view of the steam ironing appliance seen from the side opposite the aspirator side;
FIG. 7 is a diagrammatic view of the four main components of the steam ironing appliance, with the exception of the steam iron, in their disassembled condition for storage or transport; and
FIG. 8 is a perspective view of an industrial or commercial steam ironing machine for dry cleaning shops and laundries.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and first to FIGS. 1a and 1b, a conventional household ironing board A (diagrammatically shown) includes an ironing top B and a folding support formed by legs 10, 12 which are pivotally mounted about center pins 14 and end pins 16, 18 so that, as usual, the ironing board can take the work position A and the rest position A 1 . When the ironing board is in the rest position A 1 it occupies a minimum space so that it can be put away and stored in a small space.
Referring now to FIG. 8, there is shown an industrial ironing machine A 2 intended to be used in laundries and dry cleaning shops, and which has a rigid structure of relatively great overall dimensions comprised of a base platform 20 from which extends a box-type upright 22, at the upper end 24 of which is an ironing top B 2 provided with a suction chamber 26. Embodied in the upright 22 is a steam generator for feeding steam to the steam iron as well as an aspirator for drying the clothes. The reference 28 designates a control pedal of the machine A 2 .
It is clear that, because of the weight, the dimensions and the rigidity of ironing machine A 2 , it can be used only in industrial applications, in rooms of a certain capacity and as a fixed installation.
FIGS. 2-6 show the steam ironing appliance according to this invention.
The steam ironing appliance C comprises a base 30, which preferably is formed of metal tubes, and from which extends a supporting column D suitably fixed to the base. Column D is provided at the lower end thereof with a plate 32 for connection to the base 30 and at the upper end thereof with a bracket 34 for connecting an ironing board F which is suitably secured to the column D such that the ironing board F can take two main positions, namely the rest position C shown in FIG. 2 and the work position C 1 shown in FIG. 3. In the rest position of FIG. 2, the ironing board F extends in a substantially vertical plane, whereas in the work position of FIG. 3 it extends in a substantially horizontal plane.
The ironing board F is suitably formed so as to have a lower suction chamber G which, on the one hand, is in communication with the atmosphere through a plurality of holes (not shown) provided in the ironing top 36, and on the other hand is in communication with a tangential inlet 38 of a centrifugal aspirator 40, the outlet of which is axially directed so that discharge therefrom occurs in the direction of arrow X. An electric motor 42 drives the rotor of the aspirator 40.
A steam generator H is connected to the ironing board F in such a manner that, when the ironing board is fully assembled, it presents the structure indicated in FIGS. 2 and 3, ironing board F being so dimensioned as to obtain a good ironing action and to have a relatively low weight, for example of about 30 kg.
A pair of shock absorbers L, e.g. gas springs, extend parallel to each other, but only one shock absorber can be seen in FIGS. 2 and 3. Each of the two shock absorbers L is formed of a cylinder 46 and a piston rod 50, cooperating with fluid contained in the cylinder. The lower end of each cylinder 46 is hinged at 48 to the column D through a plate 49 fastened thereto, while each piston rod 50 is hinged at 52 to the ironing board F. When the ironing board F is in a horizontal position, the shock absorbers L extend parallel to the column D, while when the ironing board F is in a vertical or rest position, with its tip 51 lowered, the shock absorbers L are suitably inclined with respect to the column D.
The presence and the function of the shock absorbers L are important because of the characteristic structure of the appliance which provides a weight unbalance with respect to a hinge 54 which pivotally connects the ironing board F to the column D in order that the appliance can take the rest position of FIG. 2 presenting the minimum overall dimensions and the work position of FIG. 3 presenting the maximum overall dimensions.
When the ironing appliance is in the work position with the ironing board F horizontally disposed, the weight is unbalanced to the right hand side as shown in FIG. 3, and therefore in order to rotate the ironing board F about the hinge 54 to bring it to its vertical position it would be necessary to exert a very high force in the absence of the gas springs L. With the presence of these springs, on the contrary, the force exerted by the operator to rotate the ironing board F in the counterclockwise direction of arrow Y to bring the ironing board F from the horizontal position to the vertical position one is reduced to a minimum, since it is sufficient for the operator simply to apply finger pressure to a handle 53 in the direction of arrow X1 to lift the relative heavy portion of the ironing board F by rotating it about the hinge 54, this rotation being promoted by the gas springs L.
On the contrary, when the ironing board F is to be brought from its vertical position to the horizontal position of FIG. 3, the gas springs L operate in an opposite direction, by acting as shock absorbers and preventing the clockwise rotation to occur suddenly and therefore to cause collisions between the appliance components and possible failure thereof or injuries to the operator.
In accordance with the structure of the ironing appliance and the relative arrangement of steam generator H and aspirator 40, the ironing board F rotates to a vertical position with tip 51 directed downwardly. Rotation to the vertical position in an opposite direction would not be possible since the components H and 40 would interfere with the supporting column D.
In order to assemble or disassemble the steam ironing appliance C, four pins only are necessary, namely a pin for hinging the ironing board F to the column D, a pin for securing the ironing board to the column D in the work position, and two pins for securing the steam generator to the ironing board through the aspirator casing. These pins are indicated at 54, 56, 58, 60. Four screws indicated at 62, 64, 66, 68 in FIG. 5 secure the column D to the base 30 through the plate 32 of the column D and a plate 72 of the base 30.
The ironing board F may be arranged to rotate in a horizontal plane with respect to the base 30, either by rotatably mounting the assembly D, F about the base, or by rotatably mounting the ironing board F only about the column D which is fixed with respect to the base.
The base is advantageously provided with two rubber feet 74 or the like and two pivotable rollers 76 for the easy displacement of the appliance.
In FIG. 4, a resistor 78 is arranged below the work top 36 of the board F to heat a cover or felt covering the perforated work top 36 and to prevent items being ironed from being wetted by the felt. The steam generator H is contained in a box 80 capable of allowing support on its upper surface of a steam iron M. Box 80 contains a heating resistor, a pressure switch, a safety valve, an electric circuit for controlling the steam iron, the ironing board, the aspirator and the steam generator as well as an electronic circuit for controlling the steam iron M and the steam delivery and the suction functions. The latter circuit includes leads 84 and 86 contained in the steam iron handgrip in such a manner as to be connected to a pair of sensors 88, 90 placed in the front of a handle 92 at equal distances from the center line 94 of the handle, these sensors being able to be alternately or simultaneously energized simply by being touched by the operator to control either steam delivery through a perforated plate 96 of the steam iron M (the perforations are not shown) or air suction through the perforations of the ironing top 36, the chamber G, the aspirator inlet 40 and the aspirator outlet, or simultaneously both such steam delivery and air suction.
Elements 98, 100, 102, 104 designate indicators of the instruments controlling the operation of the ironing appliance.
The base 30 of the ironing appliance C is formed of metal tubes, in this case C-shaped tubes 106, 108, shown in FIG. 5, connected to each other by means of the plate 72 asymmetrically arranged with respect to the transverse center line of the base, for the sake of stability. Of course, the base 30 can be formed in any other suitable manner ensuring stability and also greater east of transport of the ironing appliance.
Referring now to FIG. 7, there are diagrammatically shown the four main components of the ironing appliance according to the invention, namely the ironing board F including the centrifugal aspirator 40 with electric motor 42 fastened thereto, the column D, the base 30 and the box 80 containing the steam generator H.
The capability of the machine to be immediately disassembled and reassembled from the four components thereof by means of the above-mentioned pins and screws is a basic condition for transport and storage of the ironing appliance. For transport by truck, railway, aircraft or ship, it is sufficient for the four components of FIG. 7 to be placed in a container of limited dimensions, thus being valid also for the storage of disassembled ironing appliances in relatively reduced spaces.
In such a container, the ironing appliance could be placed in the attitude of FIG. 2, but without the elements L and possibly the steam generator H. In fact, a device already used by the operator or a boiler feeding a plurality of ironing machines could be employed for steam generation.
In FIG. 6 there is shown the manner of hinging of the ironing board F, having the work top 36 covered by a felt 37, to the column D. Pivot pin 54 pivotally connects by ironing board F to the column by being inserted into holes in vertical brackets 39, 41 of the board F and into corresponding holes in column D. Safety pin 56 locks the ironing board in the work position with respect to the column D.
Having so described the ironing appliance C the operation and the advantages thereof will be apparent and are summarized in the following.
Assuming that assembly of the appliance must be performed starting from the four components shown in FIG. 7, the first step is to secure the column D to the base 30 by means of the screws 62, 64, 66, 68. Then, the ironing board F will be hinged to the column D by means of the pivot pin 54, and then the ironing board F will be secured by inserting the pin 56 into the corresponding holes of board and column. At this point the ironing board is fastened to the elements 30 and D. Then, the box 80 will be secured by means of the screws 58-60 to the aspirator 40 and the ironing board F, so as to have an assembly comprised of the steam generator, the aspirator and the ironing board. Then, the side shock absorbers L will be connected to the ironing appliance C by means of the pivot pins 48, 52. The steam iron M will be connected to the steam generator through a hose, whereas the electronic circuit 84, 86, 88, 90 will be connected to the respective components under control.
Once the ironing appliance C is mounted as illustrated in FIG. 3 and the steam generator H is filled with a relatively small water amount, the appliance is ready to operate as an industrial ironing machine while having the dimensions and other features of a simple home ironing appliance. Simultaneously with or after steam ironing by means of the steam iron, a suction operation by means of the aspirator 40, 42 occurs. This causes residual moisture in the ironed clothes to be removed, thereby drying them. The aspirator power can be set so as to produce a good adhesion of the clothes on the ironing top 36 covered by the felt. These steps can be controlled by the operator through the sensors 88, 90 in the steam iron M.
When the operator has completed use of the appliance, it is moved from the work position to the rest position of FIG. 2. It is sufficient to remove the safety pin 56 and then to exert by hand a small force of the handle 53 of the ironing board F in the direction of the arrow x 1 to obtain pivotal movement of the ironing board F in the direction of the arrow Y about the pivot pin 54. The ironing board will then rotate in a counterclockwise direction as viewed in FIGS. 2 and 3 (and the rotation will be facilitated by the shock absorbers L), until it is in the substantially vertical position C 1 of FIG. 2, where it can be locked. In this compact attitude, the ironing appliance C can be moved by means of the rollers 75 and placed in a small storeroom or the like, as in the case of conventional ironing boards with folding legs, as illustrated in FIG. 1. In this manner there is no need of a large space for storage of the ironing appliance. In the rest position of FIG. 2, the ironing appliance can be placed in a conventional closet of a kitchen.
When the ironing board F is to be brought again from the vertical rest position of FIG. 2 to the horizontal work position of FIG. 3, the operator must operate on the ironing board in a reverse direction with respect of that of arrow Y, causing the ironing board to be rotated in a clockwise direction as viewed in FIGS. 2 and 3 about the pivot pin 54. Because of the weight distribution along the ironing board F, the latter will tend to fall by gravity from the vertical position of FIG. 2 to the horizontal position of FIG. 3 until the stop plane 61 of the ironing board F is aligned with the stop plane 63 of the column D. This must be avoided for reasons of safety of the machine and of the operator. The hydraulic resistance of the shock absorbers L which are shortening by passing from the expanded condition of FIG. 2 to the retracted condition of FIG. 3 causes the clockwise rotation movement to be retarded, thereby slowing down this movement and therefore avoiding the risk of component breakage and operator injury.
Therefore the ironing appliance is very easily inclinable along all the length thereof, thereby reducing its height (1.5 m) and the occupied surface (38 cm×60 cm), which results in very small overall dimensions, for example the dimensions of a television set with associated support. The horizontal surface occupied by the appliance in the rest position is reduced by 60% of that occupied in the work position.
The electronic control means of sensors 88, 90 excludes any type of pedal 28 usually employed in industrial or commercial ironing machines.
The anatomic handgrip 71 of the steam iron M permits the use thereof without tiring the wrist of the operator. This handgrip is formed of a thermoinsulating material, while the pair of sensors 88, 90 have the form of hemispherical heads. The electronic circuit extending from the sensors 88, 90 is contained partially in the handle 71 and partially in the box of the steam generator H and the electric board 81.
The electronic circuit of conventional design is an important feature of this invention, since all conventional ironing boards include in the steam iron M a microswitch controlling an electric steam valve while suction is controlled by a pedal, the operation of which is not always easy and causes the operator to be compelled to work often in an awkward position.
The centrifugal aspirator 40 performs, at relatively low power, perfect suction and therefore drying of the ironed clothes.
It should be understood that the construction details can be changed without departing from the scope of the invention.
Briefly stated, the invention relates to disassemblable ironing board which can be reclined by means of hinge elements, which is heated and provided with suction in different areas by means of a centrifugal aspirator controlled by electronic sensors.
The steam generator is self-contained and provided with a dry resistor equipped with a pressure switch, a thermostat and a safety valve. | A steam ironing machine includes an ironing board, a steam generator to convey steam to a steam iron, a heater for the ironing board, a suction device to remove residual moisture from ironed clothes. The ironing board is rotatably mounted by hinges with respect to a support element between two positions, i.e. a work position where the board is horizontally disposed and a rest position where the board is vertically disposed. The ironing board rotates from the work position to the rest position with the board tip directed toward and adjacent the support. Rotational movement of the ironing board in both directions is controlled by shock absorbers which aid the operator in achieving this rotation movement and at the same time absorb stresses resulting from this rotational movement. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/482,908 filed May 5, 2011. The disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present disclosure relates to battery packs for automotive vehicles. More particularly, the present disclosure relates to battery cooling apparatus using a fluid state medium to cool battery packs having at least one stacked array of rechargeable battery cells.
[0003] Electric vehicles, including hybrid electric vehicles, have electric motors for propelling the vehicles along roadways, for example, and these electric motors typically rely upon onboard rechargeable batteries as their energy source. Battery packs having a fairly large number of individual rechargeable battery cells are frequently used with such vehicles. An example of a battery cell that is used in electric vehicles is a lithium ion battery cell. When recharging and when discharging to provide power to the electric motors of electric vehicles, the battery cells generate heat that needs to be removed in order to maintain the battery cells below their maximum allowable temperatures so that the battery cells are not damaged or destroyed by the heat. When removing heat from battery packs, it is desirable but not necessary to have the faces of each of the battery cells maintained at a fairly uniform temperature.
[0004] It is known in the art that liquid-cooling provides significant convection coefficients and can be used to cool battery packs. However, some of these systems include dozens or hundreds of liquid-sealed connections. This proliferation of connections may add cost and risk of leakage to the liquid coolers for use with battery packs. Accordingly, there is a need for an improved liquid cooled battery pack apparatus.
SUMMARY
[0005] A battery pack apparatus for an automotive vehicle is provided and comprises one or more of the features recited in the appended claims and/or the following features which, alone or in any combination, may comprise patentable subject matter:
[0006] A laminate cooling plate having a top surface and a bottom surface may include a fluid inlet, a fluid outlet, and a plurality of internal sheets. The internal sheets may form a plurality of fluid passages between the top surface and the bottom surface. Each of the plurality of fluid passages may form an S-shaped circuit that connects the fluid inlet to the fluid outlet. The internal sheets may be formed to include fluid pathways cooperating to define the fluid passages.
[0007] In some embodiments, some of the fluid pathways may individually define an uninterrupted flow path. Each of the plurality of fluid passages may independently connect the fluid inlet to the fluid outlet.
[0008] In some embodiments, the plurality of fluid passages may interdigitally couple to the fluid inlet and the fluid outlet. The fluid inlet and the fluid outlet may be aligned so that the fluid outlet lies in a footprint of the fluid inlet when viewing the top surface of the laminate cooling plate. It is contemplated that the plurality of passages may be substantially the same length and each of the plurality of passages may have an equal number of turns.
[0009] In some embodiments, each of the plurality of internal sheets may be formed to include a plurality of pathways. The plurality of pathways of each of the plurality of internal sheets may cooperate with the plurality of pathways of the other internal sheets to define the plurality of passageways.
[0010] A battery pack apparatus may include a first cell bank and a laminated cooling plate. The first cell bank may include a first tray and at least one battery cell coupled to the tray. The laminated cooling plate may be in contact with the first cell bank and may include a plurality of face sheets forming a fluid inlet and a fluid outlet and a plurality of internal sheets forming a plurality of fluid passages connecting the fluid inlet to the fluid outlet. The internal sheets may be formed to include fluid pathways defining the fluid passages wherein none of the fluid pathways individually defining an uninterrupted flow path.
[0011] In some embodiments, the fluid passages may provide an independent flow path between the fluid inlet and the fluid outlet. The plurality of face sheets may include a top face sheet formed to include an external inlet hole and a bottom face sheet formed to include an external outlet hole. It is contemplated that a substantially similar pressure drop may be produced along each of the plurality of fluid passages.
[0012] The plurality of internal sheets may include a first internal sheet formed to include an internal inlet hole and a first plurality of fluid pathways extending through the first internal sheet. The plurality of internal sheets may include a second internal sheet formed to include a second plurality of fluid pathways extending through the second internal sheet. The plurality of internal sheets may include a third internal sheet formed to include an internal outlet hole and a third plurality of fluid pathways extending through the third internal sheet.
[0013] A pattern of the second plurality of fluid pathways may be substantially similar to a pattern of the first plurality of internal pathways. The second internal sheet may be indexed with respect to the first internal sheet so that the second plurality of fluid pathways is aligned with the first plurality of fluid pathways.
[0014] The first internal sheet may include a first interruption blocking the first plurality of fluid pathways at a point. The second internal sheet may include a second interruption blocking the second plurality of fluid pathways at a point. The third internal sheet may include a third interruption blocking the third plurality of fluid pathways at a point. It is contemplated that the first interruption, the second interruption, and the third interruption may be spaced apart from one another.
[0015] A battery pack apparatus may include a first cell bank and a laminated cooling plate. The first cell bank may include a first tray and at least one battery cell. The laminated cooling plate may be in contact with the first cell bank and may include a plurality of sheets. Each sheet may be formed to include cutouts forming a flow path through the laminated cooling plate. Each of the cutouts may extend through the thickness of a sheet.
[0016] The laminated cooling plate may include a fluid inlet, a fluid outlet, and a plurality of fluid flow passages connecting the fluid inlet and the fluid outlet. Each of the plurality of fluid flow passages may provide an independent flow path between the fluid inlet and the fluid outlet.
[0017] The plurality of internal sheets may include a first internal sheet formed to include an internal inlet hole and a first plurality of fluid pathways extending through the first internal sheet. The plurality of internal sheets may include a second internal sheet formed to include a second plurality of fluid pathways extending through the second internal sheet. The plurality of internal sheets may include a third internal sheet formed to include an internal outlet hole and a third plurality of fluid pathways extending through the third internal sheet.
[0018] The first internal sheet, the second internal sheet, and the third internal sheet may be indexed relative to one another and brazed together so that the first plurality of pathways, the second plurality of pathways, and the third plurality of pathways cooperate to define the plurality of fluid flow passageways connecting the fluid flow inlet and the fluid flow outlet.
[0019] Additional features, which alone or in combination with any other feature(s), such as those listed above and those listed in the appended claims, may comprise patentable subject matter and will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode of carrying out the embodiments as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The detailed description particularly refers to the accompanying figures, in which:
[0021] FIG. 1 is a cross sectional diagrammatic view of a battery pack including a top cell bank, a bottom cell bank, and a cooling plate situated between the top cell bank and the bottom cell bank and showing that a top surface of the cooling plate contacts both a battery cell and a thermally conductive tray included in the top cell bank and a bottom surface of the cooling plate contacts both a battery cell and a thermally conductive tray included in the bottom cell bank to remove heat generated by the top and the bottom cell banks.
[0022] FIG. 2 is a diagrammatic view of a fluid cooling system including the battery pack of FIG. 1 showing the cooling plate fluidly coupled to a pump and a fluid reservoir and suggesting that a fluid medium can be pumped through the cooling plate to remove heat from the top and bottom cell banks;
[0023] FIG. 3 is a detailed diagrammatic view of the battery pack of FIG. 2 showing that the cooling plate is a laminate cooling plate including a plurality of sheets fused together to provide a substantially leak-proof plate;
[0024] FIG. 4 is a top plan view of a top face sheet included in the laminate cooling plate shown diagrammatically in FIG. 3 showing an external inlet hole and a plurality small fastener holes formed in the top face sheet;
[0025] FIG. 5 is a top plan view of a first interior sheet included in the laminate cooling plate of FIG. 3 showing that an interior inlet hole, a plurality small fastener holes, and a first plurality of pathways are formed through the first interior sheet and showing that each of the first plurality of pathways are blocked by a first series of interruptions;
[0026] FIG. 6 is a top plan view of a second interior sheet included in the laminate cooling plate of FIG. 3 showing a plurality small fastener holes and a second plurality of pathways formed through the second interior sheet with a pattern substantially similar to the first plurality of pathways formed in the first interior sheet of FIG. 5 and showing that each of the second plurality of pathways are blocked by a second series of interruptions that do not align with the first series of interruptions included in the first interior sheet shown in FIG. 5 ;
[0027] FIG. 7 is a top plan view of a third interior sheet included in the laminate cooling plate of FIG. 3 showing that an interior outlet hole, a plurality small fastener holes, and a third plurality of pathways are formed through the third interior sheet, the third plurality of pathways having a pattern substantially similar to the first and the second plurality of pathways formed in the first and the second interior sheets of FIGS. 5 and 6 , and showing that each of the third plurality of pathways are blocked by a third series of interruptions that do not align with the first or the second series of interruptions included in the first and the second interior sheets shown in FIGS. 5 and 6 ;
[0028] FIG. 8 is a top plan view of a bottom face sheet included in the laminate cooling plate shown diagrammatically in FIG. 3 showing an exterior outlet hole and a plurality small fastener holes formed in the bottom face sheet;
[0029] FIG. 9 is a top plan view of a cell block showing a plurality of battery cells supported by a cell retention tray and a plurality of bus bars situated along the length of the cell retention tray so that the battery cells can be connected in series and electrically coupled as a group at an end of the cell block;
[0030] FIG. 10 is a detail view of the bus bar of FIG. 9 showing that the bus bar is electrically insulated from the cell retention tray and is accessible from above and below the cell retention tray such that welding equipment can touch top and bottom surfaces of the bus bars to form connections to the battery cells through a series of weld windows; and
[0031] FIG. 11 is a partially exploded perspective view of a cell block and the cooling plate of FIG. 1 showing that the cell bank includes a first cell block, a second cell block, and a third cell block, the first, second, and third cell blocks electrically coupled in series.
DETAILED DESCRIPTION
[0032] An illustrative battery pack apparatus 10 includes laminate cooling plate 12 , a top cell bank 14 , and a bottom cell bank 16 as shown in FIG. 1 . Cooling plate 12 has a top surface 18 and a bottom surface 20 . Top cell bank 14 is coupled to top surface 18 of cooling plate 12 so that heat generated by top cell bank 14 may be transferred to cooling plate 12 . Bottom cell bank 16 is coupled to bottom surface 20 of cooling plate 12 so that cooling plate 12 so that heat generated by bottom cell bank 16 may be transferred to cooling plate 12 .
[0033] Cooling plate 12 is coupled to a fluid inlet coupling 22 and a fluid outlet coupling 24 so that a liquid cooling medium can be passed through cooling plate 12 to remove heat from cooling plate 12 . Cooling plate 12 is configured so that a cool fluid medium enters cooling plate 12 through fluid inlet coupling 22 and the fluid medium flows through cooling plate 12 and exits cooling plate 12 after absorbing heat from cooling plate 12 through fluid outlet coupling 24 . In the illustrative embodiment, a thin layer of thermal gel or another interface compound may be spread at the interface of the cooling plate 12 with the top cell bank 14 and the bottom cell bank 16 to reduce air gaps that could provide thermal barriers between the cooling plate and the cell banks 14 , 16 .
[0034] Top cell bank 14 illustratively includes a plurality of cell blocks 26 and at least one sensor 28 as shown in FIGS. 1 and 2 . Cell blocks 26 produce heat when battery pack apparatus 10 is electrically charged or loaded. At least one sensor 28 is illustratively configured to measure the temperature of each cell block 26 .
[0035] Bottom cell bank 16 illustratively includes a plurality of cell blocks 30 and at least one sensor 32 as shown in FIGS. 1 and 2 . Cell blocks 30 produce heat when battery pack apparatus 10 is electrically charged or loaded. At least one sensor 32 is illustratively configured to measure the temperature of each cell block 26 .
[0036] Battery pack apparatus 10 is configured for use in a cooling system 40 as shown diagrammatically in FIG. 2 . Cooling system 40 includes a fluid medium reservoir 42 , a pump 44 , and a controller 46 . Reservoir 42 holds a fluid medium to be pumped through cooling plate 12 . In some embodiments, reservoir 42 is also a cooler that actively or passively cools the fluid medium stored therein. Pump 44 is configured to pump fluid medium from reservoir 42 through cooling plate 12 and back into reservoir 42 as suggested by arrows 48 , 49 shown in FIG. 2 .
[0037] Controller 46 is coupled to temperature sensors 28 , 32 included in cell banks 14 , 16 to receive information about the temperature of cell banks 14 , 16 over time as shown in FIG. 2 . Controller 46 is also coupled to pump 44 so that controller 46 directs pump 44 . Controller 46 directs pump 44 to increase or decrease the flow rate of fluid medium through cooling plate 12 in response to information received from sensors 28 , 32 so that the rate of heat transfer through cooling plate 12 maintains cell banks 14 , 16 in a predetermined range.
[0038] Cooling plate 12 is a laminate plate including a plurality of sheets 51 , 52 , 53 , 54 , 55 stacked together and fused to produce a single substantially leak-proof plate as shown diagrammatically in FIG. 3 . In the illustrative embodiment, sheets 51 , 52 , 53 , 54 , 55 each have a thickness of about 4 mm so that cooling plate 12 has a combined thickness of about 20 mm. Additionally, each sheet 51 , 52 , 53 , 54 , 55 includes a platform 50 and a connection ear 56 as shown in FIGS. 4-8 . Platform 50 has a width 50 W, illustratively about 360 mm, and a length 50 L, illustratively 510 mm, as shown, for example, in FIG. 4 .
[0039] Cooling plate 12 illustratively includes top face sheet 51 , first internal sheet 52 , second internal sheet 53 , third internal sheet 54 , and bottom face sheet 55 as shown in FIGS. 4-8 . Top face sheet 51 is formed to include an external inlet hole 60 extending through connection ear 56 of top face sheet 51 and configured to couple to fluid inlet coupling 22 . Additionally, platform 50 of top face sheet 51 is substantially smooth and flat so that a continuous thermal connection can be maintained between top cell bank 14 and top face sheet 51 of cooling plate 12 as suggested in FIGS. 1-3 .
[0040] First internal sheet 52 is formed to include an internal inlet hole 76 , a plurality of feeder slots 78 , and a plurality of pathways 80 that each extend through the entire thickness of first internal sheet 52 as shown in FIG. 5 . Feeder slots 78 are illustratively about 6 mm wide. Internal inlet hole 76 and feeder slots 78 extend through connection ear 56 of first internal sheet 52 . Internal inlet hole 76 is aligned with external inlet hole 60 as suggested by FIGS. 4 and 5 .
[0041] Plurality of pathways 80 are formed through platform 50 of first internal sheet 52 and each of the plurality of pathways form an S-shape that doubles back on itself as shown in FIG. 5 so that a substantially uniform temperature can be maintained throughout cooling plate 12 . Plurality of pathways 80 of first internal sheet 52 illustratively includes eight individual pathways each coupled at a first end to internal inlet hole 76 by one of the plurality of feeder slots 78 as shown in FIG. 5 .
[0042] Plurality of pathways 80 of first internal sheet 52 are interrupted by a series of interruptions 82 included in first internal sheet 52 as shown in FIG. 5 . Series of interruptions 82 provide structural support for first internal sheet 52 prior to fusing of sheets 51 , 52 , 53 , 54 , 55 to form cooling plate 12 .
[0043] Second internal sheet 53 is formed to include a plurality of pathways 84 that each extend through the entire thickness of second internal sheet 54 as shown in FIG. 6 . Plurality of pathways 84 of second internal sheet 53 are formed through platform 50 of second internal sheet 53 and each of the plurality of pathways form an S-shape that doubles back on itself as shown in FIG. 6 so that a substantially uniform temperature can be maintained throughout cooling plate 12 . Plurality of pathways 84 of second internal sheet 53 illustratively includes eight individual pathways aligned with the plurality of pathways 80 of first internal sheet 52 as suggested by FIGS. 5 and 6 .
[0044] Plurality of pathways 84 of second internal sheet 53 are interrupted by a series of interruptions 86 included in second internal sheet 53 as shown in FIG. 6 . Series of interruptions 86 provide structural support for second internal sheet 53 prior to fusing of sheets 51 , 52 , 53 , 54 , 55 to form cooling plate 12 . Further, series of interruptions 86 of second internal sheet 53 are spaced apart from and form a pattern different than series of interruptions 82 of first internal sheet 52 so that they do not align when sheets 51 , 52 , 53 , 54 , 55 are fused to form cooling plate 12 .
[0045] Third internal sheet 54 is formed to include an internal outlet hole 88 , a plurality of feeder slots 89 , and a plurality of pathways 90 that each extend through the entire thickness of third internal sheet 54 as shown in FIG. 7 . Feeder slots 89 are illustratively about 6 mm wide. Internal outlet hole 88 and feeder slots 89 extend through connection ear 56 of third internal sheet 54 .
[0046] Plurality of pathways 90 are formed through platform 50 of third internal sheet 54 and each of the plurality of pathways form an S-shape that doubles back on itself as shown in FIG. 7 so that a substantially uniform temperature can be maintained throughout cooling plate 12 . Plurality of pathways 90 of third internal sheet 54 illustratively includes eight individual pathways aligned with the plurality of pathways 80 of first internal sheet 52 and plurality of pathways 84 of second internal sheet 53 as suggested by FIGS. 5-7 . Each of the plurality of pathways 90 included in third internal sheet 54 are coupled at a second end to internal outlet hole 88 by one of the plurality of feeder slots 89 as shown in FIG. 7 .
[0047] Plurality of pathways 90 of third internal sheet 54 are interrupted by a series of interruptions 92 included in third internal sheet 54 as shown in FIG. 7 . Series of interruptions 92 provide structural support for third internal sheet 54 prior to fusing of sheets 51 , 52 , 53 , 54 , 55 to form cooling plate 12 . Further, series of interruptions 92 of third internal sheet 54 are spaced apart from and form a pattern different than series of interruptions 82 of first internal sheet 52 and series of interruptions 86 of second internal sheet 53 so that they do not align when sheets 51 , 52 , 53 , 54 , 55 are fused to form cooling plate 12 .
[0048] Bottom face sheet 55 is formed to include an external outlet hole 94 extending through connection ear 56 of bottom face sheet 55 and configured to couple to fluid outlet coupling 24 . External outlet hole 94 is aligned with internal outlet hole 88 of third internal sheet 54 as suggested by FIGS. 7 and 8 . Additionally, platform 50 of bottom face sheet 55 is substantially smooth and flat so that a continuous thermal connection can be maintained between bottom cell bank 16 and bottom face sheet 55 of cooling plate 12 as suggested in FIGS. 1-3 .
[0049] Each pathway included in the plurality of pathways 80 , 84 , 90 of sheets 52 , 53 , 54 , 55 are illustratively about 2 mm wide and are formed by one of a water jet or a laser. The center of each cut forming the pathways of the illustrative embodiment is about 10 mm from the centerline of an adjacent cut leaving about 8 mm of sheet material between each cut forming a pathway. Additionally, in the illustrative embodiment, each of the pathways 80 , 84 , 90 are the same length. Turns in the pathways are each illustratively about ninety-degrees with about a 5 mm radius. In other embodiments, other tools or methods, such as extrusion, may be used to form pathways of alternate dimensions.
[0050] Each sheet of plurality of sheets 51 , 52 , 53 , 54 , 55 are formed to include a plurality of fastener holes 95 , 96 , 97 , 98 as shown in FIGS. 4-8 . Fastener holes 95 , 96 extend through connection ears 56 of sheets 51 , 52 , 53 , 54 , 55 . Fastener holes 97 , 98 extend through platform 50 of sheets 51 , 52 , 53 , 54 , 55 and are configured to receive fasteners (not shown) for coupling cell banks 14 , 16 to cooling plate 12 . Fastener holes 97 , 98 are located about midway along the width 50 W of platform 50 as indicated by distance 99 , illustratively about 180 mm, in FIGS. 4 and 8 . Fastener hole 97 and fastener hole 98 are each spaced approximately one-third of length 50 L from opposing ends of platform 50 along the length 50 L of platform 50 as indicated by distances 97 D and 98 D in FIGS. 4 and 8 .
[0051] To fuse the plurality of sheets 51 , 52 , 53 , 54 , 55 , the sheets are stacked as indicated diagrammatically in FIG. 3 and indexed so that the plurality of pathways 80 , 84 , 90 of internal sheets 52 , 53 , 54 are aligned. Then the stacked sheets 51 , 52 , 53 , 54 , 55 are brazed so that the contacting portions of the sheet melt together forming cooling plate 12 with an inlet 100 , an outlet 102 , and a plurality of fluid passageways 106 defined by the plurality of pathways 80 , 84 , 90 of internal sheets 52 , 53 , 54 . Sheets 51 , 52 , 53 , 54 , 55 are illustratively constructed of braze alloy aluminum sheet material. In other embodiments, other thermally conductive metals or other materials are used. The aluminum sheets 51 , 52 , 53 , 54 , 55 are anodized with a thin coating after brazing to provide electrical isolation while maintaining overall heat transfer.
[0052] Inlet 100 is formed from external inlet hole 60 and internal inlet hole 76 as suggested in FIGS. 2 and 3 . Inlet 100 is coupled to a first end of each of the internal passageways 106 by feeder slots 78 . Outlet 102 is formed from external outlet hole 94 and internal outlet hole 88 as suggested in FIGS. 2 and 3 . Outlet 102 is coupled to a second end of each of the internal passageways by feeder slots 89 so that the plurality of passageways 106 is interdigitally coupled to the inlet 100 and the outlet 102 . Each of the plurality of fluid passageways provides an independent flow path from the inlet 100 to the outlet 102 as suggested by FIGS. 5 and 7 .
[0053] Top cell bank 14 includes plurality of cell blocks 26 as shown in FIG. 1 . Bottom cell bank 16 includes plurality of cell blocks 30 as shown in FIG. 1 . Each cell block included in top cell bank 14 and bottom cell bank 16 are substantially similar and thus an exemplary cell block 110 is shown in FIG. 9 and described illustratively herein.
[0054] Cell block 110 includes a retention tray 112 , a plurality of battery cells 114 , and a plurality of bus bars 116 as shown, for example in FIG. 9 . Retention tray 112 is illustratively constructed from anodized aluminum for high thermal and low electrical conductivity and is configured to support plurality of battery cells 114 and bus bars 116 as shown in FIG. 9 . Battery cells 114 are illustratively rechargeable electrochemical lithium cells. Bus bars 116 are coupled to each of the battery cells 114 so that plurality of battery cells 114 are connected in series.
[0055] Retention tray 112 includes a base 120 and a raised divider 122 forming pockets 124 as shown in FIGS. 2 and 9 - 11 . Base 120 contacts battery cells 114 and transmits heat from battery cells 114 to retention tray 112 . Raised divider 122 contacts either cooling plate 12 or a base 120 of another retention tray 112 thereby passing heat to the cooling plate 12 as suggested in FIG. 1 .
[0056] Battery cells 114 are positioned in pockets 124 of retention tray 112 formed between raised divider 122 of retention tray 112 so that very little space if any is left between the face of the cell and the retention tray as shown, for example, in FIGS. 1 and 9 - 11 . A small amount of thermal interface gel may be applied to the battery cells 114 to reduce or eliminate any air gap that might create thermal barriers between the battery cells 114 and the retention trays 112 . In the illustrative embodiment, two by six series of battery cells 114 is utilized to achieve a desired system voltage. In other embodiments, other configurations may be used to provide different voltage outputs.
[0057] Bus bars 116 are coupled to the retention tray 112 as shown, for example in FIGS. 9 and 10 . Bus bars 116 are electrically couples to battery cells 114 so that battery cells 114 form a series along retention tray 112 . In some embodiments, bus bars 116 are made from aluminum that is anodized except at the point of connection with the battery cells 114 . Bus bars 116 are accessible for welded connection to battery cells 114 on both the top and bottom surfaces of the bus bars 116 via weld windows 126 provided in retention tray 112 as shown in FIG. 10 . Bus bars 116 include insulated areas 128 between connections to battery cells 114 as shown in FIG. 10 . The insulated areas are illustratively heat shrunk electrical insulation.
[0058] After cell block 110 is constructed, plurality of cell blocks 30 can be assembled into bottom cell bank 16 as suggested in FIG. 11 . Each cell block 110 is coupled to another cell block 110 to form a series circuit of battery cells 114 as suggested by arrows 130 , 132 shown in FIG. 11 .
[0059] The assembly process for this system begins by mounting bus bars 116 within retention tray 112 of a first cell block 110 A. Then battery cells 114 are mounted into retention tray 112 using spray adhesive. Cell terminals are electrically connected, in some embodiments ultrasonically welded, to the bus bars 116 . At least one sensor 28 is installed with sensing leads which are fastened permanently in place. Cell terminals are covered with Kapton™ tape to ensure electrical isolation from contact. Cell block 110 A is then treated with thermal interface gel compound (a thin layer) on battery cell 114 faces and thermal grease on the interface tray contact areas. Cell block 110 is then mounted to the cooling plate 12 .
[0060] The next step in the process is to assemble another cell block 110 B including battery cells 114 as before. After thermal compounds are applied, this cell block 110 B is mounted to the back of the cell block 110 A previously attached. A bus bar 116 of the second cell block is connected using a threaded fastener to the bus bar 116 of the first cell block 110 A at one end only as suggested in FIG. 11 . Next, a third cell block 110 C is built up in the same way and mounted to the back of the second cell block 110 B. The electrical bus of cell block 110 C is connected to the bus bar 116 of the second cell block 110 B at the opposite end from the previous layer in order to continue the series electrical connection as suggested in FIG. 11 .
[0061] At this point, the unit is half complete and threaded fasteners (not shown) are installed to hold the cell blocks 110 A, 110 B, 110 C to the cooling plate 12 before turning the battery pack apparatus 10 over. The process of attaching a plurality of cell blocks 30 to this second side of the cold plate is a repeat of the process of the first side. With each added cell block 110 , the bus structure is connected to the previous cell block 110 in such a way as to continue a serial electrical connection of battery cell pairs.
[0062] Once all three cell blocks 110 included in cell bank 16 are attached in piggyback fashion to the second side of the cooling plate 12 , then threaded fasteners (not shown) are installed to hold them in place. Next, in some embodiments (not shown), layers of top and bottom insulation/structure are placed on the large outer surfaces and multiple straps are attached, encircling the assembly, to hold the layers tightly together.
[0063] An alternative assembly method exists which is to start with the outermost (bottom) cell block 110 and build the entire assembly from the bottom upwards. This technique includes the benefit of eliminating the step of turning the assembly over halfway through the assembly process.
[0064] Although certain illustrative embodiments have been described in detail above, many embodiments, variations and modifications are possible that are still within the scope and spirit of this disclosure as described herein and as defined in the following claims. | A battery pack apparatus comprising a first cell bank and a laminated cooling plate. The first cell bank includes a first tray and at least one battery cell coupled to the tray. The laminated cooling plate being in contact with the first cell bank and including a plurality of face sheets and a plurality of internal sheets. The face sheets forming a fluid inlet and a fluid outlet. The plurality of internal sheets forming a plurality of fluid passages connecting the fluid inlet to the fluid outlet. The internal sheets further formed to include fluid pathways defining the fluid passages wherein none of the fluid pathways individually defining an uninterrupted flow path. | 8 |
TECHNICAL FIELD
[0001] This invention relates generally to telecommunication, particularly to a system and method for providing a universal phone number service.
BACKGROUND OF THE INVENTION
[0002] The proliferation of phone service, such as mobile phone service, Voice over IP (VoIP) service, SKYPE, or Instant Messaging (IM) based phone services such as those offered by Yahoo, MSN or Google, provides unprecedented convenience for a user to receive a phone call. For example, a user of a dual mode phone can receive a phone call from a mobile phone service while driving on a freeway and can receive another phone call from SKYPE service via a WiFi Hotspot while enjoying a relaxing afternoon in a downtown café.
[0003] Typically, each phone service is associated with a phone number with which a user receives the service. This nevertheless creates a profound problem for the user.
[0004] In one example, a user uses a WiFi-GSM dual mode phone to receive a GSM mobile phone service with a GSM phone number and Yahoo Phone In service with a Yahoo Phone In phone number. The user gives the GSM phone number to his stock broker while visiting his parents in a remote town in Kansas. The parents' house has broadband Internet access through the local cable company, but is outside of GSM signal coverage. The user uses his dual mode phone to sign on to Yahoo Phone In service using the broadband Internet access and is able to receive phone calls from his wife and children back home. Unfortunately, when his stock broker needs to consult with the user for an important stock purchase decision by dialing the GSM phone number, he is unable to reach the user.
[0005] In another example, a user uses a dual mode phone to receive a GSM mobile phone service, Yahoo Phone In service, SKYPE and two other phone services that are tailored to her participation in the local school and church. Each phone service is associated with a different phone number. A friend who knows only one of the five phone numbers can only reach the user if the associated phone service is available for her dual mode phone. A second friend who knows all five phone numbers will have to try calling the phone numbers one after another in order to reach the user.
[0006] Therefore, there is a need to provide a universal phone number service, that is, a service that allows a user to conveniently receive phone calls on any phone service with a single phone number.
SUMMARY OF THE INVENTION
[0007] In accordance with at least one aspect of the present invention a system is described for providing a universal phone number service having a universal phone number service gateway associated with at least one telephone system and a telephone associated with a universal phone number. In one embodiment the system includes a telephone connected to at least one telephone system to receive at least one phone service and is associated with at least one phone number for receiving the at least one phone service. In a preferred embodiment the telephone is connected to more than one telephone system, and the telephone is associated with more than one phone number.
[0008] In at least one embodiment a system is disclosed in which a universal phone number service gateway is provided that is associated with a datastore, the datastore optionally comprising a memory and optionally comprising a database. The datastore optionally further includes a route record associated with the universal phone number. The datastore may further include a subscriber record associated with the universal phone number, and the subscriber record preferably includes a phone number.
[0009] In another embodiment a method of routing a call to a telephone using a universal phone number is described whereby a telephone is connected to at least one telephone system to receive at least one phone service. Preferably the telephone is associated with a plurality of phone numbers, each of which is associated with a phone service. The universal telephone number is associated with the telephone and the telephone number(s), and calls destined for the universal telephone number are routed through a universal phone number service gateway using the telephone number to a telephone system associated with the telephone number. The universal phone number service gateway preferably routes a call to the telephone system using a standard-based protocol, a proprietary protocol, a corporate telephony trunking protocol or an Application Programming Interface.
[0010] In one embodiment the method includes creation of a route entry of a route record. In a preferred embodiment, the universal phone number service gateway connects to a datastore including the route record and a subscriber record, wherein the route record is associated with the universal phone number and the subscriber record is associated with the universal phone number and includes a phone number. In another embodiment, the method further includes obtaining an indication that the telephone system can route a phone call to the phone number; selecting a subscriber record based on the phone number; selecting a route record based on the universal phone number associated with the subscriber record; and creating a route entry in the route record. The route entry preferably includes the phone number and the identity of the telephone system.
[0011] Preferably the indication step takes place at the time of phone service subscription. However, this step may take place as further described herein.
[0012] In another embodiment the present invention includes a telephone associated with more than one phone number and a universal phone number, wherein any phone call placed to the universal phone number results in the call being completed to the telephone regardless of the service associated with the more than one phone number.
BRIEF DESCRIPTION OF DRAWINGS
[0013] For the purposes of illustrating the various aspects of the invention, there are shown in the drawings forms that are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0014] FIG. 1 illustrates a universal phone number service in accordance with at least one aspect of the present invention;
[0015] FIG. 2 illustrates a route entry of a route record in accordance with at least one aspect of the present invention;
[0016] FIG. 3 illustrates a universal phone number service in accordance with at least one aspect of the present invention;
[0017] FIG. 4 illustrates a universal phone number service in accordance with at least one aspect of the present invention;
[0018] FIG. 5 illustrates a universal phone number service in accordance with at least one aspect of the present invention; and
[0019] FIG. 6 illustrates a universal phone number service in accordance with at least one aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] In the following description, for the purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to a person of ordinary skill in the art, that these specific details are merely exemplary embodiments of the invention. In some instances, well known features may be omitted or simplified so as not to obscure the present invention. Furthermore, reference in the specification to “one embodiment” or “an embodiment” is not meant to limit the scope of the invention, but instead merely provides an example of a particular feature, structure or characteristic of the invention described in connection with the embodiment. Insofar as various embodiments are described herein, the appearances of the phase “in an embodiment” in various places in the specification are not meant to refer to a single or same embodiment.
[0021] With reference to the drawings, wherein like numerals indicate like elements, there is shown in FIG. 1 in accordance with at least one embodiment, a simplified block diagram depicting a system 100 providing a universal phone number service, the system 100 including a universal phone number service gateway 180 associated with at least one telephone system and a telephone 110 associated with a universal phone number 114 .
[0022] Telephone 110 is connected to at least one telephone system to receive at least one phone service and is associated with at least one phone number for receiving the at least one phone service. For example, telephone 110 connects to a first telephone system 134 to receive a first phone service, and is associated with a first phone number 164 for the first phone service. Telephone 110 connects to a second telephone system 138 to receive a second phone service and is associated with a second phone number 168 for the second phone service.
[0023] Telephone systems 134 and 138 are selected from, for example, a cellular phone system, such as a Global Service for Mobile Communications (GSM) system, or a W-CDMA (Wideband Code Division Multiple Access) system; a Voice over IP (VoIP) phone system; an Instant Message (IM) based phone system, such as, but not limited to Yahoo Phone In service; a public phone system; a corporate phone system; or a residential phone system.
[0024] A universal phone number service gateway 180 connects to a telephone network 190 . A phone call 195 through telephone network 190 destined to universal phone number 114 is routed to universal phone number service gateway 180 . Telephone network 190 may be without limitation a public telephony network such as Public Switched Telephone Network (PSTN), Voice over IP network (VoIP), or cellular telephony network; a corporate telephone network; or an IM based telephone network. Universal phone number 114 may be a public telephone number; a corporate telephone number; or an IM user identity, such as, but not limited to a screen name or a user name.
[0025] Universal phone number service gateway 180 includes the functionality of a telephone system 181 for receiving and routing a phone call. Universal phone number service gateway 180 receives phone call 195 using telephone system 181 .
[0026] In one embodiment, universal phone number service gateway 180 determines first telephone system 134 to route phone call 195 . An example of a process of determining a telephone system to route a phone call is illustrated in FIG. 3 . Universal phone number service gateway 180 routes phone call 195 to telephone system 134 using the first phone number 164 . First telephone system 134 receives phone call 195 . First telephone system 134 routes phone call 195 to telephone 110 based on first phone number 164 . Routing phone call 195 to telephone 110 from telephone system 134 is well known to those skilled in the art.
[0027] Depending on the application and particular embodiment, a universal phone number service gateway 180 may route a phone call to a telephone system 134 or 138 using a standard-based protocol such as Integrated System Digital Network (ISDN) Primary Rate (PRI) protocol, Signaling System 7 (SS7) ISDN User Part (ISUP) protocol, or Session Initiation Protocol (SIP). In another embodiment, a universal phone number service gateway 180 may route a phone call to a telephone system 134 or 138 using a proprietary protocol, such as a SIP protocol extension, or a corporate telephony trunking protocol. In yet another embodiment, and not by way of limitation, a universal phone number service gateway 180 may route a phone call using an Application Programming Interface (API).
[0028] By way of example, a caller using a universal phone number service in accordance with the present invention may use universal phone number 114 to send a short message or a multimedia message. Telephone 110 sends the message through a universal phone number service gateway 180 . In one embodiment, telephone 110 sends the message through first telephone system 134 to universal phone number service gateway 180 .
[0029] In another embodiment, a short message or a multimedia message is sent to universal phone number 114 . Universal phone number service gateway 180 delivers the message to telephone 110 as described herein. In another embodiment, universal phone number service gateway 180 delivers the message through second telephone system 138 to telephone 110 .
[0030] Now referring to FIG. 2 a process for a universal phone number service gateway 180 to create a route entry 202 of a route record 200 is depicted.
[0031] In accordance with one embodiment telephone 210 is associated with universal phone number 214 for the universal phone number service 100 . Telephone 210 is further associated with phone number 264 for receiving phone service from telephone system 234 . Universal phone number service gateway 180 connects to a datastore 287 . Datastore 287 may include a memory, a flash memory, a hard disk or the like. Datastore 287 may include a database. In one embodiment, universal phone number service gateway 180 includes datastore 287 .
[0032] Datastore 287 preferably includes route record 200 and subscriber record 220 . In one embodiment route record 200 is associated with universal phone number 214 . Subscriber record 220 is associated with universal phone number 214 and includes phone number 264 .
[0033] A universal phone number service gateway 180 obtains indication 239 that telephone system 234 can route a phone call to phone number 264 . Universal phone number service gateway 180 selects subscriber record 220 based on phone number 264 . Universal phone number service gateway 180 further selects route record 200 based on universal phone number 214 associated to subscriber record 220 . Universal phone number service gateway 180 creates a route entry 202 in route record 200 . Route entry 202 includes phone number 264 and identity of telephone system 234 .
[0034] Universal phone number service gateway 180 may obtain indication 239 through a number of means. In one embodiment, telephone system 234 provides a phone service, such as Plain Old Telephone Service (POTS), or a residential Voice over IP (VoIP) service. Universal phone number service gateway 180 preferably obtains indication 239 at the time of the phone service subscription. In one embodiment, universal phone number service gateway 180 obtains indication 239 through a service ordering process by an operator.
[0035] By way of example only, in one embodiment, telephone system 234 provides a mobile phone service, such as GSM service. In this embodiment for example universal phone number service gateway 180 obtains indication 239 from a Home Location Register (HLR) or a Home Subscriber Server (HSS).
[0036] In another embodiment, telephone system 234 provides an Instant Message based phone service such as, but not limited to Google Talk, or Yahoo Phone In. In this embodiment, universal phone number service gateway 180 may obtain indication 239 from an Instant Message Presence Server for example.
[0037] In a further embodiment, telephone system 234 provides a phone service based on IP Multimedia Subsystem (IMS). In this embodiment, universal phone number service gateway 180 may for example obtain indication 239 from IMS. In another embodiment, universal phone number service gateway 180 obtains indication 239 from a Proxy Call Session Control Function (P-CSCF) serving telephone 210 .
[0038] In one embodiment, universal phone number service gateway 180 obtains an indication 239 periodically, such as every 2 minutes, 20 minutes or 2 hours. In one embodiment, universal phone number service gateway 180 obtains an indication 239 at a random time. In one embodiment, universal phone number service gateway 180 obtains an indication 239 when the location of telephone 210 has changed. In another embodiment, universal phone number service gateway 180 obtains indication 239 when the presence status of a phone number has changed.
[0039] Now referring to FIG. 3 an example of a process of routing a phone call by a universal phone number service gateway 180 is illustrated. Universal phone number service gateway 180 includes telephone system 381 and route selector 382 . Telephone system 381 receives a phone call 395 destined for universal phone number 314 . Telephone system 381 queries route selector 382 for a routing decision by sending universal phone number 314 to route selector 382 .
[0040] Route selector 382 receives universal phone number 314 . In one embodiment, route selector 382 connects to datastore 387 . Datastore 387 includes route record 300 associated with universal phone number 314 .
[0041] Route selector 382 selects route entry 302 in route record 300 in accordance with processes further exemplified and illustrated in FIGS. 4 , 5 and 6 . Route entry 302 includes phone number 364 and identity of telephone system 334 . Route selector 382 sends phone number 364 and identity of telephone system 334 to telephone system 381 . Telephone system 381 routes phone call 395 to telephone system 334 with phone number 364 .
[0042] Route selection may be based on a variety of criteria such as, but not limited to service quality, user preference, user input and the like. Now referring to FIG. 4 , a process of selecting a route entry based on service quality is illustrated. In this embodiment, route record 400 is associated with universal phone number 414 and preferably includes route entries such as route entries 407 and 408 . Route entry 407 includes identity of telephone system 434 and route entry 408 includes identity of telephone system 438 . Telephone 410 is associated with universal phone number 414 .
[0043] In one embodiment, route entries 407 and 408 include respective service qualities 4071 and 4081 . The service qualities 4071 and 4081 respectively indicate a voice quality of a phone call routed through telephone systems 434 and 438 to telephone 410 .
[0044] Service qualities 4071 and 4081 may represent various attributes. In one embodiment, service qualities 4071 or 4081 may represent the predicted signal strength of the radio link between a cellular telephone system 434 or 438 and telephone 410 . For example, service quality 4071 / 4081 may be considered “good” if the predicated signal strength is above 20 dB-microvolts per square meter (dBμV/m 2 ); “fair” if the predicted signal strength is between 10 to 20 dBμV/m 2 ; and “poor” if the predicted signal strength is below 10 dBμV/m 2 .
[0045] In another embodiment, service quality 4071 / 4081 represents the average packet loss rate in a VoIP-based telephone system 434 / 438 respectively. For example, service quality 4071 / 4081 may be considered “good” if the predicted packet loss rate is below 1 percent; “fair” if the average packet loss rate is between 1-5 percent; and “poor” if the predicted packet loss rate is above 5 percent. In other embodiments, service quality 4071 / 4081 may represent the predicted jitter or predicted packet delay for the routed phone call.
[0046] In another embodiment, service quality 4071 / 4081 may represent the current network traffic load of a circuit switching based telephone system 434 / 438 . For example, service quality 4071 / 4081 may be considered “good” if the current network traffic load is below 20 percent; “fair” if the current network traffic load is between 20-80 percent; and “poor” if the current network traffic load is above 80 percent.
[0047] In another embodiment, route selector 482 queries for service quality 4071 / 4081 from telephone systems 434 / 438 . Route selector 482 compares service quality 4071 and service quality 4081 . For example, service quality 4071 may be found “fair” and service quality 4081 found “good”. Route selector 482 determines service quality 4081 is better and selects route entry 408 based on service quality 4081 .
[0048] Now referring to FIG. 5 a process of selecting a route entry based on user preference is illustrated. In accordance with this embodiment, route record 500 is associated with universal phone number 514 . Route record 500 includes route entry 507 associated with telephone system 534 and route entry 508 associated with telephone system 538 . Subscriber record 520 is associated with universal phone number 514 , and includes a user preference 525 . In one embodiment, user preference 525 includes a preferred phone service type 5251 . Route entries 507 and 508 include phone service types 5071 and 5081 respectively.
[0049] In one embodiment, universal phone number service gateway 180 obtains phone service types 5071 and/or 5081 as an indication 239 as illustrated in FIG. 2 . For example, preferred phone service type 5251 may be “mobile phone services”. In one scenario for example, wherein phone service type 5071 is “IM-based phone service” and phone service type 5081 is “mobile phone service”, route selector 582 determines that phone service type 5081 matches preferred phone service type 5251 ; route selector 582 selects route entry 508 .
[0050] In one embodiment, user preference 525 includes a preferred phone service type associated with a time. Route selector 582 connects to a clock that indicates the current time of day. Route selector 582 selects route entry 508 whose phone service type 5081 matches the preferred phone service type and the associated time matching the current time of day.
[0051] Now referring to FIG. 6 a process of selecting a route entry based on user input is depicted. In accordance with one embodiment route record 600 is associated with a universal phone number 614 . Route record 600 includes route entries such as for example route entry 607 associated with telephone system 634 and route entry 608 associated with telephone system 638 . Telephone 610 is associated to universal phone number 614 . It will be apparent to those skilled in the art route record 600 may include multiple route entries.
[0052] A universal phone number service gateway 180 includes route selector 682 . Route selector 682 connects to telephone 610 . In one embodiment, route selector 682 connects to telephone 610 over a network such as, but not limited to a network or cellular network; or using a message service such as, but not limited to paging service, Short Message Service, Multimedia Messaging Service (MMS) or Instant Messaging (IM) service.
[0053] Route selector 682 sends a query 686 to telephone 610 for the selection of a telephone system. Query 686 includes information about telephone systems 634 and 638 , such as the identities of telephone systems 634 and 638 . By way of examples, route selector 682 may use a Short Message Service (SMS) or an IM service to send query 686 ; or route selector 682 may send query 686 using a network or other protocol such as a proprietary protocol. Telephone 610 receives query 686 . In one embodiment, telephone 610 includes a graphic user interface (GUI) such as but not limited to a display screen (not shown). Telephone 610 displays the identities of telephone systems 634 and 638 on the GUI.
[0054] Telephone 610 provides input means, such as a dialpad, navigation keys or stylus, for a user to select a telephone system. In this illustration, telephone 610 receives from the input means that the user has selected telephone system 638 . Telephone 610 sends a reply 688 to route selector 682 indicating the selection of telephone system 638 . Route selector 682 receives reply 688 . Based on the indicated telephone system 638 , route selector 682 selects route entry 608 .
[0055] In accordance with one embodiment, route selector 682 may select a route entry 608 based on phone call type, such as a voice-only, or a video phone call. In another embodiment, a route entry 608 includes a plurality of phone call types supported by the associated telephone system. Route selector 682 in this embodiment selects a route entry 608 whose supported phone call types include the phone call type of the phone call.
[0056] In another embodiment, a preferred phone service type is associated with a caller identity. Route selector 682 selects a route entry 608 whose phone service type matches the preferred phone service type and the caller identity of phone call matches the associated caller identity.
[0057] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | A universal phone number service and method of providing a universal phone number service that allows a user to receive phone calls on any phone service with a single phone number. A telephone is disclosed that is associated with more than one phone number and a universal phone number, wherein any phone call placed to the universal phone number results in the call being completed to the telephone regardless of the service associated with the more than one phone number. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to concrete forms for materials such as concrete, polymer concrete or the like and, in particular, to forms for molding footings for structural pillars used in the construction industry.
BACKGROUND OF THE INVENTION
[0002] The use of structural pillars made from a concrete material is well known and widely practiced in the construction industry. Such pillars are typically poured into a tubular pillar form made of spirally wrapped paper, although other prefabricated pillar forms are well known and commonly used for this purpose. According to most building codes, structural pillars must be supported by a footing located below the level of maximum frost penetration and usually set on a coarse aggregate bed to ensure adequate drainage. The footing which is normally also made of concrete material provides support for the pillar and its load. Traditionally, wooden footing forms built on site were used. More recently, prefabricated forms have been introduced, which overcome the problems encountered with wooden forms, such as the need for at least one cross-piece for supporting the tubular pillar form, the labour intensive and time consuming assembly and disassembly of the wooden forms, improper filling when concrete is fed through the top of the tubular form, and the need to wait until the footing is set before backfilling.
[0003] Various types of prefabricated footing forms exist, most of which are somewhat tapered towards the top where the pillar form is adjoined. Bell-shaped (Joubert, U.S. Pat. No. 4,830,543), and conical (Jackson, U.S. Pat. No. 3,108,403; Miller U.S. Pat. No. 1,296,995; Gebelius, U.S. Pat. No. 4,648,220) or frusto-conical (Wells, U.S. Pat. No. 4,673,157; Nagle, U.S. Pat. No. 5,271,203) forms are known, with the latter being most common. A conical shape facilitates proper filling of the form with concrete material, makes the form stable and able to support the pillar form, and sometimes even allows for backfilling prior to pouring of the concrete material. However, tapered prefabricated forms have certain structural limits. Swinimer (U.S. Pat. No. 5,785,459) discloses that in order to achieve complete filling of a conical form without vibrating the concrete material, the pitch of the sidewall must be between about 45° and about 65°. Such a sidewall angle is impractical for industrial size applications with large footprint (bottom diameter), for example above 30 inch diameter, since it will lead to an impractically high form and high material cost. The higher the footing, the deeper it must be buried to remain below frost level. Moreover, the transition region between the footing and the pillar, which is a peak stress point of the pillar/footing structure should be located as far below grade as possible to reduce the lateral load at this transition region. Thus, since the vertical location of this transition region is governed by the height of the footing form, forms of large footprint and a sidewall angle of 45° or above are impractical and uneconomical due to high installation and/or excavation cost. Consequently, a more economical and practical prefabricated form is desired.
SUMMARY OF THE INVENTION
[0004] It is an object of the invention to provide a prefabricated form for the molding of a concrete footing for a structural pillar, which form overcomes the above mentioned disadvantages.
[0005] It is another object of the present invention to provide a prefabricated form for molding a pillar footing of a concrete structural material, which form is shaped to ensure complete filling with the concrete material without entrapped air pockets, while preventing excessive height of the form at large footprints.
[0006] It is still another object of the invention to provide a prefabricated form for molding a pillar footing of a concrete structural material, which form is shaped to prevent cave-in of the form upon backfilling prior to filling of the form with the concrete material.
[0007] It is yet a further object of the invention to provide a prefabricated pillar form for forming a footing of a concrete structural material which is adapted to accommodate a plurality of diameters of tubular pillar forms.
[0008] These objects are now achieved in a prefabricated footing form in accordance with the invention by controlling the dimensions of the form of substantially tapered shape according to strict structural relationships in order to reduce the amount of material needed for manufacture of the form, to ensure proper filling of the form with concrete material, to maintain the height of the form within practical limits, and to prevent cave-in upon backfilling of the form prior to pouring of the concrete material.
[0009] In accordance with the invention, a preferred footing form for molding a footing of concrete material at a bottom end of a concrete column, includes
[0010] a substantially tapered rigid hollow body having a circular top end of a first diameter D T , a bottom end of a larger, second diameter D B , the bottom end defining a base plane and being concentrically, vertically spaced from the top end by a height H, and an integral side wall extending between the top and bottom ends, at least a portion of the sidewall being inclined at a sidewall angle below 45° with respect to the base plane, the sidewall having a length S parallel in axial direction of the footing form;
[0011] a circular top flange at the top end for fittingly supporting a prefabricated tubular column form, and a bottom flange at the bottom end for supporting the footing form on a suitably prepared substrate;
[0012] whereby the dimensions of D T , D B , H and S are selected such that S≦2.4 h for reducing the amount of material used to manufacture the footing form, S≧0.55ΔD, with ΔD=D B −D T for preventing cave-in of the form upon exterior backfilling prior to molding of the footing, D B ≧1.8D T for lateral stability of the footing form, ½ΔD≧H≧¼ΔD for D B ≧24 inches for preventing excessive footing form heights, and D T ≧½D B −H for ensuring proper filling of the footing form with a concrete mixture of about 3000 psi to 4000 psi.
[0013] The invention therefore provides a prefabricated form for molding a footing of a concrete structural material at a bottom end of a tubular form for a pillar. The form is preferably molded from a thermoplastic resin such as high density polyethylene or ABS, although any other rigid, water resistant material with adequate strength is also suitable. The form is molded as a unit and is tapered in profile. It includes a bottom end with a radial flange and a top end having a top flange that is sized to frictionally engage a tubular form of a specific diameter. The flange on the top end may be adapted to engage the tubular pillar form either internally or externally, but preferably it is adapted to engage the form internally. The top flange is preferably constructed for connection of tubular forms of different diameters.
[0014] Preferably, the prefabricated footing form can be manufactured in a range of sizes each adapted to support a number of different diameter tubular forms by way of the top flange.
[0015] It is a principal advantage of the prefabricated footing form in accordance with the invention that it has a relatively small height even for large footprints, while still permitting backfilling before the concrete is poured, preventing the hazard of open trenches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention will now be described by way of example only and with reference to the following drawings, wherein:
[0017] [0017]FIG. 1 is a perspective view of a first embodiment of the prefabricated form in accordance with the invention;
[0018] [0018]FIG. 2 is a perspective view of another embodiment of the prefabricated form in accordance with the invention;
[0019] [0019]FIG. 3 is a perspective view of yet another embodiment of the prefabricated form in accordance with the invention;
[0020] [0020]FIG. 4 is a partial cross-sectional view of the embodiment shown in FIG. 1; and
[0021] [0021]FIG. 5 is an elevational view of the form shown in FIG. 2 in situ ready to be filled with concrete material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Despite the structural limitations taught in the prior art, it has now been surprisingly found that a form having a sidewall angle below 45° will reliably fill with a concrete mixture of at most about 3000 psi, as long as other structural limitations of the form follow certain strict relationships. Through extensive research, the applicant has developed certain structural relationships which, if strictly followed, allow the manufacture of prefabricated forms that will still reliably fill with a concrete mixture of up to 4500 psi, despite a sidewall angle below 45° and even as low as about 30°, and without vibration of the concrete. However, if these structural limitations as developed in accordance with the invention are not followed, the form may not fill properly, or even more disastrous results may occur, such as cave-in of the form.
[0023] [0023]FIG. 1 shows a perspective view of a first embodiment of a prefabricated footing form 10 in accordance with the invention. The prefabricated form 10 includes a substantially tapered right hollow body 12 having a circular top end 16 , of a first diameter DT and a bottom end 14 of a second diameter DB larger than the first diameter, the top and bottom ends 16 , 14 being concentrically aligned along a vertical axis of the body 12 . An integral sidewall 17 extends between the top and bottom ends 16 , 14 , which is preferably inwardly inclined at an angle of about 30° to about 45° to facilitate the evacuation of air when the form is filled with a concrete material. Integral with a bottom edge 20 of the side wall 17 is a bottom flange 18 which includes a substantially axially oriented portion 26 and a radial portion 19 . The substantially axially-oriented portion 26 extends upwardly from the radial portion 19 for about 3″ to 8″ and allows for the production of forms 10 of different overall height. Changes in height of the axially oriented portion can also be used to control the thickness of the base of the footing, at its maximum diameter. Integral with the top end 16 is an axial top flange 22 . The top flange 22 preferably includes a plurality of inwardly stepped connectors 24 for engagement with a tubular column form. The connectors 24 are preferably sized to frictionally engage the inner surface of the column form when the tubular form is forced down over one of the connectors 24 , as will be described below with reference to FIG. 5. This is achieved by the diameter of each connector increasing from a diameter at the top edge 25 which is slightly smaller than the inner diameter of the column form to a diameter at the bottom end 27 of the connector which is slightly larger than the diameter of the column form. In this way, the column form jams on the connector as it is forced downward thereon. The wall of the connector 24 is preferably inclined from vertical at an angle of up to 5°. At the top end 16 of the footing form 10 , the sidewall 17 is preferably somewhat curved to smoothly merge with the top flange 22 . This provides a finished pillar and footing combination cast with a prefabricated form in accordance with the invention in connection with a tubular form as shown in FIG. 5 with an additional structural advantage. Due to the smooth curvature at the point of juncture between the finished footing and the pillar, the stress point usually present at this juncture with conventional forming methods caused by the sharp angle between the pillar wall and the footing top surface is avoided. As a result, the danger of cracking of the finished column at this juncture upon movement of the surrounding soil is substantially reduced. The dimensions of the footing form 10 are carefully chosen to ensure proper filling of the form with concrete without the need for vibrating the concrete. In this respect, the inventor surprisingly discovered that footing forms with sidewall angles below 45° and above 30° will reliably fill if other dimensions of the form, such as sidewall length, top and bottom diameter, and height are controlled within strict limits. Moreover, forms for industrial applications and intended to support large loads require relatively large footprints (bottom diameters) of 32″ to 48″ or even higher. However, footing forms having a sidewall angle of 45° or above are not practical for such applications, since they would have an excessive overall height. Since the footing according to most building codes must be placed below maximum frost depth, excessively high footing forms would result in uneconomical installation and excavation cost. Excessively high forms also require a lot of material to manufacture and fill and, thus, are costly. To overcome these problems and to ensure proper filling, the inventor has determined through extensive experimentation that the following structural limitations will lead to the desired footing form suitable for industrial applications. The sidewall length must be at most 2.4 times the height of the form to minimize the amount of material required for manufacture of the form. The length of the side wall must be at most 0.55 times the difference in diameter between the top and bottom diameters to prevent footing form cave-in upon backfilling prior to filling the form with concrete. For lateral stability of the form, the bottom diameter 14 must be at least 1.8 times the top diameter 16 . The height of the footing must be controlled to be in the range of ½ to ¼ of the difference in diameter between the top and bottom diameters, to prevent excessive footing form heights. It has been discovered by the inventor that even if the sidewall is inclined at an angle lower than the slope angle of the concrete used for filling of the form, complete filling of the form without air entrapment can be achieved by enlarging the top diameter sufficiently, and using an accordingly large column form, so that the weight of the concrete in the column form will force the concrete into the most remote corners of the footing form and force out air through the enlarged to diameter and column form. Thus, the relationship between the top and bottom diameters at the top and bottom ends 16 , 14 respectively must be controlled to ensure proper filling of the form. In particular, the top diameter must be at least as large as the height of the footing less half the bottom diameter.
[0024] Testing of forms with different dimensional and structural limitations was carried out in accordance with CCMC's Technical Guide for Bell Shape Foundation Form, Master Format Section:03315, for below grade applications. Cardboard column forming tubes of appropriate diameter, commercially available under the trademark SONOTUBE, were attached to the footing forms tested. The cardboard tubes were fastened to the appropriate top flange of the footing form with 1 inch wood screws. The footing forms were placed in a 54 inch deep trench onto undisturbed soil. Backfilling with soil was then carried out in even lifts of 6 inch to 18 inch. The soil around the forms was tamped using a mechanical tamper after each lift. The concrete was subsequently poured directly into the form through the cardboard construction tube from a concrete truck and in lifts of about 24 inches, until the construction tube was completely filled. The concrete was rodded about 12 times after each lift. The concrete used was specified to have a compressive strength of 3500 psi and was a mixture of {fraction (3/4)} inch crushed stone aggregate, standard sand, and type 10 Portland cement. The concrete had a slump of 3 . After a setting time of two weeks, the forms were excavated and removed from the ground for evaluation. Footing forms constructed to the strict structural limitations according to the present invention were found to have withstood backfilling without cave-in or deformation and to have filled completely with concrete. Even for very large diameters such as 48 inches and low sidewall lengths resulting in sidewall angles of as low as 30°, the concrete flowed into the corners with no voids or honeycombing. It was also surprisingly discovered that the anchor flange 40 (see FIGS. 4 and 5) which will be discussed in more detail below not only anchors the form against lateral movement on the supporting surface during backfilling, but provides additional rigidity and strength to the form. The anchor flange when forced into the supporting medium maintains the geometric shape of the form and prevents deformations of the form at the bottom end, which would severely decrease the structural strength of the form. Especially for low sidewall angles (25 to 40°), maintaining the shape of the bottom flange resulted in a surprising structural strength increase compared to forms without anchor flange. The strength increase was significant enough to allow not only backfilling of the form before pouring of the footing, but even compacting of the backfill around the form. This provides an important additional advantage, since compacting of the backfill after setting of the footing and column is avoided. Moreover, if the backfill is not compacted, the soil around the column will gradually settle and sag, requiring the contractor to return to the job site months after completion of the footing to complete the backfill. This problem is also overcome with a form which allows backfilling prior to pouring of the footing.
[0025] An exemplary and non-exhaustive listing of footing forms in accordance with the invention and their structural parameters are given in the following Table I. All measurements are in inches.
TABLE 1 Ex. D T D B S H ΔD 1 18 36 10.5 5.5 18 2 16 36 11.7 6.0 20 3 14 36 12.8 6.5 22 4 12 36 13.9 7 24 5 18 48 17.5 9 30 6 20 48 16.4 8.5 28 7 22 48 15.3 8 26 8 24 48 14.1 7.5 24
[0026] [0026]FIG. 2 shows a perspective view of another embodiment footing form of the invention wherein the sidewall 12 includes a plurality of reinforcing ribs 28 . The reinforcing ribs 28 are integrally molded with the sidewall and open inwardly. They preferably extend from the axially-oriented portion 26 to a base of the axial top flange 22 . In the preferred embodiment of the invention, the reinforcing ribs 28 are straight and equally spaced apart. They serve to reinforce the sidewall so that it is self supporting in the event that earth is backfilled around the prefabricated form 10 before the form is filled with a settable material such as concrete. The reinforcing ribs 28 also provide channels which further facilitate the evacuation of air as the form is filled with concrete from the top as will be explained below with reference to FIG. 5. Moreover, the reinforcing ribs 28 are preferably provided with a multiplicity of small perforations 29 which are sufficiently small to prevent concrete or cement slurry leakage while permitting air to pass. These perforations 29 or air holes further help in evacuating entrapped air from the form 10 during filling. It should be noted that the reinforcing ribs 28 are not essential to ensure that air is evacuated from the prefabricated form 10 . The form 10 with or without reinforcing ribs 28 fills reliably without the entrapment of air and without the need for vibrating the concrete fill when it is filled from the top through the tubular form for the structural pillar. Moreover, the air holes 29 while not absolutely necessary for proper filling of the form, in most cases provide for a faster filling of the form.
[0027] [0027]FIG. 3 is a perspective view of yet another embodiment of the prefabricated form in accordance with the invention, including a modified alternate top flange 30 adapted to internally receive a tubular form for a structural pillar.
[0028] [0028]FIG. 4 is a cross-sectional view of the embodiment of the footing form shown in FIG. 1. The radial flange portion 19 of bottom flange 18 may extend radially outwardly or inwardly, or both outwardly and inwardly as shown in the drawing. If the radial flange portion 19 extends inwardly, it tends to prevent the form 10 from floating up when it is filled, in the event that earth is not backfilled around the prefabricated form 10 before it is filled with a settable material such as concrete. It should be noted, however, that the prefabricated form 10 has much less tendency to float up when filled with concrete than wooden forms built in situ. Bottom flange 18 preferably includes not only the radial flange portion 19 but also an axial anchor flange 40 which projects downwardly in a direction parallel to the axis of the form 10 . The anchor flange 40 may be a continuous cylindrical lip or may be in the form of multiple sections or spikes, which project downwardly. The anchor flange 40 is used for stabilizing the form 10 and especially for maintaining the shape of the bottom end 14 upon backfilling. A continuous lip is especially practical for softer soils or supporting media, while multiple lip portions or spikes are preferred for coarse aggregate and the like.
[0029] As described above, the top flange 22 preferably includes a plurality of connectors 24 which are adapted for the connection with different sizes of tubular forms for structural columns. Tubular forms are sold in a range of diameters and this construction of the axial top flange 22 increases the versatility of the prefabricated form 10 . It should also be noted that the sidewall of each connector 24 is tilted slightly inwardly from an axial orientation.
[0030] [0030]FIG. 5 is an elevational view of the form shown in FIG. 2 in situ ready to be filled with a concrete material such as wet concrete. As explained above, a tubular form 36 commonly sold under the trade-mark SONO TUBE is forced over a connector 24 (see FIG. 1 or 2 ) or into a connector 30 (see FIG. 3) of a prefabricated form 10 in accordance with the invention. Footing form 10 illustrated in FIG. 5 includes reinforcing ribs 28 . Normally, structural pillars are set on an aggregate bed 38 which is positioned in a trench below the maximum frost penetration for the respective geographical region of the installation site. If the tubular form 36 is not mounted to the uppermost connector 24 , any connectors 24 located above the one actually used may be cut off using a hand saw or the like before the tubular form 36 is seated. This ensures that the structural column is not weakened by the presence of a restriction caused by the unused connectors. The tubular form 36 is preferably fastened at multiple locations to the connector 24 , preferably with screws. This results in a more reliable connection, but at the same time makes the top opening of the form 10 more rigid, which means it will more reliably maintain its circular shape. After the tubular form 36 is fitted to the prefabricated form 10 and the latter is located in a proper position on the aggregate bed 38 , the stabilizing anchor flange 40 is forced into the aggregate or soil 39 on which the form 10 is supported, until the radial lip 19 of the bottom flange 18 comes to rest against the aggregate or soil 39 . This stabilizes the form 10 not only against lateral movement during backfilling, but also stabilizes the shape of the bottom flange 18 and thereby the shape of the form as a whole, as discussed above. The radial flange portion 19 is preferably constructed sufficiently strong to permit forcing of the axial flange portion 40 into the supporting surface by stepping onto the radial flange portion 19 . Subsequently, the trench may be backfilled with earth in order to ensure that the form remains in its location while the concrete material such as concrete is poured into the form. The backfilling not only further stabilizes the form in its position, it also permits better access to a top end of tubular form 36 and eliminates the potential hazard of working around open trenches, etc. After the form is in position, whether backfilled or not, reinforcing steel may be inserted into the tubular form 36 , as required, and a concrete material such as concrete poured through the top of the tubular form 36 until both the prefabricated form 10 and the tubular form 36 are filled as required.
[0031] As explained above, the shape of the prefabricated form 10 aids the filling of the footing form to capacity without the entrapment of air. The air is evacuated along the sidewall 12 and up through the tubular form 36 or through the perforations or vent openings 29 as the concrete material is poured in through the top of the tubular form 36 . A solid, optimally shaped footing for supporting a structural column is thereby reliably produced with a minimum of expense and effort. The rigid connection of the tubular form 36 to the prefabricated form 10 for the footing not only ensures that work progresses rapidly, it also ensures that each structural pillar is placed with precision. As well, as noted above, the form can be left in the ground and actually protects the footing from moisture, thus minimizing the risk of frost damage. Thus, a significant advance in the art is realized.
[0032] Modification to above-described preferred embodiments of the invention may become apparent to those skilled in the art. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims. | A prefabricated concrete form for the pouring of a footing for a structural pillar is disclosed. The form is preferably constructed from a thermoplastic such as a high density polyethylene or ABS and is molded as a single disposable unit. The form is bell-shaped and has dimensions which render it useful in industrial size applications with large footprints. The dimensioning of the form also reduces the amount of material used for the manufacture of the form, allows the form to be backfilled without cave-in and to reliably support a tubular form for the pillar without an additional bracing or supporting structure. The form is in particular a low profile form wherein the sidewall is inclined at an angle below 45° relative to the bottom edge. A top flange of the form is preferably adapted to accommodate two or more different diameters of the tubular form for the structural pillar. The sidewall may include integral ribs which open inwardly to facilitate evacuation of air as the form is filled and to lend rigidity to the sidewall. The sidewall may further include vent openings for the escape of air which is possibly temporarily entrapped during filling of the form. The advantage is an inexpensive form which does not have an excessive height despite large footprints, fills reliably and supports a tubular form for a pillar without the need for cross-pieces, even at sidewall angles below 45°. | 4 |
BACKGROUND OF THE INVENTION
The structure of a digital lock has been repeatedly improved but such a lock can be opened by a thief who can overcome its mechanical characteristics. For example, by means of a difference in precision of lock rings, one can rotate lock rings one by one and find the exact number for opening the lock. Some locks may be opened by holding or rotating the handle and finding the exact position of lock rings through shaking or by finding a defect in their mechanical structure.
From an analysis the inventor has found that an ordinary digital lock has a projection on its locking piece which is vibrated during a small movement.
The inventor, considering such a defect and with careful research, has designed a floating locking piece without projections for making a reliable digital lock.
SUMMARY OF THE INVENTION
Whenever the position of any lock ring is not proper, the lock is in a locking condition and not an opening condition. The locking piece is then pressed. If the handle is pressed (or rotated), the locking piece is being clipped firmly and it can not be raised.
Whenever the position of all lock rings are proper, i.e., all key slots of lock rings are on the locking piece, the locking piece is automatically raised due to the spring. Then, by means of pressing or rotating the handle, the locking piece is pushed and the lock is opened.
In practice, tension of a spring should be enough to float the locking piece. With a key having a radial slot on the lock ring, when pressing of the locking piece by each lock ring is at an improper position, no one will be able to open the lock with his mechanical sense rather than opening it the proper way.
Another characteristic of the invention is the availability of number adjustment. There is a turn section on a specially designed spring coil. Such a turn is called a number adjustor, which sets its relative position with the key slot of the lock ring and changes the numbers accordingly. The method of adjustment is only by picking up the number adjustor and turning it along the slot way.
Another characteristic of the invention is the design of steel balls which make noise. Steel balls are put into conical spaces so that whenever they are pressed, there is a noise which shows the degree of lock ring turning.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of the lock.
FIG. 2 is a front view of the lock.
FIG. 3 is a section view taken along line E--E of FIG. 2.
FIG. 4 is a front view of the setting lock ring.
FIG. 5 is a sectional view taken along line C--C in FIG. 4.
FIG. 6 is a back view of the setting lock ring.
FIG. 7 is a sectional view taken along line D--D of FIG. 4.
FIG. 8 is an enlarged view of the steel ball in setting the lock ring prior to its being pressed.
FIG. 9 is an enlarged view of steel ball in setting the lock ring which is being pressed.
FIG. 10 is a top plan view of the setting spring.
FIG. 11 is a front view of the setting spring.
FIG. 12 is a sectional view taken along line F--F of FIG. 1.
FIG. 13 is a sectional view taken along line G--G of FIG. 16.
FIG. 14 is a front view of the locking piece.
FIG. 15 is a side view of the locking piece.
FIG. 16 is a section view of the lock in an opened condition.
FIG. 17 is a sectional view of the lock in an locked condition.
FIG. 18 is a sectional view taken along line B--B of FIG. 1.
FIG. 19 is a sectional view taken along H--H of FIG. 17.
FIG. 20 is a sectional view taken along line A--A of FIG. 1.
______________________________________(1) Lock Barrel (31) Sliding Slot(2) Square Head (32) Aux. Vibrating Piece(3) Lock Cylinder (33) C-Type Fastener(4) Nut (34) Slider(5) Handle (35) Short Sliding Way(6) Cutting Slot (36) Line of Centers(7) Locking Piece (37) Lock Ring(8) Plate Spring (38) Setting Lock Ring(9) Pin (39) Ring Slot(10) Tip of Locking Piece (40) Resetting Block(11) Positioning Block (41) Setting Pin(12) Stop Block (42) Flange(13) Arched Edge (43) Hole(14) Brake Box (44) Steel Ball(15) Opening (45) Circular Inner Edge(16) Spring (46) Radial Key Slot(17) Fixing Disc (47) Metal Plate(18) Hole (48) Plastic Body(19) Tenon (49) Counter Sunk Screw(20) Screw (50) Key Slot(21) Tip Cover (51) Spring(22) Fixing Box (52) Conical Space(23) Tail Fin (53) Direction of Pressure(24) Floating Stop (54) Opening(25) Guide Post (55) Slot Way(26) Conical Spring (56) Setting Ring(27) Push Key (57) Hole(28) Main Vibrating Piece (58) Positioning Key(29) Hinge Pin (59) Key Slot(30) Torsional Spring______________________________________
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a sectional view indicating the lock in which the floating locking piece is above key slots of all lock rings and once the push key is pressed, the lock is in an opened condition.
The lock has a lock barrel (1). At the front of the lock barrel there is a larger square head (2). Such a square head (2) will cause extension and contraction of lock tongue (not indicated) by means of its own rotation. The lock barrel is surrounded by a lock cylinder (3). Its ends are fixed with a nut (4) and a handle (5) respectively. Its central hole provides space for rotation of the lock barrel (1). On the top of lock cylinder (3) there is a cutting slot (6) for placing a floating locking piece (7) (please refer to FIG. 14 for its detailed structure). On its bottom there is a plate spring (8). Its left lateral is an unfixed free lateral and its right lateral is fixed to the locking piece (7) by means of a pin (9) (please refer to FIG. 14). The right front end of the said locking piece (7) has a corner cut so that when all lock rings are in an opening position, locking piece (7) rises up to the key slot (50) (FIG. 20) where all locking rings are matching, front end (10) of locking piece (7) has its top contacted with a positioning block (11). When locking piece (7) is being pressed and moved forward, the said positioning block (11) can contact the front opening of the locking piece (7) and prevent the locking piece (7) from further moving (please refer FIG. 16). And when any of the lock rings is turned, locking piece (7) is being pressed downward and wholly fallen into the cutting slot (6). Then, the front end of the locking piece (7) is stopped by a stop block (12) and its forward movement becomes impossible, so that turning the lock barrel (1) is not possible and such a state is called "the locking condition" (refer to FIG. 17). At such a condition, if one is trying to open an ordinary digital lock without knowing the number, generally, he will push the handle, and then try every lock ring in order to sense a shaking. With the invention herein, since the locking piece has fallen, if the handle is pressed, the locking piece will be clipped by the pressing force and stop block (12). Therefore, even when the right number is turned, the locking piece (7) will not rise and the one who is trying to open the lock will not know that the lock is in an opened condition.
The said locking piece (7) has an arched edge (13) on the right end. Such an edge contacts with opening (15) of brake bos (14) directly. A spring (16) is also used to keep a constant and close contact between the edge (13) and opening (15). An end of the said spring (16) is fixed to hole (18) of fixing disc (17) and the other end is fixed to external of tenon (19) on the locking piece (7).
Said fixing disc (17) is fixed to the right hand extremity of lock cylinder (3). Handle (5) is directly or indirectly fixed to fixing disc (17) and lock cylinder (3) by means of screws (20) (3 screws in the embodiment herein). Handle (5) is covered with a top cover (21) (FIG. 1).
On the right side of said fixing disc (17) there is a fixing box (22). At the right end of said locking piece (7) there is a tail fin (23), the top of which is controlled by the fixing box (22). The floating stop (24) at fixing disc (17), controls the maximum floating of said locking piece (7).
The said tail fin (23) has a small projection at its bottom so that when the locking piece (7) is pressed down, said projection can stop the lock barrel (1) and improve stability of the locking piece (7) while going downward.
On the fixing box (22) there is a brake box (14), which has two guide posts on both sides of the locking piece (7) (refer to FIGS. 12-13). A concial spring (26) is designed between the fixing box (22) and brake box (14) so that when the brake box (14) is being pressed down, it can be as close as possible to the fixing box (22) (refer to FIG. 13). Above the brake box (14) there is a push key (27) which is projected beyond the handle (5). By means of two springs (26) and pressing by hand on (27), brake box (14) moves up and down. In addition, there is a transmission mechanism between lock barrel (1) and brake box (14). This mechanism transfers the up and down linear movement of push key (27) into rotating movement of lock barrel, (1) which will be discussed in detail soon.
Referring to FIG. 1, surrounding the lock cylinder (3) there are four lock rings (37) and two setting lock rings (38). Structure of the lock ring (37) is shown in FIGS. 2-3. In the ring there is a ring slot (39). At a certain place of the ring slot (39) there is a resetting block (40). Said ring slot (39) allows setting pin (41) of the setting lock ring (38) to move therewithin and by the stopping of setting pin (41) with a resetting block, the number can be reset prior to opening of lock.
The said lock ring (37) has a flange (42) which has ten holes (43) of equal distance. Such holes match with steel ball (44) on the setting lock ring (37). When lock ring (37) is turned, the degree of turning can be clearly read.
At the center of lock ring (37) there is a hole (45) for passing through lock cylinder (3) and there is a key slot (46) for passing locking piece (7) (refer to FIG. 18).
FIGS. 4-7 show the detailed structure of the setting lock ring (38). FIG. 5 is a sectional view taken from line C--C of FIG. 4. FIG. 6 is a sectional view taken from line D--D of FIG. 6. FIG. 4 and FIG. 6 are front views of a setting lock ring (38) at two different viewing directions. As shown in FIG. 6, a setting lock ring (38) is composed of two metal plates (47) with a plastic body (48) between them. It is fixed with two counter sunk screws (49) (refer to FIG. 6). Each setting lock ring (38) has a steel ball (44) and the steel ball (44) tends outwardly by means of a spring (51). A space for moving the steel ball (44) is shown in FIGS. 7-8. It is a conical space (52). When a steel ball (44) is subject to pressure in the arrow direction (53), it will fall into the position shown in FIG. 9. When external force disappears, the ball hits wall surface A directly as indicated by FIG. 9 and thus there is a noise which tells degree of the degree of turning of a lock ring (37).
Both flanges of setting lock ring (38) have ten equi-distant openings (54) respectively. An inner ring of said openings is marked with 0, 1, 2, . . . 9 correspondingly. The flange of said setting lock ring (38) has two slot ways (55) for placing of an elastic setting ring (56). The structure of said setting ring (56) is shown in FIG. 10. An end of it is turned toward the axis to form a setting pin (41) which is to be held in between openings (54) and projected outward. In selecting a number, one will only have to place the setting pin (41) in the required opening (54).
At the center of said setting lock ring (38) there is a hole (57) for inserting of the lock cylinder (3). There is also a positioning key (58) and a key slot (59). The positioning key 58 is to slide along key slot (50) of the lock cylinder (3) (as shown in FIG. 20) in order to fix the setting lock ring (38) and prevent it from rotating, while the key slot (59) is for passing and floating of the locking piece (7).
As shown in FIG. 1, the embodiment herein has four lock rings (37) and two setting lock rings (38), wherein a setting lock ring (38) is located between two lock rings (37) and the setting lock ring (38) is contacting booth lock rings (37). Steel ball (44) is fixed at lock ring (37) by means of spring tension (51) at the hole (43). Setting pin (41) on both sides of the setting lock ring (38) projects into the ring slot (39) on the lock ring (37) beside it. Because of the setting lock ring (38), the pin is fixed and not movable. Either at the locking or opening condition, the setting lock ring (38) can rotate freely along lock cylinder (3). Therefore, in the opening process, all lock rings (37) have to be turned till the resetting blocks (40) contact with and project into the ring slots (39). And then, given a predetermined number sequence, rotate each lock ring (37) and therefore the steel balls (44) which are pressed and fall into holes (43). By means of sensing the contacting noise from the steel balls (44) against the wall surface A is conical space (as shown in FIG. 9), one will know when the number desired is attained and the key slot (46) of lock ring (37) is matched with the locking piece (7). The locking piece (7), as shown in FIG. 1, floats above the key slots (46) of all lock rings (37) so that the lock is in an opened condition. The invention can be opened at night time or in a dark place by human sense and the noise of the steel balls (44) without the draw backs of ordinary digital locks which has its members marked on its surfaces and requires light when opening the lock at night or in a dark place.
For locking the lock, as shown in FIG. 17, one will only have to rotate one or more lock rings (37) which causes the locing piece (7) to fall and press into the cutting slot (6) of lock cylinder (3) (refer to FIG. 19). At this moment, since the front terminal of the locking piece is engaged by the stop block (12) it can not move forward further. Since the push key (27) is not able to be pressed downward for turning the lock barrel (1), then the lock tongue will not be moved (not indicated in the drawing) for opening. After locking, locking piece (7) is "floating" due to the uniform tension of spring (8) and so, it will not be opened easily because of the irregular floating due to stop block (12). A sample for this embodiment is available for experimental and trial use. Since the locking piece (7) will fall uniformly, no one can sense contact between the locking piece (7) and the key slot (46) of lock ring (37) and then find the position of key slot (46). Even if there were a possibility of irregular floating of the locking piece 7 (in fact it is not possible) while ring (37) is being turned, the steel balls (44) are being pressed and there is a force applied thereto which force is larger than the floating force of locking piece (7). Furthermore, when the key slot (46) of the lock ring (37) matches with the locking piece (7), at that instant, the steel ball (44) falls into the hole (43), and since the force received by the steel ball (44) is large, the impact is bigger than the impact of locking piece (7) to key slot (46).
The following describes how lock barrel (1) is rotated to a certain degree by means of pressing the push key (27) in an open condition as indicated in FIG. 1 in order to make the lock tongue contract for opening the door.
Referring to FIGS. 1, 12, and 13, there is shown a mechanism consisting of a main vibrating piece (28), which oscillates with hinge pin (29) as a pivot. There is a torsional spring (30) at hing pin (29) so that the main vibrating piece can keep a close contact with brake box (14). Furthermore, the main vibrating piece (28) has an arched sliding slot (31) on it. The sliding slot (31) provides a path for oscillation of the main vibrating piece (28) so that the scope of oscillation is limited to the sliding slot (31). On the lock barrel (1) there is an auxillary vibrating piece (32) which has a terminal fixed to the lock barrel (1) by means of C-type fasterer (33) and the other terminal slides within the short sliding way (35) of the main vibrating piece (28). Please note the difference between FIG. 12 and FIG. 13. FIG. 12 is at normal condition without pressing key (27) down and the FIG. 13 is when key (27) is pressed, i.e., with the key (27) pressed down, lock barrel (1) is turned and the door is opened.
As shown in FIG. 12, the brake box (14) is subject to tension of the spring (26) and is pushed to the highest position algon with the push key (27). At this moment the position of lock barrel (1) is as that of line of centers (36) (FIG. 12). In FIG. 12, when push key (27) is pressed down, the main vibrating piece (28) turns downward. Lock barrel (1) is driven by the auxillary vibrating piece (32) and then the door is opened (please compare the line of centers (36) and change in degree of (36') for details).
As shown in FIG. 16, when the push key (27) is in a pressed condition, the floating locking piece (7), since there is no stop at its front, allows the push key (27) to be pressed down and this is the so called open condition.
As shown in FIG. 1 and FIG. 17, when lock ring (37) is at a proper position, locking piece (7) can be floated above key slot (46) and if the lock ring (37) is not in a proper postion, the locking piece (7) is pressed into the cutting slot (6).
FIG. 20 shows the installation of setting lock ring (38) at lock cylinder (3). | Disclosed herein is a structure for an adjustable digital lock which is mainly characterized by its floating locking piece which controls rotation of a locking barrel, especially the one which can not be opened whenever the position of any lock ring is not proper or the opening method is not proper or when user can open the lock through listening to sounds; in which the number for such an adjustable digital lock can be easily changed by user. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to pumps and other apparatus in wells, and more particularly to vertical positioners and torque arrestors for submersible water pumps.
Submersible centrifugal pumps powered by electric motors are commonly suspended at the end of the length of a pipe within a well. A problem common to small diameter wells in many locations is that particulate debris is present on the bottom of the well, either from its original use or with the passage of time. It is therefore necessary that a submersible pump be located some distance above debris, to avoid entrainment of it into the pump intake with consequent damage of the impellers. Normally, this is accomplished by first measuring the depth of the well and then providing only sufficient pipe to suspend the pump the desired distance above the debris. However, if the debris is particularly light it is difficult to ascertain its depth at the bottom of the well. On the other hand it is undesirable to suspend a pump too great a distance above any debris since it is advantageous to be able to "draw down" the maximum water in the well when demand exceeds the infiltration capacity of the well.
Another problem in applications such as domestic water supplies results from periodic on-off pump cycling. When the pump motor is started there is a force between the armature and field, with the result that a torsional moment is imparted to the pump housing. The pump is characteristically fitted rather closely in the well; e.g. a four inch diameter pump may be in a six inch well bore. Thus, there is a tendency for the suspended pump to both rotate and move laterally, twisting the suspending pipe and causing contact with the well bore. This effect is especially present when pumps are suspended in a well from long thermoplastic pipes.
The lateral movement and contact of the pump with the well bore can cause abrasion and eventual failure of the pump housing. Repetitive torsion may cause pipe failure and loosening of associated pipe fittings. Therefore, means to prevent such damage are required. A conventional device presently used is comprised of a collar or multiplicity of fingers extending from the pump or the pipe line near the pump. The device, often made of a resilient material such as a thermoplastic or rubber, is adjusted to the nominal diameter of the well prior to lowering of the pump into the well. Thus, the device has a tendency to rub along the sides of the well bore, thereby impeding the lowering or raising of the pump. Further, the device must be adjusted to pass by the narrowest point in the well, and if the well bore varies in diameter the device may not fully prevent movement when the pump is at its working location in the well. Still another problem results when a conventional torque arrestor is fitted to the pipe just above the pump; in many pumps the direction of rotation is such that there is a tendency for loosening of the fitting which adapts the pipe to the pump discharge.
Accordingly, there is a need for an improved means for positively locating and fixing the position of a submersible pump within a well bore, both laterally and vertically.
SUMMARY OF THE INVENTION
According to the invention, a stabilizer for a submersible pump is attached to the bottom of the pump and engages the material at the bottom of the well, thereby resisting vertical, rotational, and lateral motion of the pump. The stabilizer is of sufficient length to support the pump above debris in the well. In a preferred embodiment, the lower end of the stabilizer has an irregular cross section to increase resistance to rotational motion; and the upper end is adapted to receive and capture the bottom end of the pump, yet allow circulation of water thereabout.
In another preferred embodiment, the stabilizer is comprised of two parts and an expansible device. The upper part is attached to the pump and the lower part is attached in axially movable fashion to the upper part; the expansible device is connected between the upper and lower parts. When the lower part contacts the well bottom, the lower part's relative movement toward the upper part actuates the expansible device, thereby causing it to contact the well bore and provide lateral and rotational stability. Vertical stability is provided by the interaction of the upper and lower parts of the stabilizer.
The invention provides a simple yet effective means for both positively positioning a pump vertically and for resisting damaging torsional forces. The invention may be readily constructed out of thermoplastics or metals in economic fashion. Further, the apparatus permits easy raising and lowering of the pump since its diameter is insubstantially larger than that of the pump body during such operations. A further advantage of the invention is that it is possible in special circumstances to use piping which is of lighter weight than heretofore, since the axial weight and torsional forces are both counteracted by the invention.
Other aspects and features of the invention will be evident from the Figures and Description of the Preferred Embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1: shows a pump suspended in a well bore with an attached stabilizer in engagement with the well bottom.
FIG. 2: shows a partial section of the attachment of the stabilizer to the pump body.
FIG. 3: shows a cross section of the lower end of the stabilizer along line 3--3 of FIG. 2.
FIG. 4: shows a cross section along line 4--4 of FIG. 5.
FIG. 5: shows an alternate embodiment of a stabilizer having movable parts and expansible arms for contacting the well bore.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention herein is described in terms of a submersible electric motor pump placed in a water well drilled in rock, although it may be used in other types of wells, and for other devices and structures wherein a similar problem is solved.
A well bore in which the invention is particularly usable is usually drilled in rock or otherwise has a rigid wall. Typically, there will be drilling debris remaining in the well; usually this is gravel and light sand. Over time, further quantities of sand and like material may infiltrate and accumulate at the bottom of the well. If entrained into the pump, damage can be caused, and therefore it is an object to hold the pump a sufficient distance above the bottom of the well to avoid this. In this disclosure, reference is often made to the well bottom. By this is meant any material in the well at its terminus which is capable of supporting the apparatus of the invention. Most commonly, this will comprise the coarser sand, gravel, and stone materials residing at the bottom of the well, having a consistency which allows partial penetration of the stabilizer.
The FIGS. 1-3 show a preferred embodiment of the invention and illustrate its general mode of operation. FIG. 1 shows a pump 20 suspended in a water well bore 24 by a pipe 22. The pump has a water inlet 26 at its mid point. A stabilizer 28 of the present invention is attached to the lower end 30 of the pump. The stabilizer is comprised of a rigid structure 28 fixed at its first end 34 to the lower end 30 of the pump in a manner which resists axial, lateral, and rotational motion. The second end 36 of the stabilizer is adapted to engage the bottom 38 of the well bore.
The attachment of the stabilizer to the pump is shown in more detail in FIG. 2. It may be seen that the first end 34 of the stabilizer is a hollow cylinder with one or more axial slots 40. Thus the pump body may be received within the hollow cylindrical end and a clamp 42 provides compressive force to the cylinder. Of course the cylinder is made of a material with properties which enable it to be deflected by action of the clamp and thereby capture the pump body. Tightening of the clamp causes frictional engagement with the pump sufficient for most purposes. But, a shoulder 38 is best further provided to engage the base of the pump, thereby ensuring that the cylinder will not progressively move along the pump under axial force. Keyways, pins, or the like may also be added to ensure the absence of relative axial and rotational motion. The outer diameter of the first end 34 is to be minimized so as to be less than the diameter of the well bore.
The second end 36 of the stabilizer engages the bottom 38 of the well, penetrating through lighter material until friction prevents further motion, or until heavier material is encountered. The stabilizer has an axial length sufficient to hold the pump vertically above the entrainable debris which is present or may accumulate over time. This length is determinable by experience in a particular area of the country, and typically will be 2 to 3 meters. The second end 36 of the stabilizer is preferably shaped to frictionally engage the loose material, as by increasing the surface area, to resist torsional and lateral movement.
As shown in the Figures, including FIG. 3, the lower end of the stabilizer preferably has an irregular and serrated cross section, such as the three-pointed star shape shown, to better engage the bottom of the well in a manner which will resist torsional motion. Other shapes may be used as well and in certain instances it will be found to be satisfactory to merely have a continuation of the simple hollow cylindrical shape of the first end with or without serrations such as comprise an internal or external spline. Also the second end may be of other irregular shapes, such as that of a flat panel or other like mechanical configuration which provides both a rotationally and axially stable engagement. But, while the exact configuration is optional, it is desired that the second end have a certain minimum cross sectional profile, especially if the material at the bottom is very fine and of low bearing strength. An embodiment of the second end especially suited for such material is comprised of an end furthest from the pump which has a low cross section and high area, then transitioning nearer the pump to a higher cross section; that is, a more abrupt section change than the taper shown in FIGS. 1-3. Accordingly, the stabilizer will first penetrate easily and then with great resistance, ensuring some penetration for resisting rotation, but avoiding overly great penetration to provide vertical locating.
In use, the stabilizer is fixed to the pump prior to the lowering of the pump into the well. As the pump is lowered toward the bottom of the well, the stabilizer will contact and penetrate the bottom until the weight of the pump (and a portion of the suspending pipe as well) is supported by the resistance of the bottom to further penetration. Thus the vertical location will be fixed and tensile stress on the pipe will be reduced. When the pump is activated, the reaction force of the motor starting forces will seek to move the pump both rotationally and laterally. But this motion will be resisted by the affixed stabilizer due to its engagement with the bottom.
There are some other aspects of the preferred embodiment of the stabilizer which deserve note. The stabilizer may of course be used in cooperation with other types of devices previously known. For example, as shown in FIG. 1, a lateral support 44 affixed to the upper end of the pump, or pipe adjacent thereto, may be added to further resist lateral motion. Also, it is preferred that water be allowed to circulate about the lower end 30 of the pump where the stabilizer is attached for proper cooling of this section of the pump body. Thus a cavity 46 is desirably provided at the first stabilizer end, with ingress and egress of water provided by axially extending slots 40 along the first end of the stabilizer which intercept the cavity. Of course other means may be readily used to attach the stabilizer to the pump, other than the slotted hollow cylinder shown. For example, a female socket may be permanently attached to the bottom of the pump, and a male mating portion of the stabilizer engaged with it, with threads, set screws, and the like. Further, the portion of the stabilizer structure connecting the upper and lower ends which is not intended to penetrate the bottom may be of arbitrary design, so long as it is sufficiently rigid to perform its function. And of course, to allow easy shipment the stabilizer may be comprised of two or more joinable pieces.
A further embodiment of the invention which provides increased lateral and torsional stability is shown in FIGS. 4 and 5. The stabilizer is now broken into two parts, 47 and 48, which can move axially with respect to one another. Expansible means for contacting the well bore are interposed between the parts and are actuated by relative motion of the parts. Referring to the Figures, the upper part 47 essentially has the configuration of the previously described first end 34 insofar as engagement with the pump is concerned. The lower part 48 has a lower end (not shown) which in configuration and function is like the second end 36 of the previous embodiment. The two parts are interconnected by a bushing 50 which is permanently fixed to the lower part 48 at its upper end 52 and which is slidably movable within a bore 54 in the upper part 47. The bushing has a head 58 to retain it within the bore 54 by engagement with the shoulder 60. Between the upper and lower parts are positioned two arms 62 and 62', pivoted from the upper part by pins 64. The arms are positioned so that they may be caused to pivot by the lower part's relative movement toward the upper part. Thus, it may be seen that essentially the upper part simply provides a means for positioning the lower part in a manner which enables it to movably actuate the expansible device comprised of the two arms.
As shown in the Figures, the arms are in their unactuated position when the upper and lower parts of the stabilizer are at their maximum separation. This is the configuration of the stabilizer as the pump is lowered into the well, and it is seen that the stabilizer has no greater diameter than that provided by the part which encompasses the pump body. As the pump is lowered, the bottom end of the stabilizer's lower part 48 will ultimately contact the bottom of the well and thereby cause the upper and lower parts to move relatively closer. The upper end 52 of the lower part 48 thereupon contacts arms 62-62' and causes them to pivot outwardly until they contact the well bore, as shown in phantom, the length of the arms having been selected to suit the well bore. Some further vertical motion may ensue as the arms slide vertically along the wall while the lower part of the stabilizer settles firmly at the bottom of the well. Thus the weight of the pump and pipe will actuate the expansion of the arms, by the relative motion of the parts and contraction of the stabilizer. The contact of the arms with the well bore provides resistance to torsional and lateral movement. As the arms contact the bore and thus can move outwardly no further, further relative motion of the lower part of the stabilizer is also stopped, and vertical support to the pump is thereby provided. Of course, a portion of the vertical load may be borne by the expansible device and suspending pipe as well, but it is desirable that the major portion of the load be borne by the stabilizer. As shown in the embodiment of FIGS. 4 and 5, there is relative rotary motion possible between the upper part and the lower part of the stabilizer. Thus the lower part of the stabilizer provides only lateral and vertical resistance. An alternate embodiment would comprise means to prevent this relative motion, such as an irregularly-shaped or keyed bushing 50 and bore 54. In such an embodiment, the resistance to torsional motion would be provided cooperatively by the expansible device and the lower part of the stabilizer.
When the pump and stabilizer are sought to be removed from the well, vertical motion is applied to the pump body, as through the suspending pipe or other conventional means. Whereupon, the reverse of the previously described motion is caused by force of gravity on the elements, and the expansible means retract, allowing free withdrawal from the well.
In the embodiment of FIGS. 4 and 5, the lower part of the stabilizer is shown as a hollow cylinder, in accord with the discussion attending the prior embodiment. One or more holes 66 are provided through the wall of the cylinder to allow venting of the cylinder when it is sought to remove the pump from the well. Thus, when the hollow cylinder is designed to be open at its bottom end where it contacts the well bottom, the release of entrapped air, water, mud, and the like will be aided. Of course, other shapes of openings may be provided. The expansible means shown in the embodiment of FIGS. 4 and 5 is comprised of two arms. A greater number of arms may be used, as well as other expansible devices, such as elastomeric cylinders or other known spring and gravity actuated devices which increase in diameter upon the application of axial force and decrease in diameter in its absence. The stabilizer may be constructed out of metals, thermoplastics, or other materials which have durability within the medium of the well. Most preferably it is economically made mostly out of a thermoplastic such as ABS plastic for a water well of the domestic type.
While our invention has been described in the foregoing preferred embodiment and alternatives, it should not be so limited, as it is capable of many modifications and changes in construction and arrangement which may be made without departing from the spirit and scope of the invention. | A stabilizer for a submersible pump in a well bore is attached to the pump so that it extends from the lower end of the pump toward the bottom of the well. When placed in the well, the stabilizer engages sandy debris in the well and thereby positions the pump vertically, while at the same time providing resistance to lateral and torsional forces caused by on-off cycling of the pump. One embodiment of the stabilizer further has expansible means which are actuated by contact of the device with the well bottom; the expansible part provides additional lateral and torsional support when the pump is in place, but conveniently retracts for easy removal of the pump as it is lifted. | 5 |
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The invention relates to a temperature-compensated semiconductor resistor. In particular, the invention relates to a semiconductor resistor which varies little with temperature in a temperature range of interest. In addition, the invention relates to a semiconductor integrated circuit in which such a semiconductor resistor is provided.
[0003] Electrical resistances can appear in various forms intentionally or unintentionally in semiconductor integrated circuits. In their unwanted form they constitute parasitic circuit elements having properties which must be estimated so that their negative effects can be minimized and countermeasures taken. If, however, semiconductor resistances are required for an electronic function, one must know their dimensions and electrical properties very precisely.
[0004] The classic form of a resistor integrated in a semiconductor circuit is a well resistor, i.e. a diffused or implanted p-region in a surrounding n-region. In standard CMOS circuits, such resistors are usually made of polycrystalline silicon with various characteristics. However, the disadvantage of typical CMOS resistors is that their resistance is highly temperature-dependent in the usual ambient temperature range. That can have detrimental effects on the performance of the semiconductor component, or lead to complete failure of the component.
SUMMARY OF THE INVENTION
[0005] It is accordingly an object of the invention to provide a temperature-compensated semiconductor resistor and a semiconductor integrated circuit having the semiconductor resistor, which overcome the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type and which have an improved temperature response, in particular with a reduced temperature dependence in a temperature range of interest.
[0006] With the foregoing and other objects in view there is provided, in accordance with the invention, a temperature-compensated semiconductor resistor, comprising two series-connected semiconductor resistance elements having mutually inverse resistive temperature responses or temperature-dependent resistance courses, in a temperature range of interest that is the normal ambient temperature during operation of the associated semiconductor circuit. Thus, within this range, one of the two resistance elements should have a positive temperature coefficient i.e. an electrical resistance that increases as the temperature rises, and the other one should have a negative temperature coefficient, i.e. an electrical resistance that decreases as the temperature rises.
[0007] A first connecting contact is disposed at one end of the semiconductor resistor, that is to say on the first of the two semiconductor resistance elements. The other connecting contact is located at the other end of the semiconductor resistor, that is to say on the second of the two semiconductor resistance elements. This results in a series circuit including the semiconductor resistance elements, and the total resistance of the semiconductor resistor equals the sum of the resistances of the two semiconductor resistance elements. The inverse resistive temperature responses of each of the resistance elements with respect to each other provide mutual compensation, so that the process of addition means that the resistive temperature characteristic of the semiconductor resistor is relatively flat.
[0008] In accordance with another feature of the invention, the semiconductor resistance elements are made of oppositely doped polycrystalline semiconductor material, in particular polycrystalline silicon. In crystalline silicon, the conductivity with respect to the temperature is determined by the decreasing mobility of the charge carriers with increasing temperature. However, in polycrystalline silicon, the charge transport mechanisms across the grain boundaries must be taken into account. One can thus obtain a negative or positive temperature coefficient depending on the charge state of the crystal defects making up a grain boundary. In experiments, one observes in p-doped, particularly p + -doped, polycrystalline silicon a resistance that increases with rising temperature, while in n-doped, particularly n + -doped, polycrystalline silicon a resistance that falls with rising temperature is observed. In the semiconductor resistor according to the invention, one can select different doping concentrations for hi the oppositely doped semiconductor resistance elements.
[0009] In accordance with a concomitant feature of the invention, if the semiconductor resistance elements are formed from n-doped and p-doped semiconductor regions, they are physically separated by a high-conductivity connecting layer. The connecting layer provides a low resistance electrical connection between the two semiconductor resistance elements. The connecting layer may be a metallic layer or possibly even a very highly doped semiconductor layer. However, the n-doped and p-doped semiconductor regions must not be directly adjacent, since that would create an unwanted p-n junction.
[0010] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0011] Although the invention is illustrated and described herein as embodied in a temperature-compensated semiconductor resistor and a semiconductor integrated circuit having the semiconductor resistor, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0012] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a diagrammatic, plan view of one embodiment of a semiconductor resistor according to the invention;
[0014] [0014]FIGS. 2A and 2B are graphs of temperature-dependent resistance curves for the semiconductor resistance elements; and
[0015] [0015]FIG. 3 is a graph of a temperature-dependent resistance curve for the semiconductor resistor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen a layout of a semiconductor resistor 10 according to the invention, which has two resistance elements 1 and 2 that are connected in series and made of oppositely doped polycrystalline substrates, in this case a relatively highly n-doped, i.e. n + -doped resistance element 1 , and a relatively highly p-doped, i.e. p + -doped resistance element 2 . A highly conductive connecting layer 3 , for instance made of metal, lies between the resistance elements 1 and 2 . Suitable contact layers, such as semiconductor alloy layers, may also be applied to interfaces between the resistance elements 1 and 2 and the metallic connecting layer 3 . The resistance elements 1 and 2 must not be directly adjacent, since that would create a p-n junction. Suitable high-conductivity contact layers 1 a and 2 a are applied to side ends of the semiconductor resistor 10 . External connections to the semiconductor resistor 10 can be made through the use of the contact layers 1 a and 2 a.
[0017] In an integrated CMOS circuit, the resistance elements 1 and 2 can be formed from suitably highly doped polysilicon layers embedded in a suitable way in the topography of the CMOS circuit and contacted at their (side) ends, as shown.
[0018] The semiconductor resistor 10 has a defined constant layer thickness (at right angles to the plane of the drawing) and a defined constant width W. Its overall length L is divided into lengths L n and L p of its resistance elements 1 and 2 , so that L=L n +L p . The parameters L, L n and L p are set in such a way that, for given temperature-dependent specific resistances:
[0019] on one hand, one obtains a defined resistance R TCOMP (T COMP ) for the semiconductor resistor 10 at a specific ambient temperature T COMP ; and
[0020] on the other hand, the temperature dependence of the resistance at this temperature is a minimum. Mathematically, this means that the first derivative of R(T) at the point T COMP should equal zero.
[0021] As a geometrical and computational aid to determining L, L n and L p , the resistance elements 1 and 2 are first divided into square base areas SQ n and SQ p , having a length which therefore equals the width W of the semiconductor resistor 10 . Such a base area is also given the arbitrary unit of 1 square. At the end of the calculation, the lengths L n and L p are each given as multiples of the lengths of SQ n and SQ p , that is to say effectively of W. Thus, one obtains L n =S n ×W and L p =S p ×W, where the numbers S n and S p give the ratio of the length/width of each resistance element, respectively. The numbers S n and S p are real positive numbers and need not be integers.
[0022] Next, one considers the temperature-dependent resistance of one square of the n + -doped and the p + -doped polysilicon, in respectively. The corresponding curves are shown in FIGS. 2A and 2B. One can clearly see the negative gradient of the n-doped polyresistance in contrast to the slightly positive gradient of the p-doped polyresistance.
[0023] These curves can be represented as a series truncated to the second term as shown below in equation (1). The first derivative with respect to the temperature is then obtained from this in equation (2).
r ( T )= r ( T 0 )·[1+ T C1 ·( T−T 0 )+ T C2 ·( T−T 0 ) 2 ]in Ω (1)
δr ( T )/δ T=r ( T 0 )·[ T C1 +2· T C2 ·( T−T 0 )]in Ω/° C. (2)
[0024] where T C1 , T C2 and r(T 0 ) are values governed by the technology.
[0025] Since the two resistance elements 1 and 2 are connected in series, the following equation holds for the dependence of the total resistance R on the temperature:
R TCOMP ( T )=R n+ ( T )+ R p+ ( T )= S n r n+ ( T )+ S p r p+ ( T ) (3)
[0026] Differentiating equation (3) with respect to T, assuming there is a local optimum, i.e. a zero point of the first derivative, one obtains the following for the temperature T COMP :
δ R TCOMP ( T=T COMP )/δ T=S n ·δr n+ ( T )/δ T+S p ·δr p+( T )/δ T= 0 (4)
[0027] Therefore, and applying equation (2), the resistance ratio is defined as:
K = R n + / R p + = S n / S p = { - r p + ( T 0 ) · [ T C1 p + + 2 · T C2 p + · ( T COMP - T 0 ) ] / { r n + ( T 0 ) · [ T C1 n + + 2 · T C2 n + · ( T COMP - T 0 ) ] } ( 5 )
[0028] From which one can obtain the resistances:
R p+ =1/(1+ k )· R TCOMP and R n+ =k (1+ k )· R TCOMP (6)
[0029] In the following exemplary embodiment, the resistance curves shown in FIGS. 2A and 2B are assumed for one square of the resistance elements 1 and 2 , respectively. The following parameter values apply to these curves:
Units n + poly-Si p + poly-Si R(T 0 ) Ω 340 175 T C1 1/° C. −1.55 × 10 −3 2.75 × 10 −4 T C2 1/° C. 2 2.827 × 10 −6 9.9 × 10 −7
[0030] Using these resistance elements one should obtain a resistance R COMP (T COMP )=100,000 Ω, T COMP =50° C. and T 0 =27° C.
[0031] Applying equations (5) and (6) under these assumptions yields k=0.116 and length/width ratios for the resistance elements of S n =54 and S p =466. The surface areas of the resistance elements are thus given by R sq p =466 squares and R sq n =54 squares.
[0032] The temperature response of the total resistance R is shown in FIG. 3. One can see the local minimum at R=100,000Ω.
[0033] The object according to the invention of creating a resistor that at a given temperature has a defined resistance which should have minimum variation with changes in the ambient temperature, is thus achieved. | A temperature-compensated semiconductor resistor includes two series-connected semiconductor resistance elements having mutually inverse resistive temperature-dependent responses in a temperature range of interest. The semiconductor resistance elements are preferably made of doped polycrystalline semiconductor material such as polycrystalline silicon that is oppositely doped, i.e. n-doped and p-doped, respectively. A semiconductor integrated circuit, in particular a CMOS circuit, containing a semiconductor resistor, is also provided. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part application which claims priority from PCT/IT02/00586, published in English, filed Sep. 16, 2002, based on Italian patent Application No. M02001A000196, filed Oct. 3, 2001; this application also claims priority from Italian Application No. M02001A000196, filed Oct. 3, 2001.
TECHNICAL FIELD OF APPLICATION
[0002] The present invention relates to a facing machine for processing hard-fired ceramic tiles, in particular to an improved facing machine which makes facing such ceramic tiles a much easier operation to perform.
BACKGROUND
[0003] The state of the art provides a variety of machines for facing stone materials. Such machines make conventional use of diamond abrasive rollers in which the abrasive material extends in helical paths around a cylindrical surface of the roller to cut in the whole surface of a stone material being processed. While it is true that at any one time during the process the generatrix line of the cutter envelope is contacting the workpiece surface only with a section of its helix, still the cutting action will affect the whole workpiece area spanned by said generatrix line on account of the contact point moving in succession all along the helix as the roller is rotated. The net result is that the whole surface of the workpiece spanned by the generatrix line is processed at once. However, a facing machine equipped with such rollers is bound to apply a high pressure to the workpiece material, reflecting on increased power requirements and wear of the diamond abrasive. A limit is placed on the power used, and hence on the production output, by the frail nature of the workpiece material, since a belt type of transport cannot be provided that is totally immune to deformation and would not strain the material beyond its breaking point. This means that a controlled amount of power must be delivered to each abrasive roller.
[0004] Also known in the art is a calibrating machine for granite slabs having, located upstream of segmental grinding wheels, a pair of grooving rollers comprised of a set of disk cutters that are formed with radial teeth in order to face a slab surface and calibrate it to thickness by cutting grooves along the feed direction of the slab. The process is carried out on the back side of the slab, so that ridges can be left on this surface, if desired for later anchoring of the slab to a foundation in a more positive manner. Subsequently at a grinding station, the process is completed by a single diamond abrasive ring plate planarizing the slab, if necessary by smoothing away the ridges between grooves.
[0005] However, the performance of this calibrating machine has not proved much of an improvement on helical abrasive roller calibrating machines, mainly because the large number of disks set side by side on said grooving rollers are difficult to adjust for a sufficient number of narrow grooves and ridges to be produced. By reducing the number of disks, the slab surface could be processed more accurately but the ridges formed on the slab surface would be wider, thereby lowering significantly the working rate of the diamond abrasive ring plates.
[0006] In addition, the above prior technique, when applied to the face side of hard-fired ceramic tiles rather than the back side of granite slabs, involves frequent tool adjustment if depths are to be achieved between ridges with very close approximation, and prevents full use of the productive potential of modern vertical-axis rotary heads because differences in depth are liable to affect both the output and removing effectiveness of up-to-date rotary abrasive tooling for such heads.
[0007] Last, whereas in the instance of the above conventional calibrating machine with diamond abrasive ring plate grinders any machining inaccuracies would occur on the back side, away from view, for hard-fired ceramic tiles the machining process is directed to bring out a desired manufacturer's pattern or logo by removing a surface layer of perhaps a few tenths of a millimeter. This surface layer often leaves the kiln in a rippled state that is the outcome of previous tile molding steps as well as the baking step itself. Also, hard-fired ceramic tiles are smoothed to achieve a required degree of planarization for the subsequent polishing operation, so that their face side need be smoothed with the utmost accuracy.
SUMMARY
[0008] The state of the art would be improved upon by a facing machine for hard-fired ceramic tiles, which could overcome the above deficiencies by affording enhanced output and decreased power consumption and/or rate of diamond abrasive wear.
[0009] From the above considerations, the need stands out to have the technical problem solved by a facing machine for hard-fired ceramic tiles that has high output capabilities at no harm for the workpieces, thereby avoiding downtime due to errors or improper processing occurred ahead of the facing machine.
[0010] An embodiment of the invention does solve the technical problem by providing a facing machine for hard-fired ceramic tiles, which comprises a structure for supporting, and setting the cutting depth of, at least one pair of rotary rollers at a grooving station, the axis of said rollers lying transverse to the infeed path of said tiles as carried on a belt transport; said rollers comprising a plurality of disks formed with diamond-tipped cutting teeth and spaced apart abreast said tiles; and a facing station comprising a plurality of vertical-axis grinding wheels with abrasive diamond-tipped tooling; the facing machine being characterized in that said disks with diamond-tipped cutting teeth have identical working diameters in one set of roller-mounted disks, the cutting edges of said teeth having very closely the same circumferential length and being made of a suitable abrasive material for even wear of the cutting edges in one roller-mounted set of disks; that said rollers comprised of disks with diamond-tipped cutting teeth are carried on a common supporting structure, said structure being adjustable in height to set the tool cutting depth in the tile; at least two of said rollers lying next to each other in the direction of tile advance, and being set and/or adjusted sideways to associate the grooves cut in the tile surface by the disks of a preceding one of the rollers with the grooves cut by the disks of the successive roller; the depths at which said grooves are cut being the same or very closely approaching a set depth; said structure being pivotable about a parallel shaft to the work surface in a transverse direction to the feed direction of the work surface, and being associated with a device for adjusting and inhibiting the pivotal movement of the structure in order to accommodate varying cutting diameters of the rollers at said station; and that said grinding wheels comprise rotary heads mounting diamond-tipped cutting tools, themselves for rotation on said heads.
[0011] In a preferred embodiment, said disks with diamond-tipped cutting teeth have all the same cutting diameter in the sets of disks mounted on the paired rollers.
[0012] In another preferred embodiment, said device for adjusting and inhibiting the pivotal movement of the structure comprises a settable tie rod for fine adjustment of said pivotal movement. The tie rod is pivoted with one end on said pivoting structure, and with the other end on the grooving station frame.
[0013] In another preferred embodiment, said rollers with disks of equal cutting width are set transversely at pitch distances selected to produce ridges or lumps substantially of equal widths between resultant grooves, according to the numbers of disks and rollers being used and to the widths of the respective cutting edges.
[0014] In a further embodiment, the rollers with diamond-tipped cutting tooth disks are split into first and second pairs along the feed direction of the tiles, and a device for turning a tile being processed 90 degrees is provided between said pairs.
[0015] In a further preferred embodiment, said vertical-axis rotary heads mount tools for rotation about a horizontal or sub-horizontal axis, or alternatively about a vertical or sub-vertical axis.
[0016] In a further embodiment, a third roller with diamond-tipped cutting tooth disks is provided additionally to said two rollers mounted on the pivoting structure, all said rollers being mounted on a height-adjustable stand, with said third roller being independently adjustable on said height-adjustable stand.
[0017] In a further embodiment, a separate frame from the grooving station, consisting of said toothed disk roller pair, carries an additional roller pair associated with a device for turning a tile being processed 90 degrees, thereby to convert a grooving station to a four-roller layout as shown in FIG. 9 .
[0018] In a further preferred embodiment, the toothed disk rollers are belt driven rotatively by electric motors mounted through mounting brackets either on the pivoting structure that carries the roller pair, or on the adjustable stand for the single roller.
[0019] In yet another preferred embodiment, cylinder actuators for retracting said rollers when the tile advance movement is stopped are provided between the height adjusting device and the adjustable stand or the pivoting structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Some embodiments of the invention are shown, for exemplification only, in the accompanying seven drawings, in which:
[0021] FIG. 1 is a schematic perspective view of the toothed disk roller pair of the grooving station in a facing machine according to the invention shown at work on a few tiles beneath;
[0022] FIG. 2 is a vertical cross-section view in perspective of the grooving station and the supporting structure for said toothed disk rollers which is adjustable pivotally in the cross and height directions;
[0023] FIG. 3 is a perspective view of the facing machine according to the invention, with the grooving station sharing a frame with a facing station equipped with vertical-axis rotary heads;
[0024] FIG. 4 is a partial side elevation view of a ceramic tile at the next stage to the ridge and groove forming operation with the toothed disk rollers;
[0025] FIG. 4A is a schematic side elevation view of a convex ceramic tile;
[0026] FIG. 4B is a similar view of a concave tile;
[0027] FIG. 5 is a partial plan view of the ceramic tile in FIG. 4 highlighting a pattern, logo or decoration provided in the sub-cortical layer;
[0028] FIG. 6 is a plan diagram of another roller layout at the grooving station, with the toothed disks that are gathered to one side in each roller instead of being interleaved;
[0029] FIG. 7 is a plan diagram of another roller layout at the grooving station, with the toothed disks that are gathered to the middle of one roller and to either ends of the other roller, instead of being interleaved;
[0030] FIG. 8 is a plan diagram of another roller layout at the grooving station, with a first pair of toothed disks that are interleaved and followed by a roller whose toothed disks are gathered to its ends for working on dual-size tiles;
[0031] FIG. 9 is a plan diagram of a roller layout at the grooving station, which layout suits a machine intended to calibrate the ceramic tiles for thickness and having four toothed disk rollers arranged in pairs with a conventional device for turning the tiles 90 degrees placed therebetween; and
[0032] FIG. 10 is a side elevation view of the structure for supporting and setting the grooving toothed disk rollers of the layout in FIG. 8 .
DESCRIPTION
[0033] FIG. 1 shows a ceramic tile 1 to be faced. A first roller 2 , comprising disks 3 formed with diamond-tipped cutting teeth 4 , is shown in the act of cutting a first set of grooves 6 in a tile 5 . A second roller 7 , following in the direction A of advance of the tiles being processed, comprises disks 3 with cutting teeth 4 that are staggered in the transverse direction and interleaved with the former disks in a cross direction to direction A, and is shown in the act of grooving the tile 8 with a second set of grooves 9 such that the width dimension of ridges 10 between adjacent grooves is reduced. Said rollers 2 and 7 are supported rotatively on bearings 11 for their respective shafts.
[0034] Shown in FIG. 2 is the pivoting structure 12 on which said bearings 11 are mounted, and with them the rollers 2 , 7 as well. This structure has a pivot shaft 13 arranged to accommodate variations in disk diameter between the first and second rollers, and ensure an even depth for the grooves, viz. achieve a desired degree of planarity.
[0035] The structure 12 has a settable tie rod 14 provided for fine adjustment of its pivotal movement. This tie rod is pivotally connected with one end on the pivoting structure 12 , and with the other end somewhere on the frame 15 of the grooving station 16 . The structure 12 is positioned vertically by the conventional device 17 for adjustment of the vertical cutting position of disks 2 , 7 ; the device 17 being also useful to set the vertical position of the pivot shaft 13 of the structure 12 following said planarity adjustment.
[0036] FIG. 2 also shows drive motors 18 for rotating the rollers 2 , 7 through belt drives 19 . Each motor 18 and respective drive 19 is connected to the pivoting structure 12 through mounting brackets 20 that are arranged to pivot with the structure 12 for tensing the drive belts evenly. Provided in the connection of the height adjustment device 17 to said pivoting structure are cylinder actuators 21 for fast withdrawal of the rollers 2 , 7 during breaks in the workpiece advance movement. Also shown are conventional devices 22 for feeding a coolant onto the rollers 2 , 7 .
[0037] FIG. 3 shows rails 23 of the facing machine on which the belt transport 24 rests to advance ceramic tiles 1 to be processed. Downstream of the grooving station 16 , the facing station 25 is shown to comprise, in this example, a set of three conventional rotary heads 26 along with respective drives 27 and working depth adjusters 28 .
[0038] FIGS. 4, 4A and 4 B show marks 29 on the underside of the ceramic tile for enhanced grip of the tile 1 on its foundation surface, and the depth dimension or reach D of the teeth 4 on the disks 3 for bringing out any tile pattern, logo, decoration or color 30 , as shown in FIG. 5 , that has been kept half-hidden in the tile 1 during previous processing steps.
[0039] FIG. 6 illustrates another embodiment of the grooving station 16 . There are shown a tile 31 being cut with grooves 34 by a first roller 32 that has its toothed disks 3 gathered to one roller end 33 . A second roller 35 with toothed disks 3 gathered to its end 36 , opposite from the end 33 of the first roller 32 , is shown cutting grooves 37 in a tile 38 .
[0040] FIG. 7 shows another embodiment of the grooving station 16 , wherein a roller 39 , equipped with toothed disks 3 that are gathered at the middle 40 thereof, is to cut grooves 41 in a tile 42 . A second roller 43 with toothed disks 3 gathered to either roller ends is to cut grooves 44 in side bands 45 of a tile 46 beneath.
[0041] FIG. 8 illustrates another embodiment of the grooving station 16 . There is shown a middle band 47 of a wider tile 48 than the rollers 2 , 7 in a grooving station 49 for dual-size tiles 1 and 48 . In addition, a third roller 51 , having the toothed disks 3 gathered to either roller ends 52 , is to cut grooves 53 in side bands 50 of the tile 48 .
[0042] FIG. 9 shows still another grooving station 54 , in this instance a multiple one, which comprises a first pair 55 of rollers 2 , 7 with toothed disks 3 for cutting a first set of grooves 6 , 9 in tiles 5 , 8 . Provided downstream of the first roller pair 55 is a conventional device 56 for turning the tile 57 90 degrees (N). A second pair 58 of rollers 2 , 7 with toothed disks 3 is provided after the tile turning device to cut a second sets of grooves 58 , 60 crosswise to the first in tiles 61 , 62 . The resultant lumps 63 at the crossings of the grooves 6 , 9 of the first roller pair 55 with the grooves 59 , 60 of the second roller pair 58 are also shown.
[0043] FIG. 10 shows a frame 59 bearing the rollers of the grooving station 49 in an adjustable manner through the height adjustment device 17 , and a vertically movable stand 60 bearing, on the one side, said pivoting structure 12 with said rollers 2 and 7 , and on the other side, the single roller 51 which is made adjustable independently of said stand 60 by a similar height adjustment device 61 , the latter allowing the roller 51 to be lifted off completely.
[0044] The facing machine operates as follows. The workpiece is moved forward by the belt transport along direction A. On coming under the first roller 2 , the diamond-tipped cutting teeth of the disks 3 will cut the surface of a tile 5 with a first set of equally spaced grooves 6 of varying vertical dimension, because of the uneven tile surface, but all reaching to the same depth dimension D in the tile. On completion of the operation under the first roller 2 , the tile 8 is taken to the second roller 7 , which will cut it with a second set of grooves 9 , interleaved with the grooves 6 of the first set, using its diamond-tipped cutting teeth 4 , thereby to reduce the width of the ridge 10 left over crosswise to direction A.
[0045] On completion of the operation at the grooving station 16 , the tiles 8 are advanced sequentially to a facing station where the vertical-axis grinding heads 26 will remove the ridges 10 left on the tiles 8 . These heads may be any known types, such as cup wheels, cylindrical rollers, or skewed rollers. The cutting action is applied according to the head type, the workpiece material, and the grit employed, so that the facing station 25 may require larger or smaller numbers of rotary heads to accommodate the above variables. The diamond abrasive of the heads will be working under optimal conditions because it is held to the workpiece, rather than throughout its generatrix line, only at points of contact with said ridges 10 or lumps 63 left over from the grooving operation at station 16 . This makes for optimal usage of the working characteristics and continual self-dressing of the head abrasives, this being a condition that could not be met heretofore when working on a truly planar surface.
[0046] The facing operation is terminated upon attainment of a flat surface on the tile 8 . This can be easily detected from a sharp increase in the power requirement of the last head 26 of the facing station 25 , which will be processing the whole surface of the tile 8 , not just the ridges 10 thereof. An error in setting the working depth D of the roller disks 3 at the grooving station would result in increased power requirements also at the vertical-axis rotary heads located ahead of the last, and consequently in an economically less advantageous process. Quite often, moreover, job time is extended as a function of the types of heads and abrasive being used.
[0047] At this point, the ceramic tile facing operation is over, and the tile will display any pattern, logo, grain or colors 30 sought by the manufacturer.
[0048] The operation of the grooving station according to the embodiments of FIGS. 6 and 7 is similar to that of station 16 above, except that the grooves 34 , 41 cut by the forward roller 32 , 39 merely lie side-by-side with the grooves 37 , 44 cut by the rearward roller 35 , 43 . In either cases, ridges 10 are left over that are to be processed at the following facing station as previously explained. Also, the applied cutting power is again spread between the working rollers, for lower tile stressing from the pressure exerted on it and improved cutting action by the diamond-tipped cutting edges of the teeth 4 , since the disks 3 of any one roller will be at work on only a portion of the tile surfaces 31 , 38 , 42 , 46 .
[0049] The operation of the embodiment of FIG. 8 , additionally to what has been mentioned above in relation to rollers 2 and 7 having interleaved disks 3 , involves arrangements for cutting across middle and side bands 47 , 50 in order to process larger size tiles 48 . Yet the grooving station 49 can effect a change of size very quickly, and is adapted to also cut grooves in smaller size tiles, such as a tile 1 , using the rollers 2 and 7 only, these rollers being arranged to process the middle band 47 , as wide as the tile 1 , while the roller 51 is held inactive, it being designed and set for processing only the side bands 50 of larger size tiles 48 . To change from one size to another, the roller 51 , although held out of the tile processing operation, is readily set for same working depth as the pair of toothed rollers 2 , 7 by independently adjusting it to dimension D through the device 61 , with due regard for the different amounts of wear undergone by the teeth 3 of each roller.
[0050] The embodiment of the multiple grooving station 54 , advantageously for ceramic tiles, shown in FIG. 9 , is operated to cut grooves 6 , 9 by the ridges 10 of the first roller pair 55 . The tile is then rotated 90 degrees (N) by the turning device 56 to present the ridges 10 crosswise under the second roller pair 58 . The grooves 59 , 60 are cut by the second roller pair to form lumps 63 on the surface of the tile 62 being processed. These lumps will then be easy to remove at the following facing station. The same advantageous situation as described above in connection with the removal of the ridges 10 also applies to the lumps 63 .
[0051] Major advantages of this invention can be summarized as follows. The grooving station 16 , 49 , 54 of the facing machine allows a desired depth D to be reached quickly in the surface of a ceramic tile, after breaking through the hard-fired surface layer to produce the planarity required for later polishing. By focusing the cutting power on the grooves only, a much harder diamond grit than that employed on helical abrasive pattern rollers can be used, with attendant improvements in durability and cutting power requirements for the same amount of material removed. The facing operation to be carried out at the following station with vertical-axis rotary heads better suits the cutting characteristics of the diamond grit employed, because the latter is kept to work only on the ridges 10 or lumps 63 , not across the whole tile surface. Last, the reduction in overall power requirements for the facing operation is a substantial one, since it may drop down to 50% or less for the same amount of material removed.
[0052] The grooving station could comprise, as mentioned before, more than two rollers mounting a set of disks with diamond-tipped cutting teeth. However, this grooving station would be a complicated and expensive construction, only partly compensated for by benefits of output and flexible operation. In other words, although benefits would accrue from an increased number of rollers, they would not in a directly proportional fashion to that number. At most two, three or four rollers is an optimum number, as above this, the cost of the construction would increase out of proportion to the benefits it can bring in.
[0053] An optimum working condition is for the rollers to cut all the same depth in the workpiece surface—tiles 1 , 5 , 8 , 31 , 38 , 42 , 46 , 48 , 61 and 62 —at the grooving stations 16 , 49 and 54 , such that the grooves 6 , 9 , 34 , 37 , 41 , 44 , 53 , 59 and 60 will enter the facing station 25 with one and the same dimension D, and the job be more equally distributed among the facing heads. In the event of mismatched roller cutting depths due to adjustment errors, different roller diameters, or different depth settings directed to accommodate different types of heads, the tile processing can still be carried to completion, although not under the best possible conditions in respect of power consumption and/or wear of the diamond cutting material on the rotary heads of the facing station 25 . Such an inferior efficiency level will reflect on increased loading of the last rotary head in the facing station, because put to work on ridges 10 or lumps 63 of greater width. Thus, the cutting depth dimension D admits of variations not in excess of a few tenths of a millimeter.
[0054] Accordingly, only the single roller 51 with diamond-tipped cutting teeth 4 in the grooving station 49 can be supported independently in a practical way, in order to minimize variations in the cutting dimension D generated by the grooving station. Advantageously, said roller 51 is carried, rather than directly on the machine frame 59 , on an adjustable stand 60 that also carries the roller pair 2 , 7 , themselves supported on the pivoting structure 12 and adjusted as explained hereinabove. Thus, the three-roller grooving station 49 can be adjusted the same way as the station 16 ahead, and jointly set to a tile 48 to be processed following initial adjustment for the different rate of wear of the roller teeth 3 .
[0055] The cutting width of the teeth 4 may differ between the disks 3 of one roller and the disks of another roller, or between disks 3 in the same roller, so that a larger amount of material can be removed from selected areas of a tile, e.g. more from the side bands or more from the middle band of its processed area, according to the removing capabilities of the rotary heads employed in the facing station 25 . The resultant ridges 10 or lumps 60 will not be the same width in said different areas of the workpiece, and will accommodate such differences in the cutting characteristics of the vertical-axis rotary heads. A target condition would be, however, a succession of alternating grooves and ridges 10 or lumps 63 , even if the grooves and the ridges or lumps may have different widths.
[0056] Furthermore, said rollers with diamond-tipped cutting tooth disks 3 may have different diameters and the number of their teeth also be different. As said before, they can be used in the same grooving station 16 , 49 or 54 if adjusted for the same cutting depth.
[0057] Therefore, the cutting rate should be adjusted to suit the diameter and the type of grit employed, and may differ between rollers in one station. Last, for ease of maintenance, each roller should be equipped with toothed disks whose cutting edges have near-equal circumferential lengths and the same or well-matched abrasive materials, such that they will wear evenly and demand less frequent servicing.
[0058] In practicing the invention, the materials, dimensions, and constructional details may be others than, yet engineering equivalents of, those specified in the foregoing, without departing from the juridical scope of the present invention.
[0059] Thus, the grooving station 16 , 49 or 54 could be built on a separate structure 15 , 23 , 59 from the just as necessary facing station 25 provided after it, for the purpose of updating existing calibrating and/or facing machines having abrasive rotary heads 26 and improve their output and operational flexibility, i.e. to adapt them for use as grooving and facing stations in a ceramic tile facing line according to the above specification. | The facing machine for hard-fired ceramic tiles comprises: a structure for supporting, and setting the cutting depth of, at least one pair or rotary rollers at a grooving station, the axis of said rollers lying transverse to the infeed path of said tiles as carried on a belt transport; said rollers comprising a plurality of disks formed with diamond-tipped cutting teeth and a facing station comprising a plurality of vertical-axis grinding wheels with abrasive diamond-tipped tooling; said rollers are carried on a common supporting structure, being adjustable in height to set the tool cutting depth in the tile; said structure being pivotable about a parallel shaft to the work surface in a transverse direction to the feed direction of the surface, and being associated with a device for adjusting and inhibiting the pivotal movement of the structure in order to accommodate varying cutting diameters of the rollers at said station. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a power supply system in which a DC output of a DC power supply whose electric energy increases and decreases, such as solar cells, wind power generators, and fuel cells, is converted to an AC output by a plurality of inverters and is supplied to a system, and concerns a technique for controlling the inverters with high efficiency. In addition, the present invention relates to a parallel-connected system in which electric power generated by a power generating means such as solar cells is converted by inverters to electric power corresponding to a commercial power supply, and is outputted to the commercial power supply.
2. Description of the Related Art
As such a power supply system, a photovoltaic power generation system using solar cells is generally known. FIG. 6 is a system diagram of a conventional photovoltaic power generation system. This photovoltaic power generation system is configured such that a plurality of solar cells (DC power supply) 101 are arranged on the roof of a house, DC outputs generated by these solar cells 101 are collected into one output by a junction box 102 , and this DC output is then converted to an AC output through an inverter 103 . Subsequently, the power is supplied to the branch circuit inside the house and a commercial-use power system 106 through a distribution board 104 . Incidentally, reference numeral 105 denotes an in-house load connected to the branch circuit.
Generally, the inverter has the characteristic that its efficiency declines extremely during a low output. There has been a problem in that if DC/AC conversion is effected by a single inverter in correspondence with the estimated maximum energy generated by the photovoltaic power generation system, the DC/AC conversion efficiency declines during a low output. To solve such a problem, Japanese Patent Application Laid-Open (JP-A) No. 6-165513, for example, discloses a system in which a plurality of inverters with small outputs are connected in parallel, and the number of inverters which are run is increased or decreased in correspondence with the energy generated by the solar cells so as to suppress the decline in the conversion efficiency during a low output.
In addition, in a parallel-connected system, the DC power generated by a generating apparatus such as a photovoltaic power generator is converted to AC power corresponding to a commercial power supply by the inverters, and is then supplied to the commercial power supply.
With the inverters used in such a parallel-connected system, independent operation due to service interruption of the commercial power supply is prevented, and the system interconnection is protected against an overvoltage, an undervoltage, a frequency rise, and a frequency drop in the commercial power supply.
With the inverters used in the parallel-connected system, the most efficient operation is possible during the output of rated power. However, with the power generator using solar cells, since the generated power increases and decreases due to the quantity of solar radiation and the like, the inverters are subjected to maximum power point tracking control (MPPT control) so that the output efficiency becomes highest in correspondence with the increase or decrease in the generated power when the input power is less than the rated power.
As described above, with the inverters whose output power is large, if the input power is excessively low with respect to the rated power, the output efficiency drops extremely. For this reason, a proposal has been made that, with the parallel-connected system, a plurality of inverters be connected in parallel, and the number of driven inverters be set in correspondence with the input power, so that even when the generated power is low, the inverters can be driven efficiently.
With the conventional method, the number of inverters which are driven is determined merely in correspondence with the output power, and no consideration is given to the selection of the inverters which are driven. For this reason, only particular inverters are driven during a low output, and the other inverters are driven only when the output has increased, with the result that the running time of the particular inverters becomes longer than that of the other inverters. Hence, there has been a problem in that the service life of the particular inverters with a long running time expires earlier than the other inverters.
Furthermore, there has been a problem in that if particular inverters among the plurality of inverters are not effective, the overall system fails to work.
In addition, there is a problem in that if the respective output powers of the plurality of inverters are individually controlled, conversely, the conversion efficiency drops depending on the generated power, the number of driven inverters, and so on. Further, if the individual inverters are separately provided with system integration protection when the plurality of inverters are run in parallel, there are cases where their mutual outputs and protective operations interfere with each other, rendering appropriate protection impossible.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a method of operating a power supply system having a plurality of inverters, such that the inverters are driven with high efficiency, thereby overcoming the above-described drawbacks of the conventional art.
To this end, in accordance with a first aspect of the invention, there is provided a method of operation for a power supply system having a plurality of inverters connected in parallel with a DC power supply whose generated electric energy increases or decreases, in which the inverters convert an electric output from the DC power supply to frequency- and voltage-controlled AC power and output the AC power to a system, the method comprising the steps of: (a) setting one of the inverters to serve as a master unit and the other inverters to serve as slave units, wherein the master unit controls the slave units; and (b) allowing the master unit to control the slave units on the basis of at least one of an increase or decrease in the electric energy from the DC power supply and an increase or decrease in the AC power outputted from the inverters.
In accordance with the above-described first aspect of the invention, of the plurality of inverters, one inverter which is set as the master unit controls the operation of the remaining inverters, whose order has been set in accordance with a predetermined rule, on the basis of the increase or decrease of electric energy of the DC power supply or an increase or decrease of the amount of AC power output from the inverter.
Further, in this aspect of the invention, when running of a generator is suspended, the master unit sets a master unit which is to be used during the start of the next running of the generator. Such a setting can be effected on the basis of integrated values of the running times of the inverters or their amounts of output power.
As a result, the integrated values of the running times or output powers can be substantially equalized among the plurality of inverters, and it is possible to prevent the running times of particular inverters from becoming long.
Further, the inverters are respectively connected to remote controllers for remote controlling, and the remote controllers are connected to each other in such a manner as to be capable of transmitting and receiving signals to and from one another. The operation of the inverters is effected through the remote controllers.
Further, the ordering of slave units to be run next may be randomly set by using random numbers.
Further, the ordering of slave units to be run next may be set in the ascending order of the running times thereof.
Further, the ordering of slave units to be run next may be set in the ascending order of the amounts of output power thereof.
Another object of the invention is to provide an efficient parallel-connected system in which a plurality of inverters are connected in parallel, and electric power generated by a generator is converted to electric power corresponding to a commercial power supply and is outputted by the inverters, thereby overcoming the above-described drawbacks of the conventional art.
To this end, in accordance with another aspect of the invention, there is provided a system for converting DC power to AC power, comprising: (a) a plurality of inverters, each inverter being adapted to receive DC power and convert the DC power to AC power; and (b) a controller connected to the inverters and controlling operation of the inverters on the basis of DC power available, the controller causing more inverters to run if sufficient DC power is available and fewer inverters to run if there is insufficient DC power, wherein the controller operates any one of the inverters such that the amount of AC power outputted from the any one of the inverters increases or decreases in correspondence with an increase or decrease in the amount of electric power outputted from the DC power supply, and the controller operates remaining ones of the inverters at a predetermined standard value.
In accordance with this aspect of the invention, when two or more inverters are running, any one of the inverters is made to effect, for example, MPPT control, and the other inverters are made to effect rated operation.
Consequently, as compared with the case where individual inverters effect MPPT control, efficient operation becomes possible. Further, it is possible to prevent an increase or decrease in the output power of any of the inverters, which increase or decrease would be caused by MPPT control effected by the individual inverters, from affecting the operation of the other inverters.
Furthermore, in accordance with still another aspect of the invention, there is provided a system for converting generated electric power to AC power, wherein a plurality of inverters provided respectively with protecting means for effecting system interconnection protection for a commercial power supply are connected in parallel, and electric power generated by a generator is converted to electric power corresponding to a commercial power supply and is outputted from a number of inverters which number is determined on the basis of the amount of generated electric power, comprising: a controller for effecting protected operation of the plurality of inverters by a protecting means provided in at least one of the inverters when at least two of the inverters are running.
In accordance with this aspect of the invention, when a plurality of inverters are running, the system interconnection protection of the other inverters is effected with respect to independent operation as well as overvoltage, undervoltage, frequency rise, and frequency drop of the commercial power supply, by using the protecting means of any one of the inverters. Namely, the system interconnection protection of the plurality of inverters is collectively effected by the protecting means of any one of the inverters.
As a result, it is possible to prevent a situation in which there occur problems such as the protective operation timing deviates due to system interconnection protection effected by a plurality of inverters, or it becomes impossible for any inverter to appropriately effect the system interconnection protection due to the deviation of this protective operation timing.
The controlling means used in this aspect of the invention may adopt an arrangement in which one master unit is set, and this master unit serves to effect MPPT control or system interconnection protection.
In addition, the controlling means may include remote controllers which are respectively connected to the plurality of inverters and communication means for connecting the remote controllers with one another.
Consequently, it is possible to accurately control the operation of the plurality of inverters without providing an exclusive-use controlling means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a power supply system which is used as a parallel-connected system in accordance with an embodiment of the invention;
FIG. 2 is a block diagram illustrating a schematic structure of an inverter used in the power supply system;
FIG. 3 is a block diagram illustrating a remote controller used in the power supply system;
FIG. 4 is a flowchart illustrating a control routine for the power supply system in accordance with the embodiment;
FIG. 5A is a diagram illustrating an example of the change in the amount of output power of a DC power supply;
FIG. 5B is a timing chart illustrating the operation of inverters in accordance with FIG. 5A; and
FIG. 6 is a diagram of a system structure of a conventional photovoltaic power generation system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereafter, a description will be given of an embodiment of the invention. FIG. 1 shows a schematic structure of a power supply system 12 . In this power supply system 12 , a plurality of inverters 14 (by way of example, three inverters 14 A to 14 C) are connected in parallel to a DC power supply 1 (e.g., solar cells consisting of a plurality of modules).
The input side of each inverter 14 is connected to the. DC power supply 1 through a magnet switch 18 ( 18 A, 18 B, 18 C) of a latch type in which the opening and closing of the contact is alternately changed over.
The output side is connected to a commercial power supply 16 . In this way, the power supply system 12 forms a parallel-connected power generating system in which DC power outputted from the DC power supply 1 is converted into AC power of a frequency which is the same as that of the commercial power supply 16 by the inverters 14 , and the AC power is outputted to a branch circuit 15 connected to the commercial power supply 16 . In the present embodiment, an example is described in which the three inverters 14 A, 14 B, 14 C (these inverters will be referred to as the inverters 14 unless otherwise specified) each having an output of 4.0 kW are used for the DC power supply 1 whose maximum output power is 12 kw.
As shown in FIG. 2, the inverter 14 has an inverter circuit 20 and a microcomputer 22 for controlling the inverter circuit 20 . The DC power inputted to the inverter 14 through the magnet switch 18 is supplied to the inverter circuit 20 through a noise filter 26 .
The DC power inputted to the inverter circuit 20 is converted to AC power of a frequency substantially identical to that of the commercial power supply 16 by the inverter circuit 20 , and the AC power is outputted. At this time, the inverter circuit 20 switches the DC power on the basis of the pulse width modulation (PWM) theory, and outputs a pseudo sine wave of a frequency substantially identical to that of the commercial power supply 16 . The AC power outputted from the inverter circuit 20 is controlled such that the voltage thereof becomes 5 to 10 volts higher than the voltage supplied from the commercial power supply 16 , and is supplied to the branch circuit 15 by a transformerless system through a filter circuit 28 , a noise filter 29 , and a contactor
Connected to the microcomputer 22 are an input-voltage detecting unit 32 formed by an isolation amplifier for detecting the DC voltage inputted to the inverter circuit 20 , an input-current detecting unit 34 formed by a current transformer (CT) for detecting the DC current, an output-current detecting unit 38 formed by a current transformer (CT) for detecting the AC current outputted from the inverter circuit 20 , and a voltage-waveform detecting unit 40 for detecting the system voltage and voltage waveform in the commercial power supply 16 by a potential transformer (PT).
On the basis of the DC power detected by the input-voltage detecting unit 32 and the input-current detecting unit 34 and the voltage detected by the voltage-waveform detecting unit 40 , the microcomputer 22 controls the on-duty ratio of a switching signal for driving an unillustrated switching element of the inverter circuit 20 .
As a result, the inverter 14 outputs AC power whose phase matches the phase of the commercial power supply 16 , whose frequency matches the frequency of the commercial power supply 16 , and whose voltage is from 5 to 10 volts higher than the voltage of the commercial power supply 16 . The phase of the AC power outputted from the inverter is made to match the phase of the commercial power supply 16 by determining the zero-cross from the detected waveform of a voltage waveform detecting section 40 and making the zero-cross of a pseudo-sine-waveform wave match the zero-cross of the detected waveform. It should be noted that the AC power outputted from the inverter circuit 20 has a sawtooth waveform, and as the filter circuit 28 eliminates harmonic components from the output voltage from the inverter circuit 20 , AC power of a sine wave is outputted from the inverter 14 .
Meanwhile, the contactor 30 is controlled by the microcomputer 22 , and the microcomputer 22 effects the connection and disconnection between the inverter 14 and the commercial power supply 16 by means of this contactor 30 .
Consequently, for example, when the output power from the DC power supply 1 is small and the running of the inverter 14 is stopped because the energy generated by the solar cell modules is small or no power is being generated, the microcomputer 22 disconnects the inverter 14 from the commercial power supply 16 , and connects the inverter 14 and the commercial power supply 16 immediately before the inverter 14 starts running again.
In addition, when it is determined from the voltage waveform detected by the voltage-waveform detecting unit 40 that the commercial power supply 16 is in a state of service interruption, the microcomputer 22 quickly disconnects the inverter 14 from the commercial power supply 16 by means of the contactor 30 so as to prevent the independent operation and the like of the inverter 14 . Further, the microcomputer 22 effects protection of the inverter 14 from an overvoltage (OVR), an undervoltage (UVR), a frequency rise (OFR), a frequency drop (UFR), and independent operation. It should be noted that, as for the inverters 14 , conventionally known structures and controlling methods can be applied, and a detailed description thereof will be omitted in this embodiment.
As shown in FIG. 1, in the power supply system 12 , remote controllers 50 ( 50 A, 50 B, and 50 C) are respectively connected to the inverters 14 .
As shown in FIG. 3, each remote controller 50 is provided with a control unit 52 having a microcomputer, a display unit 54 using an LCD or the like, and a power supply circuit 56 . The display unit 54 and the power supply circuit 56 are connected to the control unit 52 . Further, the remote controller 50 is provided with a setting switch unit 58 and a communication connector 60 , and these units are connected to the control unit 52 .
The power supply circuit 56 is provided with an unillustrated battery for backup and is connected to the commercial power supply 16 , so that the remote controller 50 is operated by power supplied from the commercial power supply 16 . Namely, the DC power is not inputted to the remote controller 50 from the DC power supply 1 , so that the remote controller 50 is operable even if the inverter 14 is in a stopped state.
The microcomputer 22 of the inverter 14 is connected to the communication connector 60 of the remote controller 50 . Consequently, the remote controller 50 is capable of management of operation such as the integration of the amount of output power from the inverter 14 . In addition, if the inverter 14 stops running due to the stopping of the independent operation, this information is inputted from the microcomputer 22 to the remote controller 50 .
Further, as shown in FIG. 1, the remote controllers 50 are connected to a drive circuit 62 for driving the magnet switches 18 on and off.
If the magnet switch 18 is turned off, the DC power is not inputted to the inverter 14 , so that the inverter 14 stops, whereas if the magnet switch 18 is turned on to supply the DC power to the inverter 14 , running of the inverter 14 becomes possible.
Each remote controller 50 turns off the magnet switch 18 when outputting a control signal for instructing the stopping of running to the microcomputer 22 of the inverter 14 , and turns on the magnet switch 18 when outputting a signal for instructing the start of running thereto. It should be noted that the microcomputer 22 may turn on and off the magnet switch 18 on the basis of an operation instruction (i.e., a start running instruction or a stop running instruction) inputted to the microcomputer 22 from the remote controller 50 .
The communication connector 60 of each remote controller 50 is connected to the other remote controllers by communication lines 64 . At this time, the remote controllers 50 are connected by the exclusive-use communication lines 64 so as to form a loop, for example.
As a result, the exchange of information on the running states of the inverters 14 A, 14 B, and 14 C connected to each other becomes possible among the remote controllers 50 A, 50 B, and 50 C.
In the power supply system 12 configured as described above, the arrangement provided is such that any one of the inverters 14 serves as a master unit, and controls, together with the remote controller 50 connected to the master unit, the operation of the other inverters 14 serving as slave units. It should be noted that the setting of the master unit and the slave units is possible by unillustrated dip switches provided in the setting switch units 58 of the remote controllers 50 connected to the respective inverters 14 , but in the present embodiment, a description will be given of an example in which the master unit is not specified. Incidentally, the dip switches are used as switches for setting addresses for specifying the remote controllers 50 .
The remote controller 50 connected to the inverter 14 which is to serve as the master unit is set in a state in which the magnet switches 18 A, 18 B, and 18 C are closed to allow any of the inverters 14 to be able to run by the power supplied from the DC power supply 1 . Then, the inverter 14 which initially started running when the solar cell modules, i.e., the DC power supply 1 , started generating electricity becomes the master unit, and the master unit and the slave units are determined as the remote controller 50 connected to that inverter 14 makes the announcement of being the master unit to the other remote controllers through signal lines.
Subsequently, the remote controller 50 connected to the inverter 14 which has been set as the master unit sets the inverter which has been set as the master unit in a constantly running state, and operates the inverters 14 which have been set as the slave units in correspondence with the increase or decrease in the output power of the DC power supply 1 .
In addition, to set the remote controller 50 connected to the inverter 14 which initially serves as the master unit without using the dip switch of the setting switch unit 58 , the setting is made in the state in which the magnet switches 18 A, 18 B, and 18 C are closed to allow any of the inverters 14 to be able to run by the power supplied from the DC power supply 1 . Subsequently, the inverter 14 which initially started running when the solar cell modules, i.e., the DC power supply 1 , started generating electricity is set as the master unit.
The remote controller 50 connected to the inverter 14 , which has thus been set as the master unit, first sets the remaining inverters 14 as the slave units so that the other inverters 14 do not start. Subsequently, the remote controller 50 connected to the inverter 14 which has been set as the master unit sets the inverter 14 which has been set as the master unit in the constantly running state, and operates the inverters 14 which have been set as the slave units in correspondence with the increase or decrease of the output power in the DC power supply 1 .
Meanwhile, in the power supply system 12 , the inverter 14 to be set as the next master unit is set at the daily suspension of running, for example, on the basis of information regarding operation, such as integrated values of output power (amounts of output power) of the inverters 14 A to 14 C and the integrated values of running times, so that the integrated values of the amounts of output power and the running times will become equalized among the inverters 14 A to 14 C.
Namely, the inverter 14 whose amount of output power or whose running time is the minimum is used as the inverter 14 which is to be set as the next master unit.
For this reason, when the inverters 14 set as the slave units are stopped, the remote controllers 50 connected to the inverters 14 set as the slave units output the integrated values of output power (amounts of output power) of these inverters 14 to the remote controller 50 connected to the inverter 14 set as the master unit.
When the DC power from the DC power supply 1 is stopped, the remote controller 50 connected to the inverter 14 set as the master unit stops the inverter 14 connected thereto, and calculates the amount of output power of this inverter 14 . Subsequently, a comparison is made among the amounts of output power of the respective inverters 14 , and the inverter 14 whose amount of output power is the minimum is set as the next master unit, whereupon processing ends.
It should be noted that, as the method of setting the next master unit, an arrangement may be provided such that the master unit is set randomly by using random numbers.
As a result, when the power supply system 12 is started the next time, the remote controller 50 connected to the inverter 14 which has been newly set as the master unit controls the operation of the inverters 14 .
The inverter 14 which has been set as the master unit effects maximum power point tracking (MPPT) control for fetching a maximum output by following the increase and decrease in the inputted DC power. In addition, the inverters 14 which have been set as the slave units are subjected to constant-level energy control for constantly obtaining maximum outputs. The remote controller 50 of the inverter 14 which has been set as the master unit operates the slave inverters 14 and opens and closes the magnet switches 18 in correspondence with the increase and decrease in the output of the DC power supply 1 , such that the slave inverters 14 can be subjected to constant-level energy control.
At this time, as shown in FIG. 1, each inverter 14 is provided with a charging-current suppressing circuit 66 (not shown in FIG. 2) so as to prevent transient variation of voltage of the DC power supply 1 due to the charging of a large-capacity condenser provided on the DC side of the inverter 14 when the magnet switch 18 is turned on.
In addition, with the power supply system 12 , the remote controller 50 connected to the inverter 14 which has been set as the master unit collectively effects the prevention of independent operation as well as interconnected protection with respect to overvoltage (OVR), undervoltage (UVR), frequency drop (UFR), and frequency rise (OFR), so as to prevent interference and malfunction occurring due to the interconnected protection effected separately by the respective inverters 14 .
In this power supply system 12 , first, the setting of the master unit of the inverters 14 is effected. In the setting of the master unit, addresses are set by the dip switches of the setting switch units 58 provided in the remote controllers 50 connected to the respective inverters 14 . It should be noted that one master unit may be set as an initial value.
In addition, when the master unit and slave units are automatically set, the magnet switches 18 A to 18 C are turned on in the state in which the output of the DC power supply 1 is being stopped, so that the inverters 14 are able to run. In this state, if the DC power supply 1 starts outputting the DC power at sunrise, for example, the inverters 14 A to 14 C start running with slight time lags. At this time, when any of the inverters 14 starts running, a signal representing the start of running is outputted to the remote controller 50 .
The remote controller 50 connected to the inverter 14 which initially started running outputs control signals to the other remote controllers 50 so that the other inverters 14 will not start. Consequently, the inverter 14 which first started running becomes the master unit, and the other inverters 14 are set as the slave units.
When the setting of the master unit and slave units is thus completed among the remote controllers 50 A to 50 C connected to the inverters 14 A to 14 C, the operation of the inverters 14 A to 14 C is controlled in correspondence with the DC power outputted from the DC power supply 1 .
The flowchart shown in FIG. 4 illustrates an outline of control of the inverters 14 A to 14 C by the remote controller 50 connected to the inverter 14 which has been set as the master unit.
Referring now to FIG. 4, a description will be given under the assumption that the inverter 14 A connected to the remote controller 50 A is set as the master unit and that the amounts of output power, a 0 kWh, b 0 kWh, and c 0 kWh, of the inverters 14 A, 14 B, and 14 C are such that a 0 <b 0 <c 0 . As a result, the remote controller 50 A connected to the inverter 14 A effects control in such a manner as to consecutively start up the inverters 14 B and 14 C as the DC power (output power Q) outputted by the DC power supply 1 increases, and in such a manner as to consecutively shut down the inverters 14 C and 14 B as the output power Q decreases. Hereafter, a description will be given by referring to the inverter 14 A as the “master unit” and the inverters 14 B and 14 C as the “slave unit b” and the “slave unit c,” respectively, and the steps of the flowchart will be indicated by numbers.
The remote controller 50 A connected to the master unit turns on the magnet switch 18 A so as to set the master unit in a runnable state (Step 200 ). Consequently, when the DC power supply 1 starts outputting the DC power at sunrise, the master unit runs to output the AC power.
Upon confirming that the master unit has started running (YES in the determination in Step 202 ), the remote controller 50 A connected to the master unit reads the input power to the master unit, i.e., the output power Q (Step 204 ). The remote controller 50 A connected to the master unit then confirms whether or not the output power Q has reached the power Q 1 at which the ensuing slave unit b can also be run (Step 206 ), or whether or not the DC power supply 1 has stopped and the DC power has ceased to be outputted (Step 208 ).
If the output power Q from the DC power supply 1 has increased and reached the power Q 1 at which the slave unit b can also be run (YES in the determination in Step 206 ), the remote controller 50 B connected to the slave unit b is turned on (Step 210 ). Upon being turned on, the remote controller 50 B connected to the slave unit b turns on the magnet switch 18 B so that the slave unit b starts running.
Consequently, as shown in FIG. 5B, in the power supply system 12 , the master unit and the slave unit b are controlled to convert the output power Q from the DC power supply 1 to AC power. In the flowchart shown in FIG. 4, the output power Q from the DC power supply 1 is then read (Step 212 ), and confirmation is made as to whether or not this output power Q has reached the power Q 2 at which the next slave unit c can also be run (Step 214 ), or whether or not the output power Q has dropped to the power Q 1 at which the slave unit b is shut down (Step 216 ).
Here, if the output power Q from the DC power supply 1 has reached the power Q 2 at which the slave unit c can be run(YES in the determination in Step 214 ), the remote controller 50 C connected to the slave unit c is turned on (Step 218 ). Upon being turned on, the remote controller 50 C connected to the slave unit c turns on the magnet switch 18 C so that the slave unit c starts running.
Consequently, as shown in FIG. 5B, in the power supply system 12 , the output power Q from the DC power supply 1 is converted to AC power and is outputted by the master unit and the slave units b and c.
Subsequently, in the flowchart shown in FIG. 4, the output power Q from the DC power supply 1 is read (Step 220 ), and confirmation is made as to whether or not this output power Q has dropped below the power Q 2 at which the slave unit c can also be run (Step 222 ), and if the output power Q has dropped below the power at which the slave unit c can be run (YES in the determination in Step 222 ), the remote controller 50 C connected to the slave unit c is turned off (Step 224 ).
Upon being turned off, the remote controller 50 C connected to the slave unit c turns off the magnet switch 18 C to stop the slave unit c. Subsequently, the remote controller 50 C connected to the slave unit c outputs to the remote controller 50 A connected to the master unit the amount of output power outputted from the slave unit c.
Consequently, the remote controller 50 A connected to the master unit reads the amount of output power from the slave unit c outputted from the remote controller 50 C connected to the stopped slave unit c (Step 226 ), and the routine returns to Step 212 .
In addition, if the output power Q from the DC power supply 1 drops further, and falls below the power Q 1 at which the slave unit b can be run (YES in the determination in Step 216 ), the remote controller 50 B connected to the slave unit b is also turned off (Step 228 ).
Upon being turned off, the remote controller 50 B connected to the slave unit b turns off the magnet switch 18 B to stop the slave unit b, and outputs to the remote controller 50 A connected to the master unit the amount of output power from the slave unit b.
Consequently, the master unit reads the amount of output power from the slave unit b outputted from the remote controller 50 B connected to the stopped slave unit b (Step 230 ), and continues the confirmation of the output power Q from the DC power supply 1 (Steps 204 to 208 ).
If the output power Q from the DC power supply 1 thus gradually drops and the DC power supply 1 stops (YES in the determination in Step 208 ), the magnet switch 18 A is turned off to stop the master unit (Step 232 ). Subsequently, the amount of output power from the master unit is read from the microcomputer 22 of the master unit (Step 234 ), a comparison is made among the amounts of output power of the master unit and the slave units b and c (Step 236 ), and the order of starting of the remote controllers connected to the next master unit and the next slave units is set (Step 238 ).
Namely, if the amounts of output power a 1 , b 1 , and c 1 of the inverters 14 A, 14 B, and 14 C are such that b 1 <c 1 <a 1 , the inverter 14 B whose amount of output power is the minimum is set as the next master unit, and the inverters 14 A and 14 C are set as the slave units. Further, since the amount of output power from the inverter 14 C is smaller than that from the inverter 14 A, setting is carried out such that the inverter 14 C is started up earlier than the inverter 14 A, and the result of this setting is outputted to the remote controller 50 B connected to the inverter 14 B which has been set as the next master unit.
Thus, the remote controller 50 B connected to the inverter 14 B which has been set as the next master unit is set in a standby state by turning on the magnet switch 18 B to set the inverter 14 B in the state in which the inverter 14 B can be made to run.
By setting the master unit and slave units and the order of starting up the slave units in the above-described manner, the amounts of output power of the plurality of inverters 14 can be substantially equalized. In addition, by setting the master unit and slave units on the basis of the running times, the running times can be substantially equalized among the plurality of inverters 14 , thereby making it possible to prolong the service life of the power supply system 12 .
In particular, the service life of electronic components such as an electrolytic condenser and a cooling fan provided in the inverter 14 is greatly affected by the running time of the inverter 14 . However, by substantially equalizing these running times, stable operation is made possible over an extended period of time.
It should be noted that, in the above-described structure, a plurality of relationships may be present as the relationship between the master unit and slave units of inverters, and the increase or decrease in the amount of AC output from the inverter 14 may be used in the determination of the starting or stopping of the master unit and slave units.
In addition, in the event that any inverter 14 is not effective, by excluding the remote controller 50 connected to that inverter 14 from the setting of the master unit and slave units, the inverter 14 can be cut off from the DC power supply 1 by the magnet switch 18 . Consequently, system interconnection becomes possible in which the inverter 14 which is not effective is prevented from running, and the inverters 14 which are effective are used.
At this time, if the fact that the inverter 14 is not effective is displayed on the display unit 54 of the remote controller 50 connected to the inverter 14 which is not effective, it is possible to clearly determine the presence or absence of an inverter 14 which is not effective in the power supply system 12 .
Meanwhile, in the power supply system 12 , MPPT control is effected only by the inverter 14 which is set as the master unit, and the inverters 14 which are set as the slave units are constantly subjected to constant-level energy control.
Namely, as shown in FIG. 5A, the inverter 14 B is constantly subjected to constant-level energy control in the range of the running time t2 to t5, whereas the inverter 14 C is constantly subjected to constant-level energy control in the range of the running time t3 to t4, thereby respectively outputting AC power of 4 kW, i.e., the rated power.
In contrast, the inverter 14 A operates in such a manner as to output the maximum power in correspondence with the increase or decrease in the output power Q constantly by MPPT control in the range of the time t1 to t6 during which the DC power is being outputted from the DC power supply 1 .
As a result, as the plurality of inverters 14 effect MPPT control, an increase or decrease in the output power from one inverter 14 can be prevented from affecting the operation of the other inverters 14 , and even if the plurality of inverters 14 are used, the power supply system 12 can be operated stably.
On the other hand, if the plurality of inverters 14 individually effect the protective operation, the operation becomes nonuniform among the plurality of inverters 14 due to the offset in the detection timing and the like. Hence, there are cases where the protective operation of one inverter 14 affects the protective operation of the other inverters 14 , thereby rendering appropriate protection impossible.
In contrast, with the power supply system 12 , independent operation as well as overvoltage, undervoltage, frequency rise, and frequency drop are monitored by the remote controller 50 connected to the inverter 14 which is set as the master unit, and the plurality of inverters 14 are collectively protected on the basis of the results of this monitoring. Consequently, protection of the plurality of inverters 14 can be effected speedily and reliably.
In addition, in a case where AC power is supplied from the inverters 14 to the commercial power supply 16 , the AC power flows backward from the inverters 14 to the commercial power supply 16 . This backward flow can cause a voltage rise in the commercial power supply 16 . At this time, with the power supply system 12 , the remote controller 50 connected to the inverter 14 which has been set as the master unit first controls the outputs of the slave inverters 14 consecutively, and lastly controls the output of the master inverter 14 .
Thus, with the power supply system 12 , when the plurality of inverters 14 are connected in parallel, the remote controller 50 connected to the inverter 14 which is to be the master unit is set, and the remote controller 50 connected to the master inverter 14 collectively controls the plurality of inverters 14 , thereby making it possible to operate the inverters 14 without causing variations in their operations.
Furthermore, in terms of the system configuration, it goes without saying that the present invention is not limited to the above-described system in which the maximum output power of the DC power supply 1 is 12 kw, and that the present invention is applicable to systems of other outputs, such as 11 kW, 13 kW, 14 kW, and 15 kW.
As another example of control for operating the slave units, first, the DC power outputted from the DC power supply 1 is sampled at a sampling frequency of, e.g., several milliseconds to several tens of milliseconds.
Next, a first differential (first difference) of the DC power sampled for the last several minutes is determined, and from these results, a determination is made as to whether the slope of a graph, in a case in which the increases and decreases in DC power are graphed, is increasing or decreasing. Here, by using the results of the first differential, it is possible to suppress the effect of an instantaneous increase or decrease in output power accompanying an instantaneous change in the weather such as instantaneous clouding over due to a cloud or a gust of wind.
Next, if the first differential is increasing, a determination is made as to whether or not the number of inverters to be run needs to be increased. Specifically, this determination is made by estimating the DC power during the next sampling from the aforementioned first differential, and a determination is made that the number of inverters needs to be increased if this estimated value has exceeded the DC power capable of being handled by the inverter(s) which are currently running.
For example, in a case where the number of inverters which are running with the present output power of 950 W is two, if it is estimated from the aforementioned first differential that the output power during the next sampling will be 1050 W, since two 500 W-compatible inverters cannot handle such a situation, a determination is made that the number needs to be increased by one. Further, if the output power during the next sampling is estimated to be 980 W, since this situation can be handled by two inverters, a determination is made that it is not necessary to increase the number of inverters.
Next, if it is necessary to increase the number of inverters which are running, an inverter which is to be made to start running is selected by random numbers from a list of inverters currently not running.
This completes the routine, and the same routine is repeated again from the first step. It should be noted that the routine also returns to the first step in the case where there is no need to increase the number of running inverters.
Meanwhile, in a case where the first differential of the DC power for the last several minutes is not increasing, a determination is made as to whether or not the number of running inverters needs to be decreased. In this determination, in the same way as described above, the DC power during the next sampling is estimated from the aforementioned first differential, and a determination is made that the number of inverters needs to be decreased if this estimated value is such that operation is possible with a number of inverters which is less than the present number.
For example, in a case where the number of inverters being run with the present output power of 1050 W is three, if it is estimated from the aforementioned first differential that the output power during the next sampling will be 980 W, since two 500 W-compatible inverters are able to handle such a situation, a determination is made that the number needs to be decreased by one. In addition, if the output power during the next sampling is estimated to be 1020 W, since three inverters are required, a determination is made that it is unnecessary to decrease the number of inverters.
Then, if it is necessary to decrease the number of inverters which are running, an inverter to be stopped is selected by random numbers from a list of inverters which are currently running.
This completes the routine, and the same routine is repeated again from the first step. It should be noted that the routine also returns to the first step in the case where there is no need to decrease the number of running inverters.
The controlling method is not limited to the above-described method, and the number of units to be run may be controlled on the basis of the value of the increase or decrease in the DC power, or by using fuzzy inference based on the value of the increase or decrease in the DC power. Alternatively, the number of units to be run may be controlled by simply comparing the value of the DC power with a set value.
Further, the present invention is applicable to not only single-phase DC/AC converters and three-phase DC/AC converters, but also to DC/AC converters of any form.
It should be noted that the present embodiment is illustrative only, and does not limit the structure of the present invention. The present invention is applicable to parallel-connected systems of various configurations in which a plurality of inverters are connected in parallel. | A method whereby a plurality of inverters for converting DC power outputted from a DC power supply, such as solar cells or fuel cells, to AC power are operated efficiently without being biased to particular inverters. The number of inverters to be run is determined in correspondence with at least one output value of the DC output or AC output, and the determined number of inverters are selected and made to run from among the plurality of inverters on the basis of a predetermined rule. In addition, a parallel-connected system is disclosed for enabling efficient and appropriate parallel-in operation by the use of inverters, with one of the inverters controlling the remaining inverters and effecting system interconnection protection. | 8 |
PRIORITY TO RELATED APPLICATION(S)
[0001] This application claims the benefit of European Patent Application No. 10159754.0, filed Apr. 13, 2010, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] In the central nervous system (CNS) the transmission of stimuli takes place by the interaction of a neurotransmitter, which is sent out by a neuron, with a neuroreceptor.
[0003] Glutamate is the major excitatory neurotransmitter in the brain and plays a unique role in a variety of central nervous system (CNS) functions. The glutamate-dependent stimulus receptors are divided into two main groups. The first main group, namely the ionotropic receptors, forms ligand-controlled ion channels. The metabotropic glutamate receptors (mGluR) belong to the second main group and, furthermore, belong to the family of G-protein coupled receptors.
[0004] At present, eight different members of these mGluR are known and of these some even have sub-types. According to their sequence homology, signal transduction mechanisms and agonist selectivity, these eight receptors can be sub-divided into three sub-groups:
[0000] mGluR1 and mGluR5 belong to group I, mGluR2 and mGluR3 belong to group II and mGluR4, mGluR6, mGluR7 and mGluR8 belong to group III.
[0005] Ligands of metabotropic glutamate receptors belonging to the first group can be used for the treatment or prevention of acute and/or chronic neurological disorders such as psychosis, epilepsy, schizophrenia, Alzheimer's disease, cognitive disorders and memory deficits, as well as chronic and acute pain.
[0006] Other treatable indications in this connection are restricted brain function caused by bypass operations or transplants, poor blood supply to the brain, spinal cord injuries, head injuries, hypoxia caused by pregnancy, cardiac arrest and hypoglycaemia. Further treatable indications are ischemia, Huntington's chorea, amyotrophic lateral sclerosis (ALS), dementia caused by AIDS, eye injuries, retinopathy, idiopathic parkinsonism or parkinsonism caused by medicaments as well as conditions which lead to glutamate-deficiency functions, such as e.g. muscle spasms, convulsions, migraine, urinary incontinence, nicotine addiction, opiate addiction, anxiety, vomiting, dyskinesia and depressions.
[0007] Disorders mediated full or in part by mGluR5 are for example acute, traumatic and chronic degenerative processes of the nervous system, such as Alzheimer's disease, senile dementia, Parkinson's disease, Huntington's chorea, amyotrophic lateral sclerosis and multiple sclerosis, psychiatric diseases such as schizophrenia and anxiety, depression, pain and drug dependency ( Expert Opin. Ther. Patents (2002), 12, (12)).
[0008] A new avenue for developing selective modulators is to identify compounds which act through allosteric mechanism, modulating the receptor by binding to a site different from the highly conserved orthosteric binding site. Allosteric modulators of mGluR5 have emerged recently as novel pharmaceutical entities offering this attractive alternative. Allosteric modulators have been described, for example in WO2008/151184, WO2006/048771, WO2006/129199 and WO2005/044797 and in Molecular Pharmacology, 40, 333-336, 1991 ; The Journal of Pharmacology and Experimental Therapeutics , Vol 313, No. 1, 199-206, 2005;
[0009] In recent years there have been significant advantages in understanding the pathophysiology of several disorders of brain development, suggesting that protein synthesis at synapses is triggered by activation of group I metabotropic glutamate receptors. Such disorders include fragile X syndrome, autism, idiopatic autism, tuberous sclerosis complex disorder, neurofibromatosis type 1 or Rett syndrome ( Annu. Rev. Med., 2011, 62, 31.1-31.19 and Neuroscience 156, 2008, 203-215).
[0010] Described in the prior art are positive allosteric modulators. They are compounds that do not directly activate receptors by themselves, but markedly potentiate agonist-stimulated responses, increase potency and maximum of efficacy. The binding of these compounds increases the affinity of a glutamate-site agonist at its extracellular N-terminal binding site. Allosteric modulation is thus an attractive mechanism for enhancing appropriate physiological receptor activation. There is a scarcity of selective allosteric modulators for the mGluR5 receptor. Conventional mGluR5 receptor modulators typically lack satisfactory aqueous solubility and exhibit poor oral bioavailability.
[0011] Therefore, there remains a need for compounds that overcome these deficiencies and that effectively provide selective allosteric modulators for the mGluR5 receptor.
SUMMARY OF THE INVENTION
[0012] The present invention provides ethynyl compounds of formula I
[0000]
[0000] wherein
U is ═N— or ═C(R 5 )—; V is —CH═ or —N═; W is ═CH— or ═N—;
with the proviso that only one of U, V or W is nitrogen,
R 5 is hydrogen, methyl or halogen; Y is —N(R 6 )—, —O—, —C(R 7′ )(R 7 )—, —CH 2 O— or —CH 2 S(O) 2 —;
wherein R 6 is hydrogen or lower alkyl and R 7 and R 7′ are each independently hydrogen, hydroxy, lower alkyl or lower alkoxy;
R 1 is phenyl or heteroaryl, each of which is optionally substituted by one or two substituents, selected from halogen, lower alkyl and lower alkoxy; R 2 and R 2′ are each independently hydrogen, lower alkyl, hydroxy, lower alkoxy, C 3 -C 6 -cycloalkyl, or CH 2 -lower alkoxy, or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group or a ring containing —CH 2 OCH 2 —; m is 0, 1 or 2;
when m is 1,
R 3 and R 3′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group;
or R 3 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl group or a ring containing —(CH 2 ) 2 OCH 2 —;
n is 0 or 1; and
when n is 1,
R 4 and R 4′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl; or
R 4 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl group;
or when n is 0 and Y is —N(R 6 )—, then R 6 and R 2 together with the carbon atom and the nitrogen atom to which they are attached form a C 3-6 -cycloalkyl group;
or when n and m are 0, then R 2 and R 7 together with the carbon atoms to which they are attached form a C 3-6 -cycloalkyl group;
or a pharmaceutically acceptable acid addition salt, a racemic mixture, an enantiomer, an isomer, and/or a stereoisomer thereof.
[0030] The present invention provides compounds of formula I per se, their pharmaceutically acceptable salts, and mixtures of enantiomers or diastereomers or their enantiomerically or diastereomerically pure forms. The invention also provides pharmaceutical compositions containing a therapeutically effective amount of such compounds and process for the production of such compounds and compositions.
[0031] Compounds of formula I are allosteric modulators of the metabotropic glutamate receptor subtype 5 (mGluR5). They can be used in the treatment or prevention of disorders relating to allosteric modulators for the mGluR5 receptor. For example, the compounds can be used for the treatment or prevention of disorders, relating to allosteric modulators for the mGluR5 receptor, such as schizophrenia, cognition, fragile X syndrome or autism, and to pharmaceutical compositions containing the compounds of formula I. The most preferred indications are schizophrenia and cognition.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The following definitions of the general terms used in the present description apply irrespective of whether the terms in question appear alone or in combination.
[0033] As used herein, the term “lower alkyl” denotes a saturated, i.e. aliphatic hydrocarbon group including a straight or branched carbon chain with 1-4 carbon atoms. Examples for “alkyl” are methyl, ethyl, n-propyl, and isopropyl.
[0034] The term “lower alkoxy” denotes a group —O—R′ wherein R′ is lower alkyl as defined above.
[0035] The term “halogen” denotes the chlorine, fluorine, bromine, or iodine.
[0036] The term “ethynyl” denotes the group —C≡C—.
[0037] The term “cycloalkyl” denotes a saturated carbon ring, containing from 3 to 6 carbon ring atoms, for example cyclopropyl, cyclobutyl, cyclopentyl or cyclohexyl.
[0038] The term “heteroaryl” denotes a 5 or 6-membered aromatic ring, containing at least one N, O or S-heteroatom, for example pyridinyl, pyrimidinyl, pyrazolyl, pyridazinyl, imidazolyl, triazolyl, thienyl or pyrazinyl.
[0039] “Pharmaceutically acceptable,” such as pharmaceutically acceptable carrier, excipient, etc., denotes pharmacologically acceptable and substantially non-toxic to the subject to which the particular compound is administered.
[0040] The term “pharmaceutically acceptable salt” or “pharmaceutically acceptable acid addition salt” embraces salts with inorganic and organic acids, such as hydrochloric acid, nitric acid, sulfuric acid, phosphoric acid, citric acid, formic acid, fumaric acid, maleic acid, acetic acid, succinic acid, tartaric acid, methane-sulfonic acid, p-toluenesulfonic acid and the like.
[0041] “Therapeutically effective amount” denotes an amount that is effective to prevent, alleviate or ameliorate symptoms of disease or prolong the survival of the subject being treated.
[0042] One embodiment of the invention provides compounds of formula I-1
[0000]
[0000] wherein
U is ═N— or ═C(R 5 )—; V is —CH═ or —N═; W is ═CH— or ═N—;
with the proviso that only one of U, V or W is nitrogen.
R 5 is hydrogen, methyl or halogen; R 1 is phenyl or heteroaryl, each of which is optionally substituted by one or two substituents, selected from halogen, lower alkyl and lower alkoxy; R 2 and R 2′ are each independently hydrogen, lower alkyl, hydroxy, lower alkoxy, C 3 -C 6 -cycloalkyl, or CH 2 -lower alkoxy, or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group or a ring containing —CH 2 OCH 2 —; and R 3 and R 3′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group;
or R 3 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl group or a ring containing —(CH 2 ) 2 OCH 2 —;
or a pharmaceutically acceptable acid addition salt, a racemic mixture, an enantiomer, an optical isomer, and/or stereoisomer thereof.
[0052] Examples of compounds of formula I-A1 are the following:
3-(3-fluoro-5-phenylethynyl-pyridin-2-yl)-5,5-dimethyl-oxazolidin-2-one; (5RS)-5-methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; (5R or 5S)-5-methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; (5S or 5R)-5-methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; 5,5-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; 3-[5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one; 5,5-dimethyl-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-oxazolidin-2-one; (5RS)-5-tert-butyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; 6-(5-phenylethynyl-pyridin-2-yl)-4-oxa-6-aza-spiro[2.4]heptan-5-one; 7-(5-phenylethynyl-pyridin-2-yl)-5-oxa-7-aza-spiro[3.4]octan-6-one; 3-(5-phenylethynyl-pyridin-2-yl)-1-oxa-3-aza-spiro[4.4]nonan-2-one; 3-(5-phenylethynyl-pyridin-2-yl)-1-oxa-3-aza-spiro[4.5]decan-2-one; (5RS)-5-tert-butyl-5-methyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; (3aRS,6aSR)-3-(5-phenylethynyl-pyridin-2-yl)-hexahydro-cyclopentaoxazol-2-one; (3 aRS,6aSR)-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-hexahydro-cyclopentaoxazol-2-one; (3aRS,6aSR)-3-[5-(5-fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-hexahydro-cyclopentaoxazol-2-one; (RS)-4,5,5-trimethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; 4,4,5,5-tetramethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; 3-[5-(5-fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one; 5,5-dimethyl-3-(5-pyrimidin-5-ylethynyl-pyridin-2-yl)-oxazolidin-2-one; 5,5-dimethyl-3-[5-(1-methyl-1H-pyrazol-4-ylethynyl)-pyridin-2-yl]-oxazolidin-2-one; 3-[5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one; 3-[5-(3,4-difluoro-phenylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one; 3-[5-(2,5-difluoro-phenylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one; 3-[5-(6-fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one; 6-(5-pyridin-3-ylethynyl-pyridin-2-yl)-4-oxa-6-aza-spiro[2.4]heptan-5-one; (6SR,7RS)-3-(5-phenylethynyl-pyridin-2-yl)-hexahydro-benzooxazol-2-one; (3aSR,7aRS)-(3aRS,7RS)-1-(5-phenylethynyl-pyridin-2-yl)-hexahydro-pyrano[4,3-d]oxazol-2-one; and 5,5-dimethyl-3-(6-(phenylethynyl-pyridazin-3-yl)oxazolidin-2-one.
[0082] A further embodiment of the invention provides compounds of formula I-B1
[0000]
[0000] wherein
U is ═N— or ═C(R 5 )—; V is —CH═ or W is ═CH— or ═N—;
with the proviso that only one of U, V or W is nitrogen.
R 5 is hydrogen, methyl or halogen; R 1 is phenyl or heteroaryl, each of which is optionally substituted by one or two substituents, selected from halogen, lower alkyl and lower alkoxy; R 2 and R 2′ are each independently hydrogen, lower alkyl, hydroxy, lower alkoxy, C 3 -C 6 -cycloalkyl, or CH 2 -lower alkoxy, or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group or a ring containing —CH 2 OCH 2 —; R 3 and R 3′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group;
or R 3 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl group or a ring containing —(CH 2 ) 2 OCH 2 —; and
R 7 and R 7′ are each independently hydrogen, hydroxy, lower alkyl or lower alkoxy;
or a pharmaceutically acceptable acid addition salt, a racemic mixture, an enantiomer, an optical isomer, and/or stereoisomer thereof.
[0093] Specific examples of compounds of formula I-B1 are the following:
4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one; (3RS)-3-hydroxy-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one; 1-(3-fluoro-5-phenylethynyl-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one; 1-[5-(5-fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one; 4,4-dimethyl-1-(5-pyridin-3-ylethynyl-pyridin-2-yl)-pyrrolidin-2-one; 1-[5-(5-chloro-pyridin-3-ylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one; 1-[5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one; 4,4-dimethyl-1-(3-methyl-5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one; 2-(5-phenylethynyl-pyridin-2-yl)-2-aza-spiro[4.4]nonan-3-one; (RS)-3-methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one; (5R or 5S)-5-methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; (5S or 5R)-5-methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one; (RS)-1-[5-(5-chloro-pyridin-3-ylethynyl)-pyridin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one; (RS)-3-methoxy-4,4-dimethyl-1-(5-m-tolylethynyl-pyridin-2-yl)-pyrrolidin-2-one; (RS)-1-[5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one; (RS)-1-[5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one; 6-(5-phenylethynyl-pyridin-2-yl)-2-oxa-6-aza-spiro[3.4]octan-7-one; 4,4-dimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one; 5′-(3-fluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one; 5′-(3-chloro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one; 5′-(5-chloro-pyridin-3-ylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one; 5′-(4-fluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one; 5′-(2,5-difluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one; 4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one; 2-(5-phenylethynyl-pyrimidin-2-yl)-2-aza-spiro[4.4]nonan-3-one; 1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one; 1-[5-(3-chloro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one; 1-[5-(4-fluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one; 1-[5-(2,5-difluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one; (RS)-3-methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one; (5R or 5S)-5-methoxymethyl-3-(5-phenylethynyl-pyrimidin-2-yl)-oxazolidin-2-one; (5S or 5R)-5-methoxymethyl-3-(5-phenylethynyl-pyrimidin-2-yl)-oxazolidin-2-one; (RS)-1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one; (R or S)-1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one; (S or R)-1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one; (R or S)-1-[5-(2,5-difluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one; 4,4-dimethyl-1-(6-(phenylethynyl)pyridazin-3-yl)pyrrolidin-2-one; and 4,4-dimethyl-1-(5-(pyridin-3-ylethynyl)pyrazin-2-yl)pyrrolidin-2-one.
[0132] A further embodiment of the invention provides compounds of formula I-C1
[0000]
[0000] wherein
U is ═N— or ═C(R 5 )—; V is —CH═ or —N═; W is ═CH— or ═N—;
with the proviso that only one of U, V or W is nitrogen.
R 5 is hydrogen, methyl or halogen; R 6 is hydrogen or lower alkyl; R 1 is phenyl or heteroaryl, each of which is optionally substituted by one or two substituents, selected from halogen, lower alkyl and lower alkoxy; R 2 and R 2′ are each independently hydrogen, lower alkyl, hydroxy, lower alkoxy, C 3 -C 6 -cycloalkyl, or CH 2 -lower alkoxy, or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group or a ring containing —CH 2 OCH 2 —; and R 3 and R 3′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group;
or R 3 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl group or a ring containing —(CH 2 ) 2 OCH 2 —;
or R 6 and R 2 together with the carbon atom and the nitrogen atom to which they are attached form a C 3-6 -cycloalkyl;
or a pharmaceutically acceptable acid addition salt, a racemic mixture, an enantiomer, an optical isomer and/or stereoisomer thereof.
[0144] Examples of compounds of formula I-C1 are the following:
4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one; 3,4,4-trimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one; 3-ethyl-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one; 3-isopropyl-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one; 1-methyl-3-(5-phenylethynyl-pyridin-2-yl)-1,3-diaza-spiro[4.4]nonan-2-one; (RS)-4-cyclopentyl-3-methyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one; 3,4,4-trimethyl-1-(5-pyridin-3-ylethynyl-pyridin-2-yl)-imidazolidin-2-one; 1-[5-(5-fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 3,4,4-trimethyl-1-[5-(1-methyl-1H-pyrazol-4-ylethynyl)-pyridin-2-yl]-imidazolidin-2-one; 1-[5-(5-chloro-pyridin-3-ylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 3,4,4-trimethyl-1-(5-pyridazin-4-ylethynyl-pyridin-2-yl)-imidazolidin-2-one; 1-[5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 1-[5-(3-chloro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 3,4,4-trimethyl-1-(5-pyrimidin-5-ylethynyl-pyridin-2-yl)-imidazolidin-2-one; 3,4,4-trimethyl-1-(5-m-tolylethynyl-pyridin-2-yl)-imidazolidin-2-one; 1-[5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; (RS)-2-(5-phenylethynyl-pyridin-2-yl)-hexahydro-imidazo[1,5-a]pyridin-3-one; (RS)-2-(5-pyridin-3-ylethynyl-pyridin-2-yl)-hexahydro-imidazo[1,5-a]pyridin-3-one; (RS)-2-[5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-hexahydro-imidazo[1,5-a]pyridin-3-one; (RS)-4-cyclopropyl-3-methyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one; (3aSR,7aRS)-(3aRS,7RS)-1-methyl-3-(5-phenylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one; (3aSR,7aRS)-(3aRS,7RS)-1-methyl-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one; (3aSR,7aRS)-(3 aRS,7RS)-1-[5-(5-fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-3-methyl-octahydro-benzoimidazol-2-one; 4-methyl-6-(5-phenylethynyl-pyridin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one; (3aSR,7aRS)-(3aRS,7RS)-1-ethyl-3-(5-phenylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one; (3aSR,7aRS)-(3aRS,7RS)-1-ethyl-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one; (3aSR,7aRS)-(3 aRS,7RS)-1-isopropyl-3-(5-phenylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one; (3 aRS,6aSR)-1-methyl-3-(5-(phenylethynyl)pyridin-2-yl)hexahydrocyclopenta[d]imidazol-2(1H)-one; (RS)-4-tert-butyl-3-methyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one; 1-[5-(3-fluoro-phenylethynyl)-3-methyl-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; (3 aSR,6aRS)-1-[5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-3-methyl-hexahydro-cyclopenta-imidazol-2-one; 1-[3-fluoro-5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 1-[3-fluoro-5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 6-[5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-4-methyl-4,6-diaza-spiro[2.4]heptan-5-one; 6-[5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-4-methyl-4,6-diaza-spiro[2.4]heptan-5-one; 3,4,4-trimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-imidazolidin-2-one; 1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 1-[5-(2,5-difluoro-phenylethynyl)-pyrimidin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 1-[5-(4-fluoro-phenylethynyl)-pyrimidin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 1-[5-(3,4-di-fluoro-phenylethynyl)-pyrimidin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one; 3-isopropyl-4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-imidazolidin-2-one; 1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-3-isopropyl-4,4-dimethyl-imidazolidin-2-one; 1-[5-(4-fluoro-phenylethynyl)-pyrimidin-2-yl]-3-isopropyl-4,4-dimethyl-imidazolidin-2-one; 1-[5-(4-fluoro-phenylethynyl)-pyrimidin-2-yl]-3-ethyl-4,4-dimethyl-imidazolidin-2-one; 1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-3-ethyl-4,4-dimethyl-imidazolidin-2-one; 4-methyl-6-(5-phenylethynyl-pyrimidin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one; 3,4,4-trimethyl-1-(6-(m-tolylethynyl)pyridazin-3-yl)imidazolidin-2-one; 1-(6-((3-chlorophenyl)ethynyl)pyridazin-3-yl)-3,4,4-trimethylimidazolidin-2-one; 3,4,4-trimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)imidazolidin-2-one; 3,4,4-trimethyl-1-(5-(pyridin-3-ylethynyl)pyrazin-2-yl)imidazolidin-2-one; 1-(5-((3-fluorophenyl)ethynyl)pyrazin-2-yl)-3,4,4-trimethylimidazolidin-2-one; 1-(5-((4-fluorophenyl)ethynyl)pyrazin-2-yl)-3,4,4-trimethylimidazolidin-2-one; (3aRS,6aSR)-1-methyl-3-(6-phenylethynyl-pyridazin-3-yl)-hexahydro-cyclopentaimidazol-2-one; and (3aSR,6aRS)-1-[6-(3-fluoro-phenylethynyl)-pyridazin-3-yl]-3-methyl-hexahydro-cyclopentaimidazol-2-one.
[0199] A further embodiment of the invention provides compounds of formula I-D1
[0000]
[0000] wherein
U is ═N— or ═C(R 5 )—; V is —CH═ or —N═; W is ═CH— or ═N—;
with the proviso that only one of U, V or W is nitrogen.
R 5 is hydrogen, methyl or halogen; R 1 is phenyl or heteroaryl, each of which is optionally substituted by one or two substituents, selected from halogen, lower alkyl and lower alkoxy; R 2 and R 2′ are each independently hydrogen, lower alkyl, hydroxy, lower alkoxy, C 3 -C 6 -cycloalkyl, or CH 2 -lower alkoxy, or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group or a ring containing —CH 2 OCH 2 —; R 3 and R 3′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group;
or R 3 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl group or a ring containing —(CH 2 ) 2 OCH 2 —; and
R 4 and R 4′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached from a C 3 -C 6 -cycloalkyl; R 4 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl;
or a pharmaceutically acceptable acid addition salt, a racemic mixture, an enantiomer, an optical isomer and/or stereoisomer thereof.
[0211] Examples of compounds of formula I-D1 are the following:
5,5-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one; 6,6-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one; 6,6-dimethyl-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one; 3-[5-(5-fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one; 3-[5-(5-chloro-pyridin-3-ylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one; 3-[5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one; 3-[5-(3-chloro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one; 6,6-dimethyl-3-(5-m-tolylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one; 3-[5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one; 3-[5-(3,4-difluoro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one; 3-[5-(2,5-difluoro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one; 7,7-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazepan-2-one; (RS)-5-hydroxy-6,6-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one; (4aRS,7aSR)-3-(5-phenylethynyl-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one; (4aRS,7aRS)-3-(5-phenylethynyl-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one; (RS)-5,6,6-trimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one; (RS)-6-methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one; (RS)-5-methoxy-6,6-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one; (RS)-5,6,6-trimethyl-3-(5-phenylethynyl-pyrimidin-2-yl)-[1,3]oxazinan-2-one; (RS)-3-[5-(2,5-difluoro-phenylethynyl)-pyrimidin-2-yl]-5,6,6-trimethyl-[1,3]oxazinan-2-one; (RS)-3-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-5,6,6-trimethyl-[1,3]oxazinan-2-one; (RS)-3-[5-(4-fluoro-phenylethynyl)-pyrimidin-2-yl]-5,6,6-trimethyl-[1,3]oxazinan-2-one; 6,6-dimethyl-3-(6-(phenylethynyl)pyridazin-3-yl)-1,3-oxazinan-2-one; 6,6-dimethyl-3-(5-(phenylethynyl)pyrazin-2-yl)-1,3-oxazinan-2-one; and (RS)-3-[5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-5-methoxy-6,6-dimethyl-[1,3]oxazinan-2-one.
[0237] A further embodiment of the invention provides compounds of formula I-E1
[0000]
[0000] wherein
U is ═N— or ═C(R 5 )—; V is —CH═ or —N═; W is ═CH— or ═N—;
with the proviso that only one of U, V or W is nitrogen.
R 5 is hydrogen, methyl or halogen; R 7 and R 7′ are each independently hydrogen, hydroxy, lower alkyl or lower alkoxy; R 1 is phenyl or heteroaryl, each of which is optionally substituted by one or two substituents, selected from halogen, lower alkyl and lower alkoxy; R 2 and R 2′ are each independently hydrogen, lower alkyl, hydroxy, lower alkoxy, C 3 -C 6 -cycloalkyl, or CH 2 -lower alkoxy, or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group or a ring containing —CH 2 OCH 2 —; R 3 and R 3′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group;
or R 3 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl group or a ring containing —(CH 2 ) 2 OCH 2 —; and
R 4 and R 4′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group; R 4 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl group;
or a pharmaceutically acceptable acid addition salt, a racemic mixture, an enantiomer, an optical isomer and/or stereoisomer thereof.
[0250] Specific examples of compounds of formula I-E1 are the following:
5,5-dimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one; 5′-(3-fluoro-phenylethynyl)-5,5-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one; 5,5-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-piperidin-2-one; 4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-piperidin-2-one; 1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-piperidin-2-one; 1-[5-(2,5-difluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-piperidin-2-one; 4,4-dimethyl-1-(6-(phenylethynyl)pyridazin-3-yl)piperidin-2-one; 1-(5-((3-fluorophenyl)ethynyl)pyrazin-2-yl)-4,4-dimethylpiperidin-2-one; 4,4-dimethyl-1-(5-(pyridin-3-ylethynyl)pyrazin-2-yl)piperidin-2-one; and 4,4-dimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)piperidin-2-one.
[0261] A further embodiment of the invention provides compounds of formula I-F1
[0000]
[0000] wherein
U is ═N— or ═C(R 5 )—; V is —CH═ or —N═; W is ═CH— or ═N—;
with the proviso that only one of U, V or W is nitrogen.
R 5 is hydrogen, methyl or halogen; R 6 is hydrogen or lower alkyl; R 1 is phenyl or heteroaryl, each of which is optionally substituted by one or two substituents, selected from halogen, lower alkyl and lower alkoxy; R 2 and R 2′ are each independently hydrogen, lower alkyl, hydroxy, lower alkoxy, C 3 -C 6 -cycloalkyl, or CH 2 -lower alkoxy, or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group or a ring containing —CH 2 OCH 2 —; R 3 and R 3′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group;
or R 3 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl group or a ring containing —(CH 2 ) 2 OCH 2 —; and
R 4 and R 4′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group; or R 4 and R 2 together with the carbon atom to which they are attached form a C 3-6 -cycloalkyl;
or a pharmaceutically acceptable acid addition salt, a racemic mixture, an enantiomer, an optical isomer and/or stereoisomer thereof.
[0274] Examples of compounds of formula I-F1 are the following:
5,5-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one; 1,5,5-trimethyl-3-(5-phenylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one; 3,4,4-trimethyl-1-(5-phenylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one; 1-[5-(2,5-difluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-tetrahydro-pyrimidin-2-one; 1-[5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-tetrahydro-pyrimidin-2-one; 3,4,4-trimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one; 5′-(3-fluoro-phenylethynyl)-3,4,4-trimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one; 5′-(2,5-difluoro-phenylethynyl)-3,4,4-trimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one; 4,4-dimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)tetrahydropyrimidin-2(1H)-one; 3,4,4-trimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)tetrahydropyrimidin-2(1H)-one; 1-(5-((3-fluorophenyl)ethynyl)pyrazin-2-yl)-4,4-dimethyltetrahydropyrimidin-2(1H)-one; and 1-(5-((3-fluorophenyl)ethynyl)pyrazin-2-yl)-3,4,4-trimethyltetrahydropyrimidin-2(1H)-one.
[0287] A further embodiment of the invention provides compounds of formula I-G1
[0000]
[0000] wherein
U is ═N— or ═C(R 5 )—; V is —CH═ or —N═; W is ═CH— or ═N—;
with the proviso that only one of U, V or W is nitrogen.
R 5 is hydrogen, methyl or halogen; Y is —N(R 6 )—, —O—, —C(R 7′ )(R 7 )—, —CH 2 O— or —CH 2 S(O) 2 —;
wherein R 6 is hydrogen or lower alkyl and R 7 and R 7′ are each independently hydrogen, hydroxy, lower alkyl and lower alkoxy;
R 1 is phenyl or heteroaryl, each of which is optionally substituted by one or two substituents, selected from halogen, lower alkyl and lower alkoxy; and R 2 and R 2′ are each independently hydrogen, lower alkyl, hydroxy, lower alkoxy, C 3 -C 6 -cycloalkyl, or CH 2 -lower alkoxy, or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group or a ring containing —CH 2 OCH 2 —; or R 6 and R 2 together with the carbon atom and the nitrogen atom to which they are attached form a C 3-6 -cycloalkyl group; or R 2 and R 7 together with the carbon atoms to which they are attached form a C 3-6 -cycloalkyl group;
or a pharmaceutically acceptable acid addition salt, a racemic mixture, an enantiomer, an optical isomer and/or stereoisomer thereof.
[0299] Examples of compounds of formula I-G1 are the following:
(1RS,5SR)-6-(5-phenylethynyl-pyridin-2-yl)-6-aza-bicyclo[3.2.0]heptan-7-one; 3,3-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-azetidin-2-one; and (1RS,5SR)-6-(5-pyridin-3-ylethynyl-pyridin-2-yl)-6-aza-bicyclo[3.2.0]heptan-7-one.
[0303] The invention further provides compounds of formula I, wherein Y is —CH 2 O—, for example
(RS)-6-methyl-4-(5-phenylethynyl-pyridin-2-yl)-morpholin-3-one and 6,6-dimethyl-4-(5-phenylethynyl-pyridin-2-yl)-morpholin-3-one.
[0306] The invention further provides compounds of formula I, wherein Y is —CH 2 S(O) 2 —, for example 1,1-dioxo-4-(5-phenylethynyl-pyridin-2-yl)-thiomorpholin-3-one.
[0307] The invention also provides compounds of formula I, wherein m is 2, for example 7,7-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazepan-2-one.
[0308] The invention provides ethynyl compounds of formula Ia
[0000]
[0000] wherein
X is N or C—R 5 ,
wherein R 5 is hydrogen or halogen;
Y is N—R 6 , O or CHR 7 ,
wherein R 6 is hydrogen or lower alkyl and R 7 is hydrogen, hydroxy, lower alkyl or lower alkoxy;
R 1 is phenyl or heteroaryl, each of which is optionally substituted by halogen, lower alkyl or lower alkoxy; R 2 and R 2′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group; m is 0 or 1; when m is 1, R 3 and R 3′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group; and n is 0 or 1; when n is 1, R 4 and R 4′ are each independently hydrogen, lower alkyl, or CH 2 -lower alkoxy or together with the carbon atom to which they are attached form a C 3 -C 6 -cycloalkyl group; or when m is 1 and n is 0, R 3 and R 2 together with the carbon atoms to which they are attached form a C 3-6 -cycloalkyl group; or when m is 0 and m is 1, R 4 and R 2 together with the carbon atoms to which they are attached form a C 3-6 -cycloalkyl group;
or a pharmaceutically acceptable acid addition salt, racemic mixture, an enantiomer, an optical isomer, and/or stereoisomer thereof.
[0321] The preparation of compounds of formula I of the present invention can be carried out in sequential or convergent synthetic routes. Syntheses of the compounds of the invention are shown in the following schemes 1 to 3. The skills required for carrying out the reaction and purification of the resulting products are known to those skilled in the art. The substituents and indices used in the following description of the processes have the significance given herein before.
[0322] The compounds of formula I can be manufactured by the methods given below, by the methods given in the examples or by analogous methods. Appropriate reaction conditions for the individual reaction steps are known to a person skilled in the art. The reaction sequence is not limited to the one displayed in the schemes, however, depending on the starting materials and their respective reactivity the sequence of reaction steps can be freely altered. Starting materials are either commercially available or can be prepared by methods analogous to the methods given below, by methods described in references cited in the description or in the examples, or by methods known in the art.
[0323] The present compounds of formula I and their pharmaceutically acceptable salts can be prepared by methods, known in the art, for example by the process variant described below, which process comprises reacting a compound of formula
[0000]
[0000] wherein X is a suitable leaving group which can be substituted by an acetylene moiety such as, for example a bromine or iodine atom, a trialkylstannyl group, a boronic acid or boronic ester group with a suitable aryl-acetylene of formula
[0000]
[0000] to obtain a compound of formula
[0000]
[0000] wherein the substituents are described above, or
if desired, converting the compounds obtained into pharmaceutically acceptable acid addition salts.
[0324] The preparation of compounds of formula I is further described in more detail in schemes 1 to 6 and in examples 1-174.
[0000]
[0325] A ethynyl-pyridine, ethynyl-pyrimidine, ethynyl-pyrazine or ethynyl-pyridazine compound of formula I-A can be obtained by substitution of an appropriate 5-iodo-2-fluoro-pyridine, 5-iodo-2-fluoro-pyrimidine, 2-chloro-5-iodopyridazine or 2-bromo-5-iodopyrazine 1 or the like and an appropriate aminoalcohol 2 with a base such as pyridine, triethylamine, or cesium carbonate in a solvent such as NMP, pyridine, or dioxane to yield the corresponding 5-iodo-2-aminoalkoxy- adducts of formula 3, which are treated with phosgene or a phosgene equivalent such as triphosgene in presence of base such as pyridine in a solvent like dichloromethane to give the corresponding cyclized urethane- or urea-derivatives 4. Sonogashira coupling of the iodo-heteroaryl derivatives 4 with an appropriately substituted arylacetylene 5 yield the desired ethynyl compounds of general formula I-A or I-D (scheme 1).
[0000]
[0326] An ethynyl-pyridine, ethynyl-pyrimidine, ethynyl-pyrazine or ethynyl-pyridazine compound of formula I-B can be obtained by reacting an appropriate 5-iodo-2-amino-pyridine- or 5-iodo-2-amino-pyrimidine-, 5-iodo-2-amino-pyrazine, or 5-iodo-2-amino-pyridazine derivative 6 or the like with an appropriately substituted anhydride 7 in a solvent such as DMF to yield the corresponding imide derivative 8, which is reduced with a reducing agent such as sodium borohydride in a solvent such as THF and/or MeOH to give the corresponding alcohol derivative 9. Reacting compound 9 with trifluoroacetic anhydride in a solvent like dichloromethane followed by reduction with triethylsilane in a solvent like TFA yields the desired amide 10. Sonogashira coupling of the amide 10 with an appropriately substituted aryl-acetylene 5 yields the desired ethynyl-compounds of formula I-B or I-E (scheme 2).
[0000]
[0327] An ethynyl-pyridine, ethynyl-pyrimidine, ethynyl-pyrazine or ethynyl-pyridazine compound of formula I-C can be obtained by substitution of an appropriate 5-iodo-2-fluoro-pyridine, 5-iodo-2-fluoro-pyrimidine, 2-chloro-5-iodopyridazine or 2-bromo-5-iodopyrazine 1 or the like (1) wherein Y is a suitable leaving group which can be displaced via nucleophillic substitution by an amine such as a fluorine, chlorine, or bromine atom or an alkysulfonyl group with an appropriate diaminoalkyl derivative 11 in presence of a base such as pyridine or cesium carbonate in a solvent like NMP, pyridine, or dioxane to yield the corresponding N-heteroaryl derivative 12, which is cyclized with phosgene or a phosgene equivalent in presence of a base such as pyridine or triethylamine in a solvent like dichloromethane or THF to give the corresponding urea derivative 13 which is then coupled with an appropriately substituted aryl-acetylene 5 to yield the desired ethynyl-compound of formula I-C or I-F (scheme 3).
[0000]
[0328] An ethynyl-pyridine or ethynyl-pyrimidine compound of formula I can be obtained for example by Sonogashira coupling of a 2-bromo-5-iodo-pyridine, 2-bromo-5-iodo-pyrimidine, 2-bromo-5-iodopyridazine or 2-bromo-5-iodopyrazine 1 or the like with ethynyltrimethylsilane 15 to yield the 2-bromo-5-trimethylsilanylethynyl-substituted heteroaryl derivatives 16. Substitution of 16 with an appropriate lactam, cyclic carbamate or cyclic urea derivative 17 in presence of a base such as cesium carbonate, or using xantphos and Pd 2 (dba) 3 in a solvent like toluene yields the corresponding 5-trimethylsilanylethynyl derivatives 18. Sonogashira coupling with in-situ desilylation of 18 in presence of fluoride and an appropriately substituted aryl-halogenide 19 yields the desired arylethynyl- compounds of formula I (scheme 4).
[0000]
[0329] An arylethynyl compound of formula I can be obtained by Sonogashira coupling of a 5-bromo- or 5-iodo-heteroaryl derivative 4, 10 or 13 (where Y=Br, I) with ethynyltrimethylsilane 15 to yield the corresponding 5-trimethylsilanylethynyl- derivatives 18. Sonogashira coupling with in-situ desilylation of 18 and an appropriately substituted aryl-halogenide 19 yields the desired ethynyl-pyridine or ethynyl-pyrimidine compounds of formula I (scheme 5).
[0330] Generally speaking, the sequence of steps used to synthesize the compounds of formula I can also be modified in certain cases, for example by first running the Sonogashira coupling with an appropriately substituted aryl- or heteroaryl-ethynyl derivative followed by the introduction of a lactam-, cyclic carbamate- or cyclic urea using procedures similar to those described in schemes 1 to 4. (scheme 6)
[0000]
[0331] The compound of formula I as described herein as well as its pharmaceutically acceptable salt is used in the treatment or prevention of psychosis, epilepsy, schizophrenia, Alzheimer's disease, cognitive disorders and memory deficits, chronic and acute pain, restricted brain function caused by bypass operations or transplants, poor blood supply to the brain, spinal cord injuries, head injuries, hypoxia caused by pregnancy, cardiac arrest and hypoglycaemia, ischemia, Huntington's chorea, amyotrophic lateral sclerosis (ALS), dementia caused by AIDS, eye injuries, retinopathy, idiopathic parkinsonism or parkinsonism caused by medicaments, muscle spasms, convulsions, migraine, urinary incontinence, gastrointestinal reflux disorder, liver damage or failure whether drug or disease induced, Fragile-X syndrome, Down syndrome, autism, nicotine addiction, opiate addiction, anxiety, vomiting, dyskinesia, eating disorders, in particular bulimia or anorexia nervosa, and depressions, particularly for the treatment and prevention of acute and/or chronic neurological disorders, anxiety, the treatment of chronic and acute pain, urinary incontinence and obesity.
[0332] The preferred indications are schizophrenia and cognitive disorders.
[0333] Present invention further relates to the use of a compound of formula I as described herein, as well as its pharmaceutically acceptable salt, for the manufacture of a medicament, preferably for the treatment and prevention of the above-mentioned disorders.
Biological Assay and Data
Intracellular Ca + Mobilization Assay
[0334] A monoclonal HEK-293 cell line stably transfected with a cDNA encoding for the human mGlu5a receptor was generated; for the work with mGlu5 Positive Allosteric Modulators (PAMs), a cell line with low receptor expression levels and low constitutive receptor activity was selected to allow the differentiation of agonistic versus PAM activity. Cells were cultured according to standard protocols (Freshney, 2000) in Dulbecco's Modified Eagle Medium with high glucose supplemented with 1 mM glutamine, 10% (vol/vol) heat-inactivated bovine calf serum, Penicillin/Streptomycin, 50 μg/ml hygromycin and 15 μg/ml blasticidin (all cell culture reagents and antibiotics from Invitrogen, Basel, Switzerland).
[0335] About 24 hrs before an experiment, 5×10 4 cells/well were seeded in poly-D-lysine coated, black/clear-bottomed 96-well plates. The cells were loaded with 2.5 μM Fluo-4AM in loading buffer (1×HBSS, 20 mM HEPES) for 1 hr at 37° C. and washed five times with loading buffer. The cells were transferred into a Functional Drug Screening System 7000 (Hamamatsu, Paris, France), and 11 half logarithmic serial dilutions of test compound at 37° C. were added and the cells were incubated for 10-30 min. with on-line recording of fluorescence. Following this pre-incubation step, the agonist L-glutamate was added to the cells at a concentration corresponding to EC 20 (typically around 80 μM) with on-line recording of fluorescence; in order to account for day-to-day variations in the responsiveness of cells, the EC 20 of glutamate was determined immediately ahead of each experiment by recording of a full dose-response curve of glutamate.
[0336] Responses were measured as peak increase in fluorescence minus basal (i.e. fluorescence without addition of L-glutamate), normalized to the maximal stimulatory effect obtained with saturating concentrations of L-glutamate. Graphs were plotted with the % maximal stimulatory using XLfit, a curve fitting program that iteratively plots the data using Levenburg Marquardt algorithm. The single site competition analysis equation used was y=A+((B−A)/(1+((x/C)D))), where y is the % maximal stimulatory effect, A is the minimum y, B is the maximum y, C is the EC 50 , x is the log 10 of the concentration of the competing compound and D is the slope of the curve (the Hill Coefficient). From these curves the EC 50 (concentration at which half maximal stimulation was achieved), the Hill coefficient as well as the maximal response in % of the maximal stimulatory effect obtained with saturating concentrations of L-glutamate were calculated.
[0337] Positive signals obtained during the pre-incubation with the PAM test compounds (i.e. before application of an EC 20 concentration of L-glutamate) were indicative of an agonistic activity, the absence of such signals were demonstrating the lack of agonistic activities. A depression of the signal observed after addition of the EC 20 concentration of L-glutamate was indicative of an inhibitory activity of the test compound.
[0338] In the list of examples below are shown the corresponding results for compounds which all have
EC 50 <300 nM.
[0339] The compounds of formula (I) and pharmaceutically acceptable salts thereof can be used as medicaments, e.g. in the form of pharmaceutical compositions. The pharmaceutical compositions can be administered orally, e.g. in the form of tablets, coated tablets, dragées, hard and soft gelatin capsules, solutions, emulsions or suspensions. However, the administration can also be effected rectally, e.g. in the form of suppositories, or parenterally, e.g. in the form of injectable solutions.
[0340] The present invention also provides pharmaceutical compositions containing compounds of the invention, for example, compounds of formula I or pharmaceutically acceptable salts thereof and a pharmaceutically acceptable carrier. Such pharmaceutical compositions can be in the form of tablets, coated tablets, dragées, hard and soft gelatin capsules, solutions, emulsions or suspensions. The pharmaceutical compositions also can be in the form of suppositories or injectable solutions.
[0341] The pharmaceutical compositions of the invention, in addition to one or more compounds of the invention, contain a pharmaceutically acceptable carrier. Suitable pharmaceutically acceptable carriers include pharmaceutically inert, inorganic or organic carriers. lactose, corn starch or derivatives thereof, talc, stearic acid or its salts and the like, for example, as such carriers for tablets, coated tablets, dragées and hard gelatin capsules. Suitable carriers for soft gelatin capsules are, for example, vegetable oils, waxes, fats, semi-solid and liquid polyols and the like; depending on the nature of the active substance no carriers are, however, usually required in the case of soft gelatin capsules. Suitable carriers for the production of solutions and syrups are, for example, water, polyols, sucrose, invert sugar, glucose and the like. Adjuvants, such as alcohols, polyols, glycerol, vegetable oils and the like, can be used for aqueous injection solutions of water-soluble salts of compounds of formula (I), but as a rule are not necessary. Suitable carriers for suppositories are, for example, natural or hardened oils, waxes, fats, semi-liquid or liquid polyols and the like.
[0342] In addition, the pharmaceutical compositions can contain preservatives, solubilizers, stabilizers, wetting agents, emulsifiers, sweeteners, colorants, flavorants, salts for varying the osmotic pressure, buffers, masking agents or antioxidants. They can also contain still other therapeutically valuable substances.
[0343] As mentioned earlier, medicaments containing a compound of formula (I) or pharmaceutically acceptable salts thereof and a therapeutically inert excipient are also an object of the present invention, as is a process for the production of such compositions which comprises bringing one or more compounds of formula I or pharmaceutically acceptable salts thereof and, if desired, one or more other therapeutically valuable substances into a galenical dosage form together with one or more therapeutically inert carriers.
[0344] As further mentioned earlier, the use of the compounds of formula (I) for the preparation of pharmaceutical compositions useful in the prevention and/or the treatment of the above-recited diseases is also an aspect of the present invention.
[0345] The dosage at which compounds of the invention can be administered can vary within wide limits and will, of course, be fitted to the individual requirements in each particular case. In general, the effective dosage for oral or parenteral administration is between 0.01-20 mg/kg/day, with a dosage of 0.1-10 mg/kg/day being preferred for all of the indications described. The daily dosage for an adult human being weighing 70 kg accordingly lies between 0.7-1400 mg per day, preferably between 7 and 700 mg per day.
Preparation of Pharmaceutical Compositions Comprising Compounds of the Invention:
[0346] Tablets of the following composition are produced in a conventional manner:
[0000]
mg/Tablet
Active ingredient
100
Powdered. lactose
95
White corn starch
35
Polyvinylpyrrolidone
8
Na carboxymethylstarch
10
Magnesium stearate
2
Tablet weight
250
List of Examples:
[0347]
[0000]
EC 50 (nM)
Ex.
Structure
Name
mG1u5PAM
Eff. (%)
1
3-(3-Fluoro-5- phenylethynyl-pyridin- 2-yl)-5,5-dimethyl- oxazolidin-2-one
30
68
2
(5RS)-5- Methoxymethyl-3-(5- phenylethynyl-pyridin- 2-yl)-oxazolidin-2-one
47
34
3
OR
(5R or 5S)-5- Methoxymethyl-3-(5- phenylethynyl-pyridin- 2-yl)-oxazolidin-2-one
18
46
4
OR
(5S or 5R)-5- Methoxymethyl-3-(5- phenylethynyl-pyridin2- yl)-oxazolidin-2-
278
98
5
5,5-Dimethyl-3-(5- phenylethynyl-pyridin- 2-yl)-oxazolidin-2-one
7
77
6
3-[5-(3-Fluoro- phenylethynyl)-pyridin- 2-yl]-5,5-dimethyl- oxazolidin-2-one
9
46
7
5,5-Dimethyl-3-(5- pyridin-3-ylethynyl- pyridin-2-yl)- oxazolidin-2-one
33
39
8
(5RS)-5-tert-Butyl-3- (5-phenylethynyl- pyridin-2-yl)- oxazolidin-2-one
17
62
9
6-(5-Phenylethynyl- pyridin-2-yl)-4-oxa-6- aza-spiro [2.4]heptan-5- one
15
83
10
7-(5-Phenylethynyl- pyridin-2-yl)-5-oxa-7- aza-spiro [3.4]octan-6- one
25
109
11
3-(5-Phenylethynyl- pyridin-2-yl)-1-oxa-3- aza-spiro[4.4]nonan-2- one
39
52
12
3 -(5-Phenylethynyl- pyridin-2-yl)-1-oxa-3- aza-spiro[4.5]decan-2- one
67
80
13
4,4-Dimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-pyrrolidin-2-one
37
129
14
(3RS)-3-Hydroxy-4,4- dimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-pyrrolidin-2-one
388
114
15
4,4-Dimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-imidazolidin-2- one
130
101
16
3,4,4-Trimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-imidazolidin-2- one
35
103
17
3-Ethyl-4,4-dimethyl-1- (5-phenylethynyl- pyridin-2-yl)- imidazolidin-2-one
66
103
18
3-Isopropyl-4,4- dimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-imidazolidin-2- one
39
133
19
(5RS)-5-tert-Butyl-5- methyl-3-(5- phenylethynyl-pyridin- 2-yl)-oxazolidin-2-one
27
85
20
5,5-Dimethyl-3-(5- phenylethynyl-pyridin- 2-yl)-[1,3]oxazinan-2- one
27
135
21
1-(3-Fluoro-5- phenylethynyl-pyridin- 2-yl)-4,4-dimethyl- pyrrolidin-2-one
30
128
22
(3aRS,6aSR)-3-(5- Phenylethynyl-pyridin- 2-yl)-hexahydro- cyclopentaoxazol-2-one
14
74
23
(3aRS,6aSR)-3-(5- Pyridin-3-ylethynyl- pyridin-2-yl)- hexahydro- cyclopentaoxazol-2-one
12
92
24
(3aRS,6aSR)-3-[5-(5- Fluoro-pyridin-3- ylethynyl)-pyridin-2- yl]-hexahydro- cyclopentaoxazol-2-one
35
73
25
5,5-Dimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-tetrahydro- pyrimidin-2-one
69
148
26
1,5,5-Trimethyl-3-(5- phenylethynyl-pyridin- 2-yl)-tetrahydro- pyrimidin-2-one
33
131
27
(RS)-4,5,5-Trimethyl-3- (5-phenylethynyl- pyridin-2-yl)- oxazolidin-2-one
15
61
28
4,4,5,5-Tetramethyl-3- (5-phenylethynyl- pyridin-2-yl)- oxazolidin-2-one
48
31
29
3-[5-(5-Fluoro-pyridin- 3 -ylethynyl)-pyridin-2- yl] -5,5-dimethyl- oxazolidin-2-one
15
45
30
5,5-Dimethyl-3-(5- pymidin-5-ylethynyl- pyridin-2-yl)- oxazolidin-2-one
80
43
31
5,5-Dimethyl-3-[5-(1- methyl-1H-pyrazol-4- ylethynyl)-pyridin-2- yl]-oxazolidin-2-one
26
55
32
3-[5-(4-Fluoro- phenylethynyl)-pyridin- 2-yl]-5 ,5-dimethyl- oxazolidin-2-one
19
60
33
3-[5-(3,4-Difluoro- phenylethynyl)-pyridin- 2-yl]-5,5-dimethyl- oxazolidin-2-one
32
44
34
3-[5-(2,5-Difluoro- phenylethynyl)-pyridin- 2-yl]-5,5-dimethyl- oxazolidin-2-one
11
38
35
3-[5-(6-Fluoro-pyridin- 3-ylethynyl)-pyridin-2- yl]-5,5-dimethyl- oxazolidin-2-one
54
52
36
6-(5-Pyridin-3- ylethynyl-pyridin-2-yl)- 4-oxa-6-aza- spiro[2.4]heptan-5-one
58
80
37
1-[5-(5-Fluoro-pyridin- 3-ylethynyl)-pyridin-2- yl]-4,4-dimethyl- pyrrolidin-2-one
22
96
38
4,4-Dimethyl-1-(5- pyridin-3-ylethynyl- pyridin-2-yl)- pyrrolidin-2-one
33
147
39
1-[5-(5-Chloro-pyridin- 3-ylethynyl)-pyridin-2- yl]-4,4-dimethyl- pyrrolidin-2-one
48
98
40
1-[5-(3-Fluoro- phenylethynyl)-pyridin- 2-yl] -4,4-dimethyl- pyrrolidin-2-one
15
100
41
4,4-Dimethyl-1-(3- methyl-5- phenylethynyl-pyridin- 2-yl)-pyrro lidin-2-one
58
89
42
5,5-Dimethyl-5′- phenylethynyl-3,4,5,6- tetrahydro- [1,2′]bipyridinyl-2-one
16
139
43
5′-(3-Fluoro- phenylethynyl)-5,5- dimethyl-3,4,5,6- tetrahydro- [1,2′]bipyridinyl-2-one
12
100
44
1 -Methyl-3-(5- phenylethynyl-pyridin- 2-yl)-1,3 -diaza- spiro[4.4]nonan-2-one
29
92
45
(RS)-4-Cyclopentyl-3- methyl-1-(5- phenylethynyl-pyridin- 2-yl)-imidazolidin-2- one
57
97
46
(1RS,5SR)-6-(5- Phenylethynyl-pyridin- 2-yl)-6-aza- bicyclo[3.2.0]heptan-7- one
26
27
47
(6SR,7RS)-3-(5- Phenylethynyl-pyridin- 2-yl)-hexahydro- benzooxazol-2-one
36
109
48
3,4,4-Trimethyl-1-(5- pyridin-3-ylethynyl- pyridin-2-yl)- imidazolidin-2-one
14
89
49
1-[5-(5-Fluoro-pyridin- 3-ylethynyl)-pyridin- 2-yl]-3,4,4-trimethyl- imidazolidin-2-one
37
91
50
3,4,4-Trimethyl-1-[5- (1-methyl-1H-pyrazol- 4-ylethynyl)-pyridin-2- yl]-imidazolidin-2-one
27
41
51
1-[5-(5-Chloro-pyridin- 3-ylethynyl)-pyridin-2- yl]-3,4,4-trimethyl- imidazolidin-2-one
29
45
52
3,4,4-Trimethyl-1-(5- pyridazin-4-ylethynyl- pyridin-2-yl)- imidazolidin-2-one
34
32
53
1-[5-(3-Fluoro- phenylethynyl)-pyridin- 2-yl]-3,4,4-trimethyl- imidazolidin-2-one
29
103
54
1-[5-(3-Chloro- phenylethynyl)-pyridin-2- yl] -3,4,4-trimethyl- imidazolidin-2-one
32
47
55
3,4,4-Trimethyl-1-(5- pyrimidin-5-ylethynyl- pyridin-2-yl)- imidazolidin-2-one
54
110
56
3,4,4-Trimethyl-1-(5- m-tolylethynyl-pyridin- 2-yl)-imidazolidin-2- one
87
56
57
1-[5-(4-Fluoro- phenylethynyl)-pyridin- 2-yl]-3,4,4-trimethyl- imidazolidin-2-one
35
78
58
(RS)-2-(5-Phenylethynyl- pyridin-2-yl)-hexahydro- imidazo[1,5-a]pyridin-3- one
33
43
59
2-(5-Phenylethynyl- pyridin-2-yl)-2-aza- spiro[4.4]nonan-3 -one
16
81
60
(RS)-3-Methoxy-4,4- dimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-pyrrolidin-2-one
35
89
61
OR
(R or S)-3-Methoxy- 4,4-dimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-pyrrolidin-2-one
75
70
62
OR
(S or R)-3-Methoxy- 4,4-dimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-pyrrolidin-2-one
12
86
63
(RS)-1-[5-(5-Chloro- pyridin-3-ylethynyl)- pyridin-2-yl]-3- methoxy-4,4-dimethyl- pyrrolidin-2-one
70
99
64
(RS)-3-Methoxy-4,4- dimethyl-1-(5-m- tolylethynyl-pyridin-2- yl)-pyrrolidin-2-one
87
56
65
(RS)-1-[5-(3-Fluoro- phenylethynyl)-pyridin- 2-yl]-3-methoxy-4,4- dimethyl-pyrrolidin-2- one
43
91
66
(RS)-1-[5-(4-Fluoro- phenylethynyl)-pyridin- 2-yl]-3-methoxy-4,4- dimethyl-pyrrolidin-2- one
75
87
67
3,4,4-Trimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-tetrahydro- pyrimidin-2-one
15
81
68
1-[5-(2,5-Difluoro- phenylethynyl)-pyridin- 2-yl]-3,4,4-trimethyl- tetrahydro-pyrimidin-2- one
41
79
69
1-[5-(4-Fluoro- phenylethynyl)-pyridin- 2-yl]-3,4,4-trimethyl- tetrahydro-pyrimidin-2- one
49
107
70
(RS)-2-(5-Pyridin-3- ylethynyl-pyridin-2-yl)- hexahydro-imidazo[1,5- a]pyridin-3-one
74
51
71
(RS)-2-[5-(3-Fluoro- phenylethynyl)-pyridin- 2-yl]-hexahydro- imidazo[1,5-a]pyridin- 3-one
17
41
72
6,6-Dimethyl-3-(5- phenylethynyl-pyridin- 2-yl)-[1,3]oxazinan-2- one
10
86
73
6,6-Dimethyl-3-(5- pyridin-3-ylethynyl- pyridin-2-yl)- [1,3]oxazinan-2-one
59
98
74
3-[5-(5-Fluoro-pyridin- 3-ylethynyl)-pyridin-2- yl]-6,6-dimethyl- [1,3]oxazinan-2-one
59
108
75
3-[5-(5-Chloro-pyridin- 3-ylethynyl)-pyridin-2- yl]-6,6-dimethyl- [1,3]oxazinan-2-one
27
87
76
3-[5-(3-Fluoro- phenylethynyl)-pyridin- 2-yl] -6,6-dimethyl- [1,3]oxazinan-2-one
13
124
77
3-[5-(3-Chloro- phenylethynyl)-pyridin- 2-yl] -6,6-dimethyl- [1,3]oxazinan-2-one
12
72
78
6,6-Dimethyl-3-(5-m- tolylethynyl-pyridin-2- yl)-[1,3]oxazinan-2-one
24
72
79
3-[5-(4-Fluoro- phenylethynyl)-pyridin- 2-yl]-6,6-dimethyl- [1,3]oxazinan-2-one
22
85
80
3-[5-(3,4-Difluoro- phenylethynyl)-pyridin- 2-yl]-6,6-dimethyl- [1,3]oxazinan-2-one
37
69
81
3-[5-(2,5-Difluoro- phenylethynyl)-pyridin- 2-yl]-6,6-dimethyl- [1,3]oxazinan-2-one
12
95
82
6-(5-Phenylethynyl- pyridin-2-yl)-2-oxa-6- aza-spiro[3.4]octan-7- one
57
72
83
(RS)-4-Cyclopropyl-3- methyl-1-(5- phenylethynyl-pyridin- 2-yl)-imidazolidin-2- one
53
86
84
(3aSR,7aRS)- (3aRS,7RS)-1-Methyl- 3-(5-phenylethynyl- pyridin-2-yl)- octahydro- benzoimidazol-2-one
11
64
85
(3aSR,7aRS)- (3aRS,7RS)-1-Methyl- 3-(5-pyridin-3- ylethynyl-pyridin-2-yl)- octahydro- benzoimidazol-2-one
27
49
86
(3aSR,7aRS)- (3aRS,7RS)-1-[5-(5- Fluoro-pyridin-3- ylethynyl)-pyridin-2- yl]-3-methyl-octahydro- benzoimidazol-2-one
32
52
87
4,4-Dimethyl-5′- phenylethynyl-3,4,5,6- tetrahydro- [1,2′]bipyridinyl-2-one
12
89
88
5′-(3-Fluoro- phenylethynyl)-4,4- dimethyl-3,4,5,6- tetrahydro- [1,2′]bipyridinyl-2 -one
19
110
89
5′-(3-Chloro- phenylethynyl)-4,4- dimethyl-3,4,5,6- tetrahydro- [1,2′]bipyridinyl-2-one
25
78
90
5′-(5-Chloro-pyridin-3- ylethynyl)-4,4-dimethyl- 3,4,5,6-tetrahydro- [1,2′]bipyridinyl-2-one
66
90
91
5′-(4-Fluoro- phenylethynyl)-4,4- dimethyl-3,4,5,6- tetrahydro- [1,2′]bipyridinyl-2-one
67
89
92
5′-(2,5-Difluoro- phenylethynyl)-4,4- dimethyl-3,4,5,6- tetrahydro- [1,2′]bipyridinyl-2-one
32
84
93
7,7-Dimethyl-3-(5- phenylethynyl-pyridin- 2-yl)-[1,3]oxazepan-2- one
36
104
94
(3aSR,7aRS)- (3aRS,7RS)-1-(5- Phenylethynyl-pyridin- 2-yl)-hexahydro- pyrano[4,3-d]oxazol-2- one
60
84
95
(RS)-5-Hydroxy-6,6- dimethyl-3-(5- phenylethynyl-pyridin- 2-yl)-[1,3]oxazinan-2- one
47
118
96
4-Methyl-6-(5- phenylethynyl-pyridin- 2-yl)-4,6-diaza- spiro [2.4] heptan-5-one
35
98
97
3,3-Dimethyl-1-(5- phenylethynyl-pyridin- 2-yl)-azetidin-2-one
36
71
98
(1RS,5SR)-6-(5- Pyridin-3-ylethynyl- pyridin-2-yl)-6-aza- bicyclo[3.2.0]heptan-7- one
39
73
99
(3 aSR,7aRS)- (3 aRS,7RS)-1-Ethyl-3- (5-phenylethynyl- pyridin-2-yl)- octahydro- benzoimidazol-2-one
18
90
100
(3aSR,7aRS)- (3aRS,7RS)-1-Ethyl-3- (5-pyridin-3-ylethynyl- pyridin-2-yl)- octahydro- benzoimidazol-2-one
69
64
101
(3aSR,7aRS)- (3aRS,7RS)-1- Isopropyl-3-(5- phenylethynyl-pyridin- 2-yl)-octahydro- benzoimidazol-2-one
39
77
102
(4aRS,7aSR)-3-(5- Phenylethynyl-pyridin- 2-yl)-hexahydro- cyclopenta[e] [1,3]oxazin- 2-one
43
115
103
(4aRS,7aRS)-3-(5- Phenylethynyl-pyridin- 2-yl)-hexahydro- cyclopenta[e][1,3]oxazin- 2-one
27
123
104
(RS)-5,6,6-Trimethyl-3- (5-phenylethynyl- pyridin-2-yl)- [1,3]oxazinan-2-one
42
109
105
(RS)-6- Methoxymethyl-3-(5- phenylethynyl-pyridin- 2-yl)-[1,3]oxazinan-2- one
68
51
106
(3aRS,6aSR)-1-Methyl- 3-(5-(phenylethynyl) pyridin-2-yl)hexa- hydrocyclopenta[d] imidazol-2(1H)-one
30
42
107
(RS)-4-tert-Butyl-3- methyl-1-(5- phenylethynyl-pyridin- 2-yl)-imidazolidin-2- one
59
106
108
1-[5-(3-Fluoro- phenylethynyl)-3-methyl- pyridin-2-yl]-3,4,4- trimethyl-imidazolidin- 2-one
102
115
109
(3aRS, 6aSR)-1-[5-(3- Fluoro-phenylethynyl)- pyridin-2-yl]-3-methyl- hexahydro-cyclopenta- imidazol-2-one
18
37
110
1-[3-Fluoro-5-(4- fluoro-phenylethynyl)- pyridin-2-yl]-3,4,4- trimethyl-imidazolidin- 2-one
96
117
111
1-[3-Fluoro-5-(3- fluoro-phenylethynyl)- pyridin-2-yl]-3,4,4- trimethyl-imidazolidin- 2-one
32
107
112
6-[5-(4-Fluoro- phenylethynyl)-pyridin- 2-yl]-4-methyl-4,6- diaza-spiro[2.4]heptan- 5-one
80
89
113
6-[5-(3-Fluoro- phenylethynyl)-pyridin- 2-yl]-4-methyl-4,6- diaza-spiro[2.4]heptan- 5-one
51
75
114
(RS)-5-Methoxy-6,6- dimethyl-3-(5- phenylethynyl-pyridin- 2-yl)-[1,3]oxazinan-2- one
22
57
115
4,4-Dimethyl-1-(5- phenylethynyl- pyrimidin-2-yl)- pyrrolidin-2-one
13
109
116
5,5-Dimethyl-1-(5- phenylethynyl- pyrimidin-2-yl)- piperidin-2-one
41
101
117
2-(5-Phenylethynyl- pyrimidin-2-yl)-2-aza- spiro [4.4]nonan-3-one
44
84
118
1-[5-(3-Fluoro- phenylethynyl)- pyrimidin-2-yl]-4,4- dimethyl-pyrrolidin-2- one
13
78
119
1-[5-(3-Chloro- phenylethynyl)- pyrimidin-2-yl]-4,4- dimethyl-pyrrolidin-2- one
11
26
120
1-[5-(4-Fluoro- phenylethynyl)- pyrimidin-2-yl]-4,4- dimethyl-pyrrolidin-2- one
92
81
121
1-[5-(2,5-Difluoro- phenylethynyl)- pyrimidin-2-yl]-4,4- dimethyl-pyrrolidin-2- one
41
70
122
3,4,4-Trimethyl-1-(5- phenylethynyl- pyrimidin-2-yl)- imidazolidin-2-one
11
36
123
1-[5-(3-Fluoro- phenylethynyl)- pyrimidin-2-yl]-3,4,4- trimethyl-imidazolidin- 2-one
18
30
124
1-[5-(2,5-Difluoro- phenylethynyl)- pyrimidin-2-yl]-3,4,4- trimethyl-imidazolidin- 2-one
7
43
125
1-[5-(4-Fluoro- phenylethynyl)- pyrimidin-2-yl]-3,4,4- trimethyl-imidazolidin-2- one
13
44
126
1-[5-(3,4-Difluoro- phenylethynyl)- pyrimidin-2-yl]-3,4,4- trimethyl-imidazolidin- 2-one
23
36
127
(RS)-3-Methoxy-4,4- dimethyl-1-(5- phenylethynyl- pyrimidin-2-yl)- pyrrolidin-2-one
29
94
128
OR
(R or S)-3-Methoxy- 4,4-dimethyl-1-(5- phenylethynyl- pyrimidin-2-yl)- pyrrolidin-2-one
46
54
129
OR
(S or R)-3-Methoxy- 4,4-dimethyl-1-(5- phenylethynyl- pyrimidin-2-yl)- pyrrolidin-2-one
18
90
130
(RS)-1-[5-(3-Fluoro- phenylethynyl)- pyrimidin-2-yl]-3- methoxy-4,4-dimethyl- pyrrolidin-2-one
41
74
131
OR
(R or S)-1-[5-(3-Fluoro- phenylethynyl)- pyrimidin-2-yl]-3- methoxy-4,4-dimethyl- pyrrolidin-2-one
35
48
132
OR
(S or R)-1-[5-(3-Fluoro- phenylethynyl)- pyrimidin-2-yl]-3- methoxy-4,4-dimethyl- pyrrolidin-2-one
21
69
133
OR
(R or S)-1-[5-(2,5- Difluoro- phenylethynyl)- pyrimidin-2-yl]-3- methoxy-4,4-dimethyl- pyrrolidin-2-one
57
49
134
4,4-Dimethyl-1-(5- phenylethynyl- pyrimidin-2-yl)- piperidin-2-one
42
90
135
1-[5-(3-Fluoro- phenylethynyl)- pyrimidin-2-yl]-4,4- dimethyl-piperidin-2- one
35
47
136
1-[5-(2,5-Difluoro- phenylethynyl)- pyrimidin-2-yl]-4,4- dimethyl-piperidin-2- one
31
49
137
3,4,4-Trimethyl-5′- phenylethynyl-3,4,5,6- tetrahydro- [1,2′]bipyrimidinyl-2- one
66
74
138
5′-(3-Fluoro- phenylethynyl)-3,4,4- trimethyl-3,4,5,6- tetrahydro- [1,2′]bipyrimidinyl-2- one
60
67
139
5′-(2,5-Difluoro- phenylethynyl)-3,4,4- trimethyl-3,4,5,6- tetrahydro- [1,2′]bipyrimidinyl-2- one
57
54
140
3-Isopropyl-4,4- dimethyl-1-(5- phenylethynyl- pyrimidin-2-yl)- imidazolidin-2-one
28
58
141
1-[5-(3-Fluoro- phenylethynyl)- pyrimidin-2-yl]-3- isopropyl-4,4-dimethyl- imidazolidin-2-one
28
39
142
1-[5-(4-Fluoro- phenylethynyl)- pyrimidin-2-yl]-3- isopropyl-4,4-dimethyl- imidazolidin-2-one
78
74
143
1-[5-(4-Fluoro- phenylethynyl)- pyrimidin-2-yl]-3-ethyl- 4,4-dimethyl- imidazolidin-2-one
47
68
144
1-[5-(3-Fluoro- phenylethynyl)- pyrimidin-2-yl]-3-ethyl- 4,4-dimethyl- imidazolidin-2-one
31
58
145
(RS)-5,6,6-Trimethyl-3- (5-phenylethynyl- pyrimidin-2-yl)- [1,3]oxazinan-2-one
38
93
146
(RS)-3-[5-(2,5- Difluoro- phenylethynyl)- pyrimidin-2-yl]-5,6,6- trimethyl[1,3]oxazinan-2-one
69
64
147
4-Methyl-6-(5- phenylethynyl- pyrimidin-2-yl)-4,6- diaza-spiro[2.4]heptan- 5-one
25
36
148
(RS)-3-[5-(3-Fluoro- phenylethynyl)- pyrimidin-2-yl]-5,6,6- trimethyl- [1,3]oxazinan-2-one
39
75
149
(RS)-3-[5-(4-Fluoro- phenylethynyl)- pyrimidin-2-yl]-5,6,6- trimethyl- [1,3]oxazinan-2-one
114
78
150
4,4-dimethyl-1-(6- (phenylethynyl) pyridazin-3-yl) pyrrolidin-2-one
21
113
151
4,4-dimethyl-1-(6- (phenylethynyl)pyridazin- 3-yl)piperidin-2-one
19
130
152
5,5-dimethyl-3-(6- (phenylethynyl)pyridazin- 3-yl)oxazolidin-2-one
15
112
153
6,6-dimethyl-3-(6- (phenylethynyl)pyridazin- 3-yl)-1,3-oxazinan-2- one
14
86
154
3,4,4-trimethyl-1-(6- (m- tolylethynyl)pyridazin- 3-yl)imidazolidin-2-one
61
108
155
1-(6-((3- chlorophenyl)ethynyl) pyridazin-3-yl)-3,4,4- trimethylimidazolidin- 2-one
73
95
156
3,4,4-trimethyl-1-(5- (phenylethynyl)pyrazin- 2-yl)imidazolidin-2-one
24
58
157
3,4,4-trimethyl-1-(5- (pyridin-3- ylethynyl)pyrazin-2- yl)imidazolidin-2-one
206
34
158
1-(5-((3- fluorophenyl)ethynyl) pyrazin-2-yl)-3,4,4- trimethylimidazolidin- 2-one
46
36
159
1-[5-(4-Fluoro- phenylethynyl)-pyrazin- 2-yl]-3,4,4-trimethyl- imidazolidin-2-one
49
49
160
1-(5-((3- fluorophenyl)ethynyl) pyrazin-2-yl)-4,4- dimethylpyrrolidin-2- one
29
39
161
1-(5-((3- fluorophenyl)ethynyl) pyrazin-2-yl)-4,4- dimethylpiperidin-2- one
29
68
162
4,4-dimethyl-1-(5- (pyridin-3- ylethynyl)pyrazin-2- yl)piperidin-2-one
681
76
163
4,4-dimethyl-1-(5- (phenylethynyl)pyrazin- 2-yl)piperidin-2-one
69
74
164
4,4-dimethyl-1-(5- (phenylethynyl)pyrazin- 2-yl)tetrahydro- pyrimidin-2(1H)-one
329
89
165
3,4,4-trimethyl-1-(5- (phenylethynyl)pyrazin- 2-yl)tetrahydro- pyrimidin-2(1H)-one
36
55
166
1-(5-((3- fluorophenyl)ethynyl) pyrazin-2-yl)-4,4- dimethyltetrahydro- pyrimidin-2( 1H)-one
140
56
167
1-(5-((3- fluorophenyl)ethynyl) pyrazin-2-yl)-3,4,4- trimethyltetrahydro- pyrimidin-2(1H)-one
26
54
168
6,6-dimethyl-3-(5- (phenylethynyl)pyrazin- 2-yl)-1,3-oxazinan-2- one
15
41
169
(RS)-3-[5-(3-Fluoro- phenylethynyl)-pyridin- 2-yl]-5-methoxy-6,6- dimethyl- [1,3]oxazinan-2-one
13
52
170
(3aRS,6aSR)-1-Methyl- 3-(6-phenylethynyl- pyridazin-3-yl)- hexahydro- cyclopentaimidazol-2- one
13
105
171
(RS)-6-Methyl-4-(5- phenylethynyl-pyridin- 2-yl)-morpholin-3-one
88
73
172
6,6-Dimethyl-4-(5- phenylethynyl-pyridin- 2-yl)-morpholin-3-one
29
82
173
1,1-Dioxo-4-(5- phenylethynyl-pyridin- 2-yl)-thiomorpholin-3- one
29
82
174
(3aRS,6aSR)-1-[6-(3- Fluoro-phenylethynyl)- pyridazin-3-yl]-3- methyl-hexahydro- cyclopentaimidazol-2- one
12
56
EXPERIMENTAL SECTION
Example 1
3-(3-Fluoro-5-phenylethynyl-pyridin-2-yl)-5,5-dimethyl-oxazolidin-2-one
[0348]
Step 1: 1-(3-Fluoro-5-iodo-pyridin-2-ylamino)-2-methyl-propan-2-ol
[0349]
[0350] 2,3-Difluoro-5-iodopyridine (500 mg, 2.07 mmol) was dissolved in NMP (500 μL) and pyridine (201 μl, 2.49 mmol, 1.2 equiv.) and 1-amino-2-methylpropan-2-ol (555 mg, 6.22 mmol, 3 equiv.) were added at room temperature. The mixture was stirred for 16 hours at 100° C. The reaction mixture was cooled and extracted with saturated NaHCO 3 solution and two times with a small volume of dichloromethane. The crude product was purified by flash chromatography by directly loading the dichloromethane layers onto a silica gel column and eluting with an ethyl acetate:heptane gradient 0:100 to 100:0. The desired 1-(3-fluoro-5-iodopyridin-2-ylamino)-2-methylpropan-2-ol (590 mg, 1.9 mmol, 91.7% yield) was obtained as a colorless oil, MS: m/e=311.0 (M+H + ).
Step 2: 3-(3-Fluoro-5-iodopyridin-2-yl)-5,5-dimethyloxazolidin-2-one
[0351]
[0352] (580 mg, 1.87 mmol) 1-(3-Fluoro-5-iodopyridin-2-ylamino)-2-methylpropan-2-ol (Example 1, step 1) was dissolved in dichloromethane (10 ml) and pyridine (300 μL, 3.74 mmol, 2 equiv.) was added at room temperature. The mixture was cooled to 0-5° C. and phosgene (20% in toluene) (1.19 ml, 2.24 mmol, 1.2 equiv.) was added dropwise over a period of 15 min at 0-5° C. The mixture was stirred for 1 hour at 0-5° C. The reaction mixture was extracted with saturated NaHCO 3 solution and two times with a small volume of dichloromethane. The crude product was purified by flash chromatography by directly loading the dichloromethane layers onto a silica gel column and eluting with a heptane:ethyl acetate gradient 100:0 to 50:50. The desired 3-(3-fluoro-5-iodopyridin-2-yl)-5,5-dimethyloxazolidin-2-one (500 mg, 1.49 mmol, 79.5% yield) was obtained as a white solid, MS: m/e=337.0 (M+H + ).
Step 3: 3-(3-Fluoro-5-phenylethynyl-pyridin-2-yl)-5,5-dimethyl-oxazolidin-2-one
[0353]
[0354] Bis-(triphenylphosphine)-palladium(II) dichloride (12.5 mg, 17.9 μmol, 0.05 equiv.) was dissolved in 1 ml DMF. (120 mg, 357 μmol) 3-(3-Fluoro-5-iodopyridin-2-yl)-5,5-dimethyloxazolidin-2-one (Example 1, step 2) and phenylacetylene (72.9 mg, 78.4 μl, 714 μmol, 2 equiv.) were added at room temperature. Triethylamine (108 mg, 149 μl, 1.07 mmol, 3 equiv.), triphenylphosphine (2.81 mg, 10.7 μmol, 0.03 equiv.) and copper(I) iodide (2.04 mg, 10.7 μmol, 0.03 equiv.) were added and the mixture was stirred for 3 hours at 70° C. The reaction mixture was cooled and extracted with saturated NaHCO 3 solution and two times with a small volume of dichloromethane. The crude product was purified by flash chromatography by directly loading the dichloromethane layers onto a silica gel column and eluting with an ethyl acetate:heptane gradient 0:100 to 40:60. The desired 3-(3-fluoro-5-(phenylethynyl)pyridin-2-yl)-5,5-dimethyloxazolidin-2-one (96 mg, 309 μmol, 86.6% yield) was obtained as a yellow solid, MS: m/e=311.2 (M+H + ).
Example 2
(5RS)-5-Methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0355]
[0356] The title compound, a light brown solid, MS: m/e=309.1 (M+H + ), was prepared using a procedure similar to that described in Example 1, step 3 from 3-(5-bromo-pyridin-2-yl)-5-methoxymethyl-oxazolidin-2-one (CAS 170011-45-7) and phenylacetylene.
Example 3
(5R or 5S)-5-Methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0357]
[0358] The title compound, a white solid, MS: m/e=309.1 (M+H + ), was prepared by separation of (5RS)-5-methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one (Example 2) using a chiral column (chiralpak AD with heptane:isopropanol 80:20 as solvent).
Example 4
(5S or 5R)-5-Methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0359]
[0360] The title compound, a white solid, MS: m/e=309.1 (M+H + ), was prepared by separation of (5RS)-5-methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one (Example 2) using a chiral column (chiralpak AD with heptane:isopropanol 80:20 as solvent).
Example 5
5,5-Dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0361]
Step 1: 3-(5-Iodo-pyridin-2-yl)-5,5-dimethyl-oxazolidin-2-one
[0362]
[0363] The title compound was obtained as a white solid, MS: m/e=292.9 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and 1-amino-2-methylpropan-2-ol.
Step 2: 5,5-Dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0364]
[0365] The title compound was obtained as a white solid, MS: m/e=293.0 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-5,5-dimethyl-oxazolidin-2-one (Example 5, step 1) and phenylacetylene.
Example 6
3-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one
[0366]
[0367] The title compound was obtained as a white solid, MS: m/e=311.2 (M+0, using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-5,5-dimethyl-oxazolidin-2-one (Example 5, step 1) and 3-fluorophenylacetylene.
Example 7
5,5-Dimethyl-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0368]
[0369] The title compound was obtained as a white solid, MS: m/e=294.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-5,5-dimethyl-oxazolidin-2-one (Example 5, step 1) and 3-ethynyl-pyridine.
Example 8
(5RS)-5-tert-Butyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0370]
Step 1: (5RS)-5-tert-Butyl-3-(5-iodo-pyridin-2-yl)-oxazolidin-2-one
[0371]
[0372] The title compound was obtained as a white solid, MS: m/e=346.9 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and (rac)-1-amino-3,3-dimethylbutan-2-ol hydrochloride.
Step 2: (5RS)-5-tert-Butyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0373]
[0374] The title compound was obtained as a white solid, MS: m/e=321.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (5RS)-5-tert-butyl-3-(5-iodo-pyridin-2-yl)-oxazolidin-2-one (Example 8, step 1) and phenylacetylene.
Example 9
6-(5-Phenylethynyl-pyridin-2-yl)-4-oxa-6-aza-spiro[2.4]heptan-5-one
[0375]
[0376] The title compound was obtained as a colourless solid, MS: m/e=291.2 (M+H + ), using procedures similar to those described in Example 1 starting from 2-fluoro-5-bromopyridine, 1-aminomethyl-cyclopropanol ( Russian J. Org. Chem. 2001, 37, 1238) and phenylacetylene.
Example 10
7-(5-Phenylethynyl-pyridin-2-yl)-5-oxa-7-aza-spiro[3.4]octan-6-one
[0377]
[0378] The title compound was obtained as a light yellow solid, MS: m/e=305.2 (M+H + ), using procedures similar to those described in Example 1 starting from 2-fluoro-5-bromopyridine, 1-aminomethyl-cyclobutanol (WO2006/29115 A2) and phenylacetylene.
Example 11
3-(5-Phenylethynyl-pyridin-2-yl)-1-oxa-3-aza-spiro[4.4]nonan-2-one
[0379]
[0380] The title compound was obtained as a light yellow solid, MS: m/e=319.2 (M+H + ), using procedures similar to those described in Example 1 starting from 2-fluoro-5-bromopyridine, 1-aminomethyl-cyclopentanol and phenylacetylene.
Example 12
3-(5-Phenylethynyl-pyridin-2-yl)-1-oxa-3-aza-spiro[4.5]decan-2-one
[0381]
[0382] The title compound was obtained as a light yellow solid, MS: m/e=333.2 (M+H + ), using procedures similar to those described in Example 1 starting from 2-fluoro-6-bromopyridine, 1-aminomethyl-cyclohexanol and phenylacetylene.
Example 13
4,4-Dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0383]
Step 1: 1-(5-Iodo-pyridin-2-yl)-3,3-dimethyl-pyrrolidine-2,5-dione
[0384]
[0385] 5-iodopyridin-2-amine (1 g, 4.55 mmol) was dissolved in DMF (5 ml) and 3,3-dimethyldihydrofuran-2,5-dione (1.28 g, 10.0 mmol, 2.2 equiv.) was added at room temperature. The mixture was stirred for 3 hr at 150° C. The reaction mixture was evaporated to dryness and loaded directly to a silica gel column. The crude material was purified by flash chromatography on silica gel (20 gr, ethyl acetate/heptane gradient, 0:100 to 100:0). The desired 1-(5-iodopyridin-2-yl)-3,3-dimethylpyrrolidine-2,5-dione (1.3 g, 3.94 mmol, 86.6% yield) was obtained as a yellow solid, MS: m/e=331.0 (M+H + ).
Step 2: (5RS)-5-Hydroxy-1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one
[0386]
[0387] (800 mg, 2.42 mmol) 1-(5-Iodopyridin-2-yl)-3,3-dimethylpyrrolidine-2,5-dione (Example 13, step 1) was dissolved in THF (6 ml) and MeOH (2 ml) and the solution was cooled to 0-5° C. NaBH 4 (101 mg, 2.67 mmol, 1.1 equiv.) was added at 0-5° C. and the mixture was stirred for 1 hr at 0-5° C. The reaction mixture was extracted with sat. NaHCO 3 solution and two times with a small volume of dichloromethane. The crude product was purified by flash chromatography by directly loading the dichloromethane layers onto a amino-silica gel column and eluting with a ethyl acetate/heptane gradient, 0:100 to 100:0. The desired (5-RS)-5-hydroxy-1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one (370 mg, 46% yield) was obtained as a white solid, MS: m/e=333.0 (M+H + ).
Step 3: 1-(5-Iodo-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one
[0388]
[0389] (275 mg, 828 μmol) (5RS)-5-Hydroxy-1-(5-iodopyridin-2-yl)-4,4-dimethylpyrrolidin-2-one (Example 13, step 2) was dissolved in CH 2 Cl 2 (2 ml) and trifluoroacetic anhydride (140 μl, 994 μmol, 1.2 equiv.) was added at room temperature. The mixture was stirred for 1 hr at 20-25° C. The solution was evaporated to dryness and the residue was dissolved in trifluoroacetic acid (957 μl, 12.4 mmol, 15 equiv.) and triethylsilane (159 μl, 994 μmol, 1.2 equiv.) was added at room temperature. The mixture was stirred 1 h at room temperature. The reaction mixture was evaporated and extracted with sat. NaHCO 3 solution and two times with a small volume of dichloromethane. The crude product was purified by flash chromatography by directly loading the dichloromethane layers onto a silica gel column (20 gr, ethyl acetate/heptane gradient, 0:100 to 100:0). The desired 1-(5-iodopyridin-2-yl)-4,4-dimethylpyrrolidin-2-one (209 mg, 80% yield) was obtained as a white solid, MS: m/e=317.0 (M+H + ).
Step 4: 4,4-Dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0390]
[0391] The title compound was obtained as a yellow oil, MS: m/e=291.1 (M+H + ), using chemistry that is described in Example 1, step 3 from 1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one (Example 13, step 3) and phenylacetylene.
Example 14
(3RS)-3-Hydroxy-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0392]
Step 1: (4RS)-4-Hydroxy-3,3-dimethyl-dihydro-furan-2,5-dione
[0393]
[0394] (3RS)-3-Hydroxy-2,2-dimethyl-succinic acid [ Tetrahedron Letters (2002), 43(52), 9513-9515] (120 mg, 0.74 mmol) was suspended in CH 2 Cl 2 (2 ml) and cooled to 0-5° C. Trifluoroacetic anhydride (260 μl, 1.85 mmol) was added and the reaction mixture stirred for 2 hours at room temperature. The reaction mixture was evaporated to dryness and used without any further purification in the next step.
Step 2: (4RS)-4-Hydroxy-1-(5-iodo-pyridin-2-yl)-3,3-dimethyl-pyrrolidine-2,5-dione
[0395]
[0396] The title compound was obtained as a light yellow solid, MS: m/e=346.8 (M+H + ), using chemistry similar to that described in Example 12, step 1 from 5-iodopyridin-2-amine and (4RS)-4-hydroxy-3,3-dimethyl-dihydro-furan-2,5-dione (Example 14, step 1).
Step 3: (4RS)-4-(tert-Butyl-diphenyl-silanyloxy)-1-(5-iodo-pyridin-2-yl)-3,3-dimethyl-pyrrolidine-2,5-dione
[0397]
[0398] (2.4 g, 3.47 mmol, 50%) (4RS)-4-Hydroxy-1-(5-iodo-pyridin-2-yl)-3,3-dimethyl-pyrrolidine-2,5-dione (Example 14, step 2) was dissolved in dichloromethane (20 ml). Imidazole (520 mg, 7.63 mmol) and tert-butyldiphenylchlorosilane (1.0 g, 3.64 mmol) were added at room temperature and the mixture was stirred for 3 hours at room temperature. Sat. NaHCO 3 solution was added and the mixture was extracted with dichloromethane. The organic extracts were dried with sodium sulfate, filtered and evaporated. The crude product was purified by flash chromatography on silica gel (ethyl acetate/heptane gradient 0:100 to 30:70). The desired compound was obtained as a white solid (1.5 g, 74% yield), MS: m/e=585.1 (M+H + ).
Step 4: (3RS,5RS)-3-(tert-Butyl-diphenyl-silanyloxy)-5-hydroxy-1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one
[0399]
[0400] The title compound was obtained as a light yellow solid, MS: m/e=587.0 (M+H + ), using chemistry similar to that described in Example 12, step 2 from (4RS)-4-(tert-butyl-diphenyl-silanyloxy)-1-(5-iodo-pyridin-2-yl)-3,3-dimethyl-pyrrolidine-2,5-dione (Example 14, step 3).
Step 5: (3RS)-3-(tert-Butyl-diphenyl-silanyloxy)-1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one
[0401]
[0402] The title compound was obtained as a colorless oil, MS: m/e=571.1 (M+H + ), using chemistry similar to that described in Example 12, step 3 from (3RS,5RS)-3-(tert-butyl-diphenyl-silanyloxy)-5-hydroxy-1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one (Example 14, step 4).
Step 6: (3RS)-3-(tert-Butyl-diphenyl-silanyloxy)-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0403]
[0404] The title compound was obtained as a brown oil, MS: m/e=545.3 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3RS)-3-(tert-butyl-diphenyl-silanyloxy)-1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one (Example 14, step 5) and phenylacetylene.
Step 7: (3RS)-3-Hydroxy-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0405]
[0406] (100 mg, 0.18 mmol) (3RS)-3-(tert-Butyl-diphenyl-silanyloxy)-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one (Example 14, step 6) was dissolved in THF (1 ml) and TBAF (1M in THF) (184 μl, 0.184) was added drop wise at room temperature. The mixture was stirred for 1 hr at 60° C. The reaction mixture was extracted with sat. NaHCO 3 -solution and two times EtOAc. The organic layers were extracted with water, dryed over Na 2 SO 4 , filtered and evaporated to dryness. The crude material was purified by flash chromatography on silica gel (20 gr, ethyl acetate/heptane gradient, 0:100 to 100:0). The desired (3RS)-3-hydroxy-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one (44 mg, 78% yield) was obtained as a white solid, MS: m/e=307.3 (M+H + ).
Example 15
4,4-Dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0407]
Step 1: N-1-(5-Iodo-pyridin-2-yl)-2-methyl-propane-1,2-diamine
[0408]
[0409] The title compound was obtained as a colorless oil, MS: m/e=292.0 (M+H + ), using chemistry similar to that described in Example 1, step 1 from 2-fluoro-5-iodopyridine and 2-methylpropane-1,2-diamine.
Step 2: 1-(5-Iodo-pyridin-2-yl)-4,4-dimethyl-imidazolidin-2-one
[0410]
[0411] The title compound was obtained as a light yellow solid, MS: m/e=318.0 (M+H + ), using chemistry similar to that described in Example 1, step 2 from N-1-(5-iodo-pyridin-2-yl)-2-methyl-propane-1,2-diamine (Example 15, step 1).
Step 3: 4,4-Dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0412]
[0413] The title compound was obtained as a yellow solid, MS: m/e=292.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-imidazolidin-2-one (Example 15, step 2) and phenylacetylene.
Example 16
3,4,4-Trimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0414]
[0415] (110 mg, 378 μmol) 4,4-Dimethyl-1-(5-(phenylethynyl)pyridin-2-yl)imidazolidin-2-one (Example 15, step 3) was dissolved in DMF (0.5 ml) and cooled to 0-5° C. NaH (55%) (19.8 mg, 453 μmol, 1.2 equiv.) was added and the mixture was stirred for 30 min at 0-5° C. Iodomethane (35.3 μl, 566 μmol, 1.5 equiv.) was added and the mixture was stirred for 30 min at 0-5° C. The reaction mixture was treated with sat. NaHCO 3 solution and extracted twice with a small volume of CH 2 Cl 2 . The organic layers were loaded directly to silica gel column and the crude material was purified by flash chromatography on silica gel (20 gr, ethyl acetate/heptane gradient, 0:100 to 100:0). The desired 3,4,4-trimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one (93 mg, 81% yield) was obtained as a yellow solid, MS: m/e=306.2 (M+H + ).
Example 17
3-Ethyl-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0416]
[0417] The title compound was obtained as a yellow oil, MS: m/e=320.2 (M+H + ), using chemistry similar to that described in Example 16 starting from 4,4-dimethyl-1-(5-(phenylethynyl)pyridin-2-yl)imidazolidin-2-one (Example 15, step 3) and iodoethane.
Example 18
3-Isopropyl-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0418]
[0419] The title compound was obtained as a yellow oil, MS: m/e=334.3 (M+H + ), using chemistry similar to that described in Example 16 starting from 4,4-dimethyl-1-(5-(phenylethynyl)pyridin-2-yl)imidazolidin-2-one (Example 15, step 3) and 2-bromopropane.
Example 19
(5RS)-5-tert-Butyl-5-methyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0420]
Step 1: 1-Dibenzylamino-3,3-dimethyl-butan-2-one
[0421]
[0422] (2.15 ml, 16.8 mmol) Dibenzylamine was dissolved in acetonitrile (30 ml). Potassium carbonate (2.3 g, 16.8 mmol, 1.5 equiv.) and 1-bromo-3,3-dimethylbutan-2-one (1.5 ml, 11.2 mmol, 1.0 equiv.) were added and the mixture was stirred for 16 hours at 90° C. The reaction mixture was extracted with sat. NaHCO 3 -solution and two times EtOAc. The organic layers were extracted with water, dryed over Na 2 SO 4 , filtered and evaporated to dryness. The crude material was purified by flash chromatography on silica gel (70 gr, ethyl acetate/heptane gradient, 0:100 to 100:0). The desired 1-(dibenzylamino)-3,3-dimethylbutan-2-one (1.6 g, 48.5% yield) was obtained as a yellow oil, MS: m/e=296.3 (M+H + ).
Step 2: (RS)-1-Dibenzylamino-2,3,3-trimethyl-butan-2-ol
[0423]
[0424] (1.6 g, 5.4 mmol) 1-Dibenzylamino-3,3-dimethyl-butan-2-one (Example 19, step 1) was dissolved in diethylether (20 ml) and cooled to 0-5° C. Methylmagnesium bromide (3M in diethylether) (2.2 ml, 6.5 mmol, 1.2 equiv.) was added drop wise at 0-5° C. and the mixture was stirred for 72 hours at room temperature. The reaction mixture was extracted with sat. NH 4 C1-solution and two times EtOAc. The organic layers were extracted with water, dryed over Na 2 SO 4 , filtered and evaporated to dryness. The crude material was purified by flash chromatography on silica gel (50 gr, ethyl acetate/heptane gradient, 0:100 to 100:0). The desired (RS)-1-dibenzylamino-2,3,3-trimethyl-butan-2-ol (1.2 g, 71% yield) was obtained as a yellow oil, MS: m/e=312.4 (M+H + ).
Step 3: (RS)-1-Amino-2,3,3-trimethyl-butan-2-ol
[0425]
[0426] The title compound was obtained as a white solid, MS: m/e=132.1 (M+H + ), was prepared from (RS)-1-dibenzylamino-2,3,3-trimethyl-butan-2-ol (Example 19, step 2) by hydrogenation 16 hours at room temperature using Pd/C (10%) in ethyl acetate.
Step 4: (RS)-1-(5-Iodo-pyridin-2-ylamino)-2,3,3-trimethyl-butan-2-ol
[0427]
[0428] The title compound was obtained as a yellow solid, MS: m/e=335.1 (M+H + ), using chemistry similar to that described in Example 1, step 1 from 2-fluoro-5-iodopyridine and (RS)-1-amino-2,3,3-trimethyl-butan-2-ol (Example 19, step 3).
Step 5: (5RS)-5-tert-Butyl-3-(5-iodo-pyridin-2-yl)-5-methyl-oxazolidin-2-one
[0429]
[0430] The title compound was obtained as a yellow oil, MS: m/e=361.1 (M+H + ), using chemistry similar to that described in Example 1, step 2 from (RS)-1-(5-iodo-pyridin-2-ylamino)-2,3,3-trimethyl-butan-2-ol (Example 19, step 4).
Step 6: (5RS)-5-tert-Butyl-5-methyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0431]
[0432] The title compound was obtained as a light brown solid, MS: m/e=335.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (5RS)-5-tert-butyl-3-(5-iodo-pyridin-2-yl)-5-methyl-oxazolidin-2-one (Example 19, step 5) and phenylacetylene.
Example 20
5,5-Dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0433]
Step 1: 3-(5-Iodo-pyridin-2-yl)-5,5-dimethyl-[1,3]oxazinan-2-one
[0434]
[0435] The title compound was obtained as a colorless oil, MS: m/e=333.1 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and 3-amino-2,2-dimethylpropan-1-ol.
Step 2: 5,5-Dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0436]
[0437] The title compound was obtained as a light brown oil, MS: m/e=307.3 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-5,5-dimethyl-[1,3]oxazinan-2-one (Example 20, step 1) and phenylacetylene.
Example 21
1-(3-Fluoro-5-phenylethynyl-pyridin-2-yl)-4,4-dimethyl-pyrrolidin-2-one
[0438]
[0439] The title compound was obtained as a orange solid, MS: m/e=309.2 (M+H + ), using procedures similar to those described in Example 13 by using 2-amino-3-fluoro-5-iodopyridine instead of 5-iodopyridin-2-amine.
Example 22
(3aRS,6aSR)-3-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-cyclopentaoxazol-2-one
[0440]
Step 1: (3aRS,6aSR)-3-(5-Iodo-pyridin-2-yl)-hexahydro-cyclopentaoxazol-2-one
[0441]
[0442] The title compound was obtained as a light brown solid, MS: m/e=331.1 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and (1SR,2RS)-2-aminocyclopentanol hydrochloride.
Step 2: (3aRS,6aSR)-3-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-cyclopentaoxazol-2-one
[0443]
[0444] The title compound was obtained as a light yellow solid, MS: m/e=305.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aRS,6aSR)-3-(5-iodo-pyridin-2-yl)-hexahydro-cyclopentaoxazol-2-one (Example 13, step 1) and phenylacetylene.
Example 23
(3aRS,6aSR)-3-(5-Pyridin-3-ylethynyl-pyridin-2-yl)-hexahydro-cyclopentaoxazol-2-one
[0445]
[0446] The title compound was obtained as a colorless oil, MS: m/e=306.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aRS,6aSR)-3-(5-iodo-pyridin-2-yl)-hexahydro-cyclopentaoxazol-2-one (Example 13, step 1) and 3-ethynyl-pyridine.
Example 24
(3aRS,6aSR)-3-[5-(5-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-hexahydro-cyclopentaoxazol-2-one
[0447]
[0448] The title compound was obtained as a light brown solid, MS: m/e=324.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aRS,6aSR)-3-(5-iodo-pyridin-2-yl)-hexahydro-cyclopentaoxazol-2-one (Example 13, step 1) and 3-ethynyl-5-fluoro-pyridine (CAS 872122-54-8).
Example 25
5,5-Dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one
[0449]
[0450] The title compound was obtained as a light brown solid, MS: m/e=306.2 (M+H + ), using procedures similar to those described in Example 15 starting from 2-fluoro-5-iodopyridine and by using 2,2-dimethylpropane-1,3-diamine instead of 2-methylpropane-1,2-diamine.
Example 26
1,5,5-Trimethyl-3-(5-phenylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one
[0451]
[0452] The title compound was obtained as a light brown solid, MS: m/e=306.2 (M+H + ), using procedures similar to those described in Example 16 from 5,5-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one (Example 25) and iodomethane.
Example 27
(RS)-4,5,5-Trimethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0453]
[0454] The title compound was obtained as a yellow solid, MS: m/e=307.2 (M+H + ), using procedures similar to those described in Example 1 from 2-fluoro-5-iodopyridine and by using (RS)-3-amino-2-methyl-butan-2-ol (CAS 6291-17-4) instead of 1-amino-2-methylpropan-2-ol.
Example 28
4,4,5,5-Tetramethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0455]
[0456] The title compound was obtained as a light yellow solid, MS: m/e=321.2 (M+H + ), using procedures similar to those described in Example 1 from 2-fluoro-5-iodopyridine and by using 3-amino-2,3-dimethyl-butan-2-ol (CAS 89585-13-7) instead of 1-amino-2-methylpropan-2-ol.
Example 29
3-[5-(5-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one
[0457]
Step 1: 5,5-Dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0458]
[0459] The title compound was obtained as a brown solid, MS: m/e=289.0 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-5,5-dimethyl-oxazolidin-2-one (Example 5, step 1) and ethynyltrimethylsilane.
Step 2: 3-[5-(5-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one
[0460]
[0461] 5,5-Dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-oxazolidin-2-one (Example 29, step 1) (100 mg, 0.35 mmol) was dissolved in THF (3 ml). 3-Fluoro-5-iodopyridine (100 mg, 0.45 mmol, 1.3 equiv.), Et 3 N (145 μl, 1.04 mmol, 3 equiv.), Bis-(triphenylphosphine)-palladium(II) dichloride (10 mg, 14 mmol, 0.05 equiv.), triphenylphosphine (11 mg, 17 μmol, 0.05 equiv.), triphenylphosphine (3 mg, 10 μmol, 0.03 equiv.) and copper(I) iodide (1 mg, 3.5 mmol, 0.01 equiv.) were added under nitrogen and the mixture was heated to 60° C. TBAF 1M in THF (520 μl, 0.52 mmol, 1.5 equiv.) was added dropwise in 20 minutes at 60° C. The reaction mixture was stirred for 3 hours at 60° C. Sat. NaHCO 3 solution was added and the mixture was extracted with dichloromethane. The organic extracts were dried with sodium sulfate, filtered and evaporated. The crude product was purified by flash chromatography on silica gel (dichloromethane/methanol gradient 100:0 to 90:10). The desired 3-[5-(5-fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one was obtained as a white solid (55 mg, 51% yield), MS: m/e=312.3 (M+H + ).
Example 30
5,5-Dimethyl-3-(5-pyrimidin-5-ylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0462]
[0463] The title compound was obtained as a light yellow solid, MS: m/e=295.2 (M+H + ), using chemistry similar to that described in Example 29, step 2 from 5,5-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-oxazolidin-2-one (Example 29, step 1) and 5-bromopyrimidine.
Example 31
5,5-Dimethyl-3-[5-(1-methyl-1H-pyrazol-4-ylethynyl)-pyridin-2-yl]-oxazolidin-2-one
[0464]
[0465] The title compound was obtained as a light yellow solid, MS: m/e=297.2 (M+H + ), using chemistry similar to that described in Example 29, step 2 from 5,5-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-oxazolidin-2-one (Example 29, step 1) and 4-iodo-1-methyl-1H-pyrazole.
Example 32
3-[5-(4-Fluoro-phenylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one
[0466]
[0467] The title compound was obtained as a yellow solid, MS: m/e=311.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-5,5-dimethyl-oxazolidin-2-one (Example 5, step 1) and 1-ethynyl-4-fluoro-benzene.
Example 33
3-[5-(3,4-Difluoro-phenylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one
[0468]
[0469] The title compound was obtained as a white solid, MS: m/e=329.2 (M+H + ), using chemistry similar to that described in Example 29, step 2 from 5,5-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-oxazolidin-2-one (Example 29, step 1) and 1,2-difluoro-4-iodobenzene.
Example 34
3-[5-(2,5-Difluoro-phenylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one
[0470]
[0471] The title compound was obtained as a white solid, MS: m/e=329.2 (M+H + ), using chemistry similar to that described in Example 29, step 2 from 5,5-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-oxazolidin-2-one (Example 29, step 1) and 1,4-difluoro-2-iodobenzene.
Example 35
3-[5-(6-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-5,5-dimethyl-oxazolidin-2-one
[0472]
[0473] The title compound was obtained as a white solid, MS: m/e=312.2 (M+H + ), using chemistry similar to that described in Example 29, step 2 from 5,5-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-oxazolidin-2-one (Example 29, step 1) and 2-fluoro-5-iodopyridine.
Example 36
6-(5-Pyridin-3-ylethynyl-pyridin-2-yl)-4-oxa-6-aza-spiro[2.4]heptan-5-one
[0474]
[0475] The title compound was obtained as a white solid, MS: m/e=292.2 (M+H + ), using procedures similar to those described in Example 1 starting from 2-fluoro-5-bromopyridine, 1-aminomethyl-cyclopropanol ( Russian J. Org. Chem. 2001, 37, 1238) and 3-ethynyl-pyridine.
Example 37
1-[5-(5-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0476]
Step 1: 2-Bromo-5-trimethylsilanylethynyl-pyridine
[0477]
[0478] 2-Bromo-5-iodopyridine (2.5 g, 8.8 mmol) was dissolved under nitrogen in 50 ml THF. Bis-(triphenylphosphine)-palladium(II) dichloride (618 mg, 880 μmol, 0.1 equiv.), ethynyltrimethylsilane (950 mg, 1.34 ml, 9.6 mmol, 1.1 equiv.), triethylamine (1.78 g, 2.44 ml, 17.6 mmol, 3 equiv.) and copper(I) iodide (84 mg, 440 μmol, 0.05 equiv.) were added and the mixture was stirred for 3 hours at 50° C. The reaction mixture was cooled and evaporated to dryness. The crude product was purified by flash chromatography on silica gel, eluting with an ethyl acetate:heptane gradient 0:100 to 15:85. The desired 2-bromo-5-trimethylsilanylethynyl-pyridine (1.95 g, 7.7 mmol, 87% yield) was obtained as a white solid, MS: m/e=254.1/256.1 (M+H + ).
Step 2: 4,4-Dimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0479]
[0480] (260 mg, 1.0 mmol) 2-Bromo-5-trimethylsilanylethynyl-pyridine (Example 37, step 1) was dissolved in toluene (2 ml) and 4,4-dimethylpyrrolidin-2-one (115 mg, 1.0 mmol, 1.0 equiv.), cesium carbonate (660 mg, 2.05 mmol, 2.0 equiv.), xantphos (CAS 161265-03-8) (24 mg, 0.04 mmol, 0.04 equiv.) and Pd 2 (dba) 3 (19 mg, 0.02 mmol, 0.02 equiv.) were added under nitrogen. The mixture was stirred for 1 hour at 90° C. The crude product was purified by flash chromatography by directly loading the toluene mixture onto a silica gel column and eluting with an ethyl acetate:heptane gradient 0:100 to 40:60. The desired 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one (230 mg, 0.81 mmol, 75% yield) was obtained as a yellow solid, MS: m/e=287.1 (M+H + ).
Step 3: 1-[5-(5-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0481]
[0482] 4,4-Dimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one (Example 37, step 2) (80 mg, 0.28 mmol) was dissolved in DMF (1 ml). 3-Fluoro-5-iodopyridine (87 mg, 0.39 mmol, 1.4 equiv.), Et 3 N (85 mg, 117 μl, 0.84 mmol, 3 equiv.), Bis-(triphenylphosphine)-palladium(II) dichloride (10 mg, 14 μmol, 0.05 equiv.), triphenylphosphine (2 mg, 8.4 μmol, 0.03 equiv.) and copper(I) iodide (2 mg, 8.4 μmol, 0.03 equiv.) were added under nitrogen and the mixture was heated to 70° C. TBAF 1M in THF (300 μl, 0.3 mmol, 1.1 equiv.) was added dropwise in 20 minutes at 70° C. The reaction mixture was stirred for 30 minutes at 70° C. and evaporated with isolute to dryness. The crude product was purified by flash chromatography with a 20 g silica gel column and eluting with heptane:ethyl acetate 100:0->0:100. The desired 1-[5-(5-fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one (36 mg, 42% yield) was obtained as a white solid, MS: m/e=310.2 (M+H + ).
Example 38
4,4-Dimethyl-1-(5-pyridin-3-ylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0483]
[0484] The title compound was obtained as a white solid, MS: m/e=292.1 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one (Example 37, step 2) and 3-iodopyridine.
Example 39
1-[5-(5-Chloro-pyridin-3-ylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0485]
[0486] The title compound was obtained as a white solid, MS: m/e=326.2/328.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one (Example 37, step 2) and 3-chloro-5-iodopyridine.
Example 40
1-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0487]
[0488] The title compound was obtained as a white solid, MS: m/e=309.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one (Example 37, step 2) and 1-fluoro-3-iodobenzene.
Example 41
4,4-Dimethyl-1-(3-methyl-5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0489]
Step 1: 2-Bromo-3-methyl-5-trimethylsilanylethynyl-pyridine
[0490]
[0491] The title compound was obtained as a yellow oil, MS: m/e=268.1/270.1 (M+H + ), using chemistry similar to that described in Example 37, step 1 by using 2-bromo-5-iodo-3-methylpyridine instead of 2-bromo-5-iodopyridine.
Step 2: 4,4-Dimethyl-1-(3-methyl-5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0492]
[0493] The title compound was obtained as a brown solid, MS: m/e=301.3 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-3-methyl-5-trimethylsilanylethynyl-pyridine (Example 41, step 1) and 4,4-dimethylpyrrolidin-2-one.
Step 3: 4,4-Dimethyl-1-(3-methyl-5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0494]
[0495] The title compound was obtained as a white solid, MS: m/e=305.3 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-1-(3-methyl-5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one (Example 41, step 2) and iodobenzene.
Example 42
5,5-Dimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0496]
Step 1: 5,5-Dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0497]
[0498] The title compound was obtained as a yellow solid, MS: m/e=301.3 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyridine (Example 37, step 1) and by using 5,5-dimethyl-piperidin-2-one (CAS 4007-79-8) instead of 4,4-dimethylpyrrolidin-2-one.
Step 2: 5,5-Dimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0499]
[0500] The title compound was obtained as a yellow oil, MS: m/e=305.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 5,5-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one (Example 42, step 1) and iodobenzene.
Example 43
5′-(3-Fluoro-phenylethynyl)-5,5-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0501]
[0502] The title compound was obtained as a yellow oil, MS: m/e=323.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 5,5-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one (Example 42, step 1) and 1-fluoro-3-iodobenzene.
Example 44
1-Methyl-3-(5-phenylethynyl-pyridin-2-yl)-1,3-diaza-spiro[4.4]nonan-2-one
[0503]
Step 1: {1-[(5-Iodo-pyridin-2-ylamino)-methyl]-cyclopentyl}-carbamic acid tert-butyl ester
[0504]
[0505] The title compound was obtained as a white solid, MS: m/e=418.2 (M+H + ), using chemistry similar to that described in Example 1, step 1 from 2-fluoro-5-iodopyridine and tert-butyl 1-(aminomethyl)cyclopentylcarbamate (CAS 889949-09-1) by using neat pyridine as solvent instead of NMP.
Step 2: (1-Amino-cyclopentylmethyl)-(5-iodo-pyridin-2-yl)-amine hydrochloride
[0506]
[0507] The BOC protecting group is removed by reacting {1-[(5-iodo-pyridin-2-ylamino)-methyl]-cyclopentyl}-carbamic acid tert-butyl ester (Example 44, step 1) with 4N HCl in dioxane for 1 hour at room temperature. The title compound was obtained by filtration of the hydrochloride salt as a light yellow solid, MS: m/e=318.1 (M+H + ).
Step 3: 3-(5-Iodo-pyridin-2-yl)-1,3-diaza-spiro[4.4]nonan-2-one
[0508]
[0509] The title compound was obtained as a white solid, MS: m/e=344.1 (M+H + ), using chemistry similar to that described in Example 1, step 2 from (1-amino-cyclopentylmethyl)-(5-iodo-pyridin-2-yl)-amine hydrochloride (Example 44, step 2).
Step 4: 3-(5-Phenylethynyl-pyridin-2-yl)-1,3-diaza-spiro[4.4]nonan-2-one
[0510]
[0511] The title compound was obtained as a light yellow solid, MS: m/e=318.2 (M+H), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-1,3-diaza-spiro[4.4]nonan-2-one (Example 44, step 3) and phenylacetylene.
Step 5: 1-Methyl-3-(5-phenylethynyl-pyridin-2-yl)-1,3-diaza-spiro[4.4]nonan-2-one
[0512]
[0513] The title compound was obtained as a light yellow oil, MS: m/e=332.2 (M+H + ), using chemistry similar to that described in Example 16 from 3-(5-phenylethynyl-pyridin-2-yl)-1,3-diaza-spiro[4.4]nonan-2-one (Example 44, step 4) and iodomethane.
Example 45
(RS)-4-Cyclopentyl-3-methyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0514]
[0515] The title compound was obtained as a light yellow solid, MS: m/e=346.2 (M+H + ), using procedures similar to those described in Example 44 from 2-fluoro-5-iodopyridine and by using (RS)-tert-butyl 2-amino-1-cyclopentylethylcarbamate (CAS 936497-76-6) instead of tert-butyl 1-(aminomethyl)cyclopentylcarbamate.
Example 46
(1RS,5SR)-6-(5-Phenylethynyl-pyridin-2-yl)-6-aza-bicyclo[3.2.0]heptan-7-one
[0516]
Step 1: (1RS,5SR)-6-(5-Bromo-pyridin-2-yl)-6-aza-bicyclo[3.2.0]heptan-7-one
[0517]
[0518] The title compound was obtained as a white solid, MS: m/e=268.2 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2,5-dibromopyridine and (1RS,5SR)-6-aza-bicyclo[3.2.0]heptan-7-one (CAS 22031-52-3).
Step 2: (1RS,5SR)-6-(5-Phenylethynyl-pyridin-2-yl)-6-aza-bicyclo[3.2.0]heptan-7-one
[0519]
[0520] The title compound was obtained as a brown solid, MS: m/e=289.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (1RS,5SR)-6-(5-bromo-pyridin-2-yl)-6-aza-bicyclo[3.2.0]heptan-7-one (Example 46, step 1) with phenylacetylene.
Example 47
(6SR,7RS)-3-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-benzooxazol-2-one
[0521]
[0522] The title compound was obtained as a yellow solid, MS: m/e=319.2 (M+H + ), using procedures similar to those described in Example 1 starting from 2-fluoro-5-bromopyridine, (5SR,6RS)-2-amino-cyclohexanol hydrochloride (CAS 190792-72-4) and phenylacetylene.
Example 48
3,4,4-Trimethyl-1-(5-pyridin-3-ylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0523]
Step 1: 1-(5-Iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one
[0524]
[0525] The title compound was obtained as a light yellow solid, MS: m/e=332.1 (M+H + ), using chemistry similar to that described in Example 16 from 1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-imidazolidin-2-one (Example 15, step 2) and iodomethane.
Step 2: 3,4,4-Trimethyl-1-(5-pyridin-3-ylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0526]
[0527] The title compound was obtained as a white solid, MS: m/e=307.3 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 1-(5-iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 48, step 1) and 3-ethynyl-pyridine.
Example 49
1-[5-(5-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0528]
Step 1: 3,4,4-Trimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0529]
[0530] The title compound was obtained as a yellow solid, MS: m/e=302.3 (M+H + ), using chemistry similar to that described in Example 37, step 1 from 1-(5-iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 48, step 1) and ethynyltrimethylsilane.
Step 2: 1-[5-(5-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0531]
[0532] The title compound was obtained as a light yellow solid, MS: m/e=325.4 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 3,4,4-trimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-imidazolidin-2-one (Example 49, step 1) and 3-fluoro-5-iodopyridine.
Example 50
3,4,4-Trimethyl-1-[5-(1-methyl-1H-pyrazol-4-ylethynyl)-pyridin-2-yl]-imidazolidin-2-one
[0533]
[0534] The title compound was obtained as a light yellow solid, MS: m/e=310.3 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 3,4,4-trimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-imidazolidin-2-one (Example 49, step 1) and 4-iodo-1-methyl-1H-pyrazole.
Example 51
1-[5-(5-Chloro-pyridin-3-ylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0535]
[0536] The title compound was obtained as a white solid, MS: m/e=341.1/343.3 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 3,4,4-trimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-imidazolidin-2-one (Example 49, step 1) and 3-chloro-5-iodopyridine.
Example 52
3,4,4-Trimethyl-1-(5-pyridazin-4-ylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0537]
[0538] The title compound was obtained as a light yellow solid, MS: m/e=308.4 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 3,4,4-trimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-imidazolidin-2-one (Example 49, step 1) and 4-bromo-pyridazine.
Example 53
1-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0539]
[0540] The title compound was obtained as a yellow solid, MS: m/e=324.3 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 1-(5-iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 48, step 1) and 1-ethynyl-3-fluoro-benzene.
Example 54
1-[5-(3-Chloro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0541]
[0542] The title compound was obtained as a yellow solid, MS: m/e=340.1/342.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 1-(5-iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 48, step 1) and 1-ethynyl-3-chloro-benzene.
Example 55
3,4,4-Trimethyl-1-(5-pyrimidin-5-ylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0543]
[0544] The title compound was obtained as a light yellow solid, MS: m/e=308.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 3,4,4-trimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-imidazolidin-2-one (Example 49, step 1) and 5-bromo-pyrimidine.
Example 56
3,4,4-Trimethyl-1-(5-m-tolylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0545]
[0546] The title compound was obtained as a brown oil, MS: m/e=320.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 1-(5-iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 48, step 1) and 1-ethynyl-3-methyl-benzene.
Example 57
1-[5-(4-Fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0547]
[0548] The title compound was obtained as a light brown solid, MS: m/e=324.2 (M+H), using chemistry similar to that described in Example 1, step 3 from 1-(5-iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 48, step 1) and 1-ethynyl-4-fluoro-benzene.
Example 58
(RS)-2-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-imidazo[1,5-a]pyridin-3-one
[0549]
Step 1: (RS)-2-(5-Iodo-pyridin-2-yl)-hexahydro-imidazo[1,5-a]pyridin-3-one
[0550]
[0551] The title compound was obtained as a white solid, MS: m/e=344.0 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and (RS)-hexahydro-imidazo[1,5-a]pyridin-3-one (CAS 76561-92-7) by using neat pyridine as solvent instead of NMP.
Step 2: (RS)-2-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-imidazo[1,5-a]pyridin-3-one
[0552]
[0553] The title compound was obtained as a white solid, MS: m/e=318.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (RS)-2-(5-iodo-pyridin-2-yl)-hexahydro-imidazo[1,5-a]pyridin-3-one (Example 58, step 1) and phenylacetylenen.
Example 59
2-(5-Phenylethynyl-pyridin-2-yl)-2-aza-spiro nonan-3-one
[0554]
[0555] The title compound was obtained as a light yellow, MS: m/e=317.2 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-phenylethynyl-pyridine (Example 58, step 1) and 2-aza-spiro[4.4]nonan-3-one (CAS 75751-72-3).
Example 60
(RS)-3-Methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0556]
Step 1: (RS)-4-Iodo-N-(5-iodo-pyridin-2-yl)-2-methoxy-3,3-dimethyl-butyramide
[0557]
[0558] The title compound was obtained as a white solid, MS: m/e=474.9 (M+H + ), using chemistry similar to that described in patent WO9637466, page 17, step 2 starting from (RS)-3-methoxy-4,4-dimethyl-dihydro-furan-2-one (CAS 100101-82-4) instead of 3-t-butylcarbamoyloxy-tetrahydrofuran-2-one and by using 2-amino-5-iodopyridine instead of 2-amino-4-trifluoromethylpyridine.
Step 2: (RS)-1-(5-Iodo-pyridin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0559]
[0560] The title compound was obtained as a light yellow solid, MS: m/e=347.0 (M+H + ), using chemistry similar to that described in patent WO9637466, page 17, step 3 from (RS)-4-iodo-N-(5-iodo-pyridin-2-yl)-2-methoxy-3,3-dimethyl-butyramide (Example 60, step 1).
Step 3: (RS)-3-Methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0561]
[0562] The title compound was obtained as a light yellow solid, MS: m/e=321.3 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (RS)-1-(5-iodo-pyridin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 60, step 2) and phenylacetylene.
Example 61
(5R or 5S)-5-Methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0563]
[0564] The title compound, a yellow oil, MS: m/e=321.3 (M+H + ), was prepared by separation of (RS)-3-methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one (Example 60) using a chiral column (chiralpak AD with heptane:isopropanol 90:10 as solvent).
Example 62
(5S or 5R)-5-Methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-oxazolidin-2-one
[0565]
[0566] The title compound, a white solid, MS: m/e=321.3 (M+H), was prepared by separation of (RS)-3-methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-pyrrolidin-2-one (Example 60) using a chiral column (chiralpak AD with heptane:isopropanol 90:10 as solvent).
[0000]
Step 1: (RS)-3-Methoxy-4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0567]
[0568] The title compound was obtained as a yellow solid, MS: m/e=317.2 (M+H + ), using chemistry similar to that described in Example 37, step 1 from (RS)-1-(5-iodo-pyridin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 60, step 2) and ethynyltrimethylsilane.
Step 2: (RS)-1-[5-(5-Chloro-pyridin-3-ylethynyl)-pyridin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0569]
[0570] The title compound was obtained as a white solid, MS: m/e=356.1/358.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from (RS)-3-methoxy-4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-pyrrolidin-2-one (Example 63, step 1) and 3-chloro-5-iodopyridine.
Example 64
(RS)-3-Methoxy-4,4-dimethyl-1-(5-m-tolylethynyl-pyridin-2-yl)-pyrrolidin-2-one
[0571]
[0572] The title compound was obtained as an orange oil, MS: m/e=335.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (RS)-1-(5-iodo-pyridin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 60, step 2) and 1-ethynyl-3-methyl-benzene.
Example 65
(RS)-1-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0573]
[0574] The title compound was obtained as a brown solid, MS: m/e=339.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (RS)-1-(5-iodo-pyridin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 60, step 2) and 1-ethynyl-3-fluorobenzene.
Example 66
(RS)-1-[5-(4-Fluoro-phenylethynyl)-pyridin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0575]
[0576] The title compound was obtained as a brown solid, MS: m/e=339.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (RS)-1-(5-iodo-pyridin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 60, step 2) and 1-ethynyl-4-fluorobenzene.
Example 67
3,4,4-Trimethyl-1-(5-phenylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one
[0577]
Step 1: [3-(5-Iodo-pyridin-2-ylamino)-1,1-dimethyl-propyl]-carbamic acid tert-butyl ester
[0578]
[0579] The title compound was obtained as a white solid, MS: m/e=406.3 (M+H + ), using chemistry similar to that described in Example 1, step 1 from 2-fluoro-5-iodopyridine and tert-butyl 4-amino-2-methylbutan-2-ylcarbamate (CAS 880100-43-6).
Step 2: N-1-(5-Iodo-pyridin-2-yl)-3-methyl-butane-1,3-diamine hydrochloride
[0580]
[0581] The BOC protecting group is removed by reacting [3-(5-iodo-pyridin-2-ylamino)-1,1-dimethyl-propyl]-carbamic acid tert-butyl ester (Example 67, step 1) with 4N HCl in dioxane for 4 hours at room temperature. The title compound was obtained by filtration of the hydrochloride salt as a pink solid, MS: m/e=306.1 (M+H + ).
Step 3: 1-(5-Iodo-pyridin-2-yl)-4,4-dimethyl-tetrahydro-pyrimidin-2-one
[0582]
[0583] The title compound was obtained as a yellow solid, MS: m/e=332.1 (M+H + ), using chemistry similar to that described in Example 1, step 2 from N-1-(5-iodo-pyridin-2-yl)-3-methyl-butane-1,3-diamine hydrochloride (Example 67, step 2).
Step 4: 1-(5-Iodo-pyridin-2-yl)-3,4,4-trimethyl-tetrahydro-pyrimidin-2-one
[0584]
[0585] The title compound was obtained as a yellow solid, MS: m/e=346.0 (M+H + ), using chemistry similar to that described in Example 16 from 1-(5-iodo-pyridin-2-yl)-4,4-dimethyl-tetrahydro-pyrimidin-2-one (Example 67, step 3) and iodomethane.
Step 5: 3,4,4-Trimethyl-1-(5-phenylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one
[0586]
[0587] The title compound was obtained as a brown solid, MS: m/e=320.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 1-(5-iodo-pyridin-2-yl)-3,4,4-trimethyl-tetrahydro-pyrimidin-2-one (Example 67, step 4) and phenylacetylene.
Example 68
1-[5-(2,5-Difluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-tetrahydro-pyrimidin-2-one
[0588]
Step 1: 3,4,4-Trimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one
[0589]
[0590] The title compound was obtained as a white solid, MS: m/e=316.2 (M+H + ), using chemistry similar to that described in Example 37, step 1 from 1-(5-iodo-pyridin-2-yl)-3,4,4-trimethyl-tetrahydro-pyrimidin-2-one (Example 67, step 4) and ethynyltrimethylsilane.
Step 2: 1-[5-(2,5-Difluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-tetrahydro-pyrimidin-2-one
[0591]
[0592] The title compound was obtained as a light yellow solid, MS: m/e=356.2 (M+H), using chemistry similar to that described in Example 37, step 3 from 3,4,4-trimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one (Example 68, step 1) and 1,4-difluoro-2-iodobenzene.
Example 69
1-[5-(4-Fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-tetrahydro-pyrimidin-2-one
[0593]
[0594] The title compound was obtained as a white solid, MS: m/e=338.3 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 3,4,4-trimethyl-1-(5-trimethylsilanylethynyl-pyridin-2-yl)-tetrahydro-pyrimidin-2-one (Example 68, step 1) and 1-fluoro-4-iodobenzene.
Example 70
(RS)-2-(5-Pyridin-3-ylethynyl-pyridin-2-yl)-hexahydro-imidazo[1,5-a]pyridin-3-one
[0595]
[0596] The title compound was obtained as a light yellow solid, MS: m/e=319.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (RS)-2-(5-iodo-pyridin-2-yl)-hexahydro-imidazo[1,5-a]pyridin-3-one (Example 58, step 1) and 3-ethynyl-pyridine.
Example 71
(RS)-2-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-hexahydro-imidazo[1,5-a]pyridin-3-one
[0597]
[0598] The title compound was obtained as a light brown solid, MS: m/e=336.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (RS)-2-(5-iodo-pyridin-2-yl)-hexahydro-imidazo[1,5-a]pyridin-3-one (Example 58, step 1) and 1-ethynyl-3-fluorobenzene.
Example 72
6,6-Dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0599]
Step 1: (3-Hydroxy-3-methyl-butyl)-carbamic acid benzyl ester
[0600]
[0601] (10 g, 42.1 mmol) Methyl 3-(benzyloxycarbonylamino)propanoate (CAS 54755-77-0) was dissolved in THF (150 ml) and cooled to 0-5° C. 3N Methylmagnesium bromide in THF (56.2 ml, 120 mmol, 4 equiv.) was added drop wise and the mixture stirred for 1 hour at 0-5° C. The reaction mixture was extracted with saturated NH 4 Cl solution and two times with EtOAc. The organic layers were dried over Na 2 SO 4 and evaporated to dryness. The desired (3-hydroxy-3-methyl-butyl)-carbamic acid benzyl ester (11.6 g, quant.) was obtained as a colorless oil, MS: m/e=238.1 (M+H + ) and used in the next step without further purification.
Step 2: 6,6-dimethyl-[1,3]oxazinan-2-one
[0602]
[0603] (11.6 g, 48.9 mmol) (3-Hydroxy-3-methyl-butyl)-carbamic acid benzyl ester (Example 72, step 1) was dissolved in THF (250 ml) and sodium hydride (60%, 5.2 g, 108 mmol, 2.2 equiv.) was added in portions. The mixture was stirred for 3 hours at room temperature. 5 ml saturated NaHCO 3 solution was added carefully and the mixture was evaporated with isolute to dryness. The crude product was purified by flash chromatography by directly loading the residue onto a silica gel column and eluting with an ethyl acetate:methanol gradient 100:0 to 90:10. The desired 6,6-dimethyl-[1,3]oxazinan-2-one (3.2 g, 51% yield) was obtained as a yellow solid, MS: m/e=130.1 (M+H + ).
Step 3: 6,6-Dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0604]
[0605] The title compound was obtained as an orange solid, MS: m/e=303.2 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyridine (Example 37, step 1) and by using 6,6-dimethyl-[1,3]oxazinan-2-one (Example 72, step 2) instead of 4,4-dimethylpyrrolidin-2-one.
Step 4: 6,6-Dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0606]
[0607] The title compound was obtained as a yellow solid, MS: m/e=307.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one (Example 72, step 3) and iodobenzene.
Example 73
6,6-Dimethyl-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0608]
Step 1: 3-(5-Iodo-pyridin-2-yl)-6,6-dimethyl-[1,3]oxazinan-2-one
[0609]
[0610] The title compound was obtained as a white solid, MS: m/e=333.1 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and 4-amino-2-methyl-butan-2-ol hydrochloride.
Step 2: 6,6-Dimethyl-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0611]
[0612] The title compound was obtained as a light yellow solid, MS: m/e=308.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-6,6-dimethyl-[1,3]oxazinan-2-one (Example 73, step 1) and phenylacetylene.
Example 74
3-[5-(5-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one
[0613]
[0614] The title compound was obtained as a white solid, MS: m/e=326.3 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one (Example 72, step 3) and 3-fluoro-5-iodopyridine.
Example 75
3-[5-(5-Chloro-pyridin-3-ylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one
[0615]
[0616] The title compound was obtained as a white solid, MS: m/e=342.1/344.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one (Example 72, step 3) and 3-chloro-5-iodopyridine.
Example 76
3-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one
[0617]
[0618] The title compound was obtained as a white solid, MS: m/e=325.4 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one (Example 72, step 3) and 1-fluoro-3-iodobenzene.
Example 77
3-[5-(3-Chloro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one
[0619]
[0620] The title compound was obtained as a white solid, MS: m/e=341.2/343.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one (Example 72, step 3) and 1-chloro-3-iodobenzene.
Example 78
6,6-Dimethyl-3-(5-m-tolylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0621]
[0622] The title compound was obtained as a light yellow solid, MS: m/e=321.4 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one (Example 72, step 3) and 1-iodo-3-methylbenzene.
Example 79
3-[5-(4-Fluoro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one
[0623]
[0624] The title compound was obtained as a light brown solid, MS: m/e=325.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-6,6-dimethyl-[1,3]oxazinan-2-one (Example 73, step 1) and 1-ethynyl-4-fluorobenzene.
Example 80
3-[5-(3,4-Difluoro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one
[0625]
[0626] The title compound was obtained as a light yellow solid, MS: m/e=343.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-6,6-dimethyl-[1,3]oxazinan-2-one (Example 73, step 1) and 4-ethynyl-1,2-difluorobenzene.
Example 81
3-[5-(2,5-Difluoro-phenylethynyl)-pyridin-2-yl]-6,6-dimethyl-[1,3]oxazinan-2-one
[0627]
[0628] The title compound was obtained as a light yellow solid, MS: m/e=343.1 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one (Example 72, step 3) and 1,4-difluoro-2-iodobenzene.
Example 82
6-(5-Phenylethynyl-pyridin-2-yl)-2-oxa-6-aza-spiro[3.4]octan-7-one
[0629]
Step 1: 6-(5-Trimethylsilanylethynyl-pyridin-2-yl)-2-oxa-6-aza-spiro[3.4]octan-7-one
[0630]
[0631] The title compound was obtained as a white solid, MS: m/e=301.3 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyridine (Example 37, step 1) and 2-oxa-6-aza-spiro[3.4]octan-7-one (CAS 1207174-87-5).
Step 2: 6-(5-Phenylethynyl-pyridin-2-yl)-2-oxa-6-aza-spiro[3.4]octan-7-one
[0632]
[0633] The title compound was obtained as a light yellow solid, MS: m/e=305.3 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 6-(5-trimethylsilanylethynyl-pyridin-2-yl)-2-oxa-6-aza-spiro[3.4]octan-7-one (Example 82, step 1) and iodobenzene.
Example 83
(RS)-4-Cyclopropyl-3-methyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0634]
[0635] The title compound was obtained as an orange solid, MS: m/e=318.1 (M+H + ), using procedures similar to those described in Example 58 from 2-fluoro-5-iodopyridine and by using (RS)-1-cyclopropyl-ethane-1,2-diamine instead of (RS)-hexahydro-imidazo[1,5-a]pyridin-3-one.
Example 84
(3aSR,7aRS)-(3aRS,7RS)-1-Methyl-3-(5-phenylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one
[0636]
Step 1: (1SR,2RS)-(1RS,2RS)—N-(5-Iodo-pyridin-2-yl)-cyclohexane-1,2-diamine
[0637]
[0638] The title compound was obtained as a brown oil, MS: m/e=318.1 (M+H + ), using chemistry similar to that described in Example 1, step 1 from 2-fluoro-5-iodopyridine and rac-cyclohexane-1,2-diamine.
Step 2: (3aSR,7aRS)-(3aRS,7aRS)-1-(5-Iodo-pyridin-2-yl)-octahydro-benzoimidazol-2-one
[0639]
[0640] The title compound was obtained as a yellow solid, MS: m/e=344.1 (M+H + ), using chemistry similar to that described in Example 1, step 2 from (1SR,2RS)-(1RS,2RS)—N-(5-iodo-pyridin-2-yl)-cyclohexane-1,2-diamine (Example 84, step 1).
Step 3: (3aSR,7aRS)-(3aRS,7aRS)-1-(5-Iodo-pyridin-2-yl)-3-methyl-octahydro-benzoimidazol-2-one
[0641]
[0642] The title compound was obtained as a white solid, MS: m/e=358.0 (M+H + ), using chemistry similar to that described in Example 16 from (3aSR,7aRS)-(3aRS,7aRS)-1-(5-iodo-pyridin-2-yl)-octahydro-benzoimidazol-2-one (Example 84, step 2) and iodomethane.
Step 4: (3aSR,7aRS)-(3aRS,7RS)-1-Methyl-3-(5-phenylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one
[0643]
[0644] The title compound was obtained as a yellow solid, MS: m/e=332.3 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aSR,7aRS)-(3aRS,7aRS)-1-(5-iodo-pyridin-2-yl)-3-methyl-octahydro-benzoimidazol-2-one (Example 84, step 3) and phenylacetylene.
Example 85
(3aSR,7aRS)-(3aRS,7RS)-1-Methyl-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one
[0645]
[0646] The title compound was obtained as a light yellow solid, MS: m/e=333.3 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aSR,7aRS)-(3aRS,7aRS)-1-(5-iodo-pyridin-2-yl)-3-methyl-octahydro-benzoimidazol-2-one (Example 84, step 3) and 3-ethynylpyridine.
Example 86
(3aSR,7aRS)-(3aRS,7RS)-1-[5-(5-Fluoro-pyridin-3-ylethynyl)-pyridin-2-yl]-3-methyl-octahydro-benzoimidazol-2-one
[0647]
[0648] The title compound was obtained as a light yellow solid, MS: m/e=351.3 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aSR,7aRS)-(3aRS,7aRS)-1-(5-iodo-pyridin-2-yl)-3-methyl-octahydro-benzoimidazol-2-one (Example 84, step 3) and 3-ethynyl-5-fluoro-pyridine (generated by in situ Sonogashira reaction of 3-fluoro-5-iodopyridine with ethynyltrimethylsilane and TBAF).
Example 87
4,4-Dimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0649]
Step 1: 4,4-Dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0650]
[0651] The title compound was obtained as a yellow solid, MS: m/e=301.3 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyridine (Example 37, step 1) and by using 4,4-dimethyl-piperidin-2-one (CAS 55047-81-9) instead of 4,4-dimethylpyrrolidin-2-one.
Step 2: 4,4-Dimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2]′bipyridinyl-2-one
[0652]
[0653] The title compound was obtained as a white solid, MS: m/e=305.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one (Example 87, step 1) and iodobenzene.
Example 88
5′-(3-Fluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0654]
[0655] The title compound was obtained as a white solid, MS: m/e=323.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one (Example 87, step 1) and 1-fluoro-3-iodobenzene.
Example 89
5′-(3-Chloro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0656]
[0657] The title compound was obtained as a light yellow solid, MS: m/e=339.2/341.1 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one (Example 87, step 1) and 1-chloro-3-iodobenzene.
Example 90
5′-(5-Chloro-pyridin-3-ylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0658]
[0659] The title compound was obtained as a light yellow solid, MS: m/e=340.1/342.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one (Example 87, step 1) and 1-chloro-3-iodopyridine.
Example 91
5′-(4-Fluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0660]
[0661] The title compound was obtained as a light yellow solid, MS: m/e=323.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one (Example 87, step 1) and 1-fluoro-4-iodobenzene.
Example 92
5′-(2,5-Difluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one
[0662]
[0663] The title compound was obtained as a white solid, MS: m/e=341.1 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyridinyl-2-one (Example 87, step 1) and 1,4-difluoro-2-iodobenzene.
Example 93
7,7-Dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazepan-2-one
[0664]
Step 1: 3-(5-Iodo-pyridin-2-yl)-7,7-dimethyl-[1,3]oxazepan-2-one
[0665]
[0666] The title compound was obtained as a colorless oil, MS: m/e=346.9 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and 5-amino-2-methylpentan-2-ol (CAS 108262-66-4).
Step 2: 7,7-Dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazepan-2-one
[0667]
[0668] The title compound was obtained as an orange solid, MS: m/e=321.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 3-(5-iodo-pyridin-2-yl)-7,7-dimethyl-[1,3]oxazepan-2-one (Example 93, step 1) and phenylacetylene.
Example 94
(3aSR,7aRS)-(3aRS,7RS)-1-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-pyrano[4,3-d]oxazol-2-one
[0669]
Step 1: (3aSR,7aRS)-(3aRS,7RS)-1-(5-Iodo-pyridin-2-yl)-hexahydro-pyrano[4,3-d]oxazol-2-one
[0670]
[0671] The title compound was obtained as a white solid, MS: m/e=346.9 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and (3RS,4RS)-(3RS,4SR)-4-aminotetrahydro-2H-pyran-3-ol (CAS 33332-01-3).
Step 2: (3aSR,7aRS)-(3aRS,7RS)-1-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-pyrano[4,3-d]oxazol-2-one
[0672]
[0673] The title compound was obtained as a brown solid, MS: m/e=321.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aSR,7aRS)-(3aRS,7RS)-1-(5-iodo-pyridin-2-yl)-hexahydro-pyrano[4,3-d]oxazol-2-one (Example 94, step 1) and phenylacetylene.
Example 95
(RS)-5-Hydroxy-6,6-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0674]
Step 1: (RS)-2-(tert-Butyl-diphenyl-silanyloxy)-3-dibenzylamino-propionic acid ethyl ester
[0675]
[0676] (5.8 g, 18.6 mmol) (RS)-3-Dibenzylamino-2-hydroxy-propionic acid ethyl ester (CAS 93715-75-4) was dissolved in DMF (40 ml) and tert-butylchlorodiphenylsilane (6.76 ml, 26 mmol, 1.4 equiv.), Imidazole (1.9 g, 27.9 mmol, 1.5 equiv.) and DMAP (227 mg, 1.9 mmol, 0.1 equiv.) were added at room temperature. The mixture was stirred for 3 hours at 80° C. The reaction mixture was evaporated and extracted with saturated NaHCO 3 solution and two times with EtOAc. The organic layers were extracted with brine, dried over Na 2 SO 4 and evaporated to dryness. The crude product was purified by flash chromatography on silica gel column and eluting with an ethyl acetate:heptane gradient 0:100 to 40:60. The desired (RS)-2-(tert-butyl-diphenyl-silanyloxy)-3-dibenzylamino-propionic acid ethyl ester (8.1 g, 79% yield) was obtained as a colorless oil, MS: m/e=552.5 (M+H + ).
Step 2: (RS)-3-(tert-Butyl-diphenyl-silanyloxy)-4-dibenzylamino-2-methyl-butan-2-ol
[0677]
[0678] (8.0 g, 14.5 mmol) (RS)-2-(tert-Butyl-diphenyl-silanyloxy)-3-dibenzylamino-propionic acid ethyl ester (Example 95, step 1) was dissolved in THF (100 ml) and methylmagnesium bromide (3M in diethylether) (19.3 ml, 58 mmol, 4 equiv.) was drop wise at room temperature. The mixture was stirred for 3.5 hours at room temperature. The reaction mixture was extracted with saturated NaHCO 3 solution and two times with EtOAc. The organic layers were extracted with brine, dried over Na 2 SO 4 and evaporated to dryness. The desired (RS)-3-(tert-butyl-diphenyl-silanyloxy)-4-dibenzylamino-2-methyl-butan-2-ol (6.9 g, 84% yield) was obtained as a white solid, MS: m/e=538.5 (M+H + ) and used in the next step without further purification.
Step 3: (RS)-4-Amino-3-(tert-butyl-diphenyl-silanyloxy)-2-methyl-butan-2-ol
[0679]
[0680] (RS)-3-(tert-Butyl-diphenyl-silanyloxy)-4-dibenzylamino-2-methyl-butan-2-ol (Example 95, step 2) was hydrogenated in EtOH with Pd(OH) 2 for 16 hours at 60° C. The desired (RS)-4-amino-3-(tert-butyl-diphenyl-silanyloxy)-2-methyl-butan-2-ol (4.2 g, 92% yield) was obtained as a colorless oil, MS: m/e=358.2 (M+H + ) and used in the next step without further purification.
Step 4: (RS)-5-(2,2-Dimethyl-1,1-diphenyl-propoxy)-6,6-dimethyl-[1,3]oxazinan-2-one
[0681]
[0682] (1.83 mg, 5.1 mmol) (RS)-4-Amino-3-(tert-butyl-diphenyl-silanyloxy)-2-methyl-butan-2-ol (Example 95, step 3) was dissolved in THF (35 ml) and cooled to 0-5° C. Triethylamine (2.14 ml, 15.4 mmol, 3 equiv.) and triphosgene (1.67 g, 5.63 mmol, 1.1 equiv.) dissolved in 15 ml THF were added drop wise at 0-5° C. The mixture was stirred for 1 hour at 0-5° C. The reaction mixture was evaporated with isolute and the crude product was purified by flash chromatography by directly loading the residue onto a silica gel column and eluting with a heptane:ethyl acetate gradient 100:0 to 0:100. The desired (RS)-5-(2,2-dimethyl-1,1-diphenyl-propoxy)-6,6-dimethyl-[1,3]oxazinan-2-one (535 mg, 27% yield) was obtained as a white solid, MS: m/e=384.3 (M+H + ).
Step 5: (RS)-5-(2,2-Dimethyl-1,1-diphenyl-propoxy)-6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0683]
[0684] The title compound was obtained as a yellow oil, MS: m/e=557.3 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyridine (Example 37, step 1) and (RS)-5-(2,2-dimethyl-1,1-diphenyl-propoxy)-6,6-dimethyl-[1,3]oxazinan-2-one (Example 95, step 4).
Step 6: (RS)-5-Hydroxy-6,6-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0685]
[0686] The title compound was obtained as a light yellow solid, MS: m/e=323.1 (M+H + ), using chemistry similar to that described in Example 37, step 3 from (RS)-5-(2,2-dimethyl-1,1-diphenyl-propoxy)-6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one (Example 95, step 5) and iodobenzene.
Example 96
4-Methyl-6-(5-phenylethynyl-pyridin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one
[0687]
Step 1: 2-Bromo-5-phenylethynyl-pyridine
[0688]
[0689] The title compound was obtained as a white solid, MS: m/e=258/260 (M+H + ), using chemistry similar to that described in Example 37, step 1 from 2-bromo-5-iodopyridine and by using phenylacetylene instead of ethynyltrimethylsilane.
Step 2: 4,6-Diaza-spiro[2.4]heptan-5-one
[0690]
[0691] (0.88 g, 5.53 mmol) 1-(Aminomethyl)cyclopropanamine dihydrochloride (CAS 849149-67-3) was dissolved in THF (10 ml) and CDI (0.9 g, 5.53 mmol, 1.0 equiv.) was added at room temperature. The mixture was stirred for 16 hours at 70° C. The reaction mixture was evaporated and extracted with saturated NaHCO 3 solution and five times with dichloromethane. The organic layers were dried over Na 2 SO 4 and evaporated to dryness. The desired 4,6-diaza-spiro[2.4]heptan-5-one (0.52 g, 50% purity, 42% yield) was obtained as a white solid, MS: m/e=113.0 (M+H + ) and was used without further purification in the next step.
Step 3: 6-(5-Phenylethynyl-pyridin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one
[0692]
[0693] The title compound was obtained as a yellow solid, MS: m/e=290.1 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-phenylethynyl-pyridine (Example 96, step 1) and 4,6-diaza-spiro[2.4]heptan-5-one (Example 96, step 2).
Step 4: 4-Methyl-6-(5-phenylethynyl-pyridin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one
[0694]
[0695] The title compound was obtained as a white solid, MS: m/e=304.1 (M+H + ), using chemistry similar to that described in Example 16 from 6-(5-phenylethynyl-pyridin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one (Example 96, step 3) and iodomethane.
Example 97
3,3-Dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-azetidin-2-one
[0696]
Step 1: N-(5-Bromo-pyridin-2-yl)-3-chloro-2,2-dimethyl-propionamide
[0697]
[0698] To a solution of 2-amino-5-bromopyridine (100 mg, 0.454 mmol) in dichloromethane (6 ml) were added triethylamine (0.19 ml, 1.364 mmol, 3 equiv.) and 3-chloro-2,2-dimethyl-propionyl chloride (CAS 4300-97-4) (140 mg, 0.909 mmol, 2 equiv.) at 0-5° C. The mixture was stirred for 16 hours at room temperature. The reaction mixture was evaporated and the crude product was purified by flash chromatography on silica gel column and eluting with an ethyl acetate:heptane gradient 5:95 to 10:90. The desired N-(5-bromo-pyridin-2-yl)-3-chloro-2,2-dimethyl-propionamide (154 mg, 74% yield) was obtained as a white solid.
Step 2: 1-(5-Bromo-pyridin-2-yl)-3,3-dimethyl-azetidin-2-one
[0699]
[0700] (250 mg, 0.738 mmol) N-(5-Bromo-pyridin-2-yl)-3-chloro-2,2-dimethyl-propionamide (Example 97, step 1) dissolved in DMF (3 ml) was added at room temperature to a solution of NaH (29.5 mg, 0.738 mmol, 1 equiv.) in 5 ml DMF. The mixture was stirred for 3 hours at 70° C. The reaction mixture was evaporated and the crude product was purified by flash chromatography on silica gel column and eluting with an ethyl acetate:heptane gradient 10:90 to 15:85. The desired 1-(5-bromo-pyridin-2-yl)-3,3-dimethyl-azetidin-2-one (160 mg, 72% yield) was obtained as a white solid.
Step 3: 3,3-Dimethyl-1-(5-phenylethynyl-pyridin-2-yl)-azetidin-2-one
[0701]
[0702] The title compound was obtained as a brown solid, MS: m/e=277.0 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 1-(5-bromo-pyridin-2-yl)-3,3-dimethyl-azetidin-2-one (Example 97, step 2) and phenylacetylene.
Example 98
(1RS,5SR)-6-(5-Pyridin-3-ylethynyl-pyridin-2-yl)-6-aza-bicyclo[3.2.0]heptan-7-one
[0703]
[0704] The title compound was obtained as a brown solid, MS: m/e=290.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (1RS,5SR)-6-(5-bromo-pyridin-2-yl)-6-aza-bicyclo[3.2.0]heptan-7-one (Example 46, step 1) with 3-ethynyl-pyridine.
Example 99
(3aSR,7aRS)-(3aRS,7RS)-1-Ethyl-3-(5-phenylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one
[0705]
Step 1: (3aSR,7aRS)-(3aRS,7aRS)-1-(5-Iodo-pyridin-2-yl)-3-ethyl-octahydro-benzoimidazol-2-one
[0706]
[0707] The title compound was obtained as a light yellow solid, MS: m/e=372.2 (M+H + ), using chemistry similar to that described in Example 16 from (3aSR,7aRS)-(3aRS,7aRS)-1-(5-iodo-pyridin-2-yl)-octahydro-benzoimidazol-2-one (Example 84, step 2) and iodoethane by stirring the reaction at 60° C. instead of 0-5° C.
Step 2: (3aSR,7aRS)-(3aRS,7RS)-1-Ethyl-3-(5-phenylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one
[0708]
[0709] The title compound was obtained as a brown oil, MS: m/e=346.4 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aSR,7aRS)-(3aRS,7aRS)-1-(5-iodo-pyridin-2-yl)-3-ethyl-octahydro-benzoimidazol-2-one (Example 99, step 1) and phenylacetylene.
Example 100
(3aSR,7aRS)-(3aRS,7RS)-1-Ethyl-3-(5-pyridin-3-ylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one
[0710]
[0711] The title compound was obtained as a brown solid, MS: m/e=347.8 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aSR,7aRS)-(3aRS,7aRS)-1-(5-iodo-pyridin-2-yl)-3-ethyl-octahydro-benzoimidazol-2-one (Example 99, step 1) and 3-ethynyl-pyridine.
Example 101
(3aSR,7aRS)-(3aRS,7RS)-1-Isopropyl-3-(5-phenylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one
[0712]
Step 1: (3aSR,7aRS)-(3aRS,7aRS)-1-(5-Iodo-pyridin-2-yl)-3-isopropyl-octahydro-benzoimidazol-2-one
[0713]
[0714] The title compound was obtained as a white solid using chemistry similar to that described in Example 16 from (3aSR,7aRS)-(3aRS,7aRS)-1-(5-iodo-pyridin-2-yl)-octahydro-benzoimidazol-2-one (Example 84, step 2) and isopropyl iodide by stirring the reaction at 60° C. instead of 0-5° C.
Step 2: (3aSR,7aRS)-(3aRS,7RS)-1-Isopropyl-3-(5-phenylethynyl-pyridin-2-yl)-octahydro-benzoimidazol-2-one
[0715]
[0716] The title compound was obtained as a brown oil, MS: m/e=360.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (3aSR,7aRS)-(3aRS,7aRS)-1-(5-iodo-pyridin-2-yl)-3-isopropyl-octahydro-benzoimidazol-2-one (Example 101, step 1) and phenylacetylene.
Example 102
(4aRS,7aSR)-3-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one
[0717]
Step 1: (4aRS,7aSR)-3-(5-Iodo-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one
[0718]
[0719] The title compound was obtained as a white solid, MS: m/e=345.0 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and (1SR,2RS)-2-aminomethyl-cyclopentanol (CAS 40482-02-8) by using triphosgene and triethylamine in THF for 12 hours at room temperature instead of the conditions used in Example 1, step 2.
Step 2: (4aRS,7aSR)-3-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one
[0720]
[0721] The title compound was obtained as a brown solid, MS: m/e=319.0 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (4aRS,7aSR)-3-(5-iodo-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one (Example 102, step 1) and phenylacetylene.
Example 103
(4aRS,7aRS)-3-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one
[0722]
Step 1: (4aRS,7aRS)-3-(5-Iodo-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one
[0723]
[0724] The title compound was obtained as a white solid, MS: m/e=345.0 (M+H + ), using procedures similar to those described in Example 1, step 1 and step 2 from 2-fluoro-5-iodopyridine and (1SR,2SR)-2-aminomethyl-cyclopentanol (CAS 40482-00-6) by using triphosgene and triethylamine in THF for 12 hours at room temperature instead of the conditions used in Example 1, step 2.
Step 2: (4aRS,7aRS)-3-(5-Phenylethynyl-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one
[0725]
[0726] The title compound was obtained as a brown solid, MS: m/e=318.8 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (4aRS,7aRS)-3-(5-iodo-pyridin-2-yl)-hexahydro-cyclopenta[e][1,3]oxazin-2-one (Example 103, step 1) and phenylacetylene.
Example 104
(RS)-5,6,6-Trimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0727]
Step 1: (RS)-(3-Hydroxy-2,3-dimethyl-butyl)-carbamic acid tert-butyl ester
[0728]
[0729] The title compound was obtained as a colorless oil, MS: m/e=218.3 (M+H + ), using chemistry similar to that described in Example 95, step 2 from methyl 3-(tert-butoxycarbonylamino)-2-methylpropanoate (CAS 182486-16-4).
Step 2: (RS)-5,6,6-Trimethyl-[1,3]oxazinan-2-one
[0730]
[0731] The title compound was obtained as a yellow solid, MS: m/e=144.0 (M+H + ), using chemistry similar to that described in Example 72, step 2 from (RS)-(3-hydroxy-2,3-dimethyl-butyl)-carbamic acid tert-butyl ester (Example 104, step 1).
Step 3: (RS)-5,6,6-Trimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0732]
[0733] The title compound was obtained as a yellow oil, MS: m/e=321.1 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-phenylethynyl-pyridine (Example 96, step 1) and (RS)-5,6,6-trimethyl-[1,3]oxazinan-2-one (Example 104, step 2).
Example 105
(RS)-6-Methoxymethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0734]
[0735] The title compound was obtained as a light yellow solid, MS: m/e=323.1 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-phenylethynyl-pyridine (Example 96, step 1) and (RS)-6-methoxymethyl-[1,3]oxazinan-2-one (CAS 39754-63-7).
Example 106
(3aRS,6aSR)-1-methyl-3-(5-(phenylethynyl)pyridin-2-yl)hexahydrocyclopenta[d]imidazol-2(1H)-one
[0736]
Step 1: (3aSR,6aRS)-2-oxo-hexahydro-cyclopentaimidazole-1-carboxylic acid tert-butyl ester
[0737]
[0738] A solution of (rac)-cis-2-(tert-butoxycarbonylamino)cyclopentanecarboxylic acid (2.28 g, 9.98 mmol) and N-methylmorpholine (1.1 g, 1.21 ml, 11.0 mmol, 1.1 equiv.) in 28 ml of dichloroethane was stirred at r.t. for 10 min. Then diphenylphosphoricacid azide (3.02 g, 2.37 ml, 11.0 mmol, 1.1 equiv.) was added dropwise at room temperature and the colorless solution was stirred for 45 min at room temperature during which the solution turned light yellow. The solution was then warmed to 75° C. and stirred overnight and allowed to cool. After workup with dichloromethane/water, the combined organic phases were evaporated to dryness. The orange solid was triturated with ethyl acetate and filtered to give 1.27 g of a white solid. The mother liquors were concentrated and the cristallized material was again filtered to yield an additional 0.55 g of product. One obtains a total yield of 1.82 g (81%) of the title compound as a crystalline white solid, MS: m/e=227.3 (M+H + ).
Step 2: (3aSR,6aRS)-3-Methyl-2-oxo-hexahydro-cyclopentaimidazole-1-carboxylic acid tert-butyl ester
[0739]
[0740] To a solution of (3aSR,6aRS)-2-oxo-hexahydro-cyclopentaimidazole-1-carboxylic acid tert-butyl ester (Example 106, step 1) (1.82 g, 8.04 mmol) in 30 ml of DMF was added a 60% suspension of sodium hydride in mineral oil (386 mg, 9.65 mmol, 1.2 equiv.). The suspension was stirred for 45 minutes at room temperature (gas evolution), then iodomethane (0.604 ml, 9.65 mmol, 1.2 equiv.) was added and the mixture was stirred at room temperature overnight. After concentration in vaccuo and workup with ethyl acetate/water, 2.05 g of a yellow oil were obtained containing mineral-oil drops which was directly used in the next step without further characterisation.
Step 3: (3aRS,6aSR)-1-Methyl-hexahydro-cyclopentaimidazol-2-one
[0741]
[0742] To a solution of (3aSR,6aRS)-3-methyl-2-oxo-hexahydro-cyclopentaimidazole-1-carboxylic acid tert-butyl ester (Example 106, step 2) (1.99 g, 8.28 mmol) in 30 ml of dichloromethane was added trifluoroacetic acid (7.55 g, 5.1 ml, 66.3 mmol, 8 equiv.) and the yellow solution was stirred at for 5 h at room temperature. The reaction mixture was quenched by addition of saturated sodium bicarbonate solution and the pH of the aqueous phase was set to 9. After workup with dichloromethane/water, the organic phases were dried, filtered and concentrated in vaccuo to yield 1.07 g of an off-white solid, which was taken up in cold ethyl acetate and filtered to yield the title compound (822 mg, 71%) as a crystalline white solid which was directly used in the next step without further characterisation.
Step 4: (3aRS,6aSR)-1-methyl-3-(5-(phenylethynyl)pyridin-2-yl)hexahydrocyclopenta[d]imidazol-2(1H)-one
[0743]
[0744] To a suspension of 2-bromo-5-(phenylethynyl)pyridine (Example 96, step 1) (55.0 mg, 0.213 mmol), (3aR,6aS)-1-methylhexahydrocyclopenta[d]imidazol-2(1H)-one (Example 106, step 3) (35.8 mg, 0.256 mmol, 1.2 equiv.), 139 mg cesium carbonate (139 mg, 0.426 mmol, 2 equiv.), and 4,5-bis(diphenylphosphino)-9,9-dimethylxanthene (xantphos) (5 mg, 0.008 mmol, 0.04 equiv.) in 1 ml of toluene was added under argon atmosphere tris(dibenzylideneacetone)dipalladium(0) (Pd 2 (dba) 3 ) (4 mg, 0.0046 mmol, 0.02 equiv.). The mixture was stirred overnight at 70° C. The mixture was directly loaded on a 20 g silicagel column and was eluted with a heptane to 33% ethylacetate in heptane gradient to yield the title compound (49 mg, 73%) as an amorphous light-yellow solid, MS: m/e=318.1 (M+H + ).
Example 107
(RS)-4-tert-Butyl-3-methyl-1-(5-phenylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0745]
[0746] The title compound was obtained as a light yellow solid, MS: m/e=334.1 (M+H + ), using procedures similar to those described in Example 106 starting from (rac)-2-(tert-butoxycarbonylamino-methyl)-3,3-dimethyl-butyric acid instead of (rac)-cis-2-(tert-butoxycarbonylamino)cyclopentanecarboxylic acid.
Examples 108
1-[5-(3-Fluoro-phenylethynyl)-3-methyl-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0747]
Step 1: 4,4-Dimethyl-1-(3-methyl-5-trimethylsilanylethynyl-pyridin-2-yl)-imidazolidin-2-one
[0748]
[0749] The title compound was obtained as a yellow solid, MS: m/e=302.1 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-3-methyl-5-trimethylsilanylethynyl-pyridine (Example 41, step 1) and 4,4-dimethyl-imidazolidin-2-one (CAS 24572-33-6).
Step 2: 1-[5-(3-Fluoro-phenylethynyl)-3-methyl-pyridin-2-yl]-4,4-dimethyl-imidazolidin-2-one
[0750]
[0751] The title compound was obtained as a light yellow solid, MS: m/e=324.4 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4,4-dimethyl-1-(3-methyl-5-trimethylsilanylethynyl-pyridin-2-yl)-imidazolidin-2-one (Example 108, step 1) and 1-fluoro-3-iodobenzene.
Step 3: 1-[5-(3-Fluoro-phenylethynyl)-3-methyl-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0752]
[0753] The title compound was obtained as a light yellow solid, MS: m/e=338.3 (M+H + ), using chemistry similar to that described in Example 16 from 1-[5-(3-fluoro-phenylethynyl)-3-methyl-pyridin-2-yl]-4,4-dimethyl-imidazolidin-2-one (Example 108, step 2) and iodomethane.
Example 109
(3aSR,6aRS)-1-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-3-methyl-hexahydro-cyclopenta-imidazol-2-one
[0754]
Step 1: (3aRS,6aSR)-1-Methyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-hexahydro-cyclopenta-imidazol-2-one
[0755]
[0756] The title compound, an off-white solid, MS: m/e=314.1 (M+H + ), was prepared in accordance with the general method of example 106, step 4 starting from 2-bromo-5-((trimethylsilyl)ethynyl)-pyridine (Example 37, step 1) and (3aRS,6aSR)-1-methylhexahydrocyclopenta[d]imidazol-2(1H)-one (Example 106, step 3).
Step 2: (3aSR,6aRS)-1-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-3-methyl-hexahydro-cyclopenta-imidazol-2-one
[0757]
[0758] The title compound, a light yellow oil, MS: m/e=336.2 (M+H + ), was prepared in accordance with the general method of Example 37, step 3 starting from (3aRS,6aSR)-1-methyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-hexahydro-cyclopenta-imidazol-2-one (Example 109, step 1) and 1-fluoro-3-iodobenzene.
Example 110
1-[3-Fluoro-5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0759]
Step 1: 1-(3-Fluoro-5-iodo-pyridin-2-yl)-4,4-dimethyl-imidazolidin-2-one
[0760]
[0761] 2,3-Difluoro-5-iodopyridine (300 mg, 1.24 mmol) was dissolved in 2 ml toluene. (140 mg, 1.24 mmol, 1 equiv.) 4,4-Dimethylimidazolidin-2-one (CAS 24572-33-6) and cesium carbonate (650 mg, 1.99 mmol, 1.6 equiv.) were added and the mixture was heated to 100° C. for 4 hours. The reaction mixture was loaded directly onto a silica gel column and purified by flash chromatography eluting with an ethyl acetate:heptane gradient 0:100 to 100:0. The desired 1-(3-fluoro-5-iodo-pyridin-2-yl)-4,4-dimethyl-imidazolidin-2-one (205 mg, 49% yield) was obtained as a white solid, MS: m/e=336.1 (M+H + ).
Step 2: 1-(3-Fluoro-5-iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one
[0762]
[0763] The title compound, a yellow oil, MS: m/e=350.0 (M+H + ), was prepared in accordance with the general method of Example 16 from 1-(3-fluoro-5-iodo-pyridin-2-yl)-4,4-dimethyl-imidazolidin-2-one (Example 110, step 1) and iodomethane.
Step 3: 1-[3-Fluoro-5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0764]
[0765] The title compound was obtained as a light yellow solid, MS: m/e=342.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 1-(3-fluoro-5-iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 110, step 2) and 1-ethynyl-4-fluorobenzene.
Example 111
1-[3-Fluoro-5-(3-fluoro-phenylethynyl)-pyridin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0766]
[0767] The title compound was obtained as a light yellow solid, MS: m/e=342.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 1-(3-fluoro-5-iodo-pyridin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 110, step 2) and 1-ethynyl-3-fluorobenzene.
Example 112
6-[5-(4-Fluoro-phenylethynyl)-pyridin-2-yl]-4-methyl-4,6-diaza-spiro[2.4]heptan-5-one
[0768]
Step 1: 4-Methyl-4,6-diaza-spiro[2.4]heptan-5-one
[0769]
[0770] The title compound was obtained as a white solid using procedures similar to those described in Example 106, step 1 to 3 starting from 1-((tert-butoxycarbonylamino)methyl)cyclopropanecarboxylic acid instead of (rac)-cis-2-(tert-butoxycarbonylamino)cyclopentanecarboxylic acid.
Step 2: 4-Methyl-6-(5-trimethylsilanylethynyl-pyridin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one
[0771]
[0772] The title compound was obtained as a white solid, MS: m/e=300.2 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyridine (Example 37, step 1) and 4-methyl-4,6-diaza-spiro[2.4]heptan-5-one (Example 112, step 1).
Step 3: 6-[5-(4-Fluoro-phenylethynyl)-pyridin-2-yl]-4-methyl-4,6-diaza-spiro[2.4]heptan-5-one
[0773]
[0774] The title compound was obtained as a light yellow solid, MS: m/e=322.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4-methyl-6-(5-trimethylsilanylethynyl-pyridin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one (Example 112, step 2) and 1-fluoro-4-iodobenzene.
Example 113
6-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-4-methyl-4,6-diaza-spiro[2.4]heptan-5-one
[0775]
[0776] The title compound was obtained as a light brown solid, MS: m/e=322.2 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 4-methyl-6-(5-trimethylsilanylethynyl-pyridin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one (Example 112, step 2) and 1-fluoro-3-iodobenzene.
Example 114
(RS)-5-Methoxy-6,6-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0777]
Step 1: (RS)-3-Benzyloxycarbonylamino-2-methoxy-propionic acid methyl ester
[0778]
[0779] The title compound was obtained using chemistry similar to that described in Example 16 starting from (RS)-3-benzyloxycarbonylamino-2-hydroxy-propionic acid methyl ester, which was directly used in the next step without further characterisation.
Step 2: (RS)-5-Methoxy-6,6-dimethyl-[1,3]oxazinan-2-one
[0780]
[0781] The title compound was obtained as a light yellow oil, MS: m/e=160.2 (M+H + ), using procedures similar to those described in Example 95, step 2 and Example 72, step 2 from (RS)-3-benzyloxycarbonylamino-2-methoxy-propionic acid methyl ester (Example 114, step 1).
Step 3: (RS)-5-Methoxy-6,6-dimethyl-3-(5-phenylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[0782]
[0783] The title compound was obtained as a light yellow oil, MS: m/e=337.3 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-phenylethynyl-pyridine (Example 96, step 1) and (RS)-5-methoxy-6,6-dimethyl-[1,3]oxazinan-2-one (Example 114, step 2).
Example 115
4,4-Dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one
[0784]
Step 1: 2-Methanesulfonyl-5-phenylethynyl-pyrimidine
[0785]
[0786] Bis-(triphenylphosphine)-palladium(II) dichloride (1.48 g, 2.11 mmol, 0.05 equiv.) was dissolved in 200 ml THF. (10 g, 42.2 mmol) 5-Bromo-2-(methylsulfonyl)pyrimidine and phenylacetylene (9.26 ml, 84.4 mmol, 2 equiv.) were added at room temperature. Triethylamine (17.6 ml, 127 mmol, 3 equiv.), triphenylphosphine (330 mg, 1.3 mmol, 0.03 equiv.) and copper(I) iodide (80 mg, 420 μmol, 0.01 equiv.) were added and the mixture was stirred for 4 hours at 65° C. The reaction mixture was cooled and extracted with saturated NaHCO 3 solution and two times with EtOAc. The organic layers were extracted with water, dried over sodium sulfate and evaporated to dryness. The crude product was purified by flash chromatography on a silica gel column and eluting with an ethyl acetate:heptane gradient 0:100 to 100:0. The desired 2-methanesulfonyl-5-phenylethynyl-pyrimidine (6.2 g, 57% yield) was obtained as a yellow solid, MS: m/e=259.1 (M+H + ).
Step 2: 4,4-Dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one
[0787]
[0788] (100 mg, 0.39 mmol) 2-Methanesulfonyl-5-phenylethynyl-pyrimidine (Example 115, step 1) was dissolved in 1 ml dioxane. 4,4-Dimethylpyrrolidin-2-one (53 mg, 465 μmol, 1.2 equiv.) and cesium carbonate (190 mg, 580 μmol, 1.5 equiv.) were added at room temperature. The mixture was stirred for 4 hours at 100° C. The reaction mixture was cooled, evaporated and extracted with saturated NaHCO 3 solution and two times with a small volume of dichloromethane. The crude product was purified by flash chromatography by directly loading the dichloromethane layers onto a silica gel column and eluting with an ethyl acetate:heptane gradient 0:100 to 100:0. The desired 4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one (32 mg, 28% yield) was obtained as a light yellow solid, MS: m/e=292.1 (M+H + ).
Example 116
5,5-Dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-piperidin-2-one
[0789]
[0790] The title compound was obtained as a brown oil, MS: m/e=306.2 (M+H + ), using chemistry similar to that described in Example 115, step 2 from 2-methanesulfonyl-5-phenylethynyl-pyrimidine (Example 115, step 1) and 5,5-dimethylpiperidin-2-one (CAS 4007-79-8).
Example 117
2-(5-Phenylethynyl-pyrimidin-2-yl)-2-aza-spiro[4.4]nonan-3-one
[0791]
[0792] The title compound was obtained as a light yellow solid, MS: m/e=318.2 (M+H + ), using chemistry similar to that described in Example 115, step 2 from 2-methanesulfonyl-5-phenylethynyl-pyrimidine (Example 115, step 1) and 2-aza-spiro[4.4]nonan-3-one (CAS 75751-72-3).
Example 118
1-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0793]
Step 1: 1-(5-Bromo-pyrimidin-2-yl)-4,4-dimethyl-pyrrolidin-2-one
[0794]
[0795] The title compound was obtained as a light yellow solid, MS: m/e=270.1/272.2 (M+H + ), using chemistry similar to that described in Example 115, step 2 from 5-bromo-2-fluoropyrimidine and 4,4-dimethylpyrrolidin-2-one.
Step 2: 1-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0796]
[0797] The title compound was obtained as a light yellow solid, MS: m/e=310.2 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-bromo-pyrimidin-2-yl)-4,4-dimethyl-pyrrolidin-2-one (Example 118, step 1) and 1-ethynyl-3-fluoro-benzene.
Example 119
1-[5-(3-Chloro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0798]
Step 1: 2-Chloro-5-(3-chloro-phenylethynyl)-pyrimidine
[0799]
[0800] The title compound was obtained as a light brown solid, MS: m/e=248/250 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 2-chloro-5-iodopyrimidine and 1-chloro-3-ethynyl-benzene.
Step 2: 1-[5-(3-Chloro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0801]
[0802] The title compound was obtained as a light yellow solid, MS: m/e=326.3/328.3 (M+H + ), using chemistry similar to that described in Example 115, step 2 from 2-chloro-5-(3-chloro-phenylethynyl)-pyrimidine (Example 119, step 1) and 4,4-dimethylpyrrolidin-2-one.
Example 120
1-[5-(4-Fluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0803]
Step 1: 2-Bromo-5-trimethylsilanylethynyl-pyrimidine
[0804]
[0805] 2-Bromo-5-iodopyrimidine (1.2 g, 4.2 mmol) was dissolved under nitrogen in 25 ml THF. Bis-(triphenylphosphine)-palladium(II) dichloride (300 mg, 420 μmol, 0.1 equiv.), ethynyltrimethylsilane (540 mg, 0.77 ml, 5.48 mmol, 1.3 equiv.), triethylamine (0.85 g, 1.17 ml, 8.4 mmol, 2 equiv.) and copper(I) iodide (40 mg, 210 mmol, 0.05 equiv.) were added and the mixture was stirred for 4 hours at 50° C. The reaction mixture was cooled and evaporated to dryness. The crude product was purified by flash chromatography on silica gel, eluting with an ethyl acetate:heptane gradient 0:100 to 40:60. The desired 2-bromo-5-trimethylsilanylethynyl-pyrimidine (0.75 g, 70% yield) was obtained as a yellow solid, MS: m/e=255/257 (M+H + ).
Step 2: 4,4-Dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one
[0806]
[0807] (200 mg, 0.78 mmol) 2-Bromo-5-trimethylsilanylethynyl-pyrimidine (Example 120, step 1) was dissolved in toluene (7 ml) and 4,4-dimethylpyrrolidin-2-one (89 mg, 0.78 mmol, 1.0 equiv.), cesium carbonate (410 mg, 1.25 mmol, 1.6 equiv.), xantphos (CAS 161265-03-8) (18 mg, 0.03 mmol, 0.04 equiv.) and Pd 2 (dba) 3 (14 mg, 0.01 mmol, 0.02 equiv.) were added under nitrogen. The mixture was stirred for 2 hours at 90° C. The crude product was purified by flash chromatography by directly loading the toluene mixture onto a silica gel column and eluting with an ethyl acetate:heptane gradient 0:100 to 100:0. The desired 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one (164 mg, 73% yield) was obtained as a light red solid, MS: m/e=288.1 (M+H + ).
Step 3: 1-[5-(4-Fluoro-phenylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0808]
[0809] 4,4-Dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one (Example 120, step 2) (30 mg, 0.1 mmol) was dissolved in DMF (1 ml). 1-Fluoro-4-iodobenzene (32 mg, 0.14 mmol, 1.4 equiv.), Et 3 N (43 μl, 0.31 mmol, 3 equiv.), Bis-(triphenylphosphine)-palladium(II) dichloride (4 mg, 5.2 μmol, 0.05 equiv.) and copper(I) iodide (0.6 mg, 3.1 μmol, 0.03 equiv.) were added under nitrogen and the mixture was heated to 70° C. TBAF 1M in THF (115 μl, 0.115 mmol, 1.1 equiv.) was added dropwise in 20 minutes at 70° C. The reaction mixture was stirred for 30 minutes at 70° C. and evaporated with isolute to dryness. The crude product was purified by flash chromatography with a 20 g silica gel column and eluting with heptane:ethyl acetate 100:0->0:100. The desired 1-[5-(4-fluoro-phenylethynyl)-pyridin-2-yl]-4,4-dimethyl-pyrrolidin-2-one (24 mg, 73% yield) was obtained as a white solid, MS: m/e=310.1 (M+H + ).
Example 121
1-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-pyrrolidin-2-one
[0810]
[0811] The title compound was obtained as a white solid, MS: m/e=328.2 (M+H + ), using chemistry similar to that described in Example 120, step 3 from 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one (Example 120, step 2) and 1,4-difluoro-2-iodobenzene.
Example 122
3,4,4-Trimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-imidazolidin-2-one
[0812]
Step 1: 1-(5-Iodo-pyrimidin-2-yl)-4,4-dimethyl-imidazolidin-2-one
[0813]
[0814] The title compound was obtained as a light yellow solid, MS: m/e=319 (M+H + ), using chemistry similar to that described in Example 115, step 2 from 2-chloro-5-iodopyrimidine and 4,4-dimethyl-imidazolidin-2-one (CAS 24572-33-6).
Step 2: 1-(5-Iodo-pyrimidin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one
[0815]
[0816] (55 mg, 173 μmol) 1-(5-Iodo-pyrimidin-2-yl)-4,4-dimethyl-imidazolidin-2-one (Example 122, step 1) was dissolved in DMF (1 ml) and cooled to 0-5° C. NaH (55%) (9 mg, 225 μmol, 1.3 equiv.) was added and the mixture was stirred for 30 min at 0-5° C. Iodomethane (13 μl, 200 mmol, 1.2 equiv.) was added and the mixture was stirred for 30 min without cooling bath. The reaction mixture was treated with sat. NaHCO 3 solution and extracted twice with a small volume of CH 2 Cl 2 . The organic layers were loaded directly to silica gel column and the crude material was purified by flash chromatography on silica gel (20 gr, ethyl acetate/heptane gradient, 0:100 to 100:0). The desired 1-(5-iodo-pyrimidin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (31 mg, 54% yield) was obtained as a white solid, MS: m/e=333.1 (M+H + ).
Step 3: 3,4,4-Trimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-imidazolidin-2-one
[0817]
[0818] The title compound was obtained as a yellow oil, MS: m/e=307.4 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-iodo-pyrimidin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 122, step 2) and phenylacetylene.
Example 123
1-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0819]
[0820] The title compound was obtained as a light yellow solid, MS: m/e=325.2 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-iodo-pyrimidin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 122, step 2) and 1-ethynyl-3-fluoro-benzene.
Example 124
1-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0821]
Step 1: 4,4-Dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-imidazolidin-2-one
[0822]
[0823] The title compound was obtained as a light yellow solid, MS: m/e=289.0 (M+H + ), using chemistry similar to that described in Example 120, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyrimidine (Example 120, step 1) and 4,4-dimethyl-imidazolidin-2-one (CAS 24572-33-6).
Step 2: 1-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-imidazolidin-2-one
[0824]
[0825] The title compound was obtained as a light brown solid, MS: m/e=329.2 (M+H + ), using chemistry similar to that described in Example 120, step 3 from 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-imidazolidin-2-one (Example 124, step 1) and 1,4-difluoro-2-iodobenzene.
Step 3: 1-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0826]
[0827] The title compound was obtained as a white solid, MS: m/e=343.1 (M+H + ), using chemistry similar to that described in Example 122, step 2 from 1-[5-(2,5-difluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-imidazolidin-2-one (Example 124, step 2) and iodomethane.
Example 125
1-[5-(4-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0828]
[0829] The title compound was obtained as a light brown solid, MS: m/e=325.2 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-iodo-pyrimidin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 122, step 2) and 1-ethynyl-4-fluoro-benzene.
Example 126
1-[5-(3,4-Difluoro-phenylethynyl)-pyrimidin-2-yl]-3,4,4-trimethyl-imidazolidin-2-one
[0830]
[0831] The title compound was obtained as a light brown solid, MS: m/e=343.1 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-iodo-pyrimidin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 122, step 2) and 4-ethynyl-1,2-difluoro-benzene.
Example 127
(RS)-3-Methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one
[0832]
Step 1: (RS)-4-Iodo-N-(5-iodo-pyrimidin-2-yl)-2-methoxy-3,3-dimethyl-butyramide
[0833]
[0834] The title compound was obtained as an orange solid, MS: m/e=476.0 (M+H + ), using chemistry similar to that described in patent WO9637466, page 17, step 2 starting from (RS)-3-methoxy-4,4-dimethyl-dihydro-furan-2-one (CAS 100101-82-4) instead of 3-t-butylcarbamoyloxy-tetrahydrofuran-2-one and by using 2-amino-5-iodopyrimidine instead of 2-amino-4-trifluoromethylpyridine.
Step 2: (RS)-1-(5-Iodo-pyrimidin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0835]
[0836] The title compound was obtained as a light yellow solid, MS: m/e=348.0 (M+H + ), using chemistry similar to that described in patent WO9637466, page 17, step 3 from (RS)-4-iodo-N-(5-iodo-pyrimidin-2-yl)-2-methoxy-3,3-dimethyl-butyramide (Example 127, step 1).
Step 3: (RS)-3-Methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one
[0837]
[0838] The title compound was obtained as a light yellow solid, MS: m/e=322.2 (M+H + ), using chemistry similar to that described in Example 115, step 1 from (RS)-1-(5-iodo-pyrimidin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 127, step 2) and phenylacetylene.
Example 128
(5R or 5S)-5-Methoxymethyl-3-(5-phenylethynyl-pyrimidin-2-yl)-oxazolidin-2-one
[0839]
[0840] The title compound, a light yellow solid, MS: m/e=322.3 (M+H + ), was prepared by separation of (RS)-3-methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one (Example 127) using a chiral column (chiralpak AD with heptane:isopropanol 90:10 as solvent).
Example 129
(5S or 5R)-5-Methoxymethyl-3-(5-phenylethynyl-pyrimidin-2-yl)-oxazolidin-2-one
[0841]
[0842] The title compound, a light yellow solid, MS: m/e=322.3 (M+H + ), was prepared by separation of (RS)-3-methoxy-4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one (Example 127) using a chiral column (chiralpak AD with heptane:isopropanol 90:10 as solvent).
Example 130
(RS)-1-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0843]
[0844] The title compound was obtained as a yellow solid, MS: m/e=340.2 (M+H + ), using chemistry similar to that described in Example 115, step 1 from (RS)-1-(5-iodo-pyrimidin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 127, step 2) and 1-ethynyl-3-fluoro-benzene.
Example 131
(R or S)-1-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0845]
[0846] The title compound, a white solid, MS: m/e=340.3 (M+H + ), was prepared by separation of (RS)-1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 130) using a chiral column (chiralpak AD with heptane:isopropanol 90:10 as solvent).
Example 132
(S or R)-1-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0847]
[0848] The title compound, a white solid, MS: m/e=340.3 (M+H + ), was prepared by separation of (RS)-1-[5-(3-fluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 130) using a chiral column (chiralpak AD with heptane:isopropanol 90:10 as solvent).
Example 133
(R or S)-1-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0849]
Step 1: (RS)-3-Methoxy-4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one
[0850]
[0851] The title compound was obtained as a light brown solid, MS: m/e=318.1 (M+H + ), using chemistry similar to that described in Example 115, step 1 from (RS)-1-(5-iodo-pyrimidin-2-yl)-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 127, step 2) and ethynyl-trimethyl-silane.
Step 2: (RS)-1-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0852]
[0853] The title compound was obtained as a yellow solid, MS: m/e=358.1 (M+H + ), using chemistry similar to that described in Example 120, step 3 from (RS)-3-methoxy-4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-pyrrolidin-2-one (Example 133, step 1) and 1,4-difluoro-2-iodo-benzene.
Step 3: (R or S)-1-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one
[0854]
[0855] The title compound, a white solid, MS: m/e=358.1 (M+H + ), was prepared by separation of (RS)-1-[5-(2,5-difluoro-phenylethynyl)-pyrimidin-2-yl]-3-methoxy-4,4-dimethyl-pyrrolidin-2-one (Example 133, step 2) using a chiral column (Reprosil Chiral NR with heptane:EtOH 70:30 as solvent).
Example 134
4,4-Dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-piperidin-2-one
[0856]
Step 1: 4,4-Dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-piperidin-2-one
[0857]
[0858] The title compound was obtained as a light yellow solid, MS: m/e=302.2 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 2 from 2-bromo-5-trimethylsilanylethynyl-pyrimidine (Example 120, step 1) and 4,4-dimethyl-piperidin-2-one (CAS 55047-81-9).
Step 2: 4,4-Dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-piperidin-2-one
[0859]
[0860] The title compound was obtained as a white solid, MS: m/e=306.3 (M+H + ), using chemistry similar to that described in Example 120, step 3 from 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-piperidin-2-one (Example 134, step 1) and iodobenzene.
Example 135
1-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-piperidin-2-one
[0861]
[0862] The title compound was obtained as a white solid, MS: m/e=324.2 (M+H + ), using chemistry similar to that described in Example 120, step 3 from 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-piperidin-2-one (Example 134, step 1) and 1-fluoro-3-iodobenzene.
Example 136
1-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-4,4-dimethyl-piperidin-2-one
[0863]
[0864] The title compound was obtained as a light yellow solid, MS: m/e=342.3 (M+H + ), using chemistry similar to that described in Example 120, step 3 from 4,4-dimethyl-1-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-piperidin-2-one (Example 134, step 1) and 2,5-difluoro-3-iodobenzene.
Example 137
3,4,4-Trimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0865]
Step 1: 4,4-Dimethyl-tetrahydro-pyrimidin-2-one
[0866]
[0867] (3.4 g, 14.3 mmol) (3-Amino-3-methyl-butyl)-carbamic acid tert-butyl ester hydrochloride was dissolved in THF (60 ml) and KOtBu (6.4 g, 57.1 mmol, 4 equiv.) was added. The mixture was stirred for 16 hours at 60° C. and evaporated then with isolute to dryness. The crude product was purified by flash chromatography by directly loading the residue onto a silica gel column and eluting with an ethyl acetate:methanol gradient 100:0 to 70:30. The desired 4,4-dimethyl-tetrahydro-pyrimidin-2-one (1.65 g, 90% yield) was obtained as a light yellow solid, MS: m/e=129.1 (M+H + ).
Step 2: 4,4-Dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0868]
[0869] The title compound was obtained as a brown solid, MS: m/e=303.2 (M+H + ), using chemistry similar to that described in Example 120, step 2 from 2 from 2-bromo-5-trimethylsilanylethynyl-pyrimidine (Example 120, step 1) and 4,4-dimethyl-tetrahydro-pyrimidin-2-one (Example 137, step 1).
Step 3: 4,4-Dimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0870]
[0871] The title compound was obtained as a yellow solid, MS: m/e=329.2 (M+H + ), using chemistry similar to that described in Example 120, step 3 from 4,4-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one (Example 137, step 2) and iodobenzene.
Step 4: 3,4,4-Trimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0872]
[0873] The title compound was obtained as a light yellow solid, MS: m/e=321.1 (M+H + ), using chemistry similar to that described in Example 122, step 2 from 4,4-dimethyl-5′-phenylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one (Example 137, step 3) and iodomethane.
Example 138
5′-(3-Fluoro-phenylethynyl)-3,4,4-trimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0874]
Step 1: 5′-(3-Fluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0875]
[0876] The title compound was obtained as a light brown solid, MS: m/e=325.2 (M+H + ), using chemistry similar to that described in Example 120, step 3 from 4,4-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one (Example 137, step 2) and 1-fluoro-3-iodobenzene.
Step 2: 5′-(3-Fluoro-phenylethynyl)-3,4,4-trimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0877]
[0878] The title compound was obtained as a yellow oil, MS: m/e=339.2 (M+H + ), using chemistry similar to that described in Example 122, step 2 from 5′-(3-fluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one (Example 138, step 1) and iodomethane.
Example 139
5′-(2,5-Difluoro-phenylethynyl)-3,4,4-trimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0879]
Step 1: 5′-(2,5-Difluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0880]
[0881] The title compound was obtained as a light brown solid, MS: m/e=343.1 (M+H + ), using chemistry similar to that described in Example 120, step 3 from 4,4-dimethyl-5′-trimethylsilanylethynyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one (Example 137, step 2) and 1,4-difluoro-2-iodobenzene.
Step 2: 5′-(2,5-Difluoro-phenylethynyl)-3,4,4-trimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one
[0882]
[0883] The title compound was obtained as a light yellow solid, MS: m/e=357.2 (M+H + ), using chemistry similar to that described in Example 122, step 2 from 5′-(2,5-difluoro-phenylethynyl)-4,4-dimethyl-3,4,5,6-tetrahydro-[1,2′]bipyrimidinyl-2-one (Example 139, step 1) and iodomethane.
Example 140
3-Isopropyl-4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-imidazolidin-2-one
[0884]
Step 1: 1-(5-Iodo-pyrimidin-2-yl)-3-isopropyl-4,4-dimethyl-imidazolidin-2-one
[0885]
[0886] The title compound was obtained as a light yellow oil, MS: m/e=361.0 (M+H + ), using chemistry similar to that described in Example 122, step 2 from 1-(5-iodo-pyrimidin-2-yl)-4,4-dimethyl-imidazolidin-2-one (Example 122, step 1) and 2-iodopropane.
Step 2: 3-Isopropyl-4,4-dimethyl-1-(5-phenylethynyl-pyrimidin-2-yl)-imidazolidin-2-one
[0887]
[0888] The title compound was obtained as a light brown solid, MS: m/e=335.2 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-iodo-pyrimidin-2-yl)-3-isopropyl-4,4-dimethyl-imidazolidin-2-one (Example 140, step 1) and phenylacetylene.
Example 141
1-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3-isopropyl-4,4-dimethyl-imidazolidin-2-one
[0889]
[0890] The title compound was obtained as a light brown solid, MS: m/e=353.3 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-iodo-pyrimidin-2-yl)-3-isopropyl-4,4-dimethyl-imidazolidin-2-one (Example 140, step 1) and 1-ethynyl-3-fluorobenzene.
Example 142
1-[5-(4-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3-isopropyl-4,4-dimethyl-imidazolidin-2-one
[0891]
[0892] The title compound was obtained as a light brown solid, MS: m/e=353.3 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-iodo-pyrimidin-2-yl)-3-isopropyl-4,4-dimethyl-imidazolidin-2-one (Example 140, step 1) and 1-ethynyl-4-fluorobenzene.
Example 143
1-[5-(4-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3-ethyl-4,4-dimethyl-imidazolidin-2-one
[0893]
Step 1: 1-(5-Bromo-pyrimidin-2-yl)-4,4-dimethyl-imidazolidin-2-one
[0894]
[0895] The title compound was obtained as a light brown solid, MS: m/e=271.1/273.1 (M+H + ), using chemistry similar to that described in Example 120, step 2 from 5-bromo-2-iodopyrimidine and 4,4-dimethyl-imidazolidin-2-one (CAS 24572-33-6).
Step 2: 145-Bromo-pyrimidin-2-yl)-3-ethyl-4,4-dimethyl-imidazolidin-2-one
[0896]
[0897] The title compound was obtained as a brown solid, MS: m/e=299.2/301.2 (M+H + ), using chemistry similar to that described in Example 122, step 2 from 1-(5-bromo-pyrimidin-2-yl)-4,4-dimethyl-imidazolidin-2-one (Example 143, step 1) and ethyl iodide.
Step 3: 1-(5-Iodo-pyrimidin-2-yl)-3-ethyl-4,4-dimethyl-imidazolidin-2-one
[0898]
[0899] (350 mg, 1.17 mmol) 1-(5-Bromo-pyrimidin-2-yl)-3-ethyl-4,4-dimethyl-imidazolidin-2-one (Example 143, step 2) was dissolved in dioxane (20 ml) and sodium iodide (700 mg, 4.68 mmol, 4 equiv.), copper(I) iodide (21 mg, 0.234 mmol, 0.2 equiv.) and trans-N,N′-dimethylcyclohexane-1,2-diamine (33 mg, 37 μl, 0.234 mmol, 0.2 equiv.) were added. The mixture was stirred for 16 hours at 100° C. The reaction mixture was cooled and extracted with saturated NaHCO 3 solution and two times ethyl acetate. The organic layers were extracted with brine, dried over sodium sulfate and evaporated to dryness. The desired 1-(5-iodo-pyrimidin-2-yl)-3-ethyl-4,4-dimethyl-imidazolidin-2-one (350 mg, 86% yield) was obtained as a brown solid, MS: m/e=347.0 (M+H + ) and was used without further purification in the next step.
Step 4: 1-[5-(4-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3-ethyl-4,4-dimethyl-imidazolidin-2-one
[0900]
[0901] The title compound was obtained as a brown solid, MS: m/e=339.3 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-iodo-pyrimidin-2-yl)-3-ethyl-4,4-dimethyl-imidazolidin-2-one (Example 143, step 3) and 1-ethynyl-4-fluorobenzene.
Example 144
1-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-3-ethyl-4,4-dimethyl-imidazolidin-2-one
[0902]
[0903] The title compound was obtained as a light brown solid, MS: m/e=339.3 (M+H + ), using chemistry similar to that described in Example 115, step 1 from 1-(5-iodo-pyrimidin-2-yl)-3-ethyl-4,4-dimethyl-imidazolidin-2-one (Example 143, step 3) and 1-ethynyl-3-fluorobenzene.
Example 145
(RS)-5,6,6-Trimethyl-3-(5-phenylethynyl-pyrimidin-2-yl)-[1,3]oxazinan-2-one
[0904]
Step 1: (RS)-(3-Hydroxy-2,3-dimethyl-butyl)-carbamic acid tert-butyl ester
[0905]
[0906] The title compound was obtained as a colorless oil, MS: m/e=218.3 (M+H + ), using chemistry similar to that described in Example 95, step 2 from methyl 3-(tert-butoxycarbonylamino)-2-methylpropanoate (CAS 182486-16-4).
Step 2: (RS)-5,6,6-Trimethyl-[1,3]oxazinan-2-one
[0907]
[0908] The title compound was obtained as a yellow solid, MS: m/e=144.0 (M+H + ), using chemistry similar to that described in Example 72, step 2 from (RS)-(3-hydroxy-2,3-dimethyl-butyl)-carbamic acid tert-butyl ester (Example 145, step 1).
Step 3: 2-Bromo-5-phenylethynyl-pyrimidine
[0909]
[0910] The title compound was obtained as a white solid using chemistry similar to that described in Example 120, step 1 from 2-bromo-5-iodopyrimidine and phenylacetylene.
Step 4: (RS)-5,6,6-Trimethyl-3-(5-phenylethynyl-pyrimidin-2-yl)-[1,3]oxazinan-2-one
[0911]
[0912] The title compound was obtained as a yellow solid, MS: m/e=322.2 (M+H + ), using chemistry similar to that described in Example 120, step 2 from 2-bromo-5-phenylethynyl-pyrimidine (Example 145, step 3) and (RS)-5,6,6-trimethyl-[1,3]oxazinan-2-one (Example 145, step 2).
Example 146
(RS)-3-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-5,6,6-trimethyl-[1,3]oxazinan-2-one
[0913]
Step 1: (RS)-5,6,6-Trimethyl-345-trimethylsilanylethynyl-pyrimidin-2-yl)-[1,3]oxazinan-2-one
[0914]
[0915] The title compound was obtained as a brown solid, MS: m/e=318.1 (M+H), using chemistry similar to that described in Example 120, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyrimidine (Example 120, step 1) and (RS)-5,6,6-trimethyl-[1,3]oxazinan-2-one (Example 145, step 2).
Step 2: (RS)-3-[5-(2,5-Difluoro-phenylethynyl)-pyrimidin-2-yl]-5,6,6-trimethyl-[1,3]oxazinan-2-one
[0916]
[0917] The title compound was obtained as a white solid, MS: m/e=358.4 (M+H + ), using chemistry similar to that described in Example 120, step 3 from (RS)-5,6,6-trimethyl-3-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-[1,3]oxazinan-2-one (Example 146, step 1) and 1,4-difluoro-2-iodobenzene.
Example 147
4-Methyl-6-(5-phenylethynyl-pyrimidin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one
[0918]
Step 1: 4-Methyl-4,6-diaza-spiro[2.4]heptan-5-one
[0919]
[0920] The title compound was obtained as a white solid using procedures similar to those described in Example 106, step 1 to 3 from starting from 1-((tert-butoxycarbonylamino)methyl)cyclopropanecarboxylic acid instead of (rac)-cis-2-(tert-butoxycarbonylamino)cyclopentanecarboxylic acid.
Step 2: 4-Methyl-6-(5-phenylethynyl-pyrimidin-2-yl)-4,6-diaza-spiro[2.4]heptan-5-one
[0921]
[0922] The title compound was obtained as a white solid, MS: m/e=305.3 (M+H + ), using chemistry similar to that described in Example 120, step 2 from 2-bromo-5-phenylethynyl-pyrimidine (Example 145, step 3) and 4-methyl-4,6-diaza-spiro[2.4]heptan-5-one (Example 147, step 1).
Example 148
(RS)-3-[5-(3-Fluoro-phenylethynyl)-pyrimidin-2-yl]-5,6,6-trimethyl-[1,3]oxazinan-2-one
[0923]
[0924] The title compound was obtained as a yellow solid, MS: m/e=340.1 (M+H + ), using chemistry similar to that described in Example 120, step 3 from (RS)-5,6,6-trimethyl-3-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-[1,3]oxazinan-2-one (Example 146, step 1) and 1-fluoro-3-iodobenzene.
Example 149
(RS)-3-[5-(4-Fluoro-phenylethynyl)-pyrimidin-2-yl]-5,6,6-trimethyl-[1,3]oxazinan-2-one
[0925]
[0926] The title compound was obtained as a yellow solid, MS: m/e=340.1 (M+H + ), using chemistry similar to that described in Example 120, step 3 from (RS)-5,6,6-trimethyl-3-(5-trimethylsilanylethynyl-pyrimidin-2-yl)-[1,3]oxazinan-2-one (Example 146, step 1) and 1-fluoro-4-iodobenzene.
Example 150
4,4-Dimethyl-1-(6-(phenylethynyl)pyridazin-3-yl)pyrrolidin-2-one
[0927]
[0928] To a solution of 3-chloro-6-(phenylethynyl)pyridazine (CAS 77778-15-5) (180 mg, 839 mop and 4,4-dimethylpyrrolidin-2-one (CAS 66899-02-3) (142 mg, 1.26 mmol, 1.5 equiv.) in 2 ml of DMF were added cesium carbonate (546 mg, 1.68 mmol, 2 equiv.). The suspension was heated 16 hours at 120° C. and then allowed to cool to room temperature. Ethyl acetate (10 ml) were added and the unsoluble salts were filtered off. After concentration in vaccuo, the residue was dissolved in 10 ml of ethyl acetate. Silicagel (4 g) were added and the suspension was evaporated to dryness. The silicagel with the adsorbed crude mixture was loaded onto a 20 g silicagel flash chromatography column and eluted three min. with heptane followed by a heptane to 45% ethyl acetate/heptane gradient over 25 min to yield 36 mg (15% yield) of the title compound as a crystalline yellow solid, MS: m/e=292.3 (M+H + ).
Example 151
4,4-Dimethyl-1-(6-(phenylethynyl)pyridazin-3-yl)piperidin-2-one
[0929]
Step 1: 3-Iodo-6-(phenylethynyl)pyridazine
[0930]
[0931] To a solution of 100 mg (0.466 mmol) of 3-chloro-6-(phenylethynyl)pyridazine in 5 ml of acetonitrile were added sodium iodide (209 mg, 1.4 mmol, 3 equiv.), acetic acid (56 mg, 53.3 ml, 0.93 mmol, 2 equiv.), and 95% sulfuric acid (4.6 mg, 2.5 ml, 0.47 mmol, 1 equiv.). The orange solution was stirred for 8 hours at 70° C. and then left to cool overnight. After standard workup with ethyl acetate/water, the residue was adsorbed onto 4 g of silicagel and purified by flash chromatography over a 20 g silicagel column over a heptane to 50% ethyl acetate in heptane gradient to yield 82 mg (58% yield) of the title compound as a crystalline light yellow solid, MS: m/e=307.1 (M+H + ).
Step 2: 4,4-Dimethyl-1-(6-(phenylethynyl)pyridazin-3-yl)piperidin-2-one
[0932]
[0933] To a well stirred suspension of 3-iodo-6-(phenylethynyl)pyridazine (Example 151, step 1) (80 mg, 261 μmol), 4,4-dimethylpiperidin-2-one (66.5 mg, 314 μmol, 1.2 equiv.) and 4,5-bis(diphenylphosphino)-9,9-dimethylxanthene (xantphos) (6.05 mg, 10.5 μmol, 0.04 equiv.) in 2 ml of toluene were added under argon atmosphere tris(dibenzylideneacetone)dipalladium(0) (Pd 2 (dba) 3 ), (4.79 mg, 5.23 μmol, 0.02 equiv.) and the mixture was stirred for 4 hours at 100° C. The crude mixture was directly purified by flash chromatography over a 20 g silicagel column using a heptane to 50% ethyl acetate in heptane gradient, and yielded 18 mg (23% yield) of the title compound as a white solid, MS: m/e=306.2 (M+H + ).
Example 152
5,5-Dimethyl-3-(6-(phenylethynyl)pyridazin-3-yl)oxazolidin-2-one
[0934]
Step 1: 2-Methyl-1-(6-phenylethynyl-pyridazin-3-ylamino)-propan-2-ol
[0935]
[0936] A solution of 3-chloro-6-(phenylethynyl)pyridazine (CAS 77778-15-5) (300 mg, 1.4 mmol) and 1-amino-2-methylpropan-2-ol (137 mg, 147 μl, 1.54 mmol, 1.1 equiv.) in 3 ml of pyridine was heated 20 hours at 120° C. in a sealed tube. The solvent was removed in vaccuo. The residue was taken up in ethyl acetate/methanol, adsorbed onto 4 g of silica and purified on a 20 g flash chromatography column using a heptane to ethyl acetate gradient to yield 90 mg (24% yield) of the title compound as a crystalline light yellow solid, MS: m/e=268.2 (M+H + ).
Step 2: 5,5-Dimethyl-3-(6-(phenylethynyl)pyridazin-3-yl)oxazolidin-2-one
[0937]
[0938] A solution of 2-methyl-1-(6-(phenylethynyl)pyridazin-3-ylamino)propan-2-ol (Example 152, step 1) (90 mg, 337 μmol) and triethylamine (102 mg, 141 μl, 1.01 mmol, 3 equiv.) in 4 ml of THF was cooled to 0-5° C. and then triphosgene (99.9 mg, 337 μmol, 1 equiv.) was added and the reaction was stirred for 1 hour at 0-5° C. The mixture was quenched with 5 ml of 5% sodium bicarbonate solution and worked up with ethyl acetate/water. The crude material was adsorbed onto silicagel and purified by flash chromatography over a heptane to 50% ethyl acetate in heptane gradient to yield the title compound (51 mg, 52% yield) as a crystalline light yellow solid, MS: m/e=294.2 (M+H + ).
Example 153
6,6-Dimethyl-3-(6-(phenylethynyl)pyridazin-3-yl)-1,3-oxazinan-2-one
[0939]
Step 1: 2-Methyl-4-(6-phenylethynyl-pyridazin-3-ylamino)-butan-2-ol
[0940]
[0941] A solution of 3-chloro-6-(phenylethynyl)pyridazine (CAS 77778-15-5) (125 mg, 0.582 mmol) and 4-amino-2-methylbutan-2-ol hydrochloride (244 mg, 1.75 mmol, 3 equiv.) and triethylamine (206 mg, 284 ml, 2.04 mmol, 2 equiv.) in 1.25 ml of pyridine was heated 20 hours at 85° C. The solvent was removed in vaccuo. The residue was taken up in ethyl acetate/methanol, adsorbed onto 4 g of silica and purified on a 20 g flash chromatography column using a heptane/ethyl acetate 85:15 to 15:85 gradient to yield 44 mg (27% yield) of the title compound as a crystalline white solid, MS: m/e=2822 (M+H + ).
Step 2: 6,6-Dimethyl-3-(6-(phenylethynyl)pyridazin-3-yl)-1,3-oxazinan-2-one
[0942]
[0943] The title compound, a crystalline light yellow solid, MS: m/e=308.3 (M+H + ), was prepared in accordance with the general method of Example 152, step 2 starting from 2-methyl-4-(6-phenylethynyl-pyridazin-3-ylamino)-butan-2-ol (Example 153, step 1) and triphosgene.
Example 154
3,4,4-Trimethyl-1-(6-(m-tolylethynyl)pyridazin-3-yl)imidazolidin-2-one
[0944]
Step 1: N-1-(6-Iodo-pyridazin-3-yl)-2-methyl-propane-1,2-diamine
[0945]
[0946] A suspension of 3-chloro-6-iodo-pyridazine (CAS 135034-10-5) (500 mg, 2.08 mmol) and 2-methylpropane-1,2-diamine (220 mg, 262 μA, 2.5 mmol, 1.2 equiv.) in 4 ml of pyridine was heated 16 hours at 100° C. The solvent was removed in vaccuo. The crude material (508 mg) was directly used in the next step.
Step 2: 1-(6-Chloro-pyridazin-3-yl)-4,4-dimethyl-imidazolidin-2-one
[0947]
[0948] To a solution of crude N-1-(6-iodopyridazin-3-yl)-2-methylpropane-1,2-diamine (Example 154, step 1) (580 mg, 1.99 mmol) and pyridine (346 mg, 353 μl, 4.37 mmol, 2.2 equiv.) in 5 ml of dichloromethane were added (1.96 g, 2.1 ml, 3.97 mmol, 2 equiv.) of a 20% solution of phosgene in toluene dropwise at 0-2° C. over a period of 10 min. After stirring for 2 hours at 0-4° C., the reaction was allowed to warm up to room temperature overnight. The mixture was quenched with 5 ml of 5% sodium bicarbonate solution and worked up with dichloromethane/water. The crude material was adsorbed onto silicagel and purified by flash chromatography using a heptane to 80% ethyl acetate in heptane gradient to yield the title compound (where the iodine was completely exchanged for chlorine) (140 mg, 31% yield) as a crystalline white solid, MS: m/e=227.2, 229.4 (M+H + ).
Step 3: 1-(6-Chloro-pyridazin-3-yl)-3,4,4-trimethyl-imidazolidin-2-one
[0949]
[0950] To a solution of 1-(6-chloropyridazin-3-yl)-4,4-dimethylimidazolidin-2-one (Example 154, step 2) (140 mg, 618 μmol) in DMF (3 ml) was added 60% sodium hydride suspension (37.1 mg, 926 μmol, 1.5 equiv.). After stirring at room temperature for 10 min, iodomethane (132 mg, 57.9 μl, 926 μmol, 1.5 equiv.) was added and the suspension was stirred for 1 hour at room temperature. The solvent was removed in vaccuo and the residue was worked up with ethyl acetate/water. The title compound was obtained as a crystalline light brown solid (129 mg, 87% yield), MS: m/e=241.2, 243.4 (M+H + ).
Step 4: 1-(6-Iodo-pyridazin-3-yl)-3,4,4-trimethyl-imidazolidin-2-one
[0951]
[0952] The title compound, crystalline light yellow solid (149 mg, 86%), MS: m/e=333.0 (M+H + ), was prepared from 1-(6-chloro-pyridazin-3-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 154, step 3) in accordance with the general method of Example 151, step 1 by acid catalyzed chlorine-iodine exchange.
Step 5: 3,4,4-Trimethyl-1-(6-(m-tolylethynyl)pyridazin-3-yl)imidazolidin-2-one
[0953]
[0954] To a solution of 1-(6-iodopyridazin-3-yl)-3,4,4-trimethylimidazolidin-2-one (Example 154, step 4) (75 mg, 226 mmol), 1-ethynyl-3-methylbenzene (44.6 mg, 49.5 μl, 384 μmol, 1.7 equiv.), triethylamine (68.5 mg, 94.4 μl, 677 mmol, 3 equiv.), bis(triphenylphosphine)palladium (II) chloride (9.51 mg, 13.5 μmol, 0.06 equiv.) and triphenylphosphine (1.78 mg, 6.77 μmol, 0.03 equiv.) in 2 ml of THF was added under an Argon atmosphere copper (I) iodide (1.29 mg, 6.77 mmol, 0.03 equiv.). The suspension was warmed to 60° C. for 2 hours, taken up in 5 ml of ethyl acetate and adsorbed on 4 g of silica. Purification by flash chromatography on silicagel using a heptane to 50% ethyl acetate/heptane gradient yielded the title compound as a crystalline light yellow solid (18 mg, 25% yield), MS: m/e=321.2 (M+H + ).
Example 155
1-(6-((3-Chlorophenyl)ethynyl)pyridazin-3-yl)-3,4,4-trimethylimidazolidin-2-one
[0955]
[0956] The title compound, a crystalline light yellow solid (36 mg, 47% yield), MS: m/e=341.2, 343.3 (M+H + ), was prepared in accordance with the general method of Example 154, step 5; starting from 1-(6-iodo-pyridazin-3-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 154, step 4) and 3-chlorophenyl-acetylene.
Example 156
3,4,4-Trimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)imidazolidin-2-one
[0957]
Step 1: N-1-(5-Iodo-pyrazin-2-yl)-2-methyl-propane-1,2-diamine
[0958]
[0959] To a solution of 2-bromo-5-iodopyrazine (CAS 622392-04-5) (250 mg, 878 mmol) in 0.7 ml of pyridine, was added 2-methylpropane-1,2-diamine (116 mg, 138 μl, 1.32 mmol, 1.5 equiv.) at room temperature. The colorless solution was stirred for 16 hours at 100° C. The reaction mixture was cooled and concentrated in vacuo. The crude material was used directly in the next step.
Step 2: 1-(5-Iodo-pyrazin-2-yl)-4,4-dimethyl-imidazolidin-2-one
[0960]
[0961] The title compound, an off-white solid (72 mg, 26% yield), was prepared in accordance with the general method of Example 154, step 2; starting from N-1-(5-iodo-pyrazin-2-yl)-2-methyl-propane-1,2-diamine (Example 156, step 1) and cyclisation with phosgene. The crude material was directly used in the next step without further characterization.
Step 3: 1-(5-Iodo-pyrazin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one
[0962]
[0963] The title compound, an off-white solid (77 mg, 99% yield), was prepared in accordance with the general method of Example 154, step 3; by alkylation of 1-(5-iodo-pyrazin-2-yl)-4,4-dimethyl-imidazolidin-2-one (Example 156, step 2) with methyl iodide. The crude material was directly used in the next step without further characterization.
Step 4: 3,4,4-Trimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)imidazolidin-2-one
[0964]
[0965] The title compound, a crystalline light yellow solid (69 mg, 75% yield), MS: m/e=307.3 (M+H + ), was prepared in accordance with the general method of Example 154, step 5; starting from 1-(5-iodo-pyrazin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 156, step 3) and phenylacetylene.
Example 157
3,4,4-Trimethyl-1-(5-(pyridin-3-ylethynyl)pyrazin-2-yl)imidazolidin-2-one
[0966]
[0967] The title compound, a crystalline yellow solid, MS: m/e=308.3 (M+H + ), was prepared in accordance with the general method of Example 154, step 5; starting from 1-(5-iodo-pyrazin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 156, step 3) and 3-pyridylacetylene.
Example 158
1-(5-((3-Fluorophenyl)ethynyl)pyrazin-2-yl)-3,4,4-trimethylimidazolidin-2-one
[0968]
[0969] The title compound, a crystalline light yellow solid, MS: m/e=325.2 (M+H + ), was prepared in accordance with the general method of Example 154, step 5; starting from 1-(5-iodo-pyrazin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 156, step 3) and 3-fluorophenylacetylene.
Example 159
1-(5-((4-Fluorophenyl)ethynyl)pyrazin-2-yl)-3,4,4-trimethylimidazolidin-2-one
[0970]
[0971] The title compound, a light yellow solid, MS: m/e=325.2 (M+H + ), was prepared in accordance with the general method of example 154, step 5; starting from 1-(5-iodo-pyrazin-2-yl)-3,4,4-trimethyl-imidazolidin-2-one (Example 156, step 3) and 4-fluorophenylacetylene.
Example 160
4,4-Dimethyl-1-(5-(pyridin-3-ylethynyl)pyrazin-2-yl)pyrrolidin-2-one
[0972]
Step 1: 1-(5-Bromo-pyrazin-2-yl)-4,4-dimethyl-pyrrolidin-2-one
[0973]
[0974] To a well stirred suspension of 2-bromo-5-iodopyrazine (300 mg, 1.05 mmol), 4,4-dimethylpiperidin-2-one (155 mg, 1.37 mmol, 1.3 equiv.) and 4,5-bis(diphenylphosphino)-9,9-dimethylxanthene (xantphos) (24.4 mg, 0.042 mmol, 0.04 equiv.) in 4 ml of toluene were added under argon atmosphere tris(dibenzylideneacetone)dipalladium(0) (Pd 2 (dba) 3 ), (19.3 mg, 0.021 mmol, 0.02 equiv.) and the mixture was stirred for 5 hours at 100° C. The crude mixture was adsorbed on silicagel and purified by flash chromatography over a 20 g silicagel column using a 2:1 heptane/ethyl acetate mixture as eluant. The title compound (151 mg, 53% yield) was obtained as a white solid, MS: m/e=270.1, 272.1 (M+H + ).
Step 2: 4,4-Dimethyl-1-(5-(pyridin-3-ylethynyl)pyrazin-2-yl)pyrrolidin-2-one
[0975]
[0976] The title compound, a light yellow solid, MS: m/e=310.4 (M+H + ), was prepared in accordance with the general method of Example 154, step 5; starting from 1-(5-bromo-pyrazin-2-yl)-4,4-dimethyl-pyrrolidin-2-one (Example 160, step 1) and 3-fluorophenylacetylene.
Example 161
1-(5-((3-Fluorophenyl)ethynyl)pyrazin-2-yl)-4,4-dimethylpiperidin-2-one
[0977]
Step 1: 1-(5-Bromo-pyrazin-2-yl)-4,4-dimethyl-piperidin-2-one
[0978]
[0979] The title compound, an off-white solid, MS: m/e=284.2, 286.0 (M+H + ), was prepared in accordance with the general method of Example 160, step 1; starting from 2-bromo-5-iodopyrazine and 4,4-dimethyl-piperidin-2-one.
Step 2: 1-(5-((3-Fluorophenyl)ethynyl)pyrazin-2-yl)-4,4-dimethylpiperidin-2-one
[0980]
[0981] The title compound, an off-white solid, MS: m/e=324.3 (M+H + ), was prepared in accordance with the general method of Example 154, step 5; starting from 1-(5-bromo-pyrazin-2-yl)-4,4-dimethyl-piperidin-2-one (Example 161, step 1) and 3-fluorophenylacetylene.
Example 162
4,4-Dimethyl-1-(5-(pyridin-3-ylethynyl)pyrazin-2-yl)piperidin-2-one
[0982]
[0983] The title compound, an off-white solid, MS: m/e=307.2 (M+H + ), was prepared in accordance with the general method of Example 154, step 5; starting from 1-(5-bromo-pyrazin-2-yl)-4,4-dimethyl-piperidin-2-one (Example 161, step 1) and 3-pyridylacetylene.
Example 163
4,4-Dimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)piperidin-2-one
[0984]
[0985] The title compound, a yellow solid, MS: m/e=306.2 (M+H + ), was prepared in accordance with the general method of Example 154, step 5; starting from 1-(5-bromo-pyrazin-2-yl)-4,4-dimethyl-piperidin-2-one (Example 161, step 1) and phenylacetylene.
Example 164
4,4-Dimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)tetrahydropyrimidin-2(1H)-one
[0986]
Step 1: 1-(5-Bromo-pyrazin-2-yl)-4,4-dimethyl-tetrahydro-pyrimidin-2-one
[0987]
[0988] The title compound, a light brown solid, MS: m/e=285.0, 287.0 (M+H + ), was prepared in accordance with the general method of Example 160, step 1; starting from 2-bromo-5-iodopyrazine and 4,4-dimethyl-tetrahydro-pyrimidin-2-one (Example 137, step 1).
Step 2: 4,4-Dimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)tetrahydropyrimidin-2(1H)-one
[0989]
[0990] The title compound, a light yellow solid, MS: m/e=307.3 (M+H + ), was prepared in accordance with the general method of example 45, step 5; starting from 1-(5-bromo-pyrazin-2-yl)-4,4-dimethyl-tetrahydro-pyrimidin-2-one (Example 164, step 1) and phenylacetylene.
Example 165
3,4,4-Trimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)tetrahydropyrimidin-2(1H)-one
[0991]
[0992] To a solution of 4,4-dimethyl-1-(5-(phenylethynyl)pyrazin-2-yl)tetrahydropyrimidin-2(1H)-one (Example 164, step 2) (30 mg, 0.098 mmol) in 2 ml of DMF was added 60% sodium hydride suspension (4.7 mg, 0.118 mmol, 1.2 equiv.). After stirring at room temperature for 15 min, iodomethane (7.4 ml, 16.7 mg, 0.118 mmol, 1.2 equiv.) was added and the reaction was stirred at room temperature overnight. The reaction mixture was concentrated in vacuo and was worked up with ethyl acetate/water. Flash chromatography over a prepacked 20 g silica column eluting with a heptane to 50% ethyl acetate in heptane gradient yielded the title compound (25.4 mg, 81% yield) as an off-white solid, MS: m/e=321.3 (M+H + ).
Example 166
1-(5-((3-Fluorophenyl)ethynyl)pyrazin-2-yl)-4,4-dimethyltetrahydropyrimidin-2(1H)-one
[0993]
[0994] The title compound, an off-white solid, MS: m/e=325.3 (M+H + ), was prepared in accordance with the general method of Example 154, step 5; starting from 1-(5-bromo-pyrazin-2-yl)-4,4-dimethyl-tetrahydro-pyrimidin-2-one (Example 164, step 1) and 3-fluorophenylacetylene.
Example 167
1-(5-((3-Fluorophenyl)ethynyl)pyrazin-2-yl)-3,4,4-trimethyltetrahydropyrimidin-2(1H)-one
[0995]
[0996] The title compound, a light yellow solid, MS: m/e=339.1 (M+H + ), was prepared in accordance with the general method of Example 165, by alkylation of 1-(5-((3-fluorophenyl)ethynyl)pyrazin-2-yl)-4,4-dimethyltetrahydropyrimidin-2(1H)-one (Example 166) with methyl iodide.
Example 168
6,6-Dimethyl-3-(5-(phenylethynyl)pyrazin-2-yl)-1,3-oxazinan-2-one
[0997]
Step 1: 2-Bromo-5-phenylethynyl-pyrazine
[0998]
[0999] To a solution of 2-bromo-5-iodopyrazine (500 mg, 1.76 mmol), phenylacetylene (224 mg, 241 μl, 2.19 mmol, 1.25 equiv.), triethylamine (533 mg, 734 μl, 5.27 mmol, 3 equiv.), bis(triphenylphosphine)palladium (II) chloride (73.9 mg, 0.105 mmol, 0.06 equiv.) and triphenyl-phosphine (13.8 mg, 0.053 mmol, 0.03 equiv.) in 10 ml of THF was added under an Argon atmosphere copper (I) iodide (10.0 mg, 0.053 mmol, 0.03 equiv.). The suspension was warmed to 60° C. overnight, taken up in 5 ml of ethyl acetate and adsorbed on 4 g of silica. Purification by flash chromatography on silicagel using a 2:1 ethyl acetate/heptane mixture yielded the title compound as a light brown solid (107 mg, 23% yield). The material was directly used in the next step without further characterization.
Step 2: 2-Methyl-4-(5-phenylethynyl-pyrazin-2-ylamino)-butan-2-ol
[1000]
[1001] A solution of 2-bromo-5-(phenylethynyl)pyrazine (Example 168, step 1) (158 mg, 0.061 mmol) and 4-amino-2-methylbutan-2-ol hydrochloride (255 mg, 1.83 mmol, 30 equiv.) and triethylamine (185 mg, 255 ul, 1.83 mmol, 30 equiv.) in 3 ml pyridine was stirred overnight at 85° C. The reaction mixture was concentrated in vaccuo. After workup with dichloromethane/water/brine, and drying over magnesium sulfate, the organic phases were concentrated in vacuo. The crude product was chromatographed over a prepacked 20 g silica column eluting with a 25% to 100% ethyl acetate in heptane gradient which yielded the title compound (87.5 mg, 51% yield) as an off-white solid, MS: m/e=282.2 (M+H + ).
Step 3: 6,6-Dimethyl-3-(5-(phenylethynyl)pyrazin-2-yl)-1,3-oxazinan-2-one
[1002]
[1003] A solution of 2-methyl-4-(5-(phenylethynyl)pyrazin-2-ylamino)butan-2-ol (Example 168, step 2) (84 mg, 0.30 mmol) and triethylamine (91 mg, 125 μl, 0.90 mmol, 3 equiv.) in 2 ml of THF was cooled to 0-5° C. and triphosgene (89 mg, 0.30 mmol, 1 equiv.) was added in portions. The mixture was stirred for 1 hr at 0-5° C. and for 2 hours at room temperature. The reaction mixture was quenched with saturated sodium carbonate solution followed by workup with ethyl acetate/water. The organic layers were combined, dried and concentrated. The crude product was chromatographed over a prepacked 20 g Silica column eluting with a heptane to 50% ethyl acetate in heptane gradient to yield the title compound (66.1 mg, 72% yield) as an off-white solid, MS: m/e=308.3 (M+H + ).
Example 169
(RS)-3-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-5-methoxy-6,6-dimethyl-[1,3]oxazinan-2-one
[1004]
Step 1: (RS)-5-Methoxy-6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one
[1005]
[1006] The title compound was obtained as a light brown solid, MS: m/e=333.2 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyridine (Example 37, step 1) and (RS)-5-methoxy-6,6-dimethyl-[1,3]oxazinan-2-one (Example 114, step 2).
Step 2: (RS)-3-[5-(3-Fluoro-phenylethynyl)-pyridin-2-yl]-5-methoxy-6,6-dimethyl-[1,3]oxazinan-2-one
[1007]
[1008] The title compound was obtained as a yellow oil, MS: m/e=355.0 (M+H + ), using chemistry similar to that described in Example 37, step 3 from (RS)-5-methoxy-6,6-dimethyl-3-(5-trimethylsilanylethynyl-pyridin-2-yl)-[1,3]oxazinan-2-one (Example 169, step 1) and 1-fluoro-3-iodobenzene.
Example 170
(3aRS,6aSR)-1-Methyl-3-(6-phenylethynyl-pyridazin-3-yl)-hexahydro-cyclopentaimidazol-2-one
[1009]
[1010] To a solution of (3aRS,6aSR)-1-methyl-hexahydro-cyclopentaimidazol-2-one (Example 106, step 3) (55 mg, 0.39 mmol, 1.5 equiv.) in 3 ml of DMF was added 60% sodium hydride suspension in mineral oil (17 mg, 0.42 mmol, 1.6 equiv.). The white suspension was stirred for 30 min. at room temperature. Then 3-chloro-6-(phenylethynyl)pyridazine (CAS 77778-15-5) (56 mg, 0.261 mmol) was added and the reaction was stirred for 1 hour at room temperature. After workup with ethyl acetate/water, drying over magnesium sulfate and concentration in vaccuo, the residue was purified by flash chromatography over silica gel eluting with a heptane to 50% ethyl acetate/heptane gradient to yield 40 mg (48% yield) of the title compound as an off-white solid, MS: m/e=319.1 (M+H + ).
Example 171
(RS)-6-Methyl-4-(5-phenylethynyl-pyridin-2-yl)-morpholin-3-one
[1011]
Step 1: (RS)-4-(5-Iodo-pyridin-2-yl)-6-methyl-morpholin-3-one
[1012]
[1013] The title compound was obtained as a white solid, MS: m/e=319.0 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2,5-diiodopyridine and (RS)-6-methyl-morpholin-3-one (CAS 127958-63-8).
Step 2: (RS)-6-Methyl-4-(5-phenylethynyl-pyridin-2-yl)-morpholin-3-one
[1014]
[1015] The title compound was obtained as a light yellow solid, MS: m/e=293.1 (M+H + ), using chemistry similar to that described in Example 1, step 3 from (RS)-4-(5-iodo-pyridin-2-yl)-6-methyl-morpholin-3-one (Example 171, step 1) with phenylacetylene.
Example 172
6,6-Dimethyl-4-(5-phenylethynyl-pyridin-2-yl)-morpholin-3-one
[1016]
Step 1: (2-Dibenzylamino-1,1-dimethyl-ethoxy)-acetic acid ethyl ester
[1017]
[1018] (4.9 g, 18.2 mmol) 1-(Dibenzylamino)-2-methylpropan-2-ol (CAS 344868-41-3) was dissolved in dichloroethane (50 ml) and ethyl 2-diazoacetate (2.83 ml, 27.3 mmol, 1.5 equiv.) and rhodium(II) acetate dimer (200 mg, 0.455 mmol, 0.025 equiv.) were added carefully at room temperature. The mixture was stirred for 3 hours at 80° C. The reaction mixture was evaporated with isolute and the crude product was purified by flash chromatography by directly loading the residue onto a silica gel column and eluting with a heptane:ethyl acetate gradient 100:0 to 70:30. The desired (2-dibenzylamino-1,1-dimethyl-ethoxy)-acetic acid ethyl ester (1.03 g, 80% purity, 13% yield) was obtained as a colorless liquid, MS: m/e=356.3 (M+H + ).
Step 2: 6,6-Dimethyl-morpholin-3-one
[1019]
[1020] (2-Dibenzylamino-1,1-dimethyl-ethoxy)-acetic acid ethyl ester (Example 172, step 1) was hydrogenated in EtOH with Pd(OH) 2 for 16 hours at 60° C. The desired 6,6-dimethyl-morpholin-3-one (585 mg, 60% purity, quant.) was obtained as a colorless liquid, MS: m/e=129 (M+H + ) and used in the next step without further purification.
Step 3: 6,6-Dimethyl-4-(5-trimethylsilanylethynyl-pyridin-2-yl)-morpholin-3-one
[1021]
[1022] The title compound was obtained as a yellow oil, MS: m/e=303.2 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2-bromo-5-trimethylsilanylethynyl-pyridine (Example 37, step 1) and 6,6-dimethyl-morpholin-3-one (Example 172, step 2).
Step 4: 6,6-Dimethyl-4-(5-phenylethynyl-pyridin-2-yl)-morpholin-3-one
[1023]
[1024] The title compound was obtained as a white solid, MS: m/e=307.3 (M+H + ), using chemistry similar to that described in Example 37, step 3 from 6,6-dimethyl-4-(5-trimethylsilanylethynyl-pyridin-2-yl)-morpholin-3-one (Example 172, step 3) and iodobenzene.
Example 173
1,1-Dioxo-4-(5-phenylethynyl-pyridin-2-yl)-thiomorpholin-3-one
[1025]
Step 1: 4-(5-Bromo-pyridin-2-yl)-thiomorpholin-3-one
[1026]
[1027] The title compound was obtained as a yellow solid, MS: m/e=273.0/274.9 (M+H + ), using chemistry similar to that described in Example 37, step 2 from 2,5-dibromopyridine and thiomorpholin-3-one.
Step 2: 4-(5-Bromo-pyridin-2-yl)-1,1-dioxo-thiomorpholin-3-one
[1028]
[1029] (240 mg, 0.88 mmol) 4-(5-Bromo-pyridin-2-yl)-thiomorpholin-3-one (Example 173, step 1) was dissolved in dichloroethane (10 ml) and mCPBA (300 mg, 1.76 mmol, 2 equiv.) was added at 0-5° C. The mixture was stirred for 2 hours at 20-25° C. The reaction mixture was extracted with saturated NaHCO 3 solution and five times dichloromethane. The organic layers were combined, dried over Na 2 SO 4 and evaporated to dryness. The desired 4-(5-bromo-pyridin-2-yl)-1,1-dioxo-thiomorpholin-3-one (167 mg, 62% yield) was obtained as a light brown solid, MS: m/e=305.1/307.1 (M+H + ).
Step 3: 1,1-Dioxo-4-(5-phenylethynyl-pyridin-2-yl)-thiomorpholin-3-one
[1030]
[1031] The title compound was obtained as a light brown solid, MS: m/e=327.2 (M+H + ), using chemistry similar to that described in Example 1, step 3 from 4-(5-bromo-pyridin-2-yl)-1,1-dioxo-thiomorpholin-3-one (Example 173, step 2) and phenylacetylene.
Example 174
(3aSR,6aRS)-1-[6-(3-Fluoro-phenylethynyl)-pyridazin-3-yl]-3-methyl-hexahydro-cyclopentaimidazol-2-one
[1032]
Step 1: 3-Chloro-6-(3-fluoro-phenylethynyl)-pyridazine
[1033]
[1034] To a well stirred solution of 2-chloro-5-iodopyrazine (600 mg, 2.5 mmol), 3-fluorophenyl-acetylene (315 mg, 303 μl, 2.62 mmol, 1.05 equiv.) in 7 ml of THF were added under argon atmosphere bis(triphenylphosphine)-palladium(II) dichloride (175 mg, 0.250 mmol, 0.02 equiv.), copper(I) iodide (23.8 mg, 0.125 mmol, 0.01 equiv.) and triethylamine (556 mg, 761 ul, 5.49 mmol, 2.2 equiv.). The mixture was stirred for 2 hours at room temperature. The crude mixture was filtered, adsorbed on silicagel and purified by flash chromatography over a 50 g silicagel column using a heptane to 25% ethyl acetate in heptane gradient. The title compound (450 mg, 78% yield) was obtained as a crystalline light-yellow solid, MS: m/e=233.1, 235.0 (M+H + ).
Step 2: (3aSR,6aRS)-1-[6-(3-Fluoro-phenylethynyl)-pyridazin-3-yl]-3-methyl-hexahydro-cyclopentaimidazol-2-one
[1035]
[1036] The title compound, an off-white solid, MS: m/e=337.2 (M+H + ), was prepared in accordance with the general method of Example 170; starting from 3-chloro-6-((3-fluorophenyl)-ethynyl)pyridazine and (3aRS,6aSR)-1-methyl-hexahydro-cyclopentaimidazol-2-one. | The present invention relates to ethynyl compounds of formula I
wherein
R1, R2, R2′, R3, R3′, R4, R4′, U, V, W, Y, m, and n are as defined herein and to a pharmaceutically acceptable acid addition salts, to a racemic mixtures, or to its corresponding enantiomers and/or optical isomers and/or stereoisomers thereof. Compounds of formula I are allosteric modulators of the metabotropic glutamate receptor subtype 5 (mGluR5). | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention generally relate to a connector for connecting a rod with a component for use in boreholes such as oil and gas wells. More particularly, the invention relates to a connector having a stress reducing design including opposing planar portions in a substantially cylindrical body. More particularly still, the invention relates to a connector and rod having a higher alloy content.
[0003] 2. Description of the Related Art
[0004] Modern oil and gas wells are typically drilled with a rotary drill bit and a circulating drilling fluid or “mud” system. The mud system (a) serves as a means for removing drill bit cuttings from the well as the borehole is advanced, (b) lubricates and cools the rotating drill bit, and (c) provides pressure within the borehole to balance internal pressures of formations penetrated by the borehole. Rotary motion is imparted to the drill bit by rotation of a drill string to which the bit is attached. Alternately, the bit is rotated by a mud motor which is attached to the drill string just above the drill bit. The mud motor is powered by the circulating mud system. Subsequent to the drilling of a well, or alternately at intermediate periods during the drilling process, the borehole is cased typically with steel casing, and the annulus between the borehole and the outer surface of the casing is filled with cement. The casing preserves the integrity of the borehole by preventing collapse or cave-in. The cement annulus hydraulically isolates formation zones penetrated by the borehole that are at different internal formation pressures.
[0005] Numerous operations occur in the well borehole after casing is “set”. All operations require the insertion of some type of instrumentation or hardware within the borehole. Examples of typical borehole operations include: (a) setting packers and plugs to isolate producing zones; (b) inserting tubing within the casing and extending the tubing to the prospective producing zone; and (c) inserting, operating, and removing pumping systems from the borehole.
[0006] Fluids can be produced from oil and gas wells by utilizing internal pressure within a producing zone to lift the fluid through the well borehole to the surface of the earth. If internal formation pressure is insufficient, artificial fluid lift means and methods must be used to transfer fluids from the producing zone and through the borehole to the surface of the earth.
[0007] The most common artificial lift technology utilized in the domestic oil industry is the sucker rod pumping system. A sucker rod pumping system consists of a pumping unit that converts a rotary motion of a drive motor to a reciprocating motion of an artificial lift pump. A pump unit is connected to a polish rod and a sucker rod “string” which, in turn, operationally connects to a rod pump in the borehole. The string can consist of a group of connected, essentially rigid, steel sucker rod sections (commonly referred to as “joints”) in lengths of 25 or 30 feet (ft), and in diameters ranging from ⅝ inches (in.) to 1¼ in. Joints are sequentially connected or disconnected as the string is inserted or removed from the borehole, respectively. Alternately, a continuous sucker rod (hereafter referred to as COROD®) string can be used to operationally connect the pump unit at the surface of the earth to the rod pump positioned within the borehole.
[0008] A COROD® and sucker rods have pin ends for connecting the rod to a pump, a motor, or another rod. The pin end has a wrench flat section which comprises four flat sections in the cross-sectional shape of a square. The wrench flat section allows an operator to grab the rod with a wrench and apply torque during connection. Because there are four flat sections at 90° angles the operator can move the wrench from one flat section to the next with only a quarter turn of the wrench.
[0009] Many modern boreholes have a highly corrosive downhole environment. Traditional rods and connectors have been manufactured with a low alloy content. The typical rod has only up to 2% of common alloy elements such as Nickel, Chromium and Copper added to their metal chemistry. These low alloy rods are insufficient for use in corrosive borehole environments. To solve this problem in the past manufacturers applied coatings to the rods to prevent corrosion. However, these coatings tend to flake, or scratch off during bending and run in of the rod.
[0010] A COROD® and sucker rods are particularly susceptible to fatigue failure caused by continuous use of the rod to operate downhole tools and pumps. Fatigue failure occurs with frequency at the fillet of the square wrench flats. The discontinuity at the fillet creates a stress concentration. The stress concentration will eventually cause the rod to fail which causes loss of time and equipment. Fatigue failure is of particular concern when using progressive cavity pumps and deviated wellbore applications where eccentricity facilitates bending and flexing of the rod connection(s).
[0011] There is a need for a connector for connecting a rod to another downhole component that reduces stress in the connector. There is a further need for a more even distribution of stresses in the connector in order to prevent fatigue failure. There is yet a further need for a corrosion resistant rod and connector.
SUMMARY OF THE INVENTION
[0012] In one aspect a connector for connecting a rod to a wellbore component has a first end for connecting to the component, a second end for connecting the body to the rod and a cross section defining a cylindrical shape with opposing planar portions for engagement with a torquing member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0014] FIG. 1 is a cross sectional view of a wellbore illustrating a rod connector for use with a spooled rod.
[0015] FIG. 2 is a cross sectional view of a wellbore illustrating a rod connector for use with a jointed rod.
[0016] FIG. 3 is a view of a connector assembly of the present invention.
[0017] FIG. 4 is a cross-sectional view of the connector assembly of the present invention.
DETAILED DESCRIPTION
[0018] The apparatus and method of the present invention allow for connection of a rod for use in a downhole operation with a component. The connector allows the rod to operate downhole equipment while reducing the amount of stress in the connection which leads to failures.
[0019] FIG. 1 depicts a cross-sectional view of a wellbore 100 . As illustrated, the wellbore 100 has a string of casing 102 fixed in formation 104 by cured cement 106 . The wellbore 100 also includes a first component 108 , shown schematically, connected to a rod 110 by a connector assembly 112 . In one embodiment the connector assembly 112 couples the first component 108 to the rod 110 , which is a spooled or continuous rod (COROD®). The COROD® can be of any diameter that is capable of being wound and unwound around a spool 114 .
[0020] In operation the spool 114 with the rod 110 wound around the spool 114 is brought to the wellbore 100 . The connector assembly 112 is then connected to the first component 108 , described in more detail below, and an end of rod 110 . The spool 114 then actuates and lowers the first component 108 by unspooling the rod 110 . When the first component 108 reaches a desired depth in the wellbore 100 the spool 114 stops. In one embodiment the rod 110 is then cut and another connector assembly 112 (not shown) is coupled to the rod and a second component 200 , shown in FIG. 2 . In one embodiment, the end of the rod 110 with the second component 200 is connected in the same manner as the end with the first component 108 .
[0021] FIG. 2 shows the rod 110 as a series of rods or joints 202 . The joints 202 are of any length desired. In an embodiment the joints 202 are 25 to 30 feet in length. The joints 202 couple together in the same way as the components 108 and 200 are coupled to the rod with connector assembly 112 , described in more detail below. The first component 108 couples to the joint 202 . The first component is then lowered into the wellbore 100 , until the top end of the joint 202 is near the top of the wellbore. Another joint 202 then couples to the first installed joint. This is repeated until the rod 110 is the desired length. The second component then couples to the rod 110 .
[0022] Although rod 110 is shown as a spooled rod and a jointed rod it should be appreciated that the rod may be any rod for use in downhole operations, such as a COROD®, a sucker rod, jointed rod, etc. Further, it should be appreciated that the rod 110 could be a solid rod or a tubular having a bore through the center. The rod 110 can be of any desired diameter in order to meet the specific requirements of the operation.
[0023] The rod 110 and connector assembly 112 may be of any metallurgical make-up. In an alternative embodiment the rod 110 and the connector 112 have increased alloy content. In another embodiment, the rod 110 and the connector 112 have an intermediate alloy level between stainless steel and low alloy carbon steel. The alloy content in another embodiment could be in the range of greater than 2½% Cr. to less than 13% Cr. In another embodiment the alloy content would be approximately 5Cr-½Mo alloy steel, similarly replicating ASME SA193 Grade B5. Although, the alloy used is discussed in respect to Cr, it should be appreciated that any alloying metal could be used such as nickel (Ni.), molybdenum (Mo.), copper (Cu.), vanadium (V.), etc. Further, the metallurgy described above can be used on any rod and any connector used in downhole operations.
[0024] FIG. 3 depicts a view of the connector assembly 112 according to one embodiment of the present invention. The connector assembly 112 includes a body 300 , a first end 302 and a second end 304 . In one embodiment, the first end 302 has threads 306 . As shown, the threads 306 are the male or pin of the connection; however, it should be appreciated that the threads 306 could be in any form to facilitate connection to another member such as a female or box end, a clamp, a flange, etc. The first end 302 adapts for easy connection to the components 108 and 200 or another connector assembly 112 . The first end 302 couples to the body 300 .
[0025] The body 300 is substantially cylindrical and has two full diameter sections 308 on each end of the body 300 . Between the full diameter sections 308 is an engaging section 310 . The engaging section 310 includes planar portions 312 . The planar portions 312 are substantially parallel and adapted to be engaged by a tool 400 , shown in FIG. 4 . The tool 400 is any tool for applying or resisting torque in the rod 110 such as a wrench, spanner, etc. As shown in FIG. 4 the planar portions 312 are arranged at edges 402 to transition smoothly from flat to the natural cylindrical diameter of the body 300 . This differs from prior connectors that had a square arrangement, thus having four 90° angles. It should be appreciated that when applying torque to a rod or tubular the highest stress concentrations are on the outer edge of the rod or tubular. In an arrangement with sharp angles the torque load is further concentrated at the angles. Thus, the engaging section 310 reduces stress concentrations in the connector assembly 112 by having tangential edges 402 rather than the angles of the prior art. It should be appreciated that the body 300 can be of any size and configuration so long as the edges 402 of the planar portions 312 have a smooth transition to the rest of the body.
[0026] The body 300 couples to the second end 304 of the connector assembly 112 . Each end of the second end 304 adapts to couple to the rod 110 and the body 300 respectively. The second end 304 may be adapted to be the same diameter as the rod 110 , and further be adapted to match the diameter of the body 300 on the other end. The second end 304 is welded directly to the rod 110 , although it should be appreciated that any connection could be used such as clamps, threads, flanges, etc.
[0027] The first component has an adapter 116 shown schematically. The adapter 116 is arranged to connect to the first end 302 . In one embodiment the adapter 116 is a female or box connection attached to a shaft that couples to the first component 108 . The adapter 116 with the first component 108 is then brought into engagement with the first end 302 . The tool 400 then engages the planar portions 312 . The connection is made between the adapter 116 and the first end 302 by rotating the adapter 116 while the tool 400 prevents rotation of the connector assembly 112 . In another embodiment the connection is made when the adapter 116 is held stationary while the tool 400 torques the connector 112 . It should be appreciated that the adapter could be any connector adapted to connect to the first end 302 . The connection of the connector assembly 112 to the second component 200 or another connector assembly is performed in the same manner as described above and thus will not detailed here.
[0028] In one embodiment the first component is a downhole pump such as a reciprocating pump, a progressive cavity pump. The second component is a motor for rotating the rod 110 . As the second component 200 rotates the rod 110 , the rod 110 turns and torques the connector 112 and transfers rotation to the adapter 116 and thus transfers rotation to the shaft of the pump, not shown. As described above due to the improved design of the connector assembly 112 , stresses in the connector assembly 112 and the risk of failure are greatly reduced over the life of the rod.
[0029] Although the first component 108 is described as a pump, it should be appreciated that the first component 108 could be any tool or component used in downhole operations such as a packer, an expander, a cutting tool, a valve, an anchor, etc. It should further be appreciated that the second component 200 could be any tool or component used at the surface of a wellbore such as, but not limited to a spider, a rotary table, a pipe spinner, a power tong, a top drive, an elevator, the spool, a human operator, etc.
[0030] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | A method and apparatus for connecting a component to a rod for use in downhole operations. Wherein the method and apparatus is design to reduce stress and the risk of failures in the connection during downhole operations. The method and apparatus having a connector assembly that is designed with only two wrench flats in order to minimize stress concentrations during operation. The method and apparatus having an optional intermediate alloy metallurgy. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus for the detection of a specifically reacting substance in a test liquid. In this apparatus a test strip is involved comprising an analytical system. The apparatus of the invention is specifically intended for home use or use by nonprofessional organisations, whereby the test is usually carried out by laymen or non skilled people.
In the state of the art there are various types of test strips for detecting specifically reacting substances. Such a test strip can for example, when provided with a certain colour indicator, be used for measurement of the pH of the test liquid. However, for the detection of specifically reacting substances by an immunoassay, test strips with a more complicated analytical system are required. Upon contact with such a test strip, which is preferably made of a porous material, the test liquid, possibly containing the specifically reacting substance to be detected, is transported along the test strip by capillary action. The test strip usually contains different reagent zones comprising for example specific reactants for the substance to be detected. One of these reactants is provided with a label, preferably a coloured label which can be observed visually. The test liquid subsequently passes the various reagent zones, whereby different immunological reactions will take place. The complexes formed will finally be bound by a reagent on the detection spot and will be visible by the label involved. Such strips are now commercially available.
2. Description of the Related Art
EP-A-0 183 442 discloses a chromatographic device comprising a housing and a strip of bibulous material non-removably confined in the housing. The inner walls of the housing contain means for supportively confining the strip in the housing. This means supportively confines the strip in the housing so that the front and back of the strip are essentially free from contact with the walls of the housing. The bottom end of the housing contains means for enabling a portion of the strip to contact the liquid medium. The housing additionally contains means for visually observing the strip.
EP-A-291 194 discloses an analytical test device which consists of a hollow casing of rigid material which is impermeable to moisture, and contains in the casing a dry porous support. The support is connected to the outside of the casing in such a way that a liquid test sample can be applied to the support. The sample then migrates through the support, on which immunological reactions take place and provide a visible analytical result in a particular zone of the support. In order to be able to observe the latter, openings are also provided in the casing. Direct labelling materials such as, for example, gold sol particles are used for visualization.
EP-A-0 349 215 discloses a test cell for detection of a ligand in a liquid sample, comprising an elongate casing for a permeable material. This permeable material is capable of transporting an aqueous solution disposed within the casing and comprises a receptor for the ligand. Receptor-coupled coloured particles are used for detection of the ligand. Observation of the test site is permitted by a hole or transparant section of the casing.
The known apparatuses for the detection of specifically reacting substances comprise a test strip, with an analytical system, enclosed in a housing. This housing is almost hermetically sealed, so that, after reaction of the test liquid with the reagents on the test strip, evaporation of the test liquid is seriously delayed or even prohibited. As a consequence the reagents may diffuse back to the detection spot, which will give rise to incorrect results.
SUMMARY OF THE INVENTION
The present invention is concerned with the improvement of the known techniques, such as those referred to in the above publications, especially with regard to the reliability of the test results. These improvements have been achieved with an apparatus for the detection of at least one specifically reacting substance in a test liquid comprising
-- a housing
-- a holding device and
-- a test strip which is held in the holding device and which consists of a material that transports the test liquid essentially by capillary forces and comprises an analytical system which indicates the presence or absence of said substance to be detected, preferably by a colour,
whereby
-- the housing has an interior space and opening for introducing said test liquid into said interior space and optionally means via which contact of the test liquid with the test strip can take place;
and
-- the holding device comprises a base and a cover, said holding device being substantially open on its longitudinal and/or tranverse sides and said holding device being provided with at least one window for observing the test result, prefarably a colour.
The important aspect of the apparatus according to the present invention is that it contains a separate holding device (for a test strip) which is substantially open, in addition to and separate from a housing that is solely designed for receiving and transferring the test liquid.
The housing is advantageously produced from a material which is impermeable to moisture, such as thermoplastic material, polystyrene or the like, and acts to receive and transfer a certain amount of the test liquid. For this purpose the housing is equipped with an interior space and an opening for introduction of the test liquid and optionally means via which contact of the test liquid with the test strip can take place.
The test liquid can directly be introduced into the housing, for example with a pipette, or indirectly with a separate sample collector, the latter obviously being preferred. When the test liquid is introduced directly, the housing is preferably provided with visible calibrations, to control the correct volume of test fluid required for detection of the specifically reacting substance. The housing may also contain a filter to remove possibly interfering substances from the test liquid.
In order to allow contact between the test liquid and the test strip the housing optionally contains means via which this contact can take place. These means are preferably a (second) opening, which can have a round or square form or a split.
The holding device is advantageously made from the same material as the housing. Its main function is to hold the test strip with the analytical system in a special way. The holding device consists of a base and a cover, whereby the longitudinal and/or transverse sides are designed substantially open to ensure an adequate and quick drying of the test strip after reaction with the test liquid. In this way the so-called "back-diffusion" of the reagents, which leads to incorrect results, is eliminated. When required this drying step can further be accelerated by for example exposure to a stream of hot (dry) air. The test results can then reliably be established for quite a long period of time. This is especially of advantage when the apparatus described in the present invention is used for detection of pregnancy.
The holding device advantageously contains spacers between the cover and the base. These spacers ensure an adequate ventilation of the test strip. In addition the holding device is provided with a number of supporting elements for the test strip. Preferably the base is provided with lateral webs, which are constructed in such a way that a split is formed between the cover and the webs. This split guarantees an adequate ventilation of the test strip, but prevents, because of its narrow form that the test strip is touched upon by accident. The lateral webs and the cover extend over the entire length of the holding device. The spacers can, however, also be present at short distances only on the longitudinal or transverse sides. Spacers, supporting elements and lateral webs are advantageously made from the same material as the holding device.
The holding device contains at least one window through which the test result can be read. The window is, for example, a hole or a transparent section of the holding device. When the analytical system is designed in such a way that the presence of the specifically reacting substance is indicated by a colour, which is fixed at a certain spot of the test strip, the holding device contains at least one window through which this spot can be observed. Preferably the holding device contains additional windows at the place of control spots, which are included to garantee a correct test performance. The latter is of special importance when the apparatus is used by the layman for example to detect pregnancy.
The test strip advantageously consists of a material which transports the test liquid essentially by capillary forces. Advantageously absorbent, porous or fibrous material is used, which is suitable for rapid uptake of liquid. Suitable materials involve amorphous spong-like structures or various porous synthetic materials such as polypropylene, polyethylene, polyvinylidene fluoride, ethylene/vinyl acetate copolymer, polyacrylonitrile and polytetrafluoroethylene. In addition certain materials with an inherent hydrophobicity can also be pretreated with surface-active agents to such an extent that they are able to take up a test liquid and transport it by capillary forces. Other suitable materials include multilayer materials and materials which are already generally used in analytical test strips such as paper or paper-like materials, for example nitrocellulose.
The test strip can either be held in a flat position in the holding device or can at one end be bend and extended into the interior space of the housing. The latter construction facilitates the contact between test strip and test liquid.
Preferably the holding device comprises also an absorber, which is located downstream adjacent to the test strip, to remove excess test liquid. The material of the absorber is not critical and can be any material that is capable of absorbing liquids, for example a paper-like material or those materials which are mentioned for use as absorbing material in the sample collector.
Advantageously the test strip can be extended so that the strip itself can function as an absorber. In the latter case no additional absorber is needed. In order to gain space this extended test strip can be rolled or zigzag-folded.
Besides the absorber the holding device might contain a moisture-absorbing agent, such as silica, to guarantee a better stability of the analytical system on the test strip.
In one preferred embodiment of the invention the holding device can be separated from the housing. This makes the apparatus and especially the production of this apparatus more flexible, as the housing and holding device can be produced separately before assembling, while also different combinations of housing and holding device can be realized.
In another preferred embodiment of the invention the housing is an elongate housing, the holding device is located on the housing and the housing has a first opening for introducing the test liquid into the interior space, and a second opening which is located at a certain distance from the first opening and through which the test liquid can contact the test strip. The elongate housing enables the use of an elongate sample collector, which, in combination of the further special features regarding handling and reading, makes this embodiment especially suited for home-use detection of pregnancy.
In another preferred embodiment of the invention said elongated housing is provided with means to facilitate the contact with the test strip. These means can preferably be formed by an elevation on the inside wall of the housing, so that when a sample collector is introduced into the housing the tip of the sample collector is diverted and pressed against the test strip. The elevation is advantageously located at a position opposite the place where contact between the sample collector, containing the test liquid, and the test strip takes place.
The present invention also provides a sample collector comprising a handle and absorbing material which absorbs the test liquid rapidly and is capable of an easy direct or indirect release of test liquid to the test strip, whereby said sample collector can be introduced through the opening of the housing into the interior space of the apparatus according to the present invention. Transfer of the liquid sample from the sample collector to the test strip can be achieved by simply pressing. This transfer can be facilitated by special means in the housing, such as an elevation on the inner wall, or by bending the top end of the tests strip so that it extends into the interior space of the housing.
Instead of direct transfer of test liquid from the sample collector to the test strip, this transfer can also be realized in an indirect way by means of a connector. This connector transfers the test liquid from the sample collector to the test strip by capillary action. The connector can be made from the same material as that of the sample collector, but preferably with another, smaller, pore size. The connector can be fitted in various ways and can for example be located against the test strip or pressed aginst the test strip by the sample collector.
The sample collector comprises a material which can readily absorb test liquid, but also easily release this test liquid for example under mechanical pressure or capillary transfer. It can thus be a sponge-like material such as, for example, cotton wool or hydrophilic and hydrophilized synthetic polymer materials, such as polyethylene vinylacetate, as well as other polyesters, and polypropylene. To this material reagents can be added as, for example, buffering compounds to adjust the pH of the test liquid, or compounds able to eliminate possibly interfering substances present in the test liquid.
Another example of a sample collector comprises material that as such is not able to absorb and release test liquid, but is able to do so merely by its shape or construction.
Next to the absorbing material the sample collector comprises a handle, which can for example be provided with a colour. This colour can serve for sample identification and thus facilitate handling of larger numbers of different samples.
In another embodiment of the present invention the sample collector is provided with a connecting rod between the handle and the absorbing material, which facilitates handling of the sample collector. Between the rod and the handle a shoulder is provided on which the housing can rest on introduction of the sample connector.
The present invention is further directed to a device comprising the apparatus and sample collector described above, as well as to a method for the detection of at least one specifically reacting substance in a test liquid, whereby the above mentioned device is used.
There are no special restrictions with respect to the analytical test system on the test strip. An example of an analytical system is described in German Utility Model DE-U-88 05 565.5. Other variants are to be found in EP-A-0 183 442, WO-A-91/12528, EP-A-0 349 215 and EP-A-0 186 799. In a preferred embodiment, the term "analytical system" used herein indicates that a specific reactant (for example an antibody) forms a complex with the specifically reacting substance (for example the pregnancy hormone hCG) in a reaction (for example an immunological reaction). This complex is then (if it does not already carry a visible label) provided with a label, for example in a reaction with a labelled anti-antibody (this is a second antibody raised against immunoglobulins in general and therefore able to bind the hCG antibodies as well). The labelled complex can then be fixed and made visible at another point on the test strip via a reaction with another reagent immobilized on the test strip.
Although in principle all kinds of labels can be used, a preferred label for use in the present apparatus according to the invention is a so-called particulate label. Most preferably a direct particulate label is used, which gives a direct visible test result without the need for additional reagents or equipment. Said direct particulate label comprises small coloured particles, such as gold sol particles, latex particles, dyestuff particles, liposomes including a dye, carbon- and selenium sol particles etc. These particles are as such insoluble in water, but resuspendible in solution. All these particulate labels are well known in the literature (see Clin. Chem. 27, 1157, 1981, EP 007 654, EP 032 270, EP 291 194, EP 154 749, EP 321 008).
Gold sol particles are particularly advantageous. The gold sol particles advantageously have a diameter of about 5 to 100 nm in size.
The various reagents of the analytical system are distributed over various zones of the test strip, and a test liquid can then diffuse through them. A suitable pregnancy test strip (when gold particles are used as direct particulate labels) has the following zones (from upstream to downstream):
1st zone: antibodies against the pregnancy hormone hCG, labelled with gold sol particles, which are freely movable in the test strip after contact with a test liquid.
2nd zone: antibodies against hCG which are immobilized on the test strip.
In the first zone of this test strip an immunological reaction takes place between the freely movable gold sol-labelled hCG antibodies and any hCG present in the test liquid. The gold sol-labelled hCG antibody/hCG complex formed diffuses into the second zone. This complex is then bound to the immobilized hCG antibodies. Gold sol-labelled hCG antibodies which are not bound to hCG diffuse freely out of this second zone.
Another suitable pregnancy test strip comprises:
1st zone: gold sol-labelled hCG antibodies (freely movable).
2nd zone: hCG antibodies coupled to biotin (freely movable).
3rd zone: avidin (immobilized).
In the first zone any hCG present in the test liquid reacts with the gold sol-labelled hCG antibodies. The gold sol-labelled hCG antibody/hCG complex formed diffuses into the second zone where a "sandwich" complex is formed (gold sol-labelled hCG antibody/hCG/biotinylated hCG antibody). This "sandwich" complex then diffuses into the third zone where it is fixed by the very strong avidin/biotin interaction. The freely movable gold sol-labelled hCG antibodies which have not been complexed again diffuse freely out of this zone.
A particularly preferred test strip has the following zones:
1st zone: hCG antibodies (freely movable)
2nd zone: gold sol-labelled anti-antibodies (freely movable), which do not react immunologically with the hCG antibodies from the third zone.
3rd zone: hCG antibodies (immobilized).
In the first zone any hCG present in the test liquid forms in the first zone an hCG antibody/hCG complex. This complex diffuses into the second zone and reacts with the gold sol labelled anti-antibodies. The gold sol-labelled anti-antibody/hCG antibody/hCG complex then diffuses into the third zone, where it is fixed by the immobilized hCG antibody and where it can be detected visually. Complexes which contain no hCG (gold sol-labelled anti-antibody/hCG antibody complexes) are not bound in this zone and diffuse out of it.
The above analytical system on the test strip is preferred for various reasons:
a) This system guarantees a high affinity and specificity of the hCG antibodies in the first zone, where the primary reaction takes place with any hCG present in the test liquid, as these antibodies are present in their "natural" form. This means that they are not bound to a labelled compound nor immobilized onto the solid phase. Therefore the special characteristics of these antibodies such as a high affinity and specificity, which may be impaired by said binding reactions, are retained.
b) Some agglutination (complex formation) will occur between the specific hCG antibodies from the first zone and the gold sol-labelled anti-antibodies from the second zone. These complexes will then be transported to the third zone and, when they contain hCG, be fixed by the immobilized hCG antibodies from the third zone. These "agglutinated" complexes will contain more gold sol-labelled anti-antibodies than the hCG antibody/anti-antibody complexes which have not agglutinated. Therefore a higher amount of label is bound per hCG molecule, which means more colour and thus a higher sensitivity. This phenemenon is not shown for the other analytical systems.
c) Finally, the hCG antibodies from the first zone also act as "spacer" between the hCG in the test fluid and the gold sol-labelled anti-antibodies from the second zone. The distance between the label and the hCG is therefore larger. The hCG/hCG antibody/gold sol-labelled anti-antibody complex will therefore more easily bind to the immobilized hCG antibodies from the third zone, as there is less steric hindrance from the labelled antibodies. This also results in a higher sensitivity.
The reagents can be introduced onto the test strip in a variety of ways. For example, it is possible to use printing processes known per se for this purpose. In this case, the reagents may either merely be applied to the surface of the test strip or impregnated into the test strip. It is sometimes also advantageous to introduce the reagents in a microencapsulated form. This may be desirable when a reagent is required for fixation of the above mentioned labelled complexes, which interferes with the unbound labelled antibodies.
The binding reagents such as antibodies or avidin can be immobilized onto the test strip by covalent binding or absorption. These reagents can be immobilized as such or bound to particles, as for example latex particles.
If the test strip consists, for example, of nitrocellulose, the antibodies can be coupled directly without a previous chemical treatment of the test strip. After coupling, however, the remaining binding sites on the test strip should be blocked with, for example, treatment with hydrophilic synthetic polymers, such as polyvinylalcohol, or hydrophylic biopolymers, such as human and bovine serum albumin, ovalbumin and the like. If the test strip consists of other materials such as paper, covalent coupling can be achieved with CNBr or carbonyldiimidazole.
The test strip has preferably also a control zone which generates a colour signal irrespective of whether the sample contains the substance to be determined or not. Such a control zone contains, for example a colour coupler which reacts with the urea in the woman's urine. Alternatively, this control zone contains immobilized antibodies, anti-antibodies or other binding reagents which react with the labelled antibodies or labelled anti-antibodies.
Exemplary embodiments of the invention are explained in detail hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 and 2 show a plan view and side view respectively of an embodiment of the apparatus described in the present invention;
FIG. 3 and 4 show a cross-section and an axial section of the embodiment shown in FIG. 1;
FIG. 5 shows a plan view of a sample connector provided with a connecting rod, which can be used in the embodiment shown in FIG. 1-4;
FIG. 6 shows an axial section of another embodiment including a sample collector;
FIG. 7 shows a plan view of a sample collector which can be used in the embodiment shown in FIG. 6;
FIG. 8 shows a plan view of a further embodiment of the invention;
FIGS. 9, 10, 11 illustrate a side view, a cross-section and an axial section respectively of the embodiment shown in FIG. 8;
FIG. 12 shows a plan view of a sample collector which can be used in the embodiment shown in FIG. 8;
FIG. 13 shows a plan view of another embodiment of the invention;
FIGS. 14, 15, 16, 17 show a plan view, a side view, an cross-section and an axial section respectively of another embodiment of the invention, wherein a connector is used;
FIG. 18 shows a sample collector which can be used in the embodiment shown in FIGS. 14-17.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus of FIG. 1-4 comprises a housing 2 as well as a holding device 3 in which a test strip 18 and an absorber 20 is held. The housing 2 has an opening 5 for introducing a test liquid, which may contain the substance to be analyzed, into the interior space 6 of the housing 2. The test liquid is introduced with a sample collector, comprising a handle 12, an absorbing material 10 a connecting rod 11 and a shoulder 13. The housing further contains an opening 7 via which contact of the test liquid with the test strip can take place. Contact between the sample collector and the test strip is facilitated by the elevation 30 on the inner wall of the housing 2, which presses the sample collector against the test strip 18. The holding device 3 comprises a cover 14, spacers 15, a base 16 and lateral webs 17 on which the cover, supported by the spacers, rests.
The lateral webs 17 are constructed in such a way that a split 19 is formed between the cover 14 and the lateral webs 17.
The holding device 3 contains one or more windows 4 and 4' through which the test result, preferably indicated by a colour on a certain spot of the test strip, can be observed.
FIG. 5 shows the sample collector used in the apparatus of FIGS. 1-4.
FIG. 6 shows another embodiment of the apparatus according to the present invention, including a sample collector, wherein the test strip 18 is held in position by the supporting elements 32 and 33.
FIG. 7 shows the sample collector used in the apparatus of FIG. 6.
FIGS. 8-11 show a further embodiment of the apparatus according to the present invention, wherein the test strip 18 is bend and extended into the interior space 6 of the housing 2 to facilitate the contact between the sample collector with the absorbing material 10 and the test strip 18.
FIG. 12 shows the sample collector used in the apparatus of FIGS. 8-11.
FIG. 13 shows another embodiment of the apparatus according to the invention, whereby the test strip 18 is extending into the interior space 6 of the housing 2 and the test liquid is introduced via the opening 5.
FIGS. 14-17 show another embodiment of the apparatus described in the present invention, wherein contact between sample collector and test strip is made via a connector 31.
Detection of, for example, hCG with the apparatus according to the present invention, whereby the analytical system comprises a first zone with hCG antibodies, a second zone with labelled anti-antibodies and a third zone with immobilized hCG antibodies, can be carried out as follows:
A test liquid, which may contain hCG, is introduced, either directly or indirectly by means of a sample collector, into the interior space of the housing of the apparatus according to the present invention. This sample collector, comprising an absorbing material, gets in contact with the test strip comprising the analytical system, when it is introduced into the housing. The test liquid is released and transported through the test strip by capillary action. Any hCG which is present in the test liquid, reacts with the specific hCG antibodies from the first zone. The hCG antibody/hCG complex formed is then transported with the test liquid into the second zone, where it reacts with the anti-antibodies labelled with gold sol particles. The complex obtained in this way is transported into a third zone, where it is fixed by the immobilized hCG antibodies from the third zone. The hCG present in the test liquid can then detected by reading the colour at this fixation spot in the third zone. Furthermore the test performance is controlled by observing the colour at the control spot in the fourth zone, which always should give a positive result.
The present invention will now be further particularly described with reference to the following Examples. The apparatus used is that depictured in FIG. 6.
EXAMPLE 1
1. Preparation of gold sol labelled monoclonal rat anti-mouse IgG (gold sol conjugate)
Gold sols with an average particle diameter of 50 nm (A 540 =5.0) were prepared according to the method described by Frens (Nature Physical Science Vol. 240, 1973, 20).
A solution of 1 mg monoclonal rat anti-mouse IgG (anti-kappa) per ml sodium chloride (9 g/l) was adjusted to pH 8.0 using 0.1M sodium hydroxide. 1 l of the gold sol solution was adjusted to pH 8.0 with 0.1M sodium hydroxide, mixed with 20 ml of the monoclonal rat anti-mouse IgG solution and subsequently postcoated by adding 40 ml of a 20M polyethylene glycol solution, pH 8.0. The postcoated gold sol conjugate was sedimented by centrigugation for 20 min. at 3500 g at ambient temperature. After removing the supernatant by suction the gold sol conjugate pellet was resuspended to an A 540 value of 50.0 in a solution containing 2% (v/v) foetal calf serum, 160 g/l sucrose, 2% (w/v) Triton X100 and 1M Tris, pH 8.0.
2. Preparation of a monoclonal anti-hCG IgG solution
Monoclonal hCG antibodies (beta-subunit specific) were prepared essentially as described in EP 045 103. 40 g of monoclonal anti-hCG IgG was dissolved in 1 l of a solution containing 1M Tris, pH 8.0, 160 g/l sucrose and 2% (w/v) Triton X100.
3. Preparation of polyclonal anti-hCG IgG
Polyclonal antibodies against hCG were prepared according to conventional techniques. 6 g of immunopurified anti-hCG IgG were dissolved in 1 l of a solution containing 3.5 mM Tris, pH 8.0, and 9 g/l sodium chloride.
4. Preparation of test strips
On a rectangular sheet of glass paper measuring 100 mm in length and 70 mm in width a first mobile reaction zone was formed by applying, along the width, a solution of monoclonal anti-hCG IgG (see under 2), in a line 5 mm wide and 10 mm from the bottom edge of the glass paper sheet.
A second mobile reaction zone was formed on the same glass paper sheet by applying, again along the width, a solution of gold sol conjugate (see under 1), in a line 5 mm wide and 16 mm from the edge of the glass paper sheet. Both mobile reaction zones were air dried (50° C.) and the sheet was cut along its length to strips which were 7 mm wide.
A third reaction zone (detection zone) was formed on each test strip by pipetting, 40 mm from the bottom edge, 1 μl of a solution of polyclonal hCG IgG (see under 3).
A fourth reaction zone (control zone) was formed on each test strip by pipetting, 50 mm from the bottom edge, 1 μl of the monoclonal anti-hCG IgG solution (see under 2).
The detection and control zones were subsequently air-dried (50° C.).
5. Assembly and testing of the apparatus
Test strips were assembled in an apparatus as described in the present invention and tested with urines from non-pregnant women spiked with various concentrations of hCG (15-25-300 000 IU/l). In addition an hLH standard was tested in a concentration of 500 IU/l. 4 min. after insertion of the apparatus into the urine sample the following results were observed:
______________________________________ detection zone control zone______________________________________hCG (IU/l)0 - +15 +/- +25 + +300 000 + +hLH (IU/l)500 - +______________________________________
EXAMPLE 2
1. Preparation of carbon sol labelled monoclonal anti-hCG IgG (carbon sol conjugate)
0.5 g of Degussa Spezial Schwarz 100 was suspended in 50 ml 5 mM borate buffer with a pH of 8.6.
This suspension was sonified (27 W, 20 kHz; Branson Sonifier) during 30 min. under stirring and cooling on ice. This 1% C-sol can be kept at ambient temperature.
A suspension was made of 10 ml 1% C-sol in 40 ml 5 mM borate buffer, pH 8.6. This suspension was proceeded further as indicated above for the 1% C-sols. The resulting 0.2% C-sol can be kept at ambient temperature.
A solution of 1 mg monoclonal anti-hCG IgG (beta-subunit specific; see Example 1) per ml sodium chloride (9 g/l) was adjusted to pH 8.0 using 0.1M sodium hydroxide.
1 l of the carbon sol solution was adjusted to pH 8.6 with 5 mM boric acid, mixed with 20 ml of the monoclonal anti-hCG solution and incubated under stirring for 2 hours at ambient temperature.
Subsequently the carbon sol conjugate was sedimented by centrifugation for 6 min. at 10 000 g at ambient temperature. After removing the supernatant by suction, the carbon pellet was resuspended to a volume of 1 l in a solution containing 2% (v/v) foetal calf serum, 160 g/l sucrose, 2% (w/v) Triton X100 and 1M Tris, pH 8.6.
2. Preparation of a monoclonal anti-hCG IgG solution
Monoclonal hCG antibodies (alpha-subunit specific) were prepared essentially as described in EP 045 103.3 g of monoclonal anti-hCG IgG was dissolved in 1 l of a solution containing 25 mM Tris, pH 8.0, and 9 g/l sodium chloride.
3. Preparation of a monoclonal rat anti-mouse IgG solution
3 g of monoclonal rat anti-mouse IgG (anti-kappa) was dissolved in 1 l of a solution containing 25 mM Tris, pH 8.0, and 9 g/l sodium chloride.
4. Preparation of test strips
On a rectangular sheet of glass paper (100 mm in length and 70 mm in width) a mobile reaction zone was formed by applying along the width, a solution of carbon sol conjugate (see under 1), in a line 5 mm wide and 10 mm from the bottom edge of the glass paper sheet. The mobile reaction zone was air dried (50° C.) and the sheet was cut along its length to strips which were 7 mm wide.
A second reaction zone (detection zone) was formed on each test strip by pipetting, 40 mm from the bottom edge, 1 μl of the monoclonal anti-hCG IgG solution (see under 2).
A third reaction zone (control zone) was formed on each strip by pipetting, 50 mm from the bottom edge, 1 μl of the monoclonal rat anti-mouse IgG solution (see under 3).
5. Assembly and testing of the apparatus
Test strips were assembled in an apparatus as described in the present invention and tested with urines from non-pregnant women spiked with various concentrations of hCG (10-25-300 000 IU/l). In addition an hLH standard was tested in a concentration of 500 IU/l.
2 min. after insertion of the apparatus into the urine sample the following results were observed:
______________________________________ detection zone control zone______________________________________hCG (IU/l)0 - +15 + +25 + +300 000 + +hLH (IU/l)500 - +______________________________________ | An apparatus detects a specifically reacting substance in a test liquid. The apparatus has a housing and a holding device thereon for holding a test strip. The test strip has a material that transports a test liquid essentially by capillary forces and has an analytical system which indicates the presence or absence of the substance to be detected. The holding device can be attached to the housing with an opening therebetween for allowing evaporation of test liquid. The housing can be elongated for accepting a sample collector therein. A contact mechanism can also be disposed for promoting contact of liquid sample from the sample collector when inserted in the housing, to the test strip held by the holding device. | 8 |
RELATED APPLICATION
This applications claims priority to U.S. Provisional Patent Application Ser. No. 61/140,467 filed Dec. 23, 2008, the entirety of which application is incorporated by reference.
BACKGROUND
The invention disclosed herein relates generally to pressure diffusers for washing pulp and particularly relates to upper and lower cylindrical bearings between a moving screen assembly and stationary bearing cylinders in the pressure diffuser.
The term “pulp” generally refers to comminuted cellulosic material, such as wood chips that have been processed in a digester to separate the fibers in the wood. Chemicals, e.g., liquor, are injected into the digester vessel to process the pulp. After the pulp is discharged from the digester vessel, the pulp may have residual amounts of chemicals.
The pulp flow from the digester vessel to a pressurized diffuser that washes the pulp to remove the residual chemicals. A pressurized diffuser is typically a large vessel, e.g., 50 feet in height or greater. Pulp with chemicals enters an annular space inside the diffuser. Wash water is injected into the annular space and flows through the pulp to remove the chemicals from the pulp. The wash water with chemicals (referred to as “wash filtrate”) passes from the annular space through slots in an internal screen assembly. The slots allow the wash filtrate to pass through to an internal chamber at the center of the screen assembly. The slots in the screen assembly are too narrow to pass the fibers or other particles in the pulp. The cleaned pulp is typically discharged from the top of the pressurized diffuser. The wash filtrate is typically discharged from a bottom outlet in the pressure diffuser.
The screen assembly moves within the pressure diffuser. Traditionally, the screen assembly moves reciprocally up and down during operation of the pressure diffuser. The screen assembly may also rotate during operation. The movement of the screen assembly promotes the flow of pulp through the annulus in the diffuser. Particularly, the movement of the screen assembly assists in clearing the slots of fibers and particles that may be blocking the slots.
Cylindrical bearings support the screen assembly in the pressure diffuser. The bearings allow the screen assembly to move vertically with respect to the diffuser housing. The bearings are arranged at upper and lower regions of the diffuser. The bearings are sandwiched between the screen assembly and a stationary bearing cylinder in the pressure diffuser.
The cylindrical bearings are adjacent the upper and lower ends of the annular space containing the pulp. A difficulty with conventional cylindrical bearings has been that sand, fiber, rocks and other impurity particles in the pulp inadvertently enter the gap between the screen assembly and the bearing cylinder, and become caught against a surface of the cylindrical bearing. These impurity particles damage the surface of the bearing cylinder, such as by gouging the surface and forming grooves and other imperfections in the surface of the cylindrical bearing. The damaged surface of the bearing cylinder tends to allow fibers from the annular region with the pulp to move past the bearing cylinder and enter the filtrate chamber in the center of the screen assembly.
The damaged surface of the bearing cylinder can also lead to permanent failure of the bearings. Additionally, the difficulty with sand and impurity particles entering the annular space between the cylindrical bearings and the bearing surfaces is most pronounced when the cylindrical bearing is cool. When cool, conventional cylindrical bearings contract and open gaps between the bearing and the bearing cylinder.
Conventional bearings are formed of a soft plastic material, e.g., a polytetrafluoreoethylene (PTFE) or other fluorocarbon plastic such as Rulon™, that expands under heat. The thermal expansion of the conventional bearings creates a tight seal between the bearing surfaces, e.g., the screen assembly and stationary bearing, and the cylindrical bearing. The expansion coefficient of conventional cylindrical bearings has been about ten (10) times the expansion coefficient of the metal materials, e.g., stainless steel, used to form the bearing surfaces in the screen assembly and bearing. The pressure diffuser typically can operate at temperatures of up to 330 degrees Fahrenheit (F.) and about 150 degrees Celsius (C.). At these elevated temperatures, conventional cylindrical bearings have expanded to form tight seals in the gap between the screen assembly bearing surface and a bearing surface of a bearing in the pressure diffuser.
When the pressure diffuser has cooled, such as when taken off-line for maintenance and service, the temperature of the cylindrical bearings may drop to ambient temperatures, such as 32 degrees F. or to zero degrees C. At these cooler temperatures, the cylindrical bearings contract and open a gap between the bearings and the bearing surfaces on the screen assembly and bearing. The gap between a cooled cylindrical bearing and the bearing surfaces may be sufficient to allow sand and other impurity particles to enter and become trapped against the bearing when the pressure diffuser heats during operation.
When the cylindrical bearing is cool, sand, rocks and other impurity particles become trapped against and embed in the soft surfaces of the cylindrical bearing. The embedded sand, rocks and other particles scrape against the surface of the bearing cylinder as the screen assembly (with cylindrical bearing) moves reciprocally up and down, and may rotate. The scraping of sand, rock and other particles can damage the bearing cylinder.
The damage caused by sand and other impurity particles to cylindrical bearings in a pressure diffuser has created a long felt need for an improved cylindrical bearing. The damage to the bearings results in fibers entering the filtrate extracted from the pulp and impurities. Because of the damage caused by sand and other impurities, the cylindrical bearings are replaced periodically. The replacement of the bearings requires the pressure diffuser to be taken off-line and results in an interruption in the pulp cleaning process and, thus, loss of time and money due to repair and maintenance of the diffuser and lost pulp production.
Typically, cylindrically bearings are replaced every year or every year and an a half. However, the cylindrical bearings may require more frequent replacement, such as three or four times a year, if the damage to the bearing due to impurity particles causes an excessive amount of fibers to enter the filtrate. There is a need for improved cylindrical bearings that are less susceptible to the encroachment of sand and other impurity particles into the space occupied by the bearing. Preferably, the improved cylindrical bearings will have an operational life of at least one year, even when operating with pulp having relatively large amounts of fine sand or other small particulate impurities.
SUMMARY
A cylindrical bearing for a pressure diffuser has been invented comprising, in one embodiment, a first annular section formed of a hard material and a second annular section formed of a softer material, both of which materials thermally expand when the pressure diffuser is heated to its operating temperature. Preferably, the first annular section is adjacent a pulp filled annular chamber of the pressure diffuser. The first annular section fits tightly in a gap between the screen assembly and bearing cylinder.
The first annular section may be formed of, for example, materials such as a non-ferrous metallic material, such as molybdenum, a carbon or glass filled thermoplastic material, such as polytetrafluoroethylene (PTFE), a graphite, a composite of graphite and a metal, and a ceramic. The hardness of the first annular section does not readily gouge or become damaged when sand and other impurity particles become caught between the section and the bearing cylinder. The hardness of the first annular section prevents sand, rocks and other particles from becoming embedded in its surface. Without sand, rock and other particles embedded in the first annular section, the cylindrical bearing is less likely to damage the bearing cylinder as the screen assembly moves up and down.
The first annular section prevents sand, rocks and other impurity particles in the pulp from migrating to the softer second annular section of the cylindrical bearing. By preventing sand, rocks and impurity particles from reaching the softer second annular section, the amount of sand, rock and impurity particles becoming embedded in the second annular section is eliminated or reduced, as compared to conventional cylindrical bearings made only of a soft material. Without sand, rock or other particles embedded in the first or second annular sections, the cylindrical bearing may move reciprocally in the bearing cylinder without damaging (or at least only minimally damaging) the surface of the bearing cylinder.
The first annular section also aligns the screen assembly radially with respect to the bearing cylinder and the pressure diffuser, especially during start-up operations of the pressure diffuser. The first annular section is hard and thick, at least as compared to the second annular section. The cylindrical bearing is affixed section by section to the screen assembly. With the cylindrical bearing affixed, the screen assembly is seated in the bearing cylinders in the upper and lower region of the pressure diffuser. When seated, the cylindrical bearing—and particularly the first annular section of the bearing—aligns the screen assembly radially in the bearing cylinders and the pressure diffuser.
The second annular section may be formed of a PTFE plastic, such as Rulon™ that is relatively soft as compared to the first annular section. The materials forming the first and second annular sections preferably have thermal coefficients of expansion several orders of magnitude, e.g., ten, greater that then thermal expansion coefficient of the metals forming the screen assembly and the bearing cylinder. As the second annular section expands when heated to the operating temperature of the pressure diffuser, it deforms to fit tightly in the gap between the screen assembly and the bearing cylinder. The expanded and deformed second annular section forms a seal in the gap that prevents fibers from the pulp from migrating through the gap and into the filtrate chamber within the pressure diffuser.
In one embodiment, the invention is a bearing cylinder for a screen assembly of a pressurized pulp diffuser, the bearing cylinder including: a plurality of segments of the bearing cylinder wherein the segments are arranged side-by-side to form the bearing cylinder; and each of said segments includes a first region formed of a hard material resistant to damage from sand and rocks, and a second region formed of a soft material that thermally expands and conforms to bearing surfaces opposite to the bearing cylinder.
In another embodiment, the invention is a bearing assembly for a pressure diffuser comprising: a screen assembly having an annular mounting surface; a bearing cylinder coaxial with the screen assembly and having an annular bearing surface facing the mounting surface of the screen assembly; an annular gap between the mounting surface of the screen assembly and the bearing surface of the bearing cylinder; a cylindrical bearing mounted on the mounting surface and positioned in the gap, wherein the cylindrical bearing includes a first annular region formed of a hard material having a thickness greater than a second annular region formed of a soft material, wherein as the soft material thermally expands it deforms to form a tight seal between the screen assembly and the bearing cylinder.
In a further embodiment, the invention is a method to minimize damage to a bearing cylinder in a pressure diffuser comprising: affixing a cylindrical bearing to a screen assembly, wherein the cylindrical bearing includes a first annular section formed of a hard material and a second annular section formed of a soft material, which is softer than the hard material; seating the screen assembly with the cylindrical bearing in a bearing cylinder to mount the screen assembly in the pressure diffuser, wherein the cylindrical bearing is adjacent the bearing cylinder; washing pulp in an annular chamber and extracting filtrate from the pulp, through the screen assembly and into a filtrate chamber; preventing sand, rock and other particles and other particles in the pulp from embedding in a surface of the first annular section due to the hard material of the first annular section; blocking by the first annular section, the sand, rock and other particles in the pulp from migrating through a gap between the cylindrical bearing and the bearing cylinder to the second annular section, and moving the screen assembly with cylindrical bearings with respect to the bearing cylinders, wherein the sand, rock and other particles are not substantially embedded in the first annular section or the second annular section of the cylindrical bearing.
SUMMARY OF THE DRAWINGS
FIG. 1 is a side schematic cross-sectional view of an exemplary conventional variable pressure diffuser.
FIG. 2 is a side schematic cross-sectional view of a lower region of the pressure diffuser shown in FIG. 1 , which shows the cylindrical bearing between the screen assembly and the bearing cylinder.
FIG. 3 is a schematic cross-sectional view of the cylindrical bearing sandwiched between the screen assembly and the bearing cylinder.
FIGS. 4 , 5 and 6 are front, top and cross-sectional views, respectively, of a section of the bearing cylinder, wherein FIG. 5 is a top view taken along line 5 - 5 in FIG. 4 and FIG. 6 is a cross-sectional view taken along line 6 - 6 in FIG. 4 .
FIG. 7 is a front view of several sections of the bearing cylinder arranged side-by-side on a screen assembly.
DETAILED DESCRIPTION
FIG. 1 shows a conventional variable pressure diffuser 10 comprising a generally upright, liquid tight, pressurized vessel 11 . Within the vessel is a first annular chamber 12 for comminuted cellulosic fibrous material (cellulosic pulp) to be treated under pressure. The pulp inlet 13 is typically at the bottom of the vessel and the pulp outlet 14 is typically at the top of the vessel. An internal screen assembly 15 includes a cylindrical screen extending the vertical length of the vessel. The screen defines an inner wall of the first annular chamber 12 . The wall of the vessel 11 defines an outer wall of the first annular volume. Exemplary pressure diffusers are shown in the U.S. Pat. No. 5,567,279 and U.S. Patent Application Publication 2003/0217822, both of which are incorporated by reference in their entirety.
Wash water or liquor is injected to the first annular volume through an array of injectors 9 arranged outside of the wall of the pressure vessel 11 and supplied with liquid through a network of wash liquid conduits 8 . The water is injected into the pulp in the first annular chamber 12 . Wash filtrate is extracted through slots in the cylindrical screen of the screen assembly and collected in a large center chamber 20 . The filtrate is discharged from the chamber 20 through a filtrate output 21 in the bottom of the vessel.
FIG. 2 is a cross-sectional view of a lower portion of the pressure diffuser vessel 11 . The screen assembly 15 includes a lower spider support 27 that includes radial support arms extending between the screen cylinder and a collar that is fixed to a center shaft 28 . The center shaft drives the reciprocal movement (see double headed line) of the screen assembly. This reciprocal movement is preferably about 24 to 30 inches.
A cylindrical bearing 33 is attached to an outer surface of a lower region of the screen assembly. The cylindrical bearing 33 is sandwiched between the lower region of the screen assembly and a cylindrical bearing cylinder 32 . Preferably, the cylindrical bearing 33 fills the gap between a surface of the screen assembly and a surface of the bearing cylinder 32 . By filling the gap, the cylindrical bearing seals the gap and prevents the passage of pulp fibers from the annular chamber 12 , through the gap and into the center chamber 20 of the screen assembly. In one embodiment, the cylindrical bearing may be three-quarters of an inch thick (20 millimeters) and seven inches (178 mm) in height.
FIG. 3 is an enlarged cross-sectional view of the cylindrical bearing 33 , the lower region of the screen assembly 15 and the bearing cylinder 32 . The cylindrical bearing 33 may fit in an annular groove 34 in a surface of the lower region of the screen assembly 15 . An annular array of clips 36 fit into recesses in the screen assembly and secures the sections of the bearing cylinder 32 in the groove 34 . The metallic clips may be attached to the screen assembly by screws or bolts 37 that extend through the clip and into the screen assembly. The clips are removed to allow the cylindrical bearing to be removed from and replaced on the screen assembly.
FIGS. 4 , 5 and 6 are front, top and cross-sectional views, respectively of a section 38 of the cylindrical bearing 33 . Each section 38 of the bearing is an arc. The sections are arranged side by side to form the cylindrical bearing. In some embodiments, eight to twelve sections 38 are arranged side-by-side to form the cylindrical bearing.
Conventional sections of cylindrical bearings were formed entirely of a uniform material, such as Rulon™. In contrast, the sections 38 of the bearings disclosed herein are formed of two materials. The first material has a hardness sufficient to resist damage due to sand, rocks and other impurity particles that may become caught between the surface of the first material and the opposing bearing surfaces of the screen assembly and bearing cylinder. The hardness of the first material should be sufficient such that sand, rock and other impurity particles do not embed in the surface of the material. For example, the first material may be a non-ferrous material, such as molybdenum, a carbon or glass filled thermoplastic material, such as polytetrafluoroethylene (PTFE), a graphite, a composite of graphite and a metal, and a ceramic. U.S. Pat. No. 6,834,862 discloses examples of materials that may be suitable for the first material. An example of the first material is a Pack Ryt™ material sold by Seal Ryt Corporation of Easthampton, Mass.
The second material is a softer material, such as Rulon™, that has a thermal expansion coefficient several times, e.g., ten times, the thermal expansion coefficient of the metal forming the screen assembly and bearing cylinder. As the second material expands under the heat of the operation of the pressure diffuser, the material expands to tightly fill the gap between the screen assembly and bearing cylinder and the material deforms to conform to the bearing surfaces of the screen assembly and bearing cylinder. The first material preferably has a thermal expansion coefficient less than the thermal expansion coefficient of the second material used to form the cylindrical. For example, the thermal expansion coefficient of the second material may be twice the thermal expansion coefficient of the first material. Similarly, the thermal expansion coefficients of the first and second material may be several orders of magnitude, e.g., ten orders, of the thermal expansion coefficient of the material, e.g., stainless steel, forming the screen assembly.
Each section 38 of the cylindrical bearing has a first panel 40 and a second panel 42 . One panel is preferably formed of the first material which is hard and does not allow sand, rocks or other impurities to embed in its surface, and the other panel is formed of the second material which is softer, has a high thermal expansion coefficient and deforms to conform to the bearing surfaces opposite to the second material. The panel formed of the first material is arranged proximal to the annular volume chamber 12 for pulp ( FIGS. 1 and 2 ) in the gap for the cylindrical bearing 33 between the screen assembly and the bearing cylinder. The panel formed of the second material is distal of the annular volume for pulp. Preferably, the panel, e.g., panel 42 , formed of the first (harder) material has a shorter height (H) than the height of the panel, e.g., 40 , formed of the second (softer) material.
The cylindrical bearing in the upper region of the pressure diffuser is above the pulp volume 15 and the cylindrical bearing in the lower region of the pressure diffuser is below the pulp volume. Accordingly, the lower panel of the cylindrical bearing in the upper region of the pressure diffuser is preferably formed of the first material. The upper panel of the cylindrical bearing in the lower region of the pressure diffuser is preferably formed of the first material.
The thickness of the first panel may be slightly greater than that of the second panel. In one embodiment, the thickness of the first (harder) panel may be 0.75 inches and the thickness of the second (softer) panel, when at ambient temperature, may be 0.72 inches thick. The greater thickness of the first (harder) panel ensures that the first panel will tightly seal in the gap between the screen assembly and the bearing cylinder, when the bearing is at ambient temperature. The tight seal form by the first panel ensures that sand and other impurity particles do not migrate onto the surfaces of the cylindrical bearing. As the cylindrical bearing is heated to the operating temperature of the pressure vessel, the thickness of the second panel expands, fills the gap between the screen assembly and the bearing cylinder and forms a tight seal in the gap that prevents the passage of fibers.
To attach the first and second panels 40 , 42 , the opposing longitudinal edges of the panels may be glued and pins 44 extend from an edge of one panel 42 may seat in holes on an opposite edge of the other panel 40 . Alternatively, the opposing longitudinal edges of the panels may respectively have a tongue and groove or dovetail arrangement that seat together when the panels are attached. Further, at least one of the longitudinal edges 46 of the panels, which do not abut another panel, may have a bevel or slant adapted to fit into an overhanging edge of the annular groove in a side wall of the screen assembly.
The sections 38 of the cylindrical bearing are arranged side-by-side to for the bearing. In one section 38 , the length (L) an upper panel 40 may be longer than the length of the lower panel 42 . In an adjacent section 38 , the length of the upper panel is shorter than the length of the lower pane. When the sections are side-by-side, the differences in lengths of the panels avoid a straight vertical line extending all the way through the height of the cylindrical bearing, which would allow pulp to flow past the cylindrical bearing and into the chamber 20 for the filtrate.
FIG. 7 shows a front view of several sections of the bearing cylinder arranged side-by-side on a screen assembly 15 . To assemble the cylindrical bearing, the sections 38 of the cylindrical bearing are sequentially placed in the annular groove 34 of the screen assembly. As each section is inserted, a clip(s) 36 is also mounted in the screen assembly to overlap an edge of the section. The clip is fixed to the screen assembly, such as by inserting a bolt through the clip and into the screen assembly. The clip holds the section 38 in the groove.
The sides of the sections abut against the sides of adjacent sections. The abutting sides form an irregular, i.e., non-vertical, joint between the sections 38 . The irregular joint avoids creating a path through which fibers may flow. Further, the irregular joint provides structural support for the sections. The sections are arranged side-by-side in the groove to form the cylindrical bearing that extends around the circumference of the annular groove 34 of the screen assembly.
The operational life of the cylindrical bearing 33 is extended because sand and other impurity particles are prevented from entering the gap between the screen assembly and the bearing cylinder while the bearing is at ambient temperature and at the hot operating temperatures. The hard material of the panels 42 adjacent the pulp filled annular region ensures that sand and other impurities do not migrate onto the surfaces of the bearing and particularly onto the soft surfaces of the other panels 40 of the cylindrical bearing. By preventing sand and other impurity particles from reaching the bearing surfaces, these particles are less likely to damage the surfaces of the bearing and the operational life of the bearing is not degraded by such damage.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A bearing cylinder for a screen assembly of a pressurized pulp diffuser, the bearing cylinder including: a plurality of segments of the bearing cylinder wherein the segments are arranged side-by-side to form the bearing cylinder; and each of said segments includes a first region formed of a hard material resistant to damage from sand and rocks, and a second region formed of a soft material that thermally expands and conforms to bearing surfaces opposite to the bearing cylinder. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser. No. 12/202,631, filed on Sep. 2, 2008 and entitled “METHOD FOR DETECTING VARIANCE IN SEMICONDUCTOR PROCESSES”, now pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to a method for variation detection; in particular, to a method for detecting variation in semiconductor processes, which performs correlation analyses on huge amount and complicated raw data outputted by semiconductor process tools to facilitate engineers to locate the sources generating such process variations.
2. Description of Related Art
Yield is a very important index in semiconductor manufactories; on one hand, yield indicates the success rate of producing wafer of a semiconductor manufacturer; on the other hand, yield also is crucially related with the potential profit of a semiconductor manufacturer. Therefore, how to enhance the yield has become one momentous issue of attention to which most semiconductor manufacturers closely and prudently pay.
Regarding this point, semiconductor manufacturers in recent years have devoted great efforts in researches and developments on Metrology integrated system technology and automatic real-time monitoring system, which monitors semiconductor process tools in order to increase wafer production yield and reduce occurrences of risks. The mostly employed system technology and automatic real-time monitoring system in current semiconductor manufacturers is the Fault Detection and Classification (FDC), used to analyze outputted data by the semiconductor tools to appreciate the causes of flaws occurred in wafers, further taking actions thereon beforehand so as to achieve the objectives about wafer yield enhancement, while avoiding wastes of massive and precious time and manpower resources on trouble-shooting.
For example, in Republic of China Patent Application No. 093118756, entitled “Method and System for Semiconductor Tools Yield Correlation Analysis and Method of Semiconductor Manufacturing implemented thereby and Storage Media for Storing Computer Application for Execution of the Method”, discloses a method for semiconductor tools yield correlation analysis using a computer system to execute the following steps: initially, selecting the required analysis on yield record data of at least one wafer, and having the yield data inputted; next, performing statistics on the frequency of passing through a semiconductor tool of the wafer during a process, accordingly generating a frequency diagram; then, generating a p-test diagram based on the yield record data; and subsequently, generating a high percentage group and a low percentage group in accordance with a percentage limit value, calculating the high percentage group and the low percentage group to generate an abnormal analysis result; and further, based on an abnormal critical value, comparing the calculated abnormal analysis result with the abnormal critical value to analyze whether said semiconductor tool is normal; finally, detecting said semiconductor tool according to the calculated analysis results. The method is depicted in FIG. 1 . However, in terms of the correlation of the machine, the aforementioned patent can only be applied in detection single semiconductor or single process step, and cannot be applied in multiple process steps to analyze the influence on yield of a plurality of semiconductor process tools. Therefore, in, terms of most monitoring methods or equipments, said Patent is unable to effectively locate the semiconductor tool among many which affects the yield the most in multiple process steps.
Furthermore, in Republic of China Patent Application No. 091138167, titled “Method for Flaw Detection Parameter Analysis”, said Patent discloses a method for flaw detection parameter analysis (refer to FIG. 2 ), which is used to analyze plural batches of products, each having a batch number, each product being fabricated by means of a plurality of tools, and one or more wafers in each batch of products having been examined through at least one flaw detection item to generate a flaw detection parameter value; engineers may accordingly determine which process has problems and leads to the reduction in wafer yield, based on the information of the flaw detection parameter value; however, the method used in the aforementioned patent application is excessively complicated and engineers need to set various rules to perform flaw detection analysis; hence much time is spent in rule setting, causing unnecessary wastes of precious resources, leading to insufficiency in practical usage.
Accordingly, having considered the above-mentioned amendable detects, the present inventors proposed the present invention for providing reasonable and effective improvement on the disadvantages described supra.
SUMMARY OF THE INVENTION
The essential objective of the present invention is to provide a method for detecting variation in semiconductor processes, by using correlation analysis to locate the causes of variation which influence semiconductor process tools, in order to achieve the objectives of wafer yield enhancement, production cost reduction and efficiency monitoring.
To achieve the aforementioned objectives, the present invention provides a method for detecting variation in semiconductor processes, comprising the following steps: collecting a plurality of tool process data, a plurality of first raw data and a plurality of second raw data; pre-processing said first raw data and said second raw data; using a first statistic analysis method to process said first raw data to reduce said first raw data and calculate a plurality of correlation data; using a second statistic analysis method to process said second raw data to locate a plurality of global index data representing said second raw data; using a third statistic analysis method to process the plurality of tool process data, the plurality of global index data and the plurality of correlation data to build a plurality of interrelationship indices; finally, locating the essential reason causing such a semiconductor process variation based on the plurality of interrelationship indices.
The present invention provides the following beneficial effects:
1. by using the method according to the present invention it is possible to locate the reason affecting the wafer production yield;
2. by using the method according to the present invention it is possible to simplify the collected raw data, reduce the complexity of analysis on raw data, facilitating engineers to locate the cause for such a semiconductor process variation, thus avoiding massive waste of time;
3. without requiring huge amount of raw data, advantageous lowering system cost down and complexity;
4. enhancing control over semiconductor process efficiency, saving much analysis time and manpower.
To further understand the characteristics and technical contents of the present invention, references are made to the detailed descriptions and appended drawings of the present invention; however, the appended drawings are simply for references and illustrations, but not for restricting the present invention thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a flowchart of a method for correlation analysis on semiconductor process tool yield in prior art;
FIG. 2 shows a flowchart of a method for flaw detection parameter analysis in prior art;
FIG. 3 shows a step-wise flowchart of a method for detecting variation in semiconductor processes according to the present invention;
FIG. 4 shows a flowchart of a method for detecting variation in semiconductor processes according to the present invention;
FIG. 5 shows a flowchart of the first statistic analysis method according to the present invention;
FIG. 6 shows a step-wise flowchart of the first statistic analysis method according to the present invention;
FIG. 7 shows a flowchart of the second statistic analysis method according to the present invention;
FIG. 8 shows a step-wise flowchart of the second statistic analysis method according to the present invention;
FIG. 9A shows a flowchart of the third statistic analysis method according to the present invention;
FIG. 9B shows a step-wise flowchart of the third statistic analysis method according to the present invention;
FIG. 9C shows a relationship diagram of the interrelationship indices according to the present invention;
FIG. 10 shows a system of detecting variation in semiconductor processes according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Refer now to FIG. 3 , wherein the present invention proposes a method for detecting variation in semiconductor processes, which method for detecting variation in semiconductor processes comprises the following steps:
S 100 : collecting a plurality of tool process data, a plurality of first raw data and a plurality of second raw data, and pre-processing said first raw data and said second raw data;
S 102 : using a first statistic analysis method to process said first raw data in order to generate a plurality of correlation data;
S 104 : using a second statistic analysis method to process said second raw data in order to generate a plurality of global index data;
S 106 : using a third statistic analysis method to process the plurality of tool process data, the plurality of global index data and the plurality of correlation data in order to build a plurality of interrelationship indices;
S 108 : locating the essential reason causing such a semiconductor process variation based on the plurality of interrelationship indices.
To help those skilled ones in the art better understand and implement the present invention, herein the details of the method according to the present invention will be explained. Referring now to FIGS. 4 and 10 , in conjunction with FIG. 3 , wherein a Wafer Acceptance Test (WAT) procedure is performed on the wafer, which executes electrical tests on the structure configured on the wafer, and provides the tested results to engineers to allow them to acquire a plurality of first raw data, and the acquired plurality of first raw data indicates the electrical test data of the tested wafer. A WAT system 10 may include numerous testing items, which specifies a number of testing sites of wafers. The first raw data of tested wafers may be stored in an event database 11 Meanwhile, engineers collects a plurality of tool process data provided by a plurality of process tools, and such a plurality of process tools indicates the wafer process data currently used by those process tools, which is stored in an auxiliary database 14 ; additionally, a Fault Detection and Classification (FDC) system 12 commonly used in semiconductor industry is used to collect the plurality of second raw data in a parameter database 13 , and the plurality of second raw data indicates the variation detection values detected and measured on each wafer by the Fault Detection and Classification (FDC) system in each real-time process state. By means of the aforementioned WAT 10 , process tools (such as deposition tools, etch tools or lithograph tools) and FDC system ( 12 ), it can allow engineers to collect these tool process data, first raw data and second raw data.
Next, the method performs pre-processes on said plurality of first raw data and said plurality of second raw data by a processing tool, such as a computer, or the operation management unit 18 for filtering out meaningless variation values existing among these first raw data and second raw data to avoid influencing the precision of the present invention.
Further, by using a first statistic analysis method on the first raw data via a feature extract device 15 , a plurality of correlation data is generated (as shown in FIG. 5 ). The correlation feature extract device 15 may calculate the feature quantity using any mathematical transformation that enhances a quality or aspect of the sample measurement for interpretation. In the exemplary embodiment, the first statistic analysis method is Factor Analysis (FA), and the process steps thereof comprise (referring to FIG. 6 ):
(A) initially, selecting the plurality of first raw data;
(B) based on the extent of correlation between the plurality of first raw data, locating the common potential factors causing the variation in the plurality of first raw data;
(C) rotating the factors of the plurality of first raw data.
The step (C) means to increase the relationship between variables and factors of said plurality of first raw data. Additionally, it is to be mentioned that, in the steps of the first statistic analysis method, the factors of the plurality of first raw data must define the lowest bound for the variation amount so as to determine the number of factor selection.
Since, after the pre-process, the plurality of first raw data still has too many dimensions, which is too complicated to allow engineers to employ, it is thus necessary for simplify the second raw data by means of a second statistic analysis method for locating a plurality of global index data (as shown in FIG. 7 ) via a latent variable extract device 16 , and for enabling usage by engineers. In the exemplary embodiment, the second statistic analysis method is the Principal Component Analysis (PCA), and the process steps performed by the second statistic analysis method on the plurality of second raw data comprise (referring to FIG. 8 ):
(A) performing a linear conversion of the plurality of second raw data based on the plurality of second raw data; that is, the plurality of second raw data existing in the original coordinate system are converted into a plurality of second raw data existing in a new coordinate system, in which the new coordinate system has a plurality of new axles respectively referred as a first new axle, a second new axle, . . . , and a Nth new axle, and the first new axle is referred as the first principal component, the second new axle as the second principal component, . . . , the Nth new axle as the Nth principal component; besides, each of the new axle is a linear combination of each original axle existing in the original coordinate system;
(B) locating the projecting amount of the second raw data projected onto the plurality of new axles by using the new coordinate system, acquiring a plurality of first principal component values over the first new axle (the first principal component), a plurality of second principal component values over the second new axle (the second principal component), . . . , and a plurality of Nth principal component values over the Nth new axle (the Nth principal component);
(C) analyzing the plurality of first principal component values, the plurality of second principal component values, . . . , and the plurality of Nth principal component values in accordance with confidence index built by engineers to calculate a plurality of principal component characteristic values, which the plurality of principal component characteristic values represents the second raw data, wherein the objective of the confidence index is to simplify the second raw data through retaining low order principal component values while ignoring high order principal component values;
(D) generating the plurality of global index data based on the principal component characteristic values of the plurality of second raw data.
After acquisition of the plurality of correlation data and global index data, a third statistic analysis method is employed to perform operations on the tool process data, the global index data and the correlation data to generate a plurality of interrelationship indices (as shown in FIG. 9 ) via a variance detect device 17 . The interrelationship indices represents the results of influence on the correlation data by the tool process data and the global index data, wherein the third statistic analysis method is an Analysis of Covariance (ANCOVA), whose process steps comprise (as shown in FIG. 9B ):
(A) building the relationship between the tool process data, global index data and correlation data by means of the design model;
(B) performing an ANCOVA operation on the built relationship between the tool process data, global index data and correlation data to calculate the interrelationship indices.
As shown in FIG. 9C , the interrelationship indices, which is shown on an operation management unit 18 , indicate results of influence on the correlation data by the tool process data and the global index data, and since the correlation data represents the first raw data and the global index data represents the second raw data, the tool process data and the second raw data mutually influence the first raw data in accordance with the meaning of the interrelationship indices; as a result, engineers may use these interrelationship indices to pre-determine whether the occurrence of variance in the first raw data is caused by the tool process data or else the second raw data, with a view to locate the problem and provide relevant measurements to avoid reduction in wafer yield. Please note that the feature extract device 15 , latent variable extract device 16 and variance detect device 17 may be installed on the operation management unit 18 .
As such, the present invention provides the following advantages:
1. fundamental causes of variation can be located by practicing the method according to the present invention;
2. variations in a semiconductor process can be controlled in advance by monitoring the fundamental causes of variation, so as to effectively monitor the target of the process in real-time to avoid consistent damage to wafers, resulting reduction in wafer yield;
3. data is collected by means of the method according to the present invention, allowing the data to retain original important real-time information contents without causing losses of fidelity in data due to various analyses and operations;
4. time can be effectively saved, and human power devoted on searches for causes of variation can be reduced, thus the method according to the present invention helps improvement on yield for wafer manufacturing control.
The aforementioned descriptions simply illustrate the preferred embodiments of the present invention, not for intend to limit the claimed scope of the present invention thereto. It should be stated that all effectively equivalent changes or modifications made based on the specifications and drawings of the present invention are to be reasonably encompassed by the claims of the present invention for legal protection. | A method of detecting variance by regression model has the following steps. Step 1 is preparing the FDC data and WAT data for analysis. Step 2 is figuring out what latent variable effect of WAT data by Factor Analysis Step 3 is utilizing Principal Component Analysis to reduce the number of FDC variables to a few independent principal components. Step 4 is demonstrating how the tools and FDC data affect WAT data by Analysis of covariance model, and constructing interrelationship among FDC, WAT and tools. The interrelationship can point out which parameter effect WAT significantly. By the method, when WAT abnormal situation happened, it is easier for engineers to trace where the problem is. | 6 |
FIELD OF THE INVENTION
The present invention relates to a process for desizing and/or the color fading of fabrics and garments. More particularly, there is provided a process for the simultaneous desizing and decolorizing of dyed fabrics and garments in a closed chamber under slow rotation utilizing ozone in the absence of steam or an aqueous medium.
BACKGROUND OF THE INVENTION
Garment and fabric processing today includes dyeing and desizing. Sizing is important in the fabric weaving and garment sewing processes. The size is usually removed in a finishing operation after the fabric is woven. In some fabrics e.g. Denim, the size is left in woven goods to give desirable properties to the denim garment so as to improve the wear properties of the fabrics or garments. However, if the garments or fabrics are further processed, for example, treated with a crosslinking agent and/or decolorized or finished in garment form, it is necessary to first remove the sizing.
The removal of sizing is today performed in most textile plants by one or more of the following methods. The primary method of desizing is enzymatically, for example utilizing amylolytic enzymes. In garment finishing this process is more costly. Mechanical action during garment desizing whereby abrasive drum linings in extractors and/or pumice stones are utilized to improve the garment softness and give the garment special features etc. Alkaline and acidic hydrolysis have also been employed but such techniques also cause chemical attack of the fabric so as to result in a loss of the tensile and tear strength of the fabric and/or garment. Oxidative desizing is generally employed using large amounts of sodium hypochlorite in solution. The use of hypochlorite creates environmental problems and further can significantly degrade the fabric. Desizing is required where the fabrics or garments are to undergo further processing such as dyeing, printing, decolorization, treatment with a crosslinker, ozone treatments and the like.
Garment dyeing technology, particularly with denim jeans, to achieve a differential color appearance has focused on treatments in which the dyer starts with a dyed garment and achieves a differential color effect by partial color removal. Removal of color is achieved by use of porous stones soaked in oxidizing agents, such as strong bleach or permanganates, and more recently, by after treatment with cellulose enzymes to remove fiber and thereby also remove some sizing.
U.S. Pat. No. 5,118,322 to Wasinger et al, which is incorporated herein by reference, relates to a process for decolorizing garments utilizing garments which are wetted and the garments are treated with ozone in combination with steam.
U.S. Pat. No. 4,283,251 in Singh discloses the bleaching of cellulosic pulp with gaseous ozone in an acidic pH followed by an alkaline treatment.
U.S. Pat. Nos. 4,214,330 and 4,200,367 to Thorsen, which are herewith incorporated by reference, describe a method and an apparatus for treatment of undyed fabrics with an ozone-steam mixture. The process is used to shrinkproof the fabric with a minimum amount of deterioration of the fabric fibers. The ozone treatment reacts with the undyed fibers and provides whiter fibers. The treatment is stated to increase subsequent dyeability and dye fastness of the garment.
W. J. Thorsen et al in their paper entitled, "Vapor-Phase Ozone Treatment of Wool Garments", Textile Research Journal, Textile Research Institute, 1979, pp. 190-197, describe the treatment of wool fabrics and garments with ozone and steam to provide shrink resistance to the fabric or garment. The process is based on the reaction of the ozone with the wool fibers.
It should be understood that the term "dye" as used herein is meant to include any of the materials which are used to provide a color to a fabric such as conventional dyes, pigments, or the like.
It should be understood that the term "ozone" as used herein denotes a preferable method of the invention and is meant to include ozone alone or ozone diluted with inert gases.
SUMMARY OF THE INVENTION
The present invention provides a process for the simultaneous desizing and/or decolorization of fabrics and garments containing cellulosic material, an ozone degradable colorant without steam or a substantial amount of water which comprises the steps of:
A. rotating said garments in a closed chamber without water at about 2 to 10 revolutions per minute; and
B. contacting said fabrics or garments with ozone in the absence of steam or any additional water for a period of time prior to any substantial degradation of the fabrics or garments.
Generally, the fabrics or garments contain about 5 to 10% by weight of water, preferably about 8 to 10% by weight.
Advantageously, the fabrics or garments are in contact with the ozone for a period of about 2 to 10 minutes, preferably 2 to 5 minutes.
Advantageously, the fabrics or garments are washed after the ozone treatment.
Accordingly, the fabric with a portion of the sizing and dye removed requires less time and bleaching agent, oxidizing agent or reducing agent in order to produce a garment having a lighter shade of the original color and/or to produce a garment having the appearance of being "stone washed" or "acid washed".
It is therefore a general object of the invention to provide a means for simultaneously desizing and decolorizing a fabric or garment which has not been wetted.
It is yet another object of the invention to prepare a fabric or garment for further treatment by removal of a sizing agent with ozone.
It is yet still further object of the invention to selectively and/or evenly decolorize or fade dyed garments with ozone to produce fashion garments without water or steam.
It is a further object of the invention to prevent yellowing of fabrics and garments during storage.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular feature of the invention selected for illustration and are not intended to define or limit the scope of the invention.
According to the present invention, sized and/or dyed fabrics and garments which are required to be desized before undergoing further processing can be treated with an ozone so as to remove the sizing. If desired, such as in the case of denim jeans, where the present fashion requirement is a bleached or washed appearance, the garment can be simultaneously decolorized. Typically, blue jeans which would normally undergo desizing in a washer-extractor, can now undergo simultaneous desizing and decolorization by treatment with ozone without steam or in an aqueous medium.
In accordance with the invention jeans or fabrics which are dyed and sized are placed into a washer/extractor equipped with a source of ozone. The fabrics or jeans are not wetted. Typically, the washer/extractor is a 500 gal. rotary drum type which normally rotates about 27-32 revolutions per minute. However, the slower rotation has been found to reduce creasing which results in streaking since the ozone does not make complete contact. A rotation of the drum at about 2 to 10 rotations per minute in an ozone atmosphere for a period of time before any substantial degradation of the cellulosic material takes place has been found suitable for most treatments. The exposure to the ozone for dyed and sized blue jeans is about 2 to 10 minutes, preferably for about 2 to 5 minutes.
Typical commercial runs in a 500 gal. washer/extractor involves about 180 jeans.
The dye ozone process is to be understood as ozone gas that is used with fabric that contains less than 30% moisture and that the fabric feels sensibly dry to the touch even though it will contain about 5-10% moisture (preferably about 8-10% moisture).
Although starch based sizing products left on the cloth after weaving seem to give the most protection, other size materials such as polyvinyl alcohol, (PVA) partially hydrolyzed PVA, among others still afford some protection from damage to the garments when they are employed as the sizing material. Obviously, their ability to protect the textile components of the cloth improves if they are blended with the starch or starch derivative containing products.
Although the starch derived from the yellow dent corn is the primary type of pearl starch (or derivatized) that is employed as a sizing agent in the United States, the starches from other sources including but not limited to potato, sago, rice, wheat starches will work equally as well; as well genetic starches having either a high amylose or a high amylopectin content.
One such loom finished goods which uniquely lends itself to a dry ozone process is indigo dyed denim garments such as "Blue Jeans". Such garments are routinely manufactured from cloth in which the warp threads are most often protected with starch containing sizes during the weaving process and which have also been dyed with indigo prior to weaving. In such goods, the starch apparently also protects the filling threads from the damaging affects of the ozone, probably as the result of being in intimate contact with the warp threads. Usually the surface of the garment will have two to three warp threads at the fabric surface for each filling thread, depending upon whether or not the base fabric employs a 2/1 or 3/1 twill construction.
The dry ozone process of the present invention also seems to be quite effective when employed with other dye decolorizing systems. Typical of these are those employed in stone washing, ice washing, acid washing, etc. when potassium permanganate is used as the preferred bleaching agent and used to produce special looks or finish in a denim garment (blue jean). This look or finish can range from a very slight random bleaching affect to an almost complete bleaching (white out) of the original blue indigo dye in the garments.
An undesirable side affect with garments processed by this technique is the gradual yellowing of the whiter portion of the finished goods after they have been exposed to light (especially ultraviolet light). Since this is a very slow or gradual affect, the damage to the goods may not be found until after they have been shipped to the retailer or even after being purchased and are being worn by the consumer.
The causes for the yellowing is generally thought to be due to isatin and/or anthranilic acid or its derivatives which may be produced during the reaction with the permanganate solutions; although a number of other compounds are also present after the reaction (See example, James W. Rucker et al "Evaluation of Factors Contributing to the Light-Induced Yellowing of Whitewashed Denim: Part I" Textile Chemist and Colorist 24, (#9), 1992, p. 66 and Part II, Textile Chemist and Colorist 24, (#10) 1992, p 21). We have found that if the garments are treated with the ozone for a short time after the permangante treatment that the yellow coloration will not occur. As a consequence it is quite likely that the ozone destroys the yellow producing compounds just as it decolorizes the indigo dye. Thus an exposure of the permanganate treated fabrics to a dry ozone process can be used to prevent the yellowing from ever occurring.
It has also been suggested that the yellowing in the permanganate frosted garments can be caused by incomplete removal of the manganese dioxide or the divalent manganese in the neutralization and rinsing steps (See example A. H. Redies et al in Textile Chemist and Colorist 24 (#5) 1992, p. 26). Since ozone treatment results in oxidation of the manganese ion into a higher oxidative form rather than the dioxide form (a red brown color rather than the black oxide form is produced from the divalent manganese ions upon exposure to the dry ozone process), the causes for potential yellowing in the treated goods are apparently removed.
Additionally, the ozone treatment can be used to destroy any yellowing that may have already occurred as a result of the process. The yellowed garments when subjected to ozone will recover their original whiteness. Only a very short ozone treatment is required in each case, i.e., as a preventative or as a cure.
Often after the treatment and washing process, some dye that has been removed by other processes will re-deposit itself onto the garments. This is sometimes severe enough to require the need for rewashing the garments. In such cases, it has been found that a short treatment with the dry ozone will remove the deposition by decolorization thereby eliminating the need for rewashing, thus, saving the time and chemicals required for a rewash. This can be done typically with as little as a 2 minute dry ozone cycle. Under such conditions virtually no damage to the fabric occurs. On the other hand, if some abrasion is desired in order to duplicate the effects of stones, enzyme treatments or the like, the dry ozone will accomplish this with much the same look but at a much lower strength loss than will be obtained by the alternative treatments.
The ozone within the chamber is preferably measured periodically and kept at a minimal and within the range of about 10 to 100 mg per liter. The ozone can be generated by an ozone generator of the type available from Griffin Technics, Inc., Model GTC-2B which produces ozone from dry air or oxygen using electrical circuit breakers or Corona discharge. The ozone may be used alone or diluted with inert gases.
The type of dye used on the garments is not critical. It is only important that the dye is ozone reactive where intended. Cellulose substantive dyes, such as vat dyes, which are common in the garment industry, are preferably used. Exemplary of the dyes which are substantive to cellulose that can be used include Acid Light Scarlet GL, an acid levelling dye, Sevron Brilliant Red 2B, indigo vat dye, a cationic dye, Sulfonine Brilliant Red B, an anionic dye, Brilliant Milling Red B, C.I. Disperse Blue, pyrazolone azomethine dye, hydroxy azo dyes, or the like. Where the dye is a xanthene dye, treatment also gives rise to chemiluminescence in the process. Other suitable dyes that can be used are identified in the paper of Charles D. Sweeney entitled, "Identifying a Dye can be Simple or it Can Involve Hours of Laboratory Analysis", Textile Chemist and Colorist, Vol. 12, No. 1, January 1980, pp. 26/11.
The following examples are illustrative of the practice of the method of the present invention. It will be understood, however, that is not to be construed in any way limitative of the full scope of the invention since various changes can be made without departing from the spirit of the teachings contained herein the light of the guiding principles which have been set forth above. All percentages stated herein are based on weight except wherein otherwise noted.
EXAMPLE I
180 jeans (normal washer load) in their new condition and still containing their original starch sizing were treated in a typical 500 gal. capacity rotary drum washer/extractor unit with ozone for 5 minutes. The ozone concentration in the chamber reached about 40 mg/l . The drum rotation was slowed from the normal 27-30 rpm to 4 rpm to inhibit streaking. The color of the jeans after the treatment showed significant reduction in their original coloration. Longer treatments gave a further color reduction. The tensile strength of the jeans fabric was not appreciable degraded even in the filling direction until the treatment times of greater than 15 minutes was employed. At about a 15 minute reaction time, approximately 50% of the starch could be removed from the jeans by a 5 minute hot (180° F.) water extraction. Therefore, the starch is still in a form to offer continuing protection to the jeans. The results for various times of the dry ozone treatments are shown in Table 1.
TABLE I______________________________________Effect of Time of Dry Ozone Treatment on theProperties of Denim JeansTreatmentTime (min) % Strength Loss % Size Removal % Color Loss______________________________________ 5 nil ˜5 1010 nil ˜20 2015 ˜nil, ˜3F ˜50 4030 ˜3W ˜5F ˜80 75______________________________________ W = Warp, F = Filling
From these results it is seen that the presence of the starch allows the ozone to affect a color loss without significant strength loss as compared to other processes.
EXAMPLE II
180 jeans that were showing significant dye redeposition were loaded into a washer/extractor unit and treated by the dry ozone process according to Example I for 2 minutes. The jeans were found to have an acceptable "pass" after this time. In severe cases, the jeans may require 3 minutes reaction time. Again the speed of the rotation was reduced to about 4 rpm during the ozone treatment.
EXAMPLE III
A. A pair of jeans that had been processed by a potassium permanganate treatment was steamed for 8 to 10 minutes in a laboratory steamer (autoclave) at 100° C. with saturated steam to accelerate the yellowing process. In this way a washer/extractor load of jeans that had the potential for high level of yellowing was identified. 90 pair of jeans from this load were subjected to a dry ozone treatment for 2-3 minutes following the procedure of Example I. Jeans from this batch along with jeans from the original batch that had not received the dry ozone treatment (i.e., the other 90 jeans) were packaged in the usual manner and stored under normal conditions for 9 months. The original jeans showed a high incidence of yellowing while the dry ozone treated jeans showed no yellowing at all.
B. In another experiment, the potential incidence of photoyellowing in a lot of permanganate treated jeans was determined by exposure of samples in an Atlas CXW #2 Sunshine Carbon Arc Weatherometer using glass filters. A lot of jeans that was identified as having a high potential for photoyellowing was similarly treated for 2-3 minutes and gave the same results as was obtained using the autoclave steaming method for the photoyellowing prediction.
EXAMPLE IV
90 pairs of jeans from a severely yellowed lot (supplied by Levi Strauss and Co.) were placed in a washer/extractor fitted for dry ozone and treated for 3 minutes following the procedure of Example I. The yellow color was removed by this treatment and did not reappear over the life of the garments.
These treatments show that the yellowing phenomena is prevented from occurring by a dry ozone treatment and can be used to treat all jeans to prevent the process from occurring on the few lots that would escape detection and cause return problems. Further, returned jeans can be salvaged by a dry ozone treatment of short duration.
EXAMPLE V
Whitewashed jeans by the potassium permanganate method and still containing a high level of permanganate were subjected to a dry ozone for 5 minutes following the procedure of Example I. The fabric became a deep reddish brown. The red manganese oxide color could be totally removed by a warm acid (0.5% acetic acid) wash. The fabric did not contain any manganese dioxide. Further, fabric treated by this method did not later develop any photoyellow coloration.
EXAMPLE VI
Jeans were treated with a 2% solution of a series of metallic salts. The jeans were then subjected to the dry ozone treatment ranging from 3 to 8 minutes following the procedure of Example I. The final color of the jeans were noted and are summarized in Table 2. The usual color of the oxide form of the salt differs in each case from the expected oxide salt obtained with peroxide or air oxidation. Thus offending ions that can result in discoloration of goods during storage can be eliminated by a dry ozone process.
TABLE 2______________________________________Effect of Ozone Treatment on Various Metallic Salts Treatment Time2% Salt Employed (minutes) Oxide Color Obtained______________________________________Copper Sulfate 3 Light GreenNickel Sulfate 5 BlackCobalt Chloride 5 BrownFerrous Chloride 5 Pale Yellow BrownFerric Chloride 3 Yellow BrownManganese Chloride 8 Red Brown______________________________________ | A process for desizing and/or color fading of fabrics and garments utilizing ozone in the absence of steam or any substantial amount of water. The process includes treating the fabrics and garments in a closed chamber under slow rotation. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of sanitary devices or appliances such as toilettes, sinks, bathtubs, bidets and the like, wherein taps, faucets, valves, and other water or liquid supplying devices are connected, which devices must be firmly retained in at least a wall of the corresponding device to facilitate the connection of the device to the water carrying pipeline of the water home or public installation.
To the purpose of the present specification the term device wall must be understood as comprising any surface and/or wall of a device preferably comprising a public or home sanitary device such a sink, bidets, tubs, or kitchen counters and the taps comprise any kind of valve devices or faucets that have a tube portion passing through the cited device wall and being connected to the water or other fluid carrying pipeline.
2. Description of the Prior Art
It is well known to provide a firm connection between the set of taps provided in any sanitary device or kitchen counter wherein the taps include a pipe portion extending through a wall of the device, with the pipe or conduit portion being provided with threads on the outer surface thereof for a nut to be threaded in the pipe threads to retain the tap against the device wall. The installation of the nut, and particularly the insertion of a tool for rotating the nut is not always possible in the very small room available under sinks, bathtubs and bidets. This situation makes the nuts to be rotated by hand and then adjusted, as much as possible, by any kind of a small tool which causes the nut to be not always well adjusted.
To overcome the above problem a clamp for retaining the tap against the device wall have been devised by the inventor of the present application and disclosed in the Argentine Pat. No. 235827. This patent discloses a clamp comprising a slight V-shaped plate with two portions angularly arranged, one portion including a large orifice for passing the conduit portion of the tap therethrough and the other portion having a small orifice with a screw passing therethrough. The large orifice is capable of clamping against the threaded portion of the tap upon tilting of the clamp by rotating the screw inserted in the small orifice and making the screw to engage the device wall to as to move the clamp with a lever movement around the pipe portion of the tap. With this movement, the large orifice is wedged against the pipe portion and the pipe portion is pulled out of the device wall so as to fix the tap against the device. This clamp, however, occupies a large space and it becomes an obstacle for the further connection of the pipe portion to the water supplying pipeline. Some times, when connecting the water pipeline, the clamp is inadvertently knocked and the retention is released.
In addition, the large and clamping orifice of the patented clamp hardly remained retained against the pipe portion because the retention, gripping or grasping effect between the inner edges of the orifice and the outer surface of the pipe portion is not enough for a well retention and no means are provided for enhancing this retention.
It would be therefore convenient to have a clamp for replacing the nut-threaded pipe retention but without the drawbacks of space consuming like with the clamp disclosed in the prior patent of the same inventor.
3. SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a compact clamp assembly for retaining a tap, such as a faucet, in a device such as a sink, bathtub, bidet and any other sanitary or kitchen appliance, wherein the clamp is arranged very close to a mounting wall of the appliance without forming an obstacle for a further installation and connection of the fluid carrying pipeline to the appliance.
It is still another object of the present invention to provide a clamp assembly for firmly connecting a tap in a sanitary or kitchen appliance without consuming a large space, the assembly comprising a compact clamp and a short screw, the clamp having a large orifice to be passed along a pipe portion of the tap and a small orifice receiving the screw, the clamp operating like a lever around the pipe portion of the tap and being retained against an outer surface of the pipe portion by screwing the screw in the small orifice and making a distal tip of the screw engaging a wall of the device so as to cause the clamp move like a lever and make the large orifice to wedge against the pipe portion of the tap.
It is a further object of the present invention to provide a clamp assembly for firmly retaining a connection of a tap in a device wall, the tap including an operating portion remaining at an outer side of the device wall and a conduit portion extending through an orifice in the device wall and remaining at an inner side of the device wall, the clamp assembly comprising:
an integrally formed clamp body including a first clamping orifice for passing along said conduit portion of the tap and a second threaded orifice having a geometrical axis normal to a main plain of the clamp body, a screw being threadably connected into said second orifice of the clamp body, the first orifice having two diametrically opposite inner sections aligned along a longitudinal geometrical axis of the clamp body, these sections defining together an oblique cylinder defining a geometrical axis oblique to said main plane of the clamp body, converging to the geometrical axis of the second orifice, towards the device wall, the clamp body defining a distal side facing said device wall and a proximal side looking far away of said device wall, the opposite clamping sections of the second orifice forming diametrically opposed clamping acute-angled edges each located at opposite sides of the main plane of the clamp body, whereby the first orifice of the clamp body may be inserted over said conduit portion and, when the clamp body is close to the device wall, the screw is threaded into the second orifice until a tip of the screw engages the device wall and moves the clamp body as a lever and causes the clamp body to incline, thus making the clamping edges to fix, by wedging, against the conduit portion of the tap.
The above and other objects, features and advantages of this invention will be better understood when taken in connection with the accompanying drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example in the following drawings wherein:
FIG. 1 shows a cross-sectional and side elevation view of a clamp assembly according to the invention mounted in a conduit on pipe portion of a tap illustrated in phantom lines;
FIG. 2 shows a perspective view taken from the distal side of the clamp assembly shown in FIG. 1;
FIG. 3 shows a perspective view taken from the proximal side of the clamp assembly shown in FIG. 1;
FIG. 4 shows a longitudinal cross-sectional view of the clamp assembly of FIGS. 1-3;
FIG. 5 shows a plant view taken from the distal side of the clamp assembly of the invention;
FIG. 6 shows a plant view taken from the proximal side of the clamp assembly of the invention;
FIG. 7 shows a cross-sectional and side elevation view similar to FIG. 1, illustrating the clamp assembly both installed onto the pipe portion of the tap and ready before being installed in the pipe portion of the tap, the projection of the pipe portion being illustrated in phantom lines; and
FIG. 8 shows a cross-sectional and side elevation view similar to FIG. 7, illustrating the clamp assembly installed onto the pipe portion of the tap.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring in detail to the drawings it may be seen from FIG. 1 that a tap, preferably a faucet a having a mounting base a', is installed in a wall b of a sanitary or kitchen device or appliance, such as a bath sink, bathtub, bidet, kitchen sink or kitchen counter. Tap a includes an operating portion (the part shown in phantom lines in FIG. 1) and a pipe or conduit portion a" passing through an orifice 1 in the device wall b, and having a portion 2 for fixing the clamp assembly of the invention and a bottom end 2' to be connected to the water or other fluid supplying pipeline.
Clamp assembly c according to the invention may be easily installed in portion a" to remain close to device wall b, preferably against a washer e, so as to be firmly fixed or clamped on portion a" and to exert a pulling force on the conduit portion to retain tap a in wall b. Clamp assembly c comprises a clamp body, preferably a unitary piece made of metal, with a leading end portion c' and a rear end portion c" and with a distal side looking towards wall b and a proximal side looking far away of this wall. Portion c' provides a washer-like portion with a first large clamping orifice 3 adapted for passing over pipe portion a" and being clamped on the outer surface of this conduit portion. Portion c" is a smaller portion including a second smaller threaded orifice 4 through which a fastening screw d having a threaded stem 5 passes to adjust and fix the clamp against wall b as it will be explained later.
Orifice 3, as it is clearly better illustrated in FIG. 4, is defined by a drilled bore the projection of which is indicated by phantom lines 6, which bore defines, at least partially, a geometrical axis II obliquely extended relative to a main plane I-I of the clamp. Axis II is contained within a vertical symmetry plane III-III depicted in FIG. 6 and containing in turn a geometrical axis IV-IV of orifice 4 and screw d, axis II converging towards wall b to intersect axis IV-IV of screw d at a side of plane I-I corresponding to the distal side of the clamp, indicated as an upper surface 7 in FIGS. 2, 4 and 5. The proximal side of the clamp body corresponds to a bottom surface 9 indicated in FIG. 4.
As indicated by inclined axis II, bore 3 defines an inner surface 8 which is biased in at least two diametrically opposite sections or surfaces 8' and 8", these inner sections being aligned along longitudinal geometrical axis I-I of the clamp body, and defining together an oblique cylinder the traces of which, as explained above, may be represented by phantom lines 6. The clamp body around sections 8', 8" has a uniform thickness, particularly at the regions indicated by numeral references 13 and 12. The intersections between inner surface 8 and upper and bottom surfaces 7, 9, at sections 8', 8", define respective clamping edges 10, 11 defining an inclined clamping plane V-V, the clamping edges being located at opposite sides of plane I-I and located symmetrically from main plane I-I. Edges 10, 11 define respective acute angles which are sharp enough to enhance the clamping effect when are clamped against pipe portion a", in other words, to operate like nails or wedges capable of being firmly retained against the pipe portion by grasping and/or clamping, and pulling from the pipe portion to retain the tap in wall b. The thickness 12 and 13 provided in the clamp body enables the clamp to be easily guided along pipe portion a" when is passed over this portion during installation of the clamp assembly. It may be said that edges 10, 11 operate like teeth to bite and grip the conduit portion of the tap.
When installing a set of taps in a sanitary or kitchen appliance, a corresponding wall of the appliance is provided with respective orifices for mounting each of the taps, faucets, etc. When a tap, for example faucet a is located in orifice 1, as illustrated in FIG. 1, clamp c provided with screw d at least partially inserted into orifice 4 is mounted in pipe portion a" by locating orifice 3 axially around the pipe portion and sliding the clamp over this portion until portion c" engages wall b. At this moment portion c' should be pushed up so as to bring this portion as close as possible to wall b and achieve a soft or slight clamping effect of edges 10, 11 against portion a". Preferably, edges 10, 11 will be seated into respective threads of the conduit portion. To bring clamp c even very closed to wall b, the clamp may be rotated by hand around a longitudinal axis (not shown) of conduit portion a" as if the clamp was a nut threaded on the conduit portion. Under these conditions, with or without rotation of the clamp around conduit portion a", the faucet or all the set of faucets, may be preadjusted in position to be then firmly fastened by screwing screw d until a distal tip d', engages wall b. The screw is further rotated, by means of a screwdriver (not shown) for example, so as to make the clamp body tilt in an anti-clockwise direction, as indicated by the arrow in FIG. 8, around conduit portion a", causing the clamp to operate like a lever. Because of this lever-like movement, edges 10, 11 are clamped or gripped against portion a", preferably in the threads provided in this portion. As the screw is further rotated, portion a" is pulled down, as seen in the figure, so as to fix and retain tap a against wall b. The thickness and design of the clamp body, particularly in 12, 13, at sections 8', 8", guarantee a firm and safe gripping and retention of the clamp against portion a". Also, as a result of the novel design of clamp body c, particularly at the orifice 3, the clamp assembly will remain very close to wall b without representing an obstacle to disturb the connection of the water supplying pipelines which must be connected to the corresponding appliance.
To improve even more the design for safety and economy purposes, the proximal and distal sides, or bottom 9 and upper 7 surfaces of the clamp body, are parallel to each other, the distal side being provided with a recess 7' at upper side or face 7 of the body, the recess being surrounded by a peripheral rib 14 to reinforce the clamp. In addition, the proximal side includes a stepped portion 15 projecting from the bottom surface 9 and said stepped portion defines, with a corresponding one 8" of the inner clamping sections of first orifice 3, one edge 11 of the clamping edges 10, 11. The general configuration of the clamp body is elongated and flat, preferably made of metal with rounded ends c' and c".
While preferred embodiments of the present invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined in the appended claims. | A clamp assembly for firmly connecting a tap in a sanitary or kitchen appliance without consuming a large space, the assembly comprising a compact clamp and a short screw, the clamp having a large orifice to be passed along a pipe portion of the tap and a small orifice receiving the screw, the clamp operating like a lever around the pipe portion of the tap and being retained against an outer surface of the pipe portion by screwing the screw in the small orifice and making a distal tip of the screw engaging a wall of the device so as to cause the clamp move like a lever and make the large orifice to wedge against the pipe portion of the tap. | 4 |
BACKGROUND OF THE INVENTION
The present invention generally relates to the preparation of semiconductor grade silicon crystals, used in the manufacture of electronics. More particularly, the invention relates to a device for feeding arsenic dopant into an apparatus for producing low resistivity silicon crystals.
Silicon crystal growth using the Czochralski (CZ) method involves changing the characteristics and properties of the silicon ingot being grown by adding a dopant material to the molten silicon before silicon ingot growth. A common dopant material used in this process is arsenic. Arsenic, however, is a volatile substance and problems often arise through conventional methods of introducing the dopant to the silicon melt.
One such method is to dump the dopant from a port positioned above the melt. However, because of the high temperatures of the process, there is a violent loss of arsenic to the argon gas environment above the melt. This results in the generation of oxide-particles which can prolong and compromise the crystal growing process. Thus, this method is very inefficient.
Another method uses a quartz vessel containing the dopant above the melt for introducing the volatile gas to the melt. This method can reduce loss of vaporized dopant if the vessel has a port extending into the melt. Regardless, these methods result in complicated operation and loss of volatile dopant. The present invention overcomes these difficulties and disadvantages associated with prior art processes by introducing the dopant to the melt at an upper surface of the melt.
SUMMARY OF THE INVENTION
In one aspect, the present invention includes a feed assembly for feeding a dopant to a silicon melt in a crystal growing apparatus. The assembly comprises a vessel for holding and releasing a dopant solid material and an elongate feed tube operatively connected to the vessel. The feed tube comprises a fixed tube and a movable tube concentrically arranged with the fixed tube. The assembly also includes an actuator connected to the moveable tube for moving the moveable tube relative to the fixed tube for advancing the moveable tube toward an upper surface of the silicon melt in the apparatus and retracting the moveable tube away from the upper surface of the silicon melt to selectively position the moveable tube for introducing the dopant material released from the vessel to the silicon melt when the feed assembly is mounted on the crystal growing apparatus.
In another aspect, the present invention includes a method for feeding arsenic dopant to a silicon melt in a silicon crystal growing apparatus having a crystal growing chamber. The method includes placing granular solid arsenic dopant in a vessel attached to a feed tube comprising a fixed tube and a movable tube in concentric arrangement. The moveable tube is lowered toward the silicon melt with an actuator connected to the moveable tube to selectively position the moveable tube at the surface of the silicon melt. In addition, the dopant is released from the vessel to allow dopant to travel down the feed tube and into the melt at an upper surface of the melt.
In still another aspect, the present invention includes a method for feeding arsenic dopant to a silicon melt in a silicon crystal growing apparatus having a crystal growing chamber. The method comprises placing granular solid arsenic dopant in a vessel attached to a feed tube comprising a fixed tube and a moveable quartz tube having an angled tip. The fixed tube and moveable quartz tube are in concentric arrangement. Further, the method includes lowering the moveable tube toward the silicon melt with an actuator connected to the moveable tube to selectively position the moveable tube at the surface of the silicon melt. Still further, the method comprises releasing the dopant from the vessel to allow the dopant to travel down the feed tube to a catch located in the moveable tube for catching the dopant material when it is released from the vessel. In addition, the method comprises introducing argon gas into the feed tube below the vessel causing sublimation of the dopant resulting in dopant laden argon exiting the angled tip of the moveable quartz tube at an upper surface of the silicon melt.
In yet another aspect, the present invention includes a feed assembly for feeding a dopant to a silicon melt in a crystal growing apparatus. The feed assembly comprises a vessel for holding and releasing a dopant solid material and an elongate feed tube attached to the vessel. The feed tube includes a fixed tube and a movable tube concentrically arranged with the fixed tube. Further, the feed assembly includes a catch located within the moveable tube for catching the dopant material when it is released from the vessel.
Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section of a first embodiment of a feed assembly in a retracted position;
FIG. 2 is a front view of a vessel-and-valve assembly of the feed assembly with a portion broken away showing the flow of dopant material;
FIG. 3 is a cross section of a second embodiment of the feed assembly in an extended position;
FIG. 4 is a perspective of the feed assembly attached to a crystal grower furnace chamber;
FIG. 5 is a perspective of the vessel-and-valve assembly and actuator of the feed assembly;
FIG. 6 is a perspective of an isolation valve of the feed assembly attached to the crystal grower.
Corresponding reference characters indicate corresponding parts throughout the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Multiple embodiments for an arsenic dopant feed assembly are illustrated. FIG. 1 illustrates a first embodiment of an arsenic dopant feed assembly, generally designated by the reference number 10 . In the first embodiment, the dopant feed assembly 10 is fabricated from a refractory material that is non-contaminating and non-reactive with arsenic, silicon and graphite.
The first embodiment of the feed assembly 10 comprises a vessel-and-valve assembly 11 for holding dopant solid (not shown), and a feed tube assembly, generally indicated at 15 , attached to the vessel-and-valve assembly 11 for delivering the dopant to a silicon melt (not shown). An actuator 19 is operatively connected between the feed tube assembly 15 and a receiving tube 21 for advancing and retracting the feed tube assembly to and from an upper surface of the silicon melt. A brake assembly 25 is operatively connected between the actuator 19 and the receiving tube 21 for restricting movement of the feed tube assembly 15 and locking the feed tube assembly at a selected position. An isolation valve 27 is provided at a bottom of the feed tube assembly 15 . The valve 27 is configured for placing the feed assembly 10 in communication with a crystal growing apparatus 31 (see FIG. 6 ).
Referring to FIG. 2 , the vessel-and-valve assembly 11 includes a dopant cartridge 41 configured for holding the dopant solid and a valve 43 attached to the feed tube assembly 15 that can be opened to release the dopant down the feed tube assembly. The valve 43 has a handle 45 for opening and closing the valve.
The feed tube assembly 15 comprises a series of elongate concentric tubes including a fixed tube 51 and one or more moveable tubes 53 situated around the fixed tube and arranged in a telescoping fashion (see FIG. 1 ). The fixed tube 51 is closed at a first end 54 by a vacuum flange 55 and is received by the moveable tubes 53 at a second end 57 (see FIG. 3 ). An end cap 59 at the first end 54 attaches the fixed tube 51 to the receiving tube 21 . The end cap 59 includes a seat 61 having an opening 63 which receives the first end 54 of the fixed tube 51 . An annular seal 65 seals the opening 63 between the end cap 59 and the fixed tube 51 .
A vacuum fitting 67 connects each moveable tube 53 to an adjacent moveable tube. Each vacuum fitting 67 includes two opposing ring fittings 69 connected to each other by a threaded coupling 71 engaging threads 73 on the ring fittings. The embodiment illustrated in FIG. 1 shows two moveable tubes, however a single moveable tube or three or more moveable tubes are contemplated as being within the scope of the present invention.
The feed tube assembly 15 provides a passage 81 through which dopant material travels when it is released from the vessel-and-valve assembly 11 . An outlet 83 of the moveable tubes 53 is in fluid communication with the vessel-and-valve assembly 11 for introducing the dopant to the silicon melt (see FIG. 3 ). In this first embodiment, the feed tube assembly 15 can be made of any refractory material that is non-contaminating and non-reactive with arsenic, silicon and graphite. As will be explained in greater detail later, a moveable tube 53 ′ of the second embodiment that is positioned at the surface of the melt is fabricated from quartz.
Referring to FIG. 1 the actuator 19 comprises a linear translator 85 including an annular magnetic sleeve 87 attached to the moveable tubes 53 and an annular magnetic slide 89 adjacent and magnetically coupled to the sleeve. The magnetic sleeve 87 is sized and shaped for receiving the moveable tubes 53 in the sleeve. The sleeve 87 is secured to the moveable tubes 53 by friction fitting. The magnetic slide 89 is sized and shaped for receiving the receiving tube 21 and directly engages the outer surface of the receiving tube 21 . A small clearance 90 between the receiving tube 21 and the magnetic slide 89 allows the magnetic slide to slide along the length of the receiving tube. The slide 89 is aligned with the magnetic sleeve 87 , creating a magnetic coupling due to the opposite polarization of the two structures. This coupling secures the slide 89 to the receiving tube 21 at the same height that the magnetic sleeve 87 is positioned on the moveable tubes 53 . As a result, movement of the slide 89 along the receiving tube 21 causes the magnetic sleeve 87 to move under the force of magnetic attraction. As the slide 89 moves up and down the receiving tube 21 , the moveable tubes 53 slide away from and toward the fixed tube 51 for positioning a tip 91 of the moveable tubes 53 at the surface of the silicon melt (see FIG. 3 ). As will be explained in greater detail below, the magnetic slide 89 also includes an extension 93 having an annular teardrop shape with an aperture 95 at its tapered end. The aperture 95 is configured for attaching to the brake assembly 25 . Although the preferred embodiment of the invention incorporates the magnetically coupled linear translator, it is envisioned that other suitable actuators (e.g., mechanical, electrical, or electromechanical) could be used without departing from the scope of this invention.
Referring to FIG. 4 , the receiving tube 21 is an elongate tube made of stainless steel. The receiving tube 21 separates a portion of the actuator 19 and feed tube assembly 15 from the surrounding environment (see FIG. 1 ). The feed assembly 10 is illustrated as having two receiving tube members 99 connected in series. However, any number of receiving tube members 99 is foreseen. A first seal assembly 101 connects the receiving tubes 21 . The seal assembly 101 comprises an o-ring 103 and a clamp 105 having semi-circular clamp halves 107 . A second seal assembly 109 connects the receiving tube 21 to the isolation valve 27 . One clamp half 111 of the second seal assembly 109 has a threaded extension 113 for connecting the receiving tube 21 to the isolation valve 27 as will be explained in greater detail below.
Referring to FIGS. 1 and 5 , the brake assembly 25 comprises stops 121 , 122 positioned on the receiving tube 21 , a rod 123 (broadly, a “braking member”) disposed between the stops and a screw 125 (broadly, a locking member) engaging the braking member and the magnetic slide 89 for locking the slide at a selected position along the receiving tube 21 . Similar to the extension 93 on the magnetic slide 89 , the stops 121 , 122 have an annular teardrop shape with a central opening 127 at its bulbous end for receiving the receiving tube 21 and a hole 129 at the tapered end extending from a top face 131 to a bottom face 133 for receiving the braking member 123 . A side face 135 on the tapered end has an adjustment opening 137 . The stops 121 , 122 are positioned on the receiving tube 21 above and below the magnetic slide 89 . The braking member 123 passes through the hole 129 in the first stop 121 , the aperture 95 in the slide 89 and the hole 129 in the second stop 122 . Thus, the braking member 123 links the stops 121 , 122 to the slide 89 creating a track 139 to guide the slide along the receiving tube 21 .
The stops 121 , 122 are also adjustable. The central opening 127 is sized and shaped for receiving the receiving tube 21 . Similar to the magnetic slide 89 , a small clearance 140 between the stops 121 , 122 and the receiving tube 21 allow the stops to slide along the length of the receiving tube. On the receiving tube 21 the stops 121 , 122 can be slid to a selected position. Once the selected position for the stops 121 , 122 is achieved, a stop screw 141 can be inserted into the adjustment bore 137 to lock the stops in place. The tip of the stop screw 141 presses against the braking member 123 holding the stops 121 , 122 in position. The stop screw 141 can then be unscrewed to allow the stops 121 , 122 to move to another position on the receiving tube 21 and re-tightened to lock the stops in place again.
Referring to FIGS. 1 and 6 , in one embodiment the isolation valve 27 comprises a ball valve 151 having a body 153 and a passageway 155 with a ball 157 disposed in the passageway mounted for selective rotation between open and closed positions (illustrated embodiment shown in open position. A pair of valve seats 159 , 161 are provided in the passageway 155 on opposing sides of the ball 157 . In the preferred embodiment, the valve seats 159 , 161 are located substantially equidistant from an axis of rotation of the ball 157 and include radial openings 163 . The ball 157 and valve seats 159 , 161 are enclosed within the body 153 by a pair of end fittings 165 . The end fittings 165 can be mounted to the body 153 by any sufficient means. In the present invention, mounting bolts 167 are utilized. At least one end fitting 165 is also provided with internal threads 169 to facilitate connecting the isolation valve 27 to the feed tube assembly 15 by the threaded extension 113 on the second seal assembly 109 . It is understood that any other convenient means of connecting the isolation valve to the feed tube assembly is within the scope of the present invention.
A stem assembly 171 and handle 173 are provided for actuating the isolation valve 27 . The handle 173 is releasably secured to the stem assembly 171 by a nut 175 that clamps to the tip of a packing nut 177 and also helps to support the ball 157 in the body 153 . The ball 157 is supported in the passageway 155 such that the ball can shift axially along the passageway. The ball valve 151 can be manually actuated with the handle 173 , or an actuator (not shown) may be provided to actuate the valve. The positions of the handle 173 and the ball 157 are limited by a depending catch member 179 carried by the handle. The catch member 179 engages a surface of the body 153 to provide fixed stops for the isolation valve 27 .
The structure of the isolation valve as described above reflects a preferred embodiment. It will be readily apparent to those skilled in the art that changes and additions to the structure may be made to accommodate specific operational requirements. Such modifications are not deemed to affect the scope of the present invention.
Operation of this first embodiment of the feed assembly 10 is as follows. Once the silicon melting process is complete, the actuator 19 advances the moveable tubes 53 of the feed tube assembly 15 so the outlet 83 of the moveable tubes 53 is located at the upper surface of the silicon melt. The locking member 125 of the brake assembly 25 is tightened to lock the magnetic slide 89 in place, thus locking the outlet 83 of the moveable tubes 53 in position at the surface of the silicon melt. The dopant held in the vessel-and-valve assembly 11 is released when the valve 43 in the dopant cartridge 41 is opened. The dopant will travel through the feed tube assembly 15 , past an opened isolation valve 27 and into the silicon melt at the surface of the melt. The moveable tubes 53 are retracted by the actuator 19 and argon gas is released below the vessel-and-valve assembly 11 into the feed tube assembly 15 for cooling the assembly 10 . Finally, the assembly 10 is isolated from the crystal growing apparatus 31 by closing the isolation valve 27 .
As illustrated in FIG. 3 , a second embodiment of the feed assembly 10 ′ is designated in its entirety by the reference number 10 ′. The components of the second embodiment are exactly the same as the first embodiment except for a modified feeding tube assembly 15 ′. The feeding tube assembly 15 ′ of the second embodiment comprises a moveable tube 53 ′ made of a special quartz material. This material is used primarily to accommodate gas phase doping. The quartz tube 53 ′ is a thick walled clear fused quartz tube with an outside diameter of about 25 mm, a wall thickness of about 3 mm and a length of about 711 mm. This tube 53 ′ has an angled tip 91 ′ allowing a maximum melt surface area to be exposed to dopant gasses flowing from the tip. Additionally, the moveable tube 53 ′ includes a guide 201 aligning the quartz tube 53 ′ and a perforated disk 203 preventing the dopant from exiting the tube 53 ′ into the silicon melt 17 . When the dopant material trapped in the tube 53 ′, argon gas can be introduced into the feed tube assembly 15 ′ causing the dopant laden argon to travel down the feed tube assembly 15 ′ under sublimation and exit the angled tip 91 ′ at the upper surface of the silicon melt.
This second embodiment of the feed assembly 10 ′ operates as follows. The process is similar to the process described for the first embodiment except the actuator 19 advances the quartz tube 53 ′ of the feed tube assembly 15 ′ so the angled tip 91 ′ is positioned at the upper surface of the silicon melt. The locking member 125 of the brake assembly 25 is tightened to lock the magnetic slide 89 in position, thus locking the angled tip 91 ′ of moveable tubes 53 ′ in position at the upper surface of the silicon melt. The dopant held in the vessel-and-valve assembly 11 is released when the valve 43 in the dopant cartridge 41 is opened by the handle 45 . The dopant travels through the feed tube assembly 15 ′ and is collected on the perforated internal disk 203 . Argon gas is introduced into the feed tube assembly 15 ′ below the vessel-and-valve assembly 11 . Sublimation of the dopant will occur as the dopant is captured at the perforated disk 203 . This process results in dopant laden argon traveling past the opened isolation valve 27 and out the angled tip 91 ′ of the quartz tube 53 ′ at the upper surface of the silicon melt. After the dopant has undergone sublimation, the quartz tube 53 ′ is retracted by the actuator 19 and the feed tube assembly 15 ′ is cooled with the flow of argon gas. Finally, the assembly 10 ′ is isolated from the crystal growing apparatus 31 by closing the isolation valve 27 .
Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A feed assembly and method of use thereof of the present invention is used for the addition of a high pressure dopant such as arsenic into a silicon melt for CZ growth of semiconductor silicon crystals. The feed assembly includes a vessel-and-valve assembly for holding dopant, and a feed tube assembly, attached to the vessel-and-valve assembly for delivering dopant to a silicon melt. An actuator is connected to the feed tube assembly and a receiving tube for advancing and retracting the feed tube assembly to and from the surface of the silicon melt. A brake assembly is attached to the actuator and the receiving tube for restricting movement of the feed tube assembly and locking the feed tube assembly at a selected position. | 8 |
FIELD OF THE INVENTION
The instant invention relates to supports for installed toilets. In particular, the instant invention relates to adjustable, portable, removable platforms for wall mounted toilets which allow additional weight to be supported. More particularly, the instant invention relates to floor supports for wall mounted toilets in hospitals and other health care facilities, where the toilet may be used by overweight, obese and extremely obese patients.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 11/450,508 filed Jun. 9, 2006 which claims priority to U.S. Provisional Application No. 60/689,323 filed on Jun. 10, 2005, the entire disclosure of which are incorporated by reference and for all purposes as if fully set forth herein.
BACKGROUND OF THE INVENTION
The invention relates to a support platform for wall mounted toilets, particularly to support the additional weight placed on the toilet by overweight, obese or severely obese individuals.
Although there are many types of toilets, those used in hospitals, clinics and other health care facilities, nursing homes and assisted living facilities, weight loss clinics, gyms, office buildings and other related buildings are often wall mounted. Part of the reason for mounting to the wall is to make cleaning easier as this type of toilet leaves a space between the floor and the bottom of the toilet. Frequently, wall mounted toilets are located in bathrooms where a floor drain is available so that the entire floor can be washed and drained easily without having to hold the wash water in a container. Where the toilet is floor mounted, cleanliness at the interface of the toilet and the floor is not assured and bacteria from urine and fecal matter are not always eliminated by normal cleaning procedures. In hospital rooms, clinics, recovery rooms and nursing homes, this is of particular concern as patients may be immune compromised and subject to secondary or hospital acquired infections from bacterial and viral contamination.
Wall mounted toilets are typically rated for a normal sized patient; 350 pounds is a common weight limit for such fixtures. With the increase in obesity in the United States and other nations, there is a high likelihood that an overweight, obese or severely obese individual will use a wall mounted toilet somewhere in the facility. With a limit in the rated weight bearing capacity of the toilet, there is a risk that the toilet mountings will fail and the overweight, obese or severely obese individual will fall. Any fall by such an individual, particularly one where a toilet fixture breaks away from a wall or one where the porcelain breaks, could lead to an injury. Furthermore, there is a risk of damage to the bathroom which can be costly to repair. The issue is of sufficient concern that Harrell and Miller discuss hospital design for bariatric patients and suggest the need for a bariatric toilet seat support (Health Facilities Management, March 2004, pp 34-38).
Current techniques to alleviate this problem in hospitals use wooden supports as a wedge between the wall mounted toilet and the floor. These supports are not easily adjustable. Their composition is not easily cleaned and can become contaminated with microorganisms such as E. coli which is commonly found in bathrooms.
In response to this problem, BAR Industries (Adairsville, Ga.) has developed the SK1000 series toilet support. The support is described in two pending and published US applications, U.S. Ser. No. 11/205,666 to Wright and U.S. Ser. No. 10/701,812 to Wright et al. This support is designed to be mounted using the wall mounts for the toilet and is adjustable using a screw type bumper positioned close to the front of the toilet. It cradles the bottom of the fixture with an arm-like single support and attaches integrally to the wall mounting bolts. The device described in the '666 and '812 applications can be used by each toilet design. Since the BAR Industries toilet support is attached at the wall mounts, it is more difficult to remove or move to a new location. This permanency makes cleaning and repairing the fixture or floor more difficult. It also increases the number of units required by a hospital by reducing the ability to move the fixture to a new bathroom. As the number of units purchased increases, the cost advantage claimed by the manufacturer decreases. Since the SK1000 uses a single bumper style foot, all of the weight of the user is held by the single foot. If the single foot fails under the load (as could occur over time and through exposure to loads), the device will no longer provide support and the toilet could still break away from the wall. Finally, the installation of the SK1000 requires removal of the mounting bolts contained on the toilet. This can cause the toilet to break its seal and can create a leak. These deficiencies make the SK1000 undesirable as a mobile and interchangeable support.
Another company, DB Industries (Little Suamico, Wis.) has developed a Bariatric Toilet Seat Support (BTSS) as described in U.S. Pat. No. 6,889,392 to Karnopp et al and published U.S. application Ser. No. 11/057,793. This support is a four legged stand made of stainless steel which is inserted between the toilet seat and the bowl. It is designed to provide additional weight bearing capacity on the toilet seat itself and not specifically on the fixture. The four legs are adjustable providing for the ability to match any unevenness in the floor. It also provides vertical adjustment with two stainless steel threaded rods with rubber end caps that are fit to the wall behind the toilet. Locking nuts are used at all six adjustable arms or legs. The device is very large and although the manufacturer claims that it takes up little room, it is cumbersome to position, use and maintain. It is also made from a complex series of components leaving multiple opportunities for stress failure. As it is placed between the toilet seat and the bowl, there is a risk that the seat may break under the weight of the bariatric patient. Furthermore, because the unit is positioned underneath the toilet seat and is exposed to the water, there is a higher risk of contamination by fecal matter and/or bacteria. This creates a need for more frequent cleanings than the instant invention. The BTSS is also too large to be heat sterilized in a standard hospital autoclave. Finally, the BTSS does not fit all wall hung toilet models and the company offers customized manufacturing.
Other devices designed for toilets are typically wall mounts that are used at the time of construction. See for example, U.S. Pat. No. 5,107,638 to Unertl which shows a permanent mounting means for a wall mounted water closet fixture. These devices are not specifically designed for bariatric use, but simply as further methods for securing wall mounted elements of the toilet assembly. These devices are permanent attachments to the toilet or its tank and cannot be easily moved. They are ideally used at installation or during renovation of the bathroom and not ideal for use on an existing wall mounted toilet.
BRIEF SUMMARY OF THE INVENTION
In view of the descriptions above and the deficiencies contained therein, the present invention can provide a platform to support wall mounted toilets, so that the weight capacity of the toilet is increased.
The present invention can further provide a removable and portable platform to support wall mounted toilets.
The present invention can also provide adjustment capability to the platform, so that the platform will support a wall mounted toilet independent of the height of the toilet.
The present invention can yet further provide a platform for a wall mounted toilet that is easy to position and adjust and does not require tools to use.
The present invention can embody a platform for wall mounted toilets that can be easily cleaned and sterilized.
The present invention can also provide a platform for wall mounted toilets that is easily transported and lightweight.
Other embodiments, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 shows a perspective view of the toilet support in use with a wall mounted toilet.
FIG. 2 shows a top view of the toilet support.
FIG. 3 shows a front side view of the toilet support.
FIG. 4 shows an oblique view of the toilet support as it is placed under a partial view of a wall mounted toilet.
FIG. 5 shows an oblique view of an alternate embodiment of the toilet support.
FIG. 6 shows a perspective view of an alternate embodiment of the toilet support in use with a wall mounted toilet.
FIG. 7 shows an oblique view of the alternate toilet support as it is placed under a partial view of a wall mounted toilet.
DETAILED DESCRIPTION OF THE INVENTION
Described herein is a bariatric support for a wall mounted toilets that is lightweight, is easily removed for cleaning or transfer to a new bathroom and is adjustable to any wall mounted toilet design. The toilet support can be sterilized chemically using common disinfectants or through heat, steam or high pressure. It is compact in design and can be easily stored in limited spaces. It has a small number of parts and uses high quality interchangeable components.
Referring now to the drawings, in FIG. 1 a front perspective view of the preferred toilet support apparatus as it is placed between the floor 2 and a wall mounted toilet 4 . The lower section 6 of the wall mounted toilet 4 is commonly configured either in a flat or a curved shape. In FIG. 1 , the lower section 6 is flat. Accordingly, the toilet support is shown with a platform 10 having a top surface 11 and a bottom surface 13 spaced by an outside edge 15 having a thickness 17 . The platform 10 also has adjustable base members 9 comprising mounting bolts 12 and feet 16 . In this perspective, only two mounting bolts 12 and feet 16 are shown but four are the preferred number spaced around the corners of the platform 10 . A threaded bore 23 is drilled into the platform 10 and the mounting bolts 12 of the adjustable base members 9 are inserted through the threaded bore 23 . The adjustable base members 9 can be made of any suitable material with a preferred design of stainless steel. The adjustable base members 9 can be adjustable glides or snap lock leveling mounts. The mounting bolts 12 can be of any height with the desirable height sufficient to raise the platform 10 such that it connects the bottom portion of the toilet. Mounting bolts 12 of multiple heights can be used depending on the space between the floor 2 and wall mounted toilet 4 . It is desirable to have at least two inches of each mounting bolt 12 remain above the top surface 11 of the platform 10 . The adjustable base members 9 are arranged around the platform 10 such that any portion of a mounting bolt 12 projecting above the top surface 11 of the platform 10 will not touch any surface of the wall mounted toilet 4 . Each adjustable base member 9 has a weight bearing capacity of at least 250 pounds with a preferred capacity of 500 pounds. The adjustable base members 9 may have greater weight bearing capacity if desired. Adjustable glides or snap lock leveling mounts can be found through multiple sources, one example is the Monroe Company (Auburn Mills, Mich.). The number of adjustable base members 9 is at least four although it can be five or more depending on the design of the toilet support apparatus. A groove 14 is cut into the platform 10 to accommodate a nipple 8 commonly found on the lower section 6 of the wall mounted toilet 4 . The nipple 8 is a common artifact of the molding process. The groove 14 is at least one-eighth inch deep in the platform 10 so that the nipple 8 does not make contact with the platform 10 while the lower section 6 of the wall mounted toilet 4 establishes direct contact with the top surface 11 of the platform 10 . To use the device, the platform 10 is placed under the wall mounted toilet 4 with the groove 14 directly under the nipple 8 . The adjustable base members 9 are adjusted by hand to raise the platform until it makes contact with the lower section 6 of the toilet 4 . Once all adjustable base members 9 have been adjusted and the platform 10 contacts the lower section 6 , the adjustable base members 9 can be adjusted using a wrench to make a firm contact between the platform 10 and the toilet 4 .
In FIG. 2 a top view of the preferred toilet support apparatus is provided. A platform 10 is shown having a top surface 11 and an outside edge 15 with four mounting bolts 12 . The platform 10 is preferably made of aluminum block but can be made from steel, including stainless steel or surgical steel. Other high strength metals that can be sterilized by heat, pressure or chemicals can be used. The platform 10 is at least three quarters of an inch thick and can be of greater thickness depending on the starting material. The mounting bolts 12 are part of the adjustable base members (not shown) which are preferably adjustable glides placed at even intervals near the corners of the platform 10 . Adding at least four mounting bolts 12 allows the force to be distributed among them so each mounting bolt 12 is carrying a portion of the load and not the full force or weight. If a single mounting bolt 12 failed, the remaining adjustable base members will distribute and support the load. The mounting bolts 12 are added by drilling threaded bores (not shown) in the platform 10 to match the diameter of the mounting bolts 12 . The mounting bolts 12 are threaded to accommodate a securing device such as a nut and so they can be inserted into the threaded bores (not shown). The mounting bolts 12 are interchangeable and can be of different thread lengths and total heights depending on the needs of the support and the layout of the bathroom floor. The mounting bolts 12 can have optional flat or Philips head screwdriver notches on their top surface. The groove 14 is cut into the platform 10 to a preferred depth of one quarter inch and a preferred width of two inches. The depth and width of the groove 14 can be varied depending on the dimensions of the wall mounted toilet. The groove 14 extends from the front edge of the platform 10 to a distance of two thirds of the length of the platform 10 . The corners of the platform 10 are preferably rounded to avoid sharp edges. The top and bottom edges of the platform 10 can also be rounded to avoid sharp edges.
In FIG. 3 , more detail is shown through a side view of the toilet support apparatus. The platform 10 and the mounting bolts 12 are shown. A threaded bore 23 is drilled into the platform 10 to provide space for the mounting bolts 12 . Now visible are the adjustable base members 9 comprised of feet 16 connected to the mounting bolts 12 . Each mounting bolt 12 has a top portion 19 extending from the top surface 11 of the platform 10 and a bottom portion 21 extending from the bottom surface 13 . The feet 16 stabilize the toilet support apparatus and provide weight bearing capability. The adjustable base members 9 raise or lower the platform 10 so that the top surface 11 of the platform 10 fits snugly under the wall mounted toilet. Each adjustable base member 9 can be adjusted manually to correct for any slope in the bathroom floor. This is particularly important in hospital bathrooms and nursing home bathrooms where a drain in the floor may exist to allow for easier cleaning. The feet 16 can be made of the same material as the mounting bolts 12 and the platform 10 . Covers or pads 20 made of rubber, Teflon, plastic or another appropriate substance can be added to provide a non-slip and/or non-marring surface if desired. These covers or pads 20 are preferably removable and replaceable although they can be fixed and permanent if made of an appropriate inert substance such as polyethylene or Teflon that is capable of chemical sterilization. The feet 16 can be configured to have covers or pads 20 on none, all or some of the feet 16 as desired.
In an alternate embodiment, a securing member can be added to the mounting bolts 12 . The mounting bolt is then threaded into the threaded bore 23 in the platform 10 so that the securing member sits just below the platform 10 . The securing member is maintained in a loosened position under the platform 10 while the adjustable base member 9 is raised or lowered to fit the platform 10 under the toilet. A wrench can be used to snugly tighten the securing member against the bottom surface 13 of the platform 10 after it has been placed under the wall mounted toilet to provide further security for the platform 10 . In yet another alternate embodiment, securing members can be added above and below the platform 10 on the mounting bolts for further security. The securing members are preferably nuts and can be regular hex nuts or lock nuts of a size that matches the mounting bolts 12 . Washers can be used to further add security between the securing member and the bottom surface 12 of the platform 10 . Both the nut and the washer are made from materials similar to the platform 10 with a preferred embodiment of stainless steel.
In FIG. 4 , a lateral oblique view of the toilet support apparatus is shown as it would appear in use. A partial view of the lower section 6 of a wall mounted toilet 4 with the platform 10 supporting the lower section 6 of the wall mounted toilet 4 is shown. Three adjustable base members 9 with mounting bolts 12 and feet 16 are visible in this view. The adjustable base members 9 are adjusted by rotating them in the threaded bore 23 so that the feet 16 are connected solidly with the floor 2 and the platform 10 is connected firmly with the lower section 6 of the wall mounted toilet 4 . In this view a single wall mount 22 is shown which affixes the toilet 4 to the wall. The toilet support apparatus does not attach to the wall mount 22 of the wall mounted toilet 4 unlike the SK1000 support described above. Furthermore, there is no need for vertical stabilization arms as in the BTSS support described above. The mounting bolts 12 can be of different heights in order to adjust for the height of the wall mounted toilet 4 and for any slope of the floor. In FIG. 4 , covers or pads are not shown but can be used on one or more of the feet 16 .
In FIG. 5 , an alternate version of the toilet support apparatus is shown in a stand alone oblique view. This version supports wall mounted toilets with rounded bottoms. The toilet support apparatus previously described in FIG. 1 through FIG. 4 can be used with a wall mounted toilet that has a rounded lower section but a smaller area of contact between the wall mounted toilet and the toilet support apparatus occurs. The alternate version provides a greater area of contact between the wall mounted toilet and the toilet support apparatus. Two support members 32 are shown with a connecting member 34 . The support members 32 have a front surface 33 and a back surface 35 that are spaced from each other by bottom edges 37 and top edges 39 . The top edges 39 of the support members 32 are curved, exemplarily in a saddle shape, and are configured to cradle the rounded lower section of the wall mounted toilet and provide additional area for the lower section 6 of the wall mounted toilet 4 to contact the toilet support apparatus. The exemplary bottom edges 37 are configured to facilitate welding to the platform 10 , and in the exemplary embodiment both the platform 10 and the bottom edge 37 are accordingly flat. The support members 32 and the connecting member 34 are welded together and are welded to the platform 10 . The support members 32 are of different heights to accommodate the curved shape of a rounded lower section of the wall mounted toilet. The mounting bolts 12 and feet 16 of the adjustable base members 9 are shown and are inserted through the threaded bore 23 in the platform 10 . In the preferred embodiment two support members 32 and a single connecting member 34 are used to add sufficient weight or force bearing capacity. Additional support members 32 and connecting members 34 can be added. The connecting member 34 has a front edge 41 , rear edge 43 , top edge 45 , bottom edge 47 , and two side surfaces 49 where the front edge 41 is connected to a more forwardly disposed (front) vertical support member 32 , the rear edge is connected to a more rearward disposed (rear) vertical support member 32 and the bottom edge 47 is connected to the platform 10 . All connections between the support members 32 , the connecting member 34 and the platform 10 are preferably welds.
In FIG. 6 an alternate version of the toilet support apparatus, as it is used on a rounded bottom, wall mounted toilet, is presented in perspective view. In this example, the wall mounted toilet 4 has a rounded lower section 6 . The platform 10 contains two support members 32 which are welded to the platform 10 with a connecting member 34 welded to the support members 32 and stabilizing them. Adjustable base members 9 inserted through threaded bores 23 in the platform 10 comprise mounting bolts 12 and feet 16 and are shown along with the optional securing member 18 , shown here as adjusting nuts. The feet 16 remain in contact with the floor 2 . To use this version on rounded bottom, wall mounted toilets 4 , the device is placed under the wall mounted toilet and adjusted so the support members 32 are positioned directly under the rounded lower section 6 of the wall mounted toilet 4 . The adjustable base members 9 are then adjusted by hand until the support members 32 cradle the rounded lower section 6 of the wall mounted toilet 4 and then are adjusted using a wrench to create a firm connection. When the optional securing members 18 are nuts they can be adjusted using a wrench until they are firmly positioned under the bottom of the platform 10 .
FIG. 7 shows an oblique view of the alternate version of the toilet support apparatus as it is in use with a partial view of the rounded lower section 6 of a wall mounted toilet. The two support members 32 are shown with the connecting member 34 between the support members 32 . The support members 32 are of different heights to accommodate the curved shape of a rounded lower section 6 of the wall mounted toilet. The mounting bolts 12 and feet 16 of the adjustable base members 9 are shown.
Continuing with the embodiments described above, an alternative can include a wrench mount on the platform and a wrench with the proper span for the mounting bolts and nuts. This provides the user with the ability to place the support quickly and without the need to search for the right tool. The wrench can be of any commercially available type, preferably having a fixed span fitted to the size of the adjustable base member and the optional securing members and more preferably having a ratcheting action due to the confined nature of the space. The wrench and its mount are placed outside of the contact area between the platform and the bottom surface of the wall mounted toilet, preferably along a side of the platform.
In an alternate embodiment, the platform has one or more levels mounted to its top surface including a simple bull's-eye bubble level as is commonly used in construction and on tripod stands. The optional level is used where the floor is determined to be level and a level toilet support is desired. The level or levels are fixed to the top surface of the platform, outside of the contact area between the platform and the bottom surface of the wall mounted toilet.
The toilet support provides additional weight bearing capacity for wall mounted toilets beyond their rated failure point. For many wall mounted toilets, the rated load is between 250 and 350 pounds. When a weight or force greater than this rating is placed on the wall mounted toilet, the toilet may pull away from the wall or crack near the wall mounts, possibly injuring the user and necessitating costly repair or replacement and downtime for the bathroom and/or hospital room. By placing the toilet support properly under the wall mounted toilet, the risk of damage to the toilet is reduced as the force or weight load of the toilet is increased.
Testing of the toilet support with weights has demonstrated that the support can bear a load of well over five hundred pounds, above the normal weight limit of the fixture and well within the weight range for overweight, obese and severely obese persons. | A support platform for wall mounted toilets is described. The platform attaches easily under the toilet and contains bolts and feet for adjustment. The platform provides support to wall mounted toilets so that persons of weight greater than the rated load of the wall mounted toilet can use the toilet in comfort and safety. It is removable for use in different bathrooms, easily transported and can be sterilized where bacterial or viral contamination is a concern. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an authentication-ticket processing apparatus that can speed up the acquisition of user information.
[0003] 2. Description of the Related Art
[0004] Authentication tickets may be used in order for a server on a network to provide prompt, safe services.
[0005] There are various specifications for authentication tickets depending on their usage. One of such specifications relates to an authentication ticket referred to as a “self-contained ticket”, which returns user information at the time of decoding process.
[0006] FIG. 1 is a drawing showing the flow of related-art processes from an authentication request to the acquisition of an authentication ticket. Prior to the receiving of services from a service server 2 , a client 1 issues an authentication request to a user authentication apparatus (UAUD: User Authentication by User Directory) 3 (step S 1 ). The user authentication apparatus 3 checks user information with a user management database 4 (step S 2 ). Upon confirmation, the user authentication apparatus 3 only obtains user ID information from the user management database 4 (step S 3 ) . The user authentication apparatus 3 then generates an authentication ticket based on the user ID information (step S 4 ), and supplies the authentication ticket to the client 1 (step S 5 ).
[0007] FIG. 2 is a drawing showing the flow of related-art processes from a service request to the start of a service. The client 1 issues a service request together with the authentication ticket to the service server 2 (step S 11 ) . In response, the service server 2 issues a decoding request to the user authentication apparatus 3 to decode the authentication ticket (step S 12 ). The user authentication apparatus 3 acquires user information (inclusive of information other than the user ID information) from the user management database 4 (steps S 13 , S 14 ), and, then, supplies the user information to the service server 2 (step S 15 ). Based on the supplied user information, the service server 2 makes a decision about the access right regarding the relevant service so as to start providing the service (step S 16 ).
[0008] Patent Document 1 discloses an image forming apparatus, an accumulated document management method, and an accumulated document processing system that can share an authentication function regarding accumulated documents, and that can supply accumulated documents without squandering the resources of the network and the resources of the multifunction machine.
[0009] [Patent Document 1] Japanese Patent Application Publication No. 2004-135291
[0010] In the configuration of FIG. 2 , the service server 2 issues a decoding request to the user authentication apparatus 3 each time it receives a new service request together with an authentication ticket even if the authentication ticket is the same as one that was previously received, and the user authentication apparatus 3 acquires user information from the user management database 4 accordingly. Such arrangement is made because, in the case of a self-contained ticket, the registration status of the user may change over a long time period during which the authentication ticket is kept in possession, resulting in a situation in which the user information at the time of a decoding process may end up differing from the user information as existed at the time of authentication. When a document is to be delivered or printed in a workflow, for example, the user may encounter a wait state at the start of operation. The time at which the function will exit from the waiting state to become operational is unknown. Because of this, an authentication ticket that is to be used after the resumption should be valid for a sufficiently long time period. There may be situations, however, in which the user information as existed at the time of authentication is different from the current user information when the function becomes available, due to assignment to another post in the organization, leave of absence, requirement from the company, or the like. For this reason, provision is made to acquire user information from the user management database 4 at the time of decoding the authentication ticket to obtain the user information.
[0011] Since the related-art system is based on such arrangement as described above, if a plurality of services at the service server 2 use the same authentication ticket simultaneously, multiple decoding requests are issued to the user authentication apparatus 3 in a short interval (e.g., at an interval of few seconds). As a result, access to the database of the user management database 4 to obtain the same user information is performed multiple times in a short interval. FIG. 3 is a drawing showing the way in which authentication ticket decoding requests are frequently issued in the related-art arrangement. Multiple decoding requests are consecutively issued at short intervals from the service server 2 to the user authentication apparatus 3 (step S 22 ). In response, the acquisition of user information from the user management database 4 is performed consecutively by the user authentication apparatus 3 (step S 23 ).
[0012] In the related-art system as described above, when multiple decoding requests in respect of the same self-contained ticket are issued at short intervals, access to the database of the user management database 4 to obtain the same user information is performed multiple times accordingly, resulting in a performance drop.
[0013] This problem may have to be accepted as a compromise because it occurs due to the intended specification of the self-contained ticket. However, a change in user information that is supposed to be taken care of by such specification does not occur frequently. Treating such special case at the expense of performance may be considered as an action that lacks a sense of balance. Namely, user information regarding users using a document management system or the like is not frequently modified. If modified, such modification mainly occurs when there is an organizational change such as staff reassignment, and the frequency of such change may be few times a year to few times a month at the maximum. Accessing the database each time a decoding request is made in order to avoid trouble at such few occasions may be an overreaction.
[0014] Accordingly, there is a need for an authentication-ticket processing apparatus that can overcome the performance problem associated with the self-contained ticket, and that can speed up the acquisition of user information.
SUMMARY OF THE INVENTION
[0015] It is a general object of the present invention to provide an authentication-ticket processing apparatus and method that substantially obviate one or more problems caused by the limitations and disadvantages of the related art.
[0016] Features and advantages of the present invention will be presented in the description which follows, and in part will become apparent from the description and the accompanying drawings, or may be learned by practice of the invention according to the teachings provided in the description. Objects as well as other features and advantages of the present invention will be realized and attained by an authentication-ticket processing apparatus and method particularly pointed out in the specification in such full, clear, concise, and exact terms as to enable a person having ordinary skill in the art to practice the invention.
[0017] To achieve these and other advantages in accordance with the purpose of the invention, the invention provides an authentication ticket processing apparatus for generating an authentication ticket for provision to a client in response to an authentication request from the client, and for supplying relevant user information in response to a decoding request from a server with respect to an authentication ticket associated with a service request from the client when the client is to receive a series of services from a plurality of servers that are operable independently of each other. The authentication ticket processing apparatus includes a temporary data storage unit configured to keep user information upon receiving the user information from a user management database for managing user information, the temporary data storage unit allowing access thereto to be performed at higher speed than access to the user management database. The authentication ticket processing apparatus is configured such that, when there is a need to acquire user information in response to a decoding request from a server, a check is made whether user information corresponding to the decoding request is present in the temporary data storage unit, and the corresponding user information is acquired from the temporary data storage unit if the corresponding user information is present in the temporary data storage unit.
[0018] According to another aspect of the present invention, the invention provides an authentication ticket processing method of generating an authentication ticket for provision to a client in response to an authentication request from the client, and of supplying relevant user information in response to a decoding request from a server with respect to an authentication ticket associated with a service request from the client when the client is to receive a series of services from a plurality of servers that are operable independently of each other. The aid authentication ticket processing method includes keeping user information in a temporary data storage unit upon receiving the user information from a user management database for managing user information, access to the temporary data storage unit being faster than access to the user management database, checking whether user information corresponding to a decoding request is present in the temporary data storage unit when there is a need to acquire user information in response to the decoding request from a server, and acquiring the corresponding user information from the temporary data storage unit if the corresponding user information is present in the temporary data storage unit.
[0019] In the authentication ticket processing apparatus according to at least one embodiment of the present invention, the temporary data storage unit that allows access thereto to be performed at higher speed than access to the user management database keeps user information upon receiving the user information from the user management database for managing user information, and the user information is acquired from the temporary data storage unit when there is a need to acquire the user information. This arrangement obviates the performance problem associated with the self-contained ticket, and speeds up the acquisition of user information.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Other objects and further features of the present invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings, in which:
[0021] FIG. 1 is a drawing showing the flow of related-art processes from an authentication request to the acquisition of an authentication ticket;
[0022] FIG. 2 is a drawing showing the flow of related-art processes from a service request to the start of a service;
[0023] FIG. 3 is a drawing showing the way in which decoding requests to decode authentication tickets are frequently issued;
[0024] FIG. 4 is a drawing showing an example of the configuration of a system according to a first embodiment of the present invention;
[0025] FIG. 5 is a drawing showing an example of the structure of a ticket pool according to the first embodiment;
[0026] FIG. 6 is a drawing showing the flow of processes from an authentication request to the acquisition of an authentication ticket according to the first embodiment;
[0027] FIG. 7 is a drawing showing the flow of processes from a service request to the start of a service according to the first embodiment;
[0028] FIG. 8 is a drawing showing an example of the removal of user information and the like from a ticket pool according to the first embodiment;
[0029] FIG. 9 is a drawing showing the flow of processes from a service request to the start of a service according to the first embodiment;
[0030] FIG. 10 is a flowchart showing an entirety of processes according to the first embodiment;
[0031] FIG. 11 is a drawing showing the flow of processes from a service request to the start of a service according to a second embodiment;
[0032] FIG. 12 is a drawing showing an example of the removal of user information and the like from a ticket pool according to the second embodiment;
[0033] FIG. 13 is a drawing showing an example of the structure of a ticket pool according to a third embodiment of the present invention;
[0034] FIG. 14 is a drawing showing the flow of processes from a service request to the start of a service according to the third embodiment;
[0035] FIG. 15 is a drawing showing an example of the removal of user information and the like from a ticket pool according to the third embodiment;
[0036] FIG. 16 is a drawing showing an example of the collaboration of service servers;
[0037] FIG. 17 is a drawing showing an example of processes performed in the collaboration of service servers;
[0038] FIG. 18 is a drawing showing an example of the collaboration of service servers;
[0039] FIG. 19 is a drawing showing an example of processes performed in the collaboration of service servers;
[0040] FIG. 20 is a drawing showing an example of the collaboration of service servers; and
[0041] FIG. 21 is a drawing showing an example of processes performed in the collaboration of service servers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] In the following, embodiments of the present invention will be described with reference to the accompanying drawings.
First Embodiment
[0043] FIG. 4 is a drawing showing an example of the configuration of a system according to a first embodiment of the present invention. The system shown in FIG. 4 includes a client 1 such as a PC (personal computer), a cellular phone, or a PDA (personal digital assistant) used by a user who is to receive a service, a plurality of service servers 2 providing services, a user authentication apparatus 3 for generating and decoding an authentication ticket, and a user management database 4 for managing user information. The user authentication apparatus 3 includes a user authentication controlling unit 31 for performing a main part of the process of generating and decoding an authentication ticket, a ticket pool (user information temporal storage unit) 32 for keeping user information for a limited time period under the control of the user authentication controlling unit 31 , and an expiration-time monitoring unit 33 for monitoring the expiration time of an entry in the ticket pool 32 and deleting the entry accordingly.
[0044] FIG. 5 is a drawing showing the structure of the ticket pool 32 according to the first embodiment. The ticket pool 32 includes keys 32 a for storing respective self-contained tickets, and also includes expiration times 32 b and user information items 32 c paired with the respective keys 32 a . The expiration time 32 b is separate from and independent of the valid period contained in the self-contained ticket, and has a value that is the date and time of creation of the authentication ticket plus a specified time period. The specified time period is set to a sufficiently short period (e.g., 30 seconds), which is within the range that can cope with the case in which decoding requests are frequently issued in a short interval, and which is not contrary to the intended purpose of the self-contained ticket that is to return user information at the time of the decoding process.
[0045] FIG. 6 is a drawing showing the flow of processes from an authentication request to the acquisition of an authentication ticket according to the first embodiment. In FIG. 6 , prior to the receiving of services from a service server 2 , the client 1 issues an authentication request to the user authentication controlling unit 31 of the user authentication apparatus 3 (step S 101 ). In response, the user authentication controlling unit 31 checks user information with the user management database 4 (step S 102 ). Upon confirmation, the user authentication controlling unit 31 obtains user information from the user management database 4 (step S 103 ). This user information not only includes user ID information, but also includes all the information necessary at the time of decoding process.
[0046] Based on the user ID information contained in the user information, the user authentication controlling unit 31 generates an authentication ticket (step S 104 ), and stores the user information in the ticket pool 32 such that the user information is associated with the authentication ticket and an expiration time (step S 105 ). The user authentication controlling unit 31 then supplies the authentication ticket to the client 1 (step S 106 ).
[0047] FIG. 7 is a drawing showing the flow of processes from a service request to the start of a service according to the first embodiment. In FIG. 7 , the client 1 issues a service request together with an authentication ticket to a service server 2 (step S 111 ). In response, the service server 2 issues a decoding request to the user authentication controlling unit 31 of the user authentication apparatus 3 to decode the authentication ticket (step S 112 ).
[0048] The user authentication controlling unit 31 acquires the user information from the ticket pool 32 without accessing the user management database 4 (step S 113 , step S 114 ), and supplies the user information to the service server 2 (step S 115 )
[0049] The service server 2 makes a decision about the access right regarding the relevant service based on the supplied user information so as to start providing the service (step S 116 ).
[0050] In the mean time, the expiration-time monitoring unit 33 constantly or periodically compares the present time with the expiration time 32 b of the user information stored in the ticket pool 32 , and deletes or invalidates the user information that has expired by exceeding the expiration time. FIG. 8 is a drawing showing an example of the deletion of user information or the like stored in the ticket pool 32 according to the first embodiment. An authentication ticket is generated, and is accessed as many times as necessary, followed by being deleted when the specified time period passes from the date and time of the creation.
[0051] FIG. 9 is a drawing showing the flow of processes from a service request to the start of a service according to the first embodiment when the relevant authentication ticket has already been deleted. In FIG. 9 , the client 1 issues a service request together with an authentication ticket to a service server 2 (step S 121 ). In response, the service server 2 issues a decoding request to the user authentication controlling unit 31 of the user authentication apparatus 3 to decode the authentication ticket (step S 122 ).
[0052] The user authentication controlling unit 31 attempts to acquire the user information from the ticket pool 32 (step S 123 , step S 124 ), and acquires the user information instead from the user management database 4 since the relevant user information is not in existence (step S 125 , step S 126 ).
[0053] The user authentication controlling unit 31 then stores the user information in the ticket pool 32 such that the user information is associated with the authentication ticket and the expiration time (step S 127 ), and supplies the user information to the service server 2 (step S 128 ).
[0054] The service server 2 makes a decision about the access right regarding the relevant service based on the supplied user information so as to start providing the service (step S 129 ).
[0055] FIG. 10 is a flowchart showing the entire procedure of the first embodiment. S 201 through S 209 relate to the procedure from an authentication request to the acquisition of an authentication ticket. S 210 through S 231 concern the procedure from a service request to the start of a service. S 241 through S 244 concern the procedure for deleting user information or the like in the ticket pool 32 .
[0056] As shown in the figure, user information is acquired preferentially from the ticket pool 32 in response to a decoding request requesting the decoding of an authentication ticket. Even when decoding requests are consecutively issued in a short interval, thus, a drop in performance can be prevented.
[0057] Moreover, user information is kept in storage together with the indication of the time relating to the time of information acquisition, and is deleted after the passage of a specified time period. With a proper setting of this period, user information with sufficient accuracy as existing at the time of a decoding request can be provided in accordance with the specification of a self-contained ticket while preserving the advantage of performance improvements in the case of multiple decoding requests occurring in a short time period.
Second Embodiment
[0058] FIG. 11 is a drawing showing the flow of processes from a service request to the start of a service according to a second embodiment. In the second embodiment, provision is made to update the expiration time of user information stored in the ticket pool.
[0059] In the first embodiment, user information in the ticket pool 32 is disposed of after the passage of the specified time period regardless of whether decoding requests are being consecutively issued as part of a series of operations. Thereafter, the user information is acquired from the user management database 4 in response to a decoding request. This may create a situation in which the decoded information differs between the first half of the decoding process and the second half of the decoding process. When multiple decoding requests are consecutively made by a plurality of services, these services often constitute mutually related applications. In such a case, thus, it is preferable to obtain the same information as the decoded results. In the second embodiment, thus, the information about the expiration time is initialized each time the user information is acquired from the ticket pool 32 .
[0060] In FIG. 11 , the client 1 issues a service request together with an authentication ticket to a service server 2 (step S 131 ). In response, the service server 2 issues a decoding request to the user authentication controlling unit 31 of the user authentication apparatus 3 to decode the authentication ticket (step S 132 ) . In this example, it is assumed that multiple decoding requests are consecutively issued by a plurality of services.
[0061] The user authentication controlling unit 31 acquires the user information from the ticket pool 32 (step S 133 , step S 135 ), and updates the expiration time each time the user information is acquired (step S 134 ).
[0062] The user authentication controlling unit 31 supplies the user information to the service servers 2 (step S 136 ). The service servers 2 make a decision about the access right regarding the relevant service based on the supplied user information so as to start providing the service (step S 137 ).
[0063] FIG. 12 is a drawing showing an example in which user information and the like is deleted in the ticket pool 32 according to the second embodiment. In the first embodiment, an authentication ticket is deleted after the passage of a specified time period following the creation of the authentication ticket as shown in (a). In the second embodiment, on the other hand, the specified period restarts each time access is made, and the authentication ticket is deleted after the passage of the specified period following the last access.
[0064] In this manner, the expiration time is extended in response to the acquisition of data from the ticket pool 32 , so that the user information in the ticket pool 32 will not be discarded while there is an ongoing series of decoding requests. This can avoid a situation in which the decoded information differs between the first half of the decoding process and the second half of the decoding process.
Third Embodiment
[0065] FIG. 13 is a drawing showing the structure of a ticket pool according to a third embodiment of the present invention. In the third embodiment, provision is made such that an upper limit is settable to an extension of the expiration time.
[0066] In the second embodiment, user information in the ticket pool 32 is never discarded if decoding requests continued to be issued at short intervals as in the case where decoding requests are congested. In such a case, there may never be a situation in which the user information is acquired from the user management database 4 . Namely, the intended purpose of the self-contained ticket, i.e., the returning of user information as existing at the time of a decoding request, is significantly undermined. In the third embodiment, thus, the user information stored in the ticket pool 32 is managed together with an upper limit of an extension in addition to the expiration time.
[0067] In FIG. 13 , the ticket pool includes the keys 32 a for storing respective self-contained tickets, the expiration times 32 b and user information items 32 c paired with the respective keys 32 a , and upper limits 32 d indicative of a limit of an extension of the expiration time. The upper limit 32 d is initialized in response to the acquisition of the user information from the user management database 4 .
[0068] FIG. 14 is a drawing showing the flow of processes from a service request to the start of a service according to the third embodiment. In FIG. 14 , the client 1 issues a service request together with an authentication ticket to a service server 2 (step S 141 ). In response, the service server 2 issues a decoding request to the user authentication controlling unit 31 of the user authentication apparatus 3 to decode the authentication ticket (step S 142 ). In this example, it is assumed that multiple decoding requests are consecutively issued by a plurality of services.
[0069] The user authentication controlling unit 31 acquires the user information from the ticket pool 32 (step S 143 , step S 145 ), and updates the expiration time each time the user information is acquired (step S 144 ). However, an extension of the expiration time is limited by the upper limit 32 d.
[0070] The user authentication controlling unit 31 supplies the user information to the service servers 2 (step S 146 ). The service servers 2 make a decision about the access right regarding the relevant service based on the supplied user information so as to start providing the service (step S 147 ).
[0071] FIG. 15 is a drawing showing an example in which user information and the like is deleted in the ticket pool 32 according to the third embodiment. In the first embodiment, an authentication ticket (user information to be exact) is deleted after the passage of a specified time period following the creation of the authentication ticket as shown in (a). In the second embodiment, the authentication ticket is not deleted as long as there are ongoing consecutive accesses as shown in (b). In the third embodiment, on the other hand, the authentication ticket is deleted after the passage of a predetermined time period from the last access or at the time corresponding to the upper limit, whichever is earlier, and new user information is retrieved in response to a following decoding request.
[0072] In this manner, provision is made to set an upper limit to an extension of the expiration time. Even when decoding requests are congested, therefore, it is possible to avoid undermining the intended purpose of the self-contained ticket, i.e., the ability to return user information as existing at the time of a decoding request.
Example of Collaboration between Service Servers
[0073] The service servers 2 described above are separate from and independent of each other, and a service server 2 can be added or removed as desired. In order to implement certain application, a plurality of service servers 2 may be operated in collaboration with each other.
[0074] Depending on which service servers 2 collaborate for a given application, different control may be performed. Three example patterns are shown in the following:
(1) a case in which the client defines the collaboration; (2) a case in which a third service server defining the application defines the collaboration; and (3) a case in which the authentication ticket includes the definition of an activated service.
[0078] FIG. 16 is a drawing showing an example of the collaboration of service servers when the client defines the collaboration. In FIG. 16 , when the client 1 is to point a document, a repository service 21 and a print service 22 are activated under the control of the client 1 . Each of the repository service 21 and the print service 22 uses the user authentication apparatus 3 to decode the respective authentication ticket in order to make a decision about the access right regarding their respective service. As a result, the user authentication apparatus 3 decodes the authentication tickets of the same user multiple times in a short interval.
[0079] FIG. 17 is a sequence diagram showing an example of processes performed in this case. S 301 through S 307 concern the process of acquiring an authentication ticket, S 308 the process of instructing to print a document by the client 1 , S 309 through S 315 the process performed by the repository service 21 , S 316 through S 321 the process performed by the print service 22 , and S 322 and S 323 the process of waiting services by the client 1 . At S 309 and S 316 , authentication tickets are supplied to the repository service 21 and the print service 22 simultaneously. Alternatively, arrangement may be made such that an authentication ticket is supplied to the print service 22 after the repository service 21 acquires the relevant document.
[0080] FIG. 18 is a drawing showing an example of the collaboration of service servers when a third service server defining an application defines the collaboration. In FIG. 18 , when the client 1 is to deliver a document, the repository service 21 and a delivery service 24 are activated under the control of a delivery application service 23 so as to decode the authentication tickets regarding their respective services. Provision may be made such that the delivery application service 23 decodes the supplied application tickets. In this case, the decoding results may be taken into account to restrict the subordinate service servers. The delivery service 24 resumes delivery after an interval period upon a delivery failure. This action can also be switched according to the decoding results. After the resumption of delivery, the user information returned upon the decoding of the authentication ticket is current user information.
[0081] FIG. 19 is a sequence diagram showing an example of processes performed in this case. S 401 through S 407 concern the process of acquiring an authentication ticket, S 408 the process of instructing to deliver a document by the client 1 , S 409 through S 428 the process performed by the repository service 21 and the delivery service 24 under the control of the delivery application service 23 , S 429 through S 439 the delivery resumption process performed upon a delivery failure. At S 410 and S 417 , authentication tickets are supplied to the repository service 21 and the print service 22 simultaneously. Alternatively, arrangement may be made such that an authentication ticket is supplied to the print service 22 after the repository service 21 acquires the relevant document.
[0082] FIG. 20 is a drawing showing an example of the collaboration of service servers when an authentication ticket includes the definition of activated services. FIG. 20 is directed to an example in which the service server 2 and the user authentication apparatus 3 are provided inside an MFP (multi-function printer). When a copy is to be made, for example, a scan filter 26 , a print filter 27 , and an image processing filter 28 are activated as the functions to implement a copy application service 25 . When the types of usable filters are limited on a user-specific basis for each user of the client 1 , an authentication ticket may include relevant information (indicative of the filter types that can be activated) , thereby specifying services that can be activated.
[0083] FIG. 21 is a sequence diagram showing an example of processes performed in this case. Through the process of acquiring an authentication ticket at steps S 501 through S 507 , an authentication ticket that defines types of services usable by a user is issued. S 508 concerns the process of instructing to deliver a document by the client 1 , and S 509 though S 535 concern the processes performed by the scan filter 26 , the print filter 27 , and the image processing filter 28 under the control of the copy application service 25 . S 536 concerns the process of waiting for a completion.
[0084] Embodiments of the present invention have been described heretofore for the purpose of illustration. The present invention is not limited to these embodiments, but various variations and modifications may be made without departing from the scope of the present invention. The present invention should not be interpreted as being limited to the embodiments that are described in the specification and illustrated in the drawings.
[0085] The present application is based on Japanese priority applications No. 2005-336871 filed on Nov. 22, 2005 and No. 2006-304257 filed on Nov. 9, 2006, with the Japanese Patent Office, the entire contents of which are hereby incorporated by reference. | An authentication ticket processing apparatus includes a temporary data storage unit configured to keep user information upon receiving the user information from a user management database for managing user information, the temporary data storage unit allowing access thereto to be performed at higher speed than access to the user management database. The authentication ticket processing apparatus is configured such that, when there is a need to acquire user information in response to a decoding request from a server, a check is made whether user information corresponding to the decoding request is present in the temporary data storage unit, and the corresponding user information is acquired from the temporary data storage unit if the corresponding user information is present in the temporary data storage unit. | 7 |
This application is a divisional of application Ser. No. 08/018,840, filed Feb. 18, 1993, now U.S. Pat. No. 5,512,591, TREATMENTS FOR CHARACTERIZED BY NEOVASCULARIZATION.
FIELD OF THE INVENTION
The invention relates to diseases characterized by neovascularization and the use of imidazoles that inhibit the Ca ++ activated potassium channel in arresting or inhibiting such neovascularization.
BACKGROUND OF THE INVENTION
A normal artery typically is lined on its inner-side by a single layer of endothelial cells, the intima. The intima overlays the media, which contains only a single cell type, the vascular smooth muscle cell. The outer-most layer of the artery is the adventitia.
Neovascularization, or anglogenesis, is the growth and development of new arteries. It is critical to the normal development of the vascular system, including injury-repair. There are, however, conditions characterized by abnormal neovascularization, including diabetic retinopathy, neovascular glaucoma, rheumatiod arthritis, psoriasis and certain cancers. For example, diabetic retinopathy is a leading cause of blindness. There are two types of diabetic retinopathy, simple and proliferative. Proliferative retinopathy is characterized by neovascularization and scarring. About one-half of those patients with proliferative retinopathy progress to blindness within about five years.
Another example of abnormal neovascularization is that associated with solid tumors. It is now established that unrestricted growth of tumors is dependant upon anglogenesis, and that induction of anglogenesis by liberation of angiogenic factors can be an important step in carcinogenesis. For example, basic fibroblast growth factor (bFGF) is liberated by several cancer cells and plays a crucial role in cancer anglogenesis. The demonstration that certain animal tumors regress when angiogenesis is inhibited has provided the most compelling evidence for the role of anglogenesis in tumor growth.
It would be desirable to identify antiangiogenesis agents useful in treating the foregoing diseases.
Imidazoles are synthetic antifungal agents that are used both topically and systemically. Indications for their use include ringworm, tinea versicolor and mucocutaneous candidiasis. These compounds are believed to act by inhibiting ergosterol synthesis in the fungal cell wall, and when given topically, may cause direct damage to the cytoplasmic membrane.
The fungi comprise five widely differing classes of primitive flora, and the variation in cell physiology and biochemistry are extreme. As a result, most antifungal agents have a very narrow spectrum of antifungal activity.
Various imidazoles have been suggested as treatments for prostate cancer. The only one known to the applicants to have been tested is ketoconazole. Ketoconazole is an antifungal agent that, in high doses, inhibits testicular and adrenal synthesis of steroid hormones, including testosterone. The ability of ketoconazole to block steroid synthesis has prompted its use in the treatment of advanced prostate carcinoma because prostate cancer cells are highly dependent on testosterone. The major sites of action appear to be in the inhibition of 17-20 desmolase, partial blockade of 17-hydroxylase and marked inhibition of 21- and/or 11-hydroxylase, all major enzymes of the androgenic hormone synthetic pathways.
In the recent past, newer methods of androgen ablation for the treatment of metastatic prostate carcinoma have been developed as alternatives to the standard forms of therapy: oral estrogens and surgical castration. Luteinizing hormone-release hormone (LHRH) analogs, potent inhibitors of testosterone production, have recently emerged as major players in the long term treatment of advanced prostate cancer. In contrasts, ketoconazole has been found to be excellent for short-term usage prior to bilateral orchiectomy and when prompt therapeutic response is needed but orchiectomy cannot be performed. In high doses, ketoconazole causes castrate levels of testosterone within 24 to 48 hours; therefore, it is extremely useful in the initial medical treatment of patients with metastatic prostate cancer who need a prompt therapeutic response. Thus, ketaconazole has been used as a hormonal adjuvant for prostate cancer treatment; it reduces plasma testosterone to castration levels. Ketoconazole, as will be described below, is not useful for inhibiting endothelial and vascular smooth muscle cell proliferation associated with neovascularization.
SUMMARY OF THE INVENTION
The applicants have identified a new class of potent anti-angiogenesis agents. There agents comprise a particular class of imidazoles that inhibit endothelial and vascular smooth muscle cell proliferation. These imidazoles can be used to beneficially treat a variety of angiogenic conditions, as described below.
According to the invention, a method for treating an angiogenic condition is provided. An imidazole is administered to a subject in need of such treatment. The imidazole is an inhibitor of the Ca ++ activated potassium channel of erythrocytes of the subject. It also is an inhibitor of endothelial and/or smooth muscle cell proliferation. Preferred imidazoles are clotrimazole, miconazole and econazole.
The treatment typically is for tissues or subjects that are otherwise free of indications for the preferred imidazoles. As such, the tissue or subject being treated preferably is substantially free of a fungal infection calling for the treatment of the subject with the imidazoles of the invention.
According to another aspect of the invention, a sustained release implant containing an imidazole as described above is provided. The implant is constructed and arranged for the long-term delivery of the imidazole when implanted in vivo. Sill another aspect of the invention, is a cocktail of anti-cancer agents, including an imidazole as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph illustrating the ability of clotrimazole to inhibit cell proliferation in vascular smooth muscle cells, and the ability to reverse the effects of clotrimazole treatment.
FIG. 2 is a graph showing that clotrimazole inhibits DNA synthesis in a dose-dependent fashion.
FIG. 3 is a graph comparing the effect upon cell proliferation of a variety of drugs.
FIG. 4 is a graph comparing the effect upon the Ca ++ activated potassium channel of the same drugs tested in connection with FIG. 3.
FIG. 5 is a graph illustrating the inhibitory effect that clotrimazole has upon complement-induced release of mitogenic activity from endothelial cells.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is used in connection with treating an angiogenic condition. As used herein, an angiogenic condition means a disease or undesirable medical condition having a pathology including neovascularization. Such diseases or conditions include diabetic retinopathy, psoriasis, neovascular glaucoma, rheumatoid arthritis, cancers that are solid tumors and cancers or tumors otherwise associated with neovascularization such as hemangioendotheliomas, hemangiomas and Kaposi's sarcoma.
Proliferation of endothelial and vascular smooth muscle cells is the main feature of neovascularization. The invention is useful in inhibiting such proliferation and, therefore, inibiting or arresting altogether the progression of the angiogenic condition which depends in whole or in part upon such neovascularization. The invention is particularly useful when that condition has as an additional element endothelial or vascular smooth muscle cell proliferation that is not necessarily associated with the unwanted neovascularization. For example, psoriasis may additionally involve endothelial cell proliferation that is independent of the endothelial cell proliferation associated with neovascularization. Likewise, a solid tumor which requires neovascularization for continued growth also may be a tumor of endothelial or vascular smooth muscle cells. In this case, the tumor cells themselves are inhibited from growing in the presence of the imidazoles used in the invention.
The invention is used in connection with treating subjects having, suspected of having, developing or suspected of developing such conditions. A subject as used herein means humans, primates, horses, cows, pigs, sheep, goats, dogs, cats and rodents.
The compounds useful in the present invention are imidazoles that inhibit the Ca ++ activated potassium channel. Such imidazoles are either known to those of ordinary skill in the art or can be identified without undue experimentation using established tests routinely employed by those of ordinary skill in the art. One such test involves human erythrocytes and is described in the examples, below. When using this test, it is desirable to select imidazoles that are inhibitory to an extent of at least about 75%.
The imidazoles of the invention also inhibit endothelial and/or vascular smooth muscle cell proliferation. Inhibition of such proliferation may be tested without undue experimentation using established tests routinely employed be those of ordinary skill in the art (See examples, below.) The imidazoles used in this invention preferably are inhibitory of endothelial and/or vascular smooth muscle cell proliferation in such tests to an extent of at least about 75%.
It was not expected that inhibitors of the Ca ++ activated potassium channel would inhibit endothelial or vascular smooth muscle cell proliferation. Other specific inhibitors of the Ca ++ activated potassium channel (such as charybdotoxin, kaliotoxin and iberiotoxin) do not inhibit proliferation of endothelial or vascular smooth muscle cells. Moreover, inhibitors of other transport systems that are activated by mitogens, such as ouabain (highly specific inhibitor of the Na/K pump) and amiloride (inhibitor of Na/H exchange) do not inhibit cell proliferation. Thus, the results obtained by the applicants are surprising.
Without limiting the invention to the use of the specific compounds listed, the following is a list of preferred compounds and well-characterized salts thereof useful in the methods of the invention. ##STR1##
The above imidazoles and salts thereof are well recognized, pharmacologically characterized, and licensed for use by the FDA today either as antimycotic agents or antiprotozoal agents. As such, established and empirically documented parameters regarding their limited toxicity and their useful dosages are well described in the scientific and medical literature.
The imidazoles used in the methods of the invention may be administered per se (neat) or in the form of a pharmaceutically acceptable salt. When used in medicine, the salts should be both pharmacologically and pharmaceutically acceptable, but non-pharmaceutically acceptable salts may conveniently be used to prepare the free active compound or pharmaceutically acceptable salts thereof. Pharmacologically and pharmaceutically acceptable salts include, but are not limited to, those prepared from the following acids: hydrochloric, hydrobromic, sulphuric, nitric, phosphoric, maleic, acetic, salicyclic, p-toluenesulfonic, tartaric, citric, methanesulphonic, formic, malonic, succinic, naphthalene-2-sulphonic, and benzenesulphonic. Also, pharmaceutically acceptable salts can be prepared as alkaline metal or alkaline earth salts, such as sodium, potassium or calcium salts of the carboxylic acid group. Thus, the present invention involves the use of pharmaceutical formulations which comprise certain imidazoles together with one or more pharmaceutically acceptable carriers and optionally other therapeutic ingredients. The carrier(s) and other ingredients of course must be pharmaceutically acceptable.
Analogs of the foregoing compounds that act as functional equivalents also are intended to be embraced as equivalents and within the scope of the invention.
A variety of administration routes are available. The particular mode selected will depend, of course, upon the particular drug selected, the particular condition being treated and the dosage required for therapeutic efficacy. The methods of this invention, generally speaking, may be practiced using any mode of administration that is medically acceptable, meaning any mode that produces therapeutic levels of the imidazoles of the invention without causing clinically unacceptable adverse effects. Such modes of administration include oral, rectal, topical, nasal, transdermal or parenteral (e.g. subcutaneous, intramuscular and intravenous) routes. Formulations for oral administration include discrete units such as capsules, tablets, lozenges and the like. Other routes include intrathecal administration directly into spinal fluid and direct introduction onto, in the vicinity of, or within the target cells.
The compositions may conveniently be presented in unit dosage form and may be prepared by any of the methods well known in the art of pharmacy. Such methods include the step of bringing the active imidazole into association with a carrier which constitutes one or more accessory ingredients. In general, the compositions are prepared by uniformly and intimately bringing the imidazole into association with a liquid carrier, a finely divided solid carrier, or both, and then, if necessary, shaping the product.
Compositions of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets, tablets or lozenges, each containing a predetermined amount of the imidazole, in liposomes or as a suspension in an aqueous liquor or non-aqueous liquid such as a syrup, an elixir, or an emulsion.
Compositions suitable for parenteral administration conveniently comprise a sterile aqueous preparation of the imidazole, which is preferably isotonic with the blood of the recipient. This aqueous preparation may be formulated according to known methods using those suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example as a solution in polythylene glycol and lactic acid. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid find use in the preparation of injectibles.
Other delivery systems can include sustained release delivery systems. Preferred sustained release delivery systems are those which can provide for release of the imidazoles of the invention in sustained release pellets or capsules. Many types of sustained release delivery systems are available. These include, but are not limited to: (a) erosional systems in which the imidazole is contained in a form within a matrix, found in U.S. Pat. Nos. 4,452,775 (Kent), U.S. Pat. No. 4,667,014 (Nestor et al.); and U.S. Pat. No. 4,748,024 and U.S. Pat. No. 5,239,660 (Leonard) and (b) diffusional systems in which an active component permeates at a controlled rate through a polymer, found in U.S. Pat. No. 3,832,252 (Higuchi et al.) and U.S. Pat. No. 3,854,480 (Zaffaroni). In addition, a pump-based hardware delivery system can be used, some of which are adapted for implantation.
Use of a long-term sustained release implant may be particularly suitable for treating solid tumors. "Long term" release, as used herein, means that the implant is constructed and arranged to deliver therapeutic levels of the imidazole of at least 30, and preferably 60 days. Such implants can be particularly useful in treating solid tumors by placing the implant near or directly within the tumor, thereby affecting localized, high-doses of the imidazole. Such implants can be especially useful in delivering imidazoles that are not successfuly ingested, or that do not pass biological barriers, such as the blood/brain barrier. They also can be used to avoid undesirable canulation, such as when brain tumors are being treated. Long-term sustained release implants are well known to those of ordinary skill in the art and include some of the release systems described above.
Oral administration for many conditions will be preferred because of the convenience to the patient, although topical and localized sustained delivery may be even more desirable for certain treatment regimens.
The imidazoles, when used in vivo, are administered in therapeutically effective amounts. A therapeutically effective amount means that amount necessary to delay the onset of, inhibit the progression of or halt altogether the onset or progression of the particular condition being treated. Such amounts will depend, of course, on the particular condition being treated, the severity of the condition, and individual patient parameters including age, physical condition, size, weight and concurrent treatment. These factors are well known to those of ordinary skill in the art and can be addressed with no more than routine experimentation. It is preferred generally that a maximum dose be used, that is, the highest safe does according to sound medical judgment. It will be understood by those of ordinary skill in the art, however, that a patient may insist upon a lower dose or tolerable dose for medical reasons, psychological reasons or for virtually any other reasons.
Generally, daily oral doses of active compound will be from about 0.01 milligrams/kg per day to 1000 milligrams/kg per day. Small doses (0.01-1 mg) may be administered initially, followed by increasing doses up to about 1000 mg/kg per day. In the event that the anti-angiogenic response in a subject is insufficient at such doses, even higher doses (or effective higher doses by a different, more localized delivery route) may be employed to the extent patient tolerance permits. Multiple doses per day are contemplated to achieve appropriate systemic levels of compounds.
Cancers treatable according to the invention are nonprostate cancers that are solid tumors. Such cancers include: biliary tract cancer; brain cancer; breast cancer; cervical cancer; choriocarcinoma; colon cancer; endometrial cancer; esophogeal cancer; gastric cancer; intraepithelial neoplasms; liver cancer; lung cancer; lymphomas; neuroblastomas; oral cancer; ovarian cancer; pancreas cancer; rectal cancer; sarcomas; skin cancer; testicular cancer; thyroid cancer; and renal cancer.
As discussed above, proliferation of prostate cancer cells can be hormone (testosterone)-dependent; that is, proliferation of prostate cancer cells can be inhibited or arrested by eliminating the presence of testosterone. One prior art method for eliminating testosterone is by treatment with ketoconazole which blocks testosterone synthesis. Ketoconazole, however, was ineffective in inhibiting the growth of epidermal and vascular smooth muscle cells.
The imidazoles useful in this invention act by a different mechanism of action and are useful in inhibiting the growth of endothelial and/or vascular smooth muscle cells. Unlike ketoconazole, they, therefore, are useful in inhibiting or arresting the growth of solid tumors that do not depend upon the presence of hormone synthesis for proliferation or nonproliferation (i.e., nonhormone-dependent cancers.)
It will be understood by those of ordinary skill in the art that the imidazoles of the invention are also useful in treating prostate cancer patients who have been castrated. Such patients have no source of testosterone and, therefore, no longer have an indication calling for treatment with ketoconozole or any other imidazole according to the teachings of the prior art. If, however, such patients do not respond sufficiently as a result of castration, then the prostate cancer may be treated according to the methods of this invention.
The imidazoles useful in the invention may be delivered in the form of anti-cancer cocktails. An anti-cancer cocktail is a mixture of any one of the imidazoles useful with this invention with another anti-cancer drug and/or supplementary potentiating agent. The use of cocktails in the treatment of cancer is routine. In this embodiment, a common administration vehicle (e.g., pill, table, implant, injectable solution, etc.) would contain both the imidazole useful in this invention and the anti-cancer drug and/or supplementary potentiating agent.
Anti-cancer drugs are well known and include: Aminoglutethimide; Asparaginase; Bleomycin; Busulfan; Carboplatin; Carmustine (BCNU); Chlorambucil; Cisplatin (cis-DDP); Cyclophosphamide; Cytarabine HCI; Dacarbazine; Dactinomycin; Daunorubicin HCI; Doxorubicin HCI; Estramustine phosphate sodium; Etoposide (V16-213); Floxuridine; Fluorouracil (5-FU); Flutamide; Hydroxyurea (hydroxycarbamide); Ifosfamide; Interferon Alfa-2a, Alfa 2b; Leuprolide acetate (LHRH-releasing factor analogue); Lomustine (CCNU); Mechlorethamine HCI (nitrogen mustard); Melphalan; Mercaptopurine; Mesna; Methotrexate (MTX); Mitomycin; Mitotane (o. p'-DDD); Mitoxantrone HCI; Octreotide; Plicamycin; Procarbazine HCI; Streptozocin; Tamoxifen citrate; Thioguanine; Thiotepa; Vinblastine sulfate; Vincristine sulfate; Amsacrine (m-AMSA); Azacitidine; Erythropoietin; Hexamethylmelamine (HMM); Interleukin 2; Mitoguazone (methyl-GAG; methyl glyoxal bis-guanylhydrazone; MGBG); Pentostatin; Semustine (methyl-CCNU); Teniposide (VM-26) and Vindesine sulfate.
Supplementary potentiating agents likewise are well characterized and include: Tricyclic anti-depressant drugs (e.g., imipramine, desipramine, amitryptyline, clomipramine, trimipramine, doxepin, nortriptyline, protriptyline, amoxapine and maprotiline); non-tricyclic anti-depressant drugs (e.g., sertraline, trazodone and citalopram); Ca ++ antagonists (e.g., verapamil, nifedipine, nitrendipine and caroverine); Calmodulin inhibitors (e.g., prenylamine, trifluoroperazine and clomipramine); Amphotericin (e.g., Tween 80 and perhexiline maleate); Triparanol analogues (e.g., tamoxifen); antiarrhythmic drugs (e.g., quinidine); antihypertensive drugs (e.g., reserpine); and Thiol depleters (e.g., buthionine and sulfoximine).
The imidazoles of the invention, when used in cocktails, are administered in therapeutically effective amounts. A therapeutically effective amount will be determined by the parameters discussed above; but, in any event, is that amount which establishes a level of the drug in the area of the tumor which is effective in inhibiting tumor growth.
EXAMPLES
Materials
Abbreviations: ChTX, Charybdotoxin; CLT, clotrimazole; ECZ, econazole; MCZ, miconazole; FCZ, fluoconazole; METZ, metronidazole; IbTX, iberotoxin; KTX, kaliotoxin; DIDS, di-isothiocyano-disulfonyl stilbene; hemoglobin concentration; MCHC, mean corpuscular hemoglobin concentration; MOPS, 3-[N-morpholino]propanesulfonic acid.
Drugs and Chemicals
Synthetic charybdotoxin (ChTX) was purchased from Peptides International (Louisville, Ky.). A23187 was purchased from Calbiochem-Behring (LaJolla, Calif.). Fluconazole was provided by Pfizer Inc., Groton, Conn., disulfonic acid (MOPS), clotrimazole (CLT), miconazole, econazole, metronidazole, and all other drugs and chemicals were purchased from Sigma Chemical Co. (St. Louis, Mo.) and Fisher Scientific Co. (Fair Lawn, N.J.), and the radioisotope 86 Rb from Dupont (Billerica, Mass.)
Assays for Cell Proliferation
DNA synthesis assessed by the uptake of [3H]thymidine: Cells are grown in either 48 or 96 wells plates (Costar, Cambridge, Mass.) at 104 and 0.8 10 3 cells per well, respectively, and grown in Dubelcco's modified Eagle's medium (DME, Gibco, Grand Island, N.Y.) supplemented with 10% heat-inactivated calf serum; they are kept at 37° C. in 5% CO 2 . When they reach confluence, usually between 3 and 4 days, the medium is replaced with DME 0.5% serum to make them quiescent, and mitogenesis assays are performed 24 hours later.
Quiescent cells are exposed to a mitogenic stimulus, such as 10% serum, PDGF (Sigma Co. St. Louis, Mo.), bFGF (Upstate Biotechnologies, Lake Placid, N.Y.), or other appropriate mitogen according to the cell line, and 3 hours later 1 μCi/ml of [3H]thymidine (Dupont, Billerica, Mass. ) is added to the wells, and the cells maintained at 37° C./5% CO2 for additional 21 hours. Then the cells are washed 3 times with DME medium and the acid-precipitable radioactivity is extracted with cold 10% TCA (Sigma, Co). After neutralization with 0.3 N NaOH (Sigma Co.), aliquots are counted in a Packard Tri-Carb Scintillation counter (Packard Instrument, Downer's Grove, Ill.).
Measurement of cell density in culture plates: Cells of a specific test cell line are seeded at precisely the same low density in culture plates and incubated for approximately 12 hours in DME 10% serum, or other culture medium depending on the cell line tested. After 12 hours, the test drug, for example clotrimazole 10 μM, is added to the cell medium of one plate and a similar amount of only the carrier of the drug, for example ethanol 10μl, to another plate. After 48 to 74 hours, the cell density in control (ethanol) and experimental (clotrimazole) plates is assessed under a light inverted microscope, by measuring the surface of the culture plate covered by the cell monolayer. Alternatively, the cells can be detached from the plate by incubation with trypsin (Sigma, Co.) 50% (v/v) in ethylene diaminotetraacetic acid (ECTA; Sigma, Co); then the cells are counted in an hemocytometer chamber (Fisher, Pittsburgh, Pa.).
Assays for Inhibitors of Ca ++ Activated K Channel
Ca ++ -sensitive K+ channels have wide distribution among cells, including the human red cell where they were originally discovered and which is the most commonly utilized assay system for activators and inhibitors of the channel for the following reasons: they are readily available, can be easily manipulated in the laboratory, and transport assays can be accurately standardized by reading the hemoglobin concentration of a red cell suspension.
Preparation of Human Red Blood Cells: Blood is collected in heparinized tubes and centrifuged in a Sorvall centrifuge (RB 5B, Du Pont Instruments, Newtown, Conn.) at 5° C. for 10 minutes at 3000 g. Plasma and buffy coat are carefully removed and the cells washed four times with a washing solution containing 150 mM choline chloride (Sigma Co), 1 mM MgCl2 (Sigma Co),10mM Tris-MOPS (Sigma, Calif.), pH 7.4 at 4° C.(CWS). An aliquot of cells is then suspended in an approximately equal volume of CWS, and from this original cell suspension hematocrit (Hct) and hemoglobin (optical density at 540 nm) are determined.
Methods to Test Inhibitors of the Ca ++ Activated K channel: To test inhibitors of the Ca ++ activated K channel, the channel is activated using the calcium ionophore A23187 (Calbiochem).
By Atomic Absorption Spectrometry: Washed human erythrocyte are suspended at an hematocrit ≃1% in CWS containing 0.150 mM CaCl2 (Sigma Co) Aliquots of 1 ml are removed at 0, 3 and 5 minutes, layered on top of 0.3 ml of the oil n-butyl phthalate (Fair Lane, N.J.) placed in an Eppendorf microtube (Fisher) and then centrifuged in a micro centrifuge for 20 seconds. At time 5.30 minutes, ionophore A23187 (1 μM final concentration) is added and samples removed and spin down through phthalate at times 6, 7, 8 and 9 minutes. The supernatant on top of the oil layer is removed and its K+ concentration is measured by atomic absorption spectrometry using a Perking Elmer model 5000 spectrometer (Perkin Elmer Corp., Norwolk, Conn.). The efflux of K+ (mmol/l cells/h) in the absence and presence of the inhibitor is calculated from the slope of the curves relating the K+ concentration in the supernatants (mmol/l cells) vs. time (min.).
By radioisotopic measurement of 86 Rb influx. The incubation medium is the same but contains 2 mM KCl and 1 μCi/ml of the radioactive tracer 86 Rb. After spinning the samples through the phthalate layer, the tubes are rapidly frozen (-80° C.) by immersion in methanol-dry ice, the tips of the tubes containing the packed red cells cut, and counted in a Packard Gamma Counter.
Example 1
The inhibitory effect of clotrimazole (CLT) on cell proliferation was assessed in normal, non-cancerous cells.
Rat vascular smooth muscle cells (murine cell line): Quiescent cells were stimulated with purified growth factors (PDGF and bFGF, 5 μM) and synthesis of DNA was assessed by the incorporation of [3H]thymidine measured 24 hours later. As shown in FIG. 1, 10 μM CLT completely inhibited both PDGF and bFGF stimulated DNA synthesis. The effect was not due to a toxic, non-specific, effect because it was reversed by removing CLT and re-stimulating the cells with the corresponding growth factor (FIG. 1).
Example 2
Dose response inhibitors of DNA synthesis by clotrimazole was tested using rat vascular smooth muscle cells as described above. Clotrimazole was tested at concentrations of 0.001 μM, 0.1 μM, 1 μM and 10μM. Cells were stimulated using 5 μM bFGF. Inhibition was dose dependent, with 45% inhibition at 1 μM and complete inhibition at 10 μM. The ID 50 was about 1.5 μM. (FIG. 2)
Example 3
Bovine endothelial (BAEC) and human umbilical vein (HUVEC): Cells were seeded at a low density (2.5×10 5 ) in cell culture flasks (75 ml flasks) containing DME 10% calf serum (BAEC) or fetal calf serum (HUVEC); after 12 hs, when the cells were attached to the surface of the flasks, CLT (10 μM) or carrier (ethanol) were added to triplicate flasks. After 48 hs cell growth was assessed by optic miscroscopy calculating the surface of the culture flask covered by the cell monolayer. Both BAEC and HUVEC cells had covered 90±2% of the flask surface in the absence and less than 10% in the presence of CLT (data not shown).
Example 4
Other antimycotics were tested for their inhibition of bFGF-stimulated DNA synthesis in rat vascular smooth muscle cells. As shown in FIG. 3, at a concentration of 10μM, 3 compounds, CLT, econazole (ECZ) and miconazole (MCZ) inhibited DNA synthesis. The order of inhibitory potency was CLT more potent than ECZ, and ECZ more potent than MCZ. In contrast, other inhibitors of the Ca ++ activated K channel, namely Charybdotoxin, kaliotoxin and iberotoxin, also failed to inhibit DNA synthesis.
Example 5
The inhibitory effect of (CLT) on the Ca ++ activated K channel of human erythrocytes was assessed in the presence of 60 μmol A23187/L cell and 100 μMCaCl 2 . CLT markedly inhibited the CA ++ activated 86Rb influx and K efflux. Mean values of ID50 (calculated with Dixon plot analysis) was 143±60 nM(n=3).
Other antimycotics were tested for their inhibition of the Ca++ activated 86Rb influx human erythrocytes. The order of inhibitory potency was clotrimazole more than miconazole; and both of these were more than econazole. There was no inhibition by fluconazole, ornidazole and tinidazole, 2 related compounds, and only marginal with mitronidazole a member of the nitroimidazole group (FIG. 4).
Example 6
CLT inhibits the mitogenic activity released from endothelial cells by activated component. When endothelial cells (EC) in culture (both BAEC and HUVEC) are treated with terminal complement components to form the MAC (membrane attack complex of complement), they release into the culture medium a potent mitogenic activity that stimulates the proliferation of quiescent cells used as indicators of the mitogens. Both, quiescent Swiss 3T3 and vascular smooth muscle cells are stimulated by the mitogens released form EC in response to the MAC (FIG. 5; Halperin et al. unpublished observation). Moreover, immunoprecipitation with specific antibodies has documented that both PDGF and bFGF released from the EC contribute in approximately equal proportion to the mitogenic activity induced by the MAC (data not shown).
To determine whether CLT inhibited the cell proliferative activity released by the MAC from EC, quiescent 3T3 and vascular smooth muscle cells were stimulated in the presence and absence of 10 μM CLT with conditioned media obtained from MAC treated EC. The results indicate that CLT completely inhibited the proliferative response to mitogens released from EC (FIG. 5).
Those skilled in the art will be able to ascertain with no more than routine experimentation numerous equivalents to the specific imidazoles and processes described herein. Such equivalents are considered to be within the scope of the invention and are intended to be embraced by the following claims in which | The applicant has identified a particular class of imidazoles that inhibit anglogenesis. These imidazoles can be used to beneficially treat a variety of angiogenic conditions. | 0 |
RELATED APPLICATION
This application is a divisional, and claims priority benefit with regard to all common subject matter, of U.S. patent application Ser. No. 11/278,793, filed Apr. 5, 2006, entitled “MEMORY FOAM SHOE INSERT,” which is now U.S. Pat. No. 7,827,707, issued Nov. 9, 2010. The above-identified, earlier-filed patent is hereby incorporated by reference in its entirety into the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is broadly concerned with shoe inserts and methods of use thereof. More particularly, the present invention concerns a shoe insert formed of memory foam and dimensioned to fit within the toe region and be compressed by at least some of the toes of the wearer so as to provide increased shoe comfort. In preferred forms, the insert body is initially of generally quadrate pillow-like form, which can be readily cut or otherwise sized to complement the toe region of desired shoe.
2. Description of the Prior Art
Shoe inserts designed to provide greater comfort during the wearing of shoes have long been provided. Most inserts of this character are formed of resilient foams or gel materials, and are of the full-sole type, meaning that they are placed within a shoe and extend the full length thereof, from toe to heel. However, these types of inserts provide no direct cushioning engagement with the forward surfaces of the wearer's toes, and in effect leave vacant the region between the wearer's toes and the extreme forward toe region of the shoes. This problem is magnified with some women's high-heel shoes having a sharply pointed toe region, such that the toes can experience an extreme amount of pressure.
Children's shoes are also problematic. In particular, children's shoes are often purchased larger than needed so that the child has opportunity to “grow” into the shoes. Oversized shoes are often loose and can cause, among other things, tripping, shuffling, etc.
Specialized shoe inserts have also been provided for dancing slippers or toe shoes, see U.S. Pat. Nos. 4,026,046 and 5,129,165. However, these types of inserts are not principally designed to give shoe comfort, but are used to facilitate toe dancing. For example, the '165 patent describes custom toe caps for ballerina pointe shoes, wherein the inserts are formed of dimensionally stable material affording no floating or distortion of the material during use. Silicone rubber-based compounds are used for this purpose. Similarly, in the '046 patent, a dancing slipper is described having a pre-molded toe insert which is initially shaped by placing the insert in boiling water.
Published Patent Application 2005/0115106 describes a full-length shoe insert used for determining whether a child's foot has outgrown a shoe. The insert is formed of a material (e.g., leather), which is marked by perspiration to show the child's foot placement within the shoe.
Heat-sensitive viscoelastic memory foams were first developed in conjunction with NASA's space programs. Such materials have the ability to conform with human body parts owing to body temperatures and pressure. Memory foams of this type have been adapted for use with beds as mattresses and mattress toppers.
SUMMARY OF THE INVENTION
The present invention provides improved resilient inserts for placement within the toe regions of shoes in order to give enhanced comfort during shoe wear. According to one aspect of the present invention, a shoe and a resilient shoe insert are provided. The shoe includes a sole and a shoe upper, which cooperatively present a substantially enclosed toe region having an open cross-sectional dimension. The insert is located within the toe region and comprises an insert body formed of memory foam. The insert body presents a shape that generally corresponds with a portion of the toe region. The insert body includes a proximal toe-engaging face that substantially spans the cross-sectional dimension, with toe-engaging face being positioned so that the insert body is compressed by at least some of the toes of a wearer of the shoe.
According to another aspect of the present invention, a shoe insert comprises a substantially quadrate body formed of heat-sensitive, viscoelastic polyurethane memory foam. The body has a length of from about two to four inches, a width of from about three-quarter to one and one-half inches, and a maximum thickness of from about one-quarter to three-quarter of an inch. The body is severable to present a preformed and pre-sized insert body adapted to be placed within the toe region of a shoe.
Yet another aspect of the present invention concerns a method of increasing the comfort of a shoe during wearing thereof, wherein the shoe presents a substantially closed toe region having a cross-sectional dimension. The method includes the step of providing a shoe insert body formed of memory foam, with the insert body including a proximal toe-engaging face dimensioned to substantially span the cross-sectional dimension of the toe region. The method also involves the step of placing the insert body within the toe region of the shoe, with the toe-engaging face directed proximally. Additionally, the method involves the step of donning the shoe so that at least some of the toes of the wearer come into contact with the toe-engaging face and compress the insert body.
In order to afford maximum flexibility in use, it is preferred that the insert bodies be initially in the form of small, substantially quadrate bodies having a configuration similar to that of a conventional bed pillow. The bodies are severable by hand scissors or other means in order to give preformed and pre-sized toe insert bodies. Similarly, the preferred use of the inserts involves providing initially quadrate bodies that are cut as necessary to provide inserts for the toes of particular shoes, and the pre-cut insert bodies are placed within the shoe toe regions. The memory foam preferably comprises heat-sensitive, viscoelastic polyurethane. Consequently, when the shoes are donned, the toe inserts are caused to deform under the conditions of temperature and pressure within the shoes so that the insert bodies substantially conform with at least some of the wearer's toes.
Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is a front elevational view of a shoe insert constructed in accordance with a preferred embodiment of the present invention, particularly showing the insert within a retail package before it has been dimensioned for the toe region of a particular shoe;
FIG. 2 is an elevational view of the shoe insert as depicted in FIG. 1 , with the inner memory foam insert body being shown partly removed from the external separable fabric casing;
FIG. 3 is a perspective view of a preferred memory foam insert body removed from the casing and prior to dimensioning by the wearer;
FIG. 4 is a side view of the insert body depicted in FIG. 3 ;
FIG. 5 is a plan view of the insert body depicted in FIGS. 3 and 4 , shown with an exemplary diagonally extending cut line for initial cutting and shaping of an insert to be located within a shoe;
FIG. 6 is a top view in partial vertical section of a woman's shoe, illustrating the placement of the initially cut and shaped insert body;
FIG. 7 is a view similar to that of FIG. 6 , but showing the insert during use thereof, while the shoe is worn;
FIG. 8 is a top view and partial vertical section of a different type of shoe, with a pre-cut and shaped insert located with the toe region of the shoe;
FIG. 9 is a view similar to that of FIG. 8 , but showing the insert during use thereof, while the shoe is worn;
FIG. 10 is a view in partial vertical section of an oversized shoe for a growing child, with an insert body having its original pre-cut dimensions when the shoe if first worn by the child;
FIG. 11 is a view similar to that of FIG. 10 , but showing the child's foot after some growth and the insert body having been cut to a smaller size to accommodate such growth;
FIG. 12 is a view similar to that of FIGS. 10 and 11 , showing the shoe without the insert after the wearer has grown into the initially oversized shoe.
The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, the shoe insert 20 (see FIGS. 1-5 ) selected for illustrated comprises an initial, generally quadrate body 21 , but is designed to be cut or otherwise severed to form a shoe insert body 22 (see FIGS. 6 and 7 ). In more detail, the initial quadrate body 21 is of substantially rectangular plan configuration, presenting a continuous peripheral edge 24 as well as a rounded, somewhat bulbous mid-section 26 . Thus, the body 20 is substantially pillow-shaped in configuration, with an outwardly tapering margin. However, other suitable body shapes and configurations are entirely within the ambit of the present invention (e.g., the body 21 could alternatively have a triangular shape, a purely rectangular non-tapering shape, or the shape of the desired insert body 22 ).
In preferred forms, the shoe insert 20 , as sold on a retail level, includes an open-ended fabric casing 28 for receiving the initial quadrate body 21 so as to present the appearance of a standard bed pillow. It is also contemplated that the body 21 and casing 28 be supported on a hang card 30 with a transparent blister-pack attachment 32 securing the body and casing in place. Of course, when it is desired to use the insert 20 , it is removed from the packaging 30 , 32 , and the initial body 21 is removed from the casing 28 (as illustrated in FIG. 2 ). Those ordinarily skilled in the art will appreciate, however, that such packaging is not required and multiple shoe inserts may alternatively be provided (instead of just one).
The body 21 preferably comprises (and more preferably consists essentially of) memory foam material. Most preferably, the memory foam is a heat-sensitive, viscoelastic, closed-cell polyurethane material, operable to react to body heat and mold itself to a body part shape. Advantageously, the memory foam should have a density of from about one to five pounds and, more preferably, about three pounds, using industry standards for such foam densities.
FIGS. 6-7 depict the use of shoe insert 20 in forming a resilient shoe insert body 22 . Specifically, the shoe 34 in this case is a standard woman's high-heeled shoe (e.g., with a heel having a height of at least about one and one-half inches) having a sole 35 and a shoe upper 36 . The sole 35 and upper 36 cooperatively present a substantially pointed and enclosed forward toe region 37 . It is particularly noted that the toe region 37 presents a cross-sectional dimension (defined by the sole 35 along a lower margin and the upper 36 along the top and side margins), which tapers distally. As will be apparent, this shoe design is relatively standard and, more specifically, provides an area of the toe region which is typically “unoccupied” by the toes of the wearer. Furthermore, the toes are often caused to conform to the distally tapering configuration of the toe region 37 , particularly when the shoe has a high heel (which causes the foot to be forced distally within the shoe).
In use with the shoe 34 , the original quadrate body 21 is cut diagonally along line 38 (see FIG. 5 ) to yield the insert body 22 (see FIGS. 6 and 7 ). It is particularly noted that the insert body 22 has a shape generally corresponding to a portion of the toe region 37 . This portion preferably consists of slightly more than “unoccupied” part of toe region 37 so that insert body 22 is engaged by the toes without crowding the toes or requiring significant compression of the body 22 . It is also noted that the toe region has a proximal boundary that terminates around the ball of the wearer's foot, and the insert body 22 is spaced distally from the proximal boundary of the toe region 37 when in use. More specifically, the insert body 22 has a proximal (or rearmost) toe-engaging surface 40 , which corresponds with the bisectional line (or cut line) of the original quadrate body 21 in the preferred embodiment. The illustrated toe-engaging surface 40 is substantially flat, although other suitable shapes (e.g., curved, grooved to conform more closely to the shape of the toes, etc.) are entirely within the ambit of the present invention. Moreover, the toe-engaging surface 40 spans the corresponding cross-sectional dimension of the toe region 37 . In other words, the insert body 22 is preferably dimensioned and configured so that the toe-engaging surface is generally coextensive with the cross-sectional dimension of the toe region 37 , with the body 22 being in substantially continuous contact (or at least close proximity) with the sole 35 and upper 36 . Furthermore, the preferred toe-engaging surface 40 is angled to project proximally more along the laterally outer margin of the shoe, which ensures contact with the smaller toes of the wearer.
It will be appreciated that the body 20 may be cut with manual scissors or through the use of a utility knife or other suitable means. Furthermore, certain aspects of the present invention encompass a shoe insert comprising an insert body that is already dimensioned for use, so that no cutting or sizing by the user is required. In any case, the insert body 22 is inserted within shoe 34 and pressed forwardly as indicated by arrow 42 ( FIG. 6 ) so that a corner apex 44 of the body 22 is positioned in close conforming relationship to the forward extent of toe region 37 . The resilient and pliable nature of the memory foam material making up the insert 22 allows the latter to closely conform with the toe region, as illustrated in FIG. 7 .
When the wearer dons shoe 34 , the toes 46 of the wearer come into direct abutting contact with the toe-engaging surface 40 of body 22 . The normal body temperature of the wearer, together with the sustained forces imposed on insert 22 , cause the latter to closely conform with the wearer's toes, as illustrated by the undulating shape 48 assumed by the surface 40 . It will be observed in this respect that the rear surface 40 of the insert 22 is substantially within the toe region 37 and in any case does not extend to a point where contact is made with the ball of the user's foot. In preferred forms, substantially the entirety of the insert 22 is positioned forwardly of the wearer's toes 46 , and does not extend beneath the toes.
FIGS. 8-9 illustrate another type of shoe 50 , in this case a man's slip-on shoe having a substantially blunt or flattened toe region 52 . In such a situation, the original quadrate body 20 is cut to present a flattened proximal (or rear) surface 54 , thereby giving an shoe insert 56 optimally designed for the shoe 50 . As illustrated, the insert 56 and surface 54 are aligned with the natural placement of the wearer's toes 58 when the shoe 50 is donned. Again, over a short period of time after donning, the surface 54 assumes an undulating configuration 60 in close conforming relationship with the forward extent of the wearer's toes.
A principal aim of the invention is to provide increased comfort during shoe wear, by providing an improved viscoelastic shoe toe insert. For example, some activities involve use of “undersized” shoes and the insert can be used to provide comfort in these extreme conditions. One such example involves ski boots worn by competitive or performance skiers. Skiers will often wear ski boots that are as much as several sizes smaller than their normal size, and the insert will facilitate comfort of the toes during use.
Another preferred embodiment of the present invention is depicted in FIGS. 10-12 . In particular, children's shoes are often purchased one to two sizes too large so that the child is permitted to “grow” into the shoe. As depicted, the child's shoe 62 is initially oversized by a size or two (see FIG. 10 ). The original quadrate body 21 is cut to provide the shoe insert body 63 conforming with the rounded toe region 64 of the shoe 62 (which may require multiple cuts). In this embodiment, the insert body 63 has a rearmost arcuate toe-engaging surface 66 best seen in FIG. 10 , which is engaged by the wearer's toes 68 when the shoe 62 is donned. Thereafter, the surface 66 assumes the undulate shape 70 in close conforming relationship with the forward surfaces of the user's toes 68 . As the user grows into the shoe 62 , the insert 63 may be resized, which preferably involves removing and trimming the insert body 63 to a new smaller size as depicted in FIG. 11 . Trimming of the insert body 63 is preferably accomplished by cutting the body 63 along its proximal margin so that a proximal portion is removed and a new toe-engaging surface 71 is defined. Furthermore, once the child has grown into the shoe 62 , the insert body 63 can be completely removed and the shoe may be conventionally worn ( FIG. 12 ). Thus, the insert of the invention allows a youth to comfortably wear what would normally be considered oversized shoes, until the youth grows into the shoes.
The preferred forms of the invention described above are to be used as illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventor hereby states her intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims. | Improved shoe inserts ( 22, 56, 63 ) are provided which are designed for placement within the toe regions ( 37, 52, 64 ) of shoes ( 34, 50, 62 ) to provide enhanced comfort to the shoe wearers. The inserts ( 22, 56, 63 ) are preferably cut from initial pillow-shaped bodies ( 20 ) to give the custom-designed inserts ( 22, 56, 63 ). The inserts ( 22, 56, 63 ) are designed to substantially occupy the distal end of the shoe toe region and present a proximal toe-engaging face that substantially spans the cross-sectional dimension of the toe-region. The inserts ( 22, 56, 63 ) are preferably formed of heat-sensitive, viscoelastic, polyurethane foam material. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part from U.S. patent application Ser. No. 08/618,319, Mar. 19, 1996.
FIELD OF THE INVENTION
This invention relates generally to a product cutter utilizing a high pressure fluid jet, and more particularly, to methods and apparatus for selectively interrupting the flow of a stream of high pressure water used to cut products.
BACKGROUND OF THE INVENTION
Fluid jets have been used to cut food, paper and other products for years. The advantages are numerous: there are no blades that need to be sharpened or replaced, no dust is created, and cuts can be quick and clean. The cutting is done with a thin, high pressure, high velocity stream of water or other fluid. Pressurized water is ejected from a very small orifice to create the jet. When the jet touches the product, a thin slice is removed without any appreciable water being absorbed into the product.
Specific manipulation of the flow of fluid emanating from the water jet accurately cuts shapes in the products. Many of the shapes desired require precise high speed interruption of the water jet. The greater the detail of the desired shape of the product, the faster the interruption of the jet must be in order to attain such detail. Also, a higher rate of interruption results in less processing time.
Various ways have been taught to interrupt the water jet at high speeds. One such method of interruption is that of inserting an object between the source of the high speed water jet and the product. A linear actuator pressurized by air that forces a plunger pin into the path of the water jet is a generally known tool for performing this method. A spring provides a retracting force for the plunger pin. Existing plunger pin devices are capable of reaching closure times of 50-90 ms and thereby limit the speed at which products may be cut by the water jet.
U.S. Pat. No. 4,693,153 (Wainwright et al.) discloses another water jet interruption technique. When interruption of the object cutting jet is desired, a second high pressure fluid is directed at the object cutting jet so as to disperse the latter and impair its object cutting properties. The device that controls the second fluid flow is similar to the plunger pin device. A solenoid device within the jet obstructer device controls the fluid flow from the jet obstructer device. An energized solenoid closes a plunger mechanism that is normally held in an open position by a spring. In the open position the mechanism provides high pressure fluid to interrupt the object cutting water jet. Similar to the plunger pin device, this device also lacks the high speed interruption capabilities necessary for cutting products as rapidly as may be desired.
International application number WO93/10950 discloses a valve for controlling a constantly running liquid cutting jet. A pneumatically powered rotary cylinder 2 is attached to one end of and elongate plate 1 to rotate the opposite end of the plate in and out of the path of flow of the liquid cutting jet. However, the opening and closing times for this rotary plate are only slightly better than that of existing plunger pin devices. Also, the cutting jet strikes one position on the plate resulting in frequent replacement of the plate.
The prior art described above fails to address the issue of efficient removal of deflected cutting fluid for avoiding absorption into the product. Also the issue of high temperature caused by high speed operation is not addressed. Consistent high temperatures will cause premature failure of the valve device.
The devices currently in use, as exemplified by those described above, do not effectively and efficiently solve the problem of cutting precise shapes at high speeds that require a high frequency of water jet interruption. Accordingly, the present invention was developed, and provides significant advantages over previous devices or methods to cut shapes with fluid jets.
SUMMARY OF THE INVENTION
In accordance with this invention, a method and apparatus for controlling the flow of a stream of high pressure fluid used for cutting an object is disclosed. The apparatus includes a main housing with a blocking device and a rotary actuator disposed within. The rotary actuator generates a rotary output torque. The apparatus also includes a coupling mechanism that provides a couple between the blocking device and the rotary actuator to transmit the rotary output torque from the rotary actuator to the blocking device to cause the blocking device to shift into the path of travel of the stream of high pressure fluid to disrupt the flow of the high pressure stream and out of the path of the high pressure fluid to not disrupt the flow of the high pressure stream.
In accordance with further aspects of this invention, the blocking device is a rod and the coupling mechanism couples one end portion of the rod to the rotary actuator.
In accordance with still further aspects of this invention, a support pivot supports the rod, wherein the support for the rod is disposed with the housing between the path of travel of the stream of high pressure fluid and the rod's connection to the coupling mechanism.
In accordance with yet other aspects of this invention, the rod is adjustable orthogonally to the flow of the high pressure stream. Also, the rod is removable from the housing and rotatable within the housing.
In accordance with other aspects of this invention, the rotary actuator toggles to predefined limits that are controlled by a controlling mechanism.
In accordance with other aspects of this invention, high pressure air is directed past the rotary actuator for cooling the rotary actuator. The directed high pressure air is further directed to expel fluid from the housing remaining from the disrupted flow of the high pressure stream.
As will be readily appreciated from the foregoing summary, the invention provides a new and improved method and apparatus for controlling the flow of a stream of high pressure fluid used for cutting. Because the method and apparatus does not require the use of a plunger pin device, the disadvantages associated with the use of connectors, briefly described above, are avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1A and 1B are horizontal cross-sectional views of a preferred embodiment of the present invention;
FIG. 2 is a vertical cross-sectional view of FIG. 1A taken substantially along lines 2--2 thereof;
FIG. 3 is a block diagram of the present invention;
FIG. 4 is a plan view of a further preferred embodiment of the present invention;
FIG. 5 is a cross-sectional view of FIG. 4 taken substantially along lines 5--5 thereof; and
FIG. 6 is an end view of the embodiment of the present invention shown in FIGS. 4 and 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A first preferred embodiment of the present invention is illustrated in FIG. 2. The high speed water jet blocker 10 includes a main housing 18, with a projecting portion 16. The main housing 18 and the projecting portion 16 include cavities with a connecting passageway for housing a rotary actuator 32, a blocking bar 22, an output shaft 30, a pivot arm 28, vertical pins 26 and a collar 24b. The main housing 18 and projecting portion 16 are preferably composed of a high density plastic, such as Delrin®. For the purposes of this detailed description, the high speed water jet blocker 10 shown in FIG. 2 is in an upright position with a top and bottom where the projecting portion 16 of the water jet blocker 10 is attached to and flush with the base of the main housing 18. Also, the views of FIGS. 1A and 1B are toward the bottom of the water jet blocker 10.
Within projecting portion 16 is a downwardly extending counterbore cavity 19 that opens at the top of the projecting portion 16. The open upper end of the counterbore cavity 19 receives a nozzle 14 attached to the discharge end of a high pressure water line (not shown). The nozzle 14 supplies (discharges) a very fine, high pressure, high speed fluid or water jet 12 in a vertically descending direction into counterbore cavity 19. A small opening 20 at the base of counterbore cavity 19 provides an opening for the high speed water jet 12 to exit projecting portion 16 for the purpose of cutting products located below the blocker 10. Small opening 20 is large enough to avoid interfering with the flow of water jet 12. Also, a disk-shaped carbide insert 23 surrounds small opening 20, protecting it from wear due to high pressure deflected fluid.
Also located within counterbore cavity 19 of projection portion 16 is the distal end of a pivotal blocking bar 22. The pivotal blocking bar 22 has two operational positions within the counterbore cavity 19. As shown in FIG. 1A, the first operational position is a water jet blocking or interrupting position. Blocking bar 22 provides interruption of the flow of the water jet 12 because of its location over small opening 20. As shown in FIG. 1B, the other operational position is a cutting position since blocking bar 22 is dislocated laterally from small opening 20 thereby providing an uninterrupted flow of water jet 12.
As shown in FIG. 1A, a lateral passageway 24a creates a path from the counterbore cavity 19 to a lower cavity 25 within main housing 18. Lower cavity 25 creates an opening at the base of main housing 18 and extends vertically to a level higher than passageway 24a, but lower than the top of projecting portion 16, as shown in FIG. 2. Blocking bar 22 is disposed within passageway 24a and supported by a collar 24b to extend into lower cavity 25. Collar 24b is preferably composed of stainless steel and press fit within the passageway 24a. An O-ring seal 24c is used to prevent water from entering lower cavity 25. The O-ring seal is seated within a groove formed in the internal diameter of the collar 24b. The internal ends of the collar 24b are beveled allowing the bar to pivot freely side-to-side, as discussed more fully below, without interference with the collar.
The proximal end of blocking bar 22 that extends into the lower cavity 25 extends between a pair of spaced apart pins 26 extending transversely downwardly from the distal end of a pivot arm 28. The proximal end of pivot arm 28 is securedly connected to an output shaft 30. As shown in FIG. 2, output shaft 30 extends through a vertical opening 31 at the top of lower cavity 25 from a rotary actuator 32 contained in an upper cavity 33 formed within main housing 18. The upper cavity has a base that is approximately at the same vertical elevation as the top of projecting portion 16. The upper and lower cavities are approximately equal in diameter and both have a larger diameter than the diameter of counterbore cavity 19. Also, upper cavity 33 is open at the top of main housing 18. Both cavity openings are closed by corresponding cavity caps 39.
As shown in FIG. 1A, the output shaft 30, pivoted by the rotary actuator 32, is at a maximum counter-clockwise position. When the output shaft 30 of rotary actuator 32 is in such maximum counter-clockwise position, pivot arm 28 is also at a maximum counter-clockwise position, thereby pivoting the blocking bar 22 in a clockwise direction about collar 24b to block the flow of water jet 12. As shown in FIG. 1B, rotary actuator 32 rotates the output shaft 30 and pivot arm 28 to a fully clockwise position. Correspondingly, the blocking bar 22 is pivoted in a counter-clockwise direction about collar 24b, thereby retracting the blocking bar 22 out of the path of the water jet 12 to allow the water jet to flow through the water jet blocker 10. The total range of rotation of the output shaft 30 and pivot arm 28 is approximately forty-five degrees with somewhat equal rotation relative to a longitudinal centerline 46 extending between the centers of small opening 20 and output shaft 30. As shown in FIGS. 1A and 1B, the longitudinal centerline 47 of passageway 24a is offset slightly from longitudinal centerline 46. Passageway 24a is offset so blocking bar 22 covers small opening 20 when the output shaft 30 and pivot arm 28 are in the fully counter-clockwise position and so blocking bar 22 does not block small opening 20 when the output shaft 30 and pivot arm 28 are in the fully clockwise position.
An exhaust port 44 provides a lateral opening from counterbore cavity 19 at a position on the counterbore cavity 19 diametrically opposed from passageway 24a. The base of exhaust port 44 is shown at the same elevation as blocking bar 22. Exhaust port 44 provides a route for fluid to escape counterbore cavity 19 during water jet interruption.
A further aspect of the present invention is illustrated in FIGS. 1A, 1B and 2. An annular cavity 40 is defined by the internal diameter of the upper cavity 33 and a metallic sleeve 43. Ideally the sleeve 43 is composed of aluminum or similar metal. Sleeve 43 includes a cylindrical body portion 43a and upper and lower flanges 43b and 43c that extend radially outwardly from the upper and lower ends of the sleeve. The sleeve body portion 43a snugly surrounds the lower portion 41 of the actuator, and the outer circumferences of the flanges 43b and 43c snugly engage against the inner surface of the main housing 18 that defines the outer diameter of the annular cavity 40. It will be appreciated that the upper, lower and inner walls of annular cavity 40 are formed by the flanges 43b and 43c and body portion 43a, respectively, of the sleeve 43. Also, sleeve 43 occupies the space in upper cavity 33 below an upper portion of rotary actuator 32 not occupied by the lower portion 41 of rotary actuator 32 and annular cavity 40.
An inlet port 38 leads into the annular cavity 40, and a pair of outlet ports 35a and 35b leads away from annular cavity 40. The input port 38 is located at the lower portion of the annular cavity 40 along longitudinal centerline 46. Input port 38 is connectable to a pressurized air source. Also, input port 38 is located on the main housing 18 distally opposed from projecting portion 16.
Exhaust ports 35a and 35b are located approximately equidistant from longitudinal centerline 46. The exhaust ports connect to air passageways 42a and 42b leading between annular cavity 40 and counterbore cavity 19. Air passageways 42a and 42b extend down main housing 18 angled slightly towards projecting portion 16. Within projecting portion 16, air passageways 42a and 42b extend horizontally at an elevation approximately equal to the elevation of passageway 24a. The horizontal sections of the air passageways 42a and 42b angle toward the center of counterbore cavity 19 to deliver, through openings in counterbore cavity 19, high pressure air on either side of blocking bar 22. When an air source is attached, pressurized air follows air path 36 and enters inlet port 38, travels through annular cavity 40, exits through exhaust ports 35a and 35b, travels through passageways 42a and 42b, and enters counterbore cavity 19 to blow excess or deflected fluid out of counterbore cavity 19 through exhaust port 44. Pressurized air continuously flows thus providing a cooling effect on sleeve 43 which conducts heat away from rotary actuator 32.
As noted above, sleeve 43 in addition to defining portions of annular cavity 40, also serves to seal the lower portion 41 of the rotary actuator 32 from moisture. Such moisture may be latent within the air supplied to the jet blocker 10 through input port 38. Also, the moisture may originate from the water jet 12 and may "back up" into the cavity 40 through the air passageways 42a and 42b and exhaust ports 35a and 35b.
Rotary actuator 32 is a device that converts electric energy into a controlled rotary force that is quickly reversible in the rotary direction. The rotary actuator can pivot the pivot arm 28 into the path of the water jet 12 and reverse direction to retract the pivot arm out of the path of the water jet in as little as 5-6 milliseconds. Electrical energy is provided to a rotary actuator 32 from a power supply through power cord port 37 located above input port 38, as shown in FIG. 2. The water jet blocker 10 is controlled by and used in various systems. As shown in FIG. 3, the present invention uses some form of processing unit or computer 49 to supply the rotary actuator 32 with a controlled electrical energy supply. Processing unit 49, with predefined routines, controls an electrical signal sent to rotary actuator 32, thereby controlling the cutting pattern of water jet blocker 10. Multiple water jet blockers can be used in conjunction with a computer controller for performing simultaneous high speed interactive cuts.
Some systems that incorporate the blocking device of the present invention are designed to operate continuously or with very little down time thereby requiring a cutting device with effective and efficient maintenance. Due to the destructive force of high speed water jet 12, blocking bar 22 is eventually eroded away, thereby reducing the efficient feature of the system. One solution is a bar adjustment mechanism 27 and 29 within the water jet blocker 10. A knurled lead screw 29 controls the longitudinal position of an adjusting backstop 27. As shown in FIGS. 1A, 1B and 2, screw 29 is sealed with respect to housing 18 by an O-ring in a through hole located below input port 38 at approximately the elevation center of lower cavity 25. Also, the thread, leading portion of screw 29 extends into lower cavity 25 to a position free from interfering with pivot arm 28.
Backstop 27 is positioned within lower cavity 25. The backstop includes a rear portion that includes an upwardly extending abutment wall having a threaded opening formed therein to receive the complementarily threaded lead portion of screw 29. The backstop also includes a front or leading end that abuts against the proximal (rear) end of blocking bar 22. Rotation of screw 29 adjusts the longitudinal (forward and rearward) position of backstop 27, thereby correspondingly adjusting the longitudinal position of blocking bar 22. Adjustment of the longitudinal position of the bar within the blocker 10, provides multiple water jet contact locations along the length of the bar, effectively delaying failure of the bar.
Another solution is a quick and efficient bar rotation or removal. Under normal operating conditions, blocking bar 22 maintains its longitudinal as well as its rotational position relative to water jet 12. This lack of "walking" movement of the bar causes water jet 12 to consistently strike blocking bar 22 at the same spot on the bar. As can be appreciated, eventually the water jet 12 erodes away enough of the bar 22 to cause the bar to sever or otherwise fail. Quick and convenient rotation of the bar provides extended bar life, thereby improving the maintainability of the bar.
Bar composition is also important in reducing maintenance time. The bar could be composed of titanium, carbide or a memory alloy such as a nickel-titanium, all of which are highly resistant to erosion by the high pressure water jet. The bar alternatively could be composed of a carbide core covered with a stainless steel or other alloy cover sized to impose a high compressive load on the core. Applicants have found that although the stainless steel cover may erode rather quickly, the loaded carbide core is highly resistant to erosion, much more so than if the stainless steel cover were not used. Alternatively, a very hard substance, such as a natural or synthetic diamond, could be inlayed into the blocking bar to serve as a wear surface.
FIGS. 4-6 illustrate a further embodiment of the present invention in the form of water jet blocker 10'. The components of the present invention shown in FIGS. 4-6 that correspond to those components shown in FIGS. 1A, 1B, and 2 are identified with the same part number but with the addition of prime (') designations. Also, the following description focuses on the differences between the embodiment shown in FIGS. 4-6 from that shown in FIGS. 1A, 1B, and 2, and thus not all aspects of the present invention shown in FIGS. 4-6 will be described in the same detail as described above with respect to FIGS. 1A, 1B, and 2.
Referring initially to FIGS. 4 and 5, a flange connector 52 is used to attach a high pressure nozzle, not shown, to housing portion 16'. The connector 52 has a pair of diametrically opposed wing portions 54 having slots 56 formed therein for engaging screws 58 extending downwardly into the housing portion 16'. The heads of the screws bear against the upper surface of wing portions 54 to thereby securely hold the flange connector 52 locked in place. Of course, other methods could be used to attach the nozzle to the housing.
A cup 62 snugly engages within a vertical bore formed through housing portion 16'. The cup 62 defines an interior cavity 19' through which the high speed water jet 12' enters and exits when not blocked. The cup 62 includes a cylindrical portion that extends vertically through the projecting portion 16'. The cup also includes an upper annular flange 64 having an upwardly open groove formed therein for receiving an O-ring 66 to form a water tight seal between the under side of the flange portion of connector 52 and cup 62. The cup 62 also includes a bottom floor 68 formed with a small diameter central opening 20 in alignment with the central vertical axis of the flange connector 52, which is in alignment with the center of the path of the water jet 12' entering the apparatus of the present invention. An annular ring 72 extends downwardly from the under side of cup floor 68, with a counter bore 74 being formed therein of a size larger than the diameter of the central opening 70. Ring 72 serves as a drip guard to prevent moisture on the exterior of housing portion 16' from dripping into the path of travel of water jet 12' thereby interfering with or disrupting the flow of the water jet.
A circular support and wear plate 76 fits within a shallow counter bore formed in the upper side of cup floor 68. An O-ring 78 is positioned within the counter bore to provide a seal with the under side of the wear plate 76, and also compensates for minor misalignments between the upper surface of the wear plate and the lower, flat surface 79 of the blocking bar 22' thereby to provide a substantially full face-to-face mating between the wear plate and the blocker bar lower surface. A small diameter central opening 80 is formed in the wear plate 23' through which the water jet 12' passes when in unblocked condition. Ideally cup 62 is composed of a hardware resistant non-corroding material, such as stainless steel.
As with blocking bar 22 described above, blocking bar 22' is supported for pivotal or toggle movement at a location intermediate its ends by a collar 24b' positioned within lateral passageway 24a'. The collar 24b' is generally triangularly shaped in cross-section, as shown in FIG. 5. Ideally, the collar 24b' is composed of a hard wear-resistant material, such as stainless steel. An O-ring seal 24c' is disposed within a groove extending around the inside diameter of the collar 24b' to seal against the outer diameter of the blocking bar 22'. However, it will be appreciated that the shape of the collar 24b' allows the blocking bar 22' to pivot freely side-to-side, and the O-ring seal 24c' allows the blocking bar to shift lengthwise, as discussed below.
The distal end portion of the blocking bar 22' engages through an opening formed in the side wall of cup 62, thereby to extend into the interior of the cup. Although the portion of the blocking bar 22' engaged through a collar 24b' is formed with a circular exterior diameter, the distal end portion of the blocking bar 24' is formed with a flattened lower surface to slidably mate with the flat upper surface of the wear plate 23', as discussed above.
The proximal end portion of the blocking bar 22' is disposed within a lower cavity 25' formed in the lower portion of housing 18'. The proximal end of the blocking bar 22' is pivoted or toggled side-to-side by a pivot arm 28' pinned to the lower end of the output shaft 30' of rotary actuator 32'. The pivot arm 28' is formed with a pair of integral, downward extending, spaced apart lugs (corresponding to pins 26 shown in FIGS. 1 and 2) for receiving the proximal end of the blocking bar 22' therebetween. As in the blocking bar 22 discussed above, blocking bar 22' is pivoted side-to-side about collar 24b' as the pivot arm 28' rotates back and forth about axis 34', corresponding to the longitudinal center of output shaft 30'. Ideally, the under side of the proximal end of the blocking bar 22' is also formed with the flat face corresponding to the distal end of the blocking bar 22'. This allows the blocking bar 22' to be removed and then repositioned end-to-end so that both end portions of the blocking bar can serve to block the water jet 12'. As discussed above, over time, the surface of the blocking bar impacted by the water jet 12' is eroded away due to the extremely high pressure of the water jet.
Referring primarily to FIG. 5, the longitudinal position of the blocking bar may be adjusted, thereby to present a different portion of the blocking bar to the high speed water jet 12' as the blocking bar is eroded under the action of the water jet. To this end, one end of the generally U-shaped, wire form connecting arm 82 extends through a close fitting hole extending transversely upwardly from the under side of the proximal end of the locking bar. Ideally, a corresponding hole is formed in the opposite (distal) end of the blocking bar for use when the blocking bar is repositioned end-to-end, as described above. The longitudinal portion of the arm 82 rests against the upper surface of a bottom cap 39b' which closes off lower cavity 25'.
The second transverse end portion of the arm 82 extends upwardly into an adjusting block 27' disposed within lower cavity 25'. Ideally, the upper surface of the adjusting block 27' is disposed closely adjacent the bottom surface of the horizontal partition 84 that separates the lower cavity 25' from the housing upper cavity 33'. The adjusting bar 27' is formed with a threaded through hole for engaging the threaded portion of lead screw 29'. The lead screw 29' includes an enlarged circular knob 86 positioned outwardly of housing 18' for convenient manual rotation. The outer circumference of the knob 86 may be knurled to help grip the knob, especially when wet. A retaining clip 88 is locked onto the shaft of the lead screw at the base of the threads thereof to maintain the lead screw engaged through a close fitting horizontal bore hole formed in the housing 18'. A spring-loaded ball detent assembly 90 is snugly engaged within a blind bore formed in the wall of housing 18 at a location corresponding to the outer perimeter portion of lead screw knob 86. The detent assembly 90 includes a spring-loaded ball 92 which presses against the under side of the lead screw knob. Ideally, an indentation is formed in the lead screw knob to serve as a seat for the detent ball 92. To present a new wear surface to the water jet 12', the lead screw 29' is periodically rotated one revolution whereupon the lead screw seats with the detent ball 92, which retains the lead screw from rotating other than when desired.
It will be appreciated that the connecting arm 82 conveniently advances and retracts the blocking bar 22' as the adjusting block 27' is advanced and retracted along the length of the lead screw 29', while at the same time permitting the proximal end portion of the blocking bar to pivot side-to-side under the control of pivot arm 28'. To this end, the portion of the connecting arm 82 adjacent the proximal end of the blocking bar simply moves side-to-side with the movement of the blocking bar.
It will be appreciated that the blocking bar 22' may be conveniently turned end-to-end by removing cap 39b' and then disengaging the connecting arm 82 from the blocking bar and the adjusting block 27', whereupon the blocking bar may be slidably removed from collar 24b'. After being rotated end-to-end, the blocking bar may be reinserted by reversing the above procedure.
Another manner in which the embodiment of the present invention shown in FIGS. 4-6 differs with the embodiment shown in FIGS. 1A, 1B, and 2 is the manner in which the deflected or blocked fluid from the water jet 12' is removed from the cavity 19', especially when the blocking bar 22' blocks the travel of the water jet. To this end, an air inlet port 38' is formed in the sloped upper ledge of the housing 18' located above and laterally to one side of lead screw 29'. A reduced diameter inlet passage 94 interconnects the inlet port 38' with an annular cavity 40' defined by the internal diameter of upper cavity 33' and the exterior of a heat conductive sleeve 43'. Such sleeve 43' is formed with upper and lower annular flanges, the outer perimeter of which snugly engages with the inside diameter of the upper cavity 33'. The gap between the upper and lower annular flanges and between the inside diameter of upper cavity 33' and the outer diameter of sleeve 43' defines the annular cavity 40'.
As shown in FIG. 4, at a location approximately diametrically opposite of the location of inlet port 38' and inlet passageway 94, an air outlet passageway 42' extends through housing 18' in a direction diametrically outwardly and downwardly from the cavity 40' to an elevation corresponding to the elevation of cavity 19' formed in housing portion 16'. The end of air outlet passageway 42' opposite annular cavity 40' intersects with a small diameter horizontal air passageway 96 which in turn exits into a larger diameter horizontal bore portion 98 that functions as a reduced pressure venturi chamber. As a result, the air flowing therethrough acts as a substantially free jet, unencumbered by the interior cylindrically shaped wall of the venturi chamber 98. As a result, the air flowing through the venturi chamber 98 tends to draw the fluid in cavity 19' through transverse passageway 100 and then out through exhaust port 44'. Thus, unlike the embodiment shown in FIGS. 1A, 1B, and 2, the embodiment of FIGS. 4-6 does not attempt to drive the overspray and blocked fluid out of counter bore cavity 19' under pressurized air, but rather effectively draws such overspray and blocked fluid out of the counter bore cavity under a reduced pressure of venturi action. Applicants have found that, as a result, the blocked water jet more quickly resumes a normal flow when unblocked, i.e., when the blocking bar 22' is removed from the path of travel of the water jet. During the unblocking of the water jet, as finite a length of time is required for the water jet to reconstitute itself and exit housing portion 16 as the same high pressure stream entering the housing portion. This time requirement for reconstitution is shorter in the embodiment of the present invention shown in FIGS. 4-6.
It will be appreciated that the air entering housing portion 18' and exiting housing portion 16' also functions to cool the actuator 32' in the same manner as described above with respect to FIGS. 1A, 1B, and 2. In addition, as shown in FIG. 4, a thermostat 102 is interposed between the electrical supply line 104 and the rotary actuator 32' to prevent electricity from reaching the rotary actuator if an overheated condition occurs.
While preferred embodiments of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | An apparatus and method for performing high speed interruption of the flow of a very fine, high pressure, high speed water jet 12 of the type used to cut foods, paper, and other goods. The water jet 12 is interrupted by a pivotal blocking bar 22 within a blocker housing. The blocking bar 22 is pivoted in a collar 24b to a first desired position out of the path of water jet 12 or to a second desired position for blocking the path of water jet 12. A pivot arm 28, controlled by an output shaft 30 of a rotary actuator 32, controls the rotation of the blocking bar 22. A high pressured airflow is introduced into the device for controlling the exhaustion of blocked water within the device and for cooling the rotary actuator 32. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to swimming pools and other pools of standing water, and in particular spas and hot tubs, and in particular to a dispensing unit that distributes a time release, scented fragrance with biomedicides.
[0003] 2. Description of the Prior Art
[0004] This invention relates to water quality, and more particularly to methods and apparatus for feeding controlled amounts of chemical solutions into swimming pools, hot tubs, spas, cooling towers and other standing water ponds. In the instant matter chemical solution is a scented fragrance with biomedicides (enzymes).
[0005] In home swimming pools and in newly popular hot tubs, spas, and other water pools, it is almost always necessary to filter and recirculate the water and to add certain chemicals, such as organic flocculating agents, which greatly improved the effectiveness of the filters in removing impurities. Other additives may include clarifiers, anti-scaling agents, algaecides, metallic stain preventors, scum line eliminators, filter cleaners and degreasers alone or in combination, plus spring pool or spa opening chemicals and winter closing chemicals.
[0006] Still further, it is often times desirable to include fragrances and scents to hot tubs and spas to enhance the sensory experience and provide aroma therapy.
[0007] It has been discovered that many of the desired water treatment chemicals needed for relatively small swimming pools, hot tubs and spas, can be packaged and shipped in closed and sealed plastic spheres of handy size. In use, one or more holes are opened in the shell of the sphere and the sphere and chemical solution enclosed is dropped in the water system. It has further been discovered that the motion of the water and of the sphere in the water can produce the desired rate of chemical feeding. A dispensor of this type and suitable for dispensing Applicant's formulation is disclosed by Etani in U.S. Pat. Nos. 4,880,547; 4,530,120; 4,853,131; 4,775,485; 4,692,314; and 4,519,814, which is incorporated by reference.
[0008] In one embodiment, the capsule is used to add a chemical from the group consisting of flocculants, coagulants, microbiocides, chelating agents, defoamers, germicides, and evaporation retarders, to the water of a backyard swimming pool, hot tub or spa. Dropped into the skimmer basket the capsule introduces the chemical at a substantially constant rate proportional to the rate of flow. Although at any instant the dispensing rate from the capsule will depend upon the position of the apertures relative to the flow, the positioned effect is eliminated, on the average, because of the movement of the capsule. This type of chemical feeding provides a cleaner pool, hot tub or spa and a more economical method of introducing the chemicals into the pool.
[0009] The same dispenser may be used to provide a scent/fragrance, aromatherapy to enhance the experience. The present invention adapts the use of these sealed plastic capsules to include a scented fragrance in combination with a biomedicide in the form of an enzyme which allows for and contributes to the dissipation of the fragrance or scent, as well as the oily bathing residues that tend to accumulate therein, so as to allow for use of a different, replacement fragrance or scent.
OBJECTS OF THE INVENTION
[0010] An object of the present invention is to provide for a novel delivery system for water treatment chemicals for swimming pools, hot tubs and spas, which includes a scented fragrance and biomedicide and/or enzyme.
[0011] Another object of the present invention is to provide for a novel delivery system in the form of a safe container for storage, shipment and introduction of water chemicals, including a scented fragrance in combination with a biomedicide or enzyme that is both simple and safe.
[0012] Another object of the present invention is to provide for a novel delivery system in the form of a safe container for storage, shipment and introduction of water chemicals, including a scented fragrance in combination with a biomedicide or enzyme that combines the scented fragrance with a biomedicide or enzyme which assists in dissipating the scented fragrance so that a different replacement fragrance may be introduced.
SUMMARY OF THE INVENTION
[0013] The present invention relates to swimming pools and other pools of standing water, particularly spas and hot tubs, and in particular to a dispensing unit that distributes a scented fragrance and biomedicide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and other objects of the present invention will become apparent, particularly when taken in light of the following illustrations wherein:
[0015] FIG. 1 is a schematic diagram of a typical home swimming pool;
[0016] FIG. 2 is a cross section of the dispensing container;
[0017] FIG. 3 is an alternative construction of the dispensing container;
[0018] FIG. 4 is a second alternative construction of the dispensing container; and
[0019] FIG. 5 is a cutaway view of the dispensing container.
DETAILED DESCRIPTION OF THE INVENTION
[0020] FIG. 1 illustrates a typical arrangement for a swimming pool or spa, the pool or spa comprises a pool 10 , which has a drain 11 and sump 12 at the bottom of the pool, and a skimmer 14 , which carries away overflow and collects floating debris, a strainer 15 at the inlet to a pump 16 , a filter 17 , a water main 18 , a source of fresh water, a system outlet 19 and a pool inlet 20 . Pipes 21 - 30 and valves 31 - 36 connect all of the aforesaid elements.
[0021] In normal operation water is taken from the pool through the skimmer 14 , the pipe 21 , the valve 31 , pipes 22 and 23 , strainer 15 , pump 16 , pipe 24 , valve 32 , pipe 25 , filter 17 , pipe 26 , valve 33 and pipe 27 , back to the pool inlet 20 . Valve 34 allows water to be recirculated in whole or in part from the bottom drain 11 and valve 35 allows water to be gravity dumped through pipe 29 to the system outlet 19 . Valve 36 connects the main 18 to replenish through pipes 28 and 23 . The valves 32 and 33 may be turned to backwash the filter 17 via pipe 30 . The skimmer 14 is arranged to collect leaves and other floating debris. To prevent the plugging of pipes 21 , 22 , 23 , and pump 16 , the skimmer 14 has perforated basket 41 of larger diameter and strainer 15 has a strainer basket 42 . While the flow velocity of the baskets is much less than in the pipes, it is still perceptible and non-uniform so that when a container of chemical of the kind described hereafter is dropped into the perforated basket in the skimmer, or in the strainer basket, it bobs or flutters with the flow through the baskets. The feeder may be inserted at these places or a special chamber.
[0022] FIG. 2 is representative of a practical embodiment for a dispensing container for chemicals, hereinafter termed a “feeder” (the Etani patents). The feeder comprises two plastic hemispheres 101 , 102 which are joined together in the manner of some table tennis balls with cement. The hemisphere 101 has a filling hole 105 , which is closed by a plug 110 . For dispensing the chemical, there are a number of small holes 112 in the hemisphere 101 . Plug 110 has a porous buoyant portion 114 .
[0023] FIG. 3 represents a construction in which two hemispheres 121 and 122 are joined at a flange. The thermo-plastic hemispheres with flanges can be made easily by the vacuum-forming process. This is the preferred construction when polyvinyl chloride (PVC) is used, or when the filling chemical is compressed into a solid ball “brickette”. The flange closure is readily achieved by ultrasonic welding, and the flange assists the rotation of the feeder in the eddies of flow. It also facilitates the handling and packaging of the feeders. The body of chemical, or an added weight 127 tends to stabilize the upward orientation of the feeder holes in conditions of low flow.
[0024] FIG. 4 represents an alternate closure of the feeder of FIG. 3 . In this construction the feeder is filled by the supplier with a desired quantity of chemical 140 , leaving an empty space 141 , and sealed with a patch 144 . The empty space may be filled with inert gas for chemicals which may be degraded in the presence of air or moisture. With this construction, the user must make the proper number of dispensing holes by piercing the feeder with a needle or the like.
[0025] FIG. 5 is a cut-away drawing of the capsule configuration preferred for most swimming pool and spa uses. The sphere is blow molded of high density polyethylene. The mold is made in two parts. When molding is complete the sphere is left with a small hole at 151 and a pair of stub wings 152 and 153 which serve the function of the flange in the configuration of FIG. 3 . In preparation for filling, the blow hole 151 is closed, and the filling hole 154 , formed in the mold, is cleanly cut through, both operations using an ultrasonic tool. It is desired that this capsule float with each dispensing hole 157 near the liquid levels inside 158 , and outside 159 , the capsule when it is resting in still water. To achieve this result, an air space 160 is left after filling with the emulsion, and zero-gauge buck shot 161 is swaged into the filler plug 162 .
[0026] With respect to the capsule previously described, and its use for aromatherapy in providing a scented fragrance to the pool or spa, the capsule would be spherical in shape in its preferred embodiment, having a diameter of approximately 1⅞ths inches. The capsule could be fabricated from a variety of materials, but high density polyethylene would be the preferred material.
[0027] The sides of the capsule would allow for approximately two ounces of solution to be contained therein, which would allow treatment of up to 500 gallons of spa water. If the user were to pierce only one of the release apertures on the capsule, the scented fragrance would last approximately 10 to 14 days in the water. If both apertures on the capsule were pierced, the scented fragrance would last approximately 5 to 10 days.
[0028] The capsule after having one or both of its apertures pierced can be placed in a floater on the surface of the spa, directly on the body of spa water, or in a skimmer cavity. The fragrance durations and strengths will vary depending upon the location of the capsule in the spa and the scented fragrance contained in the capsule. The rate of disbursement and strength of fragrance are more apparent if the capsule is placed in the skimmer cavity due to the increase in the amount of suction and flow and turbulence. The range of biomedicide or enzyme would range from 0.001% to 10.00% by weight percent.
[0029] The type of scent or fragrance contained in the capsule are myriad. The scents or fragrances can be of the fruit variety, the plant variety, or the garden variety. The scents or fragrances may be packaged as a single scent, or a combination of fragrances can be combined into a fragrance bouquet. Applicant has used scents either alone or in combination, which include cherry blossom, citrus, mango, vanilla creme, eucalyptus, gardenia, lavender, pina colada, spring mist, forest glen, pear delight, and tropical paradise.
[0030] The assortment of scented fragrances, in combination with the inclusion of biomedicide or enzyme technology in the form of biomedicides in a convenient, easy to use time release capsule, treats the spa user to an aromatherapy sensation, while at the same time preventing scum lines or oily bathing residues, eliminating odors, and enhancing sanitizer performance, while reducing filter cleaning.
[0031] The biomedicide or enzyme contributes to water quality but also aid in the dissipation of the particular scented fragrance so that a replacement capsule with a different scented fragrance may be introduced by the user.
[0032] Therefore, while the present invention has been disclosed with respect to the preferred embodiments thereof, it will be recognized by those of ordinary skill in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore manifestly intended that the invention be limited only by the claims and the equivalence thereof. | The present invention relates to hot tubs and spas, and in particular to a dispensing unit that distributes a water soluble solution of a scented fragrance in combination with a biomedicide or enzyme to provide a time release aroma therapy experience for a hot tub or spa, the biomedicide in the form of an enzyme aiding in the dissipation of the scented fragrance to allow introduction of a different replacement scented fragrance. | 2 |
FIELD OF THE INVENTION
The present invention relates generally to automatic recognition systems such as biometric identification systems.
BACKGROUND
In the information age many information systems (e.g., credit card systems, driver's license management systems) have been developed which rely on assertions of identity by people being offered services through the systems. Moreover, as modern societies have developed, the scope of people's daily interactions has expanded to the point that parties from whom they are requesting services or with whom they are doing business, may not know them and thus may not be able to independently verify their identity. Thus, the problem of identity misrepresentation has developed. An extreme form of identity misrepresentation is identity theft.
The development of the Internet over the past decade has been accompanied by development of e-commerce in which two parties to a transaction are situated at distant locations and transactions are conducted via the Internet. Unfortunately, e-commerce allows for new modalities of business fraud, in particular, because the parties need not ever meet, it is possible for one party to a transaction to misrepresent their identity.
In the area of physical security, electronic systems that rely on technologies such as Radio Frequency Identification (RFID) access cards, and biometric sensors have been developed. As with any security means, these systems are not invulnerable and a sophisticated hacker may be able to undermine them.
Biometric systems take measurements such as images of a person's facial, fingerprint, retina, or iris, for example, and process the images using, for example statistical pattern recognition algorithms, in order to estimate one or more probabilities that the person being measured by the biometric system is in fact a particular person or one of a set of people whose data is stored in the biometric system.
Systems in which multiple biometric measurements are combined for the purpose of identity checking have been proposed. One way to combine multiple biometric identity probability estimates is to use the MIN function or the MAX function. However, doing so essentially discards the information represented in one of the measurements. Another way is to take two measurements that are normalized, if necessary, so that they are on the same scale and to average them. One property of averaging is that when it is applied to a high estimate that a person matches an identity, and a moderate estimate that the person matches the identity, rather than producing an even higher estimate that the person matches the identity, averaging will produce an estimate that is between the two estimates. In other words, by the process of averaging, multiple estimates that indicate, to varying degrees, that a person has a particular identity do not reinforce each other to yield an estimate that reflects a greater degree of certainty that the person matches the identity. Yet another way of combining two estimates of the probability that a person matches an identity is to multiply the two estimates.
More generally, beyond recognizing people, pattern recognition techniques can be used to recognize other things, such as spoken words, and handwritten text, for example.
What is needed is an improved system and method for combining multiple estimates of the probability that a person or thing matches an identity.
BRIEF DESCRIPTION OF THE FIGURES
The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention.
FIG. 1 is functional block diagram of a system for performing automatic recognition, according to certain embodiments of the invention;
FIG. 2 is a surface plot of a function for combining two estimates of the probability that a particular object or person has a particular identity;
FIG. 3 is 2-D section through the surface plot shown in FIG. 2 showing a plane in which the two independent variables (two estimates) are equal;
FIG. 4 is a flow chart of a method for performing automatic recognition, according to certain embodiments of the invention;
FIG. 5 is a functional block diagram of a biometric automatic recognition subsystem that is used in the system shown in FIG. 1 according to embodiments of the invention;
FIG. 6 is a hardware block diagram of a device that is capable of performing automatic recognition according to an embodiment of the invention;
FIG. 7 is a block diagram of a probability estimate combiner according to certain embodiments of the invention;
FIG. 8 is a surface plot of a second function for combining two estimates of the probability that a particular object or person has a particular identity; and
FIG. 9 is a surface plot of a third function for combining two estimates of the probability that a particular object or person has a particular identity.
Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
DETAILED DESCRIPTION
Before describing in detail embodiments that are in accordance with the present invention, it should be observed that the embodiments reside primarily in combinations of method steps and apparatus components related to automatic recognition. Accordingly, the apparatus components and method steps have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
In this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.
It will be appreciated that embodiments of the invention described herein may be comprised of one or more conventional processors and unique stored program instructions that control the one or more processors to implement, in conjunction with certain non-processor circuits, some, most, or all of the functions of automatic recognition described herein. The non-processor circuits may include, but are not limited to, a radio receiver, a radio transmitter, signal drivers, clock circuits, power source circuits, and user input devices. As such, these functions may be interpreted as steps of a method to perform automatic recognition. Alternatively, some or all functions could be implemented by a state machine that has no stored program instructions, or in one or more application specific integrated circuits (ASICs), in which each function or some combinations of certain of the functions are implemented as custom logic. Of course, a combination of the two approaches could be used. Thus, methods and means for these functions have been described herein. Further, it is expected that one of ordinary skill, notwithstanding possibly significant effort and many design choices motivated by, for example, available time, current technology, and economic considerations, when guided by the concepts and principles disclosed herein will be readily capable of generating such software instructions and programs and ICs with minimal experimentation.
FIG. 1 is a functional block diagram of system 100 for performing automatic recognition, according to certain embodiments of the invention. The system 100 comprises a plurality of automatic recognition subsystems including a first automatic recognition subsystem 102 , a second automatic recognition subsystem 104 and an Nth automatic recognition subsystem 106 . Although only three automatic recognition subsystems 102 , 104 , 106 are shown for the purpose of illustration, in practice more than three can be utilized.
By way of example, the three automatic recognition subsystems 102 , 104 , 106 can comprise pattern recognition systems such as statistical pattern recognition systems or Artificial Neural Network (ANN) based pattern recognitions systems. The automatic recognition subsystems 102 , 104 , 106 can comprise biometric or non biometric systems. The present invention can be used with extant automatic recognition systems or automatic recognition systems that are developed in the future. Internal details of extant automatic recognition systems are well known to those of ordinary skill in the art and are therefore not provided herein.
In general automatic recognition systems such as statistical pattern recognition systems or ANN based recognition systems take measurements of aspects of a person or object to be recognized and output an estimate of a probability that the person or object corresponds to a particular identity or estimates of probabilities that the person or object corresponds to each of multiple identities. For example, the measurements can take the form of an image of a fingerprint, retina, iris or facial. The output is often normalized to the range zero to one. Such output normalization is generally possible, and methods of normalization will be apparent to persons having ordinary skill in the art.
In some applications, a user asserts a particular identity (e.g., his or her actual identity) by presenting an electronic identification device, or entering a log-on ID or name, and is then scanned by a biometric sensor. In such applications only the probability that the person has the asserted identity is typically of interest. In some applications a simple true or false output is produced by comparing the estimated probability to a predetermined threshold.
In the system 100 probability estimates produced by the first, second and Nth automatic recognition subsystems 102 , 104 , 106 are coupled to a probability estimate combiner 108 through a first data coupling 110 , a second data coupling 112 and an Nth data coupling 114 respectively. The probability estimate combiner 108 outputs a combined probability estimate that is based on the estimates output by the first, second and Nth automatic recognition subsystems 102 , 104 , 106 . The output of the probability estimate combiner 108 is coupled through a first output data coupling 116 , a second output data coupling 120 and an Nth output data coupling 124 to a first security subsystem or application 118 , a second security subsystem or applications 122 and an Nth security subsystem or application 126 respectively. The first, second and Nth data couplings 110 , 112 , 114 and the first, second and Nth output data couplings 116 , 120 , 124 can, for example, take the form of wired, optical and/or wireless communication channels. Moreover, the data couplings 110 , 112 , 114 and the output data couplings 116 , 120 , 124 can be short range links, or network circuits that carry signals over larger distances. By way of nonlimiting example, the security application or subsystems 118 , 122 , 126 can be systems that provide security to computer resources, financial transactions, personal information, or physical security at a facility. Each of the security subsystems or applications 118 , 122 , 126 can have different security requirements, and therefore may test the combined probability estimate output by the probability estimate combiner 108 to a different threshold.
According to alternative embodiments of the invention, one or more of the security subsystems or applications 118 , 122 , 126 is replaced by another type of system that relies on identification of persons or objects. For example, a variety of systems in a car, such as an audio system, electrically adjustable seats, a climate control system, and an electronically tunable suspension can be adjusted to suit a particular driver's preferences based on the combined probability estimate that a driver has a particular identity. As another example, a desktop of a computer interface can be adjusted to a particular user's preferred state based on the combined probability estimate.
The probability estimate combiner 108 implements a function that has properties that make it particularly suitable for combining probability estimates to obtain an overall probability estimate. The function implemented by the result function evaluator 108 in accordance with embodiments of the present invention is termed herein a combiner function. The combiner function accepts two or more probability estimates as input and outputs a combined probability estimate.
The aforementioned properties are described below with reference to one particular combiner function which can be represented by a closed form mathematical expression, however it should be understand that other combiner functions which share some or all of the desirable properties, to be described, can alternatively be used in certain embodiments of the invention.
A particular suitable probability estimate combiner function is given by:
C ( x , y ) = 2 xy 1 + ( 2 x - 1 ) ( 2 y - 1 ) EQU . 1
where, x is a first independent variable (input for a first probability estimate); and
y is a second independent variable (input for a second probability estimate);
FIG. 2 is a surface plot 200 of the above function for combining two estimates of the probability that a particular object or person has a particular identity. (Hereinbelow the term subject is used as a generic term referring to a person or object being automatically recognized.) In FIG. 2 , the horizontal axes are the x-axis and the y-axis and the vertical z-axis gives the function value. The domain covers an x-axis interval from zero to one and a y-axis interval from zero to one as well.
A first desirable property of a combiner function that the particular combiner function shown in equation 1 and FIG. 2 has is that the range of the function is also from zero to one. If one of the security application or subsystem 118 , 122 , 126 that rely on automatic recognition is, as is typical, designed to work with recognition probability estimates that range from zero to one, then providing two automatic recognition subsystems (e.g., 102 , 104 , 106 ) and the probability estimate combiner 108 will not necessitate modification of the security application or subsystem 118 because the probability estimate combiner 108 keeps probability estimates in the range zero to one. If necessary the inputs to, or outputs of the probability estimate combiner 108 can be scaled.
Typically a value of the 1.0 of the input or output of the combiner function shown in FIG. 1 represents the highest probability that a subject being identified matches a particular identity, a value of zero of the input or output of the function represents the highest probability that the subject does not match the particular identity and a value of 0.5 of the input or output represents a neutral point at which there is equal probability that the subject does and does not match the particular identity.
In practice when using the function given by equation 1 in the probability estimate combiner 108 , inputs should be restricted to the open domain (0,1) as opposed to the closed domain [0,1] in order to avoid divide by zero errors, which could occur in some floating point systems if one input is equal to one and the other is equal to zero.
More generally, even if a different domain is used, according to a generalization of the first property, the range is equal to the domain. A second desirable property of a combiner function that the particular combiner function shown in equation 1 and FIG. 2 has is that it is commutative. The commutative property is expressed by equation 2.
C ( x,y )= C ( y,x ) EQU. 2
The commutative property is apparent from the symmetry of the appearance of the variables in equation 1.
A third desirable property of a combiner function that the particular combiner function shown in equation 1 and FIG. 2 has is that it is associative, that is
C ( C ( u,v ), w )= C ( u,C ( v,w )) EQU. 3
To shown that the function is associative one can first plug in two arbitrary values u and v for x and y in equation 1 yielding a full expression for the inner application of the function in the left hand side of the equation 3. This yields:
C ( u , v ) = 2 uv 1 + ( 2 u - 1 ) ( 2 v - 1 ) EQU . 4
One can then plug this result and another arbitrary variable w into the function again yielding:
C ( C ( u , v ) , w ) = uvw ( 1 + ( 2 u - 1 ) ( 2 v - 1 ) ) ( 1 + ( 4 uv 1 + ( 2 u - 1 ) ( 2 v - 1 ) - 1 ) ( 2 w - 1 ) ) EQU . 5
which reduces to:
C
(
C
(
u
,
v
)
,
w
)
=
uvw
1
-
u
-
v
-
w
+
uv
+
uw
+
vw
EQU
.
6
From the symmetry of the appearance of the variables u,v,w in the expression on the right hand side of equation 6 and from the commutative property of the combiner function it follows that the combiner function is associative.
Having the associative and commutative properties allows the probability estimate combiner 108 to apply the combiner function (e.g., the function given by equation 1) recursively to more than two recognition probability estimates, taken in any order, without the concern that the result obtained on one system will differ from the result obtained on another system if the probability estimates are taken in a different order.
Moreover, because of the first property any number of recognition probability estimates (e.g., from facial recognition, retinal recognition, iris recognition, etc.) can be used while keeping the output in the range zero to one. The fact that the range is maintained between zero and one regardless of the number of probability estimates inputs, facilitates standard interfacing to the output of the probability estimate combiner 108 even though some facilities or individual systems may have more automatic recognition subsystems than others. For example in an industrial facility, access to some areas may be restricted on the basis of fingerprint recognition alone, whereas access to more important areas may be restricted on the basis of fingerprint and iris scans.
A fourth desirable property of a combiner function that the particular combiner function given in equation 1 has is that probability estimates that agree as to whether a test subject matches a tested identity reinforce each other. In a particular case of this property when the two inputs to the combiner function are equal, the output of the combiner function will be stronger (further from the neutral point, i.e., 0.5 in the case of the combiner function given by equation 1) than the inputs. The latter specific case of the fourth property is stated mathematically as:
| C ( x,x )−0.5|>| x− 0.5| for all x<> 0.5 in the open domain (0,1) EQU. 7
The particular combiner function given by equation 1 can be shown to have this property by making the substitution y=x in equation 1 which yields:
C
(
x
,
x
)
=
x
2
1
+
2
x
2
-
2
x
EQU
.
8
FIG. 3 is 2-D section through the surface plot shown in FIG. 2 showing a plane in which the two independent variables (two estimates) are equal, i.e., y=x, across the interval of interest (0,1). A first curve 302 , given by equation 8 is the particular combiner function given by equation 1 in the plane y=x. A straight line 304 which has unity slope is shown for reference. The contour of the combiner function through the plane y=x is also indicated at 202 in FIG. 2 . As shown in FIG. 3 for any value x in the open domain (0,1) not equal to 0.5, the output of the combiner function has a value that is further from 0.5 than the input value of x. The practical import of this is that if multiple assessments as to whether a subject matches an identity are in general agreement, the combined output of the probability estimate combiner 108 will be further strengthened. For example if one automatic recognition subsystem (e.g., a retinal scan) gives a probability of 0.8 that a subject matches a particular identity, and a second automatic recognition subsystem (e.g., a facial recognition system) gives a probability of 0.75 that a subject matches a particular identity, the output of the probability estimate combiner 108 , if based on equation 1, would be 0.923. Thus, the functioning of the probability estimate combiner 108 is qualitatively different than a similar subsystem based on averaging. In a system based on averaging, two probability estimates that generally agree would not combine to produce a combined estimate that is stronger than either—the combined estimate will be no higher than the higher estimate.
A generalization of the fourth property, that also applies to the particular combiner function given by equation 1 is that the quantity C(X, X) is further from a first predetermined value X 0 than X, for all values of X not equal to X 0 and not equal to bounds of a predetermined domain, where the predetermined value X 0 is an interior point in the predetermined domain that corresponds to equal probability that the subject does and does not have the particular identity.
A fifth desirable property of a combiner function that the particular combiner function given in equation 1 has is that if one input probability has a neutral value (e.g., 0.5 in the case of the particular combiner function given by equation 1), the combiner function will simply reflect the other output. To show this fifth property for equation 1 one makes the substitution x=0.5 as in equation 9 below. (Intermediate algebraic steps are not shown.)
C
(
0.5
,
y
)
->
2
(
0.5
)
y
1
+
(
2
(
0.5
)
-
1
)
(
2
y
-
1
)
=
y
EQU
.
9
The linear profiles of the combiner function through the planes x=0.5 and y=0.5 are indicated by lines 204 and 206 respectively in FIG. 2 . According to the fifth property, inputs that essentially do not contain any information do not affect the output of the probability estimate combiner 108 . Note that if simple averaging were used, neutral inputs (e.g., equal to 0.5) would pull the output closer to 0.5.
A sixth desirable property of a combiner function for combining probability estimates that the particular combiner function given in equation 1 has is that contradictory indications as to whether a test subject matches a predetermined identity tend to cancel each other. That is, if one input probability estimate indicates that a test subject does not match a particular identity (e.g., gives a probability estimate input <0.5 in the case of the combiner function shown in equation 1) and a second input probability estimate indicates that the test subject does, in fact, match the particular identity (e.g., give a probability estimate input >0.5 in the case of the combiner function shown in equation 1) the output of the combiner function implemented in the probability estimate combiner 108 will be closer to neutral than either of the two inputs. In the case of the combiner function given in equation 1, if the input probability estimates differ from 0.5 by equal magnitude, opposite sign amounts, the output of the combiner function will be neutral, i.e., equal to 0.5. This is shown in equation 10, without intermediate algebraic simplification steps.
C
(
0.5
-
m
,
0.5
+
m
)
=
2
(
0.5
-
m
)
(
0.5
+
m
)
1
+
(
2
(
0.5
-
m
)
-
1
)
(
2
(
0.5
+
m
)
-
1
)
=
0.5
EQU
.
10
The constraints x=0.5−m, y=0.5+m parametrically restrict the combiner function to a plane in which y=1−x. The profile of the combiner function in the latter plane is indicated by line 208 in FIG. 2 which is at a constant level of Z=0.5 as expected.
FIG. 4 is a flow chart 400 of a method for performing automatic recognition, according to certain embodiments of the invention. In block 402 a first automatic recognition system (e.g., 102 ) is operated to produce a first estimate of a probability of recognition of a subject. In block 404 the first estimate is input to the probability estimate combiner 108 . In block 406 a second automatic recognition system is operated to produce a second estimate of the probability of recognition of the subject. In block 408 the second estimate is input to the probability estimate combiner 108 . (If more than two automatic recognition systems are used these would be operated and the estimates they produce would be input to the combiner function evaluator.) In block 410 the combiner function (e.g., that given by equation 1) is evaluated to produced a combined estimate of the probability of recognition of the subject and in block 412 the combined estimate is output to the security application or system 118 . Optionally, rather than passing the combined estimate to the security system or application 118 , the combined estimate is compared to a threshold in order to obtain a TRUE or FALSE indication and the TRUE or FALSE indication is passed to the security system or application 118 .
FIG. 5 is a functional block diagram of a biometric automatic recognition subsystem 500 that is used in the system shown in FIG. 1 according to embodiments of the invention. One or more of the recognition subsystems 102 , 104 , 106 shown in FIG. 1 can have the architecture shown in FIG. 5 . The biometric automatic recognition subsystem 500 comprises a biometric sensor 502 , that is coupled through an analog-to-digital converter (A/D) 504 to a pattern recognition engine 506 . The biometric sensor 502 can, for example take the form of a fingerprint, iris, or retina camera. Biometric measurements are made using the biometric sensor 502 . The automatic recognition engine 506 comprises a feature vector extraction front end and can, for example include an ANN or statistical pattern recognition based module for processing feature vectors to compute a probability estimate.
FIG. 6 is a hardware block diagram of a wireless communication device 600 that is capable of performing automatic recognition according to an embodiment of the invention. As shown in FIG. 6 , the device 600 comprises a transceiver 602 , a processor 604 , an analog-to-digital converter (A/D) 606 , a digital-to-analog converter (D/A) 608 , a key input decoder 610 , a program memory 612 , a workspace memory 614 , a display driver 616 , a camera 618 , and a fingerprint sensor 620 coupled together through a signal bus 622 .
The transceiver 602 is coupled to an antenna 624 . Microwave or RF signals modulated with information pass between the transceiver 602 and the antenna 624 . The transceiver 600 can be used to communicated combined probability estimates and/or decayed combined probability estimates to other systems that rely on estimates generated by the device 600 .
The processor 604 uses the workspace memory 614 to execute control programs for the device 600 that are stored in the program memory 612 . The control programs include one or more programs that carry out the processes described above with reference to FIGS. 1-5 . The program memory 612 is one form of computer readable medium on which such programs may be stored. Alternatively, such programs are stored on other types of computer readable media.
A microphone 626 is coupled through a microphone amplifier 628 to the A/D 606 . Spoken utterances are digitized by the A/D 606 and made available to the processor 604 (or a specialized processor, not shown) for audio encoding and voice recognition. Programs for performing voice recognition are stored in the program memory 612 and executed by the processor 604 . Voice recognition is used to determine a first estimate of a probability that a user of the device 600 has a predetermined identity (e.g., the identity of a single owner of the device 600 .)
The D/A 608 is coupled through a speaker amplifier 630 to an earpiece speaker 632 . Digitally encoded audio, e.g., spoken words, are converted to analog form by the D/A 608 and output through the speaker 632 .
The key input decoder 610 is coupled to a keypad 634 . The key input decoder 610 identifies depressed keys to the processor 604 . The device 600 can generate a second estimate that the user of the device has the predetermined identity by comparing an average keystroke rate of the user, to a previously stored distribution (e.g., Gaussian mixture) of keystroke rate for the predetermined identity (e.g., the single owner).
The camera 618 is used to take a picture of the user's face which is then processed by facial recognition software that is stored in the program memory 612 and executed by the processor 604 . Facial recognition provides a third estimate of the probability that the user of the device 600 has the predetermined identity.
The fingerprint sensor 620 works in conjunction with fingerprint recognition software that is stored in the program memory 612 and executed by the processor 604 . The fingerprint recognition software provides a fourth estimate of the probability that the user of the devices has the predetermined identity. The first through fourth estimates of the probability that the user of the device has the predetermined identity are used to compute a combined estimate as described in more detail above.
The probability estimate combiner 108 is suitably implemented as a program that is stored in the program memory 612 and executed by the processor 604 . Alternatively, the probability estimate combiner 108 can be implemented using an application specific logic circuit.
The display driver 616 is coupled to a display 636 . The display 636 can be used to output messages indicating that the user has successfully been identified by the device.
FIG. 7 is a block diagram of the probability estimate combiner 108 according to certain embodiments of the invention. As shown in FIG. 7 the probability estimate combiner 108 comprises a first input 702 , a second input 704 , and an Nth input 706 coupled to a processing unit 708 . The processing unit 708 is coupled to an output 710 . The processing unit 708 suitably comprises, by way of example, a microprocessor coupled to a memory that stores programming instructions for executing the combiner function, an Application Specific Integrated Circuit (ASIC) adapted to execute the combiner function, or a Field Programmable Gate Array (FPGA) adapted to execute the combiner function. Separate probability estimates are received at the inputs 702 , 704 , 706 and a combined probability estimate is output at the output 710 .
FIG. 8 is a surface plot 800 of a second function for combining two estimates of the probability that a particular object or person has a particular identity. The second function for combining two estimates is given by equation 11.
C
(
x
,
y
)
=
x
+
y
1
+
xy
EQU
.
11
FIG. 9 is a surface plot 900 of a third function for combining two estimates of the probability that a particular object or person has a particular identity. The third function for combining two estimates is given by equation 12.
C
(
x
,
y
)
=
-
1
-
1
+
4
f
(
x
,
y
)
2
2
f
(
x
,
y
)
where
,
EQU
.
12
f
(
x
,
y
)
=
(
x
+
y
)
(
1
-
xy
)
(
1
-
x
2
)
(
1
-
y
2
)
EQU
.
13
The domain and range of the second and third function for combining estimates is (−1,1) and in the case of the second and third function for combining estimates zero is the neutral value that represents equal probability that the subject does and does not match a tested identity. The second and third functions for combining estimates, share the properties of the first function for combining estimates that are described above. One skilled in the art will appreciate that other functions which have these properties could also be used.
Automatic recognition systems according to the invention can use biometric measurements for living subjects and other recognition (e.g., pattern recognition) techniques for nonliving subjects. Although the invention has been described above with reference to embodiments in which the probability estimates that are combined indicate the likelihood that a subject matches a particular identity, the invention is not limited to applications involving identification of subjects, rather probability estimate combiners described above can be used to combine estimates (e.g., in the form in digital signals) in a variety of systems, including, but not limited to signal processing, fuzzy logic, and control systems.
In the foregoing specification, specific embodiments of the present invention have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present invention. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued. | Automatic recognition systems ( 100 ) includes multiple automatic recognition subsystems ( 102, 104, 106 ) that are cable of producing estimates of the probability that a subject matches a particular identity and a probability estimate combiner ( 108 ) that receives estimates from the multiple automatic recognition subsystems ( 102, 104, 106 ). The probability estimate combiner ( 108 ) has a number of properties which allow good use to be made of the individual estimates. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[0001] The present application claims priority to Indian Provisional Patent Application No. 2480/MUM/2014, filed on Aug. 1, 2014, the entirety of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present application generally relates to manufacturing processes simulation and products data processing. Particularly, the application provides a method and system for transforming mesh for simulating manufacturing processes and products.
BACKGROUND OF THE INVENTION
[0003] Any product or article of manufacture obtained through a manufacturing process, involves a raw material undergoing a plurality of stages or unit operations to provide the finished article. Example of such stages or unit operations include, forging, machining, carburization, quenching, tempering, shot peening, to name a few. Prior to implementing the manufacturing process, a numerical simulation may be conducted to accurately ascertain and determine the physical and state changes that may result due to different stages being implemented. Such simulation may provide a determination whether the choice of material or other design consideration are appropriate, or whether they further require any modification. Simulation generally involves obtaining an analytical model representing the article. This model in turn may be composed of one or more finite elements, also referred to as volume meshes. These simulations may be computationally very expensive. In order to implement these efficiently, one or more assumptions may be made for processing information pertaining to the analytical model. A volume mesh may be transformed based on such assumptions before simulation to reduce the computational burden. Such operations are typically referred to as mesh transformations. Thereby, transforming mesh for simulating manufacturing processes and products is still considered as one of the biggest challenges of the technical domain.
SUMMARY OF THE INVENTION
[0004] Before the present methods, systems, and hardware enablement are described, it is to be understood that this invention is not limited to the particular systems, and methodologies described, as there can be multiple possible embodiments of the present invention which are not expressly illustrated in the present disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present invention which will be limited only by the appended claims.
[0005] The present application provides a method and system for transforming mesh for simulating at least one manufacturing process and at least one product
[0006] The present application provides a computer implemented method ( 200 ) for transforming mesh for simulating at least one manufacturing process and at least one product; said method comprising processor implemented steps of selecting one or more transformation rules ( 118 ); executing the selected one or more transformation rules ( 118 ) for obtaining a transformation chain ( 122 ); and executing the obtained transformation chain ( 122 ) for obtaining a transformed mesh data ( 124 ) using a transformation engine ( 114 ).
[0007] The present application provides a mesh transformation system ( 102 ) for transforming mesh for simulating at least one manufacturing process and at least one product; said mesh transformation ( 102 ) comprising a processor(s) ( 104 ); an interface(s) ( 106 ); a memory ( 108 ) coupled to the processor(s) ( 108 ); a module(s) 110 , further comprises of a transformation engine ( 114 ); and other module ( 116 ); a data ( 112 ) further comprises of one or more transformation rules ( 118 ); a plurality of transformation operators ( 120 ); a transformation chain ( 122 ); transformed mesh data ( 124 ); and other data ( 126 ).
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components.
[0009] FIG. 1 illustrates a system for mesh transformations for simulation of manufacturing processes and products, in accordance with an embodiment of the present subject matter; and
[0010] FIG. 2 illustrates a method for implementing mesh transformations for simulation of manufacturing processes and products, in accordance with an implementation of the present subject matter.
[0011] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in computer readable medium and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Some embodiments of this invention, illustrating all its features, will now be discussed in detail.
[0013] The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.
[0014] It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred, systems and methods are now described.
[0015] The disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms.
[0016] Method(s) and system(s) for simulating manufacturing, testing and design validation processes for manufacturing an article of manufacture, are described. Methods can be implemented in systems that include, but are not limited to, computing devices, such as, desktop computers, servers, data processing machines, and the like, capable of simulating the environment akin to different stages of a manufacturing process. It should be noted that the product and process referred to in the claims includes an intermediate product and manufacturing process thereof.
[0017] As would be understood, any manufacturing process involves subjecting raw material to different stages of a manufacturing process to obtain an article of manufacture. Each of such stages would affect a physical change, and change in state of the material being processed within the different stages. The types of physical and state changes may in turn also be dependent on the design of the article which is to be manufactured, or on other factors, such as choice of material, environment of the manufacturing process, and so on.
[0018] It is also desirable that such changes do not affect the structural integrity of the article, either during the manufacturing process or at a late stage when such articles are being used. In order to determine and predict such physical and state changes brought about by the different stages, the entire process may be simulated. Based on simulations of the manufacturing processes, the different physical and state changes may be preempted. The simulations may also provide information as to how the structural integrity of the article would be affected during the manufacturing process, or even after the article has been put into use.
[0019] Simulation of such manufacturing processes generally involves obtaining an analytical model representing the article. The analytical model may be subject to various parameters which may intend to replicate the conditions of the manufacturing process. The analytical model in turn may be composed of one or more finite elements, also referred to as volume meshes. The meshes include a plurality of nodes, with each node representing local information of the material or an article which is being manufactured. Examples of such information include, but are not limited to, material composition, material structure, and material properties.
[0020] Simulating different stages of a manufacturing process require the use of computing systems. Such systems process the information pertaining to the analytical model and provide an output which is indicative of the effects of manufacturing process on the material used or the article. As would be appreciated by a person skilled in the art, simulations of the different stages of the manufacturing process may be computationally very expensive. In order to implement simulation of such processes efficiently, one or more assumptions may be made for processing information pertaining to the analytical model. The assumptions are made considering certain properties that the article may possess. Examples of such properties include dimensionality and symmetry of the article. Continuing with this example, as part of the simulation the dimensionality of the article may be reduced from 3-dimensions to 2-dimensions. As a result, the requirement of computing resources may be reduced. Similarly, symmetry of the article would allow processing the analytical model pertaining to only part of the geometry as representative of the complete part for a given simulation. Accordingly, the result of the simulation may be extended over the entire article.
[0021] In order to simulate an entire manufacturing process, an integrated simulation tool may be used. The integrated simulation tool may further include a plurality of simulation modules. Each of the simulation modules is for simulating the conditions for a specific stage within the manufacturing process. In operation, an integrated simulation involves obtaining an output volume mesh for one stage. The output mesh of one stage is provided as an input to a next simulation module. Prior to being provided to the next or subsequent simulation module, the output mesh may be further processed or transformed. Such operations are typically referred to as mesh transformations.
[0022] In conventional simulation systems, such mesh transformations may be configured by human experts. The mesh transformations are typically affected through one or more scripts which have to be created by such experts. As would be understood, specific scripts may be prepared and executed to carry out specific mesh transformations. In cases where the mesh transformations to be implemented are complex, the required scripts may also be complex which in turn may require an inordinate amount of time to prepare.
[0023] Furthermore, such mesh transformations may be based on multiple underlying factors such as physics of the underlying phenomenon, symmetry of the component, forces acting on the component, process configuration, and so on. In the absence of such other factors not being considered, the simulation may not be able to provide an accurate depiction of the physical and the state changes.
[0024] Systems and methods for mesh transformations for simulation of manufacturing processes and products are described. As mentioned previously, simulation of the different stages of a manufacturing process within an integrated simulation environment involves mesh transformations. As part of such mesh transformations, the output meshes from one simulation module corresponding to one stage of a manufacturing process is processed (i.e., transformed) and provided as input to a subsequent simulation module. In one implementation, the mesh transformations are based on one or more transformation rules. The transformation rules determine the appropriate mesh transformations which are to be applied to a mesh under consideration.
[0025] In one implementation, one or more transformation rules are populated. The transformation rules affect the transformation of one or more volume meshes corresponding to the article or product which is to be manufactured. The transformation rules are based on a plurality of current problem context variables. Examples of such context variables include current problem characteristics, such as process, phenomenon, the simulation model being used, components being designed and so on. Depending on the determined current problem context, one or more transformation rules may be obtained. In one implementation, the current problem context may be obtained from a model based on the system which is being simulated.
[0026] In another implementation, the transformation rules may further include one or more transformation operators. The transformation operators provide the manner or the mechanism based on which the mesh transformations are carried out. The transformation operators may be obtained from a predefined repository or new operators may be composed based on one or more primitive operators. In one implementation, the transformation operators are automatically selected by the system based on the current problem context. In one implementation, the transformation operators may be selected based on one or more rules or predefined conditions.
[0027] Multiple primitive operators may be used in one or more combinations to construct complex transformation operators. These operators may be stored back into the repository for later reuse. In another implementation, the transformation operators may be prescribed for implementing one or more geometric operations such as section, extrusion, rotation, translation, trimming, append, etc. In another implementation the transformation operators may include mesh refinement and coarsening operators. As would be understood by a person skilled in the art, mesh refinement and coarsening operator's increases and decreases, respectively the number of nodes and elements in a mesh region. Depending on whether the number of nodes in the mesh region has increased (i.e., as a result of the refinement) or reduced (i.e., as a result of the coarsening), the transformation process may be more accurate and requiring high computational capability, or may be less accurate and thus would require lower computational capability. The latter may be employed for portions of the mesh regions where high accuracy may not be required.
[0028] Once the transformation rules are obtained, they are executed to obtain a transformation chain. The transformation chain may be considered as involving one or more transformation operators arranged in a specific order. In one implementation, the order in which the transformation operators are arranged, is derived based on correctness and efficiency considerations. For example, transformation operations for trimming may not be done before extrusion operations in case of gear tooth cutting, where the gear disk section (output of forging) needs to be extruded first and then tooth is cut using trimming. Similarly, implementing refinement operations after sectioning is more efficient than first refining the whole body and then taking a section. The order in which the one or more transformation operators are arranged may be based on the current problem context.
[0029] Once obtained, the transformation chain is further executed on a volume mesh. The volume mesh may be a mesh obtained as an output from a simulation module. As a result of the execution of the transformation chain, the output volume mesh is transformed into an input volume mesh suitable for a subsequent simulation module.
[0030] In one implementation, a further determination may be made to ascertain whether the transformation operators included within the transformation chain are supported by a simulation module. The simulation module is configured to receive the result of the execution of the transformation chain as an input for performing simulation based analysis of the article of manufacture. Execution of such operators may as well be delegated to the simulation module.
[0031] As would be gathered, the present subject matter allows for an efficient manner of affecting mesh transformations. For example, the transformation chain is automatically generated based on the current context problem to provide a series of transformation operators arranged in a specific order. Relying on the current context problem, the mesh transformations are knowledge driven. Furthermore, the present subject matter also determines which of the transformation operators are natively supported by a simulation module, and ensures such operators are delegated to the simulation module.
[0032] The following disclosure describes system and method for simulation of manufacturing processes and products. While aspects of the described system and method can be implemented in any number of different computing systems, environments, and/or configurations, embodiments for mesh transformation system are described in the context of the following exemplary systems and methods.
[0033] FIG. 1 illustrates a mesh transformation system ( 102 ) for simulation of manufacturing processes and products, in accordance with an embodiment of the present subject matter. In said embodiment, the mesh transformation system ( 102 ) performs mesh transformations, which allow the transformation of one or more volume meshes. The transformed volume meshes then may be provided as input to one or more simulation modules.
[0034] In one implementation, the mesh transformation system ( 102 ) (hereinafter referred to as the system ( 102 )) may be implemented in a networked environment. The networked environment may be a public network environment, including thousands of individual computers, laptops, various servers, such as blade servers, and other computing devices. In another implementation, the network environment can be a private network environment with a limited number of computing devices, such as individual computers, servers, and laptops.
[0035] In one implementation, the network may be a wireless network, a wired network, or a combination thereof. The network may also be an individual network or a collection of many such individual networks, interconnected with each other and functioning as a single large network, e.g., the Internet or an intranet. The network may be implemented as one of the different types of networks, such as intranet, local area network (LAN), wide area network (WAN), the internet, and the like. The network may either be a dedicated network or a shared network, which represents an association of the different types of networks that use a variety of protocols, for example, Hypertext Transfer Protocol (HTTP), Transmission Control Protocol/Internet Protocol (TCP/IP), etc., to communicate with each other. Further, the network may include a variety of network devices, including routers, bridges, servers, computing devices, storage devices, and the like.
[0036] The system ( 102 ) may be implemented in a variety of computing systems, such as a laptop computer, a desktop computer, a notebook, a workstation, a mainframe computer, a server, a network server, and the like. According to an implementation, the system ( 102 ) includes processor(s) ( 104 ), interface(s) ( 106 ), and a memory ( 108 ) coupled to the processor(s) ( 108 ). The processor(s) ( 104 ) may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions. Among other capabilities, the processor(s) ( 104 ) may be configured to fetch and execute computer-readable instructions stored in the memory ( 108 ).
[0037] The memory ( 108 ) may include any computer-readable medium known in the art including, for example, volatile memory, such as static random access memory (SRAM), and dynamic random access memory (DRAM), and/or non-volatile memory, such as read only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and magnetic tapes.
[0038] Further, the interface(s) ( 106 ) may include a variety of software and hardware interfaces, for example, interfaces for peripheral device(s), such as a product board, a mouse, an external memory, and a printer. Additionally, the interface(s) ( 106 ) may enable the mesh transformation system ( 102 ) to communicate with other devices, such as web servers and external repositories. The interface(s) ( 106 ) may also facilitate multiple communications within a wide variety of networks and protocol types, including wired networks, for example, LAN, cable, etc., and wireless networks, such as WLAN, cellular, or satellite. For the purpose, the interface(s) ( 106 ) may include one or more ports.
[0039] The mesh transformation system ( 102 ) also includes module(s) ( 110 ) and data ( 112 ). The module(s) ( 110 ) include, for example, a transformation engine ( 114 ), and other module(s) ( 116 ). The other modules ( 116 ) may include programs or coded instructions that supplement applications or functions performed by the mesh transformation system ( 102 ). The data ( 112 ) may include transformation rules ( 118 ), transformation operators ( 120 ), transformation chain ( 122 ), transformed mesh data ( 124 ) and other data ( 126 ). The other data ( 126 ), amongst other things, may serve as a repository for storing data that is processed, received, or generated as a result of the execution of one or more modules in the module(s) ( 110 ).
[0040] Although the data ( 112 ) is shown internal to the system ( 102 ), it will be appreciated by a person skilled in the art that the data ( 112 ) can also be implemented external to the system ( 102 ), wherein the data ( 112 ) may be stored within a database communicatively coupled to the system ( 102 ). The system ( 102 ) may be further coupled to an integrated simulation system ( 128 ). The integrated simulation system ( 128 ) may further include a plurality of simulation modules ( 130 - 1 ), ( 130 - 2 ), ( 130 - n ) (collectively referred to as simulation modules ( 130 )).
[0041] In operation, the transformation engine ( 114 ) selects one or more rules from knowledge base. The rules are stored as transformation rules ( 118 ). The transformation rules ( 118 ) affect the transformation of one or more volume meshes corresponding to the article or product which is to be manufactured. The transformation rules ( 118 ) are based on a plurality of current problem context variables. Examples of such context variables include current problem characteristics, such as process, phenomenon, the simulation model being used, component's being designed and so on. In one implementation, the context variables may be stored as other data ( 126 ). Depending on the determined current problem context, one or more transformation rules ( 118 ) may be obtained. In one implementation, the current problem context may be obtained from a model based on the system which is being simulated. In another implementation, transformation rules ( 118 ) are specified by an expert in specific contexts. In operation, the transformation engine ( 114 ) generalizes the one or more specific contexts and accordingly adapts the transformation rules ( 118 ) accordingly.
[0042] In another implementation, the transformation rules ( 118 ) may further include one or more operators, such as transformation operators ( 120 ). The transformation operators ( 120 ) provide the manner or the mechanism based on which the mesh transformations are carried out. The transformation operators ( 120 ) may be obtained from a predefined repository or new operators may be composed based on one or more primitive operators. In one implementation, the transformation operators ( 120 ) are automatically selected based on the current problem context. In one implementation, the transformation operators may be selected based on one or more rules or predefined conditions.
[0043] Multiple primitive operators may be used in one or more combinations to construct complex transformation operators ( 120 ). These operators may be stored back into a repository, such as a database (not shown in FIG. 1 ) for later reuse. In another implementation, the transformation operators ( 120 ) may be prescribed for implementing one or more geometric operations such as section, extrusion, rotation, translation, trimming, append, etc. In another implementation the transformation operators ( 120 ) may include mesh refinement and coarsening operators. As explained previously, mesh refinement and coarsening operators increases and decreases, respectively the number of nodes and elements in a mesh region. Depending on whether the number of nodes in the mesh region has increased (i.e., as a result of the refinement) or reduced (i.e., as a result of the coarsening), the transformation process may be more accurate and requiring high computational capability, or may be less accurate and thus would require lower computational capability.
[0044] Once the transformation rules ( 118 ) are obtained, they are executed by the transformation engine ( 114 ) to obtain a transformation chain ( 122 ). The transformation chain ( 122 ) may be considered as involving one or more transformation operators ( 120 ) arranged in a specific order. The order in which the transformation operators ( 120 ) are arranged is to simulate the various stages of the manufacturing process. The order in which the one or more transformation operators ( 120 ) are arranged may be based on the current problem context. In one implementation, the order in which the transformation operators are arranged, is derived based on correctness and efficiency considerations. For example, transformation operations for trimming may not be done before extrusion operations in case of gear tooth cutting, where the gear disk section (output of forging) needs to be extruded first and then tooth is cut using trimming. Similarly, implementing refinement operations after sectioning is more efficient than first refining the whole body and then taking a section.
[0045] Once obtained, the transformation chain ( 122 ) is further executed by the transformation engine ( 114 ) on a volume mesh. The volume mesh may be a mesh obtained as an output from a simulation module, such as simulation module ( 130 - 1 ). As a result of the execution of the transformation chain, an output volume mesh in the form of transformed mesh data ( 124 ), is obtained. The transformed mesh data ( 124 ) may form an input volume mesh suitable for a subsequent simulation module, such as the simulation module ( 130 - 2 ).
[0046] In one implementation, a further determination may be made to ascertain whether the transformation operators ( 120 ) included within the transformation chain ( 122 ) are supported by any one or more simulation modules ( 130 ). For example, the simulation module ( 130 - 2 ) is configured to receive the result of the execution of the transformation chain ( 122 ) as an input for performing simulation based analysis of the article of manufacture. The mesh volume upon which the transformation chain ( 122 ) was executed may in turn be obtained as an output of the simulation module ( 130 - 1 ). In another implementation, execution of operators may be delegated to any one or more of the simulation modules ( 130 ).
[0047] As would be gathered, the present subject matter allows for an efficient manner of affecting mesh transformations. For example, the transformation chain ( 122 ) is automatically generated based on the current context problem to provide a series of transformation operators ( 120 ) arranged in a specific order. Relying on the current context problem, the mesh transformations are knowledge driven. Furthermore, the present subject matter also determines which of the transformation operators are natively supported by a simulation module, say simulation module ( 130 - 1 ), and ensures such operators are delegated to the simulation module ( 130 - 1 ).
[0048] FIG. 2 illustrates a method ( 200 ) for implementing mesh transformation for simulation of manufacturing processes and products, according to an embodiment of the present subject matter. The method ( 200 ) is implemented in a computing device, such as mesh transformation system ( 102 ). The method may be described in the general context of computer executable instructions. Generally, computer executable instructions can include routines, programs, objects, components, data structures, procedures, modules, functions, etc., that perform particular functions or implement particular abstract data types. The method may also be practiced in a distributed computing environment where functions are performed by remote processing devices that are linked through a communications network.
[0049] The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method, or an alternative method. Furthermore, the method can be implemented in any suitable hardware, software, firmware or combination thereof.
[0050] At block 202 , one or more transformation rules are selected. For example, the transformation engine ( 114 ) selects one or more transformation rules ( 118 ). The transformation engine ( 114 ) selects the transformation rules ( 118 ) based on a plurality of current problem context variables. In another implementation, the transformation rules ( 118 ) may further include one or more operators such as transformation operators ( 120 ). The transformation operators ( 120 ) provide the manner or the mechanism based on which the mesh transformations are carried out. The transformation operators ( 120 ) may be obtained from a predefined repository or new operators may be composed based on one or more primitive operators. In one implementation, the transformation operators ( 120 ) are automatically selected based on the current problem context. In one implementation, the transformation operators may be selected based on one or more rules or predefined conditions.
[0051] At block 204 , the transformation rules are executed to obtain a transformation chain. For example, once the transformation rules ( 118 ) are obtained, they are executed by the transformation engine ( 114 ) to obtain a transformation chain ( 122 ). The transformation chain ( 122 ) may be considered as involving one or more transformation operators ( 120 ) arranged in a specific order. The order in which the transformation operators ( 120 ) are arranged is to simulate the various stages of the manufacturing process. The order in which the one or more transformation operators ( 120 ) are arranged may be based on the current problem context. In one implementation, the order in which the transformation operators are arranged, is derived based on correctness and efficiency considerations.
[0052] At block 206 , the transformation chain is executed to obtain a transformed output mesh. For example, once obtained, the transformation chain ( 122 ) is further executed by the transformation engine ( 114 ) on a volume mesh. The volume mesh may be a mesh obtained as an output from a simulation module, such as simulation module ( 130 - 1 ). As a result of the execution of the transformation chain, an output volume mesh in the form of transformed mesh data ( 124 ), is obtained. The transformed mesh data ( 124 ) may form an input volume mesh suitable for a subsequent simulation module, such as the simulation module ( 130 - 2 ).
[0053] Although embodiments for methods and systems for mesh transformations for simulating manufacturing processes and products have been described in a language specific to structural features and/or methods, it is to be understood that the invention is not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as exemplary embodiments of the present subject matter. | A method and system is provided for transforming mesh for simulating manufacturing processes and products. The present application provides a method and system for transforming mesh for simulating at least one manufacturing process and at least one product comprises of selecting one or more transformation rules; executing the selected one or more transformation rules for obtaining a transformation chain; and executing the obtained transformation chain for obtaining a transformed mesh data using a transformation engine. | 6 |
SUMMARY OF THE INVENTION
The present invention is concerned with an electronic ignition system adopted for increasing the efficiency of a engine by instructing the same to ignite at an optimum time in any situation. The present system can not only function in accordance with the engine speed but also respond according to the condition in the vacuum advance device so that it can better reduce the oil consumption and exhaust gas in practical operation of the engine.
The present electronic ignition system uses optical coupler, instead of light-sensitive resistor Cds, to increase its heat resistance, readiness of compensation, stability, and is also equipped with a delay circuit to protect ignition coil and to improve the engine starting characteristics.
The primary object of the present invention is to provide an improved electronic ignition system which mainly includes phase shift circuits comprising capacitors, FET, pressure sensor, and optical coupler. The pressure sensor is adopted to detect variation in vacuum degree of the carbutetor with the engine under loading and to output signal to effect brightening of optical coupler which can then change the negative voltage of Gate and Source in FET, resulting in a variation of RDS value. In response to a variation of an engine load, an optimum phase shift angle can be automatically obtained for a proper spark advance operation.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of the present invention;
FIG. 2 shows a circuit diagram of the present invention.
DETAILED DESCRIPTION
Refer first to FIG. 1 and FIG. 2, major function blocks of the device are:
Block 10 engine-loading sensor, comprising pressure sensor 11, R16, R17, IC2, VR4, R14, R15, VR5, D2, and a first optical coupler Dc. Qc, VR6, R7, R8.
Block 20 first phase shifter controlled by block 10, comprising Ca R1, Cb, R5, R6, RDS of FET1.
Block 30 engine speed sensor, comprising IC1, VR3, R13, a second optical coupler Da, Qa, Db, Qb, VR1, R9, R10, C4, R4, C2, C3, Q6.
Block 40 second phase shifter controlled by block 40, comprising Cc, R'1, Cd, R2, RDS of FET2, R3.
Block 50 monostable circuit, comprising IC3, R20, C7, C8.
Block 60 current-control circuit, comprising Q2, R21, R22, R23, Q3, Q4, Q5, R29, NAND gate A, B, C, D.
Block 70 engine-starting sensor, comprising R24, C9, Q8, Q7.
Block 80: two delay circuits including a first delay circuit of R26, C10 and R27 and a second delay circuit R40, C19, and R41.
Block 10 working with block 20 enables the change in engine-loading to cause variation in phase shift circuit of block 20. Pressure sensor 11 outputs signal to change the brightness of Dc by sensing variation in the vacuum degree of a carburetor under engine-loading. The brightness of Dc controls Vce of Qc to change the negative voltage of G, S in FET 1 so as to control RDS resistance of FET 1 for variating the angle of phase shift in response to an engine load.
Block 30 working with block 40 has the capability to increase the phase shift of block 40 as a result of the increase of engine speed. Speed sensor outputs signal to change brightness of light-emitting diode Da, Db, by sensing the variation of an engine speed. The brightness of Da, Db controls Vce of Qa, Qb to change negative voltage of G, S in FET 2 to variate the RDS of FET 2 so as to increase a phase shift angle in response to an increasing engine speed.
Block 50 and Block 60 are used to control current in a primary winding of an ignition coil to prevent from sparking.
Block 70 and block 80 could prevent igniting-coil from damage by excessive heating when the engine is not started for a period over a period. If the R24, C9 sense no output signal from IC3, circuit R26, C10, R27, will cut off the current in the primary winding of an ignition coil. If there is an output signal from IC3 by using a delay circuit, it can delay advance angle at the moment of starting the engine so to improve the starting characteristics of the engine.
Other circuits included in the device are:
A voltage-stabilizing circuit for a power source consisting of IC5, C11, C12, C13, C14.
An inverse bypass circuit consisting of R31, C15, R32, C16, C17.
UZ1: preventing IC5 from damage by instant high voltage.
UZ2: preventing Q4, Q5, from damage by high voltage.
R33: current-limiting resistor of ignition coil.
D1: branching signal to prevent an overloaded inverse voltage between an emitter and a base of Q1.
R29, R30: raising voltage-loading of Vce in Q4, Q5.
C5, C6: phase compensation capacitor respectively for IC1, IC2.
D2: preventing Dc from overloading from inverse voltage.
OPERATION PRINCIPLE OF THE DEVICE
According to FIG. 2, description of operation principle of the device is as follows:
Effect Of Variation In Engine-loading (state change in block 10, 20)
(1) when the engine is at low speed; and the engine is at low loading:
pressure sensor outputs weak signal to IC2 because of low vacuum level (taking D411-61 engine as example, about 150 mmHg).
the signal after being amplified by IC2 enables Dc to light but with little brightness.
this results in small collect current Ic, and thus cause small drop in voltage of VR6, R7, R8, larger Vce in Qc.
larger Vce results in more negative voltage of G, S in FET1, and larger RDS value.
by formula (phase shift 1)θ=arc [tan (XC/REf1)], very small phase shift occurs, wherein
Xc=capacitive reactance of Ca
Ref1=R1//(XCb+R5+RDS of FET1+R6)
The phase shift angle is reduced to be very small when the engine loading is small.
(2) When an acceleator pedal is depressed deeply, and the engine-loading is increased:
pressure sensor outputs stronger signal because of the increase in vacuum degree (pressure).
the signal after being amplified by IC2 increases the brightness of Dc, also larger Ic in Qc.
larger Ic causes larger voltage drop in parallel shunt circuit VR6, R7, R8.
therefore, Vce of Qc decreases; RDS value decrease.
Since the decreased XC is so small, when an engine speed is increased, in comparison with a decrease of RDS value, the phase shift angle is still increased. thus the phase shift increases.
Since the phase shift is controlled by the engine-loading, the increase in engine-loading results in an increase in the phase shift.
Effect Of Variation in Engine Speed (state change in block 30, 40)
(1) when engine speed is low (about 600 r.p.m.):
coil L induces a signal of optimum engine spark advance to output a signal with low frequency, small amplitude.
the signal, amplified by IC1, passing VR3, R13, enable Da, Db to light, with little brightness.
little brightness in Da, Db produces larger Vce in Qa, Qb.
Vce of Qa, Qb provides more negative voltage on G, S in FET2. Thus, larger RDS value of FET2 is generated.
by formula (phase shift 2)θ=arc [tan (XCc/Ref2)], phase shift is very small. Where
Ref2=R'1//[XCd+R2+R3+RDS value of FET2].
Phase shift is small, if engine speed is low.
(2) When engine speed is increased:
output signal induced by coil L increases in frequency and amplitude.
the signal, passing Ca, Cc, IC1, VR3, R13, causes increase in the brightness of Da, Db.
thus, Ic of Qa, Qb increases; voltage drop across VR1, R9, R10 increase.
Vce of Qa, Qb decrease, therefore G, S of FET2 decreases in negative voltage, creating smaller RDS value.
though there is also decrease of XCc, it is small compared with decrease in RDS.
Therefore the phase shift increases according to the increase in engine speed. But, it would be a max. phase shift as engine speed increases to some extent, (taking D411-61 as example, 2400 r.p.m.). Exceeding this speed, phase shift would not increase as limited by Da, Db. Qa, Qb, R9, R10.
If the electric current switch of car is turned on without starting the engine for several minutes, it often does damage to the ignition coil as heated by a continuous current. The device provides a current cut-off circuit which operates as follows:
Without starting the engine, there is no induced signal from L, thus no output signal in IC1. Being a monostable circuit of IC3, C7, C8, R20, there is no output in IC3 without an input from IC1. Thus Q2 is off. Input of gate C is "1". Without output from IC3, no voltage drops across R24, C9. Thus Q7 is off, Q8 on. Input of gate A is "0", output "1". R26, C10 forms a delay circuit.
Before C10 is charged, the output of gate B is "1", and output of C "0". Q4 and Q5 are conducted, there is a current in the primary winding of an ignition coil. But after C10 is charged, Q3, Q4, Q5 are off. And, thus cut off the current in the primary winding of the igniting coil.
If the engine is started by turning on an electric current switch, an output signal from IC1, passing R18 to conduct Q1 (Vce of Q is about 0), will trigger IC3 to produce a square wave. The square wave passes R21 and conducts Q12 to input "0" to gate C. Output of C is "1", D "0". Q3 is cut off, so do the Q4, and Q5. The current in the primary winding of ignition coil is out of existance suddenly. It induces high inverse emf, amplified by the secondary winding of ignition coil, and thus producing sparks. The spark ignites fuel mixture in the cylinder. At the same time, signal from IC3, passing R24, charges R9 to conduct Q7 and cut off Q8. Q8 is now off, the voltage in B+ can charge C18. R40, C19, R41 form a delay circuit. Before C19 is charged, the input of gate E is "0", and output "1". The output of gate E, passing VR7, R42, lights Dd, to saturate the optical transistor Qd. The voltage drop is small in Qd, R38. By a by-pass circuit of VR1, R9, R10, each Vce of Qa or Qb is increased, thereby increasing a negative voltage of G,S terminals of FET2. Phase shift 2 is very small. It can delay an advance angle to improve the "starting characters" (that means to reduce engine-heating time and to reduce exhaust gas). After several minutes (decided by R40, C19, R41 time constant), C19 will be charged. Output of E is "0". Dd and Qd are off. The phase shift circuit of block 40 is recovered to its normal advance status. Therefore, a spark advance can be effected by controlling a phase shift signal input to Q1, which is controlled by two phase shift circuits.
ADJUSTMENT OF DEVICE
Test and adjustment of phase shift in the system can be performed by instrument. Adjustment of the advance angle vs. Vacuum pressure can be done as follows. The engine is started and a signal as sensed from a magnetic distributor is transmitted to T1, and the signal at T2 is input to IC1, whereby the waveforms of T1 and T2 are compared and their phase differences are measured by oscillograph. Applying the acceleator padal to increase the pressure in the carburetor, one can adjust advance angle by changing VR4, VR5, VR6, based on the characteristics curve of advance angle vs. vacuum pressure according to their repair mannuals. One can choose various optical coupler, FET to conform to various engines, and change Ca, Cb, Cc, Cd, R2, R3, R5, R6, if needed.
CONCLUSION
Based on the preceeding description, the significant characteristics of the device are summarized as follows:
(1) An optimum starting angle for spark advance can be obtained by sensing an engine speed or a carburetor vacuum (engine load).
(2) An additional delay circuit, working with engine-starting sensor, could prevent igniting coil from damage by execess heat due to continuous current after turning on electric current switch for minutes without starting the engine.
(3) The use of optical coupler increases the stability of the phase shift and operation life.
(4) Without the help of other instrument, it could effect the best control of ignition in the engine of any car.
Accordingly, IC1 is provided to amplify and transmit the signals from the two phase shift circuits 20, 40 to operate the monostable circuit 50; IC2 provided for amplifying the signal from the pressure sensor 11; IC3 served as a major element of the monostable circuit 50; IC4 comprised of plurality of NAND gates of the current control circuit 60; and IC5 provided as a major element of the voltage -stabilizing circuit of a power source. | An electronic ignition system for igniting an engine at an optimum time with respect to a variation of a phase shift in response to the engine speed and the vacuum degree in the carburetor; this electronic system mainly incorporating two sets of R-C phase shift circuit and FET transistors and IC operation amplifier, pressure sensors and optical coupler to manipulate the timing signal of the engine induced by the coil of a magnetic distributor. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a §371 from PCT/FR2005/050193 filed Mar. 24, 2005, which claims priority from FR 04/50595 filed Mar. 25, 2004, each of which is herein incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention refers to a device destined to prevent major accidental fires/explosions, to ensure safety of storage, transfer, transportation and handling of hazardous products, especially of fuels/combustible materials of which the gases and vapors, put into contact or mixed with atmospheric air, present a danger of spontaneous ignition of the explosive atmosphere thus created. It further enables, in the event of an accident causing the rupture of the confinement/reservoir structure, or the ripping out of its connections, to prevent or to considerably reduce the risks of massive accidental spillage of the contained product into the ambient environment, such spillages being the cause of major fires/explosions and dangerous pollutions.
[0003] The embodiments of the invention in the quoted industrial domains aim at controlling danger by eliminating the risk at its source, i.e. for fuels/combustible materials, by preventing the oxygen in the air from entering and remaining in contact with them or getting mixed with their vapors/gases. The other embodiments enable to ensure that these dangerous products are protected at several containment safety levels, eliminating or considerably reducing the risks of their massive spillage into the environment.
[0004] Unfortunately, major industrial accidents where fire and/or explosion of large volumes of fuels (gases or vapors) are implicated, in addition to the massive spillage of flammable, polluting and/or toxic products, in the surroundings, continue to occur, causing not only important material damage and loss of jobs, but also loss of lives. Prior art has been unable to give advance warning, prevent or explain those accidents.
BACKGROUND OF THE INVENTION
[0005] In terms of fire safety, the appearance of a flame is governed by a Creed called the “Fire Triangle”, drawn up from thermo chemical laboratory experiments, which set flammability limits outside of which the fuel or the mixing of its vapors with the air's oxygen are not flammable. Furthermore, this creed requires the existence of an ignition source to provide the explosive atmosphere with certain minimum ignition energy (MIE) to initiate the fire startup (matchstick, spark, hot spot). Research in the areas of chemical kinetics, thermodynamics and fluid mechanics carried out and validated experimentally over the past decades, has demonstrated that the “Fire Triangle” was too simplistic an approach, incapable of predicting or explaining certain major industrial fires or explosions.
[0006] The prior art requires suppliers of flammable gases and dangerous products delivered to laboratories to label them, giving the exact composition of the product delivered, specifying the nature and percentage of impurities mixed with the product, as well as the expiry date beyond which the product should no longer be used but sent back to the supplier. For reasons of economy, these measures and precautions are rarely applied to industrial usage situations.
[0007] To prevent the massive spillage of a dangerous/polluting/flammable product, the design of the industrial confinements destined for their storage, transfer, transportation and handling have proved to be inadequate in the event of accidental rupturing of such structures, generally made of sheet metal or to that of metallic piping/connections which are not sufficiently resistant to impact, breakage or to corrosion over time.
[0008] The prior art formally admitted, a long time ago, that: “Without oxygen, flames are impossible!” But, having said that, the simple rule of excluding oxygen in those industrial situations where the major accidents mentioned have occurred has never been applied. On the contrary, on every occasion, one was confronted with the presence of an explosive atmosphere containing oxygen, such as defined below.
[0009] It should be reminded here that, according to European Legislation, “explosive atmosphere” means: “a mixture with air, under atmospheric conditions, of flammable substances in the form of gases, vapors, mists or dusts in which, after ignition has occurred, combustion spreads to the entire unburned mixture”.
[0010] The prior art has, furthermore, established standards based upon experimentation in the laboratory, defining the “limits of flammability” of an “explosive atmosphere” outside of which the fuel-gas/vapor mixture cannot ignite, as well as what must be the “minimum ignition energy” that, for instance, a spark must provide, below which there is no danger of a fire startup. It has however been demonstrated that industrial atmospheres do ignite and burn outside of those limits, and that the energy to be provided by an ignition source tends exponentially towards zero at relatively low temperatures, thus leading to a false feeling of safety.
[0011] Risks can and must be eliminated at the source, by holding fuel from contact with air.
[0012] The risk of massive spillage of fuels or toxic and/or polluting products into the environment is real and gives rise to major accidents every year.
[0013] The prior art, although defining the “explosive atmosphere”, omitted to highlight that these were mixtures intrinsically at risk, in which auto-oxidation reactions take place, even at the lowest temperatures, and the vocation of which is to ignite quasi-spontaneously after an induction period of shorter or longer duration, whereas, according to the creed used as a basis for current standards, the ignition of a fuel, in contact with ambient air, under atmospheric pressure and temperature, requires necessarily an outside source of ignition (energy input).
[0014] The prior art does not either take into account the chemical kinetics modelling studies of combustible mixtures, which have shown the reality of occurrence of their spontaneous ignition following a runaway of some chain-branching reactions (after a finite induction period, all the shorter as the mixture's temperature is high), nor does it take into account the exponential decrease towards zero of the “minimal ignition energy” required, even at common industrial temperatures, nor the experimental studies which have shown that explosive atmospheres burn even when they only contain a fraction of 1% of oxygen or when their temperature is as low as minus 150 degrees Celsius.
[0015] Flammability limits are based on standardized laboratory methods, are often strongly dependent on wall effects—heat transfer (conduction, convection), catalysis, O2 and H2 adsorption neutralization of free radicals—which are often negligible in industrial dimensions.
[0016] In the case of a pre-mixed fuel-oxidant mixture, one neglects all heredity consequences, as well as the common presence of impurities or of products due to auto-oxidation capable of acting as catalysts/oxidizers.
[0017] Failure to provide an explanation regarding fires/explosions which have occurred upon simple contact or mixture of fuel and air in almost atmospheric conditions, meticulous investigations having been unable to identify the slightest presence of an outside energy input, no measure aimed at adequately warning about this type of risk have been taken, so that new accidents seem inevitable in the future.
[0018] The prior art has been unable to resolve this state of affairs.
[0019] For dangerous products which risk to ignite/explode upon contact with the air or to pollute the environment if they are massively spilled:
[0020] Major unforeseen accidents, involving the spillage of petroleum and/or chemical, toxic and/or polluting products in populated or residential areas, in the atmosphere, the sea, rivers or on land, unfortunately occur frequently.
[0021] Although it is not possible to completely eliminate all accidental risk of impact or structural failure with regard to a reservoir/fuel-storage tank/gas-pipeline or its connections, the Device according to the invention, enables, on the other hand, as explained below, to considerably improve the confinement safety of such dangerous products by ensuring that the product is properly retained inside a Device due to a succession of protection levels corresponding to the identified risks, thus eliminating them at the source.
BRIEF SUMMARY OF THE INVENTION
[0022] The subject of the invention is to overcome these two major risks.
[0023] It has been illustrated above that, under certain industrial situations, there exists a real danger of self-ignition for any explosive atmosphere made up of a fuel-oxidant mixture of vapours and/or gases, even far outside the currently admitted flammability limits. If the oxidant, especially represented by atmospheric oxygen, is prevented from coming into contact and/or being mixed with the fuel, the latter no longer constitutes a hazard as is it will not become a component of an explosive atmosphere.
[0024] Furthermore, the accident data bases demonstrate that many major accidents are due to the structural failure of reservoirs, gas pipelines or classical fuel tanks and to the massive spillage of the product contained therein into their environment, especially into the ambient air.
[0025] The object of the invention is thus a Device which, in the first instance, prevents the hazardous formation of an explosive atmosphere by imposing and maintaining a physical separation between the fuel contained within and the air, in all circumstances; should the Device detect the possible presence of an oxidizer in contact or mixed with the fuel vapors-gases, it will activate the necessary means to inform the operator and to neutralize the danger.
[0026] The means of the Device, which are aimed at preventing air intake into the containers, can be used to prevent leakage/spillage of the product contained within by activating a succession of protection/confinement levels making it possible to avoid, in the event of accidental rupture of the confinement structure (reservoir), its massive spillage into the environment.
[0027] In order to eliminate at the source the risks caused by the hazard indicated earlier, the first measure consists of:
[0028] 1.—controlling the stability of the product,
[0029] 2.—avoiding all contact or product mixture with air or the ambient oxygen,
[0030] 3.—if the wrong has already been done, then separate them and stabilize the product as quickly as possible,
[0031] 4.—if the physical separation of the mixture proves to be impossible within the necessary time and conditions, take the needed measures to neutralize the mixture, especially by chemical means, or to burn it under controlled conditions, without danger.
[0032] The Device described below has the means to control on an ongoing basis the fuel's stability during its lifetime, to detect any abnormal feature, to measure the physical and chemical parameters required and their evolution over time, to evacuate the impurities and dangerous by-products contained within it, and to activate the necessary means to eliminate the identified hazard.
[0033] The invention refers to, in a general manner, a safety/confinement Device for dangerous and/or potentially-reactive products during their storage, transportation or handling in an environment of industrial dimensions at essentially atmospheric pressure and temperature, this product being contained in a reservoir and the said device being characterised in that it comprises an envelope 202 within the reservoir, such envelope being designed to prevent the product from coming in contact with any atmospheric oxygen, even in the event of structural rupturing of the reservoir.
[0034] In an embodiment, the Device comprises means to delay or prevent spillage of the product out into the atmosphere, especially in the event of accidental impact or unforeseen heat exposure from a neighbouring fire.
[0035] According to an embodiment, the Device includes at least one sorption, or dissolution or diffusion selective permeable membrane to enable the extraction of potentially-hazardous vapors and gases contained in at least one element of the device.
[0036] According to an embodiment, the Device comprises at least one selective permeable membrane to enable injection of an inhibitor/stabilizer into the product or into its vapors, or an inert gas used to flush out and/or ventilate the ullages of the reservoir, and of the other elements, especially for storage, of this device.
[0037] According to an embodiment, the Device comprises means for generating and for injecting into the reservoir, around an envelope containing the product and/or around at least one inflatable cushion of the “airbag” type or around another element, retardant foam, self-solidifying or not, incombustible and inert with regard to the stored product, destined to contribute towards the leakproof capacity and the protection of the envelope, by physically and thermally protecting the product from the walls and from the surroundings.
[0038] According to an embodiment, the Device comprises at least one safety valve controlling the product inlet and/or outlet from an element of the device or the entry of ambient air in the event of failure of the distribution circuit or rupture of its outside connection, particularly after impact.
[0039] According to an embodiment, the Device comprises an element equipped with at least one mechanism located at one of the inlets and/or the outlets of an envelope containing the stored product for the purpose of sealing off the orifices of the envelope, as well as those of the inflatable cushion of the “airbag” type which encloses it, while separating them from the reservoir's walls.
[0040] In an embodiment at least one of the elements containing the product consists of non-permeable envelope, deformable or not, containing the product.
[0041] In such a case, the envelope in which is contained the dangerous product is, for example, an element which displays at least one of the characteristics chosen from the group comprising:
[0042] exhibiting a non-permeable and a chemical inertness, especially in relation to the stored product, to its vapours and to the by-products of its self-reactivity, decomposition and/or degradation, to the chemical or biological impurities which it might contain, to air or to another ambient reactant, the envelope preferably including for this purpose one or several layers made up of materials of varying permeability,
[0043] having a mechanical resistance, in the event of impact, to perforation and/or to tearing, for example comprised of two or more layers of materials in which are eventually incorporated mesh or fibers of “nylon”, glass, carbon or “Kevlar”, metallic and/or synthetic, woven or not,
[0044] holding a tolerance to temperatures varying from minus 50 degrees Celsius to plus 900 degrees Celsius, preferably from minus 50 to plus 150 degrees Celsius, and
[0045] exhibiting a strong longevity to exposure to solar radiation, especially for cases where the envelope is exposed for long periods, for example when containing a product stored in bulk.
[0046] In an embodiment, the Device includes micro and/or nano sensors to detect the envelope's condition and characteristics, especially of the autonomous type, wireless or connected, for example via fibre optics to a control center, for monitoring and activating means for the device to intervene.
[0047] In an embodiment, the envelope is itself completely enclosed by at least one inflatable watertight cushion of the “airbag” type.
[0048] In an embodiment, the inflating of at least one element of the “airbag” type, at the time of its activation, is ensured with an inert and incombustible gas, such as nitrogen or argon for fuels, especially non-reactive in relation to the stored product and to its decomposition by-products.
[0049] In an embodiment, the Device comprises means to control the stability and/or the initial reactivity of the product, to ensure permanent monitoring of its danger level, especially its composition, its age, its aging rate and such parameters as its temperature and the concentration of the most significant reactants, in order to activate, manually or automatically, based upon predetermined values, alarm and intervention means, such means of intervention particularly enabling to correct, as necessary, the physical or chemical parameters required to prevent an uncontrollable reactive runaway.
[0050] In an embodiment, the reactive or dangerous product under containment includes at least one of the products chosen from the group comprising: fuels, especially hydrocarbons, carbohydrates and hydrogen, organic materials, oxidizers, especially oxygen and peroxides, chemical substances likely to ignite/explode spontaneously when coming in contact with the ambient air, as well as toxic and/or polluting products with regard to the environment.
[0051] In an embodiment, the Device comprises means to ensure several levels of confinement adapted to the product or to the risks of accidental aggressions linked to the environment or to the conditions of use, such means preferably including the successive elements surrounding an envelope containing the product, the walls of which each provide an additional level of chemical, physical, thermal and/or mechanical protection to the dangerous product contained within, beyond the envelope itself.
[0052] In an embodiment, the Device includes at least one detector and/or a sensor, and/or a detector that is part of a microcomputer, having the task of transmitting data to a central processing unit or to a control center, especially via wireless transmission and/or via fibre optics.
[0053] In an embodiment, the Device includes means of intervention capable of being activated in accordance with the data transmitted by the detectors or sensors, and/or the sensors that are a part of a microcomputer, in order to react and overcome the risks incurred.
[0054] In an embodiment, the Device includes at least one means for collecting gases, reactive and/or toxic products, flammable vapours of a dangerous, toxic and/or polluting nature, extracted from an element of the device, especially from the envelope, in order to temporarily store them safely, to condense, recycle or neutralize them, should there be a risk of their self-ignition or explosion or accidental release into the environment.
[0055] According to an embodiment, the envelope has at least one high point so that the bubbles, the vapors or the gases present in the stored product may tend to accumulate in such a high point.
[0056] According to an embodiment, the Device includes means for evacuating gases and/or the accumulated vapors, especially in a high point of an envelope or of a product transfer/distribution element, in order to, for example, collect them, direct them to a safe storage, stabilise them, neutralise or burn them in a controlled manner, for example in an engine or a flare, or to inject them back into the product or into a distribution circuit.
[0057] According to an embodiment, the Device comprises means for carrying out at least one of the following operations:
[0058] monitor the product temperature and compare it with at least one value set by the operator,
[0059] cool off the product down to the prescribed level in order to to ensure the safety margin needed in relation to the ambient risk of an accidental energy input exceeding the value needed for its self-ignition/explosion,
[0060] control stability of the product,
[0061] detect the presence of hazardous vapours, especially flammable and/or explosive, in the elements of the device located outside an envelope containing the product, and evaluate their danger relative to their temperature and their concentration, as well as with those of the oxygen and/or other reactants,
[0062] compare the measured values with the pre-determined values in order the open or to close at least one valve or one gate and/or to particularly activate means for filling/emptying, for inflating, for flushing out, for ventilating, for injecting neutralising products, for cooling off and for collecting.
[0063] According to an embodiment, the Device comprises means for carrying out at least one of the following operations:
[0064] detecting an impact,
[0065] identifying a leakage of the product contained in an envelope,
[0066] detecting and measuring an increase in the temperature of the product, and/or of the walls of the reservoir and of those of (an)other element(s) of the device,
[0067] monitoring of the product's storage period and conditions, and comparing the said period with a deadline possibly prescribed by the operator,
[0068] evaluating its level and/or its rate of aging.
[0069] According to an embodiment, the Device comprises at least one sensor such as piezoelectric fibres incorporated in the wall of a component of the “airbag” type, and means such as activating a valve, in order to prevent the “airbag” type component from inflating to an excessively high pressure in relation to the specifications of the reservoir's structures, and then preventing it from deflating once the desired volume has been reached in order to ensure optimal protection of an envelope containing the product as well as of the product stored.
[0070] The invention also concerns application of the device described above to a land, air, space, maritime or river vehicle.
[0071] The invention further concerns application of the device described above to storage, to transfer, to transportation and to handling bulk products, wrapped or not, and/or in an open space, or a confined or semi-confined reservoir.
[0072] The invention also concerns application of the device described above to storage, to transfer, to transportation or to handling a product that is in gas or liquid form, especially vapors, mist, droplets, or of solids, for example as particles, grains, granules, powder, dust, flour, chips, fibers, sheets or porous material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0073] Some of the Device's embodiments are illustrated and described below, as examples and non-exhaustive, using the enclosed diagrams on which:
[0074] FIG. 1 shows an embodiment of the Device and its usage to secure large capacity road or rail transportation mobile means, such as trailers of tanker trucks or railroad tank cars;
[0075] FIG. 2 shows the elements of the device according to the invention for the delivery of fuel to an underground tank, as well as for its transfer for refueling a large capacity aircraft via a transport vehicle;
[0076] FIG. 3 shows the elements of the Device for eliminating hazards on the ground and in flight as shown in certain large reservoirs of transport category aircraft currently operated in the fleets of many airlines and by the armed air forces; and
[0077] FIG. 4 shows a detailed image of an embodiment of a component of the Device linked to an envelope with a high point according to the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0078] It is reminded that some of the aims of the Device are:
[0079] 1. To avoid all contact or mixture of the air with the fuel or with its vapours, whether this be during storage, transfer, transportation or regular handling, which would result in the formation of an explosive atmosphere pocket inside the device.
[0080] 2. Detect the accidental introduction of air (oxygen) into the Device, triggering off the alarm and activation of the automatic or manual safety means, enabling the operator to resolve the problem.
[0081] 3. To avoid that, at any time, the product/fuel temperature from increasing up to a level equivalent to or exceeding the product's flash point and its fire point, in which case its accidental contact (or that of its vapours) with the ambient air, could result in a quasi-instantaneous ignition/explosion; such extremely hazardous conditions correspond to common temperatures in industrial environments for which the minimum ignition energy and the induction period of the explosive atmosphere prior to spontaneous ignition approach zero; accidental product leakages may occur during loading or when emptying the Device.
[0082] Avoid any accidental spillage of the stored product out into the environment (zero effluent policy) as a result of an accident provoking structural rupture of the traditional confinement system, especially a direct impact or a fire surrounding the Device.
[0083] Only certain elements/components of the Device shall be singularly described below, as they relate to innovations in relation to the current confinement/fire-safety techniques.
[0084] FIG. 1 : Railroad Tank Car/Tanker Truck
[0085] The various elements of the Device illustrated in FIG. 1 of a railroad tank car/tanker truck are as follows:
[0086] 200 : rail tank car/trailer truck.
[0087] 201 : thermal insulation.
[0088] 202 : non-permeable envelope for the confinement of the dangerous product (see comments below).
[0089] 203 : inert gas inlet/outlet valve.
[0090] 205 / 214 : inert gas filling the airbag.
[0091] 206 : fuel.
[0092] 207 : cradle, ceiling and perforated walls to support and insulate the envelope and the airbag(s); it must be noted that this cradle may itself be completely or locally protected by a second airbag, not illustrated, should the risk level warrant such action.
[0093] 209 : “Bubble” situated at the high point (see details in FIG. 4 )
[0094] 211 : inlet/outlet fuel/product orifice.
[0095] 212 / 213 : means for control, washing, cleaning, filtering, stabilizing and fuel cooling; for dangerous products in general, their stability and conformity with the prescriptions must always be checked and restored as needed by the operator prior to loading.
[0096] 215 : inflatable envelope of the airbag type which encloses the envelope.
[0097] 216 - 218 : closing valves for the envelope's inlet/outlet orifices; these valves are supplemented by the programmed closing valves for the airbag and, in the case of some embodiments, there exists a cutting off mechanism to separate the envelope and the airbag which encloses it from the fuel tank's wall and from the inlet and product fill-up connections 211 .
[0098] 220 : interstitial inert gas between the envelope and the airbag.
[0099] 222 : inlet and outlet orifices for the airbag inflating gas.
[0100] 223 : inert gas inlet and outlet orifice.
[0101] In order to correctly fulfill its role, envelope 202 is non-permeable and chemically inert in relation to the product that it contains, as well as to the air, to oxygen or other oxidizers or corrosive products existing in atmosphere 220 at the outside of the envelope, in the reservoir's ullage.
[0102] To that end, various types or combinations of materials, synthetic or natural, can be made up to manufacture the envelope. According to an example, a thick polyethylene film is particularly adapted for the embodiment of the invention in terms of the bulk storage (not illustrated) of such solid fuels as flour, powders and/or granules, and especially of active carbon. In this embodiment of the invention, the envelope may take the form of a flexible and deformable lid, fixed hermetically to the walls of the confined or semi-confined space, or to the ground in the case of bulk storage without lateral walls, completely covering over the combustible material (fuel) to prevent any outside air from penetrating into the stored product.
[0103] Other composite materials, especially of nitrile, neoprene, urethane, elastomers and/or plastomers, in a single layer or in the form of multi-layered material, are used according to the type of product stored and the mechanical, chemical or thermal resistance expected from the envelope.
[0104] According to a second characteristic, envelope 202 must, in certain cases, be deformable, especially through its flexible, elastic and/or pre-folded design, in order to increase in volume to house product 206 during its loading via the valves 216 - 218 up to the prescribed capacity for the reservoir. The envelope should be able to be emptied by completely flattening it out once the fuel has been entirely evacuated, unless the space thus freed is gradually filled with inert gas through orifice 223 coming from a temporary storage. In certain cases, the injection of an inert liquid, non-mixable with the stored product, may be considered in order to fill up or to empty the envelope via orifice 211 , while the stored product is being extracted or loaded.
[0105] When the stored/transported product in such a tank/envelope is a fuel, if one wants to avoid all risk of formation of an explosive atmosphere, the “empty” fuel tank must be filled permanently and in advance with such inert gas as nitrogen or carbon dioxide in particular; such gas can be collected in a temporary storage container as the envelope is being filled up with the aim of it being used again at the time of unloading. This is achieved by using a pump, a gate, a valve, all governed by different sensors and systems, not illustrated.
[0106] Similarly, the sensors which monitor the prescribed chemical and physical parameters and will activate the alarms and means of intervention in the event of anomalous features or detection of danger, are not illustrated.
[0107] If, following an accident, the device's sensors detect a high increase in the fuel tank's wall temperature and/or that of the envelope, especially due to the presence of flames in the immediate neighbourhood, generators of retardant foam will be activated in order to provide an additional thermal protection level for the product contained in the envelope.
[0108] FIG. 2 .: Ground Refueling of a Transport Category Airplane
[0109] The various reservoirs where the fuel is stored (ground fuel tank, vehicle and aircraft) must be equipped with non-permeable envelopes, flexible or not.
[0110] FIG. 2 illustrates the necessity of checking the conformity and stability of the fuel at every step which precedes loading into the airplane's fuel tanks. This is performed in elements 303 of the Device.
[0111] The self-oxidation reactions, which took place during previous, perhaps extended, storage periods, at high ambient temperatures and in contact with the air, may have allowed the appearance of hydrogen peroxides or of other oxidizing products, destroying the expected stability of the fuel. In such a case, the fuel should on no account be loaded into the non-permeable envelopes illustrated in FIG. 3 , but sent back to the supplier by order from the Flight Captain.
[0112] In this figure:
[0113] 306 is the fuel,
[0114] 302 is the non-permeable envelope for the fuel,
[0115] 300 is the structure containing the envelope,
[0116] 307 is the bubble described below,
[0117] 305 is the high point of the non-permeable envelope,
[0118] 308 is the distribution line to the tanker truck 310 and to the airplane 320 .
[0119] The elements 303 and 309 close to the underground reservoir 302 aimed at controlling ( 303 ) the fuel's condition, cleaning and stabilising it ( 309 ) if necessary, prior to loading into the underground tank.
[0120] Means of control 303 are also planned prior to loading the tanker truck 310 , as well as before loading into the aircraft 320 .
[0121] Reference 311 represents the fuel tank of the truck 310 itself.
[0122] FIG. 3 : Example of the Device According to the Invention, Adapted to the Central Fuel Tank of a Large Transport Category Airplane, “Retrofitting” (Adaptable to Aircraft in Service)
[0123] This embodiment is based on the drawings of the structural design of a transversal bay of the Center Wing Tank CWT) of the Boeing 747 according to the plans provided during the investigation of the TWA 800 mid-air accident just off New York.
[0124] 200 : bay of the central tank.
[0125] 202 , 202 1 : envelope containing the fuel.
[0126] 205 : inert gas filling the ullages.
[0127] 206 : fuel.
[0128] 207 : perforated walls isolating the envelopes from the tank walls.
[0129] 209 : “Bubble”.
[0130] 214 : wall of the airbag which encloses an envelope 202 .
[0131] 215 : curtain-airbags for the protection of the envelopes from impacts and from and from direct contact with the tank walls.
[0132] 220 , 220 1 : inert gas filling the ullages.
[0133] 221 : passenger cabin floor support beams.
[0134] 222 : cabin floor.
[0135] 223 : envelopes' hanging brackets.
[0136] 224 : envelopes' supporting nets.
[0137] For this tank, for example, comprising several transversal bays, each one able to contain more than ten tons of fuel, it is possible to consider, for example, installation of eleven envelopes in every bay, each one containing less that one ton of fuel when fully loaded.
[0138] Each envelope is placed on a flexible or rigid cradle, made of lightweight material, protecting it from direct contact with the tank floor which is heated by the aircraft's air-conditioning and pressurization units (APU); this cradle, made either of metal, synthetic or composite materials, for example perforated, shall thermally isolate the envelope from the tank floor. Each envelope is further held in place by nets that surround it, keeping it independent from the neighbouring envelopes. These nets, composed for example of synthetic-fibre straps, such as those used on certain airplanes to secure luggage placed in the hold, allow primarily to prevent the envelopes from lateral, longitudinal and vertical slipping in the event of a bumpy flight due to atmospheric turbulence or during landing. Nets also prevent the fuel envelopes from coming into contact with the walls, heated or not, thus leaving a space for curtain-airbags to inflate in order to completely protect each envelope in the event of impact; the ullages around the envelopes are filled with “pure” inert gas. The Device includes means enabling to flush out and fill up these ullages if necessary.
[0139] Each envelope is also entirely enclosed by its individual airbag, initially filled with a small quantity of inert gas, such as pure nitrogen or carbon dioxide, enabling it to be deformed while the envelope is being loaded with fuel, maintaining at the same time a thin layer of gas between the two when loading up to maximum capacity. The airbag is inflated with cold, inert/non-reactive gas, activated immediately upon a forced landing impact, especially by a three axis accelerometer.
[0140] Should this occur, a pressure sensor, made, for example, from piezoelectric fibres incorporated into its fabric, will automatically stop inflation of the airbag as soon as it has filled up the entire ullage of the tank, the inert gas normally occupying this area having been evacuated via valves/vents (not illustrated), so as to ensure that the tank's structure is not exposed to internal overpressure exceeding the manufacturer's prescribed limit. In the case of the Boeing 747 reservoir, the permitted limit is set approximately to an overpressure of 30% respective to one atmosphere.
[0141] The Device also includes some thermal insulation elements (not illustrated) of the reservoir's “heated” walls enabling to reduce or to delay the heating of the fuel inside the envelopes, even if the reservoir is exposed to an outside fire, as can be the case during an emergency landing.
[0142] The Device may also include means of activating along the tank walls, between these and the “airbags”, generators of non-flammable retardant foam, filled with an emulsion of inert gas bubbles and having high thermal insulation characteristics. Such foam serves as an additional level of protection to delay the fuel heating up inside the envelopes in the event of a fire startup outside the tank, as well as to delay the “airbags” heating up and, in the end, to slow down the spread of fire, thus providing the necessary respite to organize human and material intervention means to fight and extinguish the fire. It is indeed necessary to delay for as long as possible, any fuel spillage, even minimal, and/or ignition out in the atmosphere or onto the ground near to the airplane so as to give passengers and crew time to evacuate the aircraft and to enable the fire-fighting team to enter into action.
[0143] The equipment device for the Boeing 747, partially illustrated in FIG. 3 , as an example among others of the consequences of the invention, is intended to be embodied according to the current design of this aircraft. Modifications, not illustrated, to the current fuel distribution systems, to the overflow and to the venting of the tank's ullages of this model and comparable models, particularly from the same manufacturer (Boeing 707, 727, 737, 767), but also from other high-capacity aircraft manufacturers, namely Airbus Industries, should be considered. The dangerous aircraft flying today number several thousand airplanes. Certain initial aircraft structural modifications in the process of design will greatly facilitate the Device's adaptation, not only in terms of lower weight and costs, but also for ease of maintenance.
[0144] It should be noted that in the case of FIG. 1 , as in the case of FIG. 3 , valves 216 and 218 ( FIG. 1 ) are planned, enabling, in the event of accidental impact to the tank ( 200 ) or of the heating of its walls due to a neighbouring fire, to separate envelope 202 and airbag 215 which encloses it ( 214 in the case of FIG. 3 ) from the vehicle In other words, gates 216 and 218 for loading and emptying are closed in the event of impact or fire and are such that, in this situation, they cause the envelope and the airbag to be disconnected from the tank's structure.
[0145] Envelope 202 1 and airbag 220 1 are illustrated after disconnection in FIG. 3 .
[0146] As non-exhaustive examples, described in FIG. 4 are certain details regarding the “Bubble” element of the device, such element being located in the high point of a confinement envelope, or of an element for storage, transfer, such as a gas or oil pipeline, transportation or handling for fuel, or any other dangerous product:
[0147] The figures referenced have the following meaning:
[0148] 400 : envelope wall,
[0149] 401 : air bubbles or those of other gases in suspension,
[0150] 402 : fuel,
[0151] 403 : reservoir or fuel tank ullage,
[0152] 404 : fuel tank or reservoir ceiling,
[0153] 405 : “Bubble”,
[0154] 406 : vapours and gases,
[0155] 407 : droplet catcher, sponge or overflow foam
[0156] 408 : porous flame-arrester,
[0157] 409 : selective extraction membranes, permeable to oxygen in particular, or to other hazardous gases or vapours existing in the tank's ullage,
[0158] 410 : membranes for extracting oxidizers or for introducing inert/non-reactive or neutralizing gas,
[0159] 411 : selective extraction membrane,
[0160] 412 and 412 bis: exhaust orifices towards temporary storage containers for unwanted or hazardous gases and vapours coming from the high point of envelope 406 , the sorting being performed by membrane 411 ,
[0161] 413 and 413 bis: orifices to evacuate the tank's ullage towards temporary storage containers, of the inert gas in the event of overpressure when the “airbag” is suddenly inflated, and of the hazardous gases or vapours possibly detected, once the sorting has been performed by the selective membranes 409 and 410 ,
[0162] 414 : vapour-cooling atomizer for the reservoir's ullage,
[0163] 415 : hydrocarbon or oxidant vapour-detector for the tank's ullage, measuring means as to their nature, concentration and temperature,
[0164] 416 : valves, for example electromagnetic, closing the orifices of the tank's ullage in the event of accident, being similar to valves 216 and 218 of FIG. 1 ,
[0165] 417 : reservoir's or fuel tank's ullage loading, emptying or draining valve,
[0166] 418 : closing valve for the envelope and the airbag, diconnectable from the wall in the event of an accident,
[0167] 420 : airbag's wall(s),
[0168] 421 : thermal insulation of the tank's external wall.
[0169] The “Bubble” 405 refers to the envelope's 400 safe connection to the environment outside the reservoir. Its role, within the Device, is on the one hand to channel the bubbles of air or of other dissolved or suspended gases, as well as the vapours evaporating from the surface of the product contained in the envelope; it enables to evacuate them towards safe temporary storage containers; it also enables to insert instruments and inert gas inside the envelope and the tank's ullage 403 .
[0170] This type of bubble for extracting hazardous gases/vapors and or for injecting inert gases may, in another embodiment, be installed at intervals along the gas and oil pipelines in order to eliminate the danger of formation of stagnant explosive atmospheres bubbles/floaters forming therein.
[0171] The droplet catcher/sponge/overflow foam ( 407 ), positioned at the entrance of the “Bubble”, enables to prevent the product from escaping towards the inner part of the “Bubble”, especially when the envelope is being loaded.
[0172] The flame-arrester element 408 fulfills the role of a porous barrier preventing a flame coming from outside the “Bubble” from spreading toward the inner part of the envelope, thus eliminating the risk of ignition, which can be found, in certain cases, probably in an over-oxygenated atmosphere, in its high point 406 .
[0173] Extraction membranes: several types of selective permeable membranes, active or not, are integrated into the device according to the needs. Some are located inside the “Bubble” ( 409 , 410 , 411 ), as illustrated, in order to enable evacuation of gases-vapors from the high point of the envelope towards appropriate temporary storage containers via exhaust orifices 412 and 412 bis, as well as evacuation of the atmosphere existing in the tank's ullage via orifices 413 and 413 bis. These membranes can, for example, be in the form of concentric tubing, or even in the form of films, plates, nano-tubing or yet be replaced by sorption/dissolution cartridges. The nature of the stored product and that of the inert gas govern the choice of membranes to be used, adapted to the gases or vapours that need to be separated. A membrane can operate under pressure, either using a pump, or by bleeding the air at, for example, the outlet of the engines' compressors, or extracting the oxygen from the unburnt exhaust gases taken at the outlet of the turbines so as to be able to use these gases as inert gases. These membranes can be a part of the means for cleaning/stabilizing or for the various elements of the device during storage, transfer, transportation or handling of the product, every time it becomes necessary to control its dangerousness and to implement means for extracting the hazardous gases-vapours, such as the oxidizers or other reactants of the product itself. Such membranes can, for example, be an integral part of certain surfaces of an envelope, or be placed in certain elements of the fuel distribution circuit or of the walls of the empty spaces of the fuel tanks or reservoirs.
[0174] Introduction membranes: likewise, selective permeable membranes can be used to inject inert, non-reactive gas, such as nitrogen or burnt exhaust gases, or neutralising gases or vapours into the device's empty spaces, for example via valve 417 .
[0175] In the case of accidental impact, these valves, originally fixed on valves 416 , must, after the simultaneous closing of both valves 416 - 418 , be freed from their linkages to the reservoir's wall, namely via frangible bolts, possibly assisted by an impulsion coming from the closing mechanism, in order to allow the “airbag” to protect the envelope's wall from those of the tank. The shape given to the airbag once inflated makes it possible to obtain such result. Such valves have the same role for closing up all the orifices, not illustrated, of the envelope's and reservoir's wall.
[0176] Device means and instrumentation according to the invention.
[0177] Means for analysis, synthesis, control and intervention, specific to an embodiment of the Device according to the invention, employ in particular, according to the needs, the products and predictable risks, an instrumentation and means adapted to the parameters prescribed by the operator.
[0178] The parameters that need to be known and of which the monitoring must be assured in terms of hazards are, in priority, those which enable to permanently control the stability of the concerned product. Such controls are often today rather rudimentary; thus the role of the Device is to carry out such task.
[0179] The chemical and physical parameters are measured and monitored throughout the product's industrial journey right up to the time when it is definitely neutralised under control, for example after complete combustion of a fuel mixed with air inside an engine.
[0180] A non-exhaustive list of the parameters concerned includes:
[0181] Physical parameters: temperatures, pressure, minimum ignition energy, follow-up of chemical or radio-active (isotopes) tracing elements, ionisation, emission and absorption of electromagnetic radiations, product contact time with hazardous reactants.
[0182] Chemical parameters: heredity and product danger level, level of hydrogen peroxide content, presence and concentration of free or dissolved oxygen or other oxidizers, disintegration by-products, chemical and biological impurities, existence of hazardous reactants.
[0183] The alarm and intervention means triggered off automatically or via manual command from the operator, activated by the Device in the event of an increase of the level of dangerousness are, among others:
[0184] Command means and functions: Alarms, gates, valves, pumps, “airbags”, retardant foam generators, atomizers/cooling elements for the product, for detected explosive atmospheres, for the walls of the structures and the elements of the Device, data transmission/reception, recording, fuel/product cleaning, stabilization by injection or extraction, recycling, safe temporary storage, flush out, ventilation, sweeping.
[0185] Triggering off intervention means may, in certain cases, be subject to sequences and programmed timeouts (upon prescriptions from the operator).
[0186] In the event of impact, valves 416 and 418 shall close shut and such mechanisms as the guillotine, frangible bolts or of the electromagnetic type shall disconnect the envelope and the airbag from the structure. | The invention relates to a device which enables to ensure or improve considerably the safety of storage, transfer, transport and handling of dangerous and/or potentially reactive products ( 206 ), under an industrial scale environment, at essentially atmospheric temperatures and pressures. The inherent danger of such products induce the risk of large-scale, unexpected and sometimes unexplained fires/explosions, and their massive spill out result in environmental pollution and sometimes toxic emissions. The inventive device introduces the principle of danger evaluation and of redundant levels of safety components and interventions aimed at keeping the risk of accident under control. In the particular embodiment concerning fuel gases-vapours, where fire/explosion can only occur in the presence of an oxidizer such as atmospheric oxygen, the device ensures that the fuel is prevented from remaining in contact or mixed with atmospheric air for instance, and prevents massive fuel spill out if the reservoir structure is ruptured following accidental impact or exposure to the heat of a surrounding fire. | 1 |
The invention relates to a method of-folding a gas bag for a vehicle occupant restraint system, a folded gas bag for a vehicle occupant restraint system and also a device for performing the method.
BACKGROUND OF THE INVENTION
A restraint system for a vehicle occupant usually consists of a compressed gas source, a triggering system for this and also a gas bag which is in flow connection with the compressed gas source and after ignition of the compressed gas source can be transferred from a space-saving, folded state into an unfolded state in which it can provide a restraint effect for a vehicle occupant.
Several requirements are set for the type of folding of the gas bag. Firstly, it is to make possible as quick a transfer of the gas bag as possible from the folded into the unfolded state. Furthermore, the folding is preferably to be possible automatically. This reduces the manufacturing costs of the vehicle occupant restraint system.
BRIEF DESCRIPTION OF THE INVENTION
The invention provides a method of folding a gas bag, which method can be carried out firstly automatically without manual steps, and secondly leads to a folded gas bag which can be unfolded in a particularly advantageous manner. The method according to the invention is intended for folding a gas bag for a vehicle occupant restraint system. This gas bag has a wall delimiting a chamber and having an inflation opening, the inflation opening having a rim. The method comprises the following steps: First, the gas bag is spread out on a base. Then, the rim of the inflation opening of the gas bag is held fixed. Thereafter, a plate is arranged parallel to the base and at a distance therefrom, so that the gas bag extends between the base and the plate. Subsequently, the chamber of the gas bag is exposed to a pressurized medium, so that the gas bag unfolds between the base and the plate. Finally, the wall of the gas bag is pressed inwards at a plurality of sites distributed over a circumference of the gas bag. In this way, a gas bag is obtained which is folded together very compactly, but which nevertheless is easy to unfold. Compared with conventional folding methods, an improvement in the unfolding time of the gas bag was able to be observed. In addition, a more uniform unfolding of the gas bag and also an improved opening behavior of a cover protecting the folded gas bag, was observed. A gas bag folded by the method according to the invention has a particularly symmetrical unfolding, whereby the positioning of the gas bag during the unfolding process is improved. Due to the particularly uniform unfolding of the gas bag, its seams and its fabric are stressed less than in gas bags which are folded by conventional methods. Owing to the improved behavior on unfolding, an impact of wall parts of the unfolding gas bag onto a vehicle occupant who is to be restrained was only observed to a distinctly lesser extent and with distinctly less energy than in gas bags which are folded by conventional methods. The method according to the invention is suitable both for gas bags on the driver's side, i.e. for gas bags which are two-dimensional in the unpressurized initial state, and also for gas bags on the passenger's side, which usually have a three-dimensional form in the unpressurized initial state.
According to a preferred embodiment of the invention, provision is made that the wall is pressed inwards by a plurality of fold tongues spaced apart from each other, which each engage along a line at the wall of the gas bag, so that wall flaps lying between the fold tongues are formed. Fold tongues represent a particularly simple means to press the wall of the gas bag inwards at a plurality of locations spaced apart from each other, so that the gas bag is folded together compactly.
According to a preferred embodiment of the invention, provision is made that the wall is pressed inwards in two steps, in which in the second step the wall flaps which were formed in the first step are pressed inwards. In this way, a particularly compact, folded gas bag is achieved, the wall of which nevertheless is folded very uniformly.
According to a preferred embodiment of the invention, provision is further made that the fold tongues are pressed towards the interior of the gas bag along a straight line. In this way, the method according to the invention can be carried out in a particularly simple manner.
Furthermore, provision can be made that the fold tongues are displaced in a parallel manner on being pressed towards the interior of the gas bag. This method is advantageous in particular in gas bags on the passenger side, because by means of the parallel displacement of the fold tongues, even a gas bag which has an elongated initial shape can be folded together particularly compactly.
According to a preferred embodiment of the invention, provision is further made that the wall of the gas bag is pressed in along lines which are perpendicular to the base and the plate. In this way, it is ensured that the wall of the gas bag, on unfolding, must merely move outwards substantially without changing its direction, so that the gas bag reaches its completely unfolded form.
According to a preferred embodiment of the invention, provision can be made that after the wall of the gas bag has been pressed inwardly by means of the fold tongues, the wall is pushed together by fold sliders towards the interior of the gas bag. Due to the combination of fold tongues and fold sliders, the method according to the invention can be carried out with a particularly small effort. The fold tongues which are firstly moved into the wall of the gas bag basically determine the folding pattern to be achieved. However, instead of folding together compactly the entire wall of the gas bag by means of a plurality of fold tongues, the wall can be pushed together compactly by means of less fold sliders in a simple manner.
According to a preferred embodiment of the invention, provision can be made that the wall is pushed towards the interior of the gas bag by means of four fold sliders, in which every two fold sliders lie opposite each other in pairs and in which four fold tongues are used which lie opposite each other in pairs. The use of four fold tongues and four fold sliders represents a good compromise in which, on the one hand, a reproducible folding of the gas bag is obtained, whilst, on the other hand, the effort to carry out the method is kept small.
According to a preferred embodiment of the invention, provision is made that the chamber of the gas bag is exposed to an excess pressure of less than 100000 Pa for unfolding between the base and the plate. This pressure is sufficient, on the one hand, to ensure a complete unfolding of the gas bag between the base and the plate, and, on the other hand, is not so high that the penetration of the fold tongues into the wall of the gas bag is opposed with an excessively high resistance. Preferably, provision is made that the chamber of the gas bag is exposed to a pressure of approximately 50000 Pa. This value has proved to be sufficient in tests.
According to a preferred embodiment of the invention, provision can further be made that after the gas bag has been exposed to pressure, the pressurized gas contained in the chamber of the gas bag can escape during the fold tongues or fold sliders being pressed in. In this way, the energy to be applied on pressing in the fold tongues or fold sliders into the wall of the gas bag is kept at a low value.
Furthermore, provision can be made that after folding the gas bag, a partial vacuum is applied to its chamber. In this way, the folded gas bag can be transferred into an even more compact form, whilst at the same time it is ensured that the folded gas bag, in particular after the removal of the fold elements, maintains its folded form before it is fixed elsewhere.
Preferably, provision is made that the base is arranged at a distance from the plate which corresponds approximately to the packing height of the folded gas bag. The packing height represents the height which the folded gas bag has in the interior of a mounting provided for it to be accommodated. When the distance between the base and the plate corresponds to this packing height, the gas bag which is folded by means of the fold tongues or fold sliders can be inserted directly into the mounting, without it having to be further folded or re-shaped.
The invention also provides a folded gas bag for a vehicle occupant restraint system. This gas bag has a wall delimiting a chamber and having an inflation opening, the inflation opening having a rim with an inflation opening in the wall of the gas bag. The wall of the gas bag runs in wall flaps which lie adjacent to each other. A gas bag of this type can be unfolded in a particularly advantageous manner. As regards the resulting advantages, reference is to be made to the explanations above.
According to a preferred embodiment of the folded gas bag, provision is made that the wall flaps, observed in a plane parallel to the plane of the inflation opening, run approximately radially with respect to the center of the gas bag. In this way, a particularly uniform unfolding behavior of the gas bag is produced.
According to the preferred embodiment, provision is further made that the gas bag has a substantially flat upper side and a substantially flat underside parallel thereto, the plane of the inflation opening being parallel to the plane defined by the underside. A gas bag, folded into such a shape, can be accommodated in a particularly space-saving manner in a mounting, as provided in the interior of a vehicle steering wheel or in a dashboard of a vehicle.
The invention also relates to a device for folding a gas bag, this gas bag having a wall delimiting a chamber and having an inflation opening, the inflation opening having a rim. The device comprises a base on which the gas bag to be folded can be spread out. The device further comprises a clamping device by which the rim of the inflation opening can be fixed, a plate which can be arranged parallel to the base at a determined distance therefrom, a device for introducing a pressurized medium into the gas bag chamber while the gas bag is held fixed by means of the clamping device, and a plurality of fold tongues displaceable between a position at a distance from a periphery of the gas bag which is unfolded between the base and the plate, and a position in which the wall of the gas bag is pressed inwardly towards the interior of the gas bag. The distance between the base and the plate is so selected that the gas bag which is unfolded between the base and the plate has a considerably flattened shape. With such a device, a gas bag can be folded together in a particularly simple and advantageous manner. With regard to the advantages of a gas bag folded together by means of this device, reference is to be made to the explanations above.
According to a preferred embodiment of the invention, provision is made that the fold tongues are displaceable in a straight line. A displacement of the fold tongues in a straight line can be achieved structurally in a particularly simple manner.
According to a preferred embodiment of the invention, provision can be made that the fold tongues are displaceable in a parallel manner along a part of their adjusting path. A parallel displacement of the fold tongues in fact requires a greater structural effort; this effort is, however, justified, because by means of such a device even a gas bag on the passenger side, which has an elongated shape in the spread-out state between the base and the plate, can be folded together particularly compactly.
Further features of the invention will be apparent from the sub-claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in further detail hereinbelow with reference to two preferred embodiments, which are illustrated in the attached drawings, in which:
FIG. 1 shows in a diagrammatic top view a gas bag on the driver's side and a device according to the invention, by which the method according to the invention can be carried out, the device being illustrated in an initial state;
FIG. 2 shows in a diagrammatic side view the gas bag and the device of FIG. 1;
FIG. 3 shows in a diagrammatic top view the gas bag and the device of FIG. 1, the device being illustrated in an intermediate state;
FIG. 4 shows in a diagrammatic top view a variant of the device illustrated in FIGS. 1 to 3 ;
FIG. 5 shows in a diagrammatic perspective view a gas bag according to the invention, which was folded together by a device according to the invention in accordance with FIGS. 1 to 3 and is arranged on a vehicle steering wheel;
FIG. 6 shows in a diagrammatic top view a gas bag on the passenger side and a device according to the invention, by which the method according to the invention can be carried out, the device being illustrated in an initial state;
FIG. 7 shows in a diagrammatic top view a gas bag according to the invention, which was folded together by the device of FIG. 6 according to the invention, using the method according to the invention;
FIG. 8 shows in a diagrammatic top view a gas bag on the passenger side, which is provided to be folded together by a method according to the invention in accordance with a second embodiment;
FIG. 9 shows the gas bag of FIG. 8 after a first folding step;
FIG. 10 shows the gas bag of FIG. 9 after a further folding step;
FIG. 11 shows the gas bag of FIG. 10 after the last folding step;
FIG. 12 shows in a diagrammatic perspective view the gas bag from FIGS. 8 to 11 , which after folding is arranged on a gas bag module;
FIG. 13 shows in a diagrammatic top view a gas bag on the passenger side, which is provided to be folded together by a method according to the invention in accordance with a third embodiment;
FIG. 14 shows the gas bag of FIG. 13 after a first folding step;
FIG. 15 shows the gas bag of FIG. 14 after a second folding step;
FIG. 16 shows the gas bag of FIG. 15 after a further folding step; and
FIG. 17 shows the gas bag of FIG. 16 after the last folding step.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1 and 2, a device according to the invention is illustrated diagrammatically, by means of which, using the method according to the invention, a gas bag, likewise illustrated in these Figures, can be folded together. An example of such a folded gas bag is illustrated in FIG. 5 . The illustrated gas bag 10 is a gas bag on the driver's side, i.e. a gas bag which in the unpressurized initial state usually has a shape which is able to be spread out flat. Such a gas bag consists for example of two fabric pieces congruent to each other and is designated as a two-dimensional gas bag. The gas bag 10 has an inflation opening 12 and also a rim 14 of the inflation opening 12 .
The device according to the invention contains a base 16 , on which the gas bag 10 to be folded can be spread out, and also a clamping device 18 , by means of which the rim 14 of the inflation opening 12 of the gas bag 10 can be fixed to the base 16 . The device according to the invention further contains a plate 19 which can be arranged parallel to the base 16 and at a distance “a” (see FIG. 2) therefrom, so that the gas bag to be folded is situated between the base 16 and the plate 19 .
The device according to the invention further contains a plurality of fold tongues 20 which are arranged around the gas bag, which is to be folded, generally radially with respect to its center and are movable along this radial direction. The fold tongues 20 can be moved by any suitable drive device 22 , for example, hydraulic cylinders or the like. The drive device 22 for each fold tongue 20 is secured to a diagrammatically illustrated holding ring 24 . For better clarity, in FIGS. 1 and 3 in each case only two drive devices 22 are illustrated. In addition, in FIG. 2 only the fold tongue 20 and the drive device 22 on the left-hand side are illustrated. As can be seen from FIG. 1, the device according to the invention is constructed symmetrically. The device according to the invention finally contains in addition a device 26 for exposing the chamber of the gas bag 10 to a desired excess pressure.
The method according to the invention is performed with the described device in the following manner: Firstly, the gas bag 10 is arranged on the base 16 . Then, the rim 14 of the inflation opening 12 is fixed by means of the clamping device 18 . Subsequently, the plate 19 is arranged at the predetermined distance “a” from the base 16 and parallel thereto. The distance between the plate 19 and the base 16 corresponds to the packing height desired for the folded gas bag. Thereafter, the gas bag 10 is unfolded between the base 16 and the plate 19 by means of the device 26 for introducing a pressurized medium into the gas bag chamber. Values of less than 100000 Pa have proved to be suitable values for the pressure for unfolding the gas bag. Preferably, 50000 Pa are used. In the unfolded state, the gas bag 10 has a substantially flattened shape; its height, measured perpendicularly on the plane defined by the inflation opening 12 , is distinctly smaller than its diameter in a direction parallel to this plane.
Subsequently, the fold tongues 20 are pressed towards the center of the gas bag 10 or inwardly of the chamber into the interior of the gas bag from the position shown in FIGS. 1 and 2, in which they are situated at a distance from the periphery of the unfolded gas bag 10 . This can be seen in FIG. 3 . Each fold tongue 20 pressed into the gas bag 10 forms an indentation and between two adjacent indentations each a wall flap 28 is formed. While the fold tongues 20 are pressed into the gas bag 10 , the device 26 for exposing the gas bag chamber to a determined pressure makes it possible for a portion of the pressurized gas present in the chamber of the gas bag 10 to be displaced. Here, any desired pressure which is advantageous for folding can be maintained in the chamber of the gas bag. However, it is also possible that during folding the gas bag, the volume of pressurized gas present therein can escape unhindered.
In FIGS. 1 to 3 , fold tongues 20 are illustrated, which each extend in one plane and are movable in this plane. All the fold tongues 20 are moved towards a central axis C of the gas bag, which is perpendicular to the plane of the inflation opening 12 . In addition, the fold tongues 20 are arranged perpendicular to the base 16 and to the plate 19 and have a height which corresponds to the distance “a”. However, other embodiments are also conceivable. For example, the fold tongues 20 could be arranged not radially with respect to the axis C, but could run obliquely so that the imaginary extension plane of two fold tongues each already intersect in front of the central line C. Fold tongues could also be used, the extension plane of which is not perpendicular to the base 16 and to the plate 19 . Likewise, the number of fold tongues used can be increased or reduced.
In FIG. 4, a variant to FIGS. 1 to 3 is illustrated. The difference consists in that two groups of fold tongues are provided, namely the fold tongues 20 known from FIG. 1 to 3 and also additional fold tongues 21 , of which only a single one is illustrated in FIG. 4 for the purpose of greater clarity. Each fold tongue 21 of the second group is arranged between two adjacent fold tongues 20 of the first group. In a second step, the fold tongues 21 are pressed into the wall flaps 28 formed the first fold tongues 20 at the first folding step, in order to further fold the gas bag. With this folding step, therefore, each wall flap 28 formed at the first folding step is divided into two wall flaps.
A partial vacuum can be applied to the chamber of the gas bag 10 by means of the device 26 which is used for exposing the gas bag chamber to a determined pressure, after the gas bag 10 has been folded by means of the fold tongues 20 or 21 into the desired shape in order to fix the folded gas bag in the obtained shape or to fold it together more compactly. In this state, the fold tongues can also be withdrawn from the gas bag without its shape altering. state, the fold tongues can also withdrawn from the gas bag without its shape altering.
In FIG. 5, a folded gas bag is illustrated, which was obtained by means of the device or the method from FIGS. 1 to 4 , and is arranged on a diagrammatically illustrated vehicle steering wheel 30 . In FIG. 5, the compact form of the folded gas bag is clearly to be seen, forming a package with a flat upper side and a flat underside. The individual wall flaps 28 are arranged in a star shape around the center of the folded gas bag. The folded gas bag has a packing height “a” which corresponds to the height of a mounting provided for the gas bag. To fix the gas bag, a band 32 is provided around the latter.
In FIG. 6, a further embodiment of the invention is to be seen diagrammatically. In contrast to FIGS. 1 to 4 , in which a gas bag on the driver's side is illustrated, in FIG. 6 a gas bag on the passenger side is folded. This gas bag can generally not be spread out flat in one plane in the unpressurized initial state, for which reason it is designated as a three-dimensional gas bag. As can be seen in FIG. 6, the arrangement of the fold elements 20 is adapted to the form of the outer periphery of the gas bag which is inflated between the base 16 and the plate 19 , which are not illustrated in this figure; the fold tongues 20 are therefore arranged along a rounded rectangle. Apart from the different shape of the gas bag illustrated in FIG. 6, this is folded substantially in the same manner as the gas bag illustrated in FIGS. 1 to 3 .
In FIG. 7, the gas bag of FIG. 6, folded by means of the fold tongues 20 , can be seen. As a passenger gas bag generally is accommodated in an elongated mounting, the gas bag is folded to a rectangular shape. Also in this case, the wall flaps formed run approximately radially with respect to the center of the folded gas bag.
In FIG. 8, a gas bag on the passenger side is illustrated, which is provided to be folded by a method according to the invention in accordance with a further embodiment. For better clarity, here only the fold tongues used for the folding are illustrated; also in this embodiment, the device has the further components known from FIGS. 1 and 2, in particular the base and the plate between which the gas bag is unfolded to its packing height. After the unfolding, firstly, first fold tongues 120 , which are arranged parallel to the longer longitudinal axis x of the gas bag 10 , are moved towards the interior of the gas bag. Here, the fold tongues 120 are firstly moved in a straight line in the plane defined thereby towards the interior of the gas bag 10 , and are subsequently displaced in a parallel manner towards each other, and finally are moved towards each other again in the plane defined by them. In the final position achieved in this way, the fold tongues are designated by the reference number 120 ′. The path covered by the fold tongues 120 is designated by the reference number 120 ″. Wall flaps 28 are formed between the fold tongues 120 ′.
As can be seen in FIG. 11, in addition to the illustrated fold tongues 20 , two further fold tongues 121 can also be used, which are arranged on the axis X and are moved along the latter without parallel displacement towards the interior of the gas bag 10 . In the end position, these fold tongues are designated by the reference number 121 ′.
In FIG. 10, further fold tongues 122 ′ are to be seen, which extend perpendicularly to the fold tongues 121 . These fold tongues 122 ′ were pressed into the large wall flaps 28 lying on the outside, which are present according to the folding step of FIG. 9 . The gas bag illustrated in FIG. 10 in a state after the fold tongues 122 have been pressed in is reminiscent of a clover leaf owing to the large wall flaps lying on the outside.
In FIG. 11, the final step for folding the gas bag 10 is illustrated. This step consists in that additional fold tongues 123 are pressed into the wall flaps lying on the outside which are present after the preceding folding step. The fold tongues 123 are arranged in an angle of 45° each with respect to the axis x.
The embodiment of the invention illustrated in FIGS. 8 to 11 therefore substantially consists of folding together the gas bag to be folded, by means of three groups of fold tongues. A first and a second group is used, consisting in the illustrated embodiment of the fold tongues 122 and 123 and lying opposite each other, and also a third group which consists of the fold tongues 120 and 121 and extends between the first and second group. If it proves to be necessary, for each of these groups more fold tongues can be used than the illustrated three or six fold tongues. Then, in each case, smaller wall flaps are produced between the individual fold tongues.
A partial vacuum is applied to its chamber by means of the device for introducing a pressurized medium into the gas bag chamber, after the gas bag 10 has been folded together to the desired shape. Then, the fold tongues can be withdrawn from the wall package of the withdrawn gas bag, without this altering its shape. Thereafter, the folded gas bag can either be inserted directly into a mounting provided for it, or it can be provided with a band so that it does not unfold again.
In FIG. 12, a gas bag 10 is illustrated in a diagrammatic perspective view, which was folded together by the method illustrated in FIGS. 8 to 11 . It can clearly be seen that the folded gas bag has a height “a” which corresponds to the packing height and is given by the distance in which the plate 19 is arranged from the base 16 . Furthermore, it can be seen that the folded gas bag consists of a plurality of wall flaps 28 lying adjacent to each other. These wall flaps run from the outside inwards and also substantially perpendicularly to the upper side of the folded gas bag.
In FIG. 13, a gas bag 10 on the passenger side is illustrated, which is provided to be folded together by a further embodiment of the invention. For this purpose, fold tongues 220 or 221 are used, which are arranged lying opposite each other in pairs. These fold tongues 220 or 221 press the wall of the gas bag 10 , which also in this embodiment is unfolded between a base and a plate of the device for folding the gas bag, inwardly towards the interior of the gas bag on four lines spaced apart from each other. In this way, four wall flaps 28 are formed which are arranged in the manner of a clover leaf.
In the next step (FIG. 15 ), two fold sliders 230 , which run parallel to the axis x, are moved perpendicularly to this axis towards the center of the gas bag. Then, the fold tongues 221 are withdrawn towards the outside (FIG. 16 ).
In the next step, two further fold sliders 231 , which extend perpendicularly to the axis x and to the fold sliders 230 , are pushed together from the outside towards the interior of the gas bag 10 (FIG. 17 ). As a final step, the fold tongues 220 which are perpendicular to the fold sliders 231 are withdrawn from the folded gas bag. The gas bag is now folded together completely.
The method according to the invention is based as a whole on the following two main steps: Firstly, the gas bag is unfolded between a base and a plate which are spaced apart from each other with the height of the folded gas bag to be obtained, and then the entire wall of the gas bag is pushed together towards the center of the gas bag. This can take place either completely by means of fold tongues or by means of a combination of fold tongues and fold sliders. All embodiments of the method according to the invention have in common the fact that the wall of the gas bag is not folded together in precisely defined flat layers, but rather is pushed together in a plurality of wall flaps. These wall flaps are given in each case precisely by the fold tongues used; within a wall flap, the course of the wall is not defined, however. It is consciously taken into account that the respectively obtained folding pattern of the gas bag differs slightly from fold to fold. These slight differences are without importance, however, for the unfolding of the gas bag; only by the wall flaps, given by the fold tongues, is an unfolding process achieved which is reproducible at any time. For this unfolding process, also, the deformations of the wall of the gas bag which arise within a wall flap on pushing the wall together are without importance. | A method of folding a gas bag for a vehicle occupant restraint system is disclosed, this gas bag having a wall delimiting a chamber and having an inflation opening, the inflation opening having a rim. The method comprises the following steps: First, the gas bag is spread out on a base. Then, the rim of the inflation opening of the gas bag is held fixed. Thereafter, a plate is arranged parallel to the base and at a distance therefrom, so that the gas bag extends between the base and the plate. Subsequently, the chamber of the gas bag is exposed to a pressurized medium, so that the gas bag unfolds between the base and the plate. Finally, the wall of the gas bag is pressed inwards at a plurality of sites distributed over a circumference of the gas bag. Further, a gas bag folded by performing this method and a device for performing the method are disclosed. | 1 |
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