description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to audio processing and, more particularly, to an apparatus and method for eliminating pop noises that are generated when playing conditions are changed during the playing of audio.
2. Description of the Related Art
FIG. 1 illustrates the construction of a circuit for eliminating pop noises in conventional audio equipment.
The pop noise elimination circuit, as illustrated in FIG. 1 , includes a power signal unit 100 for detecting the application and cutoff of power Vcc and generating a noise elimination drive signal for a predetermined period, a switching signal unit 102 for outputting a noise elimination drive signal in response to a signal that is generated when a mode or source is switched, a pop noise elimination unit 104 for receiving the noise elimination drive signal from the power signal unit 100 or switching signal unit 102 and grounding the output terminal of an audio input unit 103 , and the audio output unit 103 connected to an audio output device AO.
The power signal unit 100 includes a condenser C 2 configured to receive power Vcc via a resistor R 1 and be charged with the power Vcc, a diode D 1 connected in parallel to the resistor R 1 in the reverse direction, a condenser C 3 configured to receive the power Vcc via a diode D 2 and be charged with the power Vcc, a transistor TR 1 configured such that the charge voltage of the condenser C 2 is applied to the base thereof, the charge voltage of the condenser C 3 is applied to the emitter thereof and, thus, a noise elimination drive signal is output via the collector thereof, a ground resistor R 3 connected to the collector of the transistor TR 1 , and a diode D 3 configured to output a signal from a node N 3 of the collector of the transistor TR 1 and the ground resistor R 3 . The resistance value of the resistor R 1 is set well above the resistance value of the resistor R 2 .
The switching signal unit 102 is configured to receive a switching signal via a General Purpose Input/Output (GPIO) control terminal and output a noise elimination drive signal via a resistor R 4 and a diode D 4 .
The audio output unit 103 is configured to output an audio signal, which is received from an audio signal input device AI, to the audio output device AO via a buffer B 1 and a Direct Current (DC) coupling condenser C 1 .
The pop noise elimination unit 104 is formed of a transistor TR 2 that receives a noise elimination drive signal from the power signal unit 100 and/or the switching signal unit 102 and grounds the output terminal of the audio output unit 103 connected to the input terminal of the audio output device AO.
The operation of the pop noise elimination circuit of FIG. 1 is described below.
When power Vcc is applied, the power Vcc charges the condenser C 2 via the resistor R 1 , which has a high resistance value, so that the charge voltage of the node 1 N 1 slowly increases. In contrast, the power Vcc charges the condenser C 3 via the diode D 2 and the resistor R 2 , which has a small resistance value, so that the charge voltage of node 2 N 2 rapidly increases.
The transistor TR 1 is electrically conductive for a predetermined period corresponding to a charge time-constant period, after which the charge voltage of the condenser C 2 reaches a predetermined level, so that a noise elimination drive signal is output through the collector thereof to a node 3 N 3 . Since the noise elimination drive signal is applied to the base of the transistor TR 2 and makes the transistor TR 2 conductive, the audio output device AO is grounded via the transistor TR 2 , therefore pop noises generated while the power Vcc is applied are eliminated.
When the voltage of the condenser C 2 reaches a predetermined level after a predetermined period, the transistor TR 1 becomes closed, so that a low potential signal based on a ground potential is output from the node 3 N 3 , that is, the collector of the transistor TR 1 . Accordingly, the transistor TR 2 is closed, so that audio signals from the audio input device AI are normally output to the audio output device AO.
Meanwhile, when the power Vcc is cut off, the charge voltage of the condenser C 2 is rapidly discharged through the diode D 1 , and the node 1 N 1 enters a low state. Since the voltage of the condenser C 3 is not discharged by the diode D 2 connected in the reverse direction, the transistor TR 1 becomes conductive.
As a result, the charge voltage of the condenser C 3 is discharged through the transistor TR 1 and the resistor R 3 , so that a high potential signal, that is, a noise elimination drive signal, is output from the node 3 N 3 for a predetermined period corresponding to a discharge time-constant period, and the high-potential noise elimination drive signal makes the transistor TR 2 conductive through the diode D 3 , therefore pop noises generated while the power Vcc is cut off are eliminated.
Meanwhile, when a mode or source is switched, high-potential switching signal is applied for a predetermined period via the switching signal input terminal of the switching signal unit 102 .
The node 4 N 4 is at a high state for the predetermined period and the transistor TR 2 becomes conductive, so that the audio output device AO is grounded for the predetermined period, therefore pop noises generated while a mode or source is switched are eliminated.
The conventional pop noise elimination apparatus has both the problem of having a large system size, and the problem of the degradation of trustworthiness of a digital amplifier due to the repetition of high-speed switching.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide an apparatus and method for efficiently eliminating pop noises.
In order to accomplish the above object, the present invention provides an audio processing method, including the steps of determining whether a playing mode that abruptly changes the level of audio being played has been input; and processing data of the audio so as to mitigate the abrupt change in the level of the audio if the playing mode has been input.
In order to accomplish the above object, the present invention provides an audio processing apparatus, including a signal processing unit for performing signal processing on audio data; a digital-analog converter for converting the processed audio data into analog signals and outputting the analog signals; and a control unit for determining whether a playing mode that abruptly changes the level of audio being played has been input, and controlling the signal processing unit so as to mitigate the abrupt change in the level of the audio if the playing mode has been input.
Preferably, the playing mode may be a track skip mode or an audio file change mode that causes a jump from a current track of the audio being played to another track, and the audio data may be divided by a specific exponential function before the jump to the another track is completed.
Preferably, the playing mode may be a playing mode that rapidly moves a playing position to another location on the same track, and the audio data may be divided by an exponential function of 4, and may be multiplied by the exponential function of 4 after the playing mode has been completed.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates the construction of a circuit for eliminating pop noises in conventional audio equipment;
FIG. 2 is a block diagram illustrating an apparatus for eliminating pop noises according to an embodiment of the present invention;
FIG. 3 illustrates an embodiment of the present invention in which the PCM data of audio is differently processed according to the selected playing mode so as to eliminate pop noises; and
FIG. 4 is a flowchart illustrating the operation of a method of eliminating pop noises according to an embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference now should be made to the drawings, in which the same reference numerals are used throughout the different drawings to designate the same or similar components.
Preferred embodiments of an apparatus and method for eliminating pop noises according to the present invention are described in detail with reference to the accompanying drawings.
When playing conditions or a playing mode is changed by a user during the playing of audio, the level of the audio being played abruptly changes, so that a noise called a pop noise may be generated. For example, this is the case where the manipulation of skipping to a subsequent track (track skip), the manipulation of changing the file being played, or the manipulation of rapidly moving a playing position to another location on the same track (seek mode) is performed by the user while audio is played on a specific track.
Accordingly, the change of playing conditions, which may cause a pop noise, during the playing of audio can be detected, and the abrupt change of the level of the PCM data of the audio, that is, the pop noise, can be prevented.
FIG. 2 is a block diagram illustrating an apparatus for eliminating pop noises according to an embodiment of the present invention.
The pop noise elimination apparatus includes a control unit 208 for controlling the operation of the entire apparatus and predicting pop noises, a decoding unit 200 for preventing pop noises from being generated in the PCM data of audio using a prediction signal transmitted from the control unit 208 , and a Digital-Analog Converter (DAC) 210 for converting pop noise-free PCM data, which is output from the decoding unit 200 , into analog signals and outputting the analog signals.
The decoding unit 200 includes a first buffer 202 for storing the PCM data of audio being played, a data processing unit 204 for receiving a pop noise prediction signal from the control unit 208 and eliminating pop noises from the PCM data stored in the first buffer 202 , and a second buffer 206 for storing and outputting pop noise-free PCM data output from the data processing unit 204 .
The control unit 208 transmits a prediction signal providing notification of the generation of pop noises to the decoding unit 200 as the user changes playing conditions or selects a playing mode.
The decoding unit 200 receives a prediction signal from the control unit 208 , eliminates pop noises from the PCM data using a predetermined method, and outputs pop noise-free PCM data.
The first buffer 202 of the decoding unit 200 stores the PCM data of input audio, and transmits the PCM data to the data processing unit 204 . The data processing unit 204 eliminates pop noises by decreasing and/or increasing the PCM data stored in the first buffer 202 using a predetermined method based on the pop noise prediction signal transmitted from the control unit 208 , and transmits pop noise-free PCM data to the second buffer 206 . The second buffer 206 stores the pop noise-free PCM data transmitted from the data processing unit 204 .
The DAC 210 converts the PCM data, which is stored in the second buffer 206 , into analog signals, and outputs the analog signals.
The operation of the pop noise elimination apparatus according to the present invention, which is illustrated in FIG. 2 , is described below.
When the user selects a certain playing mode during the playing of audio, the level of the PCM data of audio being played abruptly changes, therefore a pop noise may occur. The control unit 208 realizes the selected playing mode and, at the same time, transmits a prediction signal predicting the occurrence of a pop noise to the decoding unit 200 as the user selects the playing mode.
In this case, as the playing mode is selected, the level of neighboring data is abruptly changed, so that PCM data including the pop noise can be stored in the first buffer 202 of the decoding unit 200 .
Furthermore, the data processing unit 204 eliminates the pop noise by dividing the PCM data including the pop noise, which is stored in the first buffer 202 , by an exponential function and, thus, decreasing the level when receiving the prediction signal from the control unit 208 , and transmitting pop noise-free PCM data to the second buffer 206 .
The second buffer 206 stores the pop noise-free PCM data transmitted from the data processing unit 204 , and the DAC 210 converts the PCM data, which is stored in the second buffer 206 , into analog signals and outputs the analog signals.
In the meantime, if playing conditions or a playing mode has not been changed during the playing of audio, the decoding unit 200 stores the PCM data of input audio in the second buffer 206 without the operation for eliminating pop noises.
The PCM data of audio stored in the first buffer 202 of the decoding unit 200 is processed by the data processing unit 204 using a predetermined method, and is transmitted to the second buffer 206 .
FIG. 3 illustrates an embodiment of the present invention in which the PCM data of audio is differently processed according to the selected playing mode so as to eliminate pop noises.
As illustrated in FIG. 3 , in the case where a track skip mode or file change mode, which corresponds to a file skip mode, is selected by the user during the playing of a certain audio file (see (a)), the data processing unit 204 eliminates a pop noise (a 1 ) attributable to the level difference of the PCM data by dividing the PCM data by, for example, the exponential function of 2 and, thus, making the level approach 0 (see (a 2 )), and performing playing while gradually increasing the level of the PCM data, which has been made to approach 0, when detecting the start bit of a new audio file stream.
Meanwhile, in the case where a seek mode, which rapidly moves a playing position to another location on the same track, is selected by the user during the playing of a certain track of the audio (see (b)), the data processing unit 204 makes the level of the PCM data approach 0 by dividing the PCM data by, for example, an exponential function of 4 so as to eliminate a pop noise (b 1 ) attributable to the level difference of the PCM data, and gradually increases the level of the PCM data by multiplying the PCM data by an exponential function of 4 when the user terminates the seek mode (see (b 2 )).
FIG. 4 is a flowchart illustrating the operation of a method of eliminating pop noises according to an embodiment of the present invention.
If the user has selected a certain playing mode at step S 400 , the control unit 208 determines whether the selected playing mode is a track skip mode or file change mode at step S 402 .
If the playing mode selected by the user is a track skip mode or file change mode at step S 402 , the control unit 208 transmits a prediction signal, indicating that pop noises would be generated due to the track skip mode or file change mode, to the data processing unit 204 , and the data processing unit 204 makes the PCM data approach 0 by dividing the PCM data of audio including the pop noises, which is stored in the first buffer 202 , by an exponential function of 2 at step S 404 .
The data processing unit 204 detects a start bit included in the frame of a new audio file, gradually increases the level of the PCM data made to approach 0, and outputs normal PCM data at step S 406 .
Furthermore, if the playing mode selected by the user at step 402 is not a track skip mode or file change mode, the control unit 208 determines whether the playing mode selected by the user is a seek mode at step S 408 .
If the playing mode selected by the user is a seek mode, the control unit 208 transmits a prediction signal, indicating that pop noises would be generated due to the seek mode, to the data processing unit 204 .
The data processing unit 204 receives a pop noise prediction signal according to the seek mode from the control unit 208 , and makes the PCM data of the audio, including the pop noises, which has been stored in the first buffer 202 , approach 0 by dividing the PCM data by an exponential function of 4 at step S 410 .
The control unit 208 detects the termination of the seek mode by the user, and transmits information about the termination of the seek mode to the data processing unit 204 . Accordingly, the data processing unit 204 performs output while increasing the level of the PCM data by multiplying the PCM data, which has been stored in the first buffer 202 , by the exponential function of 4 at step S 412 .
The DAC 210 converts the PCM data, from which the pop noise has been eliminated at step S 406 or S 412 and stored in the second buffer 206 , into analog signals, and outputs the analog signals at step S 414 .
The present invention may be applied to audio players, such as Compact Disc/Digital Versatile Disc (CD/DVD) players, Moving Picture Experts Group-1/2 Audio Layer-3 (MP3) players and Portable Multimedia Players (PMPs), that are capable of playing audio media, such as CDs and DVDs and/or audio files, such as MP3 files, Ogg files and WMA files.
According to the present invention, pop noise causing discomfort can be efficiently eliminated, and the problems with the prior art, that is, the large volume of a system and the repetition of high-speed switching, can be solved.
Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Disclosed herein are an audio processing apparatus and method. In an embodiment, if a playing mode that abruptly changes the level of audio being played has been input, the data of the audio is processed to mitigate the abrupt change in the level of the audio and converted into analog signals, and the analog signals are output. In an embodiment, if a playing mode that causes a jump from the current track of the audio being played to another track is input, the audio data is divided by an exponential function of 2 before the jump to the another track is completed. In another embodiment, if a playing mode that rapidly moves a playing position to another location on the same track has been input, the audio data is divided by a specific exponential function, and is then multiplied by the exponential function after the playing mode has been completed. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/303,742 filed Jul. 10, 2001, entitled “Floating Oil Boom Cleaning Apparatus,” incorporated herein by reference.
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without payment of any royalties thereon or therefore.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to cleaning an oil boom, and more particularly to an oil boom cleaning device having the capacity to simultaneously clean both sides of float and skirt type oil booms of marine growth or other contaminants.
2. Description of the Related Art
Floating oil booms that are used to contain spills of oil and flotsam and jetsam have been used for many years,. Many of these booms are deployed at the site of the spill. The oil booms are transported by boat to the spill site and when the clean up effort is complete the booms are removed from the water and stored until needed again. However, some booms are used in harbors or at fuel filling stations to contain dockside spills and the booms are left floating in the water in various length sections for quick containment of any spills.
One disadvantage that oil booms kept in the water for quick deployment have over oil booms that are stored dry and deployed as needed is the need for periodic cleaning. Booms stored in the water become havens for marine growth such as algae and barnacles. Without periodic cleanings the booms become heavy, making it harder to pull the booms into position, and negatively affect the boom buoyancy. This negative buoyancy can affect the ability of the boom to contain spills in choppy water. Additionally, boom surface marine growths make clean up of any spills harder because the growth will absorb some of the oil spill requiring the marine growth to be cleaned off the boom and treated as non-reclaimable hazardous waste.
Floating oil booms of the float and skirt type that is suitable to contain oil spills or flotsam and jetsam are well known. Such typical types of booms are shown in U.S. Pat. Nos. 4,049,170; and 5,580,185.
Presently oil booms that are left floating in the water for quick deployment are periodically cleaned in a messy and time consuming effort involving pulling the boom out of the water and scraping the boom by hand. There are known various devices to clean marine growth from boats or ships. Such devices generally would not be suitable to cleaning floating oil booms as the devices are configured to the shapes of hulls and not to the extremely narrow and pliable skirts of oil booms.
It is therefore an important object of the present invention to remove marine growth from both sides of the oil boom simultaneously in a more quick and efficient manner without requiring the removal of the booms from the station area.
It is a further object of this invention to provide a self contained cleaning apparatus that floats and may be towed to a convenient location to clean the floating oil booms without the need for the booms to be taken off station.
SUMMARY OF THE INVENTION
In accordance with the present invention, a cleaning apparatus for removing marine growth from an oil boom comprises a floating platform, a water pressure generator and a pair of tracks to guide the oil boom through a set of pressure spray washers directed at the oil boom surface. Preferably the floating platform includes ramps at the front and rear to allow for a smooth transition from the water to the deck of the floating platform. The floating platform includes a storage tank that may be used to collect the wastewater if it contains any hazardous contaminants.
The floating cleaning apparatus of the present invention preferably is self-contained and does not require a water or power source from the shore or dock. The floating cleaning apparatus includes a diesel or gasoline powered engine that pressurizes water taken from the body of water, whether fresh, salt or brackish, where the cleaning apparatus is floating and then supplies the pressurized water to the spray washers to clean the boom.
Additional objects and advantages of the invention will be set forth in the description which follows, and will in part be obvious from the description, or may be learned from practicing the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the floating oil boom cleaning apparatus according to the present invention.
FIG. 2 is a top schematic view of the floating oil boom cleaning apparatus according to the present invention.
FIG. 3 is a front perspective view showing an example of the front ramp and track according to the present invention.
FIG. 4 a is an end view of the track assembly of the floating oil boom cleaning apparatus according to the present invention with one type of continuous float and skirt oil boom supported on the track.
FIG. 4 b is an end view of the track assembly of the floating oil boom cleaning apparatus according to the present invention with another type of oil boom that uses spaced floats and a continuous skirt supported on the track.
FIG. 5 is a side view of the spray washer assembly of the floating oil boom cleaning apparatus according to the present invention.
FIG. 6 is a top view of the track assembly and spray washer assembly of the floating oil boom cleaning apparatus according to the present invention.
FIG. 7 is a schematic view of the pressure washer assembly of the floating oil boom cleaning apparatus according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference to the drawings will be made to describe the preferred embodiments of the present invention.
As shown in FIG. 1, the oil boom cleaning apparatus comprises a floating platform 100 , tracks 120 , a spray washer assembly 150 , ramps 110 , a pressure washer assembly (not shown), and a boat (not shown) or other means for pulling an oil boom 130 through the cleaning apparatus. FIG. 2 shows the general layout of the components on the platform 100 . The pressure washer assembly 140 is placed on the floating platform 100 in the preferred embodiment and supply hoses (not shown) are run to the spray washer assemblies 150 . By placing the pressure washer assembly 140 on the deck of the floating platform 100 the cleaning apparatus is entirely self-contained and may be towed to any convenient location to clean the oil boom 130 .
In the preferred embodiment an oil boom 130 that is floating in a body of water is towed or pulled to the floating platform 100 by a boat or other suitable means (not shown) and is guided into the front guide rails 121 of the track 120 . The platform 100 is approximately 20 feet long, 11 feet wide and 5 feet thick with 3 storage tanks (not shown) in the hull. The oil boom 130 is pulled up the front ramp 110 and it passes through a group of spray washer assemblies 150 that clean the oil boom of any marine growth that has accumulated. The debris and wastewater drain back down the ramp to the water. The oil boom 130 continues through the length of the track 120 and down the back ramp 110 where the oil boom 130 is returned to the body of water and towed to any desired location.
FIG. 3 shows a more detailed view of the front ramp 110 and the front guide rails 121 of the track 120 . The tracks 120 at the front and rear of the platform 100 terminate at the water line to facilitate the passage of the oil boom 130 to and from the water. The tracks 120 at the front and rear ramps 110 transitions at approximately a fifteen-degree rise to the deck 105 of the platform 100 . Referring to FIGS. 4 a and 4 b , the oil boom 130 is shown supported on the track 120 sliding surface 126 . The track 120 sliding surface 126 is preferably made of polyethylene or some other low friction easy maintenance surface. Screws attach the sliding surface 126 to a rigid pipe 124 . In the preferred embodiment the pipe 124 is made of 1½ inch non-ferrous metal that may be shaped and bent to follow the contours of the ramps 110 and the platform deck 105 . The pipe is attached to the platform 100 by several supports 122 spaced along the track 120 . In the preferred embodiment the supports are constructed of flat 2-inch non-ferrous metal and are welded or bolted to the platform 100 . In the preferred embodiment the track supports 122 are approximately twelve inches high to permit smooth passage of the oil boom 130 . The tracks 120 are kept parallel and level with respect to each other for smooth operation. Additionally, the tracks 120 are spaced approximately 2½ inches apart to permit the passage of a towing bridal (not shown).
The spray washer assembly 150 is shown in FIG. 5 . In the preferred embodiment the spray washer assembly consists of five sprayer nozzles 154 . Five nozzles 154 were chosen to completely cover the surface area of the oil boom 130 , which is approximately 14 inches. The nozzles 154 are zero degree rotating nozzles capable of three gallon per minute throughput. Each nozzle 154 is connected to a common supply manifold 151 through a set of nipples 155 . The supply manifold 151 has a pressure gauge 152 attached to the top and a drain plug 158 at the bottom. The drain plug 158 is used for cleaning or draining the supply manifold 151 . The supply manifold 151 preferably has a quick disconnect fitting 156 for the water supply pressure hose (not shown) attachment. The spray washer assembly 150 parts are preferably made of stainless steel to reduce corrosion.
The spray washer assembly 150 should be mounted with adjustable mounts (not shown) so that the nozzles 154 may be moved towards, away, up or down with respect to the oil boom 130 surface as needed to effect the most thorough cleaning without causing damage to the oil boom 130 . In the preferred embodiment the mounting brackets are slotted to permit the necessary adjustments.
FIG. 6 shows the relationship of the spray washer assembly 150 and nozzles 154 to the track sliding surface 126 . In the preferred embodiment the nozzles 154 direct the pressurized water spray onto the oil boom 130 surfaces at approximately a sixty-degree angle of impact. The track 120 has a gap 128 of approximately 1½ inches that is sized to receive the nozzles 154 so that there is no obstruction between the nozzle 154 water spray and the oil boom 130 surface. The gap 128 is located near the upper edge of the front ramp 110 so that the debris and spray water flows down the ramp to the main body of water.
Pressure washer assembly 140 is shown in FIG. 7 . In the preferred embodiment the pressure washer assembly 140 comprises a diesel engine powered pressure washer 142 and is located on the platform 100 . The pressure washer 142 uses whatever body of water the platform 100 is floating on as its working fluid source. The water is pumped from the body of water through a suction check valve 148 , through a stop valve 146 , and filtered through a strainer 144 prior to entering the pressure washer 142 . The piping 149 to the body of water may either go over the side of the platform 100 below the water line or may utilize a penetration through the hull of the platform 100 . The pressure washer 142 sends pressurized water at approximately 3000 psi and 15 gpm to each spray washer assembly through supply hoses (not shown) with quick connection fittings.
Though the preferred embodiment is as indicated in the discussion above it is possible to make changes to configure other embodiments. An example, of such a modification would be to place the pressure washer assembly 140 on shore and a supply hose (not shown) would be connected to the spray washer assemblies 150 on the platform 100 . The number of nozzles 154 can be varied to cover the width of the oil boom 130 to be cleaned. Each nozzle 154 has approximately three-inch spray coverage at a distance of three inches from the work surface. Other embodiments can be readily made by varying the track 120 height and the distance between the tracks 120 to accommodate different size float and skirt oil booms 130 . The platform 100 could be easily adapted to provide a means for propulsion of the platform 100 . Additionally, it should be recognized that other means for fastening elements together may be used in place of those disclosed such as glue, rivets, clamps, welds, screws, or bolts.
In another embodiment the oil boom cleaning apparatus could be configured to remove and collect any oily residue left on the oil boom 130 after a spill was contained and cleaned. In this embodiment the platform 100 is modified to slope the center portion of the platform 100 to a drain that empties into a storage tank inside the platform 100 (not shown). The spray washer assembly 150 would be located in the center portion of the platform 100 over a drain rather than at the top edge of the ramp 110 . Additionally, a detergent injection system (not shown) would attach to the pressure washer 140 to aid in the removal of the oily waste. The detergent would preferably be a non-ionic detergent that can be separated. The track gap 128 would also be located over the drain area for the nozzle 154 placements. After a spill and cleanup the oil boom 130 is pulled or towed to the floating platform 100 by a boat or other suitable means (not shown) and guided into the front guide rails 121 of the track 120 . The oil boom 130 is pulled up the front ramp 110 and as the oil boom transitions to a horizontal attitude it passes through spray washer assemblies 150 that clean the oil boom of any residual oily waste that was left on the oil boom 130 after the cleanup operation. The oily wastewater drains into a storage tank in the platform 100 so that it can be disposed of properly at a later time. The cleaned oil boom 130 continues through the remaining length of the track 120 and down the back ramp 110 where the oil boom 130 is returned to the body of water and towed to any desired location.
What has been described is only a few of many possible variations on the same invention and is not intended in a limiting sense. The claimed invention can be practiced using other variations not specifically described above. | A floating cleaning device that cleans marine growth from float and skirt type oil booms. The cleaning device is a floating platform with ramps at the front and rear with tracks that guide the movement of the oil boom past a series of spray washers supplied with pressurized water to remove the marine growth from the oil boom. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/826,805, entitled “Coupling Guard System”, filed Sep. 25, 2006 by Kevin Michael Majot and Charles Alan Rohrs, the entire contents of which is hereby incorporated by reference.
BACKGROUND
[0002] The present invention relates to connection members for components of pressure containing machinery and, more particularly, a coupling guard system for protecting and sealing an interior region of a coupling between components of the pressure containing machinery.
[0003] In existing close-coupled pressure containing machinery, the pressure containing device and structural support are combined into one unit. Historically, access to a coupling and its components has been limited due to generally small access ports in an outer casing of the coupling, which are provided for maintenance access. Combining the pressure sealing and structural support components leads to difficulty creating and maintaining a sealing surface between the co-joined equipment when sealing to contain low mole weight gasses.
SUMMARY
[0004] In one embodiment, the invention provides a guard system for a coupling that connects a first component to a second component in a pressurized machinery system. The guard system includes a coupling guard moveable between an open position, which allows access to an internal region of the coupling, and a closed position, which forms a seal surrounding the coupling from the first component to the second component. The guard system also includes a guide for directing movement of the coupling guard.
[0005] In another embodiment, the invention provides a guard system including a coupling guard moveable between an open position, which allows access to an internal region of the coupling, and a closed position, which forms a seal surrounding the coupling from the first component to the second component. A guide for directing movement of the coupling guard extends between the first component and the second component wherein the coupling guard is moveably coupled to the guide. An adjuster is coupled to the coupling guard for adjusting a position of the coupling guard relative to the guide.
[0006] In yet another embodiment, the invention provides a pressure containing coupling guard system for connecting a compressor casing to a drive casing in an industrial compression system. The coupling guard system includes a coupling guard moveable between an open position, which allows access to an internal region between the casings, and a closed position, which forms a seal surrounding the internal region. The coupling guard includes sealing surfaces comprising at least one radial sealing surface at one axial end of the coupling guard and at least one circumferential sealing surface at one axial end of the coupling. The system also includes a guide for directing axial movement of the coupling guard, wherein the guide has a slide bar extending between the compressor casing and the drive casing for aligning the coupling guard to at least one of the casings, and an adjuster for adjusting positioning of the coupling guard on the slide bar.
[0007] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a close-coupled pressure containing machinery.
[0009] FIG. 2 is a perspective view of the machinery shown in FIG. 1 , including a coupling guard system according to one embodiment of the invention and in a closed position.
[0010] FIG. 3 is a perspective view of the machinery shown in FIG. 1 , including the coupling guard system shown in FIG. 2 in an open position.
[0011] FIG. 4A is an end view of a coupling guard that is part of the coupling guard system shown in FIG. 2 .
[0012] FIG. 4B is a sectional view of the coupling guard taken along line 4 B- 4 B of FIG. 4A .
[0013] FIG. 5 is a perspective view of a slide adjuster that is part of the coupling guard system shown in FIG. 2 .
[0014] FIG. 6 is a perspective view of a slide guide that is part of the coupling guard system shown in FIG. 2 .
[0015] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
[0016] For example, terms like “central”, “upper”, “lower”, “front”, “rear”, and the like are only used to simplify the description of the present invention and do not alone indicate or imply that the device or element referred to must have a particular orientation. The elements of the retractable pressure containing coupling guard system referred to in the present invention can be installed and operated in any orientation desired. In addition, terms such as, “first”, “second”, and “third” are used herein for the purpose of description and are not intended to indicate or imply relative importance or significance.
DETAILED DESCRIPTION
[0017] FIG. 1 illustrates a close-coupled pressure containing machinery system of a type that is suitable for use with the present invention. In FIG. 1 there is specifically shown an industrial compression system 10 , which is used in industry to compress gasses or fluids for industrial purposes. The system 10 might, for example, be used on an oil drilling platform or an oil production platform. The industrial compression system 10 includes two compressors 14 close-coupled to a double-ended electric motor drive 18 . This arrangement allows for a compact design with significant benefits over more traditional base-plate mounted compressor trains. Each compressor 14 is surrounded by a cylindrical compressor casing 22 and the motor 18 is surrounded by a cylindrical motor casing 26 . The compressor casing 22 and the motor casing 26 are separate bodies that are positioned to facilitate installation and removal of components. The compressor casing 22 and the motor casing 26 are connected together with a coupling 30 ( FIG. 3 ), which separates pressure containing components and provides a mechanical support structure for connecting the casings 22 , 26 .
[0018] Referring to FIG. 3 , the coupling 30 includes access ports 34 . The ports 34 provide openings to facilitate removal of bearings, seals, gears, electrical connections and other components within an interior region 38 of the coupling 30 while the electrical drive 18 and the compressor 14 remain connected together. The coupling 30 is attached to the compressor casing 22 and the motor casing 26 with an attachment structure that resists various forces thereon. In the illustrated embodiment, a main case attachment structure 42 , or casing, includes threaded studs and nuts for coupling 30 the coupling to the motor casing 26 , and the like may be used for coupling the coupling 30 to the compressor casing 22 . Other means of mechanical attachment may be employed such as shear rings or other commonly used attachment structures. The attachment structure 42 should be sufficiently sound structurally to prevent separation, vibration, disattachment, torquing or other problems in the integrity of the attachment of the compressor casing 22 to the motor casing 26 .
[0019] In the illustrated embodiment, a coupling guard system 46 covers the coupling 30 to allow increased maintenance access to the coupling 30 and the associated components while maintaining a high degree of sealed joint integrity. The coupling guard system 46 is a retractable, pressure containing guard system. The coupling guard system 46 separates pressure containing components of the machinery system 10 from structural support components, and maintains a pressure seal over the access ports 34 in the coupling 30 . It is desirable that the pressure containing structure 46 is independent of the main structural mechanical connection 30 ; therefore, a pressure containing sealing surface is not subject to mechanical loads associated with support and operation of the equipment. As an independent structure, the pressure containing sealing surface provides ease of maintenance and sealing integrity.
[0020] FIG. 2 illustrates the coupling guard system 46 in a closed position to protect the coupling 30 , and FIG. 3 illustrates the coupling guard system 46 in an open position to allow access to the coupling 30 . In the open position, access to the interior region 38 of the coupling 30 is gained through the ports 34 . In the closed position, the ports 34 are covered by a coupling guard 50 , or cover, in order to seal the coupling 30 and components contained within the coupling 30 . The coupling guard 50 is mounted to the machinery system 10 for axial movement, and may be locked into position to form a sealing surface over the coupling 30 .
[0021] The coupling guard system 46 includes the coupling guard 50 ( FIGS. 4A and 4B ), two pairs of slide blocks 54 ( FIG. 5 ), or adjusters, and two slide guides 58 ( FIG. 6 ), or bars. The coupling guard 50 is generally cylindrical and includes an exterior surface 62 and an interior surface 66 . In the illustrated embodiment, the coupling guard 50 is constructed as a single ring having no bolted joints. The guard 50 includes two slots 70 defined on the exterior surface 62 with the slots 70 spaced approximately 180° apart. For example, one slot 70 is provided at a nine o'clock position and the other slot 70 is at a three o'clock position to control alignment and axial movement of the guard 50 . Each slot 70 is defined by a pair of radially extending projections 74 , and receives a slide guide 58 for sliding movement thereon. A radially extending flange 78 extends between the first and second slots 70 . Structural ribs, lifting lugs, vents, drains and injection connections in the coupling guard 50 may be varied as appropriate and necessary. Any connecting hardware, pattern of openings, construction of casing and direction that the coupling guard retracts may be varied as appropriate or necessary.
[0022] At each axial end 82 of the coupling guard 50 , sealing members 86 , 90 are positioned such that when the coupling guard system 46 is in the closed position, the sealing members 86 , 90 operate to prevent pressurized gases from escaping from the interior region 38 of the coupling 30 . The sealing members 86 , 90 provide a high integrity seal when the coupling guard system 46 is in the closed position. Various locations for the sealing members 86 , 90 may be used as long as seal integrity is maintained. In the illustrated embodiment, the coupling guard 50 includes the sealing members 86 , 90 or elements to facilitate sealing between the coupling guard system 46 , the coupling 30 and the casings 22 , 26 . Sealing member 86 is positioned on a radial surface at each axial end 82 of the coupling guard 50 . Sealing members 90 are positioned on the interior surface 66 of the coupling guard 50 at each axial end 82 . In one embodiment, the sealing members 86 , 90 each include a groove formed in the surface of the coupling guard 50 and an O-ring 94 received and retained in the groove. The diameter on which each groove is placed is minimally different so as to minimize axial forces exerted on the coupling guard 50 from the pressurized contents. In one embodiment, the sealing members 86 , 90 have similar construction in order to minimize axial forces.
[0023] As shown in FIGS. 2 and 3 , one pair of slide blocks 54 is attached to the projections 74 defining each slot 70 . Each slide block 54 ( FIG. 5 ) includes first and second end surfaces 98 and first and second side surfaces 102 . An aperture 106 extends through the first and second end surfaces 98 for slidingly receiving a slide bar 110 extending from the motor casing 26 towards the compressor casing 22 . The slide bar 110 provides directional guidance to the coupling guard system 46 . At least one side surface 102 of the slide block 54 includes a pair of apertures 114 for coupling the block 54 to the coupling guard 50 . In the illustrated embodiment, a roller 118 is positioned between the coupling apertures 114 for facilitating sliding movement of the coupling guard 50 along the slide guides 58 . The roller 118 is directed toward the slot 70 such the respective slide guide 58 is sandwiched between the coupling guard slot 70 and the slide block 54 . The slide blocks 54 are used as a manual slide adjuster to axially move the coupling guard 50 relative to the casings 22 , 26 . It should be readily apparent to those of skill in the art that other types of friction reducing components, such as low-friction inserts, may be used in the slide blocks 54 .
[0024] The coupling guard system 46 includes the two slide guides 58 for providing directional guidance and support to the coupling guard 50 in axial movement between the closed position and the open position. Each slide guide 58 extends between the compressor casing 22 and the motor casing 26 , as is coupled thereto. In one embodiment, the slide guides 58 may operate as an assembly tool. In still another embodiment, rollers may be provided in the slide guides 58 for facilitating sliding movement of the coupling guard 50 . Referring to FIG. 2 , a lock block 122 is positioned between the coupling guard 50 and a motor casing end of the slide guide 58 to prevent axial movement of the coupling guard 50 when in the closed position. It should be readily apparent to those of skill in the art that other known locking mechanisms may be used. Further, fewer or more slide guides 58 may be used. Also, other means for positioning and directing movement of the coupling guard 50 , such as a linear tab engaging a slot or other type of similar positioning member, may be used.
[0025] In FIGS. 2 and 3 , only one side of the coupling guard system 46 is shown; therefore, only one pair of slide blocks 54 and one slide guide 58 is shown. The second pair of slide blocks 54 and second slide guide 58 is located on the opposite side of the coupling guard system 46 . That is, the slide blocks 54 and slide guides 58 are positioned approximately 180° degrees apart on each side of the coupling guard 50 .
[0026] Referring to FIG. 2 , the retractable pressure containing coupling guard system 46 is shown in a closed position. In the closed position, the sealing members 86 , 90 engage mating surfaces on the compressor casing 22 and motor casing 26 to form a sealed enclosure around the coupling 30 . A lock block 122 is positioned between the coupling guard 50 and a motor casing end of the slide guide 58 to prevent axial movement of the coupling guard 50 . The lock block 122 provides a positive axial stop, while allowing the coupling guard 50 to float on the sealing surfaces 86 , 90 as necessary during equipment operation. The lock block 122 is removed or moved to a non-blocking position in order to move the coupling guard system 46 to the open position.
[0027] To move the coupling guard system 46 to the open position, a user utilizes the slide blocks 54 , or manual slide adjusters, to physically slide the coupling guard 50 along the slide guides 58 . Rollers 118 on the slide blocks 54 facilitate sliding movement of the coupling guard 50 . In a further embodiment, electric, hydraulic or pneumatic mechanisms may also be employed as a means to slide the coupling guard 50 between the closed position and the open position.
[0028] The coupling guard system 46 enables opening and closing of the coupling guard 50 with a simple, convenient process, and provides for ease of maintenance and sealing integrity.
[0029] The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention.
[0030] Since other modifications, changes and substitutions are intended in the foregoing disclosure, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | A guard system for a coupling that connects a first component to a second component in a pressurized machinery system includes a coupling guard moveable between an open position, which allows access to an internal region of the coupling, and a closed position, which forms a seal surrounding the coupling from the first component to the second component. The system also includes a guide for directing movement of the coupling guard. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for the production of multi-layer coatings at reduced pressure.
UK patent specification No. 1,545,897 discloses semi-conductor devices, useful as photovoltaic cells, in which a substrate coated with a coating comprising a layer of undoped amorphous silicon (an intrinsic layer) produced by glow discharge is sandwiched between thinner layers of n-doped and p-doped amorphous silicon also produced by glow discharge. In the production of such cells, it is important, in order to maximise the efficiency of the cells, to avoid any contamination of any one silicon layer with a dopant used to produce another layer. It has therefore been proposed that the different silicon layers should be deposited in separate chambers to reduce the risk of cross-contamination, and an apparatus comprising a line of consecutive separate vacuum chambers has been proposed for the mass production of such cells. Unfortunately the productivity of an in-line apparatus is limited by the time taken to deposit the thicker intrinsic layers, and if similar sized chambers are provided for the deposition of each of the layers, the chambers for deposition of the n-doped and p-doped layers are under-utilised.
This problem is alleviated in the apparatus described in European patent specification No. 60,651; the apparatus comprises a line of 3 separate deposition chambers through which a continuous ribbon of metal foil to be coated is advanced. By making the lengths of the separate deposition chambers approximately proportional to the deposition times required for the different coating layers, the overall efficiency of the apparatus may be improved. However, this involves the use of a long and expensive vacuum chamber for the intrinsic layer, and a continuous process increases the risk of cross-contamination between the deposition chambers.
SUMMARY OF THE INVENTION
According to the present invention, there is provided an apparatus for the deposition of multi-layer coatings on substrates comprising at least 3 evacuable deposition chambers, means for evacuating each of said deposition chambers and coating means in each of said deposition chambers for depositing a coating layer on a substrate, an evacuable transfer chamber with closable ports providing communication between said transfer chamber and each of said deposition chambers for transfer of a substrate to be coated between said deposition chambers, means for evacuating said transfer chamber, and transfer means for transferring the substrate between said deposition chambers via the transfer chamber.
An apparatus in accordance with the invention with only three deposition chambers is most useful for the application of two layer coatings in which the deposition time for one of the layers is about twice that for the other layer. For the production of the 3 layer amorphous silicon coatings described above, an apparatus according to the invention with at least 4 deposition chambers is preferred.
According to a preferred aspect of the invention, there is provided an apparatus comprising at least 4 evacuable deposition chambers, means for evacuating each of said deposition chambers and coating means in each of said chambers for depositing a coating layer on a substrate, an evacuable transfer chamber with closable ports providing communication between said transfer chamber and each of said deposition chambers for transfer of a substrate to be coated between said deposition chambers, means for evacuating said transfer chamber, and transfer means for transferring a substrate between said deposition chambers via the transfer chamber.
A single pump may be used to evacuate the deposition chambers and transfer chamber. However, at least in so far as the deposition chambers are used for the deposition of different coatings, it is generally preferred to provide each deposition chamber with its own independent evacuation system and pump in order to minimise the risk of cross-contamination between the chambers. Similarly, it is preferred that the transfer chamber should be provided with its own independent evacuation system and pump. In operation of the apparatus, the transfer chamber is preferably maintained at lower pressure than any of the deposition chambers to avoid any gas which has entered the transfer chamber from one deposition chamber being drawn into any other deposition chamber and causing contamination of the coating deposited in that chamber.
Each deposition chamber is provided with means for depositing a coating on the substrate. The nature of this coating means will depend on the nature of the coating to be deposited. When it is desired to deposit a silicon coating by a glow discharge technique, the apparatus preferably comprises means for supplying a coating gas to each of said deposition chambers and each of said deposition chambers is provided with electrode means for generation of a glow discharge in that chamber with deposition of a coating on a substrate in that chamber.
The transfer chamber is in interruptable communication through closable ports with each of the deposition chambers for transfer of a substrate to be coated between chambers. A compact arrangement may be achieved by disposing the deposition chambers on the arc of a circle around the transfer chamber. Each of the deposition chambers preferably opens directly into the transfer chamber, with a closable port separating the deposition chamber from the transfer chamber. The closures between the transfer chamber and the deposition chamber restrict the flow of gas between the deposition chambers and the transfer chamber and preferably provide gas tight seals between the chambers.
The transfer means for transferring the substrate between the chambers is preferably mounted in the transfer chamber and operable to transfer a substrate from the transfer chamber into and out of the deposition chambers. Preferably, it includes an arm rotatably mounted in the transfer chamber. The deposition chambers are then conveniently disposed on the arc of a circle about the axis of rotation of the arm, and preferably extend either parallel to that axis or radially away from that axis. In a preferred embodiment, the rotatably mounted arm is radially reciprocal and the deposition chambers are disposed on the arc of a circle about the axis of rotation of the arm and extend radially away from that axis. In use of this embodiment, the arm may rotate carrying the substrate to a position adjacent the entrance port of a deposition chamber and then advance radially carrying the substrate into the adjacent deposition chamber, release the substrate and retract. The deposition chamber is then closed off from the transfer chamber and a layer of coating material deposited on the substrate. The deposition chamber is then opened to the transfer chamber and the transfer means may operate to withdraw the substrate from the deposition chamber, rotate to a position adjacent the entrance port of a second deposition chamber, and the sequence be repeated.
The apparatus preferably includes an evacuable chamber, with means for evacuating that chamber, for introducing a substrate to be coated. The evacuable chamber preferably opens into the transfer chamber, but may alternatively open into one of the deposition chambers. Thus the apparatus preferably includes, in addition to the deposition chambers, at least one evacuable inlet and/or outlet chamber with a closable entry port for introduction and/or removal of a substrate, means for evacuating said inlet/outlet chamber, and a closable port for transfer of a substrate between said chamber and the transfer chamber.
The apparatus may further include an additional evacuable deposition chamber for deposition of a metal layer. Thus, in a preferred aspect of the invention, the apparatus comprises an additional evacuable deposition chamber, a closable port between said additional chamber and the transfer chamber, means for evacuating said additional chamber, and heating means in said chamber for evaporation of a metal and deposition of a coating of said metal on a substrate in the chamber.
Apparatus in accordance with the present invention has important advantages over an in-line apparatus of similar capacity. It may be smaller and more compact, and consequently cheaper. The coating processes and deposition times in the individual chambers may be varied independently, and individual deposition chambers may be isolated for maintenance or modification while the remaining chambers remain available for use.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated but not limited by the following description with reference to the accompanying drawings in which:
FIG. 1 is a schematic plan view of an apparatus in accordance with the invention showing the general layout of the apparatus and transfer mechanism.
FIG. 2 is a schematic horizontal section on an enlarged scale compared to FIG. 1 of a deposition chamber of the apparatus in FIG. 1.
FIG. 3 is a side elevation on an enlarged scale compared to FIG. 1 of a substrate carrier for use in the apparatus of the present invention.
FIG. 4 is a section in the line IV--IV of the carrier shown in FIG. 3.
FIG. 5 is an end elevation of the carrier shown in FIG. 3 in the direction of arrow V in FIG. 3.
FIG. 6 is a plan view on an enlarged scale compared to FIG. 1 of the transfer mechanism shown in FIG. 1, omitting the detail of the latch mechanism shown in FIG. 8.
FIG. 7 is a vertical section on line VII--VII in FIG. 6, again omitting the detail of the latch mechanism.
FIG. 8 is a rear elevation on an enlarged scale compared to FIG. 7 in the direction of arrow VIII in FIG. 7 showing a latch mechanism.
DETAILED DESCRIPTION
The apparatus, generally designated 1, shown in FIG. 1 comprises a generally hexagonal central transfer chamber 2 with closable ports opening from the transfer chamber 2 into an inlet chamber 3 of circular section, four similar deposition chambers 4, 5, 6 and 7 of rectangular vertical section for deposition of amorphous silicon layers by glow discharge and a deposition chamber 8 of circular section for deposition of a metal layer, which also serves as an outlet chamber. The transfer chamber 2 is connected to a pump P2 via valve V2 for evacuation of the chamber and is provided with transfer means, generally designated 12, and including a transfer arm generally designated 13 rotatable about vertical axis 20 at the centre of chamber 2. The transfer mechanism is more fully described hereafter with reference to FIGS. 6, 7 and 8. Referring to FIG. 1, it will be seen that the coating chambers are disposed on the arc of a circle about the axis 20 of rotation of the transfer arm 13 and extend radially away from that axis.
The inlet chamber 3 has a loading port at 25 controlled by a slide valve similar to valve 33 (see below) for introduction of substrates to be coated mounted on a substrate carrier described in detail below. The inlet chamber is connected to a pump P3 via valve V3 for evacuation of the chamber. Infra red heaters are provided in inlet chamber 3 and the inlet chamber 3 opens into transfer chamber 2 by a port at 28 controlled by a slide valve similar to valve 33 (see below).
The construction of the deposition chambers 4, 5, 6 and 7 is illustrated in more detail in FIG. 2 which is a schematic horizontal section through one of these chambers. The deposition chambers are each composed of an inner fixed part 29 and an outer detachable part 31 with a flange 32, bolted to fixed part 29, at its inner end. A slide valve 33 is provided at the inner end of the deposition chamber to seal the port between the deposition chamber and transfer chamber 2. The deposition chamber is connected by a duct 34 opening into the detachable part 31 of the chamber through valve V4 to a pump P4 for evacuation of the chamber.
Each of the inlet chamber 3, the deposition chambers 4, 5, 6 and 7 and the outlet chamber 8 opens into the transfer chamber via a port sealed by a valve similar to slide valve 33.
A vertical heated support 36 for a substrate carrier is provided in the detachable part 31 of the deposition chamber mounted on supports attached to the inner fixed part 29. An insulated electrical supply for heated support 36 is provided via fixed part 29 as shown at 37. A duct 38 for the supply of coating gas controlled by valve 39 opens into the fixed part of the chamber. Flat plate electrodes 41 and 42 are vertically mounted in detachable part 31 of the deposition chamber on either side of and parallel to the heated support 36.
Deposition chamber 8, for deposition of a metal layer, is, like deposition chambers 4, 5, 6 and 7 constructed in 2 parts, a fixed inner part and a detachable outer part. The detachable outer part includes a rotatably mounted support for a carrier for substrates to be coated, and also electrically heated evaporators for evaporation of aluminium or other electrically conducting metal to be deposited on the substrates. The chamber 8 is connected to a pump P8 via valve V8 for evacuation of the chamber. An additional port at 40, controlled by a slide valve similar to valve 33 is provided at the outer end of chamber 8 for removal of a coated substrate from the apparatus. The deposition chamber 8 thus also serves as an outlet chamber. The support in chamber 8 is mounted for rotation about a horizontal axis directed towards the axis 20 of rotation of transfer arm 13. The support is held vertical to receive a loaded substrate carrier from transfer arm 13, and can then be rotated to bring the substrate carrier horizontal while a substrate is coated from aluminium evaporators below the support. When the carrier carries two parallel substrates to be coated, the support can be rotated through 180° to coat the second substrate.
A substrate carrier shown in FIGS. 3, 4 and 5 and generally designated 50 comprises two similar light rectangular carrier frames 51 and 61 mounted back-to-back on a backbone support 80. The carrier frames 51, 61 have sides 52, 53 and 62, 63 respectively extending from backbone 80 and joined towards their outer ends by longer sides 54, 64 respectively. The sides 52, 53 and 62, 63 are of U-shaped cross section, and the longer sides 54, 64 are of L-shaped cross section, to retain a flat rectangular substrate in position in each of the frames. In addition, each of the carrier frames has a retaining bar 55, 65 secured to the outer faces of sides 52, 53 and 62, 63 adjacent to and parallel to backbone 80. The ends 56, 57 (and 66, 67 not shown) of sides 52, 53 and 62, 63 are tapered (see FIG. 3) where they extend beyond sides 54, 64. The carrier supports 36 in the deposition chambers, and similar supports in the inlet chamber and outlet chamber are provided with horizontal grooves which, in use, engage the inner faces of sides 52, 53 and 62, 63 of the carrier frames. In use, the carrier is presented to the supports 36 with its backbone support 80 vertical and carried on transfer arm 13 of the transfer means 12. The tapered ends 56, 57 and 66, 67 of the sides 52, 53 and 62, 63 of the carrier frames assist in guiding the sides 52, 53 and 62, 63 into the slots in the support 36. When a loaded carrier 50 is in position on a carrier support 36, the substrates are sandwiched between the outer retaining lips 58, 59, 60 and 68, 69, 70 (FIG. 4) of the sides 52, 53, 54 and 62, 63, 64 of the carrier frames on one side and the side faces of support 36 on the other side. The substrates mounted in the carrier frames on the support 36 are thus in contact with the support and face the flat plate electrodes 41 and 42 in the deposition chamber.
The backbone 80 of substrate carrier 50 is shown in FIG. 5. It is provided with a rectangular aperture 81 at the centre thereof for engagement of the carrier 50 by transfer arm 13 of transfer means 12, and with bored holes 82, 83 into which locating rods on the transfer arm fit when the substrate carrier is engaged by the transfer arm.
Transfer means 12 is illustrated in more detail in FIGS. 6, 7 and 8. It comprises a horizontally reciprocable transfer arm 13 comprising carriage 14 mounted on a rail 16 by rollers 84. Carriage 14 carries a rack 85 which engages a pinion 86 driven by motor 15 for horizontal reciprocation of carriage 14 along rail 16. The rail 16 is mounted on a turntable 18 by supports 87, 88 (FIG. 7) and on horizontal beam 17, also carried by turntable 18, by support 89. Turntable 18 is journalled by rollers 90 for rotation in annular support 19 about vertical axis 20 at the centre of transfer chamber 2 (FIG. 1). Motor 21 drives drive wheel 22 which engages the periphery of turntable 18 for rotation of the turntable.
Carriage 14 has front and back walls 91, 92 and a longitudinal shaft 93 mounted for rotation in the front and back walls. The shaft 93 passes through and is rotatable within a fixed sleeve 94 carried by support 95 on beam 17. Sleeve 94 has a cam surface 96 and shaft 93 has four equispaced projecting rods 97 extending radially therefrom for engagement with cam surface 96 when carriage 14 is advanced along rail 16. In the position of the shaft shown in FIGS. 6, 7 and 8, the projecting rods extend vertically and horizontally. The forward end of shaft 93 is provided with a bayonet fitting 98 comprising two prongs extending radially from shaft 93; in the position of the shaft shown in FIGS. 6, 7 and 8 the two prongs of the bayonet fitting extend vertically up and down. In use the bayonet fitting engages in rectangular aperture 81 in backbone 80 of substrate carrier 50. Carriage 14 also carries spring loaded annular collars 99, 100 on horizontal rods 101, 102 above and below shaft 93. When carriage 14 picks up a carrier 50, rods 101, 102 fit into bored holes 82, 83 in backbone 80 of the carrier and the collars 99, 100 engage the outer face of backbone 80 to positively locate the carrier in position on carriage 14.
The function of sleeve 94 with its cam surface 96 is more fully described below. As carriage 14 is advanced along rail 16 into a deposition chamber (or inlet chamber) to pick up a substrate carrier 50 mounted on a support 36 with its backbone 80 facing carriage 14, bayonet fitting 98 passes through aperture 81 in backbone 80 with its prongs vertical (as in FIG. 7). The vertical rod 97 projecting upwards from longitudinal shaft 93 engages cam surface 96 of sleeve 94, rotating shaft 93 through 90° as it slides over the cam surface; thus the bayonet fitting 98 is rotated through 90° bringing its prongs horizontal so that they engage the inner face of backbone 80 when carriage 14 is withdrawn. At the same time, rods 101, 102 engage in bored holes 82, 83 in backbone 80 of carrier 50 and spring loaded collars 99, 100 engage the outer face of backbone 80 locating the carrier 50 positively in position on carriage 14. The carriage 14 is then withdrawn along rail 16 withdrawing the substrate carrier from the support 36 into transfer chamber 2. The transfer arm may then be rotated by rotating turntable 18 by motor 21 and drive wheel 22 until transfer arm 13 is directed towards a support in a deposition chamber or outlet chamber in which the carrier is to be deposited. Carriage 14 is then advanced along rail 16 sliding carrier 50 onto a support 36 in the chosen chamber. As the carriage advances along rail 16, shaft 93 advances through sleeve 94 and the next of the projecting rods 97, now directed vertically upwards, engages cam surface 95 rotating longitudinal shaft 93 through a further 90° so that the prongs of bayonet fitting 98 are returned to the vertical. The carriage 14 is then withdrawn along rail 16. The bayonet fitting withdraws through longitudinal aperture 81 as spring loaded collars 99, 100 bear on the outer face of backbone 80 of carrier 50 ensuring that carrier 50 is released from shaft 93 and remains in position on support 36. The pick up and deposition of carriers 50 on supports 36 by carriage 14 of transfer arm 13 can be repeated as required.
Carriage 14 is provided with latch mechanism 105, the structure of which is shown in FIG. 8. A disc 106 is fixedly mounted on the rearward end of the longitudinal shaft 93 where it extends through back wall 92 of carriage 14. Four rods 107 extend rearwardly from the back face of disc 106. Rods 107 are disposed radially about the axis of shaft 93 displaced at 45° from projecting rods 97 on shaft 93. A latch member 108 is pivotally mounted at one end on pivot 109 above shaft 93 and biased downwardly at its other end by spring 110 secured to stud 111. A second latch member 112 pivotally mounted at one end on pivot 113, diametrically opposite pivot point 109, is biased upwardly at its other end by spring 114 secured to stud 115. The spring biased latch members 108, 112 bear on rods 107 carried on disc 106 mounted on shaft 93 urging the shaft into rest positions with the rods 107 in the position shown so that the prongs of bayonet fitting 98 extend either exactly horizontally or exactly vertically. The latch mechanism thus operates to ensure positive engagement and disengagement of bayonet fitting 98 with backbone 80 of substrate carrier 50.
The use of the apparatus to produce photovoltaic cells on a glass substrate will now be described. First, the ports between the deposition chambers 4, 5, 6, 7, 8 and the transfer chamber 2, the port at 28 between the inlet chamber 3 and the transfer chamber 2, and the outlet port at 40 of deposition chamber 8 were closed and the deposition chamber and transfer chamber evacuated. In order to avoid any cross-contamination of the silicon layers which were to be deposited in deposition chambers 4, 5, 6, and 7, the transfer chamber 2 was evacuated to, and maintained at, a lower pressure than any of chambers 4, 5, 6 and 7. Thus, any gas flow between these deposition chambers and the transfer chamber 2 was always in the direction of the transfer chamber and not into these deposition chambers. Two rectangular panes of 2 mm thick float glass, coated on one side with an electrically conducting indium tin oxide coating were mounted in a carrier as illustrated in FIG. 3 with the coated faces facing outward. The carrier was then mounted on a support, similar to the support 36 in the deposition chambers, and the support introduced into inlet chamber through the loading port at 25 and mounted in the inlet chamber with the backbone support 80 of the carrier vertical and facing inwards towards the transfer chamber 2. The valve controlling the loading port was closed, and the inlet chamber evacuated. The valve between the inlet chamber and transfer chamber was opened and turntable 18 rotated about axis 20 until arm 13 was directed towards the carrier 50 in inlet chamber 3. The carriage 14 was advanced along rail 16 to engage carrier 50, and then retracted withdrawing carrier 50 into the transfer chamber 2. Turntable 18 was rotated until arm 13 was directed towards the support 36 in deposition chamber 4. Valve V4, controlling the evacuation of deposition chamber 4 was closed and the slide valve 33 between deposition chamber 4 and transfer chamber 2 was opened and carriage 14 advanced towards deposition chamber 4 to deposit carrier 50 on heated support 36. Carriage 14 was then retracted along rail 16, and the valve 33 controlling the port between deposition chamber 4 and transfer chamber 2 was closed.
A coating gas containing 50% monosilane (SiH 4 ), 39.6% argon and 0.4% diborane (B 2 H 6 ) by volume was introduced into deposition chamber 4 through duct 38 and the valve V4 adjusted to maintain a gas pressure of about 0.5 torr in the deposition chamber. When the glass substrates had been heated to a temperature of about 270° C. by electrically heated support 36, a D.C. voltage of 1 Kv was applied between electrodes 41, 42 and the heated support. The resultant glow discharge caused silane and diborane to decompose depositing a p-doped layer of amorphous silicon on the oxide coated faces of the glass substrates. The discharge was continued until p-doped layers approximately 10 nm thick had been deposited on the glass substrates. The voltage supply to the electrodes was switched off and valve 39 controlling the supply of coating gas closed. When the pressure in deposition chamber 4 had fallen to a value close to the pressure in transfer chamber 2, valve V4 was closed. The slide valve 33 was opened and carriage 14 advanced towards deposition chamber 4 to engage carrier 50 and then retracted withdrawing carrier 50 into transfer chamber 2.
Turntable 18 was then rotated until arm 13 was directed towards support 36 in deposition chamber 5. The carrier was then introduced into deposition chamber 5 by carriage 14 and intrinsic silicon layers approximately 500 nm deposited on top of the p-doped layers in a similar manner to that described above, except that 100% monosilane was used as the coating gas.
While the intrinsic layers were being deposited in deposition chamber 5, a second carrier loaded with 2 rectangular panes of float glass bearing electrically conducting indium tin oxide coatings was introduced through inlet chamber 3 and transfer chamber 2 into deposition chamber 4, a p-doped layers of amorphous silicon 10 nm thick deposited on the oxide coatings. The second carrier was then transferred by transfer means 12 from deposition chamber 4 via transfer chamber 2 to deposition chamber 6 for deposition of intrinsic layers of silicon approximately 500 nm thick on the p-doped layers.
When deposition of the intrinsic layers in deposition chamber 5 was complete, the first carrier was transferred by transfer means 12 via transfer chamber 2 from deposition chamber 5 to deposition chamber 7. In deposition chamber 7, n-doped layers of amorphous silicon approximately 20 nm thick were deposited on the intrinsic layers in a similar manner to that described above, except that a coating gas containing 60% monosilane, 39.6% argon and 0.4 phosphine (PH 3 ) by volume was used. The carrier was then transferred by transfer means 12 via transfer chamber 2 to deposition chamber 8 for deposition of aluminium layers 200 nm thick on top of the n-doped silicon layers in known manner. The carrier bearing the coated substrates was then withdrawn from the apparatus through outlet port 40 at the outer end of deposition chamber 8.
After the first carrier had been withdrawn from deposition chamber 7 and the intrinsic layers had been deposited on the substrates on the second carrier in deposition chamber 6, the second carrier was transferred by transfer means 12 via transfer chamber 2 to deposition chamber 7 for deposition of layers of n-doped silicon approximately 20 nm thick on the intrinsic silicon layers. It was then transferred by transfer means 12 via transfer chamber 2 to deposition chamber 8 for deposition of layers of aluminium approximately 200 nm thick in known manner on the layers of n-doped silicon, and then withdrawn from the apparatus through outlet port 40 at the outer end of deposition chamber 8.
It will be understood that further substrates may be introduced into deposition chamber 4 as soon as it has been vacated, and, in the process described the productive capacity of the apparatus is limited by the time taken to deposit the relatively thick intrinsic silicon layers in deposition chambers 4 and 5. However, by providing two chambers for the deposition of intrinsic layers, as opposed to the single chamber of an in-line apparatus with three similar sized chambers for the deposition of the p-doped, intrinsic and n-doped layers, an apparatus with a productive capacity substantially twice that of the in-line apparatus is obtained. The capacity of the apparatus can be increased further by providing additional chambers e.g. in an octagonal arrangement, for deposition of intrinsic silicon layers. By using an octagonal arrangement, six deposition chambers may be provided for depositing silicon layers in addition to the inlet chamber and outlet chamber. Of the six chambers, four are preferably used for deposition of intrinsic layers, and one each for deposition of p-doped and n-doped layers.
A further advantage of the apparatus, when compared with a continuous in-line apparatus, is that the deposition times in the individual chambers may be varied independently without changing the dimensions of the chambers. Moreover, because of the arrangement of the deposition chambers opening into a common transfer chamber, individual chambers may be taken out of use and dismantled for maintenance or modification without affecting the operation of the other chambers. Maintenance of the chambers used for deposition by gas discharge may be further simplified by using the chamber walls as electrodes so avoiding the need for separate electrodes such as 41 and 42. In this case, at least the detachable outer part 31 of the deposition chamber is constructed of electrically conductive material, for example stainless steel (which is in fact a preferred material for fabrication of all the chambers) and is electrically isolated from fixed inner part 29 and duct 34 by PTFE insulating gaskets. The support 36 is earthed, so earthing the glass and glass carrier, and the chamber wall connected to an appropriate RF source or DC source at a negative potential relative to earth. If necessary, glass insulating pieces are placed over the top, bottom and end walls of the chamber to ensure that the gas discharge is generally normal to the glass substrates; alternatively, the need for such insulating pieces may be avoided by so dimensioning the chamber that gas discharge takes place preferentially from walls parallel to the plane of the glass and any discharge from other walls is negligible. | Compact and versatile apparatus for deposition of multi-layer coatings on substrates at reduced pressure comprises at least 3 and preferably at least 4 evacuable deposition chambers, means for evacuating each of said deposition chambers and coating means in each of said deposition chambers for depositing a coating layer on a substrate; an evacuable transfer chamber with closable ports between said transfer chamber and each of said coating chambers for transfer of a substrate to be coated between said deposition chambers; means for evacuating said transfer chamber; and transfer means for transferring a substrate between said deposition chambers via the transfer chamber. The apparatus is especially useful for the production of photovoltaic cells in which the active layers are formed of amorphous silicon deposited from a glow discharge. | 8 |
BACKGROUND ART
[0001] 1. Field of the Invention
[0002] The invention relates to a cleaning device for a motor vehicle. More particularly, the invention relates to a cleaning device for an exterior surface of a portion of a motor vehicle.
[0003] 2. Description of the Related Art
[0004] In the use of ultra-hydrophobic coatings, the water automatically rolls off the coated surface, thereby entraining dirt particles. However, if only moist dirt particles are present on the coated surface, even with ultra-hydrophobic coatings, the dirt particles may not run off, but instead may remain adherent. Such ultra-hydrophobic coatings are used for mirror glass in exterior rearview mirrors of motor vehicles, for headlights, tail lights, or camera lenses, or to cover same, or for windshields or rear windows, as well as auxiliary brake lights. It is not possible to achieve an adequate cleaning action for these parts of the motor vehicle. These disadvantages are present not only for hydrophobic coatings, but also for conventional surfaces.
SUMMARY OF THE INVENTION
[0005] A cleaning assembly cleans an exterior surface of a motor vehicle. The exterior surface defines first and second edges. The motor vehicle includes a cleaning fluid reservoir. The cleaning assembly includes a connector for connecting the cleaning fluid reservoir with the cleaning assembly for receiving fluid therefrom. A distribution chamber is in fluid communication with the connector and receives the fluid received by the connector. The cleaning assembly also includes a nozzle fixedly secured to the distribution chamber for disbursing the fluid over the exterior surface. The nozzle includes a nozzle opening that defines a slot opening such that a film of fluid exits the nozzle opening over the exterior surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Advantages of the 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:
[0007] FIG. 1 is a front view of a portion of an external rearview mirror of a motor vehicle incorporating one embodiment of the invention;
[0008] FIG. 2 is a front view of a portion of an external rearview mirror of a motor vehicle incorporating a second embodiment of the invention;
[0009] FIG. 3 is a cross-sectional side view taken along lines III-III of FIG. 1 ;
[0010] FIG. 4 is a detailed view of area IV of FIG. 3 ;
[0011] FIG. 5 is top view of the external mirror taken along arrow V of FIG. 1 ; and
[0012] FIG. 6 is a cross-sectional side view of a third embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] FIG. 1 shows a portion of an external rearview mirror 1 having a cleaning device 2 provided in a corner region of a mirror glass holder 3 . The mirror glass holder supports in a known manner a mirror glass 4 having a hydrophobic coating. The mirror glass holder 3 is accommodated in a mirror housing (not illustrated) which is attached to the vehicle by a mirror mounting bracket. The mirror housing is able to swivel with respect to the mirror mounting bracket in both the direction of travel of the vehicle and the opposite direction thereto. For the two swivel directions, one swivel axis may be provided for each direction (double-axis mirror), or only one swivel axis (single-axis mirror) may be provided. It is advantageous for the mirror head to be able to swivel in the parked position as well.
[0014] The mirror head may accommodate heating devices for heating the mirror glass 4 for a nozzle 5 , to be described below, in the cleaning device 2 , at least one ambient light, a repeating directional indicator light, at least one speaker, a GPS module, a drive for the motorized adjustment of the mirror glass holder 3 , an antenna, a camera, and the like. These built-in elements may be provided in any given combination or also singly, depending on the requirements of the vehicle manufacturer.
[0015] An ambient light, a speaker, and the like may be housed in the mirror mounting bracket. These built-in elements as well may be provided singly or in any given combination.
[0016] The cleaning device 2 has a nozzle 5 and a connector 6 for a cleaning medium. 44 , preferably water. The connector 6 is connected to a supply container 40 for the cleaning medium 44 via a line 42 (both schematically shown in FIG. 3 ). The supply container 40 may be the container for the window and/or headlight washing system. However, a separate supply container may also be provided which is installed at a suitable location in the vehicle.
[0017] The cleaning medium 44 , which is to be applied to the mirror glass 4 to be cleaned via the cleaning device 2 , is supplied under pressure from the supply container 40 to the connector 6 by means of a pump (not illustrated) using or through a controllable multi-way valve. The nozzle 5 and the connector 6 together with the mirror glass holder 3 may be manufactured in one piece from an appropriate plastic. The connector 6 is situated behind the mirror glass holder 3 , thus enabling the line 42 for supplying the cleaning medium 44 to be connected in a concealed manner. To ensure a secure seating for the line 44 , the free end 8 of the connector 6 has a conically expanded design in the direction of insertion of the line 44 in a manner known in the art.
[0018] In the embodiment according to FIG. 1 , the nozzle 5 for the cleaning device 2 is situated in the corner region of the mirror glass 4 . The nozzle 5 extends over an angular region of approximately 90°, and with its wall 9 overlaps the mirror glass 4 . According to FIG. 1 , the nozzle 5 is curved with respect to the mirror edge on which it is provided. The wall 9 runs parallel to and at a small distance from the top side 4 ′ of the mirror glass 4 , and makes a right-angle transition to a side wall 10 , which, in turn, perpendicularly adjoins the edge 11 of the mirror glass holder 3 . The side wall 10 is separated by a distance from the edge 12 of the mirror glass 4 . The walls 9 and 10 of the cleaning device 2 extend over an angular range of approximately 90°.
[0019] The exposed edge 13 of the wall 9 is slightly curved in the direction of the mirror glass 4 , and has a flat end face 14 which is parallel to the top side 4 ′ of the mirror glass 4 and together with same forms an oblong channel 23 which extends over an angular range of approximately 90°. The depth of the channel is approximately a multiple larger than the height thereof. The end-face channel opening forms a narrow, essentially rectangular nozzle opening 15 through which the cleaning medium 44 emerges from the nozzle 5 under sufficiently high pressure. Since the nozzle opening 15 extends over an angular range, the cleaning medium 44 emerges not in the form of a jet, but instead as a flat film of liquid, whereby the dirt particles on the surface 4 ′ of the mirror glass 4 are impinged on by the cleaning medium 44 over the entire surface to be cleaned, and are outwardly swept away to the edges of the mirror by the nozzle 5 . Optimum cleaning of the mirror glass is thereby achieved in a simple manner. The distance between the end face 14 and the top side 4 ′ of the mirror glass is a multiple smaller than the depth of the channel 23 , but is significantly less than the length of the nozzle edge 9 or the nozzle opening 15 . In the front view (arrow P in FIG. 1 ), the channel 23 has a rectangular contour and advantageously extends over the entire circumferential region of the nozzle 5 .
[0020] As a result of the design according to the invention, the cleaning medium 44 emerges as a flat film of liquid which impinges over the surface to be cleaned as soon as it emerges from the outlet opening. The outlet opening may be very narrow, so that the cleaning medium 44 strikes the surface to be cleaned at a high velocity and reliably removes even stubborn, deep-seated dirt. The oblong channel 23 allows the cleaning medium 44 to be supplied uniformly to the outlet opening. The emerging flat film of liquid sweeps away the dirt particles on the surface to be cleaned, thereby reliably removing even strongly adhering particles.
[0021] The cleaning medium 44 supplied via the connector 6 first passes into a distribution chamber 16 which is externally bordered by the walls 9 , 10 of the nozzle 5 and is internally bordered by the edges 11 , 12 of the mirror glass 4 and the mirror glass holder 3 . As shown in FIG. 1 , the distribution chamber 16 is bordered on its end face region by end walls 17 , 18 which are designed as one piece together with the walls 9 , 10 and the mirror glass holder 3 , and which form the side boundaries of the channel 23 .
[0022] Since the visible side 4 ′ of the mirror glass 4 is adjacent to the channel 23 and the nozzle opening 15 on one side, the cleaning medium 44 reaches the mirror glass 4 directly. Even the surface portion of the mirror glass 4 beneath the wall 9 is easily impacted by the cleaning medium 44 .
[0023] Adjoining the end face 14 or the channel 23 , the interior 19 of the distribution chamber 16 is outwardly offset, thereby forming a step and a contiguous expanded space 24 which is part of a distribution chamber 16 . The oblong channel 23 is thinner in cross section than the distribution chamber 16 . However, in the direction transverse to the direction of flow of the cleaning medium 44 the space 24 has a smaller extension than the remainder of the distribution chamber 16 ( FIG. 4 ). This assists in effective cleaning, since the flow velocity of the cleaning medium 44 is increased as a result of the cross-sectional constriction upstream from the nozzle opening 15 or upstream from the channel 23 .
[0024] In principle, the cleaning device 2 may be provided at any of the corners of the mirror glass 4 . It is also possible to provide one cleaning device 2 at each of two, three, or all four corners of the mirror glass 4 .
[0025] A second embodiment according to FIG. 2 differs from the previous exemplary embodiment in that the cleaning device 2 a extends over a considerably greater length. The cleaning device runs from the corner region 7 over the outer side edge 20 and the upper longitudinal edge 21 , almost to the inner side edge 22 of the mirror glass 4 . For supplying the cleaning medium 44 the connector is provided at a suitable location on the cleaning device 2 a , and in other respects has the same design as in the previous exemplary embodiment.
[0026] Such a long cleaning device 2 , 2 a may be divided into two or more chambers, each of which is associated with a connection. The cleaning medium 44 then emerges from each of the nozzle openings in the chambers in a flat manner, so that the mirror glass 4 is impinged on over its entire surface and dirt particles thereon are swept away.
[0027] The cleaning device 2 , 2 a may also be provided on the mirror mounting bracket (not illustrated) for the external rearview mirror. The cleaning device is positioned so that the cleaning medium 44 strikes the side window of the motor vehicle. The nozzle opening once again has a slotted shape so that the cleaning medium 44 emerges as a flat film of liquid.
[0028] As shown in FIG. 6 , a third embodiment of the cleaning device 2 b may also be a separate unit or a built-in module which is attached at the mounting location, for example by gluing, clipping, plugging in, or the like. In this case, the glass support plate 3 b is attached by its angled edge 25 in a groove 26 in the device 2 b. The groove 26 is situated in a relatively thick-walled transitional segment 27 between the nozzle 5 b and the water connector 6 b , which has essentially the same design as in FIG. 1 . In contrast to the two previous exemplary embodiments, the channel 23 b is bordered by two flat, parallel end faces 14 b and 28 which are a component of the nozzle 5 b. The end face 28 of the channel 23 b lies in the same plane as the top side 4 ′ of the mirror glass 4 . As soon as the cleaning medium 44 emerges from the slot-shaped nozzle opening 15 b , it reaches the top side 4 ′ of the mirror glass. Because of the slot-shaped design, as in the previous embodiments the cleaning liquid emerges as a thin film of liquid over the length of the nozzle opening 15 b.
[0029] The end face 28 and the top side 4 ′ of the mirror glass directly adjoin one another, so that the cleaning medium 44 reaches the top side 4 ′ of the mirror glass without difficulty. To achieve a clean connection of the end face 28 of the nozzle 5 b to the top side 4 ′ of the mirror glass, the end face adjoins a connecting side 29 of the nozzle 5 b at an acute angle.
[0030] The same as for the previous embodiments, the flat film of liquid sweeps away the dirt particles on the top side 4 ′ of the mirror glass, so that even firmly adhering particles are reliably dislodged.
[0031] The space 24 b , which is at a higher level than the channel 23 b , adjoins the channel 23 b and has the same design as in the previous exemplary embodiments.
[0032] The nozzle 5 b in other respects has the same design as the nozzles described according to FIGS. 1 through 5 . The cleaning device 2 b may extend over an angular range of 90°, for example, according to FIG. 1 . However, the cleaning device 2 b may also extend over a longer edge region of the mirror glass 4 , as described by way of example with reference to FIG. 2 .
[0033] The cleaning device 2 , 2 a , 2 b may also be provided as an integrated or separated component of the headlights, tail lights, camera lenses, windshield, back window, or auxiliary brake lights of vehicles. Of course, multiple cleaning devices may be provided on the vehicle to clean various parts thereof.
[0034] The pump or the multi-way valve may be manually switched on and off. It is also possible to actuate the pump or the multi-way valve by means of the signal from a sensor which measures the degree of soiling on the surface to be cleaned and emits a switching signal when a specified degree of soiling is exceeded. In this manner the surface is automatically cleaned.
[0035] The surfaces to be cleaned may be provided with a hydrophobic or ultra-hydrophobic coating. However, the cleaning device 2 , 2 a , 2 b may also be used for surfaces which do not have such a coating.
[0036] The invention has been described in an illustrative manner. 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.
[0037] Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described. | A cleaning assembly cleans an exterior surface of a motor vehicle. The exterior surface defines first and second edges. The motor vehicle includes a cleaning fluid reservoir. The cleaning assembly includes a connector for connecting the cleaning fluid reservoir with the cleaning assembly for receiving fluid therefrom. A distribution chamber is in fluid communication with the connector and receives the fluid received by the connector. The cleaning assembly also includes a nozzle fixedly secured to the distribution chamber for disbursing the fluid over the exterior surface. The nozzle includes a nozzle opening that defines a slot opening such that a film of fluid exits the nozzle opening over the exterior surface. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 10-2008-0136668, filed on Dec. 30, 2008, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to an attitude control method of a spacecraft of an artificial satellite, and more particularly, to a method of improving a maneuverability and a controllability by simultaneously applying a reaction wheel and a thruster among drive units used to maneuver an attitude of the spacecraft of the artificial satellite.
[0004] 2. Description of the Related Art
[0005] Existing driving units mounted on a spacecraft of an artificial satellite include a thruster-based attitude controller and a reaction wheel-based attitude controller. In the related art, the thruster-based attitude controller and the reaction wheel-based attitude controller are independently operated. Generally, the thruster-based attitude controller has a relatively poorer performance in measuring an attitude accuracy of the spacecraft of the artificial satellite, but is used for a safe operation. The reaction wheel-based attitude controller is generally used to improve an attitude control accuracy when photographing for a mission of earth observation.
[0006] A technology of using both the existing thruster-based attitude controller and the reaction wheel-based attitude controller may be an angular momentum dumping technology to dump accumulated angular momentum of reaction wheels using the thruster-based attitude controller when the angular momentum of reaction wheels accumulates due to a external disturbance. Specifically, the reaction wheel-based attitude controller is used as a main attitude controller and the thruster-based attitude controller is used as an auxiliary attitude controller.
[0007] Here, a thruster is used in the spacecraft for an attitude control and an orbit control, and thus indicates a thrust force generating device to control an attitude or an orbit of the artificial satellite. For example, the thruster used for a gas injection control device may obtain a high temperature and a high pressure gas by causing a chemical reaction or a decomposition reaction using a catalyst in a high pressure gas or liquid, and then may generate a thrust force by quickly spraying the obtained gas via a nozzle. The existing thruster is symmetrically provided with respect to a reference axis of the spacecraft.
[0008] A reaction wheel mounted on the spacecraft of the existing artificial satellite denotes a device to generate a torque for the attitude control of the spacecraft, and thus to use a reaction torque occurring by accelerating or decelerating a speed control wheel using an electric motor. A momentum wheel employed in an attitude control system using a bias momentum scheme has the same functions as the reaction wheel. However, the momentum wheel rotates in a single direction, which is different from the reaction wheel.
[0009] As shown in FIGS. 1 and 2 , reaction wheels are disposed in the spacecraft to be in a pyramid form. Specifically, as shown in FIG. 1 , four reaction wheels H RWA1 Axis, H RWA2 Axis, H RWA3 Axis, and H RWA4 Axis are disposed at 90° intervals, and are tilted at an angle of 45° with respect to axes X sc Axis and Y sc Axis of a reference plane X sc -Y sc Plane of the spacecraft. As shown in FIG. 2 , each of the reaction wheels H RWA1 Axis, H RWA2 Axis, H RWA3 Axis, and H RWA4 Axis is twisted at a torsion angle β with respect to the reference plane X sc -Y sc Plane of the spacecraft. Each of the reaction wheels has an angle of (90°-β) with an axis Z sc Axis viewing from a camera on the spacecraft.
[0010] Here, depending on how to determine the torsion angle of each of the reaction wheels H RWA1 Axis, H RWA2 Axis, H RWA3 Axis, and H RWA4 Axis, an angular momentum or a torque generated by rotating of each of the four reaction wheels H RWA1 Axis, H RWA2 Axis, H RWA3 Axis, and H RWA4 Axis may be differently projected to the axes X sc Axis, Y sc Axis, and Z sc Axis of the spacecraft.
[0011] The four reaction wheels H RWA1 Axis, H RWA2 Axis, H RWA3 Axis, and H RWA4 Axis may be provided in preparation for a failure of at least one reaction wheel by obtaining a marginal degree of freedom (DOF) corresponding to one reaction wheel. For example, in FIG. 1 , if one reaction wheel on Hrwa 1 Axis fails, it is possible to control three axes (*X sc Axis, Y sc Axis, and Z sc Axis of the spacecraft) using a limited angular momentum and torques from using the remaining three reaction wheels H RWA2 Axis, H RWA3 Axis, and H RWA4 Axis. In a case where a single reaction wheel is provided on each of three axes, that is, when a total of three reaction wheels are provided on the three axes, respectively, when any one of the three reaction wheels fails, an attitude control may be impossible using the malfunctioning reaction wheel in a corresponding axis. Accordingly, as shown in FIGS. 1 and 2 , reaction wheels may be generally disposed in the pyramid form.
[0012] In the conventional artificial satellite, even when four reaction wheels are disposed in the pyramid form, a maneuverability of the spacecraft may be significantly deteriorated due to the failure of any one of the four reaction wheels.
[0013] FIG. 3 illustrates graphs showing angular momentum envelopes of a spacecraft when all the reaction wheels normally function in the conventional artificial satellite. FIGS. 4A through 4D illustrate graphs showing angular momentum envelopes of the spacecraft when one of the reaction wheels malfunctions.
[0014] It can be known from the graphs of FIGS. 3 through 4D that, in a case where any one of the four reaction wheels fails, an angular momentum transferable to reference axes of the spacecraft using the remaining three reaction wheels decreases in comparison to a case where the four reaction wheels normally operate as shown in FIG. 3 .
SUMMARY
[0015] The present invention provides an attitude control system and method of a spacecraft that may further improve an attitude maneuverability and a controllability when a defect of a reaction wheels occurs in case of an independent use of an thruster-based attitude controller and a reaction wheel-based attitude controller.
[0016] According to an aspect of the present invention, there is provided an attitude control system of a spacecraft of an artificial satellite, the system including: a thruster-based attitude controller controlling driving of a thruster mounted on the spacecraft; and a reaction wheel-based attitude controller controlling driving of a reaction wheel mounted on the spacecraft. The spacecraft may include a plurality of reaction wheels. When a defect occurs in the spacecraft due to a partial malfunction of the reaction wheels, an attitude maneuverability of the spacecraft may be corrected by simultaneously applying the thruster-based attitude controller and the reaction wheel-based attitude controller.
[0017] When at least two reaction wheels fail, a simultaneous application of the thruster-based attitude controller and the reaction wheel-based attitude controller may make an uncontrollable axis of the spacecraft controllable to thereby obtain a controllability with respect to three axes.
[0018] According to another aspect of the present invention, there is provided an attitude control system of a spacecraft of an artificial satellite, the system including: a thruster-based attitude controller which controls firing time of a thrusters mounted on the spacecraft; a thruster model calculating a first torque in proportion to a thruster firing time input from the thruster-based attitude controller; a reaction wheel-based attitude controller controlling driving of a reaction wheel mounted on the spacecraft; a reaction wheel speed controller calculating a reaction wheel torque using a value input from the reaction wheel-based attitude controller; a reaction wheel model calculating an angular momentum and a second torque using the reaction wheel torque; a sum summing up the first torque and the second torque; and a spacecraft dynamics model simulating rotational motion of the spacecraft according to the torque inputs from the sum.
[0019] The attitude control system may further include a gyro model forming a closed loop to feed back an angular velocity and the attitude of the spacecraft changed in the spacecraft dynamics model to the thruster-based attitude controller and the reaction wheel-based attitude controller. The gyro model may measure and feed back the angular velocity and the attitude of the spacecraft in proportion to the first torque and the second torque.
[0020] The attitude control system may further include: an integrator transferring, to the thruster-based attitude controller, the angular velocity output from the gyro model; and an quaternion error propagator transferring, to the reaction wheel-based attitude controller, the angular velocity output from the gyro model. An angle signal of the spacecraft, that is information associated with the changed attitude output from the integrator, and a signal summed up with angle information associated with the change in the attitude of the spacecraft, input from an attitude angle command, may be input into the thruster-based attitude controller. An angular velocity signal output from the gyro model, and a corrected value output from the quaternion error propagator may be input into the reaction wheel-based attitude controller.
[0021] The thruster-based attitude controller may be set to have a gain in proportion to an angle dead-zone so that the thruster-based attitude controller and the reaction wheel-based attitude controller may simultaneously operate in an attitude maneuver having a great attitude error, and so that only the reaction wheel-based attitude controller may operate when the spacecraft is in an attitude stead state because the thruster-based attitude controller is not working due to the dead-zone characterisitics.
[0022] According to still another aspect of the present invention, there is provided an attitude control method of a spacecraft of an artificial satellite, the method including: calculating a thruster thrust time for an attitude control of the spacecraft; calculating a first torque in proportion to the calculated thruster thrust time, the first torque occurring in the spacecraft due to a thruster; calculating an angular momentum and a torque acting on a reaction wheel; calculating a second torque using the calculated torque of the reaction wheel, the second torque occurring in the spacecraft due to the reaction wheel; and summing up the first torque and the second torque to calculate an angular velocity of the spacecraft for the attitude control of the spacecraft.
[0023] A closed loop may be formed so that the calculated angular velocity of the spacecraft may be fed back to the calculating of the thruster thrust time and the calculating of the angular velocity and the torque in proportion to a magnitude of the first torque and the second torque. Also, the calculating of the thruster thrust time may sum up an angle signal, input for the attitude change of the spacecraft, and an angle signal, changed by integrating the angular velocity of the spacecraft, to calculate the thruster thrust time of the thruster. Also, the calculating of the angular velocity and the torque may sum up an angular velocity signal of the spacecraft and a corrected error value of the angular velocity signal to calculate the angular momentum and the torque acting on the reaction of spacecraft.
Effect
[0024] According to embodiments of the present invention, since a reaction wheel-based attitude controller and a thruster-based attitude controller are combined so that two attitude controllers may control an attitude of a spacecraft, it is possible to improve a maneuverability and a controllability.
[0025] Also, according to embodiments of the present invention, even when a defect occurs due to a failure of at least one reaction wheel drive unit, it is possible to effectively control an attitude of a spacecraft. In addition, since a maneuverability convergence time of the spacecraft becomes faster, it is possible to enhance an operation efficiency of the spacecraft.
[0026] Also, according to embodiments of the present invention, in the case of an attitude maneuver having a relatively great error such as an initial attitude maneuver of the spacecraft, a thruster-based attitude controller and a reaction wheel-based attitude controller may be simultaneously applied. Therefore, it is possible to improve a maneuverability. When the spacecraft reaches an attitude steady state, the reaction wheel-based attitude controller may operate alone. Therefore, it is possible to accurately control the attitude of the spacecraft while a camera of the spacecraft is directed towards the earth.
[0027] Also, according to embodiments of the present invention, when a spacecraft is in an attitude steady state, a thruster-based attitude controller may not operate because of it's dead-zone characterisitics. Therefore, it is possible to prevent an unnecessary torque from occurring due to a thruster. In addition, it is possible to prevent an adverse effect caused by the thruster with respect to an attitude accuracy of the spacecraft.
[0028] Also, according to embodiments of the present invention, it is possible to obtain an independent gain characteristic of each of a reaction wheel-based attitude controller and a thruster-based attitude controller without a separate switching element to combine the reaction wheel-based attitude controller and the thruster-based attitude controller. In addition, there is no need to consider an instability that may occur in switching between the reaction wheel-based attitude controller and the thruster-based attitude controller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] These and/or other aspects, features, and advantages of the invention will become apparent and more readily appreciated from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings of which:
[0030] FIGS. 1 and 2 are arrangement plans for describing arrangements of four reaction wheels in an existing spacecraft;
[0031] FIG. 3 illustrates angular momentum envelopes of the spacecraft when all the four reaction wheels normally function in the existing spacecraft;
[0032] FIGS. 4A through 4D illustrate angular momentum envelopes of the spacecraft when each one of the four reaction wheels fails in the existing spacecraft;
[0033] FIG. 5 is a block diagram illustrating an example of an attitude control system of a spacecraft according to an embodiment of the present invention;
[0034] FIG. 6 illustrates graphs showing simulation results of an attitude control of a spacecraft when a first reaction wheel among four reaction wheels fails;
[0035] FIG. 7A illustrates graphs showing a change in angular velocities of the spacecraft in FIG. 6 ;
[0036] FIG. 7B illustrates graphs showing a change in rotational speeds of the reaction wheels in FIG. 6 ;
[0037] FIG. 7C illustrates graphs showing a change in torques of the reaction wheels in FIG. 6C ;
[0038] FIG. 7D illustrates graphs showing a change in torques of the spacecraft occurring due to an effect of a thruster in FIG. 6 ;
[0039] FIG. 8 illustrates graphs showing simulation results of an attitude control of a spacecraft using an attitude control system of the spacecraft when a first reaction wheel among reaction wheels fails according to an embodiment of the present invention;
[0040] FIG. 9A illustrates graphs showing a change in angular velocities of the spacecraft in FIG. 8 ;
[0041] FIG. 9B illustrates graphs showing a change in rotational speeds of the reaction wheels in FIG. 8 ;
[0042] FIG. 9C illustrates graphs showing a change in torques of the reactions wheels in FIG. 8 ; and
[0043] FIG. 9D illustrates graphs showing a change in torques of the spacecraft occurring due to an effect of a thruster in FIG. 8 .
DETAILED DESCRIPTION
[0044] Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. Exemplary embodiments are described below to explain the present invention by referring to the figures.
[0045] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited thereto or is restricted thereby. When it is determined detailed description related to a known function or configuration they may render the purpose of the present invention unnecessarily ambiguous in describing the present invention, the detailed description will be omitted here.
[0046] Hereinafter, an attitude control method and an attitude control system 100 of a spacecraft of an artificial satellite according to an embodiment of the present invention will be described in detail with reference to FIG. 5 .
[0047] The attitude control system 100 may include a thruster-based attitude controller 110 , a reaction wheel-based attitude controller 120 , and a spacecraft dynamics model 130 .
[0048] The thruster-based attitude controller 110 corresponds to a controller controlling an attitude of the spacecraft by controlling a thruster mounted on the spacecraft. The reaction wheel-based attitude controller 120 corresponds to a controller controlling the attitude of the spacecraft by controlling a reaction wheel mounted on the spacecraft. As described with reference to FIGS. 1 and 2 , four reaction wheels may be disposed in the spacecraft in a pyramid form.
[0049] The present embodiment will be described using an example that the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 adopt a proportional-integral-derivative (PID) scheme. However, it is only an example and thus the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 may use various types of schemes.
[0050] The thruster-based attitude controller 110 may transfer, to a thruster model 111 , a thruster thrust time Thrust_Time that is an output value, and may generate a torque Torque that is in proportion to the thruster firing time Thrust_Time.
[0051] The reaction wheel-based attitude controller 120 may output, using a reaction wheel speed controller 121 , a torque Trw to act on a reaction wheel. A reaction wheel model 122 may transfer, to the spacecraft dynamics model 130 , an angular momentum Hsc and a torque Tsc of the reaction wheel using the output torque Trw. The torque Tsc input into the spacecraft dynamics model 130 may change the attitude of the spacecraft. Here, the attitude control system 100 of the spacecraft may sum up, using a sum 131 , the torque Torque output from the thruster-based attitude controller 110 and the torque Tsc output from the reaction wheel-based attitude controller 120 , and transfer the result to the spacecraft dynamics model 130 . The spacecraft dynamics model 130 influenced by a external disturbance 132 . A closed loop may be formed so that an attitude and an angular velocity changed in the spacecraft dynamics model 130 may be input via a gyro model 140 into the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 . In particular, the attitude control system 100 of the spacecraft may form the closed loop so that the changed attitude and angular velocity may be fed back in proportion to magnitudes of the torques Torque and Tsc input from the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 , respectively.
[0052] Specifically, an angular velocity signal Rate Wsc output from the gyro model 140 may pass through an integrator 141 and be summed up with a signal output from an attitude angle command 101 in a sum 103 , and thereby be input into the thruster-based attitude controller 110 . The angular velocity signal Rate Wsc output from the gyro model 140 may be converted to angle information via the integrator 141 . The angle signal output from the attitude angle command 101 , and the angle signal output from the integrator 141 may be summed up in the sum 103 and thereby be input into the thruster-based attitude controller 110 . When a corrected value ang_err of an angle where the spacecraft needs to move for its attitude change is input, the thruster-based attitude controller 110 may calculate a thruster thrust time where the thruster needs to operate for the attitude change of the spacecraft, using the input corrected angle.
[0053] The angular velocity signal Rate Wsc output from the gyro model 140 , and a corrected value Esc of the angular velocity signal Rate Wsc via a quaternion error propagator 104 may be input into the reaction wheel-based attitude controller 120 . Specifically, the reaction wheel-based attitude controller 120 may calculate a torque ACS_swTrwcom to act on the reaction wheel speed controller 121 , using the angular velocity signal Wsc input from the gyro model 140 , the error value Esc input from the quaternion error propagator 104 , and a feedback value Hmrw fed back from the reaction wheel model 122 . Also, the reaction wheel-based attitude controller 120 may receive the torque Trw of the reaction wheel calculated in the reaction wheel speed controller 121 to thereby calculate the torque Tsc that is input into the spacecraft dynamics model 130 .
[0054] In FIG. 5 , the attitude angle command 101 corresponds to a controller inputting an angle value for the attitude control of the spacecraft. A guidance profile 102 corresponds to a controller indicating an attitude movement profile of the spacecraft.
[0055] According to an embodiment of the present invention, the torques Torque and Tsc output from the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 may be summed up and thereby be transferred to the spacecraft dynamics model 130 . Therefore, even when any one reaction wheel of the reaction wheel fails, a torque control may be added using the thruster. Accordingly, it is possible to compensate for a deterioration in a maneuverability of the spacecraft occurring due to the above failure of the reaction wheel.
[0056] Here, in a case where a stability is obtained in designing of the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 , the stability may be obtained even when the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 are combined and thereby are used. Accordingly, it is possible to simultaneously employ the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 . When the above requirements are unsatisfied, it is possible to modify the design so that the requirements may be satisfied by adjusting a gain of a PID controller acting on each of the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 . However, the above matter may need to be considered in developing of an attitude controller of the spacecraft, and a gain value may be different for each spacecraft. Therefore, description related thereto will be omitted in this invention.
[0057] In general, momentum dumping technique to prevent a reaction wheel from reaching a saturation speed in the spacecraft may use a magnetic torquer. It is a well-known scheme in existing researches and thus description related thereto will be omitted.
[0058] The thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 may be set to not affect each other while setting a gain of each of the to thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 , when they reach an attitude maneuver and an attitude steady state. Also, the thruster-based attitude controller 110 may have a gain in proportion to an angle dead zone.
[0059] Specifically, in the attitude control system 100 , when an attitude error of the spacecraft is great, the thruster-based attitude controller 110 may change the thruster firing time so that the thruster may control the attitude of the spacecraft. When the spacecraft is in the angle dead zone due to an insignificant attitude error of the spacecraft, the thruster-based attitude controller 110 may be set not to fire the thruster.
[0060] Specifically, in an early attitude maneuver of the spacecraft, an error between a command attitude and an actual attitude may become great. In the case of the attitude maneuver having the great error, the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 may simultaneously operate. When the spacecraft is in the attitude steady state, the thruster-based attitude controller 110 may not operate and only the reaction wheel-based attitude controller 120 may operate. As a result, it is possible to accurately control the attitude of the spacecraft at the steady-state.
[0061] According to an embodiment of the present invention, in the case of the attitude maneuver of the spacecraft, it is possible to simultaneously operate reaction wheels and the thruster by simultaneously applying the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 , and thereby improve a maneuverability. When the spacecraft reaches the attitude steady state, the reaction wheel-based attitude controller 120 may operate alone. Through this, it is possible to accurately control the attitude of the spacecraft while a camera of the spacecraft is directed towards the earth.
[0062] Also, according to an embodiment of the present invention, the thruster-based attitude controller 110 does not operate whereby it is possible to prevent an unnecessary torque from occurring due to the thruster. Here, since the thruster-based attitude controller 110 operates in a pulse form when the torque occurs, the accurate control may be difficult. However, when the spacecraft is in the attitude steady state, the thruster-based attitude controller 110 does not operate and thus it is possible to solve the above problem automatically.
[0063] Also, according to an embodiment of the present invention, there is no need for a separate switching element to combine the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 . It is possible to obtain an independent gain characteristic of each of the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 . In addition, there is no need to consider an instability that may occur in switching between the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 .
[0064] Hereinafter, an effect of the attitude control system 100 according to an embodiment of the present invention will be described with reference to FIGS. 6 through 9D .
[0065] In the following description, four reactions wheels are disposed in the same structure as the existing reaction wheels of FIGS. 1 and 2 . For ease of description, four reactions wheels H RWA1 Axis, H RWA2 Axis, H RWA3 Axis, and H RWA4 Axis are sequentially referred to as a first reaction wheel, a second reaction wheel, a third reaction wheel, and a fourth reaction wheel.
[0066] FIGS. 6 through 7D are comparison examples, and illustrate graphs showing simulation results when an attitude maneuver of 30° from a pitch axis of an existing spacecraft is commanded due to a failure of the first reaction wheel H RWA1 Axis among the four reaction wheels.
[0067] For reference, FIG. 6 illustrates graphs showing simulation results of attitude maneuver of the existing spacecraft when only a reaction wheel-based attitude controller operates without operating a thruster-based attitude controller in the existing spacecraft.
[0068] Also, FIG. 7A illustrates graphs showing a change in angular velocities W_x, W_y, and W_z of the spacecraft in FIG. 6 , FIG. 7B illustrates graphs showing a change in rotational speeds Wrw_ 1 , Wrw_ 2 , Wrw_ 3 , and Wrw_ 4 of the spacecraft in FIG. 6 , FIG. 7C illustrates graphs showing a change in torques Trw_ 1 , Trw_ 2 , Trw_ 3 , and Trw_ 4 of the reaction wheels (*H RWA1 Axis, H RWA2 Axis, H RWA3 Axis, and H RWA4 Axis, and FIG. 7D illustrates graphs showing a change in torques Tsc_x, Tsc_y, and Tsc_z of the spacecraft occurring due to an effect of a thruster in FIG. 6 .
[0069] FIGS. 8 through 9D illustrate simulation results of an attitude control of a spacecraft using the attitude control system 100 of the spacecraft according to an embodiment of the present invention.
[0070] FIG. 8 illustrates graphs showing the simulation results of the attitude control of the spacecraft using the attitude control system 100 according to an embodiment of the present invention. FIGS. 9A through 9D illustrate graphs showing a state of each of the spacecraft and reaction wheels in FIG. 8 .
[0071] Specifically, as in FIG. 6 , FIG. 8 illustrates simulation results of the attitude control system 100 when the attitude maneuver of 30° from a pitch axis Ysc Axis of the spacecraft is commanded due to the failure of the first reaction wheel H RWA1 Axis among the four reaction wheels.
[0072] FIG. 9A illustrates graphs showing a change in angular velocities W_x, W_y, and W_z of the spacecraft in FIG. 8 , FIG. 9B illustrates graphs showing a change in rotational speeds Wrw_ 1 , Wrw_ 2 , Wrw_ 3 , and Wrw_ 4 of the reaction wheels in FIG. 8 , FIG. 9C illustrates graphs showing a change in torques Trw_ 1 , Trw_ 2 , Trw_ 3 , and Trw_ 4 of the reaction wheels (*H RWA1 Axis, H RWA2 Axis, H RWA3 Axis, and H RWA4 Axis in FIG. 8 , and FIG. 9D illustrates graphs showing a change in torques Tsc_x, Tsc_y, and Tsc_z of the spacecraft occurring due to an effect of a thruster in FIG. 8 .
[0073] According to the above comparative example, as shown in FIG. 6 , when the attitude maneuver of 30° from the pitch axis Ysc Axis of the spacecraft is order, it takes about 243 through 248 seconds for the attitude error of the spacecraft to fall within 0.005°. For example, Tss=245 seconds in θxe, Tss=243 seconds in θye, and Tss=248 seconds in θze.
[0074] Referring to FIG. 8 , it takes about 42 through 74 seconds that the attitude error of the spacecraft falls within 0.005°. For example, Tss=66 seconds in θxe, Tss=42 seconds in θye, and Tss=74 seconds in θze. Specifically, it can be known that a time for the attitude maneuver is significantly reduced in comparison to the example of FIG. 6 .
[0075] Also, according to the above comparison example, as shown in FIGS. 7B and 7C , since a first reaction wheel drive unit fails, it can be known that the rotational speed Wrw_ 1 and the torque Trw_ 1 of the first reaction wheel are zero.
[0076] According to an embodiment of the present invention, as shown in FIGS. 9B and 9C , since a first reaction wheel drive unit malfunctions, it can be known that the rotational speed Wrw_ 1 and the torque Trw_ 1 of the first reaction wheel are zero.
[0077] Here, the comparison example corresponds to a case where the attitude maneuver of the spacecraft is performed by operating only the existing reaction wheel-based attitude controller. Therefore, as shown in FIG. 7D , it can be verified that the torques Tsc_x, Tsc_y, and Tsc_z of the spacecraft do not occur due to the thruster, that is, Tsc_x=0, Tsc_y=0, and Tsc_z=0.
[0078] According to an embodiment of the present invention, as shown in FIG. 9D , in the case of the attitude maneuver, that is, before about 50 seconds have passed, since the thruster operates so that the spacecraft may rotate into the pitch direction Ysc Axis, it can be known that the pulse torque Tsc_y occurs in the spacecraft. When the spacecraft is in the attitude steady state, that is, after about 50 seconds, the thruster may not operate. Therefore, the torques Tsc_x, Tsc_y, and Tsc_z of the spacecraft caused by the thruster may not operate. Only the reaction wheels may operate to thereby accurately perform the attitude control. It can be known from FIG. 9B that the rotational speeds Wrw_ 1 , Wrw_ 2 , Wrw_ 3 , and Wrw_ 4 of the reaction wheels converge to a predetermined value, instead of zero.
[0079] Accordingly, even when at least one reaction wheel fails due to a simultaneous application of the thruster-based attitude controller 110 and the reaction wheel-based attitude controller 120 , the attitude control system 100 of the spacecraft may improve a maneuverability of the spacecraft and may also obtain a controllability with respect to three axes of the spacecraft.
[0080] In the aforementioned examples, description is made that, when at least one reaction wheel does not operate due to a malfunction of at least one reaction wheel drive unit the attitude of the spacecraft is controlled using the remaining three reaction wheels and the thruster. However, the present invention is not limited thereto. When at least two reaction wheel drive units fails, the attitude control system 100 according to an embodiment of the present invention may be similarly applicable.
[0081] For example, in a case where a single reaction wheel fails, and also in a case where two or three reaction wheels malfunction, the thruster-based attitude controller 110 may simultaneously operate, whereby it is possible to improve a maneuverability of the spacecraft. When two to three reaction wheels do not operate and thus there is a need to improve the maneuverability, or to perform an additional control with respect to an uncontrollable axis, an additional drive unit and attitude controller may be further required. The additional attitude controller may be managed by the thruster-based attitude controller 110 .
[0082] When all the four reaction wheels fails, the attitude control using the reaction wheel-based attitude controller 120 may be meaningless. Therefore, an automatic conversion to the thruster-based attitude controller 110 may be performed.
[0083] Although a few exemplary embodiments of the present invention have been shown and described, the present invention is not limited to the described exemplary embodiments. Instead, it would be appreciated by those skilled in the art that changes may be made to these exemplary embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents. | Provided are an attitude control system and method of a spacecraft of an artificial satellite that may enhance a maneuverability and a controllability by simultaneously applying a reaction wheel and a thruster among drive units used to maneuver an attitude of the spacecraft of the artificial satellite. The attitude control system may include: a thruster-based attitude controller which control firing time of thrusters mounted on the spacecraft; and a reaction wheel-based attitude controller controlling driving of a reaction wheel mounted on the spacecraft. The spacecraft may include a plurality of reaction wheels. When a defect occurs in the spacecraft due to a partial malfunction of the reaction wheels, an attitude maneuverability of the spacecraft may be corrected by simultaneously applying the thruster-based attitude controller and the reaction wheel-based attitude controller. | 1 |
This is a Continuation-In-Part patent application of Parent Case Ser. No. 714,942, entitled "Epidermal Iontophoresis Device" filed Aug. 16, 1976.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to bioelectrodes utilizing a fluid electrolyte medium. More particularly, the present invention relates to bioelectrodes which are attached at a skin surface and are utilized for applying or measuring current or potential.
2. Prior Art
The field of bioelectrodes which are attachable at a skin surface and rely on electrolyte fluids to establish electrical contact with such skin surfaces can be divided into at least two categories. The first category includes those bioelectrodes which are prepackaged with the electrolyte contained in the electrode cavity or receptacle. The second type of bioelectrode is a dry-state electrode whose receptacle is customarily filled with electrolyte immediately prior to application to a skin surface. With both types of electrodes, the user currently experiences numerous problems which make their use both inconvenient and problematic.
With respect to the prepackaged electrode, storage is a major concern. Frequently, leakage of contents from the receptacle occurs, resulting in an inoperative or defective state. Furthermore, such prefilled electrodes are difficult to apply because the protective seal which covers the electrode opening and retains the fluid within the receptacle cavity must be removed prior to application to the skin surface. After removal of this protective seal, spillage often occurs in attempting to place the electrode at the skin surface. Such spillage impairs the desired adhesive contact of the electrode to skin surface and also voids a portion of the receptacle cavity. The consequent loss of electrolyte fluid tends to disrupt electrical contact with the electrode plate contained therein and otherwise disrupts the preferred uniform potential gradient to be applied.
Although dry-state electrodes have numerous advantages in ease of storage and greater adaptability for various types of electrode applications, several problems remain. For example, the electrolyte receptacles of such electrodes are conventionally filled through their opening prior to application to the patient's skin surface. Therefore, the same problem of spillage and loss of electrolyte upon application occurs as with the prefilled electrode.
Frequently, such electrodes are not well structured to develop the proper uniform current flow required in iontophoresis applications. Such nonuniform current flow may result from improper spacial relationship between the exposed skin surface and electrode plate, as well as from the occurrence of air pockets within the receptacle cavity. This effect occurs because of the nonuniform impedance associated with such air pockets, thereby disrupting the electric field and current path established between the electrode and exposed skin surface. Such effects are particularly troublesome in iontophoresis applications, where the induction of medicaments (such as anesthetic) relies upon the amount of current flow at any given point at the skin surface. Therefore, a nonuniform current flow results in unequal distribution of anesthetic through the skin surface, along with increased risk of burns. Previous methods of filling dry-state electrodes have not attempted to remedy the disrupted influence of such air pockets within the electrode cavity or the spillage problem of conventional filling techniques.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide an electrode having self-sealing injection means for passing fluid contents into the electrode receptacle through an entry site other than the electrode opening.
It is also an object of this invention to provide a unibody electrode-fluid reservoir in which the fluid contents are prepackaged in a reservoir separate from the electrode receptacle but connected thereto by a self-sealing channel for subsequent filling procedures.
It is an object of the present invention to provide a dry-state electrode which remains substantially void of air during storage and subsequent filling with fluid, thereby reducing adverse effects of air pockets during application.
It is an additional object of the present invention to provide a bioelectrode which avoids the leakage and spillage associated with application of prefilled electrodes.
It is a further object of the present invention to provide a dry-state bioelectrode adapted for use to numerous forms of treatment or electrical monitoring, such as iontophoresis applications, EKG, EEG, etc.
It is yet another object of this invention to provide a bioelectrode which precludes localized physical contact between the electrode plate and exposed skin surface subject to the electrode treatment.
A further object of this invention is to provide a bioelectrode in combination with a reservoir means for filling such dry-state electrodes while attached at the skin surface to be treated.
A still further object of this invention is to provide an improved sealed electrode receptacle to prevent leakage of contained electrolyte.
A further specific object of this invention is to adapt such a dry-state electrode with means for limiting spillage upon removal of such electrode from the attached skin surface.
These objects are realized in a bioelectrode having self-sealing injection channel means which permits introduction of fluids, but automatically seals to preclude adverse leakage upon completion of filling. It is further adapted such that fluid introduction is not accompanied by air which develops adverse effects within the electrode during operating procedures. The basic structure of the self-sealing bioelectrode comprises a sheet-like base member having an opening therethrough, a receptacle attached to and having its opening in common with the opening of the base member. The receptacle may be made of deformable material for flattening against the base member to reduce the amount of air content within its structure. An injection channel is located to communicate between an exterior fluid reservoir which contains the desired electrolyte and the interior of the electrode receptacle. The injection channel includes a restricted access means for enabling self-sealing and blocking air passage during injection of fluid. An electrode plate is disposed within the cavity of the receptacle to provide current or other electric field influence for effecting the desired treatment or procedure.
Other objects and features of the present invention will be obvious to a person skilled in the art from the following detailed description, taken with the accompanying drawings.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross section, side view of a self-sealing bioelectrode with separate reservoir means.
FIG. 2 is a perspective top view of the subject self-sealing electrode without the reservoir means.
FIG. 3 is a partially cut away, perspective bottom view of the same bioelectrode as illustrated in FIGS. 1 and 2.
FIG. 4 shows the bioelectrode in a flattened state, with the reservoir means inserted at the injection channel means.
FIG. 5 represents a cut away top view of a self-sealing bioelectrode having an integrally attached reservoir for retaining fluid until fluid transfer to the receptacle is effected.
FIG. 6 is a cross sectional view of the electrode-reservoir combination of FIG. 5, taken along line 6--6.
FIG. 7 shows the self-sealing electrode of FIG. 5 after filling of the receptacle and separation of the attached reservoir.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the figures:
A self-sealing bioelectrode is represented by the embodiment illustrated and includes a sheet-like base member 11 which has a top surface 12 for supporting additional component members and a bottom surface 13 for fixation at a skin surface to be subjected to a particular electrical current application or monitoring procedure.
Exposure of the skin surface to be treated occurs through an opening 14 through the base member 11. Typically, the surface area of the skin subject to treatment will correspond with the area of the opening 14 and can therefore be controlled by modifying the size and shape of such opening to suit the particular purposes of treatment. For example, the shape of the base opening 14 may be elongate where an elongate area of skin is desired to be treated or otherwise monitored.
The base member 11 may be constructed of numerous materials; however, polyurethane and similar flexible materials are particularly well suited for use with the electrode. The flexibility provided by such polymer material incorporates conformable properties to the electrode which facilitate emplacement over contoured or swollen skin surfaces, fingers and other anatomical structures. Such materials are also more adaptable for trimming which may be required to locate the electrode adjacent to an ear, nose or other protrusion.
A receptacle 16 extends from the top surface 12 of the base member 11 and encloses a cavity, except for an opening which communicates in common with the base opening 14. These combined openings operate to expose contained fluid contents to the treated skin surface. The remaining receptacle-base interface is sealed to prevent leakage.
Inasmuch as a primary purpose of one embodiment of the present invention is to provide a substantially air-free bioelectrode cavity 17, the receptacle body 16 may be initially flattened against the base member 11 as illustrated in FIG. 4, minimizing air content during dry-state storage. Crease lines 18 may be included to reduce wrinkling and improve the extent of flattening and reduction of air pockets within the cavity area 17. The use of such marks also improves ease of extension of the receptacle upon charging with electrolyte.
It is apparent that the size of the receptacle member 16 will depend upon the nature of treatment or procedure to be utilized, as well as general factors of location of skin surface affected, base opening size, and type of fluid constitution. For iontophoresis applications of medication or anesthetic, for example, a uniform current flow is desired through the common base/receptacle opening 14. This uniform field is more easily obtained when the current source electrode is remote from the opening. By elongating the receptacle, such a current source can be located at the more distal end, increasing the distance from the opening 14.
Selection of materials for construction of the receptacle may be from numerous flexible plastics and other similar materials which permit deformation and subsequent fluid inflation in the respective dry and filled states. Here again, biocompatibility of material is preferable, as well as chemical compatibility with the anticipated electrolyte to be contained therein.
Filling of the receptacle 16 is accomplished at an injection channel means, shown generally as 20. The purpose of the injection channel means is to provide controlled access for fluid entry, while precluding introduction of air into the electrode cavity 17. The exclusion of air during the charging process is important, particularly in iontophoresis applications, because air pockets within the cavity 17 tend to disrupt the uniform field which is desired when applying certain medications such as anesthesia.
It is apparent that numerous forms of flow channels to the interior of the receptacle can operate as the injection channel means when such channels are blocked by a restricted access means. As used herein, restricted access means includes any device which is self-sealing with respect to an appropriate fluid filling procedure. Such access means will block fluid flow through the channel means, except as to such fluids as may be intentionally injected therethrough. A suitable restricted access means may simply comprise a self-sealing plug which closes upon withdrawal of an inserted syringe means, or it may comprise a one way valve or tube sealing system, the latter being illustrated in FIGS. 5-7.
FIGS. 1 and 4 illustrate the use of a reservoir means, such as a SYRETTE (Trademark) 21. The SYRETTE comprises deformable wall structure 22 for containing a desired electrolyte within a cavity 23 for ejection through a cannula means 24. Such a SYRETTE can be used to withdraw electrolyte (including iontophoresic medications) from a separate storage reservoir and transfer the amount withdrawn through the injection channel means 20 to the electrode cavity 17.
FIGS. 1-4 illustrate a two-stage injection channel means in which the cannula means 24 may be partially inserted into the first stage 26, represented by a narrow duct having an inner diameter corresponding to the outer diameter of the cannula means to provide a snug fit therein. The duct terminates at the second stage 27, comprising a self-sealing plug which blocks access to a communicating channel 28 leading to the interior of the receptacle 16. By inserting the cannula means into the narrow duct 26 and partially imbedding the cannula tip into the plug 27, accidental discharge of the electrolyte contents is precluded. In addition, the concealment of the cannula means reduces the anxiety customarily experienced by a patient upon seeing a needle. By sealing the inserted tip in the first stage of the injection channel means, the bioelectrode and attached SYRETTE may be conveniently affixed to the patient's skin, without spillage.
With the unfilled bioelectrode attached to the patient, the second stage of the injection channel means 27 is pierced by moving the cannula means through this blocking member to provide an open channel between the SYRETTE cavity 23 and the closed cavity of the bioelectrode 17. By locating the injection channel means 20 along the top surface 12 of the base member 11, the possibility of accidental injection of the cannula means 24 through the base member and into the patient is minimized. Instead, the injection path of needle point is substantially parallel to or away from the skin surface. It is to be realized that numerous methods of developing the general concept of two-stage injection are envisioned, and that the structure disclosed is only illustrative. Likewise, accidental injection of the cannula means can be prevented by adapting the injection channel means to limit cannula means entry by including a blocking shoulder 25.
Electrical operability of the bioelectrode is accomplished by means of an electrode plate 30 disposed within the interior of the receptacle 16. Since a uniform current flow is preferable, the electrode plate may be fixed at an inner surface of the receptacle at a location near point of intersection of the central axis of the base opening 14, when the pouch is suitably deployed. Such placement will also facilitate a parallel orientation between the electrode plate and exposed skin through the opening, further enhancing field uniformity.
The electrode plate may be of stainless steel material and is retained at the interior surface of the receptacle 16 by means of an exterior conductive plate 31, the two plates being spotwelded or otherwise electrically coupled. The external plate 31 is contacted by a wire lead 32 or other coupling means to an external circuit. To prevent fluid leakage between the plates, that portion of the receptacle wall 16 sandwiched between the plates is compressed and operates as an effective seal.
FIGS. 1-4 illustrate the inclusion of a wicking member 34 located at the base opening 14. This may be made of any highly wettable material, such as filter paper. When the bioelectrode is filled with electrolyte, the wicking member is saturated and displaces to develop intimate physical contact at the exposed skin surface. Fluid is therefore dispersed uniformly across the contacted skin area by the capillary action of the wicking member. Not only does this covering provide a more uniform current flow at the skin surface, but it also operates to prevent electrode/skin contact which can cause serious burning. When the wicking member is fixed to the base member and covers the opening thereof, it also helps to avoid spillage of electrolyte upon removal of the bioelectrode.
To further reduce spillage of electrolyte upon electrode removal, an expandable absorbent member 35 may be contained within the receptacle interior. A compressed sheet of sponge-like material having minimal air content may be inserted as shown in FIG. 4. Upon injection of electrolyte, the absorbent character of the material 35 causes expansion, partially filling the receptacle cavity. This material also serves to preclude physical contact between the electrode plate 30 and the exposed skin.
Also illustrated in FIGS. 1-4 is a flexible, pourous shield 36 which is disposed within the interior of the receptacle 16 such that when the electrode is flattened, the shield extends laterally to reduce contact between the inner receptacle walls. Migration sealing effects between contacting plastic surfaces are thereby minimized, facilitating ease of expansion in response to electrolyte fluid.
As an illustration of the use of such a deformable, self-sealing electrode, the following steps of application are provided:
1. A dry-state bioelectrode such as illustrated in FIG. 4 is obtained, in combination with a syringe means or similar reservoir. This may be a SYRETTE 21 as described in the present application, or may simply be a conventional syringe suitable for use at the injection channel means of the electrode.
2. The syringe or SYRETTE 21 is then filled with a desired electrolyte and the cannula tip 24 thereof is inserted in the first stage of the two-stage injection channel means 26. At this point the cannula tip is slightly imbedded in the sealing plug 27 which blocks the flow channel 28.
3. The bioelectrode is then placed on the patient's skin at a treatment site and retained either by an adhesive coating on the bottom surface 13 of the base member or by other suitable means.
4. With the electrode affixed at the skin surface, the cannula is thrust forward, piercing the sealing plug 27 as shown in FIG. 4. The flow channel between the syringe cavity and flattened receptacle is now open, and the fluid is ejected from the SYRETTE cavity 23 into the channel 28, causing the receptacle to extend in accordance with the amount of fluid introduced. 5. When the receptacle is sufficiently full, the syringe means 21 is withdrawn, with the sealing plug 27 closing the flow channel 28.
6. Electrical circuitry coupled to the electrode plate by means of the wire lead 32 is actuated and the treatment or procedure is commenced.
FIGS. 5-7 represent a second embodiment of the self-sealing electrode having a reservoir means 40 integrally attached to the electrode body 41 by self-sealing injection channel means 42. As illustrated, the injection channel means 42 includes an open channel 43 which extends along the reservoir neck 44 from the reservoir cavity 45 to a breakaway connection 46. The reservoir neck has a pair of radially protruding ribs 47 fixed at the outer surface of the neck and extending along the axis of the open channel 43 beyond the breakaway connection 46. The attachment of these ribs is more clearly portrayed in FIGS. 6 and 7.
The electrode channel section 50 of the injection channel means 42 includes a flow channel 51 which communicates from the receptacle cavity 52 through a self-sealing mechanism which connects the open channel 43 and the flow channel 51. FIGS. 5-7 illustrate the use of a tube sealing system for such a mechanism, to permit transfer of fluid to the electrode, while blocking back flow after filling is completed.
Such a configuration includes a tight fitting elastic tube 53 which encloses the reservoir neck 44 and the electrode channel section 51. The electrode channel section 50 has a transverse duct 54 which communicates from the flow channel 51 to lateral surfaces of the electrode channel section 50. The duct openings at the channel section surface are located so as to be proximate to the extending portion of the ribs 47. The enclosing elastic tube is thereby distended by the radially extending ribs, providing a tube flow channel 56 (FIG. 6) along the surface of the channel section to the transverse duct 54 which opens at this surface. A closed terminal section 57 blocks forward flow and provides a site for breakaway attachment of the reservoir neck 44 at the connection point 46. Until broken, this connection 46 operates as a seal to retain the fluid contents within the reservoir 45.
This embodiment of the subject invention is especially useful with dry-state electrodes which are packaged and sold with a particular electrolyte or medicament attached thereto in a separate reservoir, in ready to use form. Under such applications the electrode/reservoir combination would be attached to a patient's skin. When properly positioned, the individual or attendant bends or twists the breakway connection 46, severing the reservoir neck from the electrode channel section and forming a gap therebetween. The fluid from the reservoir cavity 45 may then be forced down the open channel 43, through the resultant gap 46, down the tube flow channel 56, in the duct opening 54, through the flow channel 51 and into the electrode cavity. When the filling operation is completed, the reservoir and attached ribs are removed from the elastic tube as illustrated in FIG. 7. The elastic tube is then free to seal the duct openings and preclude back flow of the transferred fluid.
It will be apparent that the tube sealing system is just one of numerous ways of implementing the inventive concepts disclosed herein. As specifically referenced in the parent case, a sealed bag can be attached at the flow channel as a reservoir means. A weak seal may be provided between the flow channel and reservoir to retain the fluid within the reservoir during storage. To fill the electrode receptacle, the bag is merely compressed, breaking the seal which otherwise blocks the fluid entry into the flow channel. The bag may thereafter be twisted closed or otherwise sealed at the mouth thereof. In the event that no counter pressure is exerted within the electrode cavity to cause adverse back flow to the reservoir, the voided bag may simply be ignored.
The present invention provides substantial improvement over current bioelectrodes. Because of the dry-state of the electrode, storage may be indefinite without fear of leakage or drying. Ease and convenience of application are substantially improved because electrolyte solutions need not be inserted until the electrode is fully in place on the patient's skin. The person administering the particular treatment or procedure is therefore not confronted with the mess often associated with prefilled electrodes. Likewise, removal of the electrode is less troublesome due to the fluid restraining action of the wicking member. Also significant is the fact that the self-sealing bioelectrode is substantially void of air pockets within the receptacle cavity and therefore establishes a more uniform current flow.
In the flattened electrode configuration, improved electrical contact at the electrode plate is insured inasmuch as fluid contact thereat is maintained by the inflating force of the injected electrolyte. By providing electrode structure which is substantially flattened during storage, affixed to the skin, and then deployed by inflating the receptacle with electrolyte, minimal air intake is ensured and reliability of the procedures is improved.
Although preferred forms of the invention have been herein described, it is to be understood that present disclosures are by way of example and that variations are possible without departing from the scope of the hereinafter claimed subject matter, which subject matter is to be regarded as the invention. | A dry-state bioelectrode having a self-sealing receptacle for receiving electrolyte and/or medicament fluid contents. The receptacle is attached at its opening to a sheet-like flexible base member having an opening in common with the receptacle opening, the bottom of the base member being adapted for fixation at a skin surface. A portion of the skin surface is exposed to the fluid contents of the receptacle through the common opening. An injection site communicates through the wall of the receptacle and provides controlled access for filling. Upon completion of filling, the receptacle self seals, retaining the fluid contents therein for application of iontophoresis treatment or other procedures requiring use of a potential gradient. An electrode plate is supported at an interior surface of the receptacle for supplying the desired electric potential. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of mousepads and, more particularly, to the field of mousepads for optical mice.
Most computers now have an input device that controls the movement of a cursor on a computer screen. Examples of such devices include trackballs, joysticks, and mice. A common form of the mouse is a mechanical mouse; it has a small ball on its underside in contact with the surface upon which the mouse rests. When the mouse is moved, the ball rolls and activates sensors in the mouse that translate the rolling of the ball into movement of the cursor on the computer screen. Another kind of mouse is an optical mouse. The optical mouse has an optical sensor that scans a surface and acquires a series of images of the surface. The optical mouse determines its own position relative to the surface by comparing the differences between consecutive images.
A typical optical mouse illuminates the surface it is scanning, generating shadows and reflections used by the optical sensor to acquire a good image. Depending on the surface type, the amount of light needed can vary. For instance, a dark surface absorbs light, requiring more light to adequately illuminate the surface in order for the optical sensor to acquire a usable image. The more light used by the optical mouse, however, the more power it consumes. This is a problem for low-power applications such as battery operated cordless mice, or for laptop computer users.
The performance of the optical mouse also depends on the surface that it scans. If a surface is too homogeneous, the images acquired by the optical sensor while the optical mouse is moving will all be very similar, perhaps even identical. Since the optical mouse depends on differences between images to determine its position relative to the surface, similar images trick it into thinking that it has not changed position, when in fact it has. It is therefore important that the surface has enough distinguishing characteristics to eliminate such confusion.
SUMMARY OF THE INVENTION
A surface having specular regions shaped to reflect incident light towards the optical sensor provides an ideal surface to be scanned by the optical mouse. When light is shined upon the surface, the reflections off of the specular regions appear as bright white points in the image acquired by the optical sensor, which gives the optical sensor the distinguishing characteristics it needs to differentiate between images. Since the specular regions reflect light so well, less light is needed to obtain an image, so power is conserved. The surface itself should either reflect light away from the optical sensor, or at least scatter light, so that it appears in the image to the optical sensor as a dark background, providing contrast to the light reflecting off of the specular regions.
In accordance with an illustrated preferred embodiment of the present invention, the specular regions are depressions that are either made of, or are coated with, a specular material, and are shaped to reflect incident light toward the optical sensor. The surface is made of or coated with a specular material as well, or a material that scatters light. The reflections off of the depressions give the surface its distinguishing characteristics so the mouse is able to differentiate between images as it moves. Additionally, the brightness of the reflections helps the mouse conserve power.
In another embodiment of the present invention, a surface is dotted with protrusions that reflect incident light toward the optical sensor. The protrusions are also either made of, or are coated with, a specular material, and perform the same function as the depressions.
In a third embodiment of the present invention, the surface, whether dotted with depressions or protrusions, is coated with an optically transparent material that protects the surface from contamination or damage. The optically transparent material still allows light to pass through, but prevents the optical mouse from eroding away the specular regions as it traverses over the surface.
In a fourth embodiment of the present invention, the surface has contrasting regions of two colors: one light, one dark. The lighter color is used in the background of the surface to minimize power consumption. The darker colored regions provide distinguishing characteristics on the surface for the optical sensor. Unlike the depressions and protrusions, however, the dark-colored regions do not reflect light well. As a result, when the optical sensor scans the surface, the dark colored regions appear to it as dark spots against a lighter background. This embodiment does not conserve as much power as the embodiments with the specular regions, but a colored surface may be easier to manufacture than a surface with depressions or protrusions.
Further features and advantages of the present invention, as well as the structure and operation of preferred embodiments of the present invention, are described in detail below with reference to the accompanying exemplary drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a three-dimensional view of a portion of the surface along with a lens and an optical sensor.
FIG. 2 is a cross-sectional side view of the objects in FIG. 1, taken along a vertical plane passing through line C-C′ shown in FIG. 1. A light source and relative position determinator have been added, and the light beams from the light source reflect off of multiple depressions.
FIG. 3 is a detailed view of the pixels in the optical sensor shown in FIGS. 1 and 2.
FIG. 4 is a cross-sectional side view of the objects shown in FIG. 2 . The light beams from the light source reflect off of a single depression.
FIG. 5 is a cross-sectional side view of a portion of a surface with protrusions, a lens, an optical sensor, light source, and relative position determinator.
FIG. 6A is a cross-sectional side view of the surface with depressions and an optically transparent coating.
FIG. 6B is a cross-sectional side view of the surface with protrusions and an optically transparent coating.
FIG. 7 is a top-down, blown-up and partial view of the surface with dark colored areas against a lighter colored background.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is a surface that is scanned by an optical sensor of a relative position determinator such as an optical mouse or a trackball device. The surface has characteristics to reduce the amount of power needed by the optical mouse in order to light the surface, and so it can easily differentiate between the images the optical sensor acquires of the surface.
FIG. 1 illustrates a preferred embodiment of a portion of a surface made in accordance with the teachings of the present invention, hereinafter referred to as a surface portion 11 . Depressions 13 are located on the surface portion 11 in either an ordered or random fashion. The areas between the depressions 13 are non-distorted regions 17 . The surface portion 11 is scanned by an optical sensor 16 , which exists in prior art. A lens 10 , also from prior art, is fixed in front of the optical sensor 16 , between the optical sensor 16 and the surface portion 11 . The lens 10 projects an image of the surface portion 11 onto the optical sensor 16 .
FIG. 2 shows a cross-sectional side view of the surface portion 11 , lens 10 , and optical sensor 16 , taken along a vertical plane passing through the line indicated by C-C′ in FIG. 1. A light source 14 is added, as well as a relative position determinator 18 that is electrically coupled to the optical sensor 16 . The relative position determinator 18 is a device well known in the art, and is found in common computer input devices such as trackballs and mice. The optical sensor 16 lies a distance D away from the surface portion 11 . The lens 10 has a focal length F, and lies a distance X away from the surface portion 11 . The distance X is chosen by determining the image size to be projected by the lens 10 onto the optical sensor 16 . The preferred embodiment uses a 1:1 image ratio, with X=2F and D=4F. To obtain a 2:1 image ratio, use X=3F and D=4.5F. Other image ratios are possible by varying distance X, distance D, and focal length F.
The light source 14 shines light beams onto the surface portion 11 . The light source 14 is preferably a light-emitting diode, although any light-emitting device can be used. The depressions 13 are shaped such that light beams 15 , with angles of incidence A 1 through A 2 , hit the depressions 13 and are reflected towards the lens 10 . The lens projects the light beams 15 onto the optical sensor 16 . The angles at which the light beams 15 hit the surface portion 11 will vary depending on the positioning of the light source 14 . The light beams used to develop the present invention had an angle of incidence upon the surface portion 11 of approximately 20 to 30 degrees. In the embodiment shown, the optical sensor 16 and lens 10 are located directly above the lighted region; therefore, the depressions 13 of this embodiment should be shaped to reflect the light beams 15 normal to the surface portion 11 .
The surface portion 11 is made of machined metal, molded plastic, aluminized mylar, or any other material that has the ability to hold small features. The depressions 13 should be made of or coated with a specular material that reflects light. A material is specular if a light beam hitting the material has an angle of incidence equal to its angle of reflectance. The non-distorted regions 17 are made of or coated with the same specular material as the depressions 13 . This is the preferred embodiment and the simplest to manufacture. The non-distorted regions 17 are also made of or coated with a diffuse light-scattering material, or any other material as long as the non-distorted regions 17 do not reflect incident light towards the lens 10 . The non-distorted regions 17 reflect incident light away from the lens 10 , such as the example of deflected light beam 19 . Although the surface portion 11 in FIGS. 1 and 2 is drawn as flat and planar, the surface portion 11 can be curved, bent, or any other shape that can hold the depressions 13 .
Since the light beams 15 can have varying angles of incidence due to the variance in the positioning of the light source 14 , the shape of the depressions 13 can also vary. One possibility for the shape of the depressions 13 is a smoothly curved surface, like the inside of a bowl. The curvature of the depressions 13 are shaped to allow light beams 15 with a range of angles of incidence A 1 through A 2 to be reflected toward the lens 10 and optical sensor 16 . Other shapes can also be used. For instance, a curved surface can be approximated by a faceted depression 13 with from three to an infinite number of sides. For optimal performance, the depressions 13 should be rotationally symmetric, because the orientation of the optical sensor 16 to the surface portion 11 can be random.
The relative position determinator 18 acquires the images of surface portion 11 projected onto optical sensor 16 by lens 10 , as the optical sensor 16 moves relative to the surface portion 11 . This relative movement can be achieved by moving the optical sensor 16 over the surface portion 11 , which is the situation when the relative position determinator 18 is an optical mouse. The relative movement can also be obtained by keeping the optical sensor 16 stationary while the surface portion 11 is moved, which is the case when the relative position determinator 18 is a trackball device. A combination of both methods can also be used, as long as there is relative movement between the optical sensor 16 and the surface portion 11 .
FIG. 3 depicts an exemplary optical sensor 16 that exists in prior art, showing the side of the optical sensor 16 that faces the lens 10 in FIG. 1 . The optical sensor 16 typically has a pixel array 23 , a structure well known in the art. The pixel array 23 comprises individual pixels 25 arranged in a close-packed grid. A pixel 25 is the smallest unit in the optical sensor 16 that is capable of detecting an image. A depression 13 is detectable by a pixel 25 if the image of the depression 13 is larger than the pixel 25 . Only half of the depression 13 can show up in an image sensed by the optical sensor 16 , since light can only bounce off of half of the depression 13 at any given time. If a 1:1 image of the surface portion 11 is projected by the lens 10 (shown in FIG. 2) onto the optical sensor 16 , the size of each depression 13 should be at least twice as large as a pixel 25 .
The depressions 13 are spaced such that at least one depression 13 is detectable by the pixel array 23 of the optical sensor 16 at all times. To account for the possibility of noise, and for improved performance, two or more depressions 13 should be detectable by the pixel array 23 at any given time. The depressions 13 should not be on the same spacing as the pixels 25 in the pixel array 23 in order to avoid aliasing.
The optical sensor 16 is able to detect light beams 15 reflecting off of multiple depressions 13 . FIG. 2 only shows light beams 15 reflecting off of two depressions, since it is a cross-sectional view, but the optical sensor 16 is able to detect light beams 15 reflecting off of all depressions 13 immediately underneath the optical sensor 16 and lens 10 . For example, all the depressions 13 shown in FIG. 1 will be detected by the optical sensor 16 , since they are all immediately underneath the optical sensor 16 and lens 10 . Although it is preferable to have multiple depressions 13 underneath the optical sensor 16 at all times, the relative position determinator 18 will still work if light beams 15 only reflect off of a single depression 13 toward the lens 10 and optical sensor 16 , as is shown in FIG. 4 .
FIG. 5 shows another embodiment of the present invention. The depressions 13 of FIG. 2 are replaced with protrusions 31 . The curvatures of the protrusions 31 are shaped such that light beams 15 with angles of incidence A 3 through A 4 are reflected toward the lens 10 . The protrusions 31 should be rounded and rotationally symmetric for optimal performance. If a 1:1 image of the surface portion 11 is projected by the lens 10 onto the optical sensor 16 , the size of each protrusion 31 should be at least twice as large as a pixel 25 (shown in FIG. 3 ). The protrusions 31 are spaced such that at least one protrusion 31 is detectable by the pixel array 23 of the optical sensor 16 shown in FIG. 3 at all times. To minimize the possibility of aliasing, the protrusions 31 should be on a different spacing than the pixels 25 in the pixel array 23 . The protrusions 31 can also be approximated by faceted protrusions 31 with from three to infinite sides. The surface portion 11 and non-distorted regions 17 remain as described in FIG. 2 .
In FIGS. 6A and 6B, the present invention is covered with an optically transparent coating 41 that protects the surface portion 11 from contamination and damage. In FIG. 6A, the surface portion 11 and the depressions 13 are covered with the optically transparent coating 41 . This prevents foreign particles from falling into the depressions 13 and blocking the incoming light. In FIG. 6B, the optically transparent coating 41 fills the valleys between the protrusions 31 and covers the surface portion 11 . This prevents the protrusions 31 from wearing down as the lens 10 and optical sensor 16 pass over it.
A final embodiment of the present invention is shown in FIG. 7 . FIG. 7 is a top-down, blown-up partial view of the surface portion 11 . This illustrated embodiment has contrasting regions of two colors, although more colors can be used. A first color is used in colored regions 51 against a background 53 of a second color. The colored regions 51 can be any shape, but for convenience of illustration the colored regions 51 in this embodiment are circular. For optimal performance, the colored regions 51 should be darker than the background 53 . The lighter the background 53 , the less light is needed to illuminate the surface portion 11 , which results in less power being consumed. For example, the colored regions 51 can be black while the color of the background 53 can be white, as shown in FIG. 7 . The optimal colors for the colored regions 51 and the background 53 depend on the wavelength of light being shined on the surface portion 11 from the light source 14 shown in FIG. 2 . If a 1:1 image of the surface portion 11 is projected by the lens 10 onto the optical sensor 16 , the size of each colored region 51 should be at least the size of a pixel 25 shown in FIG. 3, and spaced such that at least one colored region 51 , is detectable by the pixel array 23 of the optical sensor 16 shown in FIG. 3 . The colored regions 51 should not duplicate the spacing of the pixels 25 in the pixel array 23 to avoid aliasing.
Although the present invention has been described in detail with reference to particular preferred embodiments, persons possessing ordinary skill in the art to which this invention pertains will appreciate that various modifications and enhancements may be made without departing from the spirit and scope of the claims that follow. | A surface having specular regions shaped to reflect incident light toward an optical sensor provides an ideal surface to be scanned by an optical mouse. When light is shined upon the surface, the reflections off of the specular regions appear as white points in the image acquired by the optical sensor, which gives the optical sensor the distinguishing characteristics it needs to differentiate between images. Since the specular regions reflect light so well, less light is needed to obtain an image, and power is conserved. The surface appears as a dark background in the image, providing contrast to the light reflecting off the specular regions. To protect the specular regions, an optically transparent coating can be layered on top of the surface. An alternative surface that may be easier to manufacture is a light colored surface dotted with darker colored regions. | 6 |
RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 12/452,953 filed Jan. 27, 2010.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method of casting near-net-shape, rectangular strands from metal and a subsequent processing thereof into metal strips according to a DSC-method (direct strip casting) in a horizontal strip casting installation, wherein the metal melt is cast with a melt feeder on a horizontally circulating metal conveyor belt with a cooled bottom, and a liquid cast product is solidified to a pre-strip on the metal conveyor belt during displacement thereof and which after leaving the metal conveyor belt is fed, mechanically tensioned, to a driver by, e.g., smooth/pinch rollers. An installation with smooth/pinch rollers is not absolutely necessary, the installation can be realized without these rollers.
[0004] 2. Description of the Prior Art
[0005] Because of uneven heat dissipation during solidification process of a strip, cast according to DSC-method under inert gas atmosphere without use of a casting compound, due to the upper surface of the strip being cooled only by convection with the ambient atmosphere and by heat radiation, while the bottom is in a direct contact with a cooled metal conveyor belt, the strip deforms already during solidification, firstly, upward and then downward.
[0006] At the start of cooling, the bottom of the material layer of the strip contracts most due to a very large temperature gradient. The entire strip bends upwardly in the middle, which results in very high stresses in the upper layer. Because these stresses are greater than the flow stress, they are reduced during the course of solidification again by subsequent elongation (flow), whereby opposite bending of the strip middle downwardly takes place. As a result, the low layer remains elongated, and the upper one shortened.
[0007] When the strip, which is usually not guided on its upper surface, leaves the metal conveyor belt with which it is displaced, the temperature of the strip over the strip thickness equalizes due to the reduced cooling of the strip bottom, the thermal tension also equalizes. The upper shortened and the lower elongated strip regions are subjected only to the backward bending, whereby the strip arches upwardly. The produced, as a result, stresses are below or close to the yield point, so that no or a very small backward formation of the arch resulting from the flow process, can be observed. The curve upward remains and results in arching of the strip narrow sides and also in a strip head like a ski.
[0008] During a further displacement, the degree of freedom of these arches in a longitudinal direction is reduced due to the gravity force of the strip horizontally displaceable on the adjoined roller table and/or by one or more pinch or smooth rollers which follow the metal conveyor belt, and firstly the strip tip and then the entire strip is mechanically tensioned and is forced to plane-parallel displacement downwardly.
[0009] This reduction of the degree of freedom leads to a need to reduce the stresses in the strip in the non-tensioned region, and that is why the strip narrow sides arch upwardly immediately after the strip leaves the metal conveyor belt. This behavior extends backwardly up to the region of the metal conveyor belt, so that the solidified strip has no contact anymore with the metal conveyor belt, and, thus, with the cooling medium and, as a result, has a non-homogenous temperature distribution over width of the strip that has a gutter profile.
[0010] In order to deal with this problem and to prevent the backward displacement of the pre-strip profile in the casting region and to insure passing into the upstream located machine, WO 2006/066552A1 suggests to arrange a guide element at the end of a primary cooling zone and in front of a conventional secondary cooling zone. As a rule, the guide element consists of several rollers arranged above and below the pre-strip in top-to-top or in offset-to-each other condition.
[0011] With a particular arrangement of rollers, the pre-strip is displaced in a plane located above a casting line in order to absorb the elongation of the bottom of the pre-strip by the carried-out upward movement. A roller arrangement, with which the pre-strip passes through the rollers as a wave, is also possible, however, it has not been used up to now.
[0012] The drawback of the method disclosed in WO 2006/066552 A1 consists in that the guide element that follows the metal conveyor belt can only partially influence the thermal processes on the metal conveyor belt.
[0013] Proceeding from this known state-of-the art, it is an object of the invention to provide a method with which in a simple manner, a maximum contact of the cast product with the metal conveyor belt and, thereby, optimization and equalization of heat transfer from the cast product to the metal conveyor belt over the entire casting width can be insured.
SUMMARY OF THE INVENTION
[0014] According to the method, the stated object is archived that in order to prevent a possible backward arching of strip edges that can begin in an outlet region of the caster and in order to average heat transmission to the casting product during solidification thereof on the metal conveyor belt, the following method steps are combined with each other:
[0015] establishing a maximum contact of the cast product with the metal conveyor belt, and to this end, a pressure device, which is arranged in a region of an end of the metal conveyor belt located downstream in a casting direction, applies pressure to the cast product solidifying into the pre-strip, preferably, to the strip edges thereof from above, and
[0016] compensating a suddenly reduced cooling of a bottom of the pre-strip upon the pre-strip leaving the conveyor belt, and to this end, in a predetermined region, immediately behind the metal conveyor belt, the bottom and selectively and simultaneously, an upper surface of the pre-strip selectively over an entire width is additionally cooled.
[0017] As a result of application of pressure, according to the invention, to the cast product from above in the region of the end of the metal conveyor belt and in particular, to its edges, which induces a complete contact of the cast product bottom with the metal conveyor belt, in association with additional cooling of the pre-strip bottom, optimization and equalization of heat transfer from the cast product to the metal conveyor belt over the entire casting width and heat equalization within the pre-strip after it leaves the metal conveyor belt, can be achieved.
[0018] The necessary pressure is produced by a pressure roller acting on the entire width of the cast product or by partial pressure-applying rollers acting only on the strip edges. The pressure rollers are preferably separately driven and inwardly cooled. According to the invention, the necessary pressure can be applied with an abutting circulating pressure strip which likewise can be separately driven and cooled.
[0019] In combination with application of pressure to the cast product, according to the invention, simultaneously, cooling of the pre-strip bottom in a predetermined region immediately behind the metal conveyor belt is carried out, wherein the predetermined region can extend over the entire width of the pre-strip and, upon availability of smooth/pinch rollers, up to those. The cooling is effected by an open spray cooling, e.g., with water, and/or by closed cooling with a circulating cooling belt that, like the metal conveyor belt, is in contact with the bottom of the pre-strip. According to the invention it is possible, simultaneously, to provide a circulating cooling belt on the upper side of the pre-strip for guiding the pre-strip and for cooling the same in a predetermined adapted different manner.
[0020] Further particularities and advantages of the invention will be explained based on an exemplary embodiment shown in schematic drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The drawings show:
[0022] FIG. 1 a layout of a casting installation with its essential components;
[0023] FIG. 2 a a section of FIG. 1 at an increased scale with an open spray cooling;
[0024] FIG. 2 b a section of FIG. 1 at an increased scale with a rotary cooling conveyors;
[0025] FIG. 3 a a plan view of a section of FIG. 1 according to the state-of-the art;
[0026] FIG. 3 b cross-sections of a cast product/leadership according to the state-of-the art;
[0027] FIG. 4 a plan view of FIG. 3 with a pressure roller;
[0028] FIG. 4 b a cross-section of a cast product/pre-strip with a pressure roller;
[0029] FIG. 5 a plan view of FIG. 3 with a partial pressure-applying roller; and
[0030] FIG. 6 plan view of FIG. 3 with a pressure band.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] FIG. 1 shows a side view of a casting installation in accordance with DSC-process with its essential components. In the casting direction (in the drawing from left to right), the installation consists of a separate caster 2 with a casting ladle 2 , a distribution spout 3 , a melt feeder 3 , and a metal conveyor belt 7 . The metal melt that flows from the casting ladle 2 ′ through the distribution spout 3 downwardly, is delivered on the cooled metal conveyor belt 7 from the melt feeder 3 ′ with a predetermined thickness as a cast product 4 . The length of the metal conveyor belt 7 is so selected that the stay time of the cast product 4 on the metal conveyor belt 7 up to its most possible solidification to a pre-strip 5 is sufficient. The metal conveyor belt 7 that has, e.g., a thickness of only 1 mm, is driven and displaced by two deflection rollers 8 , 9 and, e.g., a tension roller 10 . For sidewise limiting of the cast product 4 on the metal conveyor belt, there is provided on each side of the metal conveyor belt 7 , a displaceable therewith, dam block chain 15 . Smooth/pinch rollers 14 adjoin the metal conveyor belt 7 for transporting and reliably guiding the completely solidified pre-strip 5 , and mechanically grip the pre-strip and deliver it to a driver 16 that displaces it for further processing.
[0032] In this state-of-the art, corresponding strip casting installation 1 , there are provided, according to the invention, in a region of the deflection roller 8 , which are located at the end of the metal conveyor belt 7 , above the cast product 4 , a pressure roller 11 . The pressure roller 11 , which engages on the cast product 4 , can insure, upon application of corresponding pressure, a maximal contact at least of the strip edges of the cast product 4 with the metal conveyor belt 7 .
[0033] In a section of FIG. 1 , which is shown at an increased scale in FIG. 2 a , in addition to a pressure roller 11 , which applies a predetermined pressure from above to the cast product 4 , there is provided, according to the invention, additional cooling of the bottom of the pre-strip 5 in form of spray cooling 17 . This cooling is so designed that it acts only in a predetermined region that can extend over the entire width of the pre-strip 5 and, in the embodiment shown, from the end of the metal conveyor belt 7 up to the first of the lower smooth/pinch rollers 14 .
[0034] An alternative cooling of the pre-strip 5 in form of a closed cooling is shown in FIG. 2 b . This cooling that likewise takes places in a predetermined region immediately behind the deflection roller 8 , is carried out using a cooling conveyor 19 , 19 ′. Here, as with the spray cooling 17 shown in FIG. 2 , only the bottom of the pre-strip 5 is cooled by the cooling conveyor belt 19 provided thereat and/or, if desired, also the upper surface of the pre-strip 5 is cooled by a further cooling conveyor belt 19 ′ provided thereon.
[0035] To better explain the inventive pressure application to the cast product 4 , the strip casting installation shown in FIGS. 1-2 , is shown in FIGS. 3-6 in perspective view.
[0036] FIG. 3 a shows, e.g., a section of the strip casting installation, starting from the distribution spout 3 /melt feeder 3 ′ to the end of the metal conveyor belt 7 according to the state-of-the art. In FIG. 3 a , different cross-sections A, B, C are marked on the metal conveyor belt 7 on which the strip beginning of the cast product 4 is located. The line A shows a cross-section of the cast product 4 in the first half of metal conveyor belt 7 , line B shows a cross-section of the cast product 4 at the end of the metal conveyor belt 7 , and line C shows a cross-section of the solidified pre-strip 5 that after leaving the metal conveyor belt 7 , lies on a roller table 7 . In the strip casting installation according to the state-of-the art, the cast product 4 leaves its support, the metal conveyor belt 7 , and arches with its strip edges 6 continuously upward. This arching begins in form of a wedge-shaped upwardly arched region 18 that starts somewhere in the region of the cross-section “A” and constantly increases, so that after leaving the metal conveyor belt 7 (in the region of the cross-section “C”), it has its shown end condition.
[0037] In FIG. 3 b , the described arching of the strip is represented by cross-sections of the strip obtained at respective cross-sectional lines. At the cross-sectional line “A,” the not yet completely solidified cast product 4 completely contacts its support, the metal conveyor belt 7 , due to its gravity force and its available plastic characteristics. At the cross-sectional line “B,” the strip edges 6 of the not any more plastic, cast product 4 disengage from the metal conveyor belt 7 , and the cast product 4 now assumes a slightly arc-shaped cross-section. At the cross-sectional line “C,” the arching of the strip edges 6 advanced further, and the cross-section of the, now completely solidified, pre-strip 5 that lies on the roller table 7 ′, which prolongs the metal conveyor belt 7 , has a shape somewhat resembling a gutter.
[0038] FIG. 4 a shows a change in the arching of the strip edges 6 due to the use of a pressure roller 11 in the region of the cross-section “B.” the upwardly arching region 18 of the strip edges 6 begins only at the cross-section “B” with a noticeably smaller amount. The pressure roller 11 acts so that it suppresses the arching of the strip edges 6 , reversing it, until they occupy a position corresponding to that in the region of the cross-section “A.” A further, forwardly directed, arching of the strip edges 6 up to the cross-section “C” cannot be completely suppressed by the pressure roller 11 , however, it is noticeably smaller than in FIG. 3 a , without the pressure roller 11 . The object of the invention of insuring a complete contact of the cast product 4 with its support, the metal conveyor belt 7 , is completely achieved by the use of the pressure roller 11 .
[0039] FIG. 4 shows strip cross-sections corresponding to the respective cross-sectional lines obtained with the use of the pressure roller 11 . As without the pressure roller 11 , at the cross-section “A,” the cast product 4 flatly abuts the metal conveyor belt 7 , but it also flatly abuts the metal conveyor belt 7 at its end at the cross-sectional line “B.” Only after leaving the metal conveyor belt, there is observed a small strip edge arching that can be compensated by additional, according to the invention, cooling of the pre-strip bottom.
[0040] In FIG. 5 , as an alternative to the pressure roller 11 , in the same region, at the end of the metal conveyor belt 7 , there is provided a pressure device with two rollers 12 that apply each a partial pressure and act exclusively on the strip edge 6 . The effect, which is achieved is noticeable from the arched region 18 and is totally comparable with the action of the pressure roller 11 .
[0041] A further alternative to the use of the pressure roller 11 and the partial pressure-applying rollers 12 consists in use of a pressure belt 13 that applies pressure as shown in FIG. 6 , to a large region of the cast product 4 . Therefore, the shown here arched region 18 is somewhat smaller than with the use of previously shown rollers 11 and 12 .
[0042] The invention is not limited to the shown embodiments but can be carried out, with regard to the used pressure devices and devices for additional cooling, with devices that differ from the described above if the inventive method is possible with these devices.
REFERENCE NUMERALS
[0000]
1 Strip casting installation
2 Caster
2 ′ Casting ladle
3 Distribution spout
3 ′ Melt feeder
4 Cast product
5 Pre-strip
6 Strip edges of the pre-strip
7 Metal conveyor belt
8 , 9 Deflection rollers
10 Tensioning roller
11 Pressure roller
12 Partial pressure-applying roller
13 Pressure belt
14 Smooth/pinch rollers
15 Dam block chain
16 Driver
17 Open cooling device (spray-cooling)
18 Arching region
19 Closed cooling (low circulating belt)
19 ′ Closed cooling (upper circulating belt)
A Cross-section of the casting product in the front half of the metal conveyor belt
B Cross-section of the pre-strip at the end of the metal conveyor belt
C Cross-section of the pre-strip after it leaves the metal conveyor belt | The method of casting near net-shape rectangular strands made of metal and the subsequent further processing the strands into metal strips includes applying pressure from above to the cast product ( 4 ) solidifying into the preliminary strip ( 5 ), preferably to its strip edges ( 6 ) by means of a pressure device ( 11 ) disposed at the end of the metal conveyor belt ( 7 ) and, additionally cooling of the bottom of the preliminary strip in a predetermined area directly behind the metal conveyor belt ( 7 ). | 1 |
BACKGROUND OF THE INVENTION
[0001] 1) Field of the Invention
[0002] The present invention relates to a process for producing a dialkyl carbonate, and specifically, to a process for effective utilization of allophanate by-produced during reaction or at a purifying stage in the production of a dialkyl carbonate comprising reacting urea and alcohol. The dialkyl carbonate produced according the process of the present invention is useful as a raw material of diaryl carbonate.
[0003] 2) Prior Art
[0004] Japanese Patent Kokai (Laid-open) No.55-102542 describes a process for producing a dialkyl carbonate by reaction of urea and alcohol. Japanese Patent Kokai (Laid-open) Nos. 55-102543, 57-175147 and 57-26645 describe processes for producing a dialkyl carbonate by reaction of alkyl carbamate and alcohol and further Japanese Patent Kokai (Laid-open) Nos. 10-109960, 10-259163, 10-259166 and 11-60541 disclose improved processes thereof. However, in above-mentioned prior art gazettes, the production of a by-product and its component have been not known.
SUMMARY OF THE INVENTION
[0005] The inventors have found that a solid substance having an indistinct structure is produced in the production of a dialkyl carbonate from urea and alcohol and deposited on a condenser of a distillation column and pipes in its vicinity. When operation of the distillation column was performed without removing it, there caused problems that pipes were blockaded to prevent a flow of liquid and accurate flow rate was not indicated due to its deposition on a flow meter. Thus, it was necessary to remove the solid substance with a strainer or in a settling vessel. Further, the inventors analyzed the solid substance and found that it is allophanate. However, properties of allophanate were not known in detail. Therefore, any method except waste disposal of allophanate was not found. Since allophanate is by-produced from urea or alkyl carbamate of a raw material, waste disposal of allophanate to be by-produced caused lowering unit consumption of raw material.
[0006] From the above-mentioned viewpoints, an object of the present invention is to provide a process for effective utilization of allophanate by-produced and to eliminate an apparatus for removing allophanate by-produced and operation for removal thereof.
[0007] As a result of extensive studies to utilize effectively allophanate as a by-product which has been waste disposed hitherto, the inventors have found that allophanate can be used as a raw material instead of urea or together with urea in the production of a dialkyl carbonate and furthermore can be returned to a reactor for production of a dialkyl carbonate in the state of an alcohol solution or a slurry without performing separation, and have accomplished the present invention.
[0008] That is, the present invention provides a process for producing a dialkyl carbonate which comprises performing reaction of allophanate represented by the following general formula (1) and an alkyl alcohol represented by the following general formula (2) as raw materials, thereby producing a dialkyl carbonate represented by the following general formula (3).
RO—CO—NH—CO—NH 2 (1)
ROH (2)
RO—CO—OR(3)
[0009] wherein R is an alkyl group.
[0010] Further, the present invention provides a process for producing a dialkyl carbonate which comprises performing reaction of urea and/or an alkyl carbamate represented by the following general formula (4) and an alkyl alcohol represented the following general formula (2) as raw materials, thereby producing a dialkyl carbonate represented by the following general formula (3), wherein allophanate represented by the following general formula (1) to be produced as byproduct is reused as one of raw materials.
RO—CO—NH—CO—NH 2 (1)
ROH (2)
RO—CO—OR (3)
RO—CO—NH 2 (4)
[0011] wherein R is an alkyl group.
BRIEF DESCRIPTION OF THE DRAWING
[0012] [0012]FIG. 1 is a flow sheet including apparatuses for continuous reaction and purification of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The present invention will be described in detail below.
[0014] The alkyl alcohol to be used as a raw material for the production of a dialkyl carbonate is not limited. An alkyl alcohol having 3 to 6 carbon atoms (R in above-mentioned general formulas: an alkyl group having 3 to 6 carbon atoms) is preferable. Examples of the alkyl alcohol include propanol, butanol, pentanol, hexanol and isomers thereof.
[0015] As other raw material, allophanate can be used instead of urea. Although only allophanate can be used instead of urea, it is preferable to add allophanate obtained as a by-product to urea, alkyl carbamate or a mixture of urea and alkyl carbamate as raw materials.
[0016] The alkyl carbamate of the present invention is an intermediate of a dialkyl carbonate to be obtained in the reaction of urea and above-mentioned alkyl alcohol. Although it is possible also to advance the reaction until alkyl carbamate disappears, the reaction is stopped prior to its disappearance and then alkyl carbamate is recovered from the reaction liquid and can be also reused as a raw material.
[0017] Each proportion of urea, alkyl carbamate and allophanate is not limited. In the present invention, when only allophanate is used instead of urea as a raw material, a dialkyl carbonate represented by the general formula (3) is produced by reaction of allophanate represented by the general formula (1) and an alkyl alcohol represented by the general formula (2).
RO—CO—NH—CO—NH 2 (1)
ROH (2)
RO—CO—OR (3)
[0018] wherein R is an alkyl group and preferably an alkyl group having 3 to 6 carbon atoms.
[0019] Further, when allophanate is used as one of raw materials, a dialkyl carbonate represented by the general formula (3) is produced by reaction of urea and/or alkyl carbamate represented by the general formula (4), allophanate represented by the general formula (1) of a by-product and an alkyl alcohol represented by the general formula (2).
RO—CO—NH—CO—NH 2 (1)
ROH (2)
RO—CO—OR (3)
RO—CO—NH 2 (4)
[0020] wherein R is an alkyl group and preferably an alkyl group having 3 to 6 carbon atoms.
[0021] These raw materials are mixed. The reaction in a mixture thus obtained is performed with heating in the presence of a catalyst. In order to advance readily the reaction, it is necessary to exhaust ammonia produced by the reaction outside the reaction system. Therefore, it is preferable that the reactor is equipped with a reflux condenser and the reaction is performed in the state in which the reaction liquid is refluxed. Alkyl carbamate is produced at the initial stage of the reaction from allophanate and urea. When the reaction temperature is too high at this stage, side reaction occurs. It is preferable that the reaction temperature at the initial stage of the reaction is 100 to 200° C. and the reaction temperature at the stage to produce a dialkyl carbonate from alkyl carbamate is 160 to 260° C.
[0022] It is preferable that the reaction is performed in a high boiling point solvent having a boiling point of 180° C. or above. Although it is necessary to apply a pressure in order to maintain preferable reaction temperature without using a high boiling point solvent, the reaction can be performed under about atmospheric pressure by using a high boiling point solvent. Examples of preferable high boiling point solvent include hydrocarbons and ethers. Although the hydrocarbons may be aliphatic unsaturated hydrocarbons, saturated hydrocarbons or aromatic hydrocarbons having high stability are preferable. Ethers may be aromatic ethers, aliphatic ethers or aromatic aliphatic ethers.
[0023] Examples of preferable hydrocarbon solvent include undecane, dodecane, tridecane, tetradecane, pentadecane, hexadecane, heptadecane, octadecane, nonadecane, eicosane, tetramethylpentadecane, dicyclohexyl, hexylbenzene, cyclohexylbenzene, heptylbenzene, octylbenzene, nonylbenzene, decylbenzene, undecylbenzene, diisopropylbenzene, triisopropylbenzene, pentamethylbenzene, methylnaphthalene, diphenylmethane, ethylbiphenyl, bibenzyl and isomers thereof.
[0024] Examples of preferable ether solvent include dihexyl ether, dioctyl ether, cyclododencyl methyl ether, diethyleneglycol dimethyl ether, diethyleneglycol dibutyl ether, triethyleneglycol dimethyl ether, tetraethyleneglycol dimethyl ether, butyl phenyl ether, benzyl phenyl ether, dibenzyl ether, diphenyl ether, ditolyl ether and isomers thereof.
[0025] It is preferable that the amount of high boiling point solvent is about 0.1 to 10 mol per 1 mol of sum total of urea, alkyl carbamate and allophanate as the raw materials. It is preferable that the amount of alkyl alcohol is about 0.5 to 10 mol per 1 mol of sum total of urea, alkyl carbamate and allophanate as the raw materials.
[0026] As the catalyst for the reaction, the catalyst described in Japanese Patent Kokai (Laid-open) Nos. 55-102542, 55-102543, 57-26645 and 57-175147 can be used. Among them, particularly, an oxide, a hydroxide, a halogenide, an inorganic salt, an organic salt, an alkoxide, an alkyl-substituted oxide or an alkylalkoxide of at least one metal selected from the group consisting of zinc, lead, copper, tin, titanium, gallium and indium exhibits high activity for the reaction.
[0027] The reaction can be performed in a batch process or in a continuous process. In a batch process, it is preferable that total amount of alkyl alcohol is not added at the starting time of the reaction, but gradually added with progress of the reaction. In a continuous process, it is preferable that the reaction is performed in a cascade process with plural reactors. It is preferable that the number of the reactor is 3 to 5. Alkyl alcohol can be fed to each reactor.
[0028] After the completion of the reaction, the intended dialkyl carbonate can be obtained by separating by distillation from the reaction liquid. It is possible to separate both the catalyst and the high boiling point solvent contained in the reaction liquid as high boiling matter in distillation and the alkyl alcohol as low boiling matter in distillation. Allophanate is separated together with alkyl alcohol as low boiling matter since it is a substance having a sublimation property. Although the liquid removed both low boiling matters and high boiling matters can be used as dialkyl carbonate, if necessary, further distillation purification may be performed. In this case, as described in Japanese Patent Kokai (Laid-open) No. 2000-1461, it is possible also to promote the separation by adding a third substance.
[0029] Allophanate contained in alkyl alcohol can be separated by filtration since it is deposited by cooling. In order to perform efficiently the separation, it is preferable that a settling vessel is equipped and allophanate is deposited on its bottom section and then filtered. Allophanate thus separated is not only used alone as the raw material, but used together with urea and/or alkyl carbamate as one of the raw materials.
[0030] Industrially, it is preferable that an alkyl alcohol solution of allophanate obtained by distillation or a slurry thereof is used as the raw material for the reaction since the efficiency is low when allophanate is filtered. Total amount of alcohol separated by distillation may be returned to the reactor since the alkyl alcohol is unreacted and its total amount is smaller than an amount to be required for the reaction. Therefore, the reaction can be performed again by adding urea and/or alkyl carbamate and alkyl alcohol to the liquid.
PREFERRED EMBODIMENT OF THE INVENTION
[0031] The present invention will be described in more detail below, referring to Examples, which are not intended to limit the scope of the present invention.
[0032] The word “butyl” described in Examples means “n-butyl”.
EXAMPLE 1
[0033] A reactor equipped with a separable flask of capacity 500 ml with a baffle plate connected an Allihn cooler and a stirrer of fan turbine blade was used. Hot water of 60° C. was passed through the cooler. 25.00 g (156 mmol) of butyl allophanate, 5.70 g (76.9 mmol) of butanol, 2.89 g (11.6 mmol) of dibutyl tin oxide and 214.70 g (1.26 mol) of diphenyl ether were charged to the reactor and reacted for 4 hours with stirring while heating in an oil bath. It was considered that the time when the temperature of reaction liquid reached to 130° C. was reaction start time. Then, the temperature was adjusted so as to maintain 180° C. after one hour of the reaction starting, 200° C. after 2 hours and 205 to 210° C. after 4 hours. The oil bath temperature was gradually elevated from 160° C. at the time of the reaction starting to 235° C. at the time of the reaction completion. Butanol was added during the reaction so as not to elevate the reaction temperature to excess. Total amount of butanol used as the raw material was 33.37 g (450 mmol). After the completion of the reaction, the yield of dibutyl carbonate was 36.24 g (208 mmol). The yield of dibutyl carbonate based on butyl allophanate was 66.7%.
EXAMPLE 2
[0034] The reaction was performed in the same manner as in Example 1 except that 12.50 g (78.0 mmol) of butyl allophanate and 9.37 g (156 mmol) of urea were used instead of 25.00 g of butyl allophanate as the raw material and charge of butanol was changed from 5.70 g to 17.38 g (234.5 mmol). Total amount of butanol used as the raw material became 38.54 g (520 mmol). After the completion of the reaction, the yield of dibutyl carbonate was 33.80 g (194 mmol) and the yield of dibutyl carbonate based on total amount of butyl allophanate and urea was 62.2%.
EXAMPLE 3
[0035] The reaction and purification were performed, as shown in FIG. 1, using four stage continuous reactors and three distillation columns. In each reactors 1 , 2 , 3 and 4 , a vessel of capacity 350 L equipped with a baffle and a stirrer was used. 0.037 mol of dibutyl tin oxide and 4 mol of diphenyl ether per 1 mol of urea were added to preliminary mixing vessel 15 to disperse uniformly and then continuously introduced to reactor 1 via conduit pipe 9 . The introduction rate was adjusted so as to maintain 100 kg/hr. Heating was performed by passing a heated medium of 230° C. through a coil to each reactor. The temperature in each reactor was adjusted so as to maintain 170° C. in reactor 1 , 180° C. in reactor 2 , 190° C. in reactor 3 and 200° C. in reactor 4 . Butanol was introduced via conduit pipe 10 so as to maintain the reaction temperature to a prescribed temperature. The amount of butanol to be introduced via conduit pipe 10 during steady operation became 10 kg/hr. Hot water of 60° C. was passed through reflux condensers 5 , 6 , 7 and 8 . The reaction liquid was withdrawn via reaction liquid withdrawing pipes 11 , 12 , 13 and 14 connected to each reactor so as to maintain the liquid amount in each reactor to 230 L. Ammonia generated from each reactor was separated from butanol through reflux condensers 5 , 6 , 7 and 8 and then exhausted via conduit pipe 16 .
[0036] The reaction liquid was introduced to distillation column 17 via conduit pipe 14 . The introduction rate was 108 kg/hr. Distillation column 17 was adjusted so as to maintain column top pressure of 2.7 kPa, column top temperature of 102° C. and column bottom temperature of 145° C . The column bottom liquid, which was a mixture of the catalyst and diphenyl ether, was returned to preliminary mixing vessel 15 via conduit pipe 20 to reuse.
[0037] The mixture of butanol, dibutyl carbonate, butyl carbamate, diphenyl ether and butyl allophanate obtained from the column top section was introduced to distillation column 18 via conduit pipe 21 . Distillation column 18 was adjusted so as to maintain column top pressure of 13.3 kPa, column top temperature of 67° C. and column bottom temperature of 140° C. Butanol and butyl allophanate were obtained from the column top section and introduced to reactor 1 via conduit pipe 22 as a slurry liquid of butyl allophanate. The introduction amount was butanol 3 kg/hr and butyl allophanate 150 g/hr.
[0038] The mixture of dibutyl carbonate, butyl carbamate and diphenyl ether was introduced to distillation column 19 via conduit pipe 23 . In order to ensure efficient separation of dibutyl carbonate and butyl carbamate, phenol was introduced to distillation column 19 via conduit pipe 24 . Distillation column 19 was adjusted so as to maintain column top pressure of 2.7 kPa, column top temperature of 91° C. and column bottom temperature of 125° C. A mixture of dibutyl carbonate and phenol was obtained from the column top section via conduit pipe 26 . A mixture of butyl carbamate and diphenyl ether obtained from the column bottom section was returned to preliminary mixing vessel 15 via conduit pipe 25 to reuse.
[0039] After introduction of butyl carbamate to preliminary mixing vessel 15 via conduit pipe 25 was started, the feed amount of urea was adjusted so as to maintain 1 mol of sum total of butyl carbamate and urea per 4 mol of diphenyl ether.
[0040] The apparatuses were continuously operated for 80 hours. Steady state was reached after 30 hours of operation starting. The feed rate of urea in a steady state was 72.5 mol/hr, whereas the production rate of dibutyl carbonate to be obtained via reaction liquid withdrawing pipe 14 was 72.2 mol/hr (99.6 mol % to fed urea). The yield of dibutyl carbonate based on urea was increased more by 2.6% than in Comparative Example 1 where butyl allophanate was not returned to reactor 1 .
COMPARATIVE EXAMPLE 1
[0041] The operation was performed for 80 hours in the same apparatuses and procedure as in Example 1 except that butyl allophanate was cooled to 5° C. to deposit in a settling vessel equipped in a lower portion of condenser of distillation column 18 and only butanol was returned to reactor 1 via conduit pipe 22 . But, in order to remove butyl allophanate, procedures to withdraw butyl allophanate from the settling vessel every one hour and filter out it from butanol became necessary. The feed rate of urea in a steady state was 73.3 mol/hr, whereas the production rate of dibutyl carbonate to be obtained via reaction liquid withdrawing pipe 14 was 71.1 mol/hr (97.0 mol % to fed urea).
[0042] The present invention provides a novel process for producing dialkyl carbonate. Further, according to the process of the present invention, unit consumption of raw material is enhanced and a step for separation removal of allophanate can be eliminated in a process for production of dialkyl carbonate. | A process for producing a dialkyl carbonate which comprises performing reaction of allophanate represented by the following general formula (1) and an alkyl alcohol represented by the following general formula (2) as raw materials, thereby producing a dialkyl carbonate represented by the following general formula (3).
RO—CO—NH—CO—NH 2 (1)
ROH (2)
RO—CO—OR (3)
wherein R is an alkyl group. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional and claims benefit of priority of U.S. patent application Ser No. 09/424,427, filed Feb. 28, 2000, now U.S. Pat. No. 6,316,244.
BACKGROUND
1. Field of the Invention
The present invention concerns bacterial autoinducers of growth, methods for their purification, autoinducers purified by such methods, and their use to induce the growth of bacteria, both the source organism and other species.
2. Description of the Related Art
Signalling events between bacteria and host cells are an integral component of the dynamic and complex process of infection and disease. It has recently become clear that signalling between bacteria is also of importance to this process.
Low molecular weight, diffusible signal molecules produced by bacteria, termed autoinducers (AI), play a crucial role in the development of bacterial infections, of both plants and animals. These autoinducers may determine whether or not an initial infection, often involving only a very few bacteria, will succumb to the many defence mechanisms of a host or whether these host defences are overcome, and bacterial growth and disease occur.
One class of autoinducers has already been well-characterised, the N-acyl homoserine lactones, which are composed of derivatives of amino acid and fatty acid molecules. This family of molecules play a key role in the mechanisms by which Gram negative bacteria monitor population densities, factors which are important in virulence of a number species. However, despite the fact that N-acyl homoserine lactone-type sensing systems have been shown to exist in E. coli , there is so far no evidence that N-acyl homoserine lactones themselves are made by, or play a role in the pathogenesis of this organism. In addition, no evidence has been so far been presented to suggest a role for these autoinducers in the pathogenensis of Salmonella.
The existence of an additional class of autoinducer molecule has been shown, the AI being different from the homoserine lactones. These also appear to play an important role in pathogenesis.
A purported bacterial AI was isolated by Lyte, M. et al. (1996, FEMS Microbiology Letters, 139: 155-159) having a molecular weight of approximately 10,000 Da (see also, Lyte, M., 1993, Journal of Endocrinology, 137: 343-345; U.S. Pat. No. 5,629,349).
BRIEF SUMMARY OF THE INVENTION
The present inventors have succeeded in isolating, purifying and characterising a novel autoinducer from E. coli and Hafnia alvei.
According to the present invention there is provided a bacterial autoinducer, characterised in that it has substantially the following properties:
i) it is produced in response to noradrenaline in serum SAPI medium;
ii) it is heat stable;
iii) it is stable to lyophilisation;
iv) it has a negative charge;
v) it is polar;
vi) it is hydrophilic;
vii) it will not partition into organic solvents;
viii) it is capable of binding positively charged metal ions; and
ix) it has a molecular weight of about 300-1500 daltons
The bacterium may be E. coli or Hafnia alveii.
The bacterium may be Salmonella, for example S. enteriditis or S. typhimurium.
The autoinducer is distinct from N-acyl homoserine lactones and the molecule of Lyte et al. (1996, supra) (for example, the molecular weight of an autoinducer according to the present invention is less than 1000 Da, compared to the 10,000 Da of Lyte et al.). Similarly it is not a peptide pheremone nor is it a known siderophore such as enterochelin which, amongst other things, is stable to acidification, soluble in organic solvents such as ethanol and upon crystallisation forms white needle-like crystals. Experiments (below) show that the autoinducers of the present invention appear to form a novel family of highly-related molecules.
The autoinducer has a wide range of possible uses, essentially including anything in which the growth of a bacterium or the production of a desired molecule is to be stimulated or assayed. For example, it may be used in fermentation processes, in culture media for diagnostic and environmental monitoring or in the drug discovery process in order to find agents which will inhibit autoinducer-mediated bacterial stimulation. In fermentation processes, the autoinducer may be used to stimulate starting cultures or to shorten and synchronise lag phases; in fermentation processes to stimulate the production of secondary metablolites such as antibiotics, chemicals for biological screening, and recombinant proteins; in culture media to shorten turn-around times or to assay viable but non-culturable organisms. Other uses of the autoinducer will be readily apparent to one skilled in the art.
The E. coli autoinducer is a low molecular weight diffusible signal molecule, initially found as a bacterial response to physiologically relevant concentrations of noradrenaline, such as those found in the gastrointestinal tract of mammalian hosts. This effect is not nutritionally mediated. The half-life of activity of intestinal nor-adrenaline is quite short lived—the hormone is active for only a few hours, before becoming irreversibly sulphonated. However, this transient exposure to nor-adrenaline is sufficient to induce the bacteria to synthesize their own growth stimulus, the autoinducer, which has much greater stability. The autoinducer acts by effecting both accelerated growth rate, increased bacterial cell numbers and the production of virulence factors, such as toxins and adhesins, the activity being cross-species specific.
The apparent molecular weight of the E. coli autoinducer is dependent upon the elution conditions used (see ‘Experimental’ below), due to the substantial charge the molecule has. Experiments (below) have shown the charge on the molecule to be greater than that on ATP. The molecule has also been found to be polar. It is heat stable and is capable of being autoclaved at 121° C. Similarly it is capable of withstanding lyophilisation. The molecule is also capable of inducing cross-species stimulation.
The above list of characteristics may be considered the “core” characteristics of the family of autoinducers. Other characteristics have been identified as detailed in the experimental section below and the autoinducer may have at least one of the following characteristics:
i) it has absorbtion maxima at 255,325 and 500-550 nm; and
ii) it is stable in prolonged storage in a dried state and/or in solution.
Additional characteristics (which may be specific to the E. coli , Salmonella or Hafnia autoinducers) of which the autoinducer may have at least one are:
i) it is produced in substantially smaller quantities by bacteria grown in LURIA broth, Tryptone soya broth, M9 minimal medium and Davis-Mingioli minimal medium than by the same bacteria grown in serum SAPI medium;
ii) it has a reddish-pink colour, reversibly decolorisable by reducing the pH to <4;
iii) it contains serine;
iv) its synthesis involves the entA and entB gene products;
v) its synthesis is not stimulated by conditions of Fe starvation;
vi) it is synthesised in conditions of excess Fe;
vii) its entry into bacteria occurs via a tonB dependent receptor;
viii) it is inactivated by oxidation;
ix) it is inactivated by extreme pH; and
x) it is resistant to degradation by ribonuclease, deoxyribonuclease, trypsin, pepsin, V8 protease, proteinase K, acid phosphatases, alkaline phosphates and phosphodiesterase.
Also provided according to the present invention is a method for isolating and purifying a bacterial autoinducer from a sample comprising the steps of:
i) collecting a sample containing the autoinducer;
ii) fractionating the sample to isolate fractions corresponding to molecular weights of approximately 300-1500 Daltons; and
iii) eluting the isolate of (ii) on an anion-exchange chromatographic column and selecting the fraction containing the autoinducer.
It may comprise the additional step of performing gel filtration chromatography upon the fraction containing the autoinducer selected in (iii) and selecting the fraction containing the autoinducer.
It may comprise the additional step of concentrating the sample prior to fractionation.
Concentration may be achieved by means of ultrafiltration. Such ultra-filtration may be performed with a membrane molecular weight cut-off (MWCO) of approximately 100 Daltons. Alternatively, concentration maybe by means of lyophilisation or filtration or a combination thereof.
The sample may be collected from a culture containing bacteria and the autoinducer. It may be a supernatant collected from a centrifuged culture containing bacteria and the autoinducer.
Fractionation may be by means of size exclusion gel filtration.
Size exclusion gel filtration maybe performed using a buffer of approximately 100 mM ammonium bicarbonate, pH 8.0, anion exchange purification being performed on an anion exchange column with a triethylammonium bicarbonate gradient.
Alternatively, size exclusion gel filtration may be performed using a buffer of approximately 20 mM potassium phosphate containing 150 mM NaCl, pH 7.4, anion exchange purification being performed on an anion exchange column with a NaCl gradient.
Size exclusion separation of the autoinducer may also be performed using preparative ultrafiltration with a MWCO greater than that of the autoinducer, for example 1500 Da.
Other conditions for performing anion-exchange purification and concentration of the sample will be readily apparent to one skilled in the art, particularly with regard to the highly distinctive physical characteristics of the autoinducer.
Also provided according to the present invention is a bacterial autoinducer isolated and purified according to the method of the invention.
Also provided according to the present invention is the use of a bacterial autoinducer according to the present invention in inducing bacterial growth, the production of bacteria toxins or the production of bacterial adhesins. The use may of course be with bacteria of the species from which the autoinducer was derived, or of another species.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further apparent from the following description, with reference to the several figures of the accompanying drawings, which show, by way of example only, forms of bacterial autoinducers. Of the figures:
FIG. 1 shows the role of host and bacterial cellular signalling molecules in the pathogenesis of bacterial infectious diseases;
FIG. 2 shows Step 1 of the chromatographic purification of the Escherichia coli autoinducer. Superdex 30 gel filtration elution profile of concentrated AI equivalent to 125 ml of unpurified supernatant. Top graph, Y-axis: AI activity in fractions expressed as CFU/ml (colony forming units/ml×10 4 ); X-axis, fraction number (8 ml fractions). Bottom graph, Y-axis: 280 nm UV absorbance elution profile (100% mark=absorbance of 1.0); X-axis, fraction number (8 ml fractions);
FIG. 3 shows Step 2 of the chromatographic purification of the Escherichia coli autoinducer. Mono P anion exchange elution profile of 250 ml of Step 1 -purified Escherichia coli autoinducer. Top graph, Y-axis: AI activity in Mono P fractions expressed as CFU/ml (colony forming units/ml×10 4 ); X-axis, fraction number (1 ml fractions). Middle graph, Y-axis: 280 nm UV absorbance elution profile of a Step 1-purified sample containing AI (100% mark=Absorbance of 0.5); X-axis, fraction number (1 ml fractions). Bottom graph, 280 nm UV absorbance elution profile of a Step 1-purified production medium sample without AI i.e. negative control (100% mark=absorbance of 0.5); X-axis, fraction number (1 ml fractions);
FIG. 4 shows Step 3 of the chromatographic purification of the Escherichia coli autoinducer. Superdex peptide gel filtration elution profile of the Escherichia coli autoinducer. Top graph, 280 nm UV absorbance elution profile of 5 ml of Step 2-purified AI concentrated to 50 μl. Y-axis: (100% mark=absorbance of 0.2); X-axis, elution volume, V e , ml. Middle graph: AI activity in Mono P fractions expressed as CFU/ml (colony forming units/ml×10 4 ); X-axis, fraction number (1 ml fractions). Bottom graph, 280 nm UV absorbance elution profile showing refractionation of Step 3-purified AI peak (2.5 ml of peak eluting at approx. 28.5 ml, concentrated to 50 μl). Y-axis: 280 nm UV absorbance elution profile (100% mark=absorbance of 0.2); X-axis, elution volume, V e , ml.
FIG. 5 shows the Superdex 75 gel filtration elution profiles of novel autoinducers. Plots are for Plots are for (top-bottom) E. coli, Salmonella enteriditis, Citrobacter freundii, Serratia marcescens, Klebsiella oxytoca and Proteus mirabilis . Y-axis shows the AI activity profile per fraction (CFU/ml×10 4 ); X-axis shows fraction number (1 ml fractions) [equivalent to elution volume, V e , ml]. The first peak of activity around fraction 10 shows autoinducer bound to a serum protein; the later peaks (around fraction 20) show the free AI molecules. With the esception of the Proteus AI (around 1500 Da), these are of roughly similar molecular weights (less than 1000 Da).
FIG. 6 a shows the response of test bacteria to autoinducers of other bacteria (top, E. coli ; middle, Hafnia alvei ; bottom, Proteus mirabilis ). Y-axes show CFU/ml and X-axes show (and also for FIGS. 6B, 6 C, 6 D and 6 E) the test bacteria ( 1 =control, serum/SAPI only—no autoinducer; 2 = Proteus mirabilis ; 3 = Pseudomonas aeruginosa , 4 = Yersinnia entercolitica ; 5 = Morganella morganii ; 6 = Staphylococcus albus ; 7 = Staphylococcus aureus ; 8 = Streptococcus dysgalacticae ; 9 = Listeria monocytogenes ; 10 = Enterococcus faecalis ; 11 = Enterococcus faecium ; 12 = Hafnia alvei ; 13 = Klebsiella oxytoca ; 14 = Klibsiella pnuemoniae ; 15 = Acinetobacter lwoffii ; 16 = Xanthomanas maltophiia ; 17 = Citrobacter freundii ; 18 = Serratia marcescens ; 19 = Enterobacter sakazaki ; 20 = Enterobacter aerogenes ; 21 = Enterobacter cloacae ; 22 = Enterobacter agglomerans ; 23 = Salmonella enterica Sv Enteriditis ; 24 = Escherichia coli )*=autoinduction;
FIG. 6 b shows effects of autoinducer from (top) Enterobacter agglomerans , (middle) Klebsiella pneumoniae and (bottom) Xanthomonas maltophila . Axes as for FIG. 6A;
FIG. 6 c shows effects of autoinducers from (top) Yersinnia entercolitica , (middle) Pseudomonas aeruginosa and (bottom) Morganella morganii . Axes as for FIG. 6 a;
FIG. 6 d shows effects of autoinducers from (top) Salmonella enterica Sv. Enteriditis, (middle) Enterococcus faecalis and (bottom) Enterococcus faecium . Axes as for FIG. 6 a;
FIG. 6 e shows the effect of Staphylococcus albus autoinducer. Axes as for FIG. 6 a;
FIG. 7A shows the UV/Visible spectrum from 200-800 nm of (top) homogeneous (Step 3-purified) E. coli autoinducer (0.3 mg/ml) and (bottom) homogeneous H. alvei autoinducer (0.22 mg/ml). Absorption maxima are observed at <200 nm, 255 nm, 325 nm and around 500-550 nm.
FIG. 7B shows the 200-800 nm absorption spectra for more concentrated, but less pure E. coli autoinducer (1 mg/ml) (top) and H. alvei autoinducer (0.7 mg/ml) (bottom). The materials shown are peak Step 2 Mono P fractions (approximately 50% pure).
DETAILED DESCRIPTION OF THE INVENTION
As can be seen from FIG. 1, recognition of host effector molecules (such as hormones, eg noradrenaline) are used by the bacteria (in this case, E. coli ) to detect that they are within a suitable host. Bacteria respond to host effectors by the production of virulence factors (toxins, adhesins and invasins), toxic proteins which allow them to invade cells and so establish and spread infection. These virulence factors can activate signalling pathways in host cells, which can lead to cell death and tissue damage. If the damage caused by the bacteria is sufficient, the host experiences symptoms of disease
Not only is signalling between host and bacteria important, but also signalling between bacteria, via low molecular weight diffusible molecules called autoinducers. These allow the expression of the genes which encode virulence factors to be coordinated to optimum bacterial population densities.
The experiments below detail the isolation and purification of autoinducers from E.coli and Hafnia alvei , together with studies of the effects of these and other autoinducers upon bacteria (both gram-negative and gram-positive) of the same and other species which show that the bacterial autoinducer of the present invention is capable of effecting signalling between different species of bacteria.
The experiments also detail the characterisation of the physical characteristics of the E.coli autoinducer and the autoinducers of other species and show that the autoinducers form a family of similar molecules, which may be isolated and purified using the same basic purification strategy—for example, the autoinducer of Hafnia alvei was isolated and purified using the same strategy as that employed for the E.coli autoinducer.
Extraction and Purification
E.coli O 157:H7 were cultured as follows:
Bacteria (approximately 50-500 cfu/ml) are inoculated into SAPI minimal medium (6.25 mM NH 4 NO 3 , 1.84 mM KH 2 PO 4 , 3.35 mM KCl, 1.01 mM MgSO 4 and 2.77 mM glucose, pH 7.5) supplemented with 30% (v/v) adult bovine serum (Sigma), and either 1% (v/v) previously made E.coli autoinducer or 50 mM norepinephrine.
The cultures are grown statically (i.e. without aeration by shaking) for 24 hours at 37° C. in a 5% CO 2 incubator.
The bacteria are pelleted by centrifugation, and culture supernatants containing the autoinducer are sterilised by filtration through a 0.2 μm pore diameter filter.
Purification
Purification of the autoinducer from the bacterial culture (above) was performed as follows:
Step 1—Superdex 30 Gel Filtration Chromatogaphy (FIG. 2)
The filter-sterilised culture supernatants are lyophilised, dissolved at {fraction (1/7)} their original volume in distilled water, and re-filtered. 20 ml aliquots of ×8-concentrated material are then fractionated by gel filtration (size exclusion) chromatography on a Superdex 30 (prep grade) column (2.6×65 cm, total volume 360 ml) connected to a Pharmacia FPLC. The column is run at a flow rate of 1.5 ml/min, and the chromatography buffer is 100 mM ammonium bicarbonate, pH 8.0. This was chosen because it is volatile; the use of other buffers is possible at this stage of the purification, provided they contain no more than 200 mM Na/KCl (higher concentrations may affect autoinducer binding to the Mono P column in the next stage).
The total activity of the crude autoinducer is roughly equally divided between two major peaks of activity. One represents a serum protein-bound form of the autoinducer (corresponding to the huge UV absorbance peak on the A280 profile). This was proved by heat treatment of the high molecular weight fractions in the presence of NaCl; subsequent molecular weight analysis (gel filtration) showed disappearance of the high molecular weight peak, and the appearance of a low molecular weight peak of autoinducer activity. Similarly, when whole autoinducer preparations were heat-treated in the presence of NaCl the high molecular weight peak disappeared, with a corresponding increase in the size of the low molecular weight peaks. The molecule bound by the autoinducer has a molecular weight of around 10 kDa, and is definitely not BSA (approximately 67-70 kDa).
The low molecular weight activity is the material used for further purification. We consistently observe two broad peaks, corresponding to molecular weights of around 600 and 400 Da. The extreme electronegativity of the autoinducer may cause it to interact with the gel filtration column in a charge-mediated manner so causing it to run aberrantly. However, gel filtration in the presence of elevated NaCl (0.5 M as opposed to the usual 0.15 M) does not abolish the 2-peak profile of the low molecular weight material. The heterogeneity of this activity may represent interactions of autoinducer molecules with one another and/or with other components of the serum medium.
Step 2—Mono P Anion Exchange Chromatography (FIG. 3)
The pooled fractions from 2 Superdex separations are further purified using a 1 ml Pharmacia Mono P 5/5 column, equilibrated in 20 mM triethylammonium bicarbonate (TEAB) buffer, pH 7.5. The autoinducer is isolated using a 40 ml gradient of 20 to 1000 mM TEAB. The autoinducer elutes between 500 and 700 mM TEAB. Concentration of the Mono P autoinducer fractions (approximately 10 ml) and removal of the TEAB buffer is achieved by lyophilisation; the pooled fractions are lyophilised, redissolved in distilled water, and re-lyophilised.
Mono P is a very weak anion exchanger (it is normally used for chromatofocussing), and it was chosen because of the high degree of electronegativity of the autoinducer, and the consequent problems of its elution from moderate or strong anion exchangers.
TEAB is a volatile salt which is therefore easily removed by lyophilisation (although note that concentrations of TEAB up to 20 mM are not inhibitory in the growth stimulation assays).
Stronger anion exchange columns could be used, but the extreme electronegativity of the autoinducer causes it to bind with high affinity to moderate or strong anion exchangers, and high concentrations of non-volatile salts such as NaCl or KCl (1-2 M) are then required for elution.
The strategy of reducing pH to reduce electronegativity in order to reduce the salt required for elution does not work with our molecule. Indeed, removing salt from a molecule the size of our autoinducer is extremely difficult.
The activity profile of the Mono P column fractions shows two peaks of activity, indicating two (negatively) charged states. We have also observed that autoinducer is inactivated by oxidation; treatment with 100 mM H 2 O 2 , followed by lyophilisation to remove the oxidant, causes a 20-fold reduction in activity of the autoinducer in 1 hour and total loss of activity in 4.5 hours. The peroxide effect is also concentration-dependent.
Step 3—Superdex Pep Gel Filtration Chromatography (FIG. 4)
AI-containing fractions from one Mono P fractionation (approx 10 ml) are pooled, concentrated by one lyophilisation, re-dissolved in 100 ml of 200 mM TEAB buffer, and fractionated in 50 ml aliquots on two Pharmacia Superdex peptide HR 10/30 anaytical columns connected in series (effective column dimensions 1.0×60 cm, total volume 48 ml). The columns are equilibrated in 200 mM TEAB, and run at a flow rate of 0.4 ml/min.
The autoinducer activity elutes as a single, discrete peak (1.5-2 ml) with an average V e of 28.5 ml. To achieve further purification, peak Al fractions are pooled, concentrated by lyophilisation, and refractionated as described above. If necessary, final ‘polishing’ (i.e. purification) is achieved by a third fractionation. Symmetrical autoinducer peaks are pooled, extracted three times with chloroform:isoamyl alcohol (24:1) to remove possible residual traces of polyethylene glycol (an occasional contaminant from the commercially prepared serum used in our production medium) and lyophilised to remove TEAB buffer as described above.
The symmetry of the UV absorbance and activity peaks of the Step 3-purified autoinducer and the results of various forms of MS analysis (see below) suggest that our preparation has been purified to a level approaching homogeneity.
The purification scheme (above) is highly reproducible and a typical AI purification starting with 800 ml of culture supernatant produces approximately 0.1-0.2 mg (dry weight) of Step 3 autoinducer. We estimate that the effective concentration of this material is in the micromolar to nanomolar range, indicating that the growth stimulatory effects of the autoinducer are not simply due to its use as a source of nutrition.
Experiments performed with an E. coli mutant unable to respond to nor-epinephrine or to synthesize autoinducer, show that autoinducer is actively withdrawn from media during growth, and that the extent of growth is determined by the availability of autoinducer.
The protocol described here (see also Table 1, below) involves a complex protein-rich culture medium which limits the efficiency of the initial gel filtration, making it very time-consuming.
It has been found that a fur mutant (i.e. derepressed for iron-responsive genes) of E. coli K-12 (strain H1780) appears to constitutively express substantial levels of a heat-stable autoinducer-like activity under non-inducing growth conditions such as the rich medium Tryptic Soya Broth (TSB) and, crucially, M9 minimal medium lacking serum supplementation.
However, addition of iron chelators such as a, a′-dipyridyl to TSB in order to derepress iron-responsive genes does not result in increased production of autoinducer activity by wild-type (i.e. fur + ) strains.
Moreover, various clinical isolates of E. coli produce heat-stable autoinducer-like activity in standard M9 minimal medium, although at somewhat lower levels than in the conditions described previously. Preliminary examination of the chromatographic, UV/visible, and ESMS properties of this autoinducer-like activity suggest that it is very similar, if not identical, to the autoinducer made (above) using serum-based media.
The advantages of production of autoinducer in a simple, protein-free minimal medium are enormous, in terms both of cost and of the speed and simplicity of the purification protocol. Scaling-up is simple to achieve and, with constitutive expression by the fur mutant, continuous fermenter culture is also a possibility.
Characteristics
Stability (see also Table 2)
The E. coli autoinducer is a very stable molecule. It is especially resistant to heat inactivation, and can even be autoclaved without losing activity. In its unpurified form it is stable to prolonged storage in solution, without any loss of growth stimulatory activity. It is also stable to lyophilisation, and to storage in a dry powder form for at least a year.
The autoinducer is normally stored at −20° C. as a preventative measure, since we have shown that the purified molecule is inactivated by oxidation. However, autoinducer is stable to storage either dried or in solution for at least 4 months at 4° C. The molecule is also stable to storage at room temperature for at least 6 weeks.
The autoinducer is rapidly and irreversibly inactivated at extreme pH values.
Autoinducer production in other bacterial pathogens (see also Table 4, FIGS. 5, 6 A- 6 E)
The autoinducer produced by E. coli also stimulates growth of a range of other bacteria, including many members of the family Enterobacteriaceae, as well as other Gram negative and Gram positive species (Table 4).
It has been shown that certain of these bacteria respond to norepinephrine (NE) and synthesise their own autoinducers, all of which are heat-stable low molecular weight molecules (less than 1000 Da) similar in size to the E. coli autoinducer (Table 4, FIG. 5 ).
These molecules are able to stimulate growth and autoinducer production both in E. coli and amongst each other, a similarity of action which suggests that they may share a similar chemical structure (FIGS. 5, 6 A- 6 E).
Using the purification scheme (above) developed for the E. coli autoinducer it has also been possible to purify the corresponding activity from Hafnia alvei . The autoinducer from this organism, which shares with the E. coli molecule the same wide breadth of ability to signal across species boundaries, is also highly electronegative and reddish-pink in colour, although somewhat smaller (by around 100 Da, Superdex pep V e approx 31.5 ml).
Autoinducer Structural Analysis (see also Table 5, FIGS. 7A-7D, 8 A, 8 B)
Size
Dialysis, gel filtration chromatography and various forms of Mass Spectroscopy suggest a molecular weight of around 500 Da for the E. coli autoinducer. This molecular weight is too low to be indicative of a typical Gram positive peptide pheromone-type structure (which have variable molecular weights but which are usually very much greater than 1000 Da)
AI is not a homoserine lactone
However, while the E. coli autoinducer is of a similar size to certain of the N-acyl homoserine lactones, it differs from them in several important respects. Homoserine lactones are optimally produced in standard laboratory media predominantly during stationary phase, while synthesis of autoinducer occurs primarily in specialised media maximally during exponential growth. Homoserine lactones are inactivated by heating; in contrast, the E. coli autoinducer can be autoclaved without losing activity. Homoserine lactones are moderately hydrophobic, they partition into organic solvents and they bind to reverse phase columns; the E. coli autoinducer is very hydrophilic, and will not partition into organic solvents, or bind to reverse phase columns even after acidification. Most importantly, E. coli autoinducer does not display any activity in a homoserine lactone assay using Agrobacterium tumefaciens reporter strain (11).
These results strongly suggest that the E. coli autoinducer of growth is not a homoserine lactone.
The E. coli AI may be a highly modified, novel siderophore
Amino acid analysis has shown the unequivocal presence of serine in the E. coli autoinducer. The pink/red colouration and the growth enhancing properties of the autoinducer is suggestive of a siderophore, even though the breadth of cross species activity shown by the autoinducer is unprecedented amongst siderophores. Work with E. coli and Salmonella typhimurium ‘iron-response’ mutants which are defective in the genes responsible for the early steps in the synthesis of the enterochelin ferrisiderophore (entA and entB) are also unable to synthesise autoinducer, although they are still able to respond to AI given as a supplement. Further, evidence obtained with Salmonella strains with mutations in receptor proteins for catechol (and therefore enterochelin/siderophore) uptake systems (cir, iroN and fepA), and an E. coli mutant which is defective in the exbB gene (which encodes a protein involved in energising the cir, iroN and fepA siderophore receptors), suggest that a similar pathway of entry into the cell may also be taken by autoinducer. ICP Trace metal analysis of 16 mg of Step 3 purified autoinducer showed a significant presence of iron. However, the amounts of Fe detected (approximately 2% Fe w/w of AI) were lower than the 10% w/w ratio one would expect for a siderophore of 500 Da carrying one Fe iron of 55 Da. By association, these results suggests that the autoinducer is a siderophore. However, the following functional aspects of the autoinducer suggests against this:
Induction of siderophore synthesis is specific to conditions of iron starvation. Synthesis of the E. coli autoinducer is not induced in standard laboratory media under conditions of iron deficiency (such as addition of the iron chelator dipyridyl) which other labs have shown to result in the production of mg amounts of siderophore, and crucially, the molecule is still made in serum medium despite the addition of excess iron.
The autoinducer also appears to be very much more stable than the literature suggests:
enterochelin has a half-life of around 30 minutes at room temperature, the autoinducer has a half-life measured in weeks and months.
Enterochelin, a trimer of dihydoxybenzoylserine, can be acidifed without inactivation, is soluble in organic solvents, and forms white crystals when crystallised from ethanol. Autoinducer has none of these properties.
The presence of Fe within the autoinducer, the involvement of the entA and entB genes in AI synthesis, and involvement of siderophore receptors in AI uptake are strongly suggestive of a siderophore-type structure. However, many other aspects of AI structure and conditions of synthesis are atypical of siderophores. If the autoinducer is indeed a siderophore, it is unlike enterochelin, and indeed any siderophore described previously.
Trace metal analysis
Trace metal analysis with 16 micrograms of purified E. coli AI showed a higher than background amount of iron (molecular weight approx. 55 Da) (although less than one would expect with enterochelin—only around 2% weight of AI/weight of Fe ratios, instead of the 10% that would be expected for a molecule of MWt 500).
Other Properties of the E. coli Autoinducer
Although extremely stable to heat and prolonged storage, the AI is unstable to oxidation and extremes of pH (particularly acidity). Prolonged incubation with various degradative enzymes such ribonuclease, deoxyribonuclease, proteases (trypsin, pepsin, V8 protease, proteinase K), phosphatases (acid or alkaline) or phosphodiesterase is without effect. However, the autoinducer is inactivated by a bacterial sulphatase. The presence of sulphate groups would be consistent with the electronegativity of the autoinducer, and the observation that ammonium sulfate (but not equivalent mM concentrations of ammonium chloride, formate, acetate or bicarbonate) can stimulate growth and autoinducer production in our serum assay.
The E. coli autoinducer is highly electronegative. Analysis on anion exchange columns shows two discrete peaks of activity, indicating that the molecule exists in at least two negatively charged states.
Preliminary UV/visible scans of purified E. coli and Hafnia autoinducers are shown in FIG. 7 A. Absorbance spectra from more concentrated but somewhat less pure Al preparations (around 50% of total components) of both species are also shown (FIG. 7 B). Absorption maxima are observed at <200 nm, 255 nm, 325 nm and around 500-550 nm. All preparations of the E. coli and Hafnia autoinducer to date have been reddish-pink in colour; purification of the corresponding negative control supernatants (which contain no autoinducer) are not red. This colouration is pH-dependent, and acidification (to less than pH 4) results in de-colourisation (reversible upon re-neutralisation). Despite the apparent colour of the autoinducer, the visible spectrum of the molecule is rather indeterminate.
The absorbance spectra of the E. coli and Hafnia autoinducers are not suggestive of a simple peptide structure. However, the autoinducer does stain positively with ninhydrin, and amino acid analysis of homogeneous E. coli autoinducer from two separate purifications clearly shows that an amino acid, serine, is a structural component of the molecule. No significant amount of any amino acid other than serine was detectable in the amino acid analyses.
Mass spectrometry analysis of the autoinducer has so far produced somewhat perplexing data. This is a summary of the spectra we have obtained so far. We have restricted our analysis to Step 2 (Mono P anion exchange) and Step 3 (Superdex peptide gel filtration) purified autoinducer.
Positive detection mode ESMS of highly concentrated Step 2 autoinducer consistently shows two major ion peaks of 407 and 465 Da. The 465 ion also occasionally occurs in a Na + -bound form (not shown). The 465 Da ion is also visible as a 464 Da molecule in negative ion detection mode Fast Atom Bombardment (FAB) MS. The 407 ion is undetectable in negative mode FAB MS. An additional 514 Da ion is also visible as a major species, and a 692 ion as a minor species, in negative FAB MS of Step 2 autoinducer. These ion sizes are within the range of estimates of autoinducer molecular weight indicated by other forms of analysis.
Gel filtration fractionation of Step 2 autoinducer reveals around 9 discrete UV-absorbing peaks; autoinducer activity is only associated with the peak eluting around 28.5 ml (FIG. 4 ). However, positive mode ES MS (not shown), and negative mode FAB MS of Step 3 autoinducer peak fail to show the presence of any of the 407, 465 and 514 ions. Instead, with negative mode FAB MS a strange-looking very low molecular weight polymeric molecular species is observed, with ion sizes ranging from around 100 Da to 400 Da, and a repeating interval of 15 Da. No higher molecular weight species are observed. When this material is mixed with Step 2 autoinducer, instead of seeing any peak accentuation, flight of the 464, 514 and 692 ions is actually suppressed.
It is possible that the ions seen in the Step 2 autoinducer are derived from the 8 other non-autoinducer molecules present in this preparation. However, ES and FAB analysis of concentrated preparations of each of these peaks still fails to reveal the presence of the 407, 465, 514 and 692 ions.
It is possible that the autoinducer has not been visualised using MS techiques (above).
However, the results obtained show a mixture of aliphatic di-ethanol-type groups (probably derived from TEAB bound as counterion to the autoinducer) and a much weaker aromatic signal, possibly derived from the autoinducer itself.
TABLE 1
Culture
Strain
E. coli O157:H7
Medium
SAPI minimal medium + 30% bovine serum + 1% (v/v)
autoinducer (or 50 μm nor-epinephrine)
Conditions
static culture, 5% CO 2 , 24 hours
Recovery
centrifuge, filter-sterilise supernatants, lyophilise,
re-dissolve in distilled water at 1/8 original volume
Purification
Step 1
Superdex 30 gel-filtration (size exclusion) chromatography
superdex 30 pg (Pharmacia) column (2.6 × 65 cm)
equilibrated in 100 mM NH 4 HCO 3
AI elution volume (V e ) = 220 − 330 ml
Step 2
Mono P anion exchange chromatography
Mono P 5/5 (Pharmacia) column
linear gradient elution using the volatile salt TEAB (triethyl
ammonium bicarbonate)
AI elutes between 500 and 700 mM TEAB
Step 3
Superdex peptide gel filtration (size exclusion)
chromatography
Superdex peptide column (Pharmacia) (1 × 60 cm)
equilibrated in 200 mM TEAB
AI elution volume (V e ) = 28.5 mM
TABLE 2
Stability of AI
Crude
Purified
boiling (45 minutes)
100%
100%
autoclaving (25 minutes)
100%
100%
lyophilisation
100%
100%
acid
pH 5 (24 hours)
100%
100%
pH 1 (1 hour)
30%
<10%
alkali
pH 11 (24 hours)
100%
100%
pH 14 (1 hour)
0%
0%
storage*
−20° C.
>14 months
>5 months
4° C.
>9 months
>3 months
20° C.
>3 months
6 weeks
*storage data indicate the period of time tested so far after which 100% of acitivity remains.
TABLE 3
Transposon mutants in E. coli which fail to respond to NE or AI
Phenotypic response in SAPI/30%
Mutagenesis Strategy
Mutant Type
serum media
TnphoA a
STM b
Class I
reduced for NE/reduced for AI
10
12
Class II
reduced for NE/negative for AI
2
2
Class III
negative for NE/reduced for AI
0
3
Class IV
negative for NE/negative for AI
0
9
Class V
WT for NE/reduced or negative
0
7
for AI
TABLE 4
Respsonse
to own
Response
condi-
Response
to E. coli
tioned
Species
Control
to NE
AI
medium*
Enterobacteriaceae
Acinetobacter lwoffii
1.0 × 10 4
2.9 × 10 7
8.6 × 10 6
3.2 × 10 7
Citrobacter freundii
1.9 × 10 6
3.5 × 10 7
2.4 × 10 6
1.2 × 10 7
Enterobacter aerogenes
3.2 × 10 8
5.5 × 10 8
5.1 × 10 8
4.0 × 10 8
Enterobacter
2.9 × 10 4
6.1 × 10 6
1.1 × 10 6
2.9 × 10 6
agglomerans
Enterobacter cloacae
7.2 × 10 6
1.1 × 10 8
1.7 × 10 7
5.8 × 10 7
Enterobacter sakazaki
3.0 × 10 6
4.1 × 10 7
2.5 × 10 6
4.9 × 10 6
Escherichia coli
7.5 × 10 4
5.9 × 10 8
2.3 × 10 8
2.3 × 10 8
Hafnia alvei
1.2 × 10 4
3.7 × 10 8
3.0 × 10 8
2.9 × 10 8
Klebsiella oxytoca
4.2 × 10 4
1.6 × 10 8
6.9 × 10 7
9.5 × 10 7
Klebsiella pneumoniae
3.1 × 10 4
6.7 × 10 7
1.6 × 10 7
2.2 × 10 7
Morganella morganii
3.7 × 10 4
1.6 × 10 7
7.4 × 10 6
1.9 × 10 5
Proteus mirabilis
1.1 × 10 3
1.0 × 10 7
4.1 × 10 6
6.9 × 10 6
Salmonella enterica
7.5 × 10 5
1.0 × 10 8
3.3 × 10 7
1.7 × 10 7
sv Enteriditis
Serratia marcescens
8.5 × 10 7
3.4 × 10 8
2.9 × 10 8
3.5 × 10 8
Yersinia entercolitica
4.2 × 10 4
1.7 × 10 8
5.2 × 10 6
1.3 × 10 5
Other Gram negatives
Pseudomonas aeruginosa
3.7 × 10 4
2.1 × 10 7
4.7 × 10 6
9.5 × 10 5
Xanthomonas maltophilia
1.7 × 10 5
2.1 × 10 6
1.6 × 10 6
4.5 × 10 6
Gram positives
Enterococcus faecalis
5.0 × 10 5
5.5 × 10 6
1.4 × 10 7
2.8 × 10 5
Enterococcus faecium
2.1 × 10 5
5.6 × 10 6
1.5 × 10 7
4.8 × 10 5
Listeria monocytogenes
2.5 × 10 5
3.5 × 10 6
1.2 × 10 6
1.8 × 10 4
Staphylococcus albus
1.1 × 10 3
1.5 × 10 7
5.5 × 10 5
4.5 × 10 2
Staphylococcus aureus
3.2 × 10 5
5.7 × 10 5
3.0 × 10 5
1.9 × 10 5
Streptococcus
2.0 × 10 7
2.4 × 10 6
2.8 × 10 4
2.9 × 10 6
dysgalactiae
Streptococcus sanguis
2.1 × 10 4
1.1 × 10 4
1.6 × 10 4
1.0 × 10 4
Results are given as CFU/ml
TABLE 5
Properties of the E. coli autoinducer (AI)
Small
<500 Da
Novel
Not an N-acyl homoserine lactone or peptide pheremone
Synthesis
Synthesised in exponential phase growth in “stressful”
media
Stability
Very stable to heat, lyophilisation and prolonged storage
(dried or in solution)
Absorbance
Slight absorbance at 280 and 206-212 nm
Colour
Red
Specificity
Stimulates growth of a range of other bacteria
Homology
Functionally and possibly structurally similar to
molecules made by a range of other bacteria | A bacterial autoinducer and method for isolating and purifying a bacterial autoinducer form a sample comprising the steps of collecting a sample containing the autoinducer, fractionating the sample to isolate fractions corresponding to molecular weights of approximately 300-1500 Dalton, and eluting the isolate on an anion-exchange chromatographic column and selecting the faction containing the autoinducer. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/843,683, filed Jul. 8, 2013, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present disclosure relates generally to the field of kinetic energy storage. More specifically, it relates to flywheel energy storage for stationary applications where cost, is of high importance, in some cases, of higher importance than weight. These applications include frequency-regulation, time-of-use, uninterruptible power supply (UPS), demand response, and smoothing of renewable energy generation sources, among other applications.
[0003] Flywheels have been used as energy storage devices or for smoothing mechanical or electrical power for hundreds of years. Recently, there have been significant advancements in the field of flywheel energy storage because of the availability of high strength-to-weight (the specific strength) materials, like composites. The kinetic energy stored per unit mass of flywheel material can be shown to be directly proportional to the specific strength (strength divided by density) of the material. Because some composite materials have very high specific strength, composites make attractive candidates for flywheels having a high energy storage potential per unit mass. As an example, a high-strength carbon fiber composite (e.g., T700 at 70% volume fraction) has a fracture strength of 3430 mega-pascals (MPa), or 490,000 pounds per square inch (psi) and a density of 1845 kilograms per cubic meter (kg/m 3 ), or 0.067 pounds per cubic inch (lb/in 3 ). Compare that to a non-composite material, such as a high strength alloy steel, which has yield strength of 1400 MPa (200,000 psi) and density of 7870 kg/m 3 (0.285 lb/in 3 ). On a strength-to-weight basis, therefore, composites have more than ten times higher specific strength, and, therefore, are able to store more than ten times the energy per unit mass compared to steel. This potential has led inventors to pursue designing flywheels based on composite rotors.
[0004] However, composite materials have not been cost-effective in stationary applications (i.e., applications in which weight is not the primary concern) where the primary goal is maximum energy stored per unit cost, rather than maximum energy stored per unit weight.
SUMMARY
[0005] An exemplary embodiment relates to a material used for a flywheel rotor and a method used to manufacture the rotor with integral shafts. Some preferable materials include alloy steels that are heat treatable to a high level of strength while maintaining sufficient ductility to enable plastic flow. Steel alloys have a high strength-to-cost ratio in addition to low processing and fabrication cost. The rotor may be forged in multiple stages into a monolithic shape that can then be machined to form integral shafts. Examples of suitable steel alloys include AISI 4340, 4330, 17PH, M300, and other high strength alloys.
[0006] Another exemplary embodiment relates to the shape of the rotor. When a steel rotor is heat-treated the rotors that have a higher surface area will have a higher cooling rate. Since the cooling rate affects the material properties of the resulting steel, the shape of the rotor can impact the working characteristics of the rotor. In particular, a fast cooling rate is needed to produce the transformation into martensitic steel (a high-strength steel, desirable in flywheels). Therefore, a rotor shape that allows for faster cooling may also allow for rotor materials that have a higher proportion of martensitic steel. Specifically, a thin, disc-shaped rotor may be formable into a material with a higher proportion of martensitic steel than a cylinder-shaped rotor of the same volume prepared in the same way. In this situation, the disk may have a higher specific strength than the cylinder (because of the higher proportion of martensite) and, therefore, the disc-shaped flywheel will have a higher energy density. Since the two structures would cost the same to make, the disc-shaped rotor would be more cost-effective because of the higher energy density. A disk may also exhibit a more uniform hardness (proportional to strength) throughout the cross-section compared to a cylinder, because the cooling rate would be more uniform.
[0007] Another exemplary embodiment relates to the design of a rotor and to the use of conventional bearings with such a rotor. It can be shown that, for a given level of stored energy, a larger diameter of flywheel rotor results in a slower rotational speed. This slower speed allows a large-diameter rotor to be used with conventional, low-cost rolling contact bearings, which are highly reliable, economical, and easily maintained, rather than non-contact systems (e.g., magnetic levitation) that must be used in designs with high rotational speeds and are complex, expensive, require maintenance, and compromise reliability.
[0008] Another exemplary embodiment relates to a method for reducing the load on the bearings through the use of an off-loading electromagnet. An electromagnet is arranged such that it provides a vertical off-loading force that lifts the entire rotor against the upper bearings and partially off of the lower bearings, reducing the load on the lower bearings. Since bearing life is sharply reduced by increasing load, the off-loading feature of this embodiment results in a system with a very long bearing life compared to a non-lifted rotor system while employing low-cost bearings and a heavy rotor. As a specific embodiment, a 5-ton rotor may be lifted by a coil of approximately 0.75 meters (30 inches) in diameter, consisting of 3420 turns of 18 AWG size copper wire.
[0009] Another embodiment relates to the use of a load cell at the upper bearing to measure the load applied to it when the rotor is lifted by the electromagnet, and a method for using a control system that adjusts the electromagnet's field to ensure that the desired load is always applied to the bearings. In some embodiments, this load can be maintained at a very low value, resulting in long bearing life. For example, the load on the upper bearing during operation may only be 1.3 kN (300 lbs) and the capacity of the upper load cell may only be 2 kilo-newtons (kN) or 450 lbs for one implementation.
[0010] Another embodiment relates to the use of a control system to adjust the voltage applied to the electromagnet to ensure that the desired load is maintained. Load limits may be set at the controller to initiate appropriate actions should the electromagnet and/or the bearing malfunction. A feedback loop may then be employed from the load sensing and magnet voltage circuits to automatically maintain the correct load.
[0011] Another embodiment relates to a method in which a lower bearing is used as a touchdown bearing that is rated to support the full weight of the rotor for several hours in the event of failure of the off-loader.
[0012] In another embodiment, a load cell at the lower bearing measures the load applied to it. This is used to ensure that the desired load is applied at start-up and that changes in loading are detected in case the electromagnet fails during normal operation. This load cell is also connected to a control system such that appropriate actions can be initiated. In one implementation, a desired capacity of the lower load cell for a nominal rotor mass of 5 tons is 110 kN (25,000 lbs).
[0013] Another exemplary embodiment relates to the design of the off-loading magnet and its low power consumption. In this embodiment, a single coil of insulated copper wire provides a suitable lifting force while maintaining low power loss due to the provision for a sufficiently large cross-section for the magnetic flux. In a typical application, a coil 125 mm in width and 35 mm deep at an average diameter of 750 mm will provide an off-loading force of 50 kN at a power consumption of only 45 W.
[0014] Another embodiment relates to improving the reliability of the bearings and motor/generator through the use of seals to allow for operation of these components in air while the rotor spins in a vacuum. Since the high tip speeds of the rotor will result in air drag losses, the rotor is enclosed in a vacuum housing and operated in a vacuum. Rolling contact bearings, however, may not perform reliably for long periods in a vacuum due to outgassing of the lubricant and a tendency to form metal-to-metal welds in a vacuum due to the lack of oxide formation as wear progresses. Also, placing the motor/generator inside a vacuum makes it difficult to cool since heat must be conducted outside of the vacuum. In such configurations, expensive heat pipes and/or large conductive elements may need to be added to ensure adequate cooling. For liquid cooled motors, the piping carrying the coolant may need to penetrate the vacuum envelope through joints that are expensive and prone to leaking. In some embodiments, the upper and lower shafts of the rotor pass through the vacuum envelope via low-friction fluoropolymer lip seals. This design allows for the bearings and motor to be placed outside the vacuum envelope helping to make it easy and less expensive to cool, inspect, maintain, monitor, and replace, if necessary. At the low rotational speeds characteristic of a disk-shaped rotor, the power loss from the seals is small, for example, less than 50 W for 40 mm shaft seal rotating at 6000 rpm.
[0015] In another embodiment, the energy storage system is supported on seismic-rated supports to provide for lateral motion in an earthquake. Such seismic supports are used to support large buildings in earthquake-prone locations. This embodiment provides safe operation of the flywheel storage system if it should experience an earthquake.
[0016] Another embodiment relates to a method for increasing the energy density of the rotor by a pre-conditioning treatment that also serves as the proof test of the rotor before it is put into service. In the pre-conditioning process, the rotor is over-spun past the yield point of the material. Since the maximum tensile stress occurs at the center in a rotating disk of uniform thickness, yielding proceeds from the center toward the outside diameter. If, by this process, the yield zone grows to a desired radius (for example to about 1/√2 of the rotor radius, which corresponds to half the volume of the disk), and the disk is subsequently slowed to zero, beneficial compressive stresses at the center of the disk. On rotating the disk again, the resulting stresses are lower than before the over-spinning pre-conditioning process because of these compressive residual stresses. On reaching the rotational speed at which yielding previously occurred, the new stress levels will be less than the yield stress, helping to increase the margin of safety. This pre-conditioning process, therefore, allows one to operate the disk at a speed corresponding to the yield strength, thereby increasing the energy density, while maintaining a positive margin of safety. Since the energy density (the kinetic energy stored per unit mass) is proportional to the square of the rotational speed, the increase in speed will increase energy density stored in the rotor.
[0017] Another embodiment relates to a method in which the surface of the disk is coated with a brittle paint that indicates the stress state in the rotor. The brittle paint has a very low threshold strain for brittle fracture and serves as an indicator of the magnitude of the stresses in the rotor and its distribution. As the rotor increases in speed, the strain corresponding to the rotor's stress state is recorded in the coating through a pattern of fine cracks. The spacing between the cracks is a measure of the stress; cracks closer together signify a higher state of stress than cracks further apart. By loading a tensile sample of the same material with the same coating, the crack spacing can be calibrated with respect to the stress. This technique helps one to estimate not only the magnitude and direction of the stresses experienced by the rotor, but also the stress distribution. These estimated values can be compared with analytical results to verify the fidelity of a computational model used in analysis of the rotor. In addition, the stress distribution obtained in this manner corresponds to each specific rotor that is tested. Thus, accurate statistics can be obtained on the manufacturing variability between rotors, helping to provide a quantitative measure of the reproducibility and reliability of the manufacturing process that was used to form the disk.
[0018] In another embodiment, an arrangement is described in which a video camera and a strobe light placed inside the vacuum envelope allows for real-time observation of the stress state in the rotor. The frequency of the strobe light is synchronized with the rotational speed of the rotor, facilitating real-time observation of the progression of the cracks in the brittle paint and, therefore, the stress distribution in the rotor. This capability may be useful for determining the relative margins of safety during operation of the system, particularly during the pre-conditioning process when an accurate measurement of the progression of the plastic zone with speed is essential.
[0019] Another embodiment relates to a method in which strain gages coupled with transmitters and receivers are used to monitor the stress state in the rotor. In this embodiment, strain gages are bonded to the surface of the rotor at locations of interest parallel and tangential to the radius vector. The addition of a telemetry transmitter to each strain gage allows one to read the strain in real time as the rotor rotates. A receiver inside the vacuum envelope and attached to the housing receives the strain gage reading and transmits it via a cable connected to a computer for display and recording. This arrangement provides real time measurement of the strain distribution in the rotor while it is rotating, information that may be particularly important during the pre-conditioning process since the stress distribution and the extent of the plastic zone can be accurately tracked with rotor speed.
[0020] Another embodiment relates to a method for reducing the precession-induced moment on a spinning rotor arising from the earth's rotation, while maintaining a high resonant frequency in the rotor/shaft arrangement. Thrust bearings alone are not adequate to absorb this moment at high rotational speeds. In an exemplary embodiment, the precession-induced moment on a spinning rotor arising from the earth's rotation is resisted by two angular contact bearings at the ends of the rotor shafts. The angular contact bearings provide axial support during operation and radial (or lateral) loading capability to resist precession-induced loads.
[0021] Another embodiment relates to an integrated vacuum housing and support structure for a flywheel rotor. Such an integrated housing may help to minimize the number of parts and reduce cost. The housing may be designed to maintain a vacuum in the space occupied by the rotor. To minimize cost and number of components, the vacuum chamber also serves as: the structure that supports the rotor; the alignment fixture for the shaft and bearings; and a suspension system for the rotor. The top plate of the vacuum envelope may also serve as a suspension element. During operation, the rotor is lifted by the electromagnet, which is integrated structurally into the top plate of the vacuum chamber. The stiffness of the top plate is designed so that, when the rotor is suspended, the minimum resonant frequency of the systems is at a value that is well below the operating speed range of the rotor. This arrangement helps to prevent fundamental resonances from occurring during normal operation of the system.
[0022] Another embodiment provides a method for adjusting the stiffness of the top plate by adding or removing radial rib stiffeners thereby providing a means for promoting resonances at the desired rotational speeds.
[0023] Another embodiment is a low-cost way for an accurately aligned system with tailored stiffness using three components: an upper plate, a lower plate, and a cylindrical section. By manufacturing the upper and lower plates from cast iron and the cylindrical section from a standard pipe section, one obtains an economical yet strong design. Ribs or stiffeners can be added or removed by welding to, or machining from, a basic cast iron form.
[0024] Another embodiment is a method for the use of dowel pins to accurately determine the relative position of the upper and lower plates of the three-component system.
[0025] Another embodiment is a method for the use of recessed lips in the upper and lower plates that seat at the ends of the cylindrical section to locate the upper and lower plates accurately with respect to each other.
[0026] In another embodiment, integral O-ring seal grooves at the two ends of the cylindrical section provide a low-cost mechanism for ensuring a leak-proof removable joint in the vacuum system.
[0027] In another embodiment, the electromagnet structure is integrated into the upper plate of the three-component system, resulting in an integrated structure that is multi-functional, being operable as both a housing for the coil, and a cross-section for the magnetic flux that is large enough to preclude saturation.
[0028] In another embodiment, a bearing/seal pack at each of the two bearing locations provides a convenient means to remove and inspect bearings without disassembling the system.
[0029] In another embodiment, the upper bearing pack has a means for accurately locating the axial position of the rotor shaft with respect to the air gap between the electromagnet and the rotor.
[0030] In another embodiment, the lower bearing pack has a means for accurately locating the axial position of the rotor with respect to the air gap between it and the electromagnet. With this embodiment, relative displacements between the upper and lower bearings resulting from deflections in the top and bottom plates due to rotor weight and/or vacuum pressure are compensated for such that there is adequate axial clearance between the bottom shaft stop and the lower bearing during operation.
[0031] In another embodiment, compact low-profile wavy springs ensure preloading the bearings in each bearing pack. A minimum axial preload is necessary to prevent ball-to-race sliding (instead of rolling) at high speeds which causes the temperature to rise, which in turn, can result in lubricant break-down leading to bearing failure.
[0032] In another embodiment, an actuator, such as a motor-driven worm gear, at the base of the unit provides a means for adjusting the axial position of the rotor remotely and autonomously when used in conjunction with a displacement transducer and a control system.
[0033] Another embodiment provides a means for lifting the rotor after initial assembly so that it is at the desired air gap to be magnetically held by the electromagnet. The application of vacuum to the inside of the sealed housing results in downward displacement of the top plate, and upward displacement of the bottom plate, due to the external atmospheric pressure. When the rotor is stationary and is resting on the lower plate, the force due to the external atmospheric pressure is sufficient to lift the rotor by deflecting the bottom plate such that the rotor shaft contacts the bearing stop at the upper bearing pack. This feature provides a means for achieving the desired air gap between the rotor and the magnet so that an adequate force to lift the rotor can be achieved. For example, a housing of 1.85 m (73 inches) in diameter will result in a force of 271 kN (61,600 lbs) applied downward on the top plate and the same force applied upward to the bottom plate. For a 5-ton rotor, resting on the bottom plate, this force is sufficient to lift the rotor at a pressure differential of about 20% of sea-level atmospheric pressure. By adjusting the level of vacuum, the amount of lift displacement of the rotor can be controlled. This embodiment is a low-cost yet effective means for positioning the rotor to enable it to be magnetically held prior to rotation.
[0034] Another embodiment describes a method for supporting the rotor. A hollow cylindrical structure located on the axis and at the bottom of the lower bearing pack acts as a single adjustable foot that supports the weight of the rotor when the off-loader is not activated.
[0035] Another embodiment describes the arrangement of several adjustable feet located below the bottom plate and under the cylindrical pipe section of the housing.
[0036] Another embodiment describes a method for seismic isolation of the system by adding discrete isolators at each foot.
[0037] Another embodiment describes a method for seismic isolation through the use of a continuous flexible support such as a thick rubber sheet placed under the bottom plate that allows for sliding as well as shear.
[0038] Another embodiment describes the use of non-contacting displacement sensors, such as capacitive gages, located on the inside of the vacuum chamber and spaced around the periphery of the rotor that measures the change in radius of the rotor with speed.
[0039] Another embodiment describes a means for determining and removing dynamic imbalances in the rotor. Accelerometers are mounted around the periphery of the bearing packs to measure the level of imbalance. The accelerometer signals are correlated with the motor rotary encoder for precisely determining the angular location of the net imbalance in the rotor. This information is used to remove a small amount of material at the periphery corresponding to the imbalance location to reduce or remove the imbalance.
[0040] Another embodiment describes the use of displacement gages to measure the axial displacement of the rotor relative to the structure. Displacement gages, such as extensometers, are mounted at the base of the unit within the bearing pack to record the dynamic (axial) motion of the suspended rotor over its entire operating and pre-conditioning speed ranges to determine the speeds at which the rotor experiences each resonant mode. This embodiment provides the axial component of the displacement alone, which is valuable since one is able to characterize the axial component of the dynamic response of the suspended rotor over various operational modes.
[0041] In another embodiment, temperature sensors are placed adjacent to or on the outer races of the upper and lower bearings to monitor temperature changes that may signal potential failure and/or wear.
[0042] In another embodiment, a torque noise sensor is placed beneath the upper and/or lower bearing. The signal from this sensor, when compared with the signal from the torque transducer at the motor-to-rotor coupling, is a measure of wear in the bearing and provides for early detection of a potential bearing failure.
[0043] In another embodiment, acoustic emission (AE) sensors are placed on the structure at several locations including at the bearing packs and inside the vacuum housing. The transducers are in close contact with the structural elements via gel or grease acoustic coupling media.
[0044] In another embodiment, individual or bundles of ultra-high modulus (UHM) carbon fiber are bonded (or otherwise attached) tangentially and radially to the rotor surface at various radial distances from the rotor axis. Since the failure strain of UHM carbon fiber is low (˜1000×10 −6 ) relative to strains experienced by the rotor when spinning (˜5000×10 −6 ), the individual fibers will begin to fail as the strain in the rotor increases with speed. Fiber failures have a characteristic AE signature, which can be detected by an AE sensor (for example, a 500 kHz sensor) bonded to the structure near the rotor bearing location. This embodiment provides a means to determine the strains in the rotor remotely while within the vacuum envelope. The method can be used in other applications where strain gages or other methods cannot be used, for example, in hostile environments, such as high temperature and/or oxidative and corrosive atmospheres. Other fibers such as mineral, glass and polymer fibers may also be similarly employed for different levels of failure strain capacity.
[0045] Another embodiment describes a means for efficient energy absorption in the event of rotor burst failure. A buried thick-walled steel and concrete containment structure is constructed in close proximity, and preferably, in contact with the outside cylinder wall of the housing. This arrangement keeps fragments from rotor failure to be contained while still in rotational modes (minimizing translational modes) so that energy dissipation is facilitated by friction and particle-to-particle interaction.
[0046] In another embodiment, the containment structure is constructed with a tapered geometry such that the diameter of the containment structure increases gradually with increasing depth from the bottom of the unit. At rotor failure, the fragments will tend to displace axially downward and be collected below the unit rather than move upward and be ejected above the surface.
[0047] In another embodiment, an arrangement of graded aggregate is placed such that aggregate size decreases with radial distance from the concrete wall. This results in an energy absorbing structure with larger porosity adjacent to the concrete containment structure where, crushing and compaction of the aggregate provides energy absorption. At increasing radial distance the decreasing size of the aggregate approaches that of sand particles that are also arranged with decreasing particle size with increasing radial distance. In this zone, fragment motion is resisted by friction with the sand particles.
[0048] In another embodiment, bearing packs each including an accurately aligned bearing/seal/load cell assembly are contained in housings that are provided with dowel pins or locating features that accurately locate the axis of each with respect to the housing axis and, therefore, with each other.
[0049] In another embodiment, control software provides for safe operation of the system over its various modes of operation: pre-conditioning, speed cycling, power cycling, demand response, time-of-use, and other strategies for maximizing the benefits of storage with respect to the grid and/or other generating sources such as renewables (solar, wind, tidal) and/or diesel or gas-powered generators.
[0050] In another embodiment, control logic is incorporated in the control software for safe and efficient operation under various potential failure scenarios including, but not limited to, failures of the motor/generator, bearings, off-loader, vacuum pump, cooling systems, seismic events, and temperature spikes.
[0051] In another embodiment, the rotor is connected to an electronic or mechanically controlled continuously variable transmission (CVT) or other geared transmission such that the varying speed of the rotor is output to an induction motor. Over-driving the induction motor in this fashion past the slip speed results in power output while under-driving it will result in the induction motor being driven by the external power source to store kinetic energy in the rotor by increasing its speed to its maximum rated value. This is a low-cost method for energy storage and delivery since it does not involve brushless DC motors and their associated control and driver software schemes.
[0052] In another embodiment, a radial temperature gradient is maintained along the rotor radius. When the center of the rotor is at a higher temperature than its periphery, a non-uniform thermal strain is created that results in a beneficial thermal stress (compressive at the center, tensile at the periphery), which improves the overall stress state and thereby increases the energy density in the rotor.
[0053] In another embodiment, the geometry of the rotor is a simple fixed or variable thickness disk without shafts. Shafts are machined separately from alloy steel that may be austenitic (and, therefore, non-magnetic) and bonded to the disk. Since the rotor is lifted directly by the magnetic off-loader, the stresses in the bond joints are low and primarily compressive, due to the axial compressive preload, and are easily accommodated by the bond strengths of conventional polymer structural adhesives.
[0054] In another embodiment, the rotor is a simple fixed or variable thickness disk without shafts. Shafts are machined separately from alloy steel that may be austenitic (and, therefore, non-magnetic) and welded to the disk. Following the welding operation, conventional heat treatment procedures remove stress concentrations introduced into the rotor at the weld locations. The magnetic off-loader lifts the rotor directly and not by its shafts, thus, the stresses in the welds are low.
[0055] In another embodiment, the rotor is made as a simple fixed or variable thickness disk without shafts. Shafts are machined separately from alloy steel that may be austenitic (and, therefore, non-magnetic). The shafts are friction-welded to the disk by spinning them up to a high speed and then axially pressing them onto the disk. Following the friction-welding operation, conventional heat treatment procedures remove any stress concentrations introduced into the rotor at the friction-welds. Since the rotor mass is lifted by the magnetic off-loader, the stresses in the welds are low.
[0056] In another embodiment, the rotor includes several laminated plates that are adhesively bonded together using conventional structural adhesives. The only stress in the joints between the laminations is gravity loading which occurs when the rotor is lifted. This stress is low and easily accommodated by the adhesive tensile strength. For example, for ten laminations each 25 mm in thickness (1 inch), the tensile stress in the first lamination joint (the most highly loaded bonded joint) is less than 0.021 MPa (3 psi). Structural adhesives have tensile strengths readily exceeding 7 MPa (1000 psi). Thin laminas can be individually heat-treated to higher strengths thereby increasing the rotor energy density. In addition, laminated rotors have a high degree of redundancy since flaw propagation in one lamina tends to be restricted by the adjacent laminas. In addition, failure of one lamina does not result in failure of the entire rotor. Also, since the laminas are thin, they are in a state of biaxial plane stress when the rotor is spinning, a more uniform stress state corresponding to a higher energy density, than the biaxial plane strain state that exists in a thick monolithic rotor.
[0057] In another embodiment, the materials used in each lamination may be different for a fail-safe failure mode. For example, the laminations adjacent to the shafts may be made from a ductile yet relatively lower strength steel since fracture of the shaft-to-rotor failure would be catastrophic. The inner laminations may be made from a higher strength steel whose failure would be detectable and would not be catastrophic.
[0058] Another embodiment describes the use of permanent magnets instead of electromagnets. This arrangement is a more reliable, less expensive, and less complex off-loading scheme, since the power supply, coil, leads and feed-through connections are not required.
[0059] In another embodiment, a remotely controlled actuator establishes an adjustable and controllable air-gap between the rotor and the permanent magnet off-loader.
[0060] In another embodiment, the air-gap between the rotor and the electromagnetic or permanent magnet off-loader is maintained through feedback from the load cell that measures the lifting magnet forces. This arrangement provides closed loop control of lift loads that may vary due to dynamics, wear, and temperature variations during operation.
[0061] In another embodiment, single or multiple coupled DC motor/generators powered by DC power from two inverters mounted on the downstream end of a bidirectional controller connected to the grid at 460V, 3 phase (or other distribution voltages) is a low-cost scheme for energy storage at grid-scale. The arrangement provides modularity in both energy storage and power. For example, a 150 kWh capacity flywheel coupled with a 30 kW motor/generator can deliver 30 kW continuously for 5 hours to take advantage of differential pricing for time-of-use storage. For demand response and higher power, short time, applications, a motor/generator of 150 kW rating can be readily substituted to deliver 150 kW for 1 hour. The addition of a second 150 kW motor/generator at the bottom shaft location doubles the power rating by supplying 300 kW power for 30 minutes.
[0062] Another embodiment relates to a method for high-speed manufacture of composite rotors. In this embodiment, a composite fiber-reinforced ring is manufactured using a high-speed rotating cylindrical mold into which is fed a fiber bundle from a rotating spool located inside the mold. The spin axis of the fiber-dispensing spool is parallel to the rotating mold axis. As the fiber bundle is unwound from the spool, it is held against the inside surface of the rotating mold by centrifugal force. Room temperature curing pre-catalyzed thermosetting resin is sprayed from a nozzle perpendicular to the vertical wall of the rotating mold onto the fiber bundle lying against the wall. The high g-force provides adequate pressure for the liquid resin to infiltrate the fiber bundle as curing of the resin proceeds. When the cure is complete, the mold is stopped and the ring ejected from the mold. This process is 10 to 50 times faster than filament winding, the conventional process for manufacturing composite rings. For example, fiber dispensing rates of 4,500 m/min are possible with this arrangement compared to filament winding rates of 60-90 m/min. Alternatively, a resin system that cures at elevated temperature may be used, together with a method for heating the mold surface either by internal electrical resistance heaters, gas fired heaters, or infrared lamps illuminating the mold from the inside. Alternatively, the rotating mold has a central shaft and shaft lip seals so that infiltration and curing is done in vacuum to minimize voids in the composite. Additional spools may be simultaneously deployed such that processing times can be further reduced and/or different fibers or wires (glass, carbon, Kevlar, polymers, metal wires, etc.) can be dispensed simultaneously or in sequence such that the final composite ring has a layered or mixed configuration of different fiber types, which may be advantageous for certain applications. Alternatively, different resin systems can be applied in sequence to vary properties radially. For example, a composite ring can be readily fabricated in this manner with carbon fibers at its outside diameter and glass fibers at its inside diameter. Due to the high g-loading in this embodiment, for example, 300 g's in a 2 m diameter mold rotating at 520 rpm, void-free composite rings can be produced at high rates.
[0063] In another embodiment, a metal wire coil is manufactured using a high-speed rotating cylindrical mold into which is fed a metal wire, such as copper wire, dispensed from a rotating spool located inside the mold whose spin axis is parallel to the rotating mold axis. As the fiber bundle is unwound from the spool, it is held against the inside surface of the rotating mold by centrifugal force. Room temperature curing pre-catalyzed potting resin is sprayed from a nozzle perpendicular to the vertical wall to pot the coil for use as an electromagnet coil, for electric motors, or other electrical devices.
[0064] Another embodiment describes a method for making a composite ring using a pre-impregnated fiber bundle, or tow-preg, that is dispensed into a high-speed rotating cylindrical mold a rotating spool located inside the mold whose spin axis is parallel to the rotating mold axis. As the fiber bundle is unwound from the spool, it is held against the inside surface of the rotating mold by centrifugal force. Infrared, hot air, or other types of heaters provide the heat for curing the matrix polymer in the tow-preg. As before, various fibers and/or metal wires can be dispensed in this manner, simultaneously or sequentially.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] The exemplary embodiments will be explained in more detail in the following text with reference to the attached drawings, in which:
[0066] FIG. 1 is a process flow drawing showing a sequence of processing steps for the manufacture of a high energy density rotor at low cost.
[0067] FIG. 2 is a schematic drawing showing a kinetic energy storage device in the form of a spinning rotor supported by bearings inside a vacuum envelope and driven by an external motor/generator;
[0068] FIGS. 3A-D show plots of the beneficial effect of pre-conditioning on the stress state in the rotor.
[0069] FIG. 4A is a schematic drawing showing the use of a brittle paint coating for determining the stress state in the rotor.
[0070] FIG. 4B is an example pattern of cracks in the brittle paint coating, the cracks resulting from spin up of the rotor.
[0071] FIG. 5 is a schematic drawing showing an arrangement of a video camera coupled with a strobe light for obtaining images of the crack patterns in the brittle paint coating while the rotor is spinning
[0072] FIG. 6 is a schematic drawing showing an arrangement of strain gages connected to radio frequency transmission circuits and antennas for determining the strains in the rotor while it is spinning
[0073] FIG. 7 is a schematic drawing showing us of the top plate of the vacuum housing as an elastic suspension element of the rotor.
[0074] FIG. 8 is a schematic drawing showing stiffening ribs in a top plate, which acts as a suspension element of the rotor, the added or removed ribs altering the stiffness of the top plate and, therefore, the resonant frequency of the rotor suspension system.
[0075] FIG. 9A is a schematic drawing showing how the top plate (and upper bearing) may be accurately located with respect to the bottom plate (and lower bearing) through a machined recessed lip for precise alignment of the rotor axis.
[0076] FIG. 9B is a schematic drawing showing how the lower central support may be raised or lowered to maintain the desired air gap between the rotor and the lifting off-loading magnet by employing a motor-driven mechanism supported on thrust bearings.
[0077] FIG. 10 is a schematic drawing showing details of the central support foot.
[0078] FIG. 11 is a schematic drawing showing the use of a rubber or elastomer-based sheet for providing seismic isolation to the unit.
[0079] FIG. 12 is a schematic drawing showing the use of displacement gages for monitoring rotor diameter change while spinning
[0080] FIG. 13 is a schematic drawing showing the use of accelerometers to measure and monitor rotating imbalances in the rotor.
[0081] FIG. 14 is a schematic drawing showing the use of an extensometer to measure axial shaft displacement and vibration during operation.
[0082] FIG. 15 is a schematic drawing showing the use of acoustic emission sensors for monitoring bearing wear and progressive damage in the device during operation.
[0083] FIG. 16 is a schematic drawing showing a containment design for capturing fragments from a failed rotor.
[0084] FIG. 17 is a schematic drawing showing a graded aggregate and sand arrangement for stopping fragments released during a rotor failure.
[0085] FIG. 18 is a schematic drawing showing an arrangement for using an induction motor as a motor/generator when coupled to the rotor through a continuously variable transmission (CVT).
[0086] FIG. 19 is a schematic drawing showing the imposition of a thermal gradient in the rotor to improve the storage energy density through the introduction of beneficial thermal stresses.
[0087] FIG. 20 is a schematic drawing showing a method for the attachment of a separately machined shaft to a rotor by adhesive bonding.
[0088] FIG. 21 is a schematic drawing showing a method for the attachment of a separately machined shaft to a rotor by fusion or friction welding.
[0089] FIG. 22 is a schematic drawing showing a rotor made from several laminations.
[0090] FIG. 23 is a schematic drawing showing a method for the rapid manufacture of a composite ring using dry fiber bundles dispensed into a rotating mold together with pre-catalyzed resin.
[0091] FIG. 24 is a schematic drawing showing a method for the rapid manufacture of a composite ring using pre-impregnated fiber bundles (tow preg) dispensed into an internally heated rotating mold.
DETAILED DESCRIPTION
[0092] With reference to the accompanying FIGURES, the present disclosure relates to kinetic energy storage, specifically flywheel-based energy storage, for use in electrical grids, renewable energy generation systems such as wind turbines, solar panels, tidal machines, and industrial applications where smoothing of power demand reduces both capital and operational costs. The present disclosure also relates to methods of producing, controlling, and integrating such storage devices with existing grid and micro-grid energy distribution systems. While the subject matter herein is presented in the context of energy storage devices in the field of grid-scale applications, such devices may be utilized in alternate applications such as stand-alone energy storage for electric vehicle charging stations, rail transportation systems, elevators, cranes, shipboard systems, or any other devices utilizing kinetic energy storage, as will be appreciated by those of skill in the art who review this disclosure.
[0093] Referring to FIG. 1 , an exemplary sequence of metal forming operations is shown for producing a rotor with the desired strength and uniformity at low cost. The rotor may be one of the most expensive components in the design of the energy storage device disclosed herein. It may be of constant or variable thickness. When rotating at high speed, the stresses in a constant thickness rotor are at a maximum at its center where the radial and tangential stresses are both tensile. Structural integrity at the center is, therefore, more important than material integrity at the edges, since flaws are more likely to initiate and propagate at the center of the rotor. The manufacturing sequence shown in FIG. 1 is a method for helping to reduce the size of the flaws in an economical and reproducible manner.
[0094] A cast ingot of the desired alloy, for example, American Iron and Steel Institute (AISI) designation 4340 , is cut to the desired volume and subjected to one or more upsetting operations in an open die set-up in a hydraulic press at the hot forging temperature. This process compresses voids in the ingot and stretches inclusions into thin and finer particles called stringers. Since the loading is axisymmetric, the process may also result in dispersion of stringers. In an exemplary embodiment, the blank is further hot-forged into a shape containing bosses on either surface using a closed-die set of tools. In some embodiments, the heights of the bosses exceed the final heights of the integral shafts of the rotor. The bosses may be of different heights for specific applications. Following this operation, the rotor is now almost in its final shape. This shape may present a relatively thin cross-section for rapid and uniform cooling during the quench operation in the heat treatment process.
[0095] Transformation-hardening steel alloys such as AISI 4340 depend upon a minimum cooling rate for the formation of martensite which, after the tempering process determines the strength and ductility of the final product. The minimum cooling rate occurs in the thickest location of the cross-section farthest from the surface. Thus, the design of the rotor, for maximum energy storage density capacity at minimum cost, depends upon a low aspect ratio (thickness-to-diameter ratio). In one example, an aspect ratio of about 15% results in a thickness of 0.25 m (10 inches) for a maximum energy storage capacity of 150 kWh when AISI 4340 heat-treated alloy steel is used. In other embodiments, thicknesses of less than 0.25 m may be used (e.g., thickness in the range of 0.05 m-0.25 m).
[0096] Following the closed-die operation to form the bosses, the blank is rough-machined to further reduce the maximum thickness in the blank. This process may be followed by quenching and tempering (heat-treating). An exemplary quenching is to heat the blank to 850 C, quench in a polymer-modified water bath, followed by tempering at 210-250 C. Following the quenching operation, the part is finish-machined and balanced. Such a process sequence may result in a minimum yield strength of about 1200 MPa (170,000 psi), ultimate tensile strength of about 1300 MPa (185,000 psi), and ductility of at least 6% for an exemplary rotor of the dimensions discussed above. It may be important to ensure adequate ductility so that the rotor, when subjected to the pre-conditioning process disclosed below, will have the desired beneficial residual stress state that improves energy density and ensures adequate margins of safety.
[0097] Referring to FIG. 2 , a system 10 shows a flywheel energy storage device that includes a rotor 12 that is located within a hermetically sealed housing including a top plate 14 , a cylindrical vertical enclosure 16 , and a bottom plate 18 . Two bearing packs 20 allow the rotor to rotate freely in rolling contact with the bearings held within each bearing pack. Dowel pins 22 accurately locate the upper and lower plates with respect to each other. O-ring seals 24 in the cylindrical enclosure 16 seal the top and bottom plates to form the vacuum enclosure. Ribs 26 in the top and bottom plates provide the desired level of stiffness to each plate. An electromagnet 28 in close proximity to the top surface of the rotor provides a vertical force large enough to lift the rotor. An annular slot 30 whose axis coincides with the axis of the rotor is cut into the body of the electromagnet. The annular slot is filled with a copper coil 32 including several coils of a single insulated wire which, when connected to a DC power supply will provide a controllable lifting force on the rotor.
[0098] A series of externally mounted feet 34 support the device on a pad 36 including a number of bonded and laminated steel/rubber layers that provide isolation to the device from seismic events. The bearing pack 20 contains a lip seal 38 that seals the rotating shaft against air infiltrating into the vacuum envelope. A wavy spring 40 ensures that a minimum axial preload exists on the rolling contact bearing 42 and a load cell 44 provides a means for tracking the axial load on the bearing during operation. The shaft of the rotor 12 has a series of steps machined into it to accommodate the seal, spring, bearing, and load cell. The bearing pack outer housing 46 is located accurately on the top plate via dowels 48 . The axial position of the shaft is adjusted by an internally threaded hollow cylindrical insert 50 which, when rotated establishes the upper set point that locates the load cell's (and, therefore, the shaft's) axial position. This feature provides a means for adjustment of the air gap between the top surface of the rotor 12 and the electromagnet 20 . A coupling shaft 52 connects the top of the rotor shaft to the motor/generator 54 .
[0099] FIGS. 3A-D shows plots of the stress distribution in the rotor when a pre-conditioning treatment as disclosed below is performed on the rotor. FIG. 3A shows the stress distribution (radial and tangential stresses) in a rotor spinning at a speed at which yielding just begins to occur at the center of the rotor. This point is considered to be the maximum level of loading for the rotor and its maximum operating speed is usually set to a value well below this value. However, increasing the rotor speed above the point corresponding to the initiation of yield creates a plastic zone that grows as shown in FIG. 3B to a radius r p . On reducing the rotor speed to zero, a residual stress state now exists as shown in FIG. 3C , which is characterized by a central compressive zone. On re-spinning the rotor to the speed reached in FIG. 3A , the residual compressive zone reduces the maximum stress so that a positive margin now exists at the speed corresponding to the yield speed. This pre-conditioning process thus increases the energy storage density in the rotor.
[0100] In some embodiments, the rotor strain may be estimated using computational models. In such an embodiment, the desired amount of strain may be converted to the rotation speed for a given rotor material and geometry. In this way, a sufficient amount of strain would simply be a given spin speed, without actually measuring the strain in each rotor. In other cases, as will be shown, the strain may be measured while spinning is carried out such that the strain may be determined and the spinning speed may be increased until the desired yielded zone is produced.
[0101] FIG. 4A shows the application of a brittle paint 56 onto the rotor 12 . On spinning up the rotor, the strain in the rotor produces a crack pattern 57 , shown in FIG. 4B , in the brittle paint that represents the stress state in the rotor. The crack pattern includes tangential and radially distributed cracks whose spacing is a measure of the magnitude of the stress; the closer the spacing the larger the stress. Quantitative values of the stress distribution can be obtained through calibration from loading a tensile specimen to known loads and measuring the crack pattern. In addition to the magnitude of the stresses, the directions of the principal stresses are also displayed in the pattern since the orientations of the cracks are perpendicular to the principal stress directions.
[0102] FIG. 5 illustrates the use of a video camera 58 and a strobe light 60 whose frequency is synchronized with the rotor speed. In this manner, the progression of the cracks in the brittle paint layer on the rotor 12 within the vacuum envelope 16 can be recorded as a function of rotor speed.
[0103] In FIG. 6 , strain gages with radio-frequency (RF) transmitters 62 are bonded to the surface of the rotor 12 inside the vacuum chamber wall 16 and oriented along directions of interest parallel and tangential to the radial vector. A receiver inside the vacuum envelope communicates the strain gage readings to a recorder via a cable for display and recording. This arrangement provides real time measurement of the strain distribution on the rotor while it is rotating, information that is particularly important during the pre-conditioning process, since the stress distribution and the extent of the plastic zone is accurately tracked with rotor speed. In addition, control software can use this information to warn of responses that are not nominal, and shut down the unit, if necessary.
[0104] FIG. 7 is a sketch that illustrates the use of the elastic response of the top plate from which the rotor is suspended as a spring that determines the minimum resonant frequency of the system. The weight of the rotor deflects the top plate depending upon its stiffness. The resonant frequency is proportional to the square root of the ratio of the plate stiffness (the rotor weight divided by the deflection of the plate, shown as the dotted line in the figure) to the rotor weight. Thus, if the stiffness of the top plate can be adjusted, one can obtain a desired resonant frequency of the system. This feature is illustrated in FIG. 8 , which shows how the stiffness of the top plate 14 can be adjusted by adding or removing rib stiffeners 64 . The lateral loads depend, for a given rotor speed, on the lengths of the rotor shafts, with the load decreasing with increasing shaft length. The resonant frequency of the first-bending mode of the rotor/shaft structure, however, increases with decreasing shaft length. While the resonant frequency decreases with shaft length as L 3/2 , it increases with shaft diameter as d 2 . Thus, a suitable ratio of the shaft diameter to length provides a system that has both low lateral loading on the bearings from rotor precession as well as high resonant frequency.
[0105] Referring to FIG. 9A , a recessed lip 66 in the top plate 14 accurately locates it with respect to the vacuum chamber wall 16 . This feature, also present in the bottom plate, ensures that the alignment between the top and bottom bearing packs is accurate.
[0106] Referring to FIG. 9B , a worm gear 68 is used to accurately locate the axial position of the bearing pack 20 and, therefore, the rotor with respect to the air gap between it and the electromagnet. The worm gear is driven by a motor (not shown), or manually, to rotate the output shaft 70 , which, by virtue of a screw mating with the bearing pack, lifts or lowers the entire assembly. With this embodiment, relative displacements between the upper and lower bearings due to deflections in the top and bottom plates resulting from rotor weight and/or vacuum pressure are compensated for such that there is adequate axial clearance between the bottom shaft stop and the lower bearing during operation. These adjustments can be carried out remotely and, if necessary, autonomously when used in conjunction with a displacement transducer and controller.
[0107] Referring to FIG. 10 , a hollow cylindrical structure 72 located on the axis and at the bottom of the lower bearing pack acts as a single adjustable foot that supports the bottom plate 26 when the rotor 12 is stationary and/or the off-loader is not activated.
[0108] Referring to FIG. 11 , the entire unit is placed on a thick rubber sheet, or a laminated assembly of steel plates and rubber sheets 74 to provide seismic isolation.
[0109] Referring to FIG. 12 , non-contacting displacement sensors 76 , such as capacitive gages, located on the inside of the vacuum chamber wall 16 and spaced around the periphery of the rotor 12 determines the change in radius of the rotor with change in its speed. This information is useful to verify the numerical model as well as warn of anomalous displacement changes that may indicate impending rotor or bearing failure.
[0110] Referring to FIG. 13 , two or more accelerometers 78 are mounted around the periphery of each bearing pack to measure the level of imbalance. The amplitudes of the accelerometer signals provide information on the mass of the imbalance when the rotor speed is known. When the time signature of each accelerometer signal is correlated with the motor rotary encoder, the angular location of the net imbalance in the rotor can be identified and removed in a subsequent machining operation. In addition, changes in the accelerometer signals during operation can be used as indicators of bearing wear and/or impending failure of the system.
[0111] Referring to FIG. 14 , a displacement gage 80 is mounted at the base of the unit within the bearing pack to record the dynamic (axial) motion of the suspended rotor over its entire operating and pre-conditioning speed ranges to determine the speeds at which the rotor experiences each resonant mode. This information can also be used to indicate anomalous behavior of the system.
[0112] Referring to FIG. 15 , acoustic emission (AE) sensors 82 are placed on the structure at several locations, including at the bearing packs and inside the vacuum housing. These sensors measure high frequency (for example, 500 kHz) sounds emanating from bearings and or flaw propagation in the rotor thereby providing a measure of the wear or impending failure of one or more components in the system
[0113] Referring to FIG. 16 , a buried thick-walled steel and concrete containment structure 84 , 86 is constructed to be in close proximity, preferably, in contact with the outside cylinder wall of the device 10 . This arrangement keeps fragments resulting from rotor failure to be contained in rotational modes (minimizing translational modes) so that energy dissipation is facilitated by friction and particle-to-particle interaction. The containment structure has a tapered geometry 84 such that the diameter of the containment structure increases gradually with increasing depth from the bottom of the unit. At rotor failure, the fragments will tend to displace axially and be collected below the unit rather than move upward and be ejected above the surface.
[0114] Referring to FIG. 17 , an arrangement of graded aggregate 88 is placed such that aggregate size decreases with radial distance from the concrete wall. This results in an energy absorbing structure with larger porosity adjacent to the concrete containment structure and decreasing size of the particles with increasing radial distance.
[0115] Referring to FIG. 18 , the device 10 is connected to an induction motor 90 through an electronic or mechanically controlled continuously variable transmission (CVT) 100 or other geared transmission. Over-driving the induction motor in this fashion past the slip speed makes it operate like a generator outputting power to the grid. Under-driving the motor by changing the gear ratio in the CVT will result in the induction motor being driven by the external power source to accelerate the rotor and thereby store energy. This is a low-cost method since it does not involve brushless DC motors, inverters, and their associated control and driver software schemes.
[0116] Referring to FIG. 19 , a radial temperature gradient is imposed on the rotor 12 by heaters 110 . When the center of the rotor is at a higher temperature than its periphery, the resulting non-uniform thermal strain results in beneficial thermal stress (compressive at the center, tensile at the periphery), which improves the overall stress state and thereby increases the energy density in the rotor.
[0117] FIG. 20 illustrates a concept for using discrete, separately machined shafts 120 , which may be made from an alloy steel that may be austenitic (and, therefore, non-magnetic) and adhesively bonded to the rotor 12 with a structural adhesive 122 . Since the rotor is lifted directly by the magnetic off-loader, the stresses in the bond joints are low and primarily compressive, due to the axial compressive preload, and are easily accommodated by the bond strengths of conventional polymer structural adhesives. This approach allows one to use a rotor of very simple geometry that is easy to forge and machine since it does not have integral shafts.
[0118] Referring to FIG. 21 , the rotor 12 is a simple fixed or variable thickness disk without shafts as in FIG. 20 . In this case, the shafts 120 are welded to the rotor. In some embodiments, the shafts may be welded to the motor with conventional fusion fillet welds between contact surface 126 and rotor 12 . Following the welding operation, conventional heat treatment procedures remove stress concentrations introduced into the rotor at the weld locations. Since the rotor is lifted directly by the magnetic off-loader, the stresses in the welds are low.
[0119] In another embodiment, the shafts 120 are friction-welded to the rotor using a high axial force 128 to press the shaft onto a rotating rotor blank. The contact surface 126 reaches a high temperature sufficient to weld the interface. Following the welding operation, conventional heat treatment procedures remove stress concentrations introduced into the rotor at the weld. Since the rotor is lifted directly by the magnetic off-loader, the stresses in the welds are low.
[0120] Referring to FIG. 22 , the rotor is constructed from several laminated plates that are adhesively bonded together using conventional structural adhesives. The only stress in the joints between the laminations is gravity loading which occurs when the rotor is lifted. This stress is low and easily accommodated by the adhesive tensile strength. For example, for ten laminations each 25 mm in thickness (1 inch), the tensile stress in the first lamination joint (the most highly loaded bonded joint) is less than 0.021 MPa (3 psi). Structural adhesives have tensile strengths readily exceeding 7 MPa (1000 psi). Thin laminas can be individually heat-treated to higher strengths thereby increasing the rotor energy density. In addition, laminated rotors have a high degree of redundancy since flaw propagation in one lamina tends to be restricted by the adjacent laminas. In addition, failure of one lamina does not result in failure of the entire rotor. Also, since the laminas are thin, they are in a state of biaxial plane stress when the rotor is spinning which is a more uniform stress state than the biaxial plane strain state that exists in a thick monolithic rotor. In addition, thin plates can be heat-treated to a higher yield strength than thick plates; thus, a rotor comprising of thin plates laminated together will exhibit a higher energy density than in a monolithic rotor of the same total thickness.
[0121] Referring to FIG. 23 , a composite fiber-reinforced ring is manufactured using a high-speed rotating cylindrical mold 132 into which is fed a fiber bundle from a rotating spool 134 located inside the mold whose spin axis is parallel to the rotating mold axis. As the fiber bundle is unwound from the spool, it is held against the inside surface of the rotating mold by centrifugal force. Room temperature curing pre-catalyzed thermosetting resin is sprayed from a nozzle 136 perpendicular to the vertical wall of the rotating mold onto the fiber bundle lying against the wall. The high g-force provides adequate pressure for the liquid resin to infiltrate the fiber bundle as curing of the resin proceeds. When the cure is complete, the mold is removed and the ring ejected from the mold. This process is 10 to 50 times faster than filament winding, the conventional process for manufacturing composite rings. For example, fiber dispensing rates of 4500 m/min are possible compared to filament winding rates of 60-90 m/min. Alternatively, a resin system that cures at elevated temperature may be used together with a method for heating the mold surface either by internal electrical resistance heaters, gas fired heaters, or infrared lamps illuminating the mold from the inside. Alternatively, the rotating mold has a central shaft and shaft lip seals so that infiltration and curing may be done in vacuum to minimize voids in the composite. Additional spools may be simultaneously deployed such that processing times can be further reduced and/or different fibers (glass, carbon, Kevlar, metal wires, etc.) can be dispensed simultaneously or in sequence such that the final composite ring has a layered structure of different fiber types that may be advantageous in certain applications. Alternatively, different resin systems can be applied in sequence to vary properties radially. For example, a composite ring can be readily fabricated in this manner with carbon fibers at its outside diameter and glass fibers at its inside diameter. Due to the high g-loading in this application, void-free composite rings can be produced at high rates.
[0122] Referring to FIG. 24 , a pre-impregnated and partially cured fiber bundle (tow preg, 138 ) is dispensed from a spool 134 as in FIG. 23 into a high-speed rotating cylindrical mold 132 . An internal 142 (or external) heater heats the dispensed tow preg enabling it to flow and cure. | A flywheel energy storage system incorporates various embodiments in design and processing to achieve a very high ratio of energy stored per unit cost. The system uses a high-strength steel rotor rotating in a vacuum envelope. The rotor has a geometry that ensures high yield strength throughout its cross-section using various low-cost quenched and tempered alloy steels. Low-cost is also achieved by forging the rotor in a single piece with integral shafts. A high energy density is achieved with adequate safety margins through a pre-conditioning treatment. The bearing and suspension system utilizes an electromagnet that off-loads the rotor allowing for the use of low-cost, conventional rolling contact bearings over an operating lifetime of several years. | 7 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to cyclized amide derivatives for treating or preventing neuronal damage associated with neurological diseases. The invention also provides compositions comprising the compounds of the present invention and methods of utilizing those compositions for treating or preventing neuronal damage.
BACKGROUND OF THE INVENTION
[0002] Neurological diseases are associated with the death of or injury to neuronal cells. Typical treatment of neurological diseases involves drugs capable of inhibiting neuronal cell death. A more recent approach involves the promotion of nerve regeneration by promoting neuronal growth.
[0003] Neuronal growth, which is critical for the survival of neurons, is stimulated in vitro by nerve growth factors (NGF). For example, Glial Cell Line-Derived Neurotrophic Factor (GDNF) demonstrates neurotrophic activity both, in vivo and in vitro, and is currently being investigated for the treatment of Parkinson's disease. Insulin and insulin-like growth factors have been shown to stimulate growth of neurites in rat pheochromocytoma PC12 cells and in cultured sympathetic and sensory neurons [Recio-Pinto et al., J. Neurosci., 6, pp. 1211-1219 (1986)]. Insulin and insulin-like growth factors also stimulate the regeneration of injured motor nerves in vivo and in vitro [Near et al., Proc. Natl. Acad. Sci., pp. 89, 11716-11720 (1992); and Edbladh et al., Brain Res., 641, pp. 76-82 (1994)]. Similarly, fibroblast growth factor (FGF) stimulates neural proliferation [D. Gospodarowicz et al., Cell Differ., 19, p. 1 (1986)] and growth [M. A. Walter et al., Lymphokine Cytokine Res., 12, p. 135 (1993)].
[0004] There are, however, several disadvantages associated with the use of nerve growth factors for treating neurological diseases. They do not readily cross the blood-brain barrier. They are unstable in plasma and they have poor drug delivery properties.
[0005] Recently, small molecules have been shown to stimulate neurite outgrowth in vivo. In individuals suffering from a neurological disease, this stimulation of neuronal growth protects neurons from further degeneration, and accelerates the regeneration of nerve cells. For example, estrogen has been shown to promote the growth of axons and dendrites, which are neurites sent out by nerve cells to communicate with each other in a developing or injured adult brain [(C. Dominique Toran-Allerand et al., J. Steroid Biochem. Mol. Biol., 56, pp. 169-78 (1996); and B. S. McEwen et al., Brain Res. Dev. Brain. Res., 87, pp. 91-95 (1995)]. The progress of Alzheimer's disease is slowed in women who take estrogen. Estrogen is hypothesized to complement NGF and other neurotrophins and thereby help neurons differentiate and survive.
[0006] Other target sites for the treatment of neurodegenerative disease are the immunophilin class of proteins. Immunophilins are a family of soluble proteins that mediate the actions of immunosuppressant drugs such as cyclosporin A, FK506 and rapamycin. Of particular interest is the 12 kDa immunophilin, FK-506 binding protein (FKBP12). FKBP12 binds FK-506 and rapamycin, leading to an inhibition of T-cell activation and proliferation. Interestingly, the mechanism of action of FK-506 and rapamycin are different. For a review, see, S. H. Solomon et al., Nature Med., 1, pp. 32-37 (1995). It has been reported that compounds with an affinity for FKBP12 that inhibit that protein's rotomase activity possess nerve growth stimulatory activity. [Lyons et al., Proc. Natl. Acad. Sci. USA, 91, pp. 3191-3195 (1994)]. Many of these such compounds also have immunosuppressive activity.
[0007] FK506 (Tacrolimus) has been demonstrated to act synergistically with NGF in stimulating neurite outgrowth in PC12 cells as well as sensory ganglia [Lyons et al. (1994)]. This compound has also been shown to be neuroprotective in focal cerebral ischemia [J. Sharkey and S. P. Butcher, Nature, 371, pp. 336-339 (1994)] and to increase the rate of axonal regeneration in injured sciatic nerve [B. Gold et al., J. Neurosci., 15, pp. 7509-16 (1995)].
[0008] The use of immunosuppressive compounds, however, has drawbacks in that prolonged treatment with these compounds can cause nephrotoxicity [Kopp et al., J. Am. Soc. Nephrol., 1, p. 162 (1991)], neurological deficits [P. C. DeGroen et al., N. Eng. J. Med., 317, p. 861 (1987)] and vascular hypertension [Kahan et al., N. Eng. J. Med., 321, p. 1725 (1989)].
[0009] More recently, sub-classes of FKBP binding compounds which inhibit rotomase activity, but which purportedly lack immunosuppressive function have been disclosed for use in stimulating nerve growth [see, U.S. Pat. No. 5,614,547; WO 96/40633; WO 96/40140; WO 97/16190; J. P. Steiner et al., Proc. Natl. Acad. Sci. USA, 94, pp. 2019-23 (1997); and G. S. Hamilton et al., Bioorg. Med. Chem. Lett., 7, pp. 1785-90 (1997)].
[0010] Stimulation of neural axons in nerve cells by piperidine derivatives is described in WO 96/41609. Clinical use of the piperidine and pyrrolidine derivatives known so far for stimulating axonal growth has not been promising, as the compounds are unstable in plasma and do not pass the blood-brain barrier in adequate amounts.
[0011] Though a wide variety of neurological degenerative diseases may be treated by promoting repair of neuronal damage, there are relatively few agents known to possess these properties. Thus, there remains a need for new compounds and compositions that have the ability to either prevent or treat neuronal damage associated with neuropathological diseases.
SUMMARY OF THE INVENTION
[0012] The present invention provides compounds having formula (I):
[0013] and pharmaceutically acceptable derivatives thereof, wherein:
[0014] A and B are independently E, (C 1 -C 10 )-straight or branched alkyl, (C 2 -C 10 )-straight or branched alkenyl or alkynyl, or (C 5 -C 7 )-cycloalkyl or cycloalkenyl; wherein 1 or 2 hydrogen atoms in said alkyl, alkenyl or alkynyl are optionally and independently replaced with E, (C 5 -C 7 )-cycloalkyl or cycloalkenyl; and wherein 1 to 2 of the —CH 2 — groups in said alkyl, alkenyl, or alkynyl groups is optionally and independently replaced by —O—, —S—, —S(O)—, —S(O) 2 —, ═N—, —N═ or —N(R 3 )—;
[0015] or, B is hydrogen;
[0016] wherein R 3 is selected from hydrogen, (C 1 -C 4 )-straight or branched alkyl, (C 3 -C 4 )-straight or branched alkenyl or alkynyl, or (C 1 -C 4 ) bridging alkyl, wherein a bridge is formed between the nitrogen atom to which said R 3 is bound and any carbon atom of said alkyl, alkenyl or alkynyl to form a ring, and wherein said ring is optionally benzofused;
[0017] wherein E is a saturated, partially saturated or unsaturated, or aromatic monocyclic or bicyclic ring system, wherein each ring comprises 5 to 7 ring atoms independently selected from C, N, O or S; and wherein no more than 4 ring atoms are selected from N, O or S;
[0018] wherein 1 to 4 hydrogen atoms in E are optionally and independently replaced with halogen, hydroxyl, hydroxymethyl, nitro, SO 3 H, trifluoromethyl, trifluoromethoxy, (C 1 -C 6 )-straight or branched alkyl, (C 2 -C 6 )-straight or branched alkenyl, O—[(C 1 -C 6 )-straight or branched alkyl], O—[(C 3 -C 6 )-straight or branched alkenyl], (CH 2 ) n —N(R 4 ) (R 5 ), (CH 2 ) n —NH (R 4 )—(CH 2 ) n —Z, (CH 2 ) n —N(R 4 —(CH 2 ) n —Z) (R 5 —(CH 2 ) n —Z), (CH 2 ) n —Z, O—(CH 2 ) n —Z, (CH 2 ) n —O—Z, S—(CH 2 ) n —Z, CH═CH—Z, 1,2-methylenedioxy, C(O)OH, C(O)O—[(C 1 -C 6 )-straight or branched alkyl], C(O)O—(CH 2 ) n —Z or C(O)—N(R 4 ) (R 5 );
[0019] wherein each of R 4 and R 5 are independently hydrogen, (C 1 -C 6 )-straight or branched alkyl, (C 3 -C 5 )-straight or branched alkenyl, or wherein R 4 and R 5 , when bound to the same nitrogen atom, are taken together with the nitrogen atom to form a 5 or 6 membered ring, wherein said ring optionally contains 1 to 3 additional heteroatoms independently selected from N, O or S; wherein said alkyl, alkenyl or alkynyl groups in R 4 and R 5 are optionally substituted with Z.
[0020] each n is independently 0 to 4;
[0021] each Z is independently selected from a saturated, partially saturated or unsaturated, monocyclic or bicyclic ring system, wherein each ring comprises 5 to 7 ring atoms independently selected from C, N, O or S; and wherein no more than 4 ring atoms are selected from N, O or S;
[0022] wherein 1 to 4 hydrogen atoms in Z are optionally and independently replaced with halo, hydroxy, nitro, cyano, C(O)OH, (C 1 -C 3 )-straight or branched alkyl, O—(C 1 -C 3 )-straight or branched alkyl, C(O)O—[(C 1 -C 3 )-straight or branched alkyl], amino, NH [(C 1 -C 3 )-straight or branched alkyl], or N—[(C 1 -C 3 )-straight or branched alkyl] 2 ;
[0023] J is selected from H, (C 1 -C 6 )-straight or branched alkyl, (C 2 -C 6 )-straight or branched alkenyl or alkynyl, or cyclohexylmethyl, wherein 1 to 2 hydrogen atoms in said alkyl, alkenyl or alkynyl is optionally and independently replaced with E;
[0024] wherein J is optionally substituted with up to 3 substituents selected from halogen, OH, O—(C 1 -C 6 )-alkyl, O—(CH 2 )n—Z, NO 2 , C(O)OH, C(O)—O—(C 1 -C 6 )-alkyl, C(O)NR 4 R 5 , NR 4 R 5 and (CH 2 ) n —Z;
[0025] K, when present, is J;
[0026] K 1 and R 1 , taken together with the nitrogen atom and the —C(O)— group, form a 5-7 membered saturated or unsaturated heterocyclic ring, optionally containing up to 3 additional heteroatoms selected from O, N, S and S(O 2 ), wherein 1 to 4 hydrogen atoms in said heterocyclic ring are optionally and independently replaced with (C 1 -C 6 )-straight or branched alkyl, (C 2 -C 6 )-straight or branched alkenyl or alkynyl, oxo, hydroxyl or Z; and wherein any —CH 2 — group said heterocyclic ring is optionally and independently replaced by —O—, —S—, —S(O)—, —S(O 2 )—, or —N(R 3 )—; and wherein said heterocyclic ring is optionally fused with E;
[0027] G, when present, is —S(O) 2 —, —C(O)—, —S(O) 2 —Y—, —C(O)—Y—, —C(O)—C(O)—, or —C(O)—C(O)—Y—;
[0028] Y is oxygen, or N(R 6 );
[0029] wherein R 6 is hydrogen, E, (C 1 -C 6 )-straight or branched alkyl, (C 3 -C 6 )-straight or branched alkenyl or alkynyl; or wherein R 6 and D are taken together with the atoms to which they are bound to form a 5 to 7 membered ring system wherein said ring optionally contains 1 to 3 additional heteroatoms independently selected from O, S, N, NH, SO, or SO 2 ; and wherein said ring is optionally benzofused;
[0030] D is hydrogen, (C 1 -C 7 )-straight or branched alkyl, (C 2 -C 7 )-straight or branched alkenyl or alkynyl, (C 5 -C 7 )-cycloalkyl or cycloalkenyl optionally substituted with (C 1 -C 6 )-straight or branched alkyl or (C 2 -C 7 )-straight or branched alkenyl or alkynyl, [(C 3 -C 7 )-alkyl]-E, [(C 2 -C 7 )-alkenyl or alkynyl]-E, or E;
[0031] wherein 1 to 2 of the CH 2 groups of said alkyl, alkenyl or alkynyl chains in D is optionally replaced by —O—, —S—, —S(O)—, —S(O 2 )—, or —N(R 3 );
[0032] provided that when J is hydrogen or G is selected from —S(O) 2 —, C(O)C(O)—, SO 2 —Y, C(O)—Y, or C(O)C(O)—Y, wherein Y is O; then D is not hydrogen;
[0033] m is 0 to 3; and
[0034] x is 0 or 1.
[0035] In another embodiment, the invention provides pharmaceutical compositions comprising the compounds of formula (I). These compositions may be utilized in methods treating various neurological diseases which are influenced by neuronal regeneration and axon growth or for stimulating neuronal regeneration in an ex vivo nerve cell. Examples of such diseases include peripheral nerve destruction due to physical injury or diseases such as diabetes; physical injuries to the central nervous system (e.g., brain or spinal cord); stroke; neurological disturbances due to nerve degeneration, such as Parkinson's disease, Alzheimer's disease, and amylotrophic lateral sclerosis.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The present invention provides compounds having formula (I):
[0037] and pharmaceutically acceptable derivatives thereof, wherein:
[0038] A and B are independently E, (C 1 -C 10 )-straight or branched alkyl, (C 2 -C 10 )-straight or branched alkenyl or alkynyl, or (C 5 -C 7 )-cycloalkyl or cycloalkenyl; wherein 1 or 2 hydrogen atoms in said alkyl, alkenyl or alkynyl are optionally and independently replaced with E, (C 5 -C 7 )-cycloalkyl or cycloalkenyl; and wherein 1 to 2 of the —CH 2 — groups in said alkyl, alkenyl, or alkynyl groups is optionally and independently replaced by —O—, —S—, —S(O)—, —S(O) 2 —, ═N—, —N═ or —N (R 3 )—;
[0039] or, B is hydrogen;
[0040] wherein R 3 is selected from hydrogen, (C 1 -C 4 )-straight or branched alkyl, (C 3 -C 4 )-straight or branched alkenyl or alkynyl, or (C 1 -C 4 ) bridging alkyl, wherein a bridge is formed between the nitrogen atom to which said R 3 is bound and any carbon atom of said alkyl, alkenyl or alkynyl to form a ring, and wherein said ring is optionally benzofused;
[0041] wherein E is a saturated, partially saturated or unsaturated, or aromatic monocyclic or bicyclic ring system, wherein each ring comprises 5 to 7 ring atoms independently selected from C, N, O or S; and wherein no more than 4 ring atoms are selected from N, O or S;
[0042] wherein 1 to 4 hydrogen atoms in E are optionally and independently replaced with halogen, hydroxyl, hydroxymethyl, nitro, SO 3 H, trifluoromethyl, trifluoromethoxy, (C 1 -C 6 )-straight or branched alkyl, (C 2 -C 6 )-straight or branched alkenyl, O—[(C 1 -C 6 )-straight or branched alkyl], O—[(C 3 -C 6 )-straight or branched alkenyl], (CH 2 ) n —N(R 4 ) (R 5 ), (CH 2 ) n —NH(R 4 )—(CH 2 ) n —Z, (CH 2 ) n —N(R 4 —(CH 2 ) n —Z) (R 5 —(CH 2 ) n —Z), (CH 2 ) n —Z, O—(CH 2 ) n —Z, (CH 2 ) n —O—Z, S—(CH 2 ) n —Z, CH═CH—Z, 1,2-methylenedioxy, C(O)OH, C(O)O—[(C 1 -C 6 )-straight or branched alkyl], C(O)O—(CH 2 ) n —Z or C(O) —N(R 4 ) (R 5 );
[0043] wherein each of R 4 and R 5 are independently hydrogen, (C 1 -C 6 )-straight or branched alkyl, (C 3 -C 5 )-straight or branched alkenyl, or wherein R 4 and R 5 , when bound to the same nitrogen atom, are taken together with the nitrogen atom to form a 5 or 6 membered ring, wherein said ring optionally contains 1 to 3 additional heteroatoms independently selected from N, O or S; wherein said alkyl, alkenyl or alkynyl groups in R 4 and R 5 are optionally substituted with Z.
[0044] each n is independently 0 to 4;
[0045] each Z is independently selected from a saturated, partially saturated or unsaturated, monocyclic or bicyclic ring system, wherein each ring comprises 5 to 7 ring atoms independently selected from C, N, O or S; and wherein no more than 4 ring atoms are selected from N, O or S;
[0046] wherein 1 to 4 hydrogen atoms in Z are optionally and independently replaced with halo, hydroxy, nitro, cyano, C(O)OH, (C 1 -C 3 )-straight or branched alkyl, O—(C 1 -C 3 )-straight or branched alkyl, C(O)O—[(C 1 -C 3 )-straight or branched alkyl], amino, NH[(C 1 -C 3 )-straight or branched alkyl], or N—[(C 1 -C 3 )-straight or branched alkyl] 2 or
[0047] J is selected from H, (C 1 -C 6 )-straight or branched alkyl, (C 2 -C 6 )-straight or branched alkenyl or alkynyl, or cyclohexylmethyl, wherein 1 to 2 hydrogen atoms in said alkyl, alkenyl or alkynyl is optionally and independently replaced with E;
[0048] wherein J is optionally substituted with up to 3 substituents selected from halogen, OH, O—(C 1 -C 6 )-alkyl, O—(CH 2 )n—Z, NO 2 , C(O)OH, C(O)—O—(C 1 -C 6 )-alkyl, C(O)NR 4 R 5 , NR 4 R 5 and (CH 2 ) n —Z;
[0049] K, when present, is J;
[0050] K 1 and R 1 , taken together with the nitrogen atom and the —C(O)— group, form a 5-7 membered saturated or unsaturated heterocyclic ring, optionally containing up to 3 additional heteroatoms selected from O, N, S and S(O 2 ), wherein 1 to 4 hydrogen atoms in said heterocyclic ring are optionally and independently replaced with (C 1 -C 6 )-straight or branched alkyl, (C 2 -C 6 )-straight or branched alkenyl or alkynyl, oxo, hydroxyl or Z; and wherein any —CH 2 — group said heterocyclic ring is optionally and independently replaced by —O—, —S—, —S(O)—, —S(O 2 )—, or —N(R 3 )—; and wherein said heterocyclic ring is optionally fused with E;
[0051] G, when present, is —S(O) 2 —, —C(O)—, —S(O) 2 —Y—, —C(O)—Y—, —C(O)—C(O)—, or —C(O)—C(O)—Y—;
[0052] Y is oxygen, or N(R 6 );
[0053] wherein R 6 is hydrogen, E, (C 1 -C 6 )-straight or branched alkyl, (C 3 -C 6 )-straight or branched alkenyl or alkynyl; or wherein R 6 and D are taken together with the atoms to which they are bound to form a 5 to 7 membered ring system wherein said ring optionally contains 1 to 3 additional heteroatoms independently selected from O, S, N, NH, SO, or SO 2 ; and wherein said ring is optionally benzofused;
[0054] D is hydrogen, (C 1 -C 7 )-straight or branched alkyl, (C 2 -C 7 )-straight or branched alkenyl or alkynyl, (C 5 -C 7 )-cycloalkyl or cycloalkenyl optionally substituted with (C 1 -C 6 )-straight or branched alkyl or (C 2 -C 7 )-straight or branched alkenyl or alkynyl, [(C 1 -C 7 )-alkyl]-E, [(C 2 -C 7 )-alkenyl or alkynyl]-E, or E;
[0055] wherein 1 to 2 of the CH 2 groups of said alkyl, alkenyl or alkynyl chains in D is optionally replaced by —O—, —S—, —S(O)—, —S(O 2 )—, or —N(R 3 );
[0056] provided that when J is hydrogen or G is selected from —S (O) 2 —, C(O)C(O)—, SO 2 —Y, C(O)—Y, or C(O)C(O)—Y, wherein Y is O; then D is not hydrogen;
[0057] m is 0 to 3; and
[0058] x is 0 or 1.
[0059] According to a preferred embodiment, each of A and B in formula (I) is (C1-C10) straight or branched alkyl, wherein 1-2 hydrogen atoms in said alkyl are optionally substituted with E.
[0060] In another preferred embodiment, B is hydrogen.
[0061] According to another preferred embodiment, each of A and B in formula (I) is —CH 2 —CH 2 —E or —CH 2 —CH 2 —CH 2 —E.
[0062] According to another preferred embodiment, D in formula (I) is (C1-C7) straight or branched alkyl, E or [(C1-C6)-straight or branched alkyl]-E.
[0063] According to a more preferred embodiment, D is an aromatic monocyclic or bicyclic ring system, wherein each ring comprises 5-7 ring atoms independently selected from C, N, O or S, and wherein no more than 4 ring atoms are selected from N, O or S.
[0064] According to an even more preferred embodiment, D is phenyl or C 1 -C 7 straight or branched alkyl group.
[0065] According to another preferred embodiment, E in formula (I) is a monocyclic or bicyclic aromatic ring system, wherein said ring comprises 5-7 ring atoms independently selected from C, N, O or S, and wherein 1 to 4 ring atoms are independently selected from N, O or S.
[0066] Preferred embodiments of E include phenyl, napthyl, indenyl, azulenyl, fluorenyl, anthracenyl, furyl, thienyl, pyridyl, pyrrolyl, oxazolyl, thiazolyl, imidazolyl, pyrazolyl, pyrazolinyl, pyrazolidinyl, isothiazolyl, 1,3,4-thiadiazolyl, pyridazinyl, pyrimidinyl, 1,3,5-trazinyl, 1,3,5-trithianyl, benzo [b] furanyl, benzo [b] thiophenyl, purinyl, cinnolinyl, phthalazinyl, isoxazolyl, triazolyl, oxadiazolyl, pyrimidinyl, pyrazinyl, indolinyl, indolizinyl, isoindolyl, benzimidazolyl, benzothiophenyl, quinolinyl, isoquinolinyl, quinazolinyl, quinoxalinyl, 1,8-naphthyridinyl, pteridinyl, carbazolyl, acridinyl, phnazinyl, phenothiazinyl, phenoxazinyl and benzothiazolyl, wherein E is optionally substituted as described above.
[0067] More preferred embodiments of E include phenyl, furyl, thienyl, pyridyl, pyrrolyl, oxazolyl, thiazolyl, imidazolyl, pyrazolyl, isoxazolyl, triazolyl, oxadiazolyl, pyrimidinyl, pyrazinyl, indolyl, isoindolyl, benzimidazolyl, benzothiophenyl, quinolinyl, isoquinolinyl, and benzothiazolyl, wherein E is optionally substituted as described above.
[0068] According to another preferred embodiment, J is H, methyl, ethyl or benzyl.
[0069] According to another preferred embodiment, K is selected from (C 1 -C 6 )-straight or branched alkyl, (C 2 -C 6 )-straight or branched alkenyl or alkynyl, or cyclohexylmethyl, wherein 1 to 2 hydrogen atoms in said alkyl, alkenyl or alkynyl is optionally and independently replaced with E.
[0070] According to a more preferred embodiment, K is benzyl.
[0071] According to another preferred embodiment, K 1 and R 1 together with the nitrogen atom and the —C(O)-group form a ring selected from the following:
[0072] werein P is N or CH, X is O, S, SO 2 , CH 2 , C═O, or NH, and each of the above rings optionally contains substituents, as described above.
[0073] The compounds of formula (I) may be stereoisomers, geometric isomers or stable tautomers. The invention envisions all possible isomers, such as E and Z isomers, S and R enantiomers, diastereoisomers, racemates, and mixtures of those. It is preferred that the substituent in the 2 position have the S configuration.
[0074] The compounds of the present invention may be readily prepared using known synthetic methods. For example, compounds of formula (I) may be prepared as shown below in Scheme I:
[0075] One of skill in the art will be well aware of analogous synthetic methods for preparing compounds of formula (I).
[0076] According to another embodiment, this invention provides compositions comprising a compound of formula (I) and a pharmaceutically acceptable carrier.
[0077] Pharmaceutically acceptable carriers that may be used in these compositions include, but are not limited to, ion exchangers, alumina, aluminum stearate, lecithin, serum proteins, such as human serum albumin, buffer substances such as phosphates, glycine, sorbic acid, potassium sorbate, partial glyceride mixtures of saturated vegetable fatty acids, water, salts or electrolytes, such as protamine sulfate, disodium hydrogen phosphate, potassium hydrogen phosphate, sodium chloride, zinc salts, colloidal silica, magnesium trisilicate, polyvinyl pyrrolidone, cellulose-based substances, polyethylene glycol, sodium carboxy methylcellulose, polyacrylates, waxes, polyethylene-polyoxypropylene-block polymers, polyethylene glycol and wool fat.
[0078] In another embodiment, the composition of the present invention is comprised of a compound of formula (I), a pharmaceutically acceptable carrier, and a neurotrophic factor.
[0079] The term “neurotrophic factor,” as used herein, refers to compounds which are capable of stimulating growth or proliferation of nervous tissue. Numerous neurotrophic factors have been identified in the art and any of those factors may be utilized in the compositions of this invention. These neurotrophic factors include, but are not limited to, nerve growth factor (NGF), insulin-like growth factor (IGF-1) and its active truncated derivatives such as gIGF-l and Des(l-3)IGF-I, acidic and basic fibroblast growth factor (aFGF and bFGF, respectively), platelet-derived growth factors (PDGF), brain-derived neurotrophic factor (BDNF), ciliary neurotrophic factors (CNTF), glial cell line-derived neurotrophic factor (GDNF), neurotrophin-3 (NT-3)and neurotrophin 4/5 (NT-4/5). The most preferred neurotrophic factor in the compositions of this invention is NGF.
[0080] As used herein, the described compounds used in the compositions and methods of this invention, are defined to include pharmaceutically acceptable derivatives thereof. A “pharmaceutically acceptable derivative” denotes any pharmaceutically acceptable salt, ester, or salt of such ester, of a compound of this invention or any other compound which, upon administration to a patient, is capable of providing (directly or indirectly) a compound of this invention, or a metabolite or residue thereof, characterized by the ability to promote repair or prevent damage of neurons from disease or physical trauma.
[0081] If pharmaceutically acceptable salts of the described compounds are used, those salts are preferably derived from inorganic or organic acids and bases. Included among such acid salts are the following: acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, bisulfate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, fumarate, glucoheptanoate, glycerophosphate, hemisulfate, heptanoate, hexanoate, hydrochloride, hydrobromide, hydroiodide, 2-hydroxyethanesulfonate, lactate, maleate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, oxalate, palmoate, pectinate, persulfate, 3-phenyl-propionate, picrate, pivalate, propionate, succinate, tartrate, thiocyanate, tosylate and undecanoate. Base salts include ammonium salts, alkali metal salts, such as sodium and potassium salts, alkaline earth metal salts, such as calcium and magnesium salts, salts with organic bases, such as dicyclohexylamine salts, N-methyl-D-glucamine, and salts with amino acids such as arginine, lysine, and so forth. Also, the basic nitrogen-containing groups can be quaternized with such agents as lower alkyl halides, such as methyl, ethyl, propyl, and butyl chloride, bromides and iodides; dialkyl sulfates, such as dimethyl, diethyl, dibutyl and diamyl sulfates, long chain halides such as decyl, lauryl, myristyl and stearyl chlorides, bromides and iodides, aralkyl halides, such as benzyl and phenethyl bromides and others. Water or oil-soluble or dispersible products are thereby obtained.
[0082] The described compounds utilized in the compositions and methods of this invention may also be modified by appending appropriate functionalities to enhance selective biological properties. Such modifications are known in the art and include those which increase biological penetration into a given biological system (e.g., blood, lymphatic system, central nervous system), increase oral availability, increase solubility to allow administration by injection, alter metabolism and alter rate of excretion.
[0083] The compositions of the present invention may be administered orally, parenterally, by inhalation spray, topically, rectally, nasally, buccally, vaginally or via an implanted reservoir. The term “parenteral” as used herein includes subcutaneous, intravenous, intramuscular, intra-articular, intra-synovial, intrasternal, intrathecal, intrahepatic, intralesional and intracranial injection or infusion techniques. Preferably, the compositions are administered orally, intraperitoneally or intravenously.
[0084] Sterile injectable forms of the compositions of this invention may be aqueous or oleaginous suspension. These suspensions may be formulated according to techniques known in the art using 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 1,3-butanediol. 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 di-glycerides. Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions may also contain a long-chain alcohol diluent or dispersant, such as Ph. Helv or similar alcohol.
[0085] The compositions of this invention may be orally administered in any orally acceptable dosage form including, but not limited to, capsules, tablets, aqueous suspensions or solutions. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions are required for oral use, the active ingredient is combined with emulsifying and suspending agents. If desired, certain sweetening, flavoring or coloring agents may also be added.
[0086] Alternatively, the compositions of this invention may be administered in the form of suppositories for rectal administration. These can be prepared by mixing the agent with a suitable non-irritating excipient which is solid at room temperature but liquid at rectal temperature and therefore will melt in the rectum to release the drug. Such materials include cocoa butter, beeswax and polyethylene glycols.
[0087] The compositions of this invention may also be administered topically, especially when the target of treatment includes areas or organs readily accessible by topical application, including diseases of the eye, the skin, or the lower intestinal tract. Suitable topical formulations are readily prepared for each of these areas or organs.
[0088] Topical application for the lower intestinal tract can be effected in a rectal suppository formulation (see above) or in a suitable enema formulation. Topically-transdermal patches may also be used.
[0089] For topical applications, the compositions may be formulated in a suitable ointment containing the active component suspended or dissolved in one or more carriers. Carriers for topical administration of the compounds of this invention include, but are not limited to, mineral oil, liquid petrolatum, white petrolatum, propylene glycol, polyoxyethylene, polyoxypropylene compound, emulsifying wax and water. Alternatively, the compositions can be formulated in a suitable lotion or cream containing the active components suspended or dissolved in one or more pharmaceutically acceptable carriers. Suitable carriers include, but are not limited to, mineral oil, sorbitan monostearate, polysorbate 60, cetyl esters wax, cetearyl alcohol, 2-octyldodecanol, benzyl alcohol and water.
[0090] For ophthalmic use, the compositions may be formulated as micronized suspensions in isotonic, pH adjusted sterile saline, or, preferably, as solutions in isotonic, pH adjusted sterile saline, either with our without a preservative such as benzylalkonium chloride. Alternatively, for ophthalmic uses, the compositions may be formulated in an ointment such as petrolatum.
[0091] The compositions of this invention may also be administered by nasal aerosol or inhalation. Such compositions are prepared according to techniques well-known in the art of formulation and may be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other conventional solubilizing or dispersing agents.
[0092] The amount of both a described compound and the optional neurotrophic factor that may be combined with the carrier materials to produce a single dosage form will vary depending upon the host treated and the particular mode of administration. Preferably, the compositions should be formulated so that a dosage of between 0.01-100 mg/kg body weight/day of the described compound can be administered. If a neurotrophic factor is present in the composition, then a dosage of between 0.01 μg-100 mg/kg body weight/day of the neurotrophic factor can be administered to a patient receiving these compositions.
[0093] It should also be understood that a specific dosage and treatment regimen for any particular patient will depend upon a variety of factors, including the activity of the specific compound employed, the age, body weight, general health, sex, diet, time of administration, rate of excretion, drug combination, and the judgment of the treating physician and the severity of the particular disease being treated. The amount of active ingredients will also depend upon the particular described compound and neurotrophic factor in the composition.
[0094] According to another embodiment, this invention provides methods for promoting repair or preventing neuronal damage in vivo or in an ex vivo nerve cell. Such methods comprise the step of treating nerve cells with any of the compounds described above. Preferably, this method promotes repair or prevents neuronal damage in a patient, and the compound is formulated into a composition additionally comprising a pharmaceutically acceptable carrier. The amount of the compound utilized in these methods is between about 0.01 and 100 mg/kg body weight/day.
[0095] According to an alternate embodiment, the method of promoting repair or preventing neuronal damage comprises the additional step of treating nerve cells with a neurotrophic factor, such as those contained in the compositions of this invention. This embodiment includes administering the compound and the neurotrophic agent in a single dosage form or in separate, multiple dosage forms. If separate dosage forms are utilized, they may be administered concurrently, consecutively or within less than about 5 hours of one another.
[0096] Preferably, the methods of this invention are used to stimulate axonal growth in nerve cells. The compounds are, therefore, suitable for treating or preventing neuronal damage caused by a wide variety of diseases or physical traumas. These include, but are not limited to, Alzheimer's disease, Parkinson's disease, ALS, Huntington's disease, Tourette's syndrome, stroke and ischemia associated with stroke, neural paropathy, other neural degenerative diseases, motor neuron diseases, sciatic crush, spinal cord injuries and facial nerve crush.
[0097] In a particularly preferred embodiment of the invention, the method is used to treat a patient suffering from trigeminal neuralgia, glosspharyngeal neuralgia, Bell's Palsy, myasthenia gravis, muscular dystrophy, muscle injury, progressive muscular atrophy, progressive bulbar inherited muscular atrophy, herniated, ruptured, or prolapsed invertebrae disk syndrome's, cervical spondylosis, plexus disorders, thoracic outlet destruction syndromes, peripheral neuropathies, such as those caused by lead, dapsone, ticks, or porphyria, other peripheral myelin disorders, Alzheimer's disease, Gullain-Barre syndrome, Parkinson's disease and other Parkinsonian disorders, ALS, Tourette's syndrome, multiple sclerosis, other central myelin disorders, stroke and ischemia associated with stroke, neural paropathy, other neural degenerative diseases, motor neuron diseases, sciatic crush, neuropathy associated with diabetes, spinal cord injuries, facial nerve crush and other trauma, chemotherapy- and other medication-induced neuropathies, and Huntington's disease.
[0098] More preferably, the compositions of the present invention are used for treating Parkinson's disease, amylotrophic lateral sclerosis, Alzheimer's disease, stroke, neuralgias, muscular atrophies, and Guillain-Barré syndrome.
[0099] For use of the compounds according to the invention as medications, they are administered in the form of a preparation containing not only the active ingredient but also carriers, auxiliary substances, and/or additives suitable for enteric or parenteral administration. Administration can be oral or sublingual as a solid in the form of capsules or tablets, as a liquid in the form of solutions, suspensions, elixirs, aerosols or emulsions, or rectal in the form of suppositories, or in the form of solutions for injection which can be given subcutaneously, intramuscularly, or intravenously, or which can be given topically or intrathecally. Auxiliary substances for the desired medicinal formulation include the inert organic and inorganic carriers known to those skilled in the art, such as water, gelatin, gum arabic, lactose, starches, magnesium stearate, talc, vegetable oils, polyalkylene glycols, etc. The medicinal formulations may also contain preservatives, stabilizers, wetting agents, emulsifiers, or salts to change the osmotic pressure or as buffers.
[0100] Solutions or suspensions for injection are suitable for parenteral administration, and especially aqueous solutions of the active compounds in polyhydroxy-ethoxylated castor oil.
[0101] Surface-active auxiliary substances such as salts of gallic acid, animal or vegetable phospholipids, or mixtures of them, and liposomes or their components, can be used as carrier systems.
[0102] The neurotrophic effect of the compounds of formula (I) of the present invention and their physiologically acceptable salts can be determined by the methods of W. E. Lyons et al., Proc. Natl. Acad. Sci. USA, Vol. 91, pp. 3191-3195 (1994) and W. E. Lyons et al., Proc. Natl. Acad. Sci. USA, Vol. 91, pages 3191-3195 (1994). | The present invention relates to cyclized amide derivatives for treating or preventing neuronal damage associated with neurological diseases. The invention also provides compositions comprising the compounds of the present invention and methods of utilizing those compositions for treating or preventing neuronal damage. | 2 |
FIELD OF THE INVENTION
THIS INVENTION relates to a process for peroxide bleaching of pulp. Pulps which may be bleached in the process of the invention include lignocellulose pulp which may be produced mechanically and chemi-mechanically with yields in the region of greater than 75% which are otherwise known as high yield pulps.
BACKGROUND OF THE INVENTION
In a conventional peroxide bleaching process, sodium hydroxide is used as an alkali source. To achieve a desired brightness with maximum efficiency, auxiliary substances are also used. Such auxiliary substances include sodium silicate, magnesium sulphate and chelating agents inclusive of DTPA (sodium salt of diethylene triamino pentaacetic acid).
Reference may be made to a prior art article by Soteland et al., 1988, TAPPI Proceedings 231-236, which describes a peroxide bleaching process which utilises magnesium oxide as a sole alkaline source. The pulp was pretreated with DTPA and magnesium oxide particles were utilised in a size range of 1.00 mm-0.25 mm or smaller. The magnesium oxide were also used in a concentration of 2-3% based on the dry weight of the pulp. The MgO used in the process was light-burnt MgO and finely crushed. It was found that brightness levels obtained were very close to that which was achieved by conventional bleaching using NaOH. In the bleaching process, the pulp was diluted to form a pulp suspension and the amount of MgO was added to the suspension under vigorous stirring. Hydrogen peroxide was subsequently added to the suspension at a concentration of 3% based on the weight of the pulp. This reference also made the observation that coarse particles are less effective as an alkaline source during peroxide bleaching.
Having regard to the abovementioned reference, an observation was also made in the corresponding patent specification DE3617942 that use of MgO as sole alkaline source considerably simplified the bleaching process since sodium hydroxide as alkaline source and auxiliary chemicals such as sodium silicate could be omitted.
Another advantage of using MgO as sole alkaline source was that only a small amount of waste is produced in the bleaching plant. Thus, for example, in integrated mills which produce magnesium sulphite pulp and peroxide bleached high-yield pulps, the used bleaching liquor is combusted and the MgO may be recovered for re-use.
However, the use of MgO as sole alkaline source in a peroxide bleaching process has not as yet achieved widespread commercial acceptance because although the principle of utilising MgO as sole alkaline source was described in the Soteland at al. references, the means of reducing the principle to practice on a commercial scale has not yet been fully elucidated.
SUMMARY OF THE INVENTION
Surprisingly, it has now been discovered that commercial usage of magnesium oxide as a sole alkaline source in peroxide bleaching of wood pulp may be achieved by employing MgO particles with a particle size of less than 500 micron and more preferably less than 75 micron and having particle surface area (PSA) of between 20-60 m 2 /g and more preferably between 30-50 m 2 /g. By using such parameters, an efficient peroxide bleaching process may be carried out most efficiently on a commercial scale which may be achieved within a maximum bleaching time of 180 minutes and achievement of a maximum target of ISO brightness of 65 in regard to freshly prepared pulp.
Utilizing MgO with parameters outside those stated above will result in a less efficient bleaching process leading to higher usage of chemicals and therefore higher operating costs.
The dosages of MgO that may be utilised in the process of the invention is 0.3-2% based on the weight of the pulp.
The amount of hydrogen peroxide that may be utilised in the process of the invention is from 1-5% based on the weight of the pulp.
To achieve maximum efficiency, the MgO particles are preferably added to the pulp in the form of a powder or slurry prepared in situ.
Preferably the MgO is added to the pulp simultaneously with the peroxide or prior to the addition of the peroxide.
Chelating agents also may be used in the process of the invention and such chelating agents may comprise DTPA, EDTA or HEDTA (hydroxy-ethylene diamine tetracetic acid). Preferably the chelating agent is added to the pulp simultaneously with addition of MgO particles, as well as prior to addition of MgO particles.
Bleaching times of 60-180 minutes may also be utilised by the process of the invention to achieve a target ISO brightness of 55-65.
BRIEF DESCRIPTION OF DRAWINGS
In several preferred embodiments concerning the process of the invention which are discussed hereinafter in relation to Experiments 1 and 2;
FIG. 1 is a graph showin the effect of particle size on CCS (Cold Caustic Soda) pulp and more specifically showing particle size vs brightness at different times;
FIG. 2 refers to the results of Experiment 2 whereby various samples are plotted against final brightness;
FIG. 3 also refers to the result of Experiment 2 and shows the effect of surface area on CCS pulp and more specifically showing particle size vs brightness at different times; and
FIG. 4 shows the results of FIG. 3 when plotted against time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXPERIMENT 1
EFFECT OF MGO PARTICLE SIZE ON THE BLEACABILITY OF CCS PULP
Introduction
This work was performed to establish a relationship between MgO particle size and alkali performance in the bleaching of CCS (Cold Caustic Soda) wood pulp. Four grades of MgO were trialled, each one identified by its particle size distribution. Each sample of MgO had approximately the same surface area. Particle size and surface area for each of the samples is given in Table 1.
Summary of bleaching work
CCS (chemi-mechanical pulp), pretreated with DTPA to remove metal ions, was retrieved from the washers in the bleach plant at the Boyer mill. An equivalent mass of 20 grams OD of pulp was weighed out and placed in a plastic breaker. DTPA was then added as 0.15% v/w on the pulp and mixed. MgO as 0.4% wow, enough water to give a stock consistency of 12% and peroxide as 1.6% v/w on pulp was added and mixed for 2 minutes. The pulp was wrapped in plastic bags and placed into a constant temperature water bath at 65° C. A 3 gram OD sample was removed from the bath at intervals of 2, 3 and 4 hours. This was then made into a brightness hand sheet using the standard Boyer pulp mill method. These were dried overnight in a constant temperature/humidity room and tested for ISO brightness. This procedure was repeated for all MgO samples as well as with control pulp containing no MgO (sample J)
Results
The results of this study indicate that particle size is a key parameter for achieving efficient peroxide bleaching of chemic-mechanical pulp. The results shown in Table 2 and FIG. 1 of this study indicate that an MgO particle size of <75μ (samples G and F, d90=65 and 35 respectively) is required to achieve a target brightness for a given retention time of 2, 3 or 4 hours.
To achieve an equivalent brightness with samples C (d90=1500) or D (d90=3500), the chemical dosages of MgO and H 2 O 2 would need to be increased.
EXPERIMENT 2
EFFECT OF MGO PARTICLE SURFACE AREA ON THE BLEACHABILITY OF CCS PULP
Introduction
This work was performed to establish a relationship between MgO particle surface area and alkali performance in the bleaching of CCS (Cold Caustic Soda) wood pulp. Five grades of MgO were trialled, each one identifiable by its particle surface area. Each sample of MgO had approximately the same particle size. Particle size and surface area data for each of the samples is given in Table 3.
Summary of bleaching work
CCS (chemi-mechanical) pulp, pre-treated with DTPA to remove metal ions, was retrieved from the washers in the bleach plant at the Boyer mill. For each sample, a mass of 10 g O.D. pulp was placed into a beaker and the approximate mass of chemicals added. The pulp was mixed for 2 minutes in a bench top mixer. The pulp was then wrapped in plastic bags and placed into a constant temperature water bath at 65° C. After two hours retention, the samples were removed from the bath and divided into two. Half the sample was returned to the bath for a further hour of reaction while the other half was made into 5 gram brightness hand sheets. These were dried overnight and then tested for ISO brightness. The work was repeated with samples taken at 2, 3 and 4 hours.
Results
In the previous study (Experiment 1), we determined that MgO particle size was important for peroxide bleaching efficiency. The results of this study indicate that particle surface area is also a key parameter for achieving maximum brightness for a given chemical dose. The results from these two independent studies (Tables 4 and 5, FIGS. 2 and 3) indicate that a surface area in the range 30-50 m 2 /g (samples B and C) is required to achieve maximum brightness for a given retention time and chemical dose. Surprisingly, when the surface area is either decreased or increased, the peroxide bleaching efficiency is reduced as indicated in FIGS. 2 and 3 by the bell shaped curves with brightness plateaus between samples B and C. To achieve an equivalent brightness to samples B and C with samples A, D or E, the chemical charges of H 2 O and MgO would need to be increased.
The results in FIG. 3, when plotted against time (FIG. 4), appear to indicate that a similar brightness will be achieved with four of the five samples when the bleaching time is extended indefinitely. However, indefinite bleaching time is not a commercial reality and there is a clear benefit, based on these results, in employing MgO particles with a specific size and surface area. In fact, if MgO particles, with parameters outside those stated in this document are used, then the target brightness may not be achieved without increasing chemical dose rates.
TABLE 1______________________________________ Particle size d90Sample micron Surface area m.sup.2 /g______________________________________F 35 38G 65 35H 1500 30I 3500 30______________________________________
TABLE 2______________________________________ Surface Area BrightnessSample m.sup.2 /g 2 hr 3 hr 4 hr______________________________________F <40 61.39 62.17 62.88G <75 61.22 61.94 62.69H <2000 56.85 57.98 59.17I <5000 56.32 56.19 56.97J 0 54.3 55.03 55.04______________________________________
TABLE 3______________________________________ Particle size d90Sample micron Surface area m.sup.2 /g______________________________________A 14 1B 10 35C 10 43D 15 (d90 = 70) 96E 11 142______________________________________
TABLE 4______________________________________ Surface Area BrightnessSample m.sup.2 /g 2 hr 3 hr______________________________________A 1 58.5 59.1B 35 60.2 60.5C 43 60.1 60.6D 98 58.3 59.0E 142 56.8 58.8______________________________________
TABLE 5______________________________________ Surface Area BrightnessSample m.sup.2 /g 2 hr 3 hr 4 hr______________________________________A 1 56.02 57.75 58.54B 35 58.89 60.58 60.96C 43 59.17 31.37 61.09D 98 58.15 59.1 60.29E 142 57.45 59.13 60.27______________________________________
LEGENDS
TABLE 2______________________________________Bleaching conditions______________________________________ MgO% w/w on oven dry pulp = 0.4% H.sub.2 O.sub.2 - 1.6% DTPA = 0.15% Temperature = 65° C. Initial brightness 47.1______________________________________
TABLE 4______________________________________Bleaching conditions______________________________________ MgO% w/w on oven dry pulp = 0.3% H.sub.2 O.sub.2 = 1.8% DTPA = 0.1% Temperature = 65° C. Initial brightness 43.5______________________________________
TABLE 5______________________________________Bleaching conditions______________________________________ MgO% w/w on oven dry pulp = 0.4% H.sub.2 O.sub.2 = 1.6% DTPA = 0.15% Temperature - 65° C. Initial brightness 47.1______________________________________ FIG. 1 Effect of particle size on CCS pulp Particle size vs brightness at different times. FIG. 2 Sample number vs final final brightness. FIG. 3 Effect of surface area on CCS pulp Surface area vs brightness at different FIG. 4 Effect of surface area on CCS pulp Time vs brightness for different surface areas | A process for peroxide bleaching of pulp using magnesium oxide as sole alkaline source wherein said pulp is bleached in the presence of hydrogen peroxide for a maximum period of 180 minutes and achievement of a maximum target ISO brightness of 65 in regard to freshly prepared pulp characterized in that said magnesium oxide is utilized as MgO particles having a particle size of 5-500 microns and a particle surface area (PSA) of between 20-60 m 2 /g. By using such parameters, a peroxide bleaching process may be carried out most efficiently on a commercial scale. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a rotation transmitting mechanism in which a shaft rotates in the fixed direction irrespective of the direction of rotation of another shaft.
2. Description of the Related Art
A kind of apparatus in which an output shaft is driven in the fixed direction irrespective of the direction of rotation of an input shaft is known as, for example, feed tables for machine tools. Ordinarily, in this apparatus, a rotation transmitting mechanism for reverse rotation is interposed between the feed table and a main shaft, and the direction of the rotation transmitted to the feed table is changed over by the rotation transmitting mechanism if the direction of rotation of the main shaft is changed by following a driving unit separately provided.
Conventionally, mechanisms based on the combination of gears are generally used as this kind of rotation transmitting mechanism. For example, a drive gear is provided on an input shaft of a rotation transmitting mechanism to mesh with a driven gear fixed to an output shaft. As the input shaft connected to a driving source such as a motor is rotated counterclockwise, the output shaft is rotated clockwise and opposite to the rotation of the input shaft through the drive gear and the driven gear. The drive gear is axially slidable on the input shaft by the function of, for example, a slide key, and meshes with an intermediate gear provided on an intermediate shaft when axially moved. The intermediate gear meshes with another driven gear disposed on the output shaft parallel to the former driven gear. The rotation of the input shaft is transmitted to the output shaft through the drive gear, the intermediate gear and the latter driven gear, thereby rotating the output shaft counterclockwise in the same direction as the input shaft. That is, it is possible for the rotation transmitting mechanism to change over the direction of rotation of the output shaft by artificially sliding the drive gear on the input shaft. Accordingly, even if the rotation of the motor provided as the drive source is reversed according to the direction of rotation of the other connected drive unit, the output shaft can be rotated in the same direction as previous by changing over the drive gear.
In this type of conventional rotation transmitting mechanism, however, there is a need for the operation of changing over the drive gear according to the direction of rotation of the drive source as well as a need for providing the changeover mechanism having a complicate structure. This rotation transmitting mechanism therefore entails the problem of the operation being complicated and inconvenient as well as the problem of increase in the production cost. Moreover, because the rotation is transmitted through gear, it cannot be smoothly transmitted owing to backlashes between the gears when the rotation is reversed.
SUMMARY OF THE INVENTION
The present invention has been achieved in consideration of these problems of the conventional art, and a first object of the present invention is to provide a rotation transmitting mechanism in which there are provided input and output shafts having transmission surfaces brought into contact with each other by a first pressing force, and there are further provided a transmission roller contacting the input and output shafts by a second pressing force, so that the rotation of the input shaft is directly transmitted to the output shaft when the input shaft is rotated in the normal direction, the rotation is transmitted through the transmission roller when the input shaft is rotated in the reverse direction, thereby enabling the output shaft to rotate always in the fixed direction without using any complicate changeover mechanism or artificial changeover operation and enabling the rotation to be smoothly transmitted while limiting the manufacture cost.
A second object of the present invention is to provide a rotation transmitting mechanism in which there are provided an input shaft and a plurality of driven shafts, which input shaft and driven shafts have transmission surfaces on which the input shaft is brought into contact with each of the driven shafts by a first pressing force, and there are further provided transmission rollers which is of the same number as the driven shafts and each contact the input shaft and the driven shaft by a second pressing force, so that the rotation of the input shaft is directly transmitted to the driven shafts when the input shaft is rotated in the normal direction, the rotation is transmitted through the transmission rollers when the input shaft is rotated in the reverse direction, the output shaft is rotated through the driven shafts, thereby enabling the output shaft to rotate always in the fixed direction without using any complicate changeover mechanism or artificial changeover operation and enabling the rotation to be smoothly transmitted while limiting the manufacture cost. In accordance with this construction, the input and output shafts are coaxially disposed and the change in the distance between the input shaft and each driven shaft and side force, which change and side force are caused when the transmission rollers are inserted, are radially distributed and absorbed. Therefore the distance between the input and output shafts is constantly maintained, thereby eliminating restrictions in terms of use and improving the rotation transmission efficiency as well as the reliability of the mechanism.
The first object is achieved by the its first to third inventions, and the second object is achieved by the fourth invention.
The first invention relates to a rotation transmitting mechanism comprising: a first cylindrical body rotatably disposed around a first axis; a second cylindrical body rotatably disposed around axis parallel to the first axis; a rotary body rotatably disposed around a third axis parallel to the first axis, disposed in such a manner as to contact at an outer circumferential surface thereof outer circumferential surfaces of the first cylindrical body and the second cylindrical body, and disposed movably along a direction of crossing perpendicularly a plane including the first axis and the second axis; pressing unit for pressing one of the first and second cylindrical bodies against the other of the first and second cylindrical bodies to make the first and second cylindrical bodies contact with each other; and moving unit for moving said rotary body in the perpendicularly crossing direction so as to make the rotary body contact the first and second cylindrical bodies while inhibiting contact between said first and second cylindrical bodies, and for making the rotary body retreat along the perpendicularly crossing direction to allow the first and second cylindrical bodies to be brought into contact with each other by the pressing unit.
The second invention relates to a rotation transmitting mechanism comprising: a flat plate body translationally disposed in a predetermined direction; a cylindrical body rotatably disposed around a first axis extending perpendicular to the predetermined direction and in parallel to one of two surfaces of the flat plate body; a rotary body rotatably disposed around a second axis parallel to the first axis, disposed in such a manner that outer circumferential surface thereof is circumscribed with the one of the two surfaces of the flat plate body and an outer circumferential surface of the cylindrical body, and disposed movably in the predetermined direction; pressing unit for pressing one of the flat plate body and the cylindrical body against the other of the flat plate body and the cylindrical body to make the flat plate body and the cylindrical body contact with each other; and a moving unit for moving forward the rotary body in the predetermined direction so as to make the rotary body contact the flat plate body and the cylindrical body while inhibiting contact between the flat plate body and the cylindrical body, and for making the rotary body retreat in the predetermined direction to allow the flat plate body and the cylindrical body to be brought into contact with each other by the pressing means.
The third invention relates to a rotation transmitting mechanism comprising: a hollow cylindrical body rotatably disposed around a first axis; a solid cylindrical body rotatably disposed around a second axis parallel to the first axis, and inscribed at an outer circumferential surface thereof with an inner circumferential surface of the hollow cylindrical body; a rotary body rotatably disposed around a third axis parallel to the first axis, and disposed in such a manner that an outer circumferential surface thereof is inscribed with the inner circumferential surface of the hollow cylindrical body and is circumscribed with an outer circumferential surface of the solid cylindrical body, and disposed movably along the outer circumferential surface of the solid cylindrical body and the inner circumferential surface of the hollow cylindrical body; pressing unit for pressing one of the solid and hollow cylindrical bodies against the other of the solid and hollow cylindrical bodies to make the hollow and solid cylindrical bodies contact with each other; and moving unit for moving the rotary body along the outer circumferential surface of the solid cylindrical body and the inner circumferential surface of the hollow cylindrical body so as to make the rotary body contact the hollow and solid cylindrical bodies while inhibiting contact between the hollow and solid cylindrical bodies, and for making the rotary body retreat along the outer circumferential surface of the solid cylindrical body and the inner circumferential surface of the hollow cylindrical body to allow the hollow and solid cylindrical bodies to be brought into contact with each other by the pressing unit.
The fourth invention relates to a rotation transmitting mechanism comprising: a first solid cylindrical body rotatably disposed around a first axis; a hollow cylindrical body rotatably disposed coaxially with the first axis in such a manner as to surround the first solid cylindrical body, and made of an elastically deformable material; a second solid cylindrical body rotatably disposed around a second axis parallel to the first axis and located between the first solid cylindrical body and the hollow cylindrical body, and arranged in such a manner that an outer circumferential surface of the second solid cylindrical body is inscribed with an inner circumferential surface of the hollow cylindrical body and circumscribed with an outer circumferential surface of the first solid cylindrical body; a third solid cylindrical body rotatably disposed around a third axis parallel to the first axis and located between the first solid cylindrical body and the hollow cylindrical body so as to form equal-angular distance with respect to the second axis, and arranged in such a manner that an outer circumferential surface of the third solid cylindrical body is inscribed with the inner circumferential surface of the hollow cylindrical body and circumscribed with the outer circumferential surface of the first solid cylindrical body; a first stationary retainer disposed in one of two spaces defined between the inner circumferential surface of the hollow cylindrical body and the outer circumferential surfaces of the first to third solid cylindrical bodies, the first stationary retainer being formed in such a manner that a first surface thereof facing the inner circumferential surface of the hollow cylindrical body slidably contacts the inner circumferential surface of the hollow cylindrical body, a second surface thereof facing the outer circumferential surface of the first solid cylindrical body slidably contacts the outer circumferential surface of the first solid cylindrical body, and a third surface thereof facing the second solid cylindrical body and a fourth surface thereof facing the third solid cylindrical body have respectively shapes complementary with the outer circumferential surfaces of the second and third solid cylindrical bodies so as to permit the second and third solid cylindrical bodies to radially move; a second stationary retainer disposed in the other of the two spaces, the second stationary retainer being formed in such a manner that a fifth surface thereof facing the inner circumferential surface of the hollow cylindrical body slidably contacts the inner circumferential surface of the hollow cylindrical body, sixth surface thereof facing the outer circumferential surface of the first solid cylindrical body slidably contacts the outer circumferential surface of the first solid cylindrical body, and a seventh surface thereof facing the second solid cylindrical body and a eighth surface thereof facing the third solid cylindrical body have respectively shapes complementary with the outer circumferential surfaces of the second and third solid cylindrical bodies so as to permit the second and third solid cylindrical bodies to radially move; a fourth solid cylindrical body rotatably disposed around a fourth axis parallel to the first axis, and arranged so as to be circumscribed with the first and second solid cylindrical bodies; a fifth solid cylindrical body rotatably disposed around a fifth axis parallel to the first axis, and arranged so as to be circumscribed with the first and third cylindrical bodies; a first moving unit for moving the fourth solid cylindrical body toward a first point where the first solid cylindrical body contacts the second solid cylindrical body so as to inhibit contact of the first solid cylindrical body with the second solid cylindrical body, and for retreating the fourth solid cylindrical body in a direction opposite to the first point so as to permit contact of the first solid cylindrical body with the second solid cylindrical body, which contact is caused by resilient force of the hollow cylindrical body; and a second moving unit for moving the fifth solid cylindrical body toward a second point where the first solid cylindrical body contacts the third solid cylindrical body so as to inhibit contact of the first solid cylindrical body with the third solid cylindrical body and to contact the fifth solid cylindrical body with the first and third solid cylindrical bodies, and for retreating the fifth solid cylindrical body in a direction opposite to the second point so as to permit contact of the first solid cylindrical body with the third solid cylindrical body, which contact is caused by a resilient force of the hollow cylindrical body.
In accordance with the first to third inventions, input and output shafts brought into contact with each other by the pressing force of a first pressing means is provided along with a rotation transmitting member which contacts the input and output shafts by the pressing force of a second pressing unit. The rotation of the input shaft is directly transmitted to the output shaft when the input shaft is rotated clockwise, or is transmitted through the rotation transmitting member when the input shaft is rotated counterclockwise, thereby enabling the output shaft to be rotated always in the fixed direction without using any complicated changeover mechanism or artificial changeover operation. The structure of the rotation transmitting mechanism can therefore be simplified, thereby reducing the manufacture cost. Since the rotation is transmitted by frictional force through the input shaft, the rotation transmitting member and the output shaft, there is therefore no unevenness of transmission owing to backlashes of rotation transmitting gears, and the rotation can be transmitted always smoothly through the rotation transmitting mechanism.
In accordance with the fourth invention, an output shaft and a plurality of driven shafts each of which is brought into contact with the output shaft by the pressing force based on the resiliency of an output shaft are provided along with the number of torque transmitting rollers corresponding to the number of driven shafts, the torque transmitting rollers contacting the input shaft and the plurality of driven shafts by the pressing force of a pressing unit. The rotation of the input shaft is directly transmitted to the driven shafts when the input shaft is rotated clockwise, or is transmitted to the driven shafts through the rotation transmitting rollers when the input shaft is rotated counterclockwise, and the output shaft is rotated through the driven shafts, thereby enabling the output shaft to be rotated always in the fixed direction irrespective of the direction of rotation of the input shaft. The same effects as those attained in the first to third invention can therefore be obtained. Moreover, in the fourth invention, the input and output shafts are disposed coaxially and the change in the distance between the input shaft and each driven shaft and side force caused when the transmission rollers are inserted into gaps between the input shaft and the driven rollers are radially distributed and absorbed, so that the distance between the input and output shafts is constantly maintained, thereby eliminating restrictions of in terms of use owing to variations in this distance and improving the rotation transmission efficiency as well as the reliability of the mechanism.
Further objects and advantages of the present inventions will be apparent from the following description of the preferred embodiments of the inventions as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view showing the construction of a conventional rotation transmitting mechanism;
FIG. 2 is a perspective diagram taken in the direction of the arrows 2 of FIG. 1;
FIG. 3 is a partially sectional view showing the construction of a rotation transmitting mechanism according to a first embodiment of the first invention;
FIGS. 4 and 5 are partially sectional views taken in the direction of the arrows 4 of FIG. 3, showing the operation of the mechanism according to the first embodiment;
FIG. 6 is a partially sectional view taken in the same direction as FIG. 4, showing a rotation transmitting mechanism which represents a second embodiment of the first invention;
FIG. 7 is a perspective view of the transmission roller of a rotation transmitting mechanism which represents a third embodiment of the first invention;
FIGS. 8 and 9 are schematic diagrams taken in the same direction as FIG. 4, showing rotation transmitting mechanisms which represent respectively an embodiment and another embodiment of the second invention;
FIGS. 10 and 11 are schematic perspective views of rotation transmitting mechanisms which represent respectively an embodiment and another embodiment of the third invention;
FIG. 12 is a front sectional view showing the construction of a rotation transmitting mechanism according to an embodiment of the fourth invention;
FIG. 13 is a sectional view taken in the direction of the arrows 13 of FIG. 12; and
FIG. 14 is a sectional view corresponding to FIG. 13, showing another embodiment of the output shaft.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For ease of understanding of the present invention, the related art will be described below with reference to the arrangement shown in FIGS. 1 and 2 before the description of the present invention.
A kind of device driven in the fixed direction irrespective of the direction of rotation of a main shaft is known as, for example, a feed table for machine tools. Ordinarily, a rotation transmitting mechanism for reverse rotation is interposed between the feed table and a main shaft, and the direction of the rotation transmitted to the feed table is changed over by the rotation transmitting mechanism if the direction of rotation of the main shaft is changed by following a driving unit separately provided.
Conventionally, mechanisms based on the combination of gears are generally used as this kind of rotation transmitting mechanism. For example, a type of mechanism shown in FIGS. 1 and 2 is known. Referring to FIG. 1, a drive gear 3 is provided on an input shaft 1 of a rotation transmitting mechanism 2 to mesh with a first driven gear 5 fixed to an output shaft 4. As the input shaft 1 connected to an unillustrated driving source such as a motor is rotated counterclockwise as indicated by the arrow A, the output shaft 4 is rotated clockwise as indicated by the arrow B, i.e., opposite to the rotation of the input shaft 1 through the drive gear 3 and the driven gear 5. The drive gear 3 is axially slidable on the input shaft 1 by the function of, for example, a slide key provided therebetween, and meshes with an intermediate gear 7 provided on an intermediate shaft 6 when moved to a position indicated by the double-dot-dash line on the left-hand side of FIG. 1. The intermediate gear 7 meshes with a second driven gear 8 disposed on the output shaft 4 parallel to the driven gear 5. The rotation of the input shaft 1 is transmitted to the output shaft 4 through the drive gear 3, the intermediate gear 7 and the driven gear 8, thereby rotating the output shaft 4 counterclockwise in the same direction as the input shaft 1, as indicated by the arrow C in FIG. 2. That is, it is possible for the rotation transmitting mechanism 2 to change over the direction of rotation of the output shaft 4 by artificially sliding the drive gear 3 on the input shaft 1. Accordingly, even if the rotation of the motor provided as the driven source is reversed according to the direction of rotation of the other connected driven unit, the output shaft 4 can be rotated in the same direction as previous by changing over the drive gear 3.
Embodiments of the present invention will be described below with reference to the accompanying drawings.
FIGS. 3 to 5 show a rotation transmitting mechanism which represents a first embodiment of the first invention. The construction of this rotation transmitting mechanism is as described below.
Referring to FIG. 3, a cylindrical body 11 is supported on a frame 16 by shaft necks 12 and 13 projecting from its opposite end portions and bearings 14 and 15 so as to be rotatable on an axis X 1 -X 2 . The cylindrical body 11 has a transmission surface 17 having a circular cross-sectional shape, as shown in FIG. 4, and constitutes and input shaft 18. Another cylindrical body 19 is disposed parallel to the cylindrical body 11 and is supported on the frame 16 by shaft necks 20 and 21 and bearings 22 and 23 constructed in the same manner as those for the cylindrical body 11. The cylindrical body 19 is rotatable on an axis X 3 -X 4 parallel to the axis X 1 -X 2 . As in the case of the cylindrical body 11, the cylindrical body 19 has a transmission surface 24 having a circular cross-sectional shape as shown in FIG. 4 and constitutes an output shaft 25. Referring to FIGS. 3 and 4, a transmission roller 26 is disposed so as to be rotatable on an axis X 5 -X 6 parallel to the axis X 1 -X 2 and the axis X 3 -X 4 . The transmission roller 26 is constituted by a cylindrical body 28 having an outer circumferential surface 27 having a certain outer diameter D R . Referring again to FIG. 3, a pair of first springs 29 and 30 are interposed between the bearings 14 and 15 and the frame 16. The input shaft 18 is pressed against the output shaft 25 by a first pressing force F applied to the input shaft 18 by the springs 29 and 30, so that the transmission surface 17 of the input shaft 18 and the transmission surface 24 of the output shaft 25 contact each to her on a contact line L. Further, as shown in FIG. 4, a pair of second springs 32 are interposed between a sub-frame 16a disposed at an upper portion of the frame 16 and a base end of metallic retaining member 31 having an extreme end slidably contacting the outer circumferential surface 27 of the transmission roller 26. The outer circumferential surface 27 of the roller 26 is brought into contact with the transmission surfaces 17 and 24 of the input and output shafts 18 and 25 by a second pressing force f applied to the roller 26 downward as viewed in FIG. 4 by the springs 32. The positional relationship between the input shaft 18 and the output shaft 25 is adjusted in such a manner that when the input shaft 18 and the output shaft 25 are moved apart from each other against the pressing force F of the springs 29 and 30 as shown in FIG. 5, the movements of the bearings 29 and 30 as shown in FIG. 5, the movements of the bearings 14 and 15 are limited by unillustrated guides provided in the frame 16 so that the range of the distance S between the transmission surfaces 17 and 24 is very small in comparison with the predetermined outer diameter D R of the roller 26. That is, such a relationship as defined by an equation (1) shown below is established between the outer diameter D R of the roller 26 and the limited distance S between the transmission surfaces 17 and 18. Accordingly, if the outer diameters of the cylindrical bodies 11 and 19 constituting the input and output shafts 18 and 25 are D i and D o , respectively, and if the distance between the center axes of the input and output shafts 18 and 25 when the same are spaced apart from each other is O 1 -O 2 , a relationship defined by an equation (2) shown below is established. The pressing force F, of course, acts in such directions as to always reduce the distance S.
S<<D.sub.R (1)
1/2(D.sub.i +D.sub.o)≦O.sub.1 -O.sub.2
<<1/2(D.sub.i +D.sub.o)+D.sub.R (2)
The pressing force f by which the springs 32 press the roller 26 is smaller than the pressing force F of the springs 29 and 30 so that when the input shaft 18 and the output shaft 25 are not rotated, the transmission roller 26 is maintained in a state where the transmission roller 26 is retreated upward by the input and output shafts 18 and 25, as shown in FIG. 4, and that in this state the outer circumferential surface 27 lightly contacts the transmission surfaces 17 and 24 of the input and output shafts 18 and 25. In this embodiment, both the pressing forces F and f are produced by the resiliency of the springs, but means for producing the pressing forces F and f may be any other pressing or urging means which uses a different type of resilient member or a means for applying magnetic forces in a case where the cylindrical bodies 11 and 19 constituting the input and output shafts 18 and 25 and the cylindrical body 28 constituting the transmission roller 26 are formed of a steel material. The outer diameter D R of the transmission roller 26 is not larger than 1/10 of each of the outer diameters D i and D o of the input and output shafts 18 and 25. It is not always necessary to apply the pressing force F from the side of the input shaft 18 alone; the pressing force F may be applied from the side of the output shaft 25 or from the two sides of the input and output shafts 18 and 25. Balls 33 having a small diameter are rotatably attached to the extreme end of the metallic retaining member 31 to be brought into contact with the roller 26, thereby enabling the transmission roller 26 to rotate smoothly. Each of the cylindrical bodies 11, 19, and 28 is formed of a material having a large stiffness and a large surface friction coefficient; it may be formed of one material selected from metallic materials including the above-mentioned steel material, ceramics, plastics, and the like or may be formed of a mixture or combination of these materials selected to utilize the characteristics of each material.
In this embodiment, the arrangement may alternatively be such that the output shaft 25 constituted by the cylindrical body 11 is rotatable in each of the normal and reverse directions while the input shaft 18 constituted by the cylindrical body 19 is rotated in the fixed direction.
Next, the operation of this embodiment will be described below. It is assumed here that rotation of the input shaft 18 with which the point on the input shaft 18 indicated by the contact line L approaches the transmission roller 26 as shown in FIG. 4, i.e., clockwise rotation indicated by the arrow M in FIG. 4 is normal rotation, and that rotation of the input shaft with which the point of the input shaft 18 indicated by the contact line L moves away from the transmission roller 26 as shown in FIG. 5, i.e., counterclockwise rotation indicated by the arrow N in FIG. 5 is reverse rotation.
In a case where the input shaft 18 is rotated in the normal direction as shown in FIG. 4 to transmit the torque to the output shaft 25, the transmission roller 26 in contact with the transmission surface 17 of the input shaft 18 is forced upward against the pressing force f with the rotation of the input shaft 18 because the pressing force f of the springs 32 is small. Simultaneously, the input shaft 18 is pressed against the output shaft 25 by the pressing force F, and transmission surfaces 17 and 24 contact each other, and the rotation of the input shaft 18 is transmitted to the output shaft 25 by the effect of the friction between the transmission surfaces 17 and 18. The output shaft 25 thereby rotates opposite to the rotation of the input shaft 18, as indicated by the arrow P in FIG. 4. In a case where the input shaft 18 is rotated in the reverse direction as shown in FIG. 5 to transmit the rotation to the output shaft 25, the transmission roller 26 is rolled in between the input and output shafts 18 and 25 by the force of friction with the input shaft 18 and by the pressing force f as the input shaft 18 rotates, thereby being inserted in the gap between the transmission surfaces 17 and 24 of the input and output shafts 18 and 25. Simultaneously, the input and output shafts 18 and 25 are spaced apart from each other against the pressing force F. At this time, the distance between the transmission surfaces 17 and 24 is limited by the guides of the bearings 14 and 15, and its maximum value is S expressed by the equation (1). The contact between the input and output shafts 18 and 25 is shut off, and the rotation of the input shaft 18 is transmitted to the output shaft 25 through the transmission roller 26. The reverse rotation of the input shaft 18 indicated by the arrow N is therefore reversed by the roller 26, and the output shaft 25 rotates in the direction indicated by the arrow P, i.e., in same direction as in the case of the normal rotation of the input shaft 18. At this time, as expressed by the equation (1), S is extremely small in comparison with D R , and there is therefore no possibility of the transmission roller 26 being further wrapped in and moving beyond the line O 1 -O 2 connecting the centers of the input and output shafts 18 and 25 to come off from these shafts. The output shaft 25 to which the torque of the input shaft 1 is transmitted can be rotated in the fixed direction as indicated by the arrow P in FIGS. 4 and 5 irrespective of the normal/reverse rotation of the input shaft 18, as described above.
In this embodiment, as described above, the input and output shafts 18 and 25 having the transmission surfaces 17 and 18 capable of contacting each other by the pressing force F and the roller 26 contacting the input and output shafts 18 and 25 by the pressing force f are disposed, and the input shaft 18 is brought into contact with the output shaft 25 to directly transmit the torque of the input shaft 18 to the output shaft 25 when the input shaft 18 is rotated in the normal direction, or the torque of the input shaft 18 is transmitted to the output shaft 25 through the transmission roller 26 while being reversed when the input shaft 18 is rotated in the reverse direction. Thus, it is possible to constantly maintain the direction in which the output shaft 25 rotates without artificially changing over a complicate changeover mechanism such as that required by the related art. The transmission mechanism is therefore simplified in structure and reduced in production cost. Moreover, because the rotation is transmitted by the friction between the input shaft 18, the output shaft 25 and the transmission roller 26, the problem of unevenness of rotation owing to backlashes of rotation transmitting gears can be eliminated and the rotation can be transmitted always smoothly.
As mentioned above, it is preferable to set the outer diameter D R of the roller 26 to 1/10 or less of the outer diameters D i and D o of the input and output shafts 18 and 25. If D R is larger than this value, the roller 26 is not suitably rolled in when the input shaft 18 is rotated in the reverse direction. It is also preferable to limit the force f of pressing the roller 26 to a magnitude enough to prevent the roller 26 from moving apart from the input and output shafts 18 and 25. If the pressing force f is excessively large, the force F of pressing the input shaft 18 against the output shaft 25 is apparently reduced and the frictional force produced between the transmission surfaces 17 and 24 of the input and output shafts 18 and 25 during normal rotation of the input shaft 18 becomes insufficient, resulting in failure to transmit the rotation. The pressing force must be large enough to produce sufficient frictional force between the transmission surfaces 17 and 24 of the input and output shafts 18 and 25 during normal rotation of the input shaft 18. If this force makes it difficult to move apart the input and output shafts 18 and 25, the outer diameter D R may be reduced to facilitate wrapping-in of the transmission roller 26 or the friction coefficients of the transmission surfaces 17 and 24 of the input and output shafts 18 and 25 and the outer circumferential surface 27 of the transmission roller 26 may be increased.
If in this embodiment the output shaft 25 constituted by the cylindrical body 19 is rotatable in the normal and reverse directions while the input shaft 18 constituted by the cylindrical body 11 is rotated in the fixed direction, an output of normal/reverse rotation can be obtained from an input rotating in the fixed direction.
FIG. 6 shows a rotation transmitting mechanism which represents a second embodiment of the first invention. In this embodiment, as shown in FIG. 6, the input shaft 18 is rotatable on the axis X 1 -X 2 , and is constituted by a cut cylindrical body 42 having a transmission surface 41 defined on its radial peripheral portion and having a cross-sectional shape of a partially cut circle. The transmission surface of the input shaft 18 is brought into contact with the transmission surface 24 of the output shaft 25 on the contact line L. Except for this portion, the construction and functions of this embodiment are similar to those of the first embodiment, and this embodiment therefore has the same effects as the first embodiment. In this embodiment, the construction of the cut cylindrical body 42 is not limited to the input shaft 18, and the same construction may be alternatively applied to the output shaft 25 alone or to both the input and output shafts 18 and 25.
In the second embodiment, the cylindrical body 24 may constitute the input shaft rotating in the fixed direction while the cut cylindrical body 42 constitutes the output shaft rotatable in the normal and reverse directions. An output of normal or reverse rotation is thereby obtained from an input rotating in the fixed direction.
FIG. 7 shows a rotation transmitting mechanism which represents a third embodiment of the first invention. In this embodiment, as shown in FIG. 7, the transmission roller 26 is constituted by a plurality of balls 52 with outer peripheral surfaces 51 having an outer diameter D B . The balls 52 are respectively supported by a metallic retaining member 31 such as that shown in FIG. 4. The balls 52 are rotatable about their respective centers while receiving the second pressing force f from the second springs 32 and contacting at the outer peripheral surfaces 51 the transmission surfaces 17 and 24 of the input and output shafts 18 and 25. The outer diameter of each ball 52 is equal to the outer diameter D R of the cylindrical body 28 constituting the transmission roller 26 of the first embodiment and therefore satisfies the conditions expressed by the equations (1) and (2). Except for the balls, the construction and functions of this embodiment are similar to those of the first embodiment, and this embodiment therefore has the same effects as the first embodiment. Needless to say, the roller 26 of this embodiment can be used in the second embodiment.
Next, rotation transmitting mechanisms according to the second invention will be described below. FIG. 8 shows a rotation transmitting mechanism which represents an embodiment of the second invention. FIG. 8 is a schematic diagram taken in the same direction as in FIG. 4 showing the first embodiment of the first invention. In this embodiment, as shown in FIG. 8, the input shaft 18 is constituted by a flat plate 61, while the output shaft 25 is constituted by the cylindrical body 19 as in the first embodiment provided in the first invention. The flat plate 61 has a flat transmission surface 62 which contacts the transmission surface 24 on the contact line L. When the input shaft 18 is moved in a normal direction so that the flat plate 61 moves along the transmission surface 62 and that the point on the flat plate 61 indicated by the contact line L approaches the transmission roller 26, the transmission roller 26 is forced upward against the pressing force f and the transmission surface 62 and the transmission surface 24 are brought into contact with each other by the pressing force F, thereby enabling the movement of the input shaft 18 in the normal direction to be transmitted as rotation to the output shaft 25. When the input shaft 18 is moved in a reverse direction such that the point on the flat plate 61 indicated by the contact line L moves away from the transmission roller 26, the roller 26 is inserted into the gap between the transmission surface 62 and the transmission surface 24 while the input shaft 18 and the output shaft 25 are spaced apart from each other, and the movement of the input shaft 18 is transmitted to the output shaft 25 through the roller 26, thereby rotating the output shaft 25 in the same direction as in the case of the normal movement of the input shaft 18. Thus, the output shaft 25 is rotated always in the fixed direction irrespective of the movement of the input shaft in the normal or reverse direction. Except for these points, the construction and functions of this embodiment are similar to those of the first embodiment provided in the first invention, and this embodiment therefore has the same effects.
In this embodiment, the arrangement may alternatively be such that the output shaft 25 constituted by the cylindrical body 19 is rotatable in the normal and reverse directions while the input shaft 18 constituted by the flat plate 61 is moved in the fixed direction. An output of normal/reverse rotation is thereby obtained from an input moving in the fixed direction.
FIG. 9 shows a rotation transmitting mechanism which represents another embodiment of the second invention. FIG. 9 is a schematic diagram similar to FIG. 8. In this embodiment, as shown in FIG. 9, the input shaft 18 is constituted by the cylindrical body 11 as in the first embodiment of the first invention, while the output shaft 25 is constituted by a flat plate 72 having a flat transmission surface 71. The output shaft 25 is moved always in the fixed direction irrespective of the direction of rotation of the input shaft 18 in the same manner as the embodiment mentioned above. Except for these points, the construction and functions of this embodiment are similar to those of the first embodiment provided in the first invention, and this embodiment therefore has the same effects. The embodiment shown in FIG. 8 exemplifies a case where the input shaft 18 is constituted by a flat plate which corresponds to one of the two components, i.e., the cylindrical body and the flat plate provided in the second invention while the output shaft 25 is constituted by a cylindrical body which corresponds to the other of these two components. The embodiment shown in FIG. 9 exemplifies a case where the input shaft 18 is constituted by a cylindrical body which corresponds to one of the two components while the output shaft 25 is constituted by a flat plate which corresponds to the other of the two components. Needles to say, this embodiment can be applied to the arrangement in which the roller 26 is constituted by a plurality of balls 52 as in the third embodiment provided in the first invention.
In this embodiment, the arrangement may alternatively be such that the output shaft 25 constituted by the flat plate 72 is movable in opposite directions while the input shaft 18 constituted by the cylindrical body 11 is rotated in the fixed direction. Reciprocative output movements in the opposite directions are thereby obtained from an input rotating in the fixed direction.
FIG. 10 is a schematic perspective view of a rotation transmitting mechanism which represents an embodiment of the third invention. In this embodiment, as shown in FIG. 10, the input shaft 18 is constituted by a hollow cylindrical body 81 rotatable on the axis X 1 -X 2 , while the output shaft 25 is constituted by a solid cylindrical body 82 rotatable on the axis X 3 -X 4 . The hollow cylindrical body 81 has a transmission surface 83 formed on its inner radial periphery, and the solid cylindrical body 82 has a transmission surface 84 formed on its outer radial periphery. The solid cylindrical body 82 constituting the output shaft 25 is inserted in the hollow cylindrical body 81 constituting the input shaft 18, and the transmission surfaces 83 and 84 are brought into contact with each other on the contact line L by the first pressing force F. Except for these points the construction and functions of this embodiment are the same as the first embodiment of the first invention, and this embodiment also has the same effects.
In this embodiment, the arrangement may alternatively be such that the output shaft 25 constituted by the solid cylindrical body 82 is rotatable in the normal and reverse directions while the input shaft 18 constituted by the hollow cylindrical body 81 is rotated in the fixed direction. An output of normal/reverse rotation is thereby obtained from an input rotating in the fixed direction.
FIG. 11 is a schematic perspective view of a rotation transmitting mechanism which represents another embodiment of the third invention. In this embodiment, as shown in FIG. 11, the input shaft 18 is constituted by a solid cylindrical body 91 rotatable on the axis X 1 -X 2 , while the output shaft 25 is constituted by a hollow cylindrical body 92 rotatable on the axis X 3 -X 4 . The solid cylindrical body 91 has a transmission surface 93 formed on its outer radial periphery, and the hollow cylindrical body 92 has a transmission surface 94 formed on its inner radial periphery. The solid cylindrical body 91 constituting the input shaft 18 is inserted in the hollow cylindrical body 92 constituting the output shaft 25, and the transmission surfaces 93 and 94 are brought into contact with each other on the contact line L by the first pressing force F. Except for these points the construction and functions of this embodiment are the same as the first embodiment provided in the first invention, and this embodiment, of course, has the same effects.
The embodiment shown in FIG. 10 exemplifies a case where the input shaft 18 is constituted by a hollow cylindrical body which corresponds to one of the two components, i.e., the solid cylindrical body and the hollow cylindrical body provided in the third invention while the output shaft 25 is constituted by a solid cylindrical body which corresponds to the other of these two components. The embodiment shown in FIG. 11 exemplifies a case where the input shaft 18 is constituted by a solid cylindrical body which corresponds to one of the two components while the output shaft 25 is constituted by a hollow cylindrical body which corresponds to the other of the two components. This embodiment can be applied to the arrangement in which the roller 26 is constituted by a plurality of balls 52 as in the case of the third embodiment in the first invention.
In this embodiment, the arrangement may alternatively be such that the output shaft 25 constituted by the hollow cylindrical body 92 is rotatable in the normal and reverse directions while the input shaft 18 constituted by the solid cylindrical body 91 is rotated in the fixed direction. An output of normal/reverse rotation is thereby obtained from an input rotating in the fixed direction.
FIGS. 12 to 14 show a rotation transmitting mechanism which represents an embodiment of the fourth invention.
In the rotation transmitting mechanisms provided in the first to third inventions, the distance between the axes of the input and output shafts is slightly changed when the direction of rotation of the input shaft is changed over. The present fourth invention further aims to constantly maintain the distance between the axes of the input and output shafts for the purpose of eliminating restrictions of use, and also to cancel side force applied to the bearings when the input and output shafts are spaced apart from each other.
Referring to FIG. 12, a hollow cylindrical output shaft 101 has a cylindrical transmission surface on its inner radial periphery and is integrally connected to a support shaft 103 through a flange 102 at its right end as viewed in FIG. 12. The output shaft 101 is coaxial with the support shaft 103. The support shaft 103 connected to the output shaft 101 is axially supported by a bearing 105 on one of a pair of side frames 104b and 104c provided on a base 104a, i.e., on the side frame 104b on the right hand side as viewed in FIG. 12. The output shaft 101 is rotatable on an axis X 1 -X 2 . The base 104a and the side frames 104b and 104c constitute a frame 107 of the rotation transmitting mechanism 106 in accordance with this embodiment. A cylindrical input shaft 108 is disposed coaxially with the output shaft 101 and is rotatable on the axis X 1 -X 2 . The input shaft 108 is axially supported on the other of the pair of side frames 104b and 104c on the frame 107, i.e., the side frame 104c through a bearing 109 at its left end as viewed in FIG. 12. The other end of the input shaft 108 is
inserted in the output shaft 101 so as to face the inner circumferential surface of the output shaft 101. The input shaft 108 has a cylindrical transmission surface 108a formed on its outer radial periphery so as to face the transmission surface 101a of the output shaft 101. As shown in FIG. 13, in accordance with this embodiment, a plurality of, i.e., three cylindrical driven shafts 110, 111, and 112 are disposed between the output shaft 101 and the input shaft 108. The driven shafts 110, 111, and 112 have cylindrical transmission surfaces 110a, 111a, and 112a on their outer radial peripheries, and these transmission surfaces are in contact with the transmission surface 101a of the output shaft 101. Stationary retainers 113, 114, and 115 are disposed between the output shaft 101 and the input shaft 108 so as to be successively interposed between two of the driven shafts 110, 111, and 112, and are fixed to the side frame 104c on the frame 107. The number of these retainers is equal to the number of the driven shafts 110, 111, and 112. The stationary retainers 113, 114, and 115 have circular-arc concave slide surfaces 113a, 113b, 114a, 114b, 115a, and 115b which are slidable on the transmission surfaces 110a, 111a, and 112a of the driven shafts 110, 111, and 112. The driven shafts 110, 11, and 112 are equally spaced apart from each other in the circumferential direction of the transmission surface 101a of the output shaft by the stationary retainers 113, 114, and 115, and are supported by the slide surfaces 113a, 113b, 114a, 114b, 115a, and 115b so as to be rotatable on axes parallel to the axis X 1 -X 2 . The diameter of the circle defined by the circular-arc sectional shape of each of the slide surfaces 113a, 113b, 114a, 114b, 115a and 115b of the slide stationary retainers 113, 114, and 115 is slightly larger than the diameter of each of the driven shafts 110, 11, and 112, thereby enabling the driven shafts 110, 111, and 112 to slightly move in the radial direction. Gaps are formed between the transmission surface 101a of the output shaft 101 and the outer peripheral surfaces of the stationary retainers 113, 114, and 115 extending along the transmission surface 101a, thereby rendering the output shaft 101 easily rotatable.
As shown in FIG. 13, transmission rollers 116, 117, and 118 are disposed between the input shaft 108 and each of the driven shafts 110, 111, and 112. The number of the transmission rollers 116, 117, and 118 is equal to the number of the driven shafts 110, 111, and 112, and the construction relating to each transmission roller is similar to that of the transmission roller 26 shown in FIG. 4 and described in connection with the first embodiment provided in the first invention or to that of the transmission roller 26 shown in FIG. 7 and described in connection with the third embodiment. The construction of members for applying the second pressing force F to each of the transmission rollers 116, 117, and 118 is similar to that of the metal retaining member 31, the second springs 32 and the balls 33 which are shown in FIG. 4. The corresponding members of this embodiment shown in FIG. 13 are indicated by the same reference characters and the description for the functions of the corresponding members will not be repeated. Each of recesses 113c, 114c, and 115c formed in the stationary retainers 113, 114, and 115 has the same function as the sub-frame 16a shown in FIG. 4.
In the thus-constructed rotation transmitting mechanism 106, the transmission surfaces 110a, 111a, and 112a of the driven shafts 110, 111, and 112 are respectively in contact with the transmission surface 101a of the output shaft 101 as mentioned above, and are brought into contact with the transmission surface 108a of the input shaft 108 by the first pressing force F applied in the radial direction by the resiliency of the output shaft 101 which resiliency acts in the circumferential direction. The driven shafts 110, 111, and 112 contact the input shaft 108 on contact lines L formed on the transmission surface 108a. When the input shaft 18 if rotated in the normal direction, i.e., in the clockwise direction so that points on the input shaft 108 indicated by the contact lines L respectively approach the transmission rollers 116, 117, and 118, or when the input shaft 18 is rotated in a reverse direction, i.e., in the counterclockwise direction so that points on the input shaft 108 indicated by the contact lines L respectively move away from the transmission rollers 116, 117, and 118, the input shaft 108, the driven shafts 110, 111, and 112 and the transmission rollers 116, 117, and 118 operate in the same manner as the input and output shafts 18 and 25 and the transmission roller 26 shown in FIGS. 4 and 5 and described with respect to the first embodiment provided in the first invention. The driven shafts 110, 111, and 112 therefore rotate in the fixed direction, i.e., in a counterclockwise direction as viewed in FIG. 13 irrespective of the normal/reverse rotation of the input shaft 108, as in the case of the output shaft 25 mentioned previously. The output shaft 101 thereby rotates in the fixed direction with the rotation of the driven shafts 110, 111, and 112 whose transmission surfaces 110a, 111a, and 112a are in contact with the transmission surface 101a. Thus, the output shaft 101 can be rotated in the fixed direction irrespective of the direction of rotation of the input shaft 108. When the driven shafts 110, 111, and 112 are spaced apart from the input shaft 108 against the pressing force F produced by the elastic deformation of the output shaft 101, the distance S between each of the transmission surface 110a, 111a, and 112a and the input shaft 108 is extremely small in comparison with the outer diameter D R of the transmission rollers 116, 117, and 118, as in the case of the first embodiment provided in the first invention. Needless to say, if the diameter of the input shaft 108 is D i , the diameter of each of the driven shafts 110, 111, and 112 is D o , and the distance between the center axes of the input shaft 108 and each of the driven shafts 110, 111, and 112 when the same are spaced apart from each other is O 1 -O 2 , the equations (1) and (2) are satisfied.
In this embodiment, the input shaft 108 and the output shaft 101 are coaxially disposed on the axis X 1 -X 2 , and the distance between the input shaft 108 and each of the driven shafts 110, 111 and 112 is changed in a radial direction of the input shaft 108 and the output shaft 101 when the transmission rollers 116, 117, and 118 are inserted into the gaps between the input shaft 108 and each of the driven shafts 110, 111, and 112 while the input shaft 108 is rotated counterclockwise. At this time, the output shaft 101 deforms in the circumferential direction of the output shaft 101 alone, the distance between the output shaft 101 and the input shaft 108 is therefore constantly maintained. It is therefore possible to eliminate restrictions which may be imposed on the use of the rotation which may be imposed on the use of the rotation transmitting mechanism 106 if this distance is changed. Moreover, side forces produced when the input shaft 108 and the driven shafts 110, 111, and 112 are spaced apart from each other, i.e., the reaction forces against the first pressing force F are distributed radially and balanced with each other. No side force is therefore applied to the bearing 105 or 109, the rotation can be smoothly transmitted at an improved efficiency, and errors in the rotations of the input and output shafts can be eliminated, thus improving the reliability of the rotation transmitting mechanism.
FIG. 14 shows another embodiment of the output shaft 101 which is arranged to avoid the reduction in its durability caused by the fact that when the input shaft 108 is rotated counterclockwise as viewed in FIG. 13, i.e., in the reverse direction, the transmission rollers 116, 117, and 118 are inserted into the gaps between the input shaft 108 and each of the driven shafts 110, 111, and 112, the output shaft 101 deformed by the pressing force of the driven shafts 110, 111, and 112 so as to have a cross-sectional shape of a rounded triangle. That is, as shown in FIG. 14, the output shaft 101 has a double layer structure consisting of a rigid layer 101b formed as an outer cylindrical layer 101c having a smaller thickness and fitted to the inner circumferential surface of the rigid layer 101b. The rigid layer 101b is formed of a material having a large rigidity, e.g., a metal, a ceramic or a hard plastic, and the elastic layer 101c is formed of a material having high elasticity, e.g., a rubber, an elastic plastic or leather. The elastic layer 101c absorbs the above-mentioned radial movements of the driven shafts 110, 111, and 112 by deforming itself to prevent deformation of the rigid layer 101b. Needless to say, the extent of deformation of the elastic layer 101c is set so as to satisfy the equations (1) and (2). Also, the efficiency of the rotation transmission can be improved because the driven shafts 110, 111, and 112 contact the output shaft 101 through the elastic layer 101c.
In this embodiment, the input shaft 108 having the transmission surface 108a, and the three driven shafts 110, 111, and 112 having the transmission surfaces 110a, 111a, and 112a having the transmission surfaces 110a, 111a, and 112a brought into contact with the transmission surface 108a by the first pressing force F based on the resiliency of the output shaft 101 are provided along with the transmission rollers 116, 117, and 118 contacting the input shaft 108 and each of the driven shafts 110, 111, and 112 by the second pressing force F. When the input shaft 108 is rotated in the normal direction, the rotation is directly transmitted to the driven shafts 110, 111, and 112. When the input shaft 108 is rotated in the reverse direction, the rotation is transmitted to the driven rollers 110, 111, and 112 through the transmission rollers 116, 117, and 118. The output shaft 101 is rotated through the driven shafts 110, 111, and 112, and it therefore rotates always in the fixed direction irrespective of the direction of rotation of the input shaft 108. Thus, this embodiment has the same effects as the embodiments provided in the first to third inventions. Further, the input shaft 108 and the output shaft 101 are disposed coaxially with each other, and the side forces and the change in the distance between the input shaft 108 and each of the driven shafts 110, 111, and 112 produced when the transmission rollers 116, 117, and 118 are respectively inserted into the gaps between the input shaft 108 and each of the driven shafts 110, 111, and 112 are therefore distributed in radial directions and absorbed. The distance between the input shaft 108 and the output shaft 101 is thereby constantly maintained, thereby eliminating restrictions of the use of the rotation transmitting mechanism 106 and improving the rotation efficiency and the reliability of the rotation transmitting mechanism 106.
In this embodiment, the three driven shafts and the corresponding three transmission rollers are provided. However, the number of driven shafts or transmission rollers is not limited to this and may alternatively be two or four or more. It is also possible to replace the output shaft 101 and the input shaft 108 with each other, that is, the output shaft 101 may be used as an input shaft while the input shaft 108 is used as an output shaft. To change the fixed direction of rotation of output shaft 101, the positions of the transmission rollers 116, 117, and 118 may be shifted symmetrically with respect to the lines connecting the center O 1 of the input shaft 108 and the centers O 2 of the driven shafts 110, 111, and 112. In this embodiment, as shown in FIG. 12, the support shaft 103 of the output shaft 101 and the input shaft 108 are placed in opposite positions with respect to the flange 102 of the output shaft 101. However, the input shaft 108 and the output shafts 101 may be disposed coaxially to extend the same direction such a manner that the input shaft 108 is loosely fitted in a through hole 119 penetrating the flange 102 and the support shaft 103 along the axis X 1 -X 2 , as indicated by the double-dot-dash line in FIG. 12.
In this embodiment, the arrangement may alternatively such that the output shaft 101 is rotatable in the normal and reverse directions while the cylindrical input shaft 108 is rotated in the fixed direction, thereby obtaining an output of normal/reverse rotation from an input rotating in the fixed direction.
Many widely different embodiments of the present inventions may be constructed without departing from the spirit and scope of the present inventions. It should be understood that the present inventions are not limited to the specific embodiments described in the specification, except as defined in the appended claims. | A rotation transmitting mechanism includes a first cylindrical body, a second cylindrical body arranged parallel to the first cylindrical body, a rotary body disposed parallel to the first cylindrical body, and circumscribed with the first and second cylindrical body, a pressing unit for pressing one of the first and second cylindrical bodies against the other of the first and second cylindrical bodies so as to make the first and second cylindrical bodies contact each other, and a moving unit for moving the rotary body toward a point where the first cylindrical body contacts the second cylindrical body so as to inhibit contact of the first cylindrical body with the second cylindrical body, and to contact the rotary body with the first and second cylindrical bodies, and for retreating the rotary body in a direction opposite to the aforementioned point so as to permit contact of the first cylindrical body with the second cylindrical body, which contact is caused by the pressing unit. The rotation transmitting mechanism can smoothly transmit rotation because transmission of rotation is performed by frictional force. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to liquid containers having a drip prevention feature and more particularly to drinking containers, such as cups, and associated dishes, such as saucers, having this feature.
The common beverage containers, such as pitchers, coffee cups, or water glasses, are intended to receive and hold liquid within the vessel. However, there are times when, due to spilling or condensation, liquid is present on the exterior surfaces of the container. When this occurs, it is common for the liquid to collect on the bottom of the container. The accumulation of the liquid on the bottom of the container often results in the liquid dripping onto the user or his/her apparel during drinking or pouring. The present invention is designed to prevent this dripping of liquid found on the exterior of a liquid container.
SUMMARY OF THE INVENTION
The present invention provides a liquid receptacle apparatus comprising a drinking vessel or container and a receiver, such as a saucer. The saucer has a generally flat surface on which the container rests. The saucer is typically provided with a lip to define a container-receiving area. The container has a liquid-receiving body with a flange provided at the bottom of the body adapted to fit on the container-receiving area of the saucer. A series of indentations is provided in the flange, with each indentation extending above the top of the lip on the saucer. The indentations prevent dripping during drinking or pouring by retaining the liquid present on the exterior of the container when the container is lifted and tilted.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of the drinking apparatus of the present invention, showing a cross-section of a receiver in the form of a saucer;
FIG. 2 is a plan view along line 2--2 of FIG. 1, showing the bottom of the container;
FIG. 3 is an enlarged partial cross-section view of a portion of the container and saucer shown in FIG. 1;
FIG. 4 is an enlarged detail plan view of the bottom flange of the container of FIG. 1; and
FIG. 5 is an enlarged elevational view of a portion of the container of FIG. 1, in which the container is tilted at an angle suitable for consumption of the contents.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a liquid receptacle apparatus 2 comprises a beverage vessel or container, such as coffee cup 4, and saucer 6. Saucer 6 is of conventional construction, presenting a concave surface 8. Concave surface 8 has an upstanding circular lip 10, to define a generally flat container-receiving area 11.
Cup 4 has a liquid-receiving body 12, with attached handle 14. Cup 4 is constructed of any suitable material, such as ceramic or glass.
Liquid-receiving body 12 of cup 4 is provided at its bottom, with circular flange 16, as shown in FIG. 2. Flange 16 is shaped so as to fit within container-receiving area 11 defined by lip 10. A series of indentations 18 is provided in flange 16. Indentations 18 are spaced around the circumference of flange 16. Indentations 18 are arcuate in cross-section, and the topmost point of the arc of each indentation 18 extends above the top of lip 10 when cup 4 is placed within container-receiving area 11.
In operation, the apparatus of the present invention works as follows. Liquid which is present on the exterior surface of cup 4, such as condensate or spillage, eventually collects in container-receiving area 11 of saucer 6. When the user lifts cup 4 off saucer 6, the liquid present in container-receiving area 11 tends to adhere to flange 16 of cup 4. Indentations 18 serve to reduce the surface area on the interior and exterior sides of flange 16 to which the liquid can adhere. Thus, the areas of flange 16 between indentations 18 tend to shed the liquid present within container-receiving area 11 when cup 4 is lifted from saucer 6. However, it is inevitable that a certain amount of liquid adheres to flange 16. The liquid which does so adhere to flange 16, and which presents a potential for dripping, is drawn into indentations 18, as shown in FIG. 5. When cup 4 is lifted and tilted to an angle suitable for emptying the contents, the liquid found in indentations 18 tends to remain there. It appears that the surface tension formed by the drops of liquid located within indentations 18, such as that shown at 19, is sufficient to overcome the forces which tend to make the liquid drip from cup 4. Thus, during a normal drinking sequence, liquid which is present within container-receiving area 11 is either shed by the areas of flange 16 between indentations 18 so as to remain on the saucer, or is retained within indentations 18 by surface tension as cup 4 is lifted, so that no dripping from the cup occurs.
The liquid-shedding and retention properties of flange 16, as modified by indentations 18, are optimal when the topmost portion of the arc of indentations 18 is at a higher elevation than the top of lip 10 in view of the venting so provided, the amount of liquid contacting flange 16 and the amount of surface tension required to retain liquid within indentations 18 during use. Further, it appears that the areas of flange 16 between indentations 18 are best able to shed liquid when the liquid is at a lower elevation than the top of the indentations 18.
Referring to FIG. 4, the following dimensions for indentations 18 have been found to be preferred. Dimension "a", the width of each indentation, is approximately 1/4 inch. Dimension "b", the outer peripheral dimension of flange 16, is approximately 1/16 inch, and dimension "c", the inner circumferential dimension of flange 16, is approximately 1/32 inch. Further, it has been found that the depth of each indentation 18 should be approximately 1/8 inch, which is sufficient to place the topmost point of each indentation at a higher elevation than lip 10 of saucer 6 and thus above the level of the liquid within container-receiving area 11.
While the present invention has been exemplarily described with reference to a cup and saucer, it will be appreciated that the present invention may also be employed with other containers, such as glasses or pitchers, and with coasters or even table tops.
Various modes for carrying out the invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention. | An apparatus for providing dripless consumption of a consumable liquid includes a preferably concave saucer and a container having a liquid-receiving body with a flange provided at its bottom. The flange has a series of indentations formed therein that act to retain liquid during the drinking sequence, and prevent liquid found on the exterior of the container from dripping onto the user. | 0 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to prodrugs of a class of sulfonamides which are aspartyl protease inhibitors. In one embodiment, this invention relates to a novel class of prodrugs of HIV aspartyl protease inhibitors characterized by favorable aqueous solubility, high oral bioavailability and facile in vivo generation of the active ingredient. This invention also relates to pharmaceutical compositions comprising these prodrugs. The prodrugs and pharmaceutical compositions of this invention are particularly well suited for decreasing the pill burden and increasing patient compliance. This invention also relates to methods of treating mammals with these prodrugs and pharmaceutical compositions.
BACKGROUND OF THE INVENTION
[0002] Aspartyl protease inhibitors are considered the most effective current drug in the fight against HIV infection. These inhibitors, however, require certain physicochemical properties in order to achieve good potency against the enzyme. One of these properties is high hydrophobicity. Unfortunately, this property results in poor aqueous solubility and low oral bioavailability.
[0003] U.S. Pat. No. 5,585,397 describes a class of sulfonamide compounds that are inhibitors of the aspartyl protease enzyme. These compounds illustrate the drawbacks concomitant to pharmaceutical compositions comprising hydrophobic aspartyl protease inhibitors. For example, VX-478 (4-amino-N-((2-syn,3S)-2-hydroxy-4-phenyl-2((S)-tetrahydrofuran-3-yl-oxycarbonylamino)-butyl-N-isobutyl-benzenesulfonamide) is an aspartyl protease inhibitor disclosed in the '397 patent. It has a relatively low aqueous solubility. While the oral bioavailability of this inhibitor in a “solution” formulation is excellent, the dosage of VX-478 in this form is severely limited by the amount of liquid present in the particular liquid dosage from, e.g., encapsulated into a soft gelatin capsule. A higher aqueous solubility would increase drug load per unit dosage of VX-478.
[0004] Currently, the solution formulation of VX-478 produces an upper limit of 150 mg of VX-478 in each capsule. Given a therapeutic dose of 2400 mg/day of VX-478, this formulation would require a patient to consume 16 capsules per day. Such a high pill burden would likely result in poor patient compliance, thus producing sub-optimal therapeutic benefit of the drug. The high pill burden is also a deterrent to increasing the amount of the drug administered per day to a patient. Another drawback of the pill burden and the concomitant patient compliance problem is in the treatment of children infected with HIV.
[0005] Furthermore, these “solution” formulations, such as the mesylate formulation, are at a saturation solubility of VX-478. This creates the real potential of having the drug crystallize out of solution under various storage and/or shipping conditions. This, in turn, would likely result in a loss of some of the oral bioavailability achieved with VX-478.
[0006] One way of overcoming these problems is to develop a standard solid dosage form, such as a tablet or a capsule or a suspension form. Unfortunately, such solid dosage forms have much lower oral bioavailability of the drug.
[0007] Thus, there is a need to improve the drug load per unit dosage form for aspartyl protease inhibitors. Such an improved dosage form would reduce the pill burden and increase patient compliance. It would also provide for the possibility of increasing the amounts of the drug administered per day to a patient.
SUMMARY OF THE INVENTION
[0008] The present invention provides novel prodrugs of a class of sulfonamide compounds that are inhibitors of aspartyl protease, in particular, HIV aspartyl protease. These prodrugs are characterized by excellent aqueous solubility, increased bioavailability and are readily metabolized into the active inhibitors in vivo. The present invention also provides pharmaceutical compositions comprising these prodrugs and methods of treating HIV infection in mammals using these prodrugs and the pharmaceutical compositions thereof.
[0009] These prodrugs can be used alone or in combination with other therapeutic or prophylactic agents, such as anti-virals, antibiotics, immunomodulators or vaccines, for the treatment or prophylaxis of viral infection.
[0010] It is a principal object of this invention to provide a novel class of prodrugs of sulfonamide compounds that are aspartyl protease inhibitors, and particularly, HIV aspartyl protease inhibitors. This novel class of sulfonamides is represented by formula I:
[0000]
[0000] wherein:
[0011] A is selected from H; Ht; —R 1 —Ht; —R 1 —C 1 -C 6 alkyl, which is optionally substituted with one or more groups independently selected from hydroxy, C 1 -C 4 alkoxy, Ht, —O-Ht, —NR 2 —CO—N(R 2 ) 2 or —CO—N(R 2 ) 2 ; —R 1 —C 2 -C 6 alkenyl, which is optionally substituted with one or more groups independently selected from hydroxy, C 1 -C 4 alkoxy, Ht, —O-Ht, —NR 2 —CO—N(R 2 ) 2 or —CO—N(R 2 ) 2 ; or R 7 ;
[0012] each R 1 is independently selected from —C(O)—, —S(O) 2 —, —C(O)—C(O)—, —O—C(O)—, —O—S(O) 2 , —NR 2 —S(O) 2 —, —NR 2 —C(O)— or —NR 2 —C(O)—C(O)—;
[0013] each Ht is independently selected from C 3 -C 7 cycloalkyl; C 5 -C 7 cycloalkenyl; C 6 -C 10 aryl; or a 5-7 membered saturated or unsaturated heterocycle, containing one or more heteroatoms selected from N, N(R 2 ), O, S and S(O) n ; wherein said aryl or said heterocycle is optionally fused to Q; and wherein any member of said Ht is optionally substituted with one or more substituents independently selected from oxo, —OR 2 , SR 2 , —R 2 , —N(R 2 )(R 2 ), —R 2 —OH, —CN, —CO 2 R 2 , —C(O)—N(R 2 ) 2 , —S(O) 2 —N(R 2 ) 2 , —N(R 2 )—C(O)—R 2 , —C(O)—R 2 , —S(O) n —R 2 , —OCF 3 , —S(O) n -Q, methylenedioxy, —N(R 2 )—S(O) 2 (R 2 ), halo, —CF 3 , —NO 2 , Q, —OQ, —OR 7 , —SR 7 , —R 7 , —N(R 2 )(R 7 ) or —N(R 7 ) 2 ;
[0014] each R 2 is independently selected from H, or C 1 -C 4 alkyl optionally substituted with Q;
[0015] B, when present, is —N(R 2 )—C(R 3 ) 2 —C(O)—;
[0016] each x is independently 0 or 1;
[0017] each R 3 is independently selected from H, Ht, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 3 -C 6 cycloalkyl or C 5 -C 6 cycloalkenyl; wherein any member of said R 3 , except H, is optionally substituted with one or more substituents selected from —OR 2 , —C(O)—NH—R 2 , —S(O) n —N(R 2 )(R 2 ), Ht, —CN, —SR 2 , —CO 2 R 2 , NR 2 —C(O)—R 2 ;
[0018] each n is independently 1 or 2;
[0019] G, when present, is selected from H, R 7 or C 1 -C 4 alkyl, or, when G is C 1 -C 4 alkyl, G and R′ are bound to one another either directly or through a C 1 -C 3 linker to form a heterocyclic ring; or
[0020] when G is not present (i.e., when x in (G) x is 0), then the nitrogen to which G is attached is bound directly to the R 7 group on —OR 7 ;
[0021] D and D′ are independently selected from Q; C 1 -C 6 alkyl, which is optionally substituted with one or more groups selected from C 3 -C 6 cycloalkyl, —OR 2 , —R 3 , —O-Q or Q; C 2 -C 4 alkenyl, which is optionally substituted with one or more groups selected from C 3 -C 6 cycloalkyl, —OR 2 , —R 3 , —O-Q or Q; C 3 -C 6 cycloalkyl, which is optionally substituted with or fused to Q; or C 5 -C 6 cycloalkenyl, which is optionally substituted with or fused to Q;
[0022] each Q is independently selected from a 3-7 membered saturated, partially saturated or unsaturated carbocyclic ring system; or a 5-7 membered saturated, partially saturated or unsaturated heterocyclic ring containing one or more heteroatoms selected from O, N, S, S(O), or N(R 2 ); wherein Q is optionally substituted with one or more groups selected from oxo, —OR 2 , —R 2 , —N(R 2 ) 2 , —N(R 2 )—C(O)—R 2 , —R 2 —OH, —CN, —CO 2 R 2 , —C(O)—N(R 2 ) 2 , halo or —CF 3 ;
[0023] E is selected from Ht; O-Ht; Ht-Ht; —O—R 3 ; —N(R 2 )(R 3 ); C 1 -C 6 alkyl, which is optionally substituted with one or more groups selected from R 4 or Ht; C 2 -C 6 alkenyl, which is optionally substituted with one or more groups selected from R 4 or Hit; C 3 -C 6 saturated carbocycle, which is optionally substituted with one or more groups selected from R 4 or Ht; or C 5 -C 6 unsaturated carbocycle, which is optionally substituted with one or more groups selected from R 4 or Ht;
[0024] each R 4 is independently selected from —OR 2 , —SR 2 , —C(O)—NHR 2 , —S(O) 2 —NHR 2 , halo, —NR 2 —C(O)—R 2 , —N(R 2 ) 2 or —CN;
[0025] each R 7 is independently selected from
[0000]
[0026] wherein each M is independently selected from H, Li, Na, K, Mg, Ca, Ba, —N(R 2 ) 4 , C 1 -C 12 -alkyl, C 2 -C 12 -alkenyl, or —R 6 ; wherein 1 to 4 —CH 2 radicals of the alkyl or alkenyl group, other than the —CH 2 that is bound to Z, is optionally replaced by a heteroatom group selected from O, S, S(O), S(O 2 ), or N(R 2 ); and wherein any hydrogen in said alkyl, alkenyl or R 6 is optionally replaced with a substituent selected from oxo, —OR 2 , —R 2 , N(R 2 ) 2 , N(R 2 ) 3 , R 2 OH, —CN, —CO 2 R 2 , —C(O)—N(R 2 ) 2 , S(O) 2 —N(R 2 ) 2 , N(R 2 )—C(O)—R 2 , C(O)R 2 , —S(O) n —R 2 , OCF 3 , —S(O) n —R 6 , N(R 2 )—S(O) 2 (R 2 ), halo, —CF 3 , or —NO 2 ;
[0027] M′ is H, C 1 -C 12 -alkyl, C 2 -C 12 -alkenyl, or —R 6 ; wherein 1 to 4 —CH 2 radicals of the alkyl or alkenyl group is optionally replaced by a heteroatom group selected from O, S, S(O), S(O 2 ), or N(R 2 ); and wherein any hydrogen in said alkyl, alkenyl or R 6 is optionally replaced with a substituent selected from oxo, —OR 2 , —R 2 , —N(R 2 ) 2 , N(R 2 ) 3 , —R 2 OH, —CN, —CO 2 R 2 , —C(O)—N(R 2 ) 2 , —S(O) 2 —N(R 2 ) 2 , —N(R 2 )—C(O)—R 2 , —C(O)R 2 , —S(O) n —R 2 , —OCF 3 , —S(O) n —R 6 , —N(R 2 )—S(O) 2 (R 2 ), halo, —CF 3 , or —NO 2 ;
[0028] Z is CH 2 , O, S, N(R 2 ) 2 , or, when M is absent, H;
[0029] Y is P or S;
[0030] X is O or S; and
[0031] R 9 is C(R 2 ) 2 , O or N(R 2 ); and wherein when Y is S, Z is not S; and
[0032] R 6 is a 5-6 membered saturated, partially saturated or unsaturated carbocyclic or heterocyclic ring system, or an 8-10 membered saturated, partially saturated or unsaturated bicyclic ring system; wherein any of said heterocyclic ring systems contains one or more heteroatoms selected from O, N, S, S(O) n or N(R 2 ); and wherein any of said ring systems optionally contains 1 to 4 substituents independently selected from OH, C 1 -C 4 alkyl, O—C 1 -C 4 alkyl or OC(O)C 1 -C 4 alkyl.
[0033] It is a also an object of this invention to provide pharmaceutical compositions comprising the sulfonamide prodrugs of formula I and methods for their use as prodrugs of HIV aspartyl protease inhibitors.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In order that the invention herein described may be more fully understood, the following detailed description is set forth. In the description, the following abbreviations are used:
[0000]
Designation
Reagent or Fragment
Ac
acetyl
Me
methyl
Et
ethyl
Bzl
benzyl
Trityl
triphenylmethyl
Asn
D- or L-asparagine
Ile
D- or L-isoleucine
Phe
D- or L-phenylalanine
Val
D- or L-valine
Boc
tert-butoxycarbonyl
Cbz
benzyloxycarbonyl (carbobenzyloxy)
Fmoc
9-fluorenylmethoxycarbonyl
DCC
dicyclohexylcarbodiimide
DIC
diisopropylcarbodiimide
EDC
1-(3-dimethylaminopropyl)-3-
ethylcarbodiimide hydrochloride
HOBt
1-hydroxybenzotriazole
HOSu
1-hydroxysuccinimide
TFA
trifluoroacetic acid
DIEA
diisopropylethylamine
DBU
1,8-diazabicyclo (5.4.0) undec-7-ene
EtOAc
ethyl acetate
[0035] The following terms are employed herein:
[0036] Unless expressly stated to the contrary, the terms “—SO 2 —” and “—S(O) 2 -” as used herein refer to a sulfone or sulfone derivative (i.e., both appended groups linked to the S), and not a sulfinate ester.
[0037] For the compounds of formula I, and intermediates thereof, the stereochemistry of OR 7 is defined relative to D on the adjacent carbon atom, when the molecule is drawn in an extended zig-zag representation (such as that drawn for compounds of formula XI, XV, XXII, XXIII and XXXI). If both OR 7 and D reside on the same side of the plane defined by the extended backbone of the compound, the stereochemistry of OR 7 will be referred to as “syn”. If OR 7 and D reside on opposite sides of that plane, the stereochemistry of OR 7 will be referred to as “anti”.
[0038] The term “aryl”, alone or in combination with any other term, refers to a carbocyclic aromatic radical containing the specified number of carbon atoms.
[0039] The term “heterocyclic” refers to a stable 5-7 membered monocycle or 8-11 membered bicyclic heterocycle which is either saturated or unsaturated, and which may be optionally benzofused if monocyclic. Each heterocycle consists of carbon atoms and from one to four heteroatoms selected from the group consisting of nitrogen, oxygen and sulfur. As used herein, the terms “nitrogen and sulfur heteroatoms” include any oxidized form of nitrogen and sulfur, and the quaternized form of any basic nitrogen. The heterocyclic ring may be attached by any heteroatom of the cycle which results in the creation of a stable structure. Preferred heterocycles defined above include, for example, benzimidazolyl, imidazolyl, imidazolinoyl, imidazolidinyl, quinolyl, isoquinolyl, indolyl, pyridyl, pyrrolyl, pyrrolinyl, pyrazolyl, pyrazinyl, quinoxolyl, piperidinyl, morpholinyl, thiamorpholinyl, furyl, thienyl, triazolyl, thiazolyl, β-carbolinyl, tetrazolyl, thiazolidinyl, benzofuranoyl, thiamorpholinyl sulfone, benzoxazolyl, oxopiperidinyl, oxopyrroldinyl, oxoazepinyl, azepinyl, isoxazolyl, tetrahydropyranyl, tetrahydrofuranyl, thiadiazoyl, benzodioxolyl, thiophenyl, tetrahydrothiophenyl and sulfolanyl.
[0040] The terms “HIV protease” and “HIV aspartyl protease” are used interchangeably and refer to the aspartyl protease encoded by the human immunodeficiency virus type 1 or 2. In a preferred embodiment of this invention, these terms refer to the human immunodeficiency virus type 1 aspartyl protease.
[0041] The term “pharmaceutically effective amount” refers to an amount effective in treating HIV infection in a patient. The term “prophylactically effective amount” refers to an amount effective in preventing HIV infection in a patient. As used herein, the term “patient” refers to a mammal, including a human.
[0042] The term “pharmaceutically acceptable carrier or adjuvant” refers to a non-toxic carrier or adjuvant that may be administered to a patient, together with a compound of this invention, and which does not destroy the pharmacological activity thereof.
[0043] Pharmaceutically acceptable salts of the compounds of this invention include those derived from pharmaceutically acceptable inorganic and organic acids and bases. Examples of suitable acids include hydrochloric, hydrobromic, sulfuric, nitric, perchloric, fumaric, maleic, phosphoric, glycollic, lactic, salicylic, succinic, toluene-p-sulfonic, tartaric, acetic, citric, methanesulfonic, formic, benzoic, malonic, naphthalene-2-sulfonic and benzenesulfonic acids. Other acids, such as oxalic, while not in themselves pharmaceutically acceptable, may be employed in the preparation of salts useful as intermediates in obtaining the compounds of the invention and their pharmaceutically acceptable acid addition salts.
[0044] Salts derived from appropriate bases include alkali metal (e.g., sodium), alkaline earth metal (e.g., magnesium), ammonium and N—(C 1-4 alkyl) 4+ salts.
[0045] The term “thiocarbamates” refers to compounds containing the functional group N—SO 2 —O.
[0046] The compounds of this invention contain one or more asymmetric carbon atoms and thus occur as racemates and racemic mixtures, single enantiomers, diastereomeric mixtures and individual diastereomers. All such isomeric forms of these compounds are expressly included in the present invention. Each stereogenic carbon may be of the R or S configuration. The explicitly shown hydroxyl is also preferred to be syn to D, in the extended zigzag conformation between the nitrogens shown in compounds of formula I.
[0047] Combinations of substituents and variables envisioned by this invention are only those that result in the formation of stable compounds. The term “stable”, as used herein, refers to compounds which possess stability sufficient to allow manufacture and administration to a mammal by methods known in the art. Typically, such compounds are stable at a temperature of 40° C. or less, in the absence of moisture or other chemically reactive conditions, for at least a week.
[0048] The compounds of the present invention may be used in the form of salts derived from inorganic or organic acids. Included among such acid salts, for example, are the following: acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, bisulfate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, fumarate, glucoheptanoate, glycerophosphate, hemisulfate, heptanoate, hexanoate, hydrochloride, hydrobromide, hydroiodide, 2-hydroxy-yethanesulfonate, lactate, maleate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, oxalate, pamoate, pectinate, persulfate, 3-phenylpropionate, picrate, pivalate, propionate, succinate, tartrate, thiocyanate, tosylate and undecanoate.
[0049] This invention also envisions the quaternization of any basic nitrogen-containing groups of the compounds disclosed herein. The basic nitrogen can be quaternized with any agents known to those of ordinary skill in the art including, for example, lower alkyl halides, such as methyl, ethyl, propyl and butyl chloride, bromides and iodides; dialkyl sulfates including dimethyl, diethyl, dibutyl and diamyl sulfates; long chain halides such as decyl, lauryl, myristyl and stearyl chlorides, bromides and iodides; and aralkyl halides including benzyl and phenethyl bromides. Water or oil-soluble or dispersible products may be obtained by such quaternization.
[0050] The novel sulfonamides of this invention are those of formula I:
[0000]
[0000] wherein:
[0051] A is selected from H; Ht; —R 1 —Ht; —R 1 —C 1 -C 6 alkyl, which is optionally substituted with one or more groups independently selected from hydroxy, C 1 -C 4 alkoxy, Ht, —O-Ht, —NR 2 —CO—N(R 2 ) 2 or —CO—N(R 2 ) 2 ; —R 1 —C 2 -C 6 alkenyl, which is optionally substituted with one or more groups independently selected from hydroxy, C 1 -C 4 alkoxy, Ht, —O-Ht, —NR 2 —CO—N(R 2 ) 2 or —CO—N(R 2 ) 2 ; or R 7 ;
[0052] each R 1 is independently selected from —C(O)—, —S(O) 2 —, —C(O)—C(O)—, —O—C(O)—, —O—S(O) 2 , —NR 2 —S(O) 2 —, —NR 2 —C(O)— or —NR 2 —C(O)—C(O)—;
[0053] each Ht is independently selected from C 3 -C 7 cycloalkyl; C 5 -C 7 cycloalkenyl; C 6 -C 10 aryl; or a 5-7 membered saturated or unsaturated heterocycle, containing one or more heteroatoms selected from N, N(R 2 ), O, S and S(O) n ; wherein said aryl or said heterocycle is optionally fused to Q; and wherein any member of said Ht is optionally substituted with one or more substituents independently selected from oxo, —OR 2 , SR 2 , —R 2 , —N(R 2 )(R 2 ), —R 2 —OH, —CN, —CO 2 R 2 , —C(O)—N(R 2 ) 2 , —S(O) 2 —N(R 2 ) 2 , —N(R 2 )—C(O)—R 2 , —C(O)—R 2 , —S(O) n —R 2 , —OCF 3 , —S(O) n -Q, methylenedioxy, —N(R 2 )—S(O) 2 (R 2 ), halo, —CF 3 , —NO 2 , Q, —OQ, —OR 7 , —SR 7 , —R 7 , —N(R 2 )(R 7 ) or —N(R 7 ) 2 ;
[0054] each R 2 is independently selected from H, or C 1 -C 4 alkyl optionally substituted with Q;
[0055] B, when present, is —N(R 2 )—C(R 3 ) 2 —C(O)—;
[0056] each x is independently 0 or 1;
[0057] each R 3 is independently selected from H, Ht, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 3 -C 6 cycloalkyl or C 5 -C 6 cycloalkenyl; wherein any member of said R 3 , except H, is optionally substituted with one or more substituents selected from —OR 2 , —C(O)—NH—R 2 , —S(O), —N(R 2 )(R 2 ), Ht, —CN, —SR 2 , —CO 2 R 2 , NR 2 —C(O)—R 2 ;
[0058] each n is independently 1 or 2;
[0059] G, when present, is selected from H, R 7 or C 1 -C 4 alkyl, or, when G is C 1 -C 4 alkyl, G and R 7 are bound to one another either directly or through a C 1 -C 3 linker to form a heterocyclic ring; or
[0060] when G is not present (i.e., when x in (G) x is 0), then the nitrogen to which G is attached is bound directly to the R 7 group in —OR 7 with the concomitant displacement of one -ZM group from R 7 ;
[0061] D and D′ are independently selected from Q; C 1 -C 6 alkyl, which is optionally substituted with one or more groups selected from C 3 -C 6 cycloalkyl, —OR 2 , —R 3 , —O-Q or Q; C 2 -C 4 alkenyl, which is optionally substituted with one or more groups selected from C 3 -C 6 cycloalkyl, —OR 2 , —R 3 , —O-Q or Q; C 3 -C 6 cycloalkyl, which is optionally substituted with or fused to Q; or C 5 -C 6 cycloalkenyl, which is optionally substituted with or fused to Q;
[0062] each Q is independently selected from a 3-7 membered saturated, partially saturated or unsaturated carbocyclic ring system; or a 5-7 membered saturated, partially saturated or unsaturated heterocyclic ring containing one or more heteroatoms selected from O, N, S, S(O) n or N(R 2 ); wherein Q is optionally substituted with one or more groups selected from oxo, —OR 2 , —R 2 , —N(R 2 ) 2 , —N(R 2 )—C(O)—R 2 , —R 2 —OH, —CN, —CO 2 R 2 , —C(O)—N(R 2 ) 2 , halo or —CF 3 ;
[0063] E is selected from Ht; O-Ht; Ht-Ht; —O—R 3 ; —N(R 2 )(R 3 ); C 1 -C 6 alkyl, which is optionally substituted with one or more groups selected from R 4 or Ht; C 2 -C 6 alkenyl, which is optionally substituted with one or more groups selected from R 4 or Ht; C 3 -C 6 saturated carbocycle, which is optionally substituted with one or more groups selected from R 4 or Ht; or C 5 -C 6 unsaturated carbocycle, which is optionally substituted with one or more groups selected from R 4 or Ht;
[0064] each R 4 is independently selected from —OR 2 , —SR 2 , —C(O)—NHR 2 , —S(O) 2 —NHR 2 , halo, —NR 2 —C(O)—R 2 , —N(R 2 ) 2 or —CN;
[0065] each R 7 is independently selected from
[0000]
[0066] wherein each M is independently selected from H, Li, Na, K, Mg, Ca, Ba, —N(R 2 ) 4 , C 1 -C 12 -alkyl, C 2 -C 12 -alkenyl, or —R 6 ; wherein 1 to 4 —CH 2 radicals of the alkyl or alkenyl group, other than the —CH 2 that is bound to Z, is optionally replaced by a heteroatom group selected from O, S, S(O), S(O 2 ), or N(R 2 ); and wherein any hydrogen in said alkyl, alkenyl or R 6 is optionally replaced with a substituent selected from oxo, —OR 2 , —R 2 , N(R 2 ) 2 , N(R 2 ) 3 , R 2 OH, —CN, —CO 2 R 2 , —C(O)—N(R 2 ) 2 , S(O) 2 —N(R 2 ) 2 , N(R 2 )—C(O)—R 2 , C(O)R 2 , —S(O) n —R 2 , OCF 3 , —S(O) n —R 6 , N(R 2 )—S(O) 2 (R 2 ), halo, —CF 3 , or —NO 2 ;
[0067] M′ is H, C 1 -C 12 -alkyl, C 2 -C 12 -alkenyl, or —R 6 ; wherein 1 to 4 —CH 2 radicals of the alkyl or alkenyl group is optionally replaced by a heteroatom group selected from O, S, S(O), S(O 2 ), or N(R 2 ); and wherein any hydrogen in said alkyl, alkenyl or R 6 is optionally replaced with a substituent selected from oxo, —OR 2 , —R 2 , —N(R 2 ) 2 , N(R 2 ) 3 , —R 2 OH, —CN, —CO 2 R 2 , —C(O)—N(R 2 ) 2 , —S(O) 2 —N(R 2 ) 2 , —N(R 2 )—C(O)—R 2 , —C(O)R 2 , —S(O) n —R 2 , —OCF 3 , —S(O) n —R 6 , —N(R 2 )—S(O) 2 (R 2 ), halo, —CF 3 , or —NO 2 ;
[0068] Z is CH 2 , O, S, N(R 2 ) 2 , or, when M is not present, H.
[0069] Y is P or S;
[0070] X is O or S; and
[0071] R 9 is C(R 2 ) 2 , O or N(R 2 ); and wherein when Y is S, Z is not S; and
[0072] R 6 is a 5-6 membered saturated, partially saturated or unsaturated carbocyclic or heterocyclic ring system, or an 8-10 membered saturated, partially saturated or unsaturated bicyclic ring system; wherein any of said heterocyclic ring systems contains one or more heteroatoms selected from O, N, S, S(O) n or N(R 2 ); and wherein any of said ring systems optionally contains 1 to 4 substituents independently selected from OH, C 1 -C 4 alkyl, O—C 1 -C 4 alkyl or O—C(O)—C 1 -C 4 alkyl.
[0073] Preferably, at least one R 7 is selected from:
[0000]
[0074] It will be understood by those of skill in the art that component M or M′ in the formulae set forth herein will have either a covalent, a covalent/zwitterionic, or an ionic association with either Z or R 9 depending upon the actual choice for M or M′. When M or M′ is hydrogen, alkyl, alkenyl, or R 6 , M or M′ is covalently bound to R 9 or Z. If M is a mono- or bivalent metal or other charged species (i.e., NH 4 + ), there is an ionic interaction between M and Z and the resulting compound is a salt.
[0075] When x is 0 in (M) x , Z may be a charged species. When that occurs, the other M may be oppositely charged to produce a 0 net charge on the molecule. Alternatively, the counter ion may located elsewhere in the molecule.
[0076] Except where expressly provided to the contrary, as used herein, the definitions of variables A, R 1 -R 4 , R 6 -R 9 , Ht, B, x, n, D, D′, M, Q, X, Y, Z and E are to be taken as they are defined above for the compounds of formula I.
[0077] According to a preferred embodiment, the compounds of this invention are those represented by formulas XXII, XXIII or XXXI:
[0000]
[0000] wherein A, R 3 , R 7 , Ht, D, D′, x, E are as defined above for compounds of formula I. For ease of reference, the two R 3 moieties present in formula XXXI have been labeled R 3 and R 3′ .
[0078] For compounds of formula XXII, more preferred compounds are those wherein:
[0079] A is selected from 3-tetrahydrofuryl-O—C(O)—, 3-(1,5-dioxane)-O—C(O)—, or 3-hydroxy-hexahydrofura[2,3-b]-furanyl-O—C(O)—;
[0080] D′ is C 1 -C 4 alkyl which is optionally substituted with one or more groups selected from the group consisting of C 3 -C 6 cycloalkyl, —OR 2 , —R 3 , —O-Q and Q;
[0081] E is C 6 -C 10 aryl optionally substituted with one or more substituents selected from oxo, —OR 2 , SR 2 , —R 2 , —N(R 2 ) 2 , —R 2 —OH, —CN, —CO 2 R 2 , —C(O)—N(R 2 ) 2 , —S(O) 2 —N(R 2 ) 2 , —N(R 2 )—C(O)—R 2 , —C(O)—R 2 , —S(O), —R 2 , —OCF 3 , —S(O) n -Q, methylenedioxy, —N(R 2 )—S(O) 2 (R 2 ), halo, —CF 3 , —NO 2 , Q, —OQ, —OR 7 , —SR 7 , —R 7 , —N(R 2 )(R 7 ) or —N(R 7 ) 2 ; or a 5-membered heterocyclic ring containing one S and optionally containing N as an additional heteroatom, wherein said heterocyclic ring is optionally substituted with one to two groups independently selected from —CH 3 , R 4 , or Ht.
[0082] Ht, insofar as it is defined as part of R 3 , is defined as above except for the exclusion of heterocycles; and
[0083] all other variables are as defined for formula I.
[0084] Even more preferred are compounds of formula XXII, wherein A is 3-tetrahydrofuryl-O—C(O)—; G is hydrogen; D′ is isobutyl; E is phenyl substituted with N(R 7 ) 2 ; each M is independently selected from H, Li, Na, K, Mg, Ca, Ba, C 1 -C 4 alkyl or —N(R 2 ) 4 ; and each M′ is H or C 1 -C 4 alkyl.
[0085] Another preferred embodiment for the formula XXII compounds are those wherein:
[0086] E is a 5-membered heterocyclic ring containing one S and optionally containing N as an additional heteroatom, wherein said heterocyclic ring is optionally substituted with one to two groups independently selected from —CH 3 , R 4 , or Ht; and
[0087] all other variables are as defined for formula I.
[0088] Even more preferred are any of the formula XXII compounds set forth above, wherein R 7 in —OR 7 is —PO(OM) 2 or C(O)CH 2 OCH 2 CH 2 OCH 2 CH 2 OCH 3 and both R 7 in —N(R 7 ) 2 are H, wherein M is H, Li, Na, K or C 1 -C 4 alkyl; or wherein R 7 in —OR 7 is C(O)CH 2 OCH 2 CH 2 OCH 3 , one R 7 in —N(R 7 ) 2 is C(O)CH 2 OCH 2 CH 2 OCH 3 and the other is H.
[0089] The most preferred compound of formula XXII has the structure:
[0000]
[0090] For compounds of formula XXIII, most preferred compounds are those wherein:
[0091] R 3 is C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 5 -C 6 cycloalkyl, C 5 -C 6 cycloalkenyl or a 5-6 membered saturated or unsaturated heterocycle, wherein any member of said R 3 may be optionally substituted with one or more substituents selected from the group consisting of —OR 2 , —C(O)—NH—R 2 , —S(O) n N(R 2 )(R 2 ), Ht, —CN, —SR 2 , —C(O) 2 R 2 and NR 2 —C(O)—R 2 ; and
[0092] D′ is C 1 -C 3 alkyl or C 3 alkenyl, wherein said alkyl or alkenyl may optionally be substituted with one or more groups selected from the group consisting of C 3 -C 6 cycloalkyl, —OR 2 , —O-Q and Q (with all other variables being defined as above for compounds of formula I).
[0093] Even more preferred are compounds of formula XXIII described above, wherein R 7 is —PO(OM) 2 or —C(O)-M′.
[0094] For compounds of formula XXXI, most preferred compounds are those wherein A is R 1 —Ht, each R 3 is independently C 1 -C 6 alkyl which may be optionally substituted with a substituent selected from the group consisting of —OR 2 , —C(O)—NH—R 2 , —S(O) n N(R 2 )(R 2 ), Ht, —CN, —SR 2 , —CO 2 R 2 or —NR 2 —C(O)—R 2 ; and D′ is C 1 -C 4 alkyl, which may be optionally substituted with a group selected from the group consisting of C 3 -C 6 cycloalkyl, —OR 2 , —O-Q; and E is Ht, Ht-Ht and —NR 2 R 3 .
[0095] Even more preferred are those compounds of formula XXXI described above wherein R 7 is —PO(OM) 2 or —C(O)-M′.
[0000]
TABLE I
CMPD
R 7
W
198
—NO 2
199
—NH 2
200
—NH 2
201
—NH 2
202
—NH 2
203
—NH 2
204
—NH 2
205
—NH 2
206
—NH 2
207
—NH 2
208
—NO 2
209
—NO 2
210
—NH 2
211
—NH 2
212
—NH 2
213
—NH 2
214
—NH 2
215
—NH 2
216
—NH 2
217
—NH 2
219
H
220
H
221
H
222
H
223
H
224
H
225
226
—NO 2
227
—NO 2
228
—NH 2
229
—NH 2
230
H
231
237
—NO 2
238
—NO 2
239
—SO 3 H
—NO 2
240
—SO 3 H
—NH 2
241
—NO 2
242
—NH 2
245
—NH 2
246
—NH 2
247
—NH 2
248
—NH 2
249
—NH 2
250
—NH 2
251
—NH 2
252
—NH 2
253
—NH 2
254
—NH 2
255
H
—NH—CHO
256
H
257
H
258
H
259
H
260
H
261
262
263
264
PO 3 K 2
—NH 2
265
PO 3 Ca
—NH 2
266
PO 3 Mg
—NH 2
267
—NH 2
308
—NH 2
402
H
403
H
404
H
405
H
406
H
407
H
408
—NH 2
[0000]
TABLE II
COMPOUND
A
R 7
232
233
H
234
H
235
236
[0000]
TABLE III
COMPOUND
R 7
W
243
—NO 2
244
—NH 2
400
—NO 2
401
—NH 2
[0096] According to another embodiment, the invention provides compounds of the following formulae:
[0000]
[0000] wherein, in compound 1005, when R 7 is PO 3 M, (G) x is not H; and wherein R 10 is selected from isopropoyl or cyclopentyl; R 11 is selected from NHR 7 or OR; and x, R 7 and G are as defined above.
[0097] The prodrugs of the present invention may be synthesized using conventional synthetic techniques. U.S. Pat. No. 5,585,397 discloses the synthesis of compounds of formula:
[0000]
[0000] wherein A, B, n, D, D′, and E are as defined above. Prodrugs of formula (I) of the present invention can be readily synthesized from the '397 compounds using conventional techniques. One of skill in the art would be well aware of conventional synthetic reagents to convert the —OH group of the '397 compounds to a desired —OR 7 functionality of the present invention, wherein R 7 is as defined above. The relative ease with which the compounds of this invention can be synthesized represents an enormous advantage in the large scale production of these compounds.
[0098] For example, VX-478, a compound disclosed in the '397 patent, can be readily converted to the corresponding bis-phosphate ester derivative, as shown below:
[0000]
[0099] Alternatively, if the monophosphate ester of VX-478 is desired, then the synthetic scheme can be readily adapted by beginning with the 4-nitrophenyl derivative of VX-478, as shown below:
[0000]
[0100] Examples of specific compounds in addition to VX-478 which may be converted to the prodrugs of this invention by similar techniques (and the syntheses of those intermediates to the compounds of the present invention) are disclosed in WO 94/05639 and WO 96/33184, the disclosures of which are herein incorporated by reference.
[0101] Pharmaceutically acceptable salts of the compounds of the present invention may be readily prepared using known techniques. For example, the disodium salt of the mono-phosphate ester shown above can be prepared as shown below:
[0000]
[0102] The compounds of this invention may be modified by appending appropriate functionalities to enhance selective biological properties. Such modifications are known in the art and include those which increase biological penetration into a given biological system (e.g., blood, lymphatic system, central nervous system), increase oral availability, increase solubility to allow administration by injection, alter metabolism and alter rate of excretion.
[0103] Without being bound by theory, we believe that two different mechanisms are involved in converting the prodrugs of this invention into the active drug, depending upon the structure of the prodrug. The first mechanism involves the enzymatic or chemical transformation of the prodrug species into the active form. The second mechanism involves the enzymatic or chemical cleavage of a functionality on the prodrug to produce the active compound.
[0104] The chemical or enzymatic transformation can involve to transfer of a functional group (i.e., R 7 ) from one heteroatom within the molecule to another heteroatom. This transfer is demonstrated in the chemical reactions shown below:
[0000]
[0105] The cleavage mechanism is demonstrated by the reaction below where a phosphate ester-containing prodrug is converted into the active form of the drug by removal of the phosphate group.
[0000]
[0106] These protease inhibitors and their utility as inhibitors of aspartyl proteases are described in U.S. Pat. No. 5,585,397, the disclosure of which is incorporated herein by reference.
[0107] The prodrugs of the present invention are characterized by unexpectedly high aqueous solubility. This solubility facilitates administration of higher doses of the prodrug, resulting in a greater drug load per unit dosage. The prodrugs of the present invention are also characterized by facile hydrolytic cleavage to release the active aspartyl protease inhibitor in vivo. The high aqueous solubility and the facile in vivo metabolism result in a greater bioavailability of the drug. As a result, the pill burden on a patient is significantly reduced.
[0108] The prodrugs of this invention may be employed in a conventional manner for the treatment of viruses, such as HIV and HTLV, which depend on aspartyl proteases for obligatory events in their life cycle. Such methods of treatment, their dosage levels and requirements may be selected by those of ordinary skill in the art from available methods and techniques. For example, a prodrug of this invention may be combined with a pharmaceutically acceptable adjuvant for administration to a virally-infected patient in a pharmaceutically acceptable manner and in an amount effective to lessen the severity of the viral infection.
[0109] Alternatively, the prodrugs of this invention may be used in vaccines and methods for protecting individuals against viral infection over an extended period of time. The prodrugs may be employed in such vaccines either alone or together with other compounds of this invention in a manner consistent with the conventional utilization of protease inhibitors in vaccines. For example, a prodrug of this invention may be combined with pharmaceutically acceptable adjuvants conventionally employed in vaccines and administered in prophylactically effective amounts to protect individuals over an extended period time against HIV infection. As such, the novel protease inhibitors of this invention can be administered as agents for treating or preventing HIV infection in a mammal.
[0110] The prodrugs of this invention may be administered to a healthy or HIV-infected patient either as a single agent or in combination with other anti-viral agents which interfere with the replication cycle of HIV. By administering the compounds of this invention with other anti-viral agents which target different events in the viral life cycle, the therapeutic effect of these compounds is potentiated. For instance, the co-administered anti-viral agent can be one which targets early events in the life cycle of the virus, such as cell entry, reverse transcription and viral DNA integration into cellular DNA. Anti-HIV agents targeting such early life cycle events include, didanosine (ddI), alcitabine (ddC), d4T, zidovudine (AZT), polysulfated polysaccharides, sT4 (soluble CD4), ganiclovir, dideoxycytidine, trisodium phosphonoformate, eflornithine, ribavirin, acyclovir, alpha interferon and trimenotrexate. Additionally, non-nucleoside inhibitors of reverse transcriptase, such as TIBO or nevirapine, may be used to potentiate the effect of the compounds of this invention, as may viral uncoating inhibitors, inhibitors of trans-activating proteins such as tat or rev, or inhibitors of the viral integrase.
[0111] Combination therapies according to this invention exert a synergistic effect in inhibiting HIV replication because each component agent of the combination acts on a different site of HIV replication. The use of such combinations also advantageously reduces the dosage of a given conventional anti-retroviral agent which would be required for a desired therapeutic or prophylactic effect as compared to when that agent is administered as a monotherapy. These combinations may reduce or eliminate the side effects of conventional single anti-retroviral agent therapies while not interfering with the anti-retroviral activity of those agents. These combinations reduce potential of resistance to single agent therapies, while minimizing any associated toxicity. These combinations may also increase the efficacy of the conventional agent without increasing the associated toxicity. In particular, we have discovered that these prodrugs act synergistically in preventing the replication of HIV in human T cells. Preferred combination therapies include the administration of a prodrug of this invention with AZT, ddI, ddC or d4T.
[0112] Alternatively, the prodrugs of this invention may also be co-administered with other HIV protease inhibitors such as Ro 31-8959 (Roche), L-735,524 (Merck), XM 323 (Du-Pont Merck) and A-80,987 (Abbott) to increase the effect of therapy or prophylaxis against various viral mutants or members of other HIV quasi species.
[0113] We prefer administering the prodrugs of this invention as single agents or in combination with retroviral reverse transcriptase inhibitors, such as derivatives of AZT, or other HIV aspartyl protease inhibitors. We believe that the co-administration of the compounds of this invention with retroviral reverse transcriptase inhibitors or HIV aspartyl protease inhibitors may exert a substantial synergistic effect, thereby preventing, substantially reducing, or completely eliminating viral infectivity and its associated symptoms.
[0114] The prodrugs of this invention can also be administered in combination with immunomodulators (e.g., bropirimine, anti-human alpha interferon antibody, IL-2, GM-CSF, methionine enkephalin, interferon alpha, diethyldithiocarbamate, tumor necrosis factor, naltrexone and rEPO); and antibiotics (e.g., pentamidine isethiorate) to prevent or combat infection and disease associated with HIV infections, such as AIDS and ARC.
[0115] When the prodrugs of this invention are administered in combination therapies with other agents, they may be administered sequentially or concurrently to the patient. Alternatively, pharmaceutical or prophylactic compositions according to this invention may be comprised of a combination of a prodrug of this invention and another therapeutic or prophylactic agent.
[0116] Although this invention focuses on the use of the prodrugs disclosed herein for preventing and treating HIV infection, the compounds of this invention can also be used as inhibitory agents for other viruses which depend on similar aspartyl proteases for obligatory events in their life cycle. These viruses include, as well as other AIDS-like diseases caused by retroviruses, such as simian immunodeficiency viruses, but are not limited to, HTLV-I and HTLV-II. In addition, the compounds of this invention may also be used to inhibit other aspartyl proteases, and in particular, other human aspartyl proteases, including renin and aspartyl proteases that process endothelin precursors.
[0117] Pharmaceutical compositions of this invention comprise any of the compounds of the present invention, and pharmaceutically acceptable salts thereof, with any pharmaceutically acceptable carrier, adjuvant or vehicle. Pharmaceutically acceptable carriers, adjuvants and vehicles that may be used in the pharmaceutical compositions of this invention include, but are not limited to, ion exchangers, alumina, aluminum stearate, lecithin, serum proteins, such as human serum albumin, buffer substances such as phosphates, glycine, sorbic acid, potassium sorbate, partial glyceride mixtures of saturated vegetable fatty acids, water, salts or electrolytes, such as protamine sulfate, disodium hydrogen phosphate, potassium hydrogen phosphate, sodium chloride, zinc salts, colloidal silica, magnesium trisilicate, polyvinyl pyrrolidone, cellulose-based substances, polyethylene glycol, sodium carboxymethylcellulose, polyacrylates, waxes, polyethylene-polyoxypropylene-block polymers, polyethylene glycol and wool fat.
[0118] The pharmaceutical compositions of this invention may be administered orally, parenterally, by inhalation spray, topically, rectally, nasally, buccally, vaginally or via an implanted reservoir. We prefer oral administration or administration by injection. The pharmaceutical compositions of this invention may contain any conventional non-toxic pharmaceutically-acceptable carriers, adjuvants or vehicles. The term parenteral as used herein includes subcutaneous, intracutaneous, intravenous, intramuscular, intra-articular, intrasynovial, intrasternal, intrathecal, intralesional and intracranial injection or infusion techniques.
[0119] The pharmaceutical compositions may be in the form of a sterile injectable preparation, for example, as a sterile injectable aqueous or oleaginous suspension. This suspension may be formulated according to techniques known in the art using suitable dispersing or wetting agents (such as, for example, Tween 80) and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are mannitol, water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose, any bland fixed oil may be employed including synthetic mono- or diglycerides. Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions may also contain a long-chain alcohol diluent or dispersant such as Ph. Helv or a similar alcohol.
[0120] The pharmaceutical compositions of this invention may be orally administered in any orally acceptable dosage form including, but not limited to, capsules, tablets, and aqueous suspensions and solutions. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions are administered orally, the active ingredient is combined with emulsifying and suspending agents. If desired, certain sweetening and/or flavoring and/or coloring agents may be added.
[0121] The pharmaceutical compositions of this invention may also be administered in the form of suppositories for rectal administration. These compositions can be prepared by mixing a compound of this invention with a suitable non-irritating excipient which is solid at room temperature but liquid at the rectal temperature and therefore will melt in the rectum to release the active components. Such materials include, but are not limited to, cocoa butter, beeswax and polyethylene glycols.
[0122] Topical administration of the pharmaceutical compositions of this invention is especially useful when the desired treatment involves areas or organs readily accessible by topical application. For application topically to the skin, the pharmaceutical composition should be formulated with a suitable ointment containing the active components suspended or dissolved in a carrier. Carriers for topical administration of the compounds of this invention include, but are not limited to, mineral oil, liquid petroleum, white petroleum, propylene glycol, polyoxyethylene polyoxypropylene compound, emulsifying wax and water. Alternatively, the pharmaceutical composition can be formulated with a suitable lotion or cream containing the active compound suspended or dissolved in a carrier. Suitable carriers include, but are not limited to, mineral oil, sorbitan monostearate, polysorbate 60, cetyl esters wax, cetearyl alcohol, 2-octyldodecanol, benzyl alcohol and water. The pharmaceutical compositions of this invention may also be topically applied to the lower intestinal tract by rectal suppository formulation or in a suitable enema formulation. Topically-transdermal patches are also included in this invention.
[0123] The pharmaceutical compositions of this invention may be administered by nasal aerosol or inhalation. Such compositions are prepared according to techniques well-known in the art of pharmaceutical formulation and may be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art.
[0124] Dosage levels of between about 0.01 and about 100 mg/kg body weight per day, preferably between about 0.5 and about 50 mg/kg body weight per day of the active ingredient compound are useful in the prevention and treatment of viral infection, including HIV infection. Typically, the pharmaceutical compositions of this invention will be administered from about 1 to about 5 times per day or alternatively, as a continuous infusion. Such administration can be used as a chronic or acute therapy. The amount of active ingredient that may be combined with the carrier materials to produce a single dosage form will vary depending upon the host treated and the particular mode of administration. A typical preparation will contain from about 5% to about 95% active compound (w/w). Preferably, such preparations contain from about 20% to about 80% active compound.
[0125] Upon improvement of a patient's condition, a maintenance dose of a compound, composition or combination of this invention may be administered, if necessary. Subsequently, the dosage or frequency of administration, or both, may be reduced, as a function of the symptoms, to a level at which the improved condition is retained when the symptoms have been alleviated to the desired level, treatment should cease. Patients may, however, require intermittent treatment on a long-term basis upon any recurrence of disease symptoms.
[0126] As the skilled artisan will appreciate, lower or higher doses than those recited above may be required. Specific dosage and treatment regimens for any particular patient will depend upon a variety of factors, including the activity of the specific compound employed, the age, body weight, general health status, sex, diet, time of administration, rate of excretion, drug combination, the severity and course of the infection, the patient's disposition to the infection and the judgment of the treating physician.
[0127] In order that this invention be more fully understood, the following examples are set forth. These examples are for the purpose of illustration only and are not to be construed as limiting the scope of the invention in any way.
Example 1
General Conditions
[0128] (A) Analytical HPLC 0-100% B/30 min, 1.5 mL/min, A=0.1% TFA in water, B=0.1% TFA in acetonitrile. Detection at 254 and 220 nm, C18 reverse phase Vydac, t0=2.4 min.
[0129] (B) ⅓ v/v EtOAc/hexane
[0130] (C) ½ v/v EtOAc/hexane
[0131] (D) Analytical HPLC 0-100% B/10 min, 1.5 mL/min, A=0.1% TFA in water, B=0.1% TFA in acetonitrile. Detection at 254 and 220 nm, C18 reverse phase Vydac, t 0 =2.4 min.
[0000]
[0132] A mixture of 2.0 g (3.7 mMol) of 197 and 3.0 g (16 mMol) of di-p-nitrophenyl carbonate in 10 ml of dimethylformamide was treated at 25° with 4 ml (4 mMol) of P4-phosphazene base (Fluka, 1M in hexane). The mixture was stirred for 6 h at 25° until all of the starting alcohol was consumed. The reaction mixture was partitioned between ethyl acetate and 1N hydrochloric acid. The organic layer was washed with 1N sodium hydroxide and brine, dried over magnesium sulfate and concentrated in vacuo. Titration with dichloromethane gave the desired mixed carbonate (1.2 g crop 1 and 0.6 g crop 2) as a fine powder. Combined yield: 69%. Rf=0.13 (1/3 EtOAc/hexane, conditions B), Rf=0.40 (1/2 EtOAc/hexane, conditions C), tHPLC=23.83 min (A), MS (ES+) 701 (M+1).
[0133] 1H-NMR (CDCl3): 0.82 (6H, dd), 1.9 (2H, m), 2.15 (1H, m), 2.8 (1H, m), 3.0 (4H, m), 3.5 (2H, m), 3.6 (1H, m), 3.8 (4H, m), 4.3 (1H, bs), 4.8 (1H, m), 5.17 (2H, m), 7.7 (7H, m), 7.95 (2H, d), 8.35 (4H, m).
[0134] 13C (CDCl3): 155.2 152.2, 149.9, 145.6, 135.9, +129.0, +128.8, +128.5, +127.2, +125.4, +124.4, +121.8, +78.1, +75.8, −73.1, −66.9, −56.5, +52.7, −48.2, −35.9, −35.9, 32.6, −+26.4, +19.9, +19.8.
Example 2
[0135]
[0136] To 0.20 g (0.286 mM) of 198 dissolved in 3 ml of THF was added 0.11 g (1.14 mM) of 1-Methyl-piperidine and the mixture was stirred overnight at room temperature (“rt”). All the solvents were then evaporated and the solid residue partitioned between EtOAc and water. The volatiles were removed and, where appropriate, the residue was treated with 1:1 TFA/DCM over 30 min at rt to remove the Boc protecting group. The product was dissolved in 0.25 ml TFA and 1.5 ml THF. Hydrogenolysis for 10 hours in presence of 30 mg of 10% Pd/C gave the desired compound. The final purification was on preparative reversed phase C18 using conditions Example 1, except that the flow rate was 18 ml/min.
[0137] C,H,N: calc: 49.27, 5.57, 8.25, found 49.15, 5.76, 8.29. C 33 H 45 N 5 O 7 S 1 .1.9CF 3 COOH
[0138] LC/MS (ES+) 632 (M+1) 1 peak at 4.71 min
[0139] Analytical HPLC(A) t=N/A min
[0140] 1H, 0.71 (3H, d), 0.74 (3H, d), 1.80 (2H, m), 2.03 (1H, m), 2.63 (2H, m), 2.74 (1H, m), 2.82 (3H, s), 2.92 (2H, m), 3.20 (4H, m), 3.42 (3H, m), 3.62 (2H, m), 3.75 (1H, m), 4.05 (3H, m), 4.97 (2H, m), 6.2 (1H, bs), 6.60 (2H, m), 7.22 (5H, m), 7.40 (3H, m),
[0141] 13C (DMSO): 156.4, 154.0, 153.8, 138.8, 129.6, 129.5, 128.3, 126.5, 123.7, 112.7, 74.8, 72.9, 66.7, 58.2, 54.0, 53.1, 49.3, 42.3, 40.8, 36.0, 33.3, 25.8, 20.4, 20.3
Example 3
[0142]
[0143] The synthesis of compound 200 from compound 198 was carried as described in Example 1, except that N,N-dimethyl-aminoethanol was used in place of di-p-nitrophenyl carbonate.
[0144] 1HNMR (acetone-d6): 0.82 (6H, dd), 1.83 (2H, m), 2.07 (1H, m), 2.64 (2H, m), 2.82 (6H, s), 2.90 (2H, m), 3.19 (1H, m), 3.38 (4H, m), 3.63 (2H, m), 3.76 (1H, m), 4.17 (2YH, m), 4.40 (1H, m), 4.56 (1H, m), 4.96 (1H, m), 5.06 (1H, m), 6.06 (1H, d), 6.68 (2H, d), 7.23 (5H, m), 7.47 (2H, d).
[0145] 13CNMR (acetone d6): 20.2, 20.3, 27.5, 33.4, 35.6, 43.8, 50.1, 54.2, 56.4, 58.5, 63.1, 67.4, 73.6, 76.2, 79.9, 114.2, 118.3, 127.4, 129.2, 130.1, 130.3, 139.3, 153.4, 157.0.
[0146] LC/MS: 1 peak, 621 (MH+).
Example 4
[0147]
[0148] The synthesis of compound 201 from compound 198 was carried as described in Example 1, except that N-acetyl-ethylenediamine was used in place of di-p-nitrophenyl carbonate.
[0149] C,H,N: calc: 49.66, 5.64, 8.83, found 49.76, 5.98, 8.93. C 30 H 43 N 5 O 8 S 1 .1.4CF 3 COOH.
[0150] LC/MS (ES+) 634 (M+1) 1 peak at 5.08 min.
[0151] Analytical HPLC(A) t=15.92 min.
[0152] 1H: d-3 acetonitrile: 0.88 (6H, dd), 1.92 (3H, s), 1.94 (2H, m), 2.17 (1H, m), 2.72 (2H, m), 2.96 (2H, m), 3.07 (3H, m), 3.29 (1H, m), 3.42 (3H, m), 3.69 (1H, m), 3.77 (1H, m), 3.82 (1H, m), 4.133 (1H, m), 4.40 (1H, bs), 5.05 (2H, m), 5.80 (1H, m), 6.10 (1H, d), 6.78 (2H, d), 6.83 (1H, bs), 7.28 (5H, m), 7.58 (2H, d).
[0153] 13C (d3-acetonitrile): 157.1, 157.0, 153.2, 139.6, +130.3, +130.2, +129.2, +127.2, 126.2, +114.2, +76.0, +75.4, −73.6, −67.4, −58.2, +54.9, −50.2, −41.6, −39.8, −35.9, −33.4, +27.3, +23.1, +20.4, +20.2.
Example 5
[0154]
[0155] The synthesis of compound 202 from compound 198 was carried as described in Example 1, except that mono N-Boc-piperazine was used in place of di-p-nitrophenyl carbonate.
[0156] C,H,N: calc: 48.28, 5.68, 8.41, found 48.28, 5.36, 8.28. C 30 H 43 N 5 O 7 S 1 ×2 CF 3 COOH
[0157] LC/MS (ES+) 618 (M+1) 1 peak at 4.36 min.
[0158] Analytical HPLC(A) t=14.84 min.
[0159] 1H: d6-DMSO: 0.72 (3H, d), 0.77 (3H, d), 1.78 (2H, m), 2.09 (1H, m), 2.64 (2H, m), 2.73 (1H, m), 2.80 (1H, m), 3.08 (4H, m), 3.32 (2H, m), 3.41 (1H, m), 3.50 (4H, m), 3.54 (1H, m), 3.63 (1H, m), 3.70 (1H, m), 3.98 (1H, m), 4.89 (1H, m), 4.97 (1H, m), 6.61 (2H, d), 7.23 (5H, m), 7.42 (3H, m), 8.88 (2H, bs).
[0160] 13C: (DMSO): 155.7, 153.6, 153.0, 138.4, +129.1, +129.0, +128.1, +126.1, 123.2, +112.7, +75.2, +74.4, −72.5, −66.2, −56.9, +53.1, −48.8, −42.5, −40.8, −35.0, −32.2, +26.2, +20.0, +19.8.
Example 6
[0161]
[0162] The synthesis of compound 203 from compound 198 was carried as described in Example 1, except that mono-N-Boc-ethylenediamine was used in place of di-p-nitrophenyl carbonate.
[0163] C,H,N: calc: 46.89, 5.29, 8.54, found 46.50, 5.51, 8.54. C 28 H 41 N 5 O 7 S 1 ×2 CF 3 COOH.
[0164] LC/MS (ES+) 592 (M+1) 1 peak at 4.32 min.
[0165] Analytical HPLC(A) t=14.69 min.
[0166] 1H:d-6 DMSO: 0.77 (6H, d), 1.82 (2H, m), 2.06 (1H, m), 2.57 (2H, m), 2.82 (4H, m), 2.97 (1H, m), 3.30 (5H, m), 3.55 (1H, m), 3.65 (1H, m), 3.70 (1H, m), 3.95 (1H, m), 4.88 (1H, m), 4.95 (1H, m), 6.62 (2H, d), 7.20 (6H, m), 7.39 (3H, m), 7.78 (3H, bs).
[0167] 13C (dmso): 155.9, 152.9, 138.5, 129.2, 128.9, 128.1, 126.1, 122.9, 112.7, 74.7, 74.5, 72.6, 66.2, 57.2, 53.2, 49.4, 38.8, 37.94, 35.1, 32.1, 26.3, 20.0, 19.8.
[0000]
Example 7
[0168] The synthesis of compound 204 from compound 1.9 was carried as described in Example 1, except that mono-1,3-diamino-3-N-Boc-propane was used in place of di-p-nitrophenyl carbonate.
[0169] C,H,N: calc: 49.07, 5.64, 8.89, found 48.95, 6.00, 8.92. C 29 H 43 N 5 O 7 S 1 ×1.6CF 3 COOH
[0170] LC/MS (ES+) 605 (M+1) 1 peak at 4.27 min.
[0171] Analytical HPLC(A) t=14.72 min.
[0172] 1H:d-6 DMSO: 0.78 (6H, dd), 1.64 (2H, m), 1.83 (2H, m), 2.03 (1H, m), 2.57 (1H, m), 2.78 (4H, m), 2.94 (1H, m), 3.03 (2H, m), 3.32 (2H, m), 3.58 (1H, m), 3.63 (1H, m), 3.73 (1H, m), 3.87 (1H, m), 4.84 (1H, m), 4.92 (1H, m), 6.61 (2H, d), 7.22 (6H.m), 7.36 (1H, d), 7.28 (2H, d), 7.76 (3H, ns).
[0173] 13C (dmso): 155.8, 155.7, 138.5, +129.1, +129.0, +128.0, +126.1, 122.9, +112.7, +74.6, +74.3, −72.7, −66.2, −57.2, +53.6, −49.5, −37.4, −36.7, −35.5, −32.1, −27.6, +26.2, +20.0, +19.8.
Example 8
[0174]
[0175] The synthesis of compound 205 from compound 198 was carried as described in Example 1, except that 1,4-diamino-4-N-Boc-butane was used in place of di-p-nitrophenyl carbonate.
[0176] C,H,N: calc: 48.17, 5.59, 8.26, found 48.02, 5.96, 8.24. C 30 H 45 N5O 7 S 1 .2CF 3 COOH
[0177] LC/MS (ES+) 620 (M+1) 1 peak at 4.36 min.
[0178] Analytical HPLC(A) t=14.93 min.
[0179] 1H: d-6 DMSO: 0.77 (6H, dd), 1.43 (4H, m), 1.82 (2H, m), 2.03 (1H, m), 2.77 (4H, m), 2.95 (3H, m), 3.31 (2H, m), 3.56 (1H, m), 3.63 (1H, m), 3.70 (1H, bq), 3.82 (1H, m), 4.85 (1H, m), 4.92 (1H, m), 6.62 (2H, d), 7.2 (7H, m), 7.38 (2H, d), 7.72 (3H, bs).
[0180] 13C: 155.7, 152.9, +138.6, +129.1, +129.0, +128.0, +126.1, +123.0, +112.7, +74.4, +74.3, −72.7, −66.2, −57.2, +53.7, −49.7, −38.6, −38.5, −35.4, −32.1, −26.3, +26.2, −24.4, +20.1, +19.9.
Example 9
[0181]
[0182] The synthesis of compound 206 from compound 198 was carried as described in Example 1, except that (3R)-(+)-3-Boc-aminopyrrolidine was used in place of di-p-nitrophenyl carbonate.
[0183] C,H,N: calc: 48.28, 5.36, 8.28, found 47.89, 5.53, 8.57. C 30 H 43 N 5 O 7 S 1 ×2 TFA
[0184] LC/MS (ES+) 618 (M+1) 1 peak at 4.32 min.
[0185] Analytical HPLC(A) t=14.31 min.
[0186] 1H and 13C NMR: complex and overlapping mixtures of rotomers.
Example 10
[0187]
[0188] The synthesis of compound 207 from compound 198 was carried as described in Example 1, except that (3S)-(−)-3-Boc-aminopyrrolidine was used in place of di-p-nitrophenyl carbonate.
[0189] LC/MS (ES+) 618 (M+1) 1 peak at 4.19 min.
[0190] Analytical HPLC(A) t=14.75 min.
[0191] 1H and 13C NMR: complex and overlapping mixtures of rotomers.
Example 11
[0192]
[0193] The synthesis of compound 308 from compound 198 was carried as described in Example 1, except that N-triphenylmethyl-N,N′-dimethylethanediamine was used in place of di-p-nitrophenyl carbonate.
[0194] 1H-NMR: 0.76 (6H, dd), 1.65 (2H, m), 1.95 (1H, m), 2.07 (1H, m), 2.7 (2H, m), 2.75 (3H, s), 2.95 (3H, m), 3.45 (2H, m), 3.7 (4H, m), 4.2 (2H, bm), 5.05 (2H, bd), 6.62 (2H, d), 7.2 (5H, m), 7.5 (2H, d).
[0195] LC/MS: 1 peak, 620 (MH+).
Example 12
General Procedures
Acylation:
[0196]
[0197] To 200 mg (0.37 mM) of 197 dissolved in 5 ml CH 2 Cl 2 was added N-CBz-L-Benzyl tyrosine 183 mg (0.41 mM) followed by 231 mg (1.12 mM) DCC, followed by 29 mg (0.23 mM) DMAP. The reaction is stirred at rt for 24 hr. The precipitates present were removed by filtration. The filtrate was then concentrated in vacuo. The final compound was purified on preparative reversed phase C 18 using purification by HPLC C 18 Waters Delta Prep 3000 Column: YMC-Pack ODS AA 12S05-2520WT 250×20 mm I.D. S-5 mm, 120 Å, 0-100% B over ½ h, flow=18 ml/min, monitored at 220 nm, B=0.1% trifluoroacetic acid in acetonitrile, A=0.1% trifluoroacetic acid in water. Analytical Column: YMC-Pack ODS AA1 2S05-2520WT 250×4.6 mmI.D. S-5 mm, 120 Å, 0-100% B at 1.5 ml/min. over ½ h, monitored at 220 nm, B=0.1% trifluoroacetic acid in acetonitrile, A=0.1% trifluoroacetic acid in water.
[0198] The aqueous phase was lyophilized to give 59 mg, (16.3%) GW431896X, (U11484-72-10) t HPLC =11.71 min., MW=966.04, LC/MS=MH+967.
Reduction of the Nitro Functionality:
[0199]
[0200] A slurry of 209 (170 mg) and 10 mg of 10% Pd.C in 95% EtOH was flushed with hydrogen in a scintillation vial equipped with septum and a stir bar. Continuous overnight hydrogenolysis under hydrogen balloon resulted in a complete conversion. The crude preparation was then filtered off the catalyst, and purified on RP C18 HPLC (Prep Nova-Pack C186 um, 60 A, gradient 0-100% B over 30 min. The desired product was collected and lyophilized affording a white fluffy solid (50 mg, 30.8%).
Example 13
[0201]
[0202] Compound 211 was obtained following the acylation and reduction procedures of Example 12.
[0203] ES+ 669.2 (M+1), tHPLC=8.06 min (D), 13C NMR (DMSO) 168.9, 156.9, 155.7, 153.1, 138.1, 130.5, 129.2, 129.1, 128.1, 126.2, 124.7, 122.5, 112.8, 76.2, 74.5, 72.5, 66.1, 58.0, 53.6, 52.6, 49.2, 33.6, 32.1, 26.6, 25.3, 20.0.
[0204] tHPLC=11.71 min (D), ES+ 967 (M+1).
Example 14
[0205]
[0206] 212 was obtained following the procedures of Example 12.
[0207] tHPLC=9.45 min (D), ES+ 592.2 (M+1).
[0208] 13C NMR (DMSO) 171.5, 155.8, 148.9, 137.8, 129.5, 129.3, 128.5, 126.7, 115.2, 75.2, 73.8, 73.1, 68.3, 67.0, 58.7, 57.1, 53.3, 49.2, 35.4, 32.4, 26.7, 20.1, 19.8.
[0209] 1H (CDCl3, 399.42 KHz): 8.33 (2H, d, J=8.8), 7.95 (2H, d, J=8.8), 7.23 (5H, m) 5.22 (m, 2H), 5.08 (m, 1H), 4.08 (m, 1H), 3.80-3.45 (7H, m), 3.41 (3H, s), 2.98 (m, 3H), 2.66 (m, 1H), 2.57 (m, 2H), 2.10 (s, 1H), 1.93 (2H, m), 0.82 (3H, d), 0.78 (3H, d).
[0210] ES+ 622 (M+1), 644 (M+Na)
[0211] tHPLC=10.29 min (D).
[0212] 13C NMR (CDCl3): 171.3, 155.5, 149.9, 145.6, 136.9, 129.2, 128.6, 128.5, 126.8, 124.4, 76.7, 75.3, 73.2, 72.9, 68.2, 66.9, 58.7, 55.9, 53.1, 48.3, 35.3, 32.7, 26.3, 19.9, 19.8.
Example 15
[0213]
[0214] Compound 213 was obtained following the procedure of Example 12. tHPLC=9.21 min (D); ES+ 622 (M+1).
[0215] 13C NMR (CDCl3): 170.54, 156.2, 148.6, 136.8, 129.4, 129.2, 128.6, 126.6, 115.7, 76.7, 74.6, 73.2, 71.8, 70.6, 68.2, 6.6.9, 58.9, 57.3, 53.8, 49.4, 36.2, 33.1, 26.8, 19.8, 19.5.
[0216] Intermediate: t HPLC=10.05 min (D); ES+=652 (M+H) 674 (M+Na).
Example 16
[0217]
[0218] 214 was obtained following the procedure of Example 12.
[0219] ES+ 634.4 (M+1); t HPLC=7.17 min (D).
[0220] 13C (DMSO): 169.3, 155.8, 153.1, 138.0, 129.1, 129.0, 128.1, 126.3, 122.6, 112.8, 94.3, 75.6, 74.6, 72.4, 66.1, 57.8, 52.7, 52.0, 49.3, 38.4, 34.7, 32.2, 29.1, 26.6, 21.4, 20.1, 20.0.
Example 17
[0221]
[0222] 215 was obtained following the procedure of Example 12.
[0223] t HPLC=9.12 min (D)
[0224] 1H (DMSO) all signals broad: 7.38 (3H, br m), 7.20 (5H, br m), 6.62 (2H, br m), 5.15 (1H, br m), 4.92 (1H, br m), 4.00 (3H, m), 3.7-3.0 (16H, m), 2.78 (2H, m), 2.57 (3H, m), 2.04 (m, 1H), 1.78 (m, 2H), 0.77 (6H, m)
[0225] 13C (DMSO) 170.6, 156.3, 153.7, 139.1, 129.8, 128.4, 126.7, 123.7, 113.3, 79.8, 79.2, 77.3, 76.1, 75.4, 75.2, 73.0, 71.9, 52.3, 51.8, 48.2, 46.7, 39.9, 38.7, 25.8, 22.6.
[0226] Intermediate:
[0227] t HPLC=10.18 min (D); ES+ 696.3 (M+1).
Example 18
[0228]
[0229] 216 was obtained following the procedure of Example 12.
[0230] 1H-NMR: 0.97 (6H, t), 1.95 (2H, m), 2.20 (1H, m), 2.9 (2H, m), 2.96 (6H, s), 3.00 (3H, s), 3.38 (1H, m), 3.42 (3H, m), 3.36 (1H, m), 3.6 (2H, m), 3.7 (6H, m), 3.98 (2H, m), 4.2 (2H, dd), 5.1 (1H, bs), 5.4 (1H, m), 6.8 (2H, d), 7.4 (5H, m), 7.6 (2H, d).
[0231] LC-MS: 1 peak, 692 (MH+).
Example 19
[0232]
[0233] 217 was obtained following the procedure of Example 12.
[0234] 1H-NMR (CDCl3): 0.78 (6H, dd), 1.9 (2H, m), 2.1 (1H, m), 2.3 (3H, s), 2.9 (8H, m), 2.9 (2H, m), 3.15 (1H, m), 3.35 (1H, m), 3.5 (1H, m), 3.75 (4H, m), 4.06 (2H, s), 4.15 (2H, m), 4.9 (1H, dd), 5.05 (1H, bs), 5.2 (1H, bs), 6.63 (2H, d), 7.2 (5H, m), 7.55 (2H, d), 8.0 (2H, m).
[0235] ESMSP: 676 (MH+).
Example 20
General Procedure for N-Acylated Compounds
[0236]
[0237] A mixture of 0.5 g (1 mMol) of (3S)-Tetrahydro-3-furfuryl-N-((1S,2R)-1-benzyl-2-hydroxy-3-(N-isobutyl-4-aminobenzenesulfonamido)propyl) carbamate, 0.4 g (1.5 mMol) of Boc-(S)-3-pyridyl alanine, 0.29 g (1.5 mMol) EDCI and 0.1 g 4-dimethylamino pyridine in 10 ml of N,N-dimethylformamide was stirred at 25° for 12 hours. The volatiles were removed in vacuo and the residue was partitioned between ethyl acetate and 1N hydrochloric acid. The organic layer was washed with 1N sodium hydroxide and brine, dried over magnesium sulfate and concentrated in vacuo. The residue was chromatographed on a 2 inch plug of silica gel (1:1 ethyl acetate:hexane) to give the desired N-acylated material. Deprotection by treatment with 50 ml of trifluoroacetic acid, followed by co-evaporation of residual acid with methanol gave the desired prodrug as a white foam (0.2 g, 26%).
[0238] H1-NMR (acetonitrile-D3): 0.95 (6H, dd), 2.0 (2H, m), 2.25 (1 h, m), 2.8-3.1 (5H, m), 3.6-4.0 (7H, m), 4.25 (1H, m), 4.75 (1H, m), 5.18 (1H, m), 5.45 (1H, m), 7.0 (2H, d), 7.4 (5H, m), 7.75 (2H, d), 8.2 (1H, m), 8.8 (1H, d), 8.85 (1H, d), 9.15 (1H, s).
[0239] LC/MS: 1 peak, 654 (MH+).
Example 21
[0240]
[0241] 220 was obtained using the general procedure in Example 20.
[0242] 1H-NMR (acetone-d6/methanol-d4): 0.95 (6H, t), 2.0 (2H, m), 2.2 (1H, m), 2.90 (1H, dd), 2.95 (2H, d), 3.12 (1H, dd), 3.4 (2H, m), 6 (1H, d), 3.8 (5H, m), 4.4 (2H, bm), 6.82 (2H, d), 7.20 (1H, s), 7.4 (5H, m), 7.65 (2H, d), 8.0 (1H, s).
[0243] LC/MS: 1 peak, 643 (MH+).
Example 22
[0244]
[0245] 221 was obtained using the general procedure in Example 20.
[0246] 1H-NMR (DMSO d-6): 0.76 (6H, t), 1.80 (2H, m), 2.10 (1H, m), 3.7 (4H, m), 3.75 (3H, s), 3.2 (5H, m), 3.58 (2H, s), 3.7 (4H, m), 4.97 (1H, bm), 5.18 (1H, bs), 6.7 (2H, d), 7.22 (5H, m), 7.45 (2H, d).
[0247] LC/MS: 1 peak, 646 (MH+).
Example 23
[0248]
[0249] 222 was obtained using the general procedure in Example 20.
[0250] 1HNMR (acetonitrile d-3): 1.0 (6H, t), 2.0 (2H, m), 2.2 (1H, m), 3.00 (6H, s), 3.02 (3H, s), 3.1 (4H, m), 3.5 (3H, m), 3.8 (8H, m), 4.4 (2H, s), 5.15 (1H, bs), 7.4 (5H, m), 7.97 (2H, d), 8.04 (2H, d).
[0251] LC/MS: 1 peak, 692 (MH+).
Example 24
[0252]
[0253] 223 was obtained using the general procedure in Example 20.
[0254] t HPLC=9.22 min (D); ES+ 622 (M+1).
[0255] 1H NMR d6-DMSO: 0.76 (6H, dd), 1.0-1.8 (15H, m), 2.03 (1H, m), 2.58 (2H, m), 2.79 (2H, m), 3.11 (1H, m), 3.28 (3H, s), 3.3-3.5 (12H, m), 3.94 (1H, m), 4.08 (1H, m), 4.94 (1H, m), 5.14 (1H, m), 6.61 (2H, d), 7.22 (5H, m), 7.40 (3H, m).
[0256] 13C (DMSO) 169.7, 165.9, 152.9, 138.4, 129.2, 129.1, 128.1, 126.2, 123.1, 112.8, 74.4, 74.1, 72.5, 71.2, 69.8, 66.1, 58.1, 57.1, 52.9, 47.5, 33.4, 33.2, 26.3, 24.5, 18.9, 18.8.
Example 25
[0257]
[0258] 224 was obtained using the general procedure in Example 20.
Example 26
O,N-Diacylated Prodrugs
[0259] The general procedure for N,O-diacylated compounds followed the protocol outlined in Example 20, above, except that a five fold excess of reagents was used relative to the starting material.
[0000]
[0260] t HPLC 9.26 min (D); ES+ 738 (M+1) 760 (M+Na).
[0261] 13C (DMSO): 170.2, 169.8, 156.4, 143.4, 138.8, 129.5, 128.8, 128.5, 126.8, 119.7, 74.9, 74.2, 73.7, 71.6, 70.7, 70.3, 68.0, 67.2, 59.3, 57.6, 53.8, 49.6, 35.7, 33.8, 27.1, 20.4.
[0262] 1H (DMSO): 10.1 (1H, s), 7.84 (d, 2H, J=8.5), 7.76 (d, J=8.7, 2H), 7.40 (1H, d, J=9.2), 7.22 (m, 5H), 5.14 (1H, m), 4.95 (1H, m), 4.1 (m, 8H), 3.7-3.3 (m, 13H), 3.28 (s, 3H), 3.26 (s, 3H), 2.86 (m, 2H), 2.73 (m, 1H), 2.59 (m, 1H), 2.04 (m, 1H), 1.83 (m, 2H), 0.78 (m, 6H).
Example 27
[0263]
[0264] To a mixture of 197 (2.93 g, 5.47 mmol) and phosphorous acid (Aldrich, 2.2 equiv., 12.03 mmol, 987 mg) in 20 ml pyridine was added 1,3-dicyclohexylcarbodiimide (Aldrich, 2.1 equiv., 11.49 mmol, 2.37 g) and the reaction heated to 60° C. under nitrogen for 3 h. Solvent was removed in vacuo, the residue treated with 200 ml 0.1N aqueous sodium bicarbonate and stirred 1 h at ambient temperature. The mixture was filtered, the filtrate acidified to pH 1.5 by addition of conc. HCl and extracted with ethyl acetate (3×100 ml). The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo to give 3.15 g (96%) of desired product 226 which was used directly in the next reaction. HPLC: Rt=8.91 min (96%), MS (AP+) 600.5 (M+1).
Example 28
[0265]
[0266] A suspension of 226 (˜5.47 mmol) in 18 ml hexamethyldisilazane was stirred at 120° C. until homogeneous followed by addition of bis(trimethylsilyl) peroxide (Gelest, Inc., 2.3 equiv., 12.58 mmol, 2.24 g, 2.71 ml). After 1 h the mixture was cooled to ambient temperature, solvent removed in vacuo, the residue stirred with 100 ml methanol, solvent removed in vacuo, the residue stirred with 100 ml 0.1N aqueous sodium bicarbonate, acidified to pH 1.5 by addition of conc. HCl, saturated with brine and extracted with ethyl acetate (3×100 ml). The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo to give 2.98 g (88%) of desired product 227, which was used directly in the next reaction. HPLC: Rt=9.28 min (90%), MS (AP+) 616.5 (M+1).
[0267] Alternatively, 227 can be synthesized directly from 197. In this method, 197 was dissolved in pyridine (300 mL). The resulting solution was concentrated in vacuo to about 150 ml at 50-55° C. The solution was then cooled under N 2 to 5° C., and treated with POCl 3 (6.5 ml, 1.24 equiv.) over 2 minutes. The cooling bath was removed and the reaction stirred at ambient temperature for 2.5 hrs. The solution was then cooled to 5° C. and water (300 ml) was added over 30 minutes.
[0268] The resulting mixture was extracted with 4-methylpentan-2-one (MIBK, 2×150 ml). The combined extracts were washed with 2N HCl (2×250 ml). The acid washes were back extracted with MIBK (60 ml), then the combined MIBK solutions were treated with 2N HCl (150 ml). The two phase mixture was stirred rapidly and heated to 50° C. for 2 hours. The reaction mixture was cooled to 20° C., the phases were separated and the MIBK solution was washed with brine (150 ml). The product, 227, was isolated by drying the solution with magnesium sulfate, filtering of the drying agent and concentrating in vacuo at 40° C. to give the product as a pale yellow foam (31 g, 90% yield).
Example 29
[0269]
[0270] A solution of 227 (2.98 g, 4.84 mmol) in 50 ml ethyl acetate was treated with 10% palladium on carbon (Aldrich, 300 mg) and put under 35 psi of hydrogen on a Parr shaker for 15 h. Catalyst was removed by filtration and solvent removed in vacuo to give 2.66 g (94%) of desired product 228. HPLC: Rt=7.23 min (92%), MS (ES+) 586.3 (M+1).
Example 30
[0271]
[0272] Solid 228 (2.66 g, 4.54 mmol) was treated with ml aqueous sodium bicarbonate (Baker, 3.0 equiv., 13.63 mmol, 1.14 g) and loaded onto a resin column (Mitsubishi Kasei Corp., MCI-gel, CHP-20). Distilled water was run through until the eluent was neutral followed by product elution with 1% acetonitrile in water. Pure fractions were pooled and lyophilized to give 918 mg of pure bis-sodium salt 229.
[0273] Alternatively, 7 g of 228 was dissolved in 100 ml of EtOAc with warming and the solution was extracted with 100 ml of aqueous 250 mM triethylammonium bicarbonate (TEABC) (2×). The aqueous extracts were combined and diluted to 1500 ml with water. This solution was applied to a 300 ml DEAE-52 column (Whatman) which was equilibrated with 50 mM TEABC. The column was washed with 8 L of 50 mM TEABC and the TEA salt was eluted with 2 L of 250 mM TEABC. The solution was evaporated en vacuo to 100 ml then lyophilized to yield the TEA salt (1.5 TEA equivalents). The TEA salt was (5.8 g) was dissolved in 200 ml water, 300 ml of 1 N HCl was added and the mixture was extracted with EtOAc (3×200 ml). The ethyl acetate solution was dried with MgSO 4 then evaporated en vacuo to yield 4 g of the free acid. Two grams of the free acid was dissolved in 50 ml of acetonitrile and a solution of 573 mg NaHCO 3 in 200 ml water was added. The mixture was lyophilized yielding 2.1 g of the bis sodium salt (compound 229).
Example 31
[0274]
[0275] 0.53 g (3.0 mmol) 2-[2-(2-Methoxyethoxy)ethoxy]acetic acid was added to a stirred solution of 1.2 g (3.15 mmol) HATU 0.2 g (1.47 mmol) HOAt 0.4 g (4.0 mmol) NMM in 10 ml anhydrous N,N-dimethylformamide. The mixture was stirred at room temperature for 30 minutes, then 0.5 g (1 mmol) of (3S)-Tetrahydro-3-furfuryl-N-((1S,2R)-1-benzyl-2hydroxy-3-(N-isobutyl-4-aminobenzenesulfonamido)-propyl) carbamate was added to the solution in one portion. The mixture was stirred at 20° C. for an hour then at 50° C. for an additional 12 hours. It was then cooled to 20° C., 50 ml of ether was added, and the solution was washed with water three times. The aqueous phase was washed with ether, and then the combined organic phases were dried with anhydrous magnesium sulfate and filtered. The filtrate was concentrated under reduced pressure and the residue was purified by silica gel chromatography to obtain the desired Mono-(N)acylated (102 mg, 15%) and Bis-(O,N) acylated (262 mg, 32%) compounds.
[0276] Mono-(N)-acylated: 1H-NMR (CDCl3): 0.85 (dd, 6H), 1.85 (m, 2H), 2.08 (m, 1H), 2.8-3.1 (m, 7H), 3.33 (s, 3H), 3.55 (m, 3H), 3.70-3.90 (m, 8H), 4.1 (s, 2H), 5.0 (d, 1H), 5.08 (s(br), 1H), 7.2 (m, 5H), 7.70 (d, 2H), 7.80 (d, 2H), 9.09 (s, 1H).
[0277] MS (FAB+): 666 (M+1).
[0278] Bis-(O,N)-acylated: 1H-NMR (CDCl3): 0.77 (m, 6H), 1.81 (m, 1H), 1.95 (m, 1H), 2.05 (m, 1H), 2.6-3.0 (m, 6H), 3.2 (m, 1H), 3.332 (s, 3H), 3.338 (s, 3H), 3.5-3.8 (m, 18H), 4.1 (s, 2H), 4.14 (s, 2H), 4.17 (m, 1H), 5.05 (m, 2H), 5.25 (s(br), 1H), 7.2 (m, 5H), 7.69 (d, 2H), 7.78 (d 2H), 9.06 (s, 1H).
[0279] MS (FAB+): 826 (M+1), 848 (M+Na).
Example 32
[0280]
[0281] We dissolved 0.521 g (1 mM) of 1273W94 in 5 ml THF, then cooled to −78° C. under nitrogen, and added 1.56 ml (2.5 mM) of a 1.6 M solution of nBuLi in hexane. After 20 min at −78° C., we added 105 μL (1.1 mM) of ethyl chlorocarbamate and warmed up the reaction to room temperature, followed by addition of another 105 μL of ethyl chlorocarbamate.
[0282] After stirring for additional 4 hrs, the reaction was quenched with water and the organic solvent evaporated. Part of the crude product was purified on a silica gel (Rf=0.69 (1:2 ethyl acetate:hexane)), yielding 0.131 g of the product.
[0283] C,H,N: calc: 46.06, 4.97, 5.88, found 45.90, 4.97, 5.88. C 23 H 33 N 5 O 5 S 1 . 2.2 TFA
[0284] LC/MS (ES+) 594 (M+1) 1 peak at 6.96 min.
[0285] Analytical HPLC(A) t=24.57 min. 13C (CDCl3): 155.8, 154.4, 149.9, 145.7, 136.8, +129.2, +128.7, +126.8, +124.2, 80.1, +76.9, −64.3, −56.2, −52.5, −48.7, −36.2, +28.1, +26.4, +20.0, +19.8, +14.3.
Example 33
[0286]
[0287] We dissolved 0.131 g of the above ethyl carbonate in 4 ml DCM, followed by 4 ml of TFA. Solvents were then removed after 45 min at room temperature, resulting in the title compound.
[0288] 1H (DMSO): 8.37 (2H, d, J=7.2), 8.15 (2H, m), 8.00 (2H, d, J=7.0), 7.37 (5H, m), 5.04 (1H, d, J=6.9), 4.06 (2H, q, J=7.0), 3.82 ((1H, m), 3.35 (2H, m), 2.95 (4H, m), 1.82 (1H, m), 1.20 (3H, t, J=7.0), 0.72 (overlapping doublets, 6H, J=6.2).
[0289] LC/MS 1 peak at 4.76 min.
[0290] ES+ 497.3 (M+1).
Example 34
[0291]
[0292] C,H,N: calc: 53.26, 6.14, 7.57, found 53.22, 6.14, 7.57. C 23 H 33 N 5 O 5 S 1 ×0.8 TFA
[0293] LC/MS (ES+) 594 (M+1) 1 peak at 6.96 min.
[0294] Analytical HPLC(A) t=24.57 min. 1H (DMSO): 8.34 (2H, d, J=8.7), 8.02 (2H, d, J=8.0), 7.19 (5H, m), 6.98 (1H, d, J=7.2), 5.00 (1H, m), 3.83 (2H, q), 3.50 (2H, m), 3.06 (m, 2H), 2.96 (2H, m), 2.43 (1H, m), 1.97 (1H, m), 1.02 (3H, t), 0.84 (3H, d), 0.82 (3H, d).
[0295] 13C (DMSO): 156.2, 150.1, 145.7, 140.0, +129.7, +129.2, +128.5, +126.3, +125.0, +71.8, −60.0, +56.2, −56.0, −51.8, −36.0, +26.3, +20.3, +20.1, +14.6.
Example 35
[0296]
[0297] Synthesis of 235 was accomplished analogous to that set forth in Example 1.
[0298] Yield 15.2%; tHPLC=25.2 min (A).
[0299] Rf=0.54 (B); ES+ 687.3 (M+1).
[0300] 1H (CDCl3): 8.34 (overlapping d+d, 4H), 7.97 (d, 2H, J=8.9), 7.35 (7H, m), 5.09 (1H, m), 4.56 (1H, d, J=8.4), 4.20 (1H, m), 3.54 (1H, m), 3.00 (3H, m), 2.82 (1H, m), 1.84 (1H, m), 1.37 (9H, s), 0.84 (3H, d), 0.82 (3H, d).
Example 36
[0301]
[0302] We dissolved 150 mg of 235 in 3 ml of anhydrous dioxane, added 0.35 ml of S(+)-3-OH-THF and 0.14 ml triethyl amine. The mixture was refluxed gently under nitrogen for 2 days. Conversion to 236 was quantitative. Solvents were removed and the compound purified on silica (B).
[0303] tHPLC=22.98 min (A); ES+ 636.2 (M+1).
[0304] 1H NMR (CDCl3): 8.29 (2H, d), 7.91 (2H, d), 7.22 (5H, m), 5.13 (1H, m), 4.96 (1H, m), 4.52 (1H, d), 4.02 (1H, m), 3.84 (2H, m), 3.44 (1H, m), 3.36 (1H, m), 3.10 (3H, m, overlap), 2.88 (2H, m), 2.64 (1H, m), 2.14 (1H, m), 2.05 (1H, m), 1.84 (1H, m), 1.27 (9H, s), 0.78 (6H, two overl. d).
Example 37
Carbohydrate-Based Prodrugs
[0305]
[0306] A mixture of 0.54 g (1 mMol) of (3S)-Tetrahydro-3-furfuryl-N-((1S,2R)-1-benzyl-2-hydroxy-3-(N-isobutyl-4-aminobenzenesulfonamido)propyl) carbamate, 0.46 g (2 mMol) of 5-dimethyl-tert-butyosilyloxypentanoic acid, 0.346 g (1.8 mMol) of EDCI and 0.556 mL (4 mMol) of triethylamine in 10 ml of dimethyl formamide was stirred at rt for 24 h. Another 3 mMol each of acid, EDCI and triethylamine were added and stirring was continued for an additional 96 h. A third batch of acid and EDCI was added (3 mMol each) and the mixture was stirred 72 h to complete the reaction.
[0307] The reaction mixture was then diluted with ethyl acetate and extracted with 1N hydrochloric acid, saturated sodium bicarbonate and water. Evaporation of the solvent and purification on silica gel (30% ethyl acetate-hexane) gave the desired product (500 mg) as a waxy solid.
[0308] LCMS: 1 peak, 772.5 (M+Na)
[0309] 1H NMR (CDCL3): 0.01 (6H, s), 0.78 (6H, dd), 0.95 (9H, s), 1.4-1.8 (6H, m), 1.9 (2H, m), 2.05 (1H, m), 2.3 (2H, m), 2.65 (1H, m), 2.95 (2H, m), 3.22 (1H, m), 3.4 (1H, m), 3.6 (2H, m), 3.75 (3H, m), 4.8 (1H, d), 5.1 (1H, bs), 5.2 (1H, bs), 7.2 (5H, m), 7.95 (2H, d), 8.36 (2H, d).
[0310] 450 mg of the 238 was dissolved in 30 ml of tetrahydrofuran and treated with 20 ml of water and 50 ml of acetic acid. The mixture was stirred at rt for 2 h and evaporated. Titration with hexane gave the desired alcohol (290 mg) as a white solid.
[0311] A mixture of 0.15 g (0.24 mMol) of the alcohol produced above from the previous reaction, 0.205 g (0.5 mMol) of tetraacetylglucosylbromide and 0.191 g (0.7 mMol) of silver carbonate in 3 ml of dichloromethane was stirred at rt for 6 h. 150 mg of additional glucosyl bromide and 150 mg of silver carbonate were added and the mixture was stirred at rt overnight. The mixture was loaded onto a pad of silica gel and eluted with 30% ethylacetate-hexane to afford the desired protected carbohydrate pro-drug as a white foam (200 mg).
[0312] LCMS: 1 peak, 966 (M+H).
[0313] 1H-NMR (CDCl3): 0.78 (6H, dd), 1.9 (2H, m), 2.00 (3H, s), 2.02 (3H, s), 2.05 (3H, s), 2.06 (3H, s), 2.1 (2H, m), 2.3 (2H, m), 2.7 (1H, m), 2.94 (3H, bd), 3.35 (2H, m), 3.45 (2H.m), 3.8 (5H, m), 4.1 (3H, m), 4.5 (1H, d), 4.9 (1H, bs), 4.95 (1H, t), 5.08 (4H, m), 2H, d), 8.35 (2H, d).
Example 38
[0314]
[0315] 1.5 g (9.4 mmol) SO3.py complex was added to a stirred solution of 1 g (1.87 mmol) of 197 in 25 mL anhydrous tetrahydrofurane. The mixture was stirred at 20° C. for 12 hours, then filtered. The filtrate was concentrated at reduced pressure, and the residue was transferred to a silica gel column and eluted with EtOAc (neat), followed by EtOAc:EtOH (4:1) to obtain 471 mg (47%) 239 as a colorless foam.
[0316] 1H-NMR (CDCl3): 0.80 (m, 6H), 1.8-2.1 (m, 3H), 4.15 (s(br), 1H), 4.8 (t, 1H), 5.04 (s (br), 1H).
[0317] MS (ES−): 614 (M−1).
[0000]
[0318] 100 mg (0.162 mmol) 239 dissolved in 15 ml anhydrous tetrahydrofuran and 200 mg Pd/BaSO4 (5%) was added to the solution. The mixture was stirred under atmospheric pressure of hydrogen for 8 hours, and then the catalyst was filtered. The filtrate was concentrated under reduced pressure then dried under vacuum (˜1 Hg mm, 48 hrs.) to produce 80 mg (81%) 240 as a colorless foam.
[0319] 1H-NMR (DMSO-d6): 0.85 (dd, 6H), 0.90 (m, 1H), 2.05 (m, 2H), 2.58 (m, 3H), 2.84 (dd, 1H), 3.05 (m, 2H), 3.55-3.80 (m, 6H), 4.20 (t, 1H), 4.42 (m, 1H), 4.93 (s(br), 1H), 6.09 (s, 2H), 6.70 (d, 2H), 6.80 (d, 1H), 7.15-7.40 (m, 4H), 7.51 (d, 2H).
[0320] MS (ES−): 584 (M−1).
Example 39
[0321]
[0322] 780 mg (3 mmol) 2-Chloro-1,3,2-dioxaphospholane was added to a stirred solution of 1.07 g (2 mmol) 197 and 0.7 ml (4 mmol) N,N-Diisopropylethylamine in 25 ml dichloromethane at 0° C. The mixture was allowed to warm up to room temperature and it was stirred for 2 hours. The mixture was then cooled to 0° C. and 1.5 g (9.3 mmol) bromine was added in 5 ml dichloromethane. The mixture was stirred for 1 hour at 20° C., followed by evaporation under reduced pressure. An aqueous solution (50%) of 15 ml trimethylamine was added to the residue, and the mixture was stirred at 20° C. for 12 hours.
[0323] Solvents were removed under reduced pressure and 50 ml EtOAc:EtOH (9:1) was added to the residue. The solid was filtered, washed with EtOAc:EtOH (9:1) then the filtrate was concentrated under reduced pressure. The residue was chromatographed on a 3 inch plug of silica gel using ethyl acetate (neat), then methanol (neat), as eluents to obtain 1.15 g (82%) 241 as an off-white solid.
[0324] 1H-NMR (CDCl3): 0.60 (dd, 6H), 1.70 (m, 1H), 1.95 (m, 1H), 2.10 (m, 1H), 2.8-3.2 (m, 6H), 3.4 (s (br), 9H), 5.09 (s(br), 1H), 7.25 (m, 5H), 7.83 (d, 2H), 8.28 (d, 2H).
[0325] MS (ES+): 701 (M+1), 184 (phosphatidyl choline+).
Example 40
[0326]
[0327] 250 mg Pd/C (10%) was added to a solution of 250 mg (0.35 mmol) 241 in 10 ml methanol, and the mixture was stirred under atmospheric pressure of hydrogen for 4 hours at 20° C. The mixture was filtered, and the filtrate was concentrated under reduced pressure. The residue was then dissolved in 10 ml water and lyophilized to obtain 174 mg (74%) 242 as white solid.
[0328] 1H-NMR (DMSO-d6): 0.82 (dd, 6H), 1.80-2.00 (m, 2H), 2.10 (m, 1H), 2.80 (m, 3H), 3.00 (m, 2H), 3.2 (s (br), 9H), 4.0-4.3 (m, 4H), 4.91 (s(br), 1H), 6.08 (s(br), 2H), 6.67 (d, 2H), 7.30 (m, 5H), 7.48 (d, 2H), 8.12 (d, 1H).
[0329] MS (ES+): 671 (M+1), 184 (phosphatidyl choline+).
Example 41
[0330]
[0331] 0.175 ml (2 mmol) phosphorus trichloride was added to a stirred solution of 1.07 g (2 mmol) 197 and 0.35 ml (2 mmol) N,N-Diisopropylethylamine in 25 ml dichloromethane at 20° C. The mixture was stirred for 4 hours at 20° C., then 1 ml water was added and stirred for an additional 12 hours at 20° C. 3 g anhydrous magnesium sulfate was added to the mixture and it was stirred for minutes, then filtered. The filtrate was concentrated under reduced pressure and purified by silica gel chromatography using EtOAc:Hexane (4:1), then EtOAc:EtOH (1:1), to obtain 402 mg (48%) 226 and 427 mg (36%) 243. 226:
[0332] 1H-NMR (DMSO-d6): 0.82 (dd, 6H), 1.84 (m, 1H), 1.98 (m, 1H), 2.10 (m, 1H), 2.68 (dd, 1H), 2.9-3.2 (m, 4H), 3.6-3.8 (m, 3H), 3.94 (t, 1H), 4.30, (s(br), 1H), 4.97 (s(br), 1H), 7.30 (m, 5H), 8.14 (d, 2H), 8.43 (d, 2H).
[0333] MS (ES−): 598 (M−1).
[0334] 243: (1:1 mix of diastereomers):
[0335] 1H-NMR (CDCl3): 0.80 (m, 6H), 1.8-2.1 (m, 4H), 2.8-3.2 (m, 6H), 3.7-3.9 (m, 4H), 4.15 (m, 1H), 4.8-5.15 (m, 2H), 5.57, 5.72 ((d, d), 1H), 7.25 (m, 5H), 7.95 (dd, 2H), 8.35 (m, 2H).
[0336] MS (ES−): 580 (M−1), 598 ((M+H2O)−1).
Example 42
[0337]
[0338] The reduction was carried out as described in Example 40; (Yield: 79%).
[0339] 1H-NMR (DMSO-d6): 0.81 (dd, 6H), 1.82 (m, 1H), 1.95 (m, 1H), 2.08 (m, 1H), 2.6-3.15 (m, 6H), 3.6-3.75 (m, 3H), 4.03 (t, 1H), 4.28, (m, 1H), 4.96 (s(br), 1H), 6.07 (s, 2H), 6.65 (d, 2H), 7.25 (m, 5H), 7.42 (d, 2H).
[0340] MS (ES−): 568 (M−1).
Example 43
[0341]
[0342] The reduction was carried out as described in Example 40; (Yield: 98%).
[0343] (1:1 mix of diastereomers):
[0344] 1H-NMR (DMSO-d6): 0.82 (m, 6H), 1.75-2.0 (m, 2H), 2.05 (m, 1H), 2.6-3.2 (m, 6H), 3.55-3.8 (m, 4H), 4.02, 4.22 (m, t, 1H), 4.75 (m, 1H), 4.90, 5.01 ((d, d), 1H), 6.12 (s, 1H), 6.68 (d, 2H), 7.30 (m, 5H), 7.49 (d, 2H).
[0345] MS (ES−): 550 (M−1), 568 ((M+H2O)−1).
Example 44
Pharmacokinetics in Sprague-Dawley Rats Following Single Oral Dose
[0346] In order to study the pharmacokinetics of the prodrugs of this invention, we administered single oral doses of a series of prodrugs of this invention, as well as VX-478, to male and female Sprague-Dawley rats. Administration of molar equivalents of a series of prodrugs of this invention in a variety of pharmaceutical vehicles was tested.
[0347] Separate groups of male and female Sprague-Dawley rats (3/sex/group) received oral doses of compound 229 by oral gavage, in different vehicles at the same dose equivalent (40 mg/kg molar equivalent of VX-478). The different vehicles for compound 229 were: 1) water; 2) 5/4/1; 3) PEG 400; 4) TPGS/PEG 400; and 5) PEG. The vehicles for VX-478 were: 1) 33% TPGS/PEG400/PEG; and 2) 12.5% TPGS/PEG 400/PEG.
[0348] Blood samples were collected following administration at various time intervals and analyzed for the presence of both compound 229 and its metabolite, VX-478, by HPLC and MS methods. The results of this study are tabulated below (Table IV).
[0000]
TABLE IV
Compound
229
229
229
229
VX-478
VX-478
vehicle
H 2 O
H 2 O:PG:EtOH
PEG 400
TPGS/PEG
33% TPGS/
12.5% TPGS/
5:4:1
400/PG
PEG 400/PG
PEG 400/PG
number of rats
3
3
3
3
6
3
Molar equiv.
40 PO
40 PO
40 PO
40 PO
41 PO
50 PO
dose/478 Dose
(mg/Kg)
AUC
11.7 ± 4.8
10.6 ± 7.4
7.4 ± 1.8
8.2 ± 1.6
29.6 ± 5.8
16.2 ± 1.8
(ug*hr/ml)
Cmax (μM)
7.1 ± 1.7
3.3 ± 0.6
3.1 ± 0.3
3.0 ± 0.7
14.0 ± 2.2
6.0 ± 1.0
half life (hr)
1.7*
3.4*
2.8*
2.8*
2.5 ± 0.9
2.2 ± 1.0
Relative Avail. of
39.5†
35.8†
25.0†
27.7†
reference
reference
VX-478
90.2††
81.8††
57.1††
63.3††
a dose of 50 mg/kg of compound 229 is equal to 40 mg/Kg of VX-478.
no compound 229 was detected in plasma at 15 min. (first data point).
*Represents the harmonic mean
†Relative availability of VX-478 when compared to a prototype clinical formulation
††Relative availability of VX-478 when compared to a prototype toxicology formulation
[0349] We performed a similar study on dogs using both a solid capsule formulation of compound 229 and an ethanolic/methyl cellulose solution formulation, as compared to a TPGS-containing solution formulation of VX-478. The results from this study are presented below in Table V.
[0000]
TABLE V
Compound
229
229
VX-478
vehicle
solid
methyl
22%
capsule
cellulose in 5%
TPGS/PEG
EtOH/water
400/PG
number of dogs
2
2
>2
Molar equiv. dose/478
17 PO
17 PO
17 PO
Dose (mg/Kg)
AUC
16.7 ± 2.7
14.2 ± 3.2
23.5 ± 7.4
(ug*hr/ml)
Cmax (μg/ml)
6.1 ± 1.7
6.3 ± 0.3
6.8 ± 1.1
Tmax (hr)
2.3 ± 0.6
0.5 ± 0.5
1.0 ± 0.8
Relative Avail.
71.1
60.4
reference
of VX-478 (%)
[0350] The results demonstrate that oral administration of compound 229 as an aqueous solution resulted in improved bioavailability in comparison to the other vehicles studied. Also, following administration of compound 229, none of that compound was detected in the first time point blood sample (or later samples), suggesting first pass metabolism to VX-478. Comparison of the aqueous dose of compound 229 with the two non-aqueous formulations used for VX-478 indicated equivalence in delivery as illustrated by the range found for the bioavailability.
Example 45
[0351]
[0352] We added 0.28 ml (3.0 mmol) POCl 3 to a stirred solution of 1.07 g (2.0 mmol) of compound 197 in 10 ml anhydrous pyridine at 5° C. The mixture was allowed to warm up to room temperature and stirred at 20° C. for 3 hours. The mixture was cooled to 0° C., and quenched with 10 ml water. The solvents were removed under reduced pressure, the residue was dissolved in 100 ml ethyl acetate and washed with 20 ml 1M sodium bicarbonate solution. The organic phase was dried with anhydrous magnesium sulfate, filtered then concentrated. Chromatographic purification (SiO2, EtOAc) produce 280 mg of compound 400 (Yield=23%).
[0353] 1H-NMR (DMSO-d6): 0.86 (dd, 6H), 2.05 (m, 2H), 2.84 (d, 2H), 2.95 (dd, 1H), 3.06 (m, 1H), 3.25 (dd, 1H), 3.50-3.70 (m, 4H), 4.20 (m, 1H), 4.35 (m, 1H), 7.2-7.4 (m, 5H), 7.9-8.1 (m, 2H), 8.40 (m, 2H).
[0354] MS (ES−): 596 (M−1).
[0000]
[0355] Compound 400 was converted to compound 401 using the standard hydrogenation method described above employing H2/PdC (10%), atmospheric pressure, 4 hours at room temperature, solvent: MeOH—H 2 O (5:1). Yield of 401=68%.
[0356] 1H-NMR (DMSO-d6): 0.85 (dd, 6H), 2.0 (m, 2H), 2.6-3.1 (m, 4H), 4.15 (m, 1H), 4.40 (m, 1H), 6.1 (s(br), 1H), 6.61 m (2H), 7.2-7.5 (m, 7H).
[0357] MS (ES−): 566 (M−1).
Example 46
[0358]
[0359] We added 1.0 g (2.8) mmol Na-t-Boc-nd-Cbz-L-Ornithine was added to stirred solution of 1.2 g (3.15 mmol) HATU, 0.2 g (1.47 mmol) HOAt, 0.4 g (4.0 mmol) NMM in 10 ml DMF. The mixture was stirred at room temperature for 2 hrs. then 0.5 g (1.0 mmol) of compound 218 was added and the solution was stirred at 50° C. for 12 hours. The mixture was cooled to room temperature, 100 ml ether was added and extracted with 5×50 ml water. The organic phase was dried with anhydrous magnesium sulfate, filtered and concentrated under reduced pressure. The residue was purified by silica gel chromatography (Hexane-EtOAc (1:1) then EtOAc (neat)) to yield 410 mg (48%) of compound 350.
Compound 350 A
[0360] 1H-NMR (CDCl3): 0.85 (dd, 6H), 1.41 (s, 3H), 1.45 (s, 6H), 1.60 (m, 4H), 1.90 (m, 2H), 2.1 (m, 1H), 2.75-3.25 (m, 6H), 3.60-3.90 (m, 6H), 5.15 (dd, 2H), 7.2-7.4 (m, 10H), 7.68 (dd, 4H).
[0361] MS (ES−): 852 (M−1).
[0362] MS (ES+): 854 (M+1).
[0363] Compound 350 B
[0364] 1H-NMR (CDCl3): 0.81 (dd, 6H), 1.39 (s, 9H), 1.40-2.10 (m, 9H), 2.70-3.20 (m, 8H), 3.60-3.90 (m, 6H), 4.10 (m, 1H), 4.80 (d, 1H), 5.04 (s(br), 2H), 7.1-7.3 (m, 10H), 7.61 (s, 4H).
[0365] MS (ES−): 866 (M−1).
[0366] MS (ES+): 868 (M+1).
[0367] Compound 350 C
[0368] 1H-NMR (CDCl3): 0.86 (dd, 6H), 1.40 (s, 3H), 1.46 (s, 6H), 1.60-2.10 (m, 7H), 2.70-3.15 (m, 6H), 3.60 (d, 1H), 3.70-4.10 (m, 6H), 4.81 (d, 1H), 5.05-5.30 (m, 7H), 7.18-7.4 (m, 17H), 7.55 (d, 2H).
[0000]
[0369] Compounds 350A, 350B and 350C were converted to Compounds 402, 403, and 404, respectively, using the standard hydrogenation method set forth above:
[0370] H2/PdC (10%), atmospheric pressure, 4 hours, room temperature, solvent: EtOH, Yield: 81%.
[0371] Compound 402
[0372] 1H-NMR (CDCl3): 0.80 (dd, 6H), 1.38 (s, 9H), 1.8 (m, 6H), 2.10 (m, 2H), 2.75-3.30 (m, 8H), 3.50-4.00 (m, 7H), 4.55 (s(br), 1H), 7.2 (m, 5H), 7.60 (d, 2H), 7.81 (d, 2H).
[0373] MS (ES+): 720 (M+1).
[0374] Compound 403
[0375] 1H-NMR (CDCl3): 0.87 (dd, 6H), 1.45 (s, 9H), 1.50-2.00 (m, 8H), 2.08 (m, 1H), 2.75-3.15 (m, 8H), 3.60 (d, 1H), 3.75-3.90 (m, 5H), 4.28 (s(br), 1H), 4.92 (d, 1H), 5.11 (m, 1H), 5.27 (s(br), 1H), 7.28-7.35 (m, 5H), 7.70 (s, 4H).
[0376] MS (ES+): 734 (M+1).
[0377] Compound 404
[0378] 1H-NMR (CDCl3): 0.80 (dd, 6H), 1.32 (s, 9H), 1.50-2.10 (m, 7H), 2.60-3.20 (m, 8H), 3.40-3.80 (m, 5H), 5.0 (s(br), 1H), 7.05-7.2 (m, 5H), 7.50-7.80 (m, 4H).
[0379] MS (ES+): 762 (M+1).
Example 47
[0380]
[0381] We added 5 ml TFA to a stirred solution of 260 mg (0.3 mmol) Compound 350A, 350B, or 350C in 20 ml chloroform. The mixture was stirred for 5 hours at room temperature, and then the solvents were removed under reduced pressure. The residue was dissolved in 20 ml dichloromethane, 2 ml (11 mmol) N,N-diisopropylethylamine and 1 ml (10 mmol) acetic anhydride was added to the reaction mixture. The solution was stirred for 1 hour, then the solvents were removed. The residue was purified by silica gel chromatography (eluant: EtOAc-EtOH (9:1)) to obtain 170 mg (71%) of compound 351A, 351B or 351C, respectively.
[0382] Compound 351A
[0383] 1H-NMR (CDCl3): 0.85 (dd, 6H), 1.60 (m, 3H), 1.80-2.00 (m, 3H), 2.06 (2, 3H), 2.75 (dd, 1H), 2.80-3.20 (m, 5H), 3.60-3.90 (m, 7H), 4.85 (d, 2H), 5.10 (m, 3H), 6.46 (d, 1H), 7.25 (m, 10H), 7.67 (s, 4H), 9.30 (s, 1H).
[0384] MS (ES+): 796 (M+1), 818 (M+Na).
[0385] Compound 351B
[0386] 1H-NMR (CDCl3): 0.80 (dd, 6H), 1.38 (m, 2H), 1.50 (m, 2H), 1.70 (m, 0.2H), 1.85 (m, 2H), 2.00 (s, 3H), 2.70 (dd, 1H), 2.75-3.20 (m, 7H), 3.55 (d, 1H), 3.75 (m, 6H), 4.45 (q, 1H), 4.83 (d, 1H), 4.95 (t, 1H), 5.03 (s(br), 3H), 6.46 (d, 1H), 7.20 (m, 10H), 7.61 (s, 4H), 9.29 (s, 1H).
[0387] MS (ES+): 810 (M+1), 832 (M+Na).
[0388] Compound 351C
[0389] 1H-NMR (CDCl3): 0.85 (dd, 6H), 1.70-2.00 (m, 6H), 2.07 (s, 3H), 2.70 (dd, 1H), 2.80-3.00 (m, 3H), 3.10 (dd, 1H), 3.60 (d, 1H), 3.65-4.00 (m, 6H), 4.1 (m, 1H), 4.62 (q, 1H), 4.82 (d, 1H), 5.00-5.30 (m, 5H), 7.10-7.40 (m, 15H), 7.55 (d, 2H), 7.65 (m, 3H) 9.18 (s(br), 1H), 9.45 (s(br), 1H), 9.56 (s(br), 1H).
[0390] MS (FAB+): 972 (M+1), 994 (M+Na).
[0000]
[0391] The conversion of compounds 351A, 351C, and 351C to 405, 406, and 407, respectively was achieved by standard hydrogenation using H2/PdC (10%), atmospheric pressure, 4 hours at room temperature, solvent: EtOH,
[0392] Yield=46%.
[0393] Compound 405
[0394] 1H-NMR (DMSO-d6): 0.85 (dd, 6H), 1.62 (m, 3H), 1.81 (m, 2H), 1.94 (s, 3H), 2.00-2.2 (m, 2H), 2.75-3.00 (m, 5H), 3.10 (m, 2H), 3.50-3.80 (m, 5H), 4.54 (m, 1H), 5.00 (m, 1H), 5.11 (d, 1H), 7.2-7.4 (m, 5H), 7.80-8.00 (m, 5H), 10.72 (s, 1H).
[0395] MS (ES+): 662 (M+1).
[0396] Compound 406
[0397] 1H-NMR (DMSO-d6): 0.80 (dd, 6H), 1.30-1.80 (m, 7H), 1.85 (s, 3H), 1.95-2.10 (m, 2H), 2.70 (m, 4H), 2.99 (m, 2H), 3.30 (m, 5H), 3.40-3.80 (m, 4H), 4.35 (m, 1H), 4.90 (s, 1H), 5.00 (d, 1H), 7.08-7.25 (m, 5H), 7.50 (s(br), 1H), 7.71 (d, 2H), 7.79 (d, 2H), 10.54 (s, 1H).
[0398] MS (ES+): 676 (M+1).
[0399] Compound 407
[0400] 1H-NMR (DMSO-d6): 0.80 (dd, 6H), 1.40-1.60 (m, 4H), 1.75 (m, 2H), 1.86 (s, 3H), 2.00 (m, 2H), 2.75 (dt, 2H), 3.00 (m, 2H), 3.10 (q, 2H), 3.40-3.70 (m, 5H), 4.39 (q, 1H), 4.92 (s (br), 1H), 5.01 (d, 1H), 7.20 (m, 5H), 7.70 (d+m, 3H), 7.81 (d, 2H), 8.30 (d, 1H), 10.60 (s, 1H).
[0401] MS (ES+): 704 (M+1).
Example 48
[0402]
[0403] We added 1.0 g (7.5 mmol) methanephosphonyl dichloride to a stirred solution of 2.14 g (4.00 mmol) of compound 197 in 20 ml toluene, containing 10% pyridine. The mixture was stirred at 100° C. for 5 hours, then cooled to 40° C., 2 g (18.5 mmol) benzyl alcohol was added to the reaction, and the mixture was stirred at 20° C. for 12 hours. The solid was filtered, washed with 2×10 ml toluene and the filtrate was concentrated under reduced pressure. The residue was purified using silica gel chromatography (eluants: Hexane-EtOAc (1:1), then EtOAc (neat)) to yield 550 mg (20%) of compound 352.
[0404] 1H-NMR (CDCl3): 0.67 (dd, 6H), 1.53 (d, 3H), 1.70 (m, 1H), 1.90-2.10 (m, 2H), 2.65-3.20 (m, 6H), 3.55 (d, 1H), 3.80 (m, 3H), 4.10 (m, 1H), 4.70 (q, 1H), 4.90-5.20 (m, 4H), 6.37 (d, 1H), 7.2-7.4 (m, 10H), 7.90 (d, 2H), 8.30 (d, 2H).
[0405] MS (ES+): 704 (M+1), 726 (M+Na).
[0000]
[0406] Compound 352 was converted to compound 408 using standard hydrogenation method: H2/PdC (10%), atmospheric pressure, 2 hours, room temperature, solvent: MeOH; Yield: 78%.
[0407] 1H-NMR (DMSO-d6): 0.84 (dd, 6H), 1:44 (d, 3H), 1.82 (m, 1H), 1.90-2.10 (m, 2H), 2.62 (m, 2H), 2.95 (m, 2H), 3.10 (d, 1H), 3.39 (d, 1H), 3.45-3.80 (m, 4H), 4.14 (t, 1H), 4.53 (m, 1H), 5.00 (s (br), 1H), 6.68 (d, 2H), 7.2-7.4 (m, 5H), 7.50 (d, 2H).
[0408] MS (ES−): 582 (M−1).
[0409] While we have described a number of embodiments of this invention, it is apparent that our basic constructions may be altered to provide other embodiments which utilize the products and processes of this invention. Therefore, it will be appreciated that the scope of this invention is to be defined by the appended claims, rather than by the specific embodiments which have been presented by way of example. | The present invention relates to prodrugs of a class of sulfonamides which are aspartyl protease inhibitors. In one embodiment, this invention relates to a novel class of prodrugs of HIV aspartyl protease inhibitors characterized by favorable aqueous solubility, high oral bioavailability and facile in vivo generation of the active ingredient. This invention also relates to pharmaceutical compositions comprising these prodrugs. The prodrugs and pharmaceutical compositions of this invention are particularly well suited for decreasing the pill burden and increasing patient compliance. This invention also relates to methods of treating mammals with these prodrugs and pharmaceutical compositions. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to dispensers of the type having a dispensing transport device, for dispensing strips which contain medicine. These strips are transported from a storage space within the dispenser to a discharge passageway and are divided in individual sections as they are dispensed.
The problem underlying the invention is to so design a dispenser of this type which is simple-to-manufacture, easy to use and which is effective to dispense medicinal strips in a hygenic condition.
SUMMARY OF THE PRESENT INVENTION
The present invention contemplates a dispenser including a housing having a storage compartment for holding a medicinal strip which can be divided along a series of transverse perforations, a discharge passageway through which the strip exits the housing and a transport device for advancing the strip incrementally from the storage compartment through the discharge passageway.
In accordance with the present invention the strip is not touched during dispensing. The dispenser is activated by means of an actuator member; e.g., a button on the housing. The cross sectional area of the discharge slot substantially matches the cross section of the strip so that the strip within the housing is maintained in a hygenic condition. The transport mechanism includes a wheel having peripheral teeth which engage the strip and when rotated advance the strip through the discharge passageway. The wheel is advanced by means of a drive pawl carried by the actuating member which acts on the peripheral teeth on the wheel.
One advantage of the present dispenser is that it is simple to use. Furthermore, the product stored; e.g., a detachable "tablet" strip coated with a reactive agent is optimally protected. Finger contact with the contents is prevented. Thus, the dispenser serves as an effective protective package, which can be readily carried by the user, for instance, in a coat pocket. The present container can function as a small package by filling it with an elongated strip in loop form. Alternatively, the package can serve as a large size container by eventually filling it with a rolled strip. Moreover, the present container which dispenses a "tablet" strip has not only the advantage of saving space but also is quieter in comparison with a container filled with loose tablets. Moreover, the immobility of the tablets combined in a strip reduces the degree of abrasion. This eliminates the unfavorable disintegration of tablets or the necessity of providing a stronger bond of the tablet substance. A strip appropriately coated or saturated with reactive agent may consist of so-called edible paper as the substrate. Gelatin type strips can be utilized as well. In order to optimize the hygenic conditions, the feed wheel of the dispensing transport mechanism is sealed and is located adjacent to the discharge passageway. Due to cross sectional similarity of the discharge passageway and strip, the stored strip and wheel are substantially sealed by the strip itself. The transport feed wheel itself covers the strip in noncontact fashion. The wheel is activated by a push button which is preferably incorporated in a protective cover in that it forms part of the dispenser housing. Consequently, the only opening in the housing is sealed by the strip which acts the same as a plug. The dispensing transport device engaging the strip is so constructed that the tear-off line of a strip section which is positioned for dispensing lies within the discharge passageway. Consequently, the following strip section is not touched by the finger of the user as the strip section ready for dispensation is detached. The dispensing end of the dispenser housing is covered by a cap which is lock onto the dispenser housing so as to form a safety catch to protect against dispensing by a child. In one embodiment the child safety catch and a pawl interacting with the transport feed wheel are joined on opposite sides of the same wall section of the dispenser housing. Both functional components are thus joined in a single zone of the housing and mutually stiffen one another. One advantageous actuator for the transport wheel includes a drive pawl formed on the inside wall of the cap. In this embodiment the front wall of the cap is spaced from the mouth end of the discharge passageway. As the cap is put in place, the next strip section moves into the advanced position ready for tearing off. The spacing between the cap and discharge passageway avoids buckling of this section of the strip. It has further been found advantageous to provide a ramp between the storage space and discharge passageway. The strip extends into the discharge passageway which is disposed parallel to the housing support bottom for the strip.
These and other objects and advantages of the present invention will be more fully explained hereafter in relation to the drawings illustrating three embodiments of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the first embodiment of the present dispenser;
FIG. 2 a plan view of the dispenser of FIG. 1;
FIG. 3 is a rear view of the dispenser of FIG. 1;
FIG. 4 is a cross sectional view taken along line IV--IV of FIG. 5;
FIG. 5 is a plan view of the dispenser with the cap;
FIG. 6 is a cross sectional view taken along line VI--VI in FIG. 7, illustrating a second embodiment of the dispenser;
FIG. 7 is a plan of a second embodiment of the dispenser with the cap removed;
FIG. 8 is a cross sectional view taken along line VIII--VIII of FIG. 9, illustrating a third embodiment of the dispenser;
FIG. 9 is a plan view of the dispenser of FIG. 8 with the cap, which in addition to the child safety forms here the actuating button, partly cut away.
DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIG. 4, a preferred form of dispenser includes an oblong housing 1. Most of its longitudinal section of the housing forms a storage space 2 for medicine having the form of a strip 3.
In the area of the dispenser head 4 illustrated at the left of the drawing, the housing forms at bottom left a horizontally extending, relatively short discharge passageway 5. The inner end of the passageway is adjacent to a ramp 7 having an acute-angle inclination toward horizontal support bottom 6 of housing 1. The angle of inclination is about 30°. The length of the ramp equals about twice to three times the length of discharge passageway 5.
The long rectangular cross section of the discharge passageway corresponds to that of the strip 3, so that the latter will fill the passageway cross section.
A line through the center of ramp 7 and perpendicular thereto intersects the axis of transport feed wheel 8. The latter is part of a dispensing transport device V in the area of the dispenser head 4. The transport wheel 8 extends across the entire clearance of the discharge passageway 5 and includes a sealed gear rim 9 disposed on the transverse center portion of the transport wheel. The gear rim has a saw tooth structure, that is, the one face 10' of the teeth 10 extends radially to the horizontal transport wheel axle 11 which, in turn, extends transverse to the dispensing direction y, whereas the other face 10" extends at a small angle from the circumference of the narrow gear rim web 12. The face 10' is shown slightly relieved in the drawing. The tooth points engage the strip passing across the ramp 7.
The dispensing transport device V also comprises a button 13. In the first and second embodiments, the latter is formed by a tab 15 which is slit from the top wall 14 of the housing 1. The slitting lines are marked 13'. The free end of the tab, which according to FIG. 6 is grooved crosswise, includes a tongue 16 pointing downward. A drive pawl 17, angled in the direction of the transport wheel 8, engages the tooth gaps of the gear rim 9. The tongue 16 is slightly prestressed, preferably as a result of the injection molding operation, so that it is a spring-loaded into engagement with the teeth of gear 9. In the first and second embodiments, pawl 17 engages a tooth located approximately on the level of the wheel axle 11. When it is pushed down, the pawl 17 puts a load on the steep face 10', rotating the transport wheel in the direction of arrow z until the pawl 17 disengages the tooth gap after an angular travel of about 30°.
The slight spring loading acts transverse to two vertical upwardly open mounting slots 19 for the journals of the wheel axle 11 which protrude sideways beyond the transport wheel. These mounting slots are located in the vertical side walls 20 of the housing and extend parallel to each other. The slots 19 are open on their inner portions; i.e., they are open toward each other. Locking projections 21 extend on both side of the slots above the bottom bearing trough, portion of the slots securing the axle in position.
The outer tips of the teeth 10 sweep across the ramp 7 at a spacing such that the strip 3 will be shifted by the teeth when the button is actuated. To prevent the transport wheel 8 from being carried in the direction of arrow z as the button retracts, the transport wheel is fashioned as a pawl wheel and interacts with a pawl 22 in the fashion of a rachet lock. Pawl 22 is formed from an elastic wall section 23 of the dispenser housing 1. According to the embodiments shown in FIGS. 4 through 7, this wall section 23 extends diametrically opposite to the driver pawl 17. The pawl 22 also has a slight prestress. Its head bears on the radially aligned or slightly relieved, respectively, face 10' of the teeth. In the embodiment shown in FIGS. 8 and 9, however, the pawl 22 originates on the inside of the top wall 14 of the housing 1. There, its head is not angled radially inward as illustrated in FIG. 4; instead, the pointed from end bears in locking fashion, in FIG. 8, on the steep or relieved face 10'.
The dispensing transport device v engaging in the strip 3 is constructed so that a tear-off line 24 of the strip 3, formed for instance by transverse perforation, will in dispensing position (FIGS. 5, 7, 9) of a strip section 3' still be located within the discharge passageway 5. About three fourths of the length of the section ready for dispensation extends through the mouth end 5' of the discharge passageway 5 for easy gripping. This prevents the following strip section 3' from coming into contact with the operator's hand.
To actuate the button 13, a cap 25 covering five sides of the housing 1 must be removed first. The cap serves as a child safety feature (i.e., it prevents dispensing of contents by children) and snaps over the dispenser housing 1. The housing has on the top side of its top wall 14 a locking projection 26 which interacts with a depression or cutout 27 in the cap. In the assembled position of the cap, which is limited by a stop, a steep locking face 26' of the locking projection 26 is positioned in a blocking fashion in engagement with the corresponding cutout edge 27'. To remove the cap and thereby defeat the child safety, the locked connection must be released which is a procedure which is not readily apparent. To facilitate releasing the locked connection, the section of the cap wall 28 opposing the top well 14 in the snap connection area is separated by slits extending inwardly from the open end. Slit lines 29 can be seen clearly in FIG. 2.
A transverse bead 30 is provided just behind cut-out 27 so that the snap-in tab 31 can swing upwardly without breaking off. The rim face of the releasable cap 25 is coplanar with the back of a plug 32 which seals a filling opening 33 which is located in the housing opposite the discharge passageway 5. The plug 32 has a small depression 34 below the snap in tab 31. A user can insert his fingernail in depression 34 reaching from inside underneath the free end of the tab and pushing it upward around the hinge point 35 created by the bead 30. For convenient insertion of the fingernail or tip of the finger, respectively, depression 34 is rounded crosswise, as can be seen from FIG. 5. The plug 32 is designed as a hollow plug so that it does not reduce the storage space 2. The hollow plug can readily be inserted into the dispenser housing, after the free end of the strip 3 is introduced into the discharge passageway 5 by moving it along ramp 7 with the aid of the button 13. This feeding action is facilitated by the upper wall of the passageway which protrudes in rooflike fashion in the feeding direction of the strip.
To assist the operator in holding the housing 1 as the cap is removed, the side walls 36 of the housing have a semi-circular cut out or niche in the area of the end comprising the refill opening. The respective niches are marked 37. These latter are engaged by gripper jaws 38 of the dispenser housing 1 that are similar in contour. The jaws are molded to the housing as outward protrusions and are configurated to form grooves 39 transverse to the direction of pull-off. The grooves 39 extend without interruption into a plug head 40. The plug is held by a pinch fit so that a deliberate removal force is required. Plug 40 is not recognizable as a separate component and forms only a relatively narrow gripping area near the end of the housing and consequently a force applied to the center portion of the jaws; i.e., across the joint, will not readily result in the release of the plug. For this reason, quite effective protection is provided against accidental opening by a child.
The embodiment shown in FIGS. 8 and 9 uses a cap 25 of shorter length than the cap of the previous embodiments. Components of this embodiment corresponding to those previously described are not redescribed in detail. The snap projection 26 retaining the cap 25 extends outward in the immediate vicinity of the transport wheel 10. Pawl 22 extends inwardly adjacent to projection 26 so that pawl and child safety catch (snap projection 26) extend from generally the same section of the wall 14, but in opposite directions. Thus, the root areas of both functional components are mutually stabilized. This is advantageous for removal of the part from the mold.
A further difference from the earlier embodiments relates to the activator member 13, which is fashioned here as a drive on the cap 25 which interacts directly with the gear rim 9. As the cap is slipped in place, limited by a stop, the strip section 3' is being advanced to a position ready for dispensation. This is because the steep face 13' of the activator member 13, shown vertical in FIG. 8, will seat on the steep face 10' of the respective tooth 10 in capping. In uncapping, however, the member 13 due to the small height of its back face, slips over the backs of the teeth 10 without entraining the transport wheel 8, with the pawl 22 retaining the wheel against movement.
The capping stop is formed by a projection 41 which is molded to the outside of the support bottom 6.
In the embodiment of FIGS. 8 and 9 a recess is molded in the snap tab 31. This recess facilities raising the snap tab 31 in a manner similar to recess 34.
In another variation snap tab 31 is formed as a section which is not separated by slits but is rigid, while the section facing the snap projection 26 and the pawl 22 are separated from the adjacent housing by slits in the fashion of a tongue. In this variation, pawl 22 can be pushed down as a button when slipping the cap 25 in place. The dispensation of the strip is accomplished during the retraction stroke of the cap. In this embodiment a racket type pawl would be provided by molding, as explained in conjunction with FIG. 4.
In both the embodiment shown in FIGS. 8 and 9 and the above described variation (not shown), the front wall 42 of the cap 25 extends a distance A from the mouth end 5' of the discharge passageway 5, so that the section 3' of the strip can freely be advanced from mouth 5'.
The storage space 2 contains only one strip which extends along the entire length of the housing and extends into a loop. This degree of filling equals a small pack. Similarly, a large pack could be obtained simply by utilizing all the volume of space 2 with a strip which is stored in a rolled condition. Upon inserting the plug 32, the contents are sealed at the filling end and thus are not easily accessible to touch. When placing a cap 25 over the transport wheel 8, the strip is further protected from contact.
From the above disclosure of the general principles of the present invention and the above description of three preferred embodiments, those skilled in the art will readily comprehend the various modifications to which the present invention is susceptible. Accordingly, we desire to be limited only by the scope of the following claims. | A dispenser is disclosed for dispensing strips which contain medicine and can be divided into individual sections as they are dispensed. The dispenser includes a housing having a storage space for strips and a discharge passageway through which strips are dispensed. A ramp interconnects the storage space and passageway. A feed wheel having a peripheral gear feeds strips along the ramp. The feed wheel is actuated by a member operable from outside the housing. The actuating member shifts a drive pawl which engages the peripheral gear on the feed wheel. A cap is secured over the dispensing end of the housing and is held in place by a snap connection. | 8 |
PRIORITY
This application claims priority to an application entitled “LOCAL WIRELESS COMMUNICATION MODULE COMBINED WITH ANTENNA AND MOBILE TERMINAL HAVING THE SAME” filed in the Korean Intellectual Property Office on Oct. 2, 2006 and assigned Serial No. 2006-96901, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mobile terminal, and, more particularly, to a local wireless communication module combined with an antenna and a mobile terminal having the same.
2. Description of the Related Art
With rapid development in communication technology, mobile voice communication can be conducted, essentially without restriction of time and place. Additionally, with an increased memory capacity of mobile terminals, various functions, such as character data, image data, MP3 data, and games, are provided to a user. The mobile terminal may include a mobile communication terminal, Personal Digital Assistant (PDA), and Portable Multimedia Player (PMP).
The mobile terminal may be connected to a desktop computer or a notebook computer using a data cable, and data or programs may thereby be transmitted through the data cable.
For this, a conventional mobile terminal requires a data cable for connection to a computer. However, carrying a data cable all times is inconvenient.
If both the mobile terminal and the computer are digital devices supporting wireless communication, desired data or programs may be easily transmitted. However, in this case, an inconvenient authentication process is necessary for connection between the mobile terminal and the computer.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above problems, and an object of the present invention is to eliminate an inconvenience of carrying a data cable for connecting of a mobile terminal to a computer.
Another object of the present invention is to enable easy connection of a mobile terminal to a computer whenever necessary.
In order to achieve the above objects, the present invention provides a local wireless communication module combined with an antenna for a mobile terminal, for use as an RF communication antenna when connected to a Universal Serial Bus (hereinafter USB) socket of the mobile terminal or as a local wireless communication module for executing local wireless communication between the mobile terminal and a computer when detached from the mobile terminal and connected to a USB socket of the computer.
A local wireless communication module combined with an antenna for a mobile terminal having a first local wireless communication module according to the present invention includes a USB connector; a Radio Frequency (hereinafter RF) antenna for transmitting and receiving an RF signal when the USB connecter is joined to a USB socket of the mobile terminal; a second local wireless communication module for executing local wireless communication between the mobile terminal and a computer when the USB connector is detached from the mobile terminal and joined to a USB socket of the computer; and a switch for connecting the USB connector to the RF antenna or to the second local wireless communication module according to whether the USB connector is joined to the USB socket of the mobile terminal or detached from the USB socket of the mobile terminal.
The local wireless communication module combined with an antenna preferably further includes a local wireless communication antenna connected to the second local wireless communication module. The switch, RF antenna, second local wireless communication module, and local wireless communication antenna are preferably protected by a module body. The USB connector preferably protrudes outside of the module body with a predetermined length.
A mobile terminal according to another embodiment of the present invention includes a USB socket; a terminal body installed with a first local wireless communication module; and a local wireless communication module combined with an antenna, having a USB connector able to be joined to the USB socket of the mobile terminal body. The local wireless communication module combined with an antenna includes a USB connector; an RF antenna for transmitting and receiving an RF signal when the USB connecter is joined to the USB socket of the mobile terminal; a second local wireless communication module for executing local wireless communication between the mobile terminal and a computer when the USB connector is detached from the mobile terminal and joined to a USB socket of the computer; and a switch for connecting the USB connector to the RF antenna or to the second local wireless communication module according to whether the USB connector is joined to the USB socket of the mobile terminal or detached from the USB socket of the mobile terminal.
The terminal body preferably includes a first terminal body having the USB socket of the mobile terminal and the first local wireless communication module; and a second terminal body joined to the first terminal body, and having a display unit. Alternatively, the terminal body includes the first terminal body having a first local wireless communication module; and a second terminal body joined to the first terminal body, and having a display unit and the USB socket of the mobile terminal. As another alternative, the terminal body includes a first terminal body having the USB socket of the mobile terminal; and a second terminal body joined to the first terminal body, and having a display unit and the first local wireless communication module. In another alternative, the terminal body includes a first terminal body; and a second terminal body joined to the first terminal body, and having a display unit, the USB socket of the mobile terminal, and the first local wireless communication module. The USB socket may be formed on the outer surface of the terminal body.
The mobile terminal preferably further includes a cover for surrounding the USB socket of the terminal body. The mobile terminal can be either bar type terminal, flip type terminal, folder type terminal, slide type terminal, and swing type terminal.
The terminal body preferably generates an alarm if the local wireless communication module combined with an antenna is detached and displaced further than a predetermined distance from the terminal body. The terminal body generates an alarm if sensitivity of local wireless communication between the terminal body and the local wireless communication module combined with an antenna is less than a predetermined level. The predetermined distance may be one meter.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic view showing a mobile terminal having a local wireless communication module combined with an antenna according to the present invention;
FIG. 2 is a schematic view showing an assembled state of the mobile terminal shown in FIG. 1 ;
FIG. 3 is a block diagram showing a configuration of the local wireless communication module combined with the antenna shown in FIG. 1 ; and
FIG. 4 is a schematic view showing an environment of a local wireless communication between a computer and the mobile terminal having a local wireless communication module combined with the antenna shown in FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Hereinafter, preferred embodiments of the present invention are described in detail with reference to the accompanying drawings. The same reference numbers are used throughout the drawings to refer to the same or like parts. Detailed descriptions of constructions or processes known in the art may be omitted to avoid obscuring the subject matter of the present invention.
FIG. 1 is a schematic view showing a mobile terminal 50 having a local wireless communication module 40 combined with an antenna according to the present invention. FIG. 2 is a schematic view showing an assembled state of the mobile terminal 50 shown in FIG. 1 . FIG. 3 is a block diagram showing a configuration of the local wireless communication module 40 combined with the antenna shown in FIG. 1 .
In FIGS. 1 to 3 , the mobile terminal 50 is shown as a sliding type mobile terminal that includes terminal bodies 10 and 20 and the local wireless communication module 40 (hereinafter ‘module’) combined with an antenna. The module 40 is detachably installed onto the terminal bodies 10 and 20 . The mobile terminal has a USB socket 13 and a first local wireless communication module (not shown). A local wireless communication protocol enabling communication between the module 40 and the mobile terminal may be selected from Bluetooth, Zigbee, infrared, UWB (Ultra Wide Band), NFC (Near Field Communication), and Rubee.
The mobile terminal bodies are configured with a first terminal body 10 , with a second terminal body 20 joined to and slidably moving along the first terminal body 10 .
The first terminal body 10 includes a PCB (Printed Circuit Board) mounted with the first local wireless communication module and the USB socket 13 electrically connected to the PCB. A key input unit 15 ( FIG. 4 ) is formed at a surface of the first terminal body 10 facing towards the second terminal body 20 , and a battery pack 30 for supplying electric power to the mobile terminal 50 is installed at an opposite surface of the first terminal body 10 .
The second terminal body 20 includes a display unit 21 installed on a surface of the second terminal body 20 on a side opposite to another side that faces towards the first terminal body 10 and a navigation key 23 installed under the display unit 21 . The second terminal body 20 covers the key input unit 15 by sliding towards the first terminal body 10 , and uncovers the key input unit 15 by sliding away from the first terminal body 10 .
The module 40 includes a module body 41 and a USB connector 43 protruding from one surface of the module body 41 by a predetermined length. The module body 41 includes a switch 42 , RF antenna 44 , second local wireless communication module 46 , and local wireless communication antenna 48 . The module 40 provided with the mobile terminal 50 as a package may be supplied to a user after completing authentication for local wireless communication, or the user may execute the authentication after receiving the mobile terminal 50 .
The surface of the module 40 furthest from the first terminal body 10 when the module 40 is joined therewith is a module upper surface 45 , which may be formed such that the module upper surface 45 is located at the same level as a second terminal body upper surface 25 when the second terminal body 20 is fully slid towards and installed in the first terminal body 20 . If the module upper surface 45 is higher than the second terminal body upper surface 25 when the module 40 is joined to the first terminal body 10 , the USB connector 43 may be damaged by an external force applied from the second terminal body upper surface 25 to the module 40 . However, If sufficient connection strength between the first terminal body 10 and the module 40 is secured, the module 40 may be designed such that the module upper surface 45 is higher than the second terminal body upper surface 25 .
The USB connector 43 is formed such that the USB connector 43 conforms with and may easily be joined to the USB socket 13 . Although a USB connector is shown in the figure as an exposed connection, the USB connector 43 may be formed with a cover surrounding the connection part. The USB connector 43 shown with the exposed connection part minimizes the thickness of the mobile terminal 50 .
According to the connection state of the USB connector 43 with the USB socket 13 of the first terminal body 10 , the switch 42 connects the USB connector 43 to one of the RF antenna 44 and the second local wireless communication module 46 . That is, if the USB connector 43 is joined to the USB socket 13 of the first terminal body 10 , the switch 42 connects the USB connector 43 to the RF antenna 44 . If the USB connector 43 is detached from the USB socket 13 of the first terminal body 10 , the switch 42 connects the USB connector 43 to the second local wireless communication module 46 .
The RF antenna 44 is connected to the USB connector 43 through the switch 42 , and receives an RF signal when the USB connector 43 is joined to the USB socket 13 of the first terminal body 10 .
The second local wireless communication module 46 is connected to the USB connector 43 through the switch 42 , and performs local wireless communication between a computer and the mobile terminal 50 when the USB connector 43 is detached from the USB socket 13 of the first terminal body 10 and joined to a USB socket of the computer.
Transmission and reception of a signal for local wireless communication is performed through the local wireless communication antenna 48 connected to the second local wireless communication module 46 . The RF antenna 44 and the local wireless communication antenna 48 may be installed together or may be separately installed.
Accordingly, if the module 40 is joined to the USB socket 13 of the first terminal body 10 , the module 40 is used as an RF antenna, and if the module 40 is detached from the USB socket 13 of the first terminal body 10 and joined to a computer USB socket, the module 40 is used as a communication module for performing local wireless communication between the mobile terminal 50 and the computer.
In addition, an alarm is generated when the module 40 detached from the mobile terminal body 50 moves further than a predetermined distance away from the mobile terminal 50 . The distance between the mobile terminal 50 and the module 40 may be indirectly identified by checking sensitivity of radio reception, because the sensitivity of radio reception differs according to the distance between the mobile terminal 50 and the module 40 . Accordingly, the alarm is generated by the mobile terminal 50 when the sensitivity of radio reception is less than a predetermined limit value. The limit value of the sensitivity preferably corresponds to a distance of one meter between the mobile terminal 50 and the module 40 . The alarm may be generated by using a sound or vibration that can be output by the mobile terminal 50 . The purpose of generating an alarm is to prevent the detached module 40 from being lost.
Additionally, the mobile terminal 50 may further include a cover 17 for protecting the exposed USB socket 13 from contamination by dust or other contaminants when the module 40 is detached from the first terminal body 10 . The cover 17 may be formed on the first terminal body upper surface 11 such that the entrance of the USB socket 13 may be covered or uncovered.
In addition to the above-described embodiment, those of skill in art will recognize that the first local wireless communication module or the USB socket 13 may be installed in the second terminal body 20 , and that the USB socket 13 may be formed at another location of the first terminal body 10 and the second terminal body 20 where an installation space is available. However, the USB socket 13 is preferably formed on the first terminal body upper surface 11 or on the second terminal body upper surface 25 , allowing use of the module 40 as an RF antenna 44 when joined to the first terminal body 10 or the second terminal body 20 .
Those of skill in the art will recognize that the present invention may also be applied to a mobile terminal of a bar type terminal, flip type terminal, or swing type terminal.
FIG. 4 is a schematic view showing an environment of a local wireless communication between a computer 60 and the mobile terminal 50 having the local wireless communication module 40 combined with the antenna. The module 40 is normally joined to the first terminal body 10 , and the mobile terminal 50 is used as a mobile communication terminal for transmitting and receiving an RF signal through the RF antenna 44 of the module 40 .
When data transmission between the mobile terminal 50 and the computer 60 is required, a local wireless communication environment may be provided by using the module 40 of the mobile terminal 50 . For this, the module 40 is detached from the first terminal body 10 and the USB connector 43 of the detached module 40 is joined to a computer USB socket 61 of the computer 60 . Here, the distance between the mobile terminal 50 and the module 40 connected to the computer 60 must be in a serviceable range of the local wireless communication.
A local wireless communication environment between a mobile terminal and a computer is thereby provided by detaching a local wireless communication module combined with an antenna from the mobile terminal and assembling with a USB socket of the computer.
Accordingly, an inconvenience of carrying a data cable to connect a mobile terminal to a computer is eliminated, and an environment of data transmission between the mobile terminal and the computer is provided easily.
Although exemplary embodiments of the present invention have been described in detail hereinabove, it should be understood that many variations and modifications of the basic inventive concept herein described, which may appear to those skilled in the art, will still fall within the spirit and scope of the exemplary embodiments of the present invention, as defined in the appended claims. | A mobile terminal having a local wireless communication module combined with an antenna is disclosed that eliminates the inconvenience of carrying a data cable for connecting of a mobile terminal to a computer and enabling easy connection of the mobile terminal to a computer whenever necessary. A local wireless communication module combined with an antenna for a mobile terminal Is provided that is usable as an RF communication antenna when joined to a USB socket of the mobile terminal or as a local wireless communication module for executing local wireless communication between the mobile terminal and a computer when detached from the mobile terminal and joined to a USB socket of the computer. | 6 |
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates generally to a photosensitive polymer and a resist composition using the same. More particularly, the present invention relates to a photosensitive polymer including silicon and a resist composition including the same.
2. Discussion of Related Art
As semiconductor devices become more highly integrated, a photolithography process requires patterns with finer detail. In addition, the fabrication of semiconductor devices on a scale of one gigabit requires a new light source having a shorter wavelength, such as an ArF excimer laser (λ=193 nm) or a F2 (λ=157 nm) laser, than the conventional light source, such as a KrF excimer laser (λ=248 nm). Further, a new resist composition is required for the new light source.
However, the new resist composition created for use with the ArF or F2 has some problems, e.g., dry etch resistance or pattern collapse, as compared with a conventional resist composition used in conjunction with a KrF or i-line (λ=365 nm) in a conventional photolithography process. Thus, a new process and a new material for the resist composition are required to prevent the above identified problems.
Generally, there are two types of photolithography processes. One is a single-layer resist (SLR) process and another is a bi-layer resist (BLR) process. In the SLR process, a photoresist is patterned by using a photolithography process. Next, a desired layer is patterned by using the patterned photoresist. In the BLR process, a bottom layer and a top photoresist (TPR) are sequentially stacked. The TPR is patterned by a photolithography process. The bottom layer is then patterned by using the TPR pattern as a dry etch mask, thereby forming a bottom layer mask. Next, a desired layer is patterned by using the bottom layer mask. The BLR process provides no pattern collapse and greater dry etch resistance as compared to the SLR process. Thus, the BLR process is preferred for forming a very fine pattern. The BLR process usually employs TPR compositions containing a polymer in which a monomer containing a group with silicon is polymerized.
Foster discloses a photosensitive polymer for a TPR having the following formula in “Second Generation 193 nm Bilayer Resist”, Proc. SPIE. Vol. 3678, pp. 1034-1039.
In the above formula, a third monomer contains a bulky group of Si—O—Si. Since Silicon (Si) has a high resistance with respect to a dry etch process, it is preferable to have a high concentration of Si. However, silicon is hydrophobic. Due to the bulky Si—O—Si group contained in the above formula, the hydrophobicity of the photosensitive polymer increases causing a decrease in adhesive strength or a decrease in wet-ability to a hydrophilic bottom layer. Thus, the photoresist polymer having a high concentration of Si has a low resolution and a decrease in performance.
Therefore, a need exists to provide a photosensitive polymer to be used as a top photoresist in a BLR process that has a greater dry etch resistance and adhesive strength than a conventional photosensitive polymer. In addition, there is also a need to provide a resist composition using the same.
SUMMARY OF THE INVENTION
An aspect of the present invention is to provide a photosensitive polymer for a top photoresist in a BLR process that has an increase in dry etch resistance and adhesive strength as compared to a conventional photoresist, and to provide a resist composition using the same.
Embodiments of the invention are directed to a photosensitive polymer having the following formula 1 composed of a first, a second and a third monomers.
In the formula 1, R 1 of the first monomer and R 3 of the third monomer are an alkyl group, and R 2 of the first monomer is hydrogen, an alkyl group, an alkoxy group, or a carbonyl group. X of the first monomer is an integer from 1 to 4. And, m/(m+n+p) is about 0.1 to about 0.4, n/(m+n+p) is about 0.1 to about 0.5, and p/(m+n+p) is about 0.1 to about 0.4. A weight-average molecular weight of the photosensitive polymer is preferably about 3,000 to about 100,000. Preferably, R 1 of the first monomer and R 3 of the third monomer are either hydrogen or a methyl group. Preferably, R 2 is hydrogen, a methoxy group, or an ethoxy group.
In the first and second monomers contained in the photosensitive polymer of the formula 1, an ether group is hydrophilic and provides an increase in adhesive strength, and a cyclic structure provides an increase in resistance with respect to a dry etch as compared to a conventional photosensitive polymer. The third monomer of the photosensitive polymer, as shown above, has a silicon-containing group that is, preferably, a bis(trimethylsilyl)propyl group. Since the silicon-containing group of the photosensitive polymer has a smaller volume than a silicon-containing group of a conventional photoresist polymer, there is a decrease in the hydrophobicity of the photosensitive polymer represented by formula 1. Further, the concentration of Si may be increased to improve the resistance with respect to a dry etch of the photosensitive polymer.
When the photosensitive polymer is exposed to light, a portion of the third monomer comprising silicon is decomposed under a catalyst of acid, thereby substituting the silicon group with hydrogen. Thus, the third monomer then comprises a carboxyl group which causes the structure to become hydrophilic. In addition, after being exposed to light, the photosensitive polymer will readily dissolve in a developing solution.
According to another aspect of the present invention, the photosensitive polymer illustrated by formula 1 above may further include a fourth monomer. The fourth monomer may be acrylate, methacrylate, acrylonitrile, methacrylonitrile, norbornene, styrene, or any derivative thereof. At this time, the third monomer is about 5 to about 30 wt. % of the photosensitive polymer. The fourth monomer may alleviate a repulsive force between the first and second monomers of hydrophilicity and the third monomer of with respect to hydrophobicity.
Embodiments of the present invention directed to a resist composition include a photo acid generator (PAG) and a photosensitive polymer comprising three or four monomers. The PAG is about 1.0 to about 15.0 wt. % of the photosensitive polymer. The PAG may be triarylsulfonium salts or diaryliodonium salts. Preferably, the PAG is selected from a group consisting of triphenylsulfonium triflate, diphenyliodonium triflate and di-t-butylphenyliodonium triflate.
The resist composition may further include a base additive. The base additive may be about 0.01 to about 2.0 wt. % of the photosensitive polymer. The base additive is preferably an organic tertiary amine.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
In a flask, about 0.85 g (10 mmol) of 3,4-dihydro-2H-pyran (I), about 1.0 g (10 mmol) of maleic anhydride (II), and about 5.5 g (20 mmol) of bis(trimethylsilyl)propyl methacrylate (III) were dissolved in a combination of about 8 g of anhydrous tetrahydrofuran (THF) and about 0.13 g of azobisisobutyronitrile, AIBN, (2 mol %). After degassing by using N 2 gas, reactants I, II and III were polymerized at a temperature of about 65° C. for about 20 hours. After finishing the polymerization, preliminary products were slowly precipitated in excessive quantity of isopropyl alcohol. A sediment was collected by filtration and dissolved in a predetermined quantity of THF. The dissolved sediment was then re-precipitated in n-hexane. Next, the re-precipitated sediment was dried for about 24 hours in a vacuum oven at a temperature of about 50° C. A photosensitive polymer IV having a yield of about 60% was collected. In addition, the photosensitive polymer IV had a weight-average molecular weight of about 8,700 and dispersion (weight-average molecular weight/number-average molecular weight) of about 1.9.
A photosensitive polymer IV, formed by synthesis 1 discussed above, comprises a group containing Si represented by a bis(trimethylsilyl)propyl methacrylate (III) as shown above in the third monomer. Since the group including Si has a smaller volume than a group containing Si in a conventional photosensitive polymer, there is a decrease in the hydrophobicity of the photosensitive polymer IV as compared to the conventional photosensitive polymer. Further, the concentration of Si may be increased to improve the resistance with respect to a dry etch of the photosensitive polymer. Additionally, the 3-4-dihydro-2H-pyran (I) and the maleic anhydride (II) have ether group (—O—), which is hydrophilic and improves the adhesive force and resolution of the photosensitive polymer. Also, monomers I and II have an aliphatic structure that improves the high resistance with respect to a dry etching of the photosensitive polymer.
In a flask, about 0.70 g (10 mmol) of 2,3-dihydro-2H-furan (V), about 1.0 g (10 mmol) of maleic anhydride (II), and about 5.5 g (20 mmol) of bis(trimethylsilyl)propyl methacrylate (III) were dissolved in a combination of 8 g of anhydrous THF and about 0.13 g of AIBN (2 mol %). About a 60% yield of photosensitive polymer VI was obtained, using the same steps as discussed above with respect to synthesis 1, having a weight-average molecular weight of about 7,600 and a dispersion of about 1.9.
In a flask, about 0.84 g (10 mmol) of 4,5-dihydro-2-methylfuran (VII), about 1.0 g (10 mmol) of maleic anhydride (II), and about 5.5 g (20 mmol) of bis(trimethylsilyl)propyl methacrylate (III) were dissolved in a combination of about 0.8 g of anhydrous THF and about 0.13 g of AIBN (2 mol %). About a 55% yield of photosensitive polymer VIII was obtained, using the same steps as discussed above with respect to synthesis 1, having a weight-average molecular weight of about 7,100 and a dispersion of about 2.0.
In a flask, about 1.1 g (10 mmol) of 3,4-dihydro-6-methyl-2H-pyran-2-one (IX), about 1.0 g (10 mmol) of maleic anhydride (II), and about 5.5 g (20 mmol) of bis(trimethylsilyl)propyl methacrylate (III) were dissolved in combination of about 8 g of anhydrous THF and about 0.13 g of AIBN (2 mol %). About a 50% yield of photosensitive polymer X was obtained, using the same steps as discussed above with respect to synthesis 1, having a weight-average molecular weight of about 7,000 and a dispersion of about 2.0.
In a flask, about 1.3 g (10 mmol) of 3,4-dihydro-2-ethoxy-2H-pyran (XI), about 1.0 g (10 mmol) of maleic anhydride (II), and about 5.5 g (20 mmol) of bis(trimethylsilyl)propyl methacrylate (III) were dissolved in a combination of about 8 g of anhydrous THF and about 0.13 g of AIBN (2 mol %). About a 60% yield of photosensitive polymer XII was obtained, using the same steps as discussed above with respect to synthesis 1, having a weight-average molecular weight of about 8,300 and a dispersion of about 2.0.
In a flask, about 0.85 g (10 mmol) of 3,4-dihydro-2H-pyran (XIII), about 1.0 g (10 mmol) of maleic anhydride (II), about 0.5 g (5 mmol) of norbornene (XIV), and about 5.5 g (20 mmol) bis(trimethylsilyl)propyl methacrylate (III) were dissolved in a combination of about 8 g of anhydrous THF and about 0.15 g of AIBN (2 mol %). After degassing by using N 2 gas, reactants XIII, II, XIV and III were polymerized at a temperature of about 65° C. for about 20 hours. After finishing the polymerization, preliminary products were slowly precipitated in an excessive quantity of isopropyl alcohol. A sediment was filtered, collected, and dissolved in a predetermined quantity of THF. The dissolved sediment was then re-precipitated in n-hexane. Next, the re-precipitated sediment was dried for about 24 hours in a vacuum oven at a temperature of about 50° C. Thus, a photosensitive polymer XV was obtained, at a yield of about 60%, having a weight-average molecular weight of about 8,100 and a dispersion of about 1.9.
Embodiment 1
The present embodiment illustrates a method for forming a top photoresist pattern by using the photosensitive polymer IV obtained in synthesis 1.
About 1 g of photosensitive polymer IV was dissolved in about 10 g of propylene glycol methyl ether acetate (PGMEA) with about 0.02 g of triphenylsulfonium triflate (TPSOTf). Then, about 1 mg of triisobutylamine was dissolved in the solution above, thereby making a resist solution. Next, the resist solution was filtered using a 0.2 μm membrane filter. A bare Si wafer treated with hexamethyldisilazane (HMDS) was then coated with the filtered resist solution. Preferably, the resist solution coated on the wafer has a thickness of about 0.25 μm. Next, the wafer coated with the resist solution was pre-baked at a temperature of about 120° C. for about 60 seconds. And then, the pre-baked wafer was exposed to light by using an ArF stepper (0.6NA, σ 0.75). Next, a post-exposure bake (PEB) process was performed with respect to the exposed wafer at a temperature of about 120° C. for about 60 seconds. After the PEB process, the wafer was developed by using a 2.38 wt % of tetramethylammonium hydroxide (TMAH) solution for about 60 seconds. Further, a top photoresist pattern of 160 nm line/space could be obtained with about a 15 mJ/cm 2 dose.
A mechanism illustrating how the photosensitive polymer IV is changed when exposed to light is shown by the following reaction equation.
<Reaction equation>
Before the photosensitive polymer, shown above, is exposed to light, the photosensitive polymer is shown comprising a third monomer (p) having a Si group. After the photosensitive polymer is exposed to light, the Si group of the third monomer is substituted with hydrogen thereby forming a carboxyl group, which is hydrophilic. Thus, the photosensitive polymer with the carboxyl group can be readily dissolved in a developing solution.
The photosensitive polymer formed above represents an improved top photoresist over a conventional top photoresist in a BLR photolithography process whose light sources are KrF (λ=248 nm), ArF(λ=193 nm) and F2(λ=157 nm) excimer lasers.
Embodiment 2
The present embodiment illustrates a method for forming a silicon nitride pattern by using a top photoresist pattern.
A silicon nitride layer of about 3000 Å is formed on a silicon wafer. The silicon wafer with the silicon nitride is then coated by an i-line resist with a thickness of about 500 nm and thermally treated at a temperature of about 220° C., thereby forming a bottom layer on the silicon nitride layer. Next, a resist composition is made by using the same method as discussed above with respect to embodiment 1 by using the photosensitive polymer IV formed in synthesis 1. The silicon wafer with the bottom layer is then coated with the resist composition having a thickness of about 250 nm. Next, the silicon wafer with the resist composition is pre-baked at a temperature of about 120° C. for about 90 seconds, thereby forming a top photoresist. The wafer with the top photoresist is exposed to light by using an ArF stepper (0.6 NA, σ=0.75). A PEB process is performed on the exposed wafer at a temperature of about 110° C. for about 60 seconds. After the PEB process, the wafer is developed by using a 2.38 wt. % TMAH solution for about 60 seconds. And then, a post-development bake (PDB) is performed at a temperature of about 110° C. for about 60 seconds, thereby forming a top photoresist pattern. A dry etch process is then performed with respect to the bottom layer by using the top photoresist pattern as a etch mask and by supplying plasma of oxygen(O 2 ) and sulfur dioxide(SO 2 ), thereby forming a bottom layer pattern. The top photoresist pattern is removed. A dry etch process is performed with respect to the silicon nitride layer by using the bottom layer pattern as a mask by supplying plasma of CF 4 and etc, thereby forming a silicon nitride pattern. The bottom layer pattern is removed.
Accordingly, the photosensitive polymer of the present invention includes first and second monomers having an ether group, thereby having a photosensitive polymer that is hydrophilic with an improved adhesive strength over a conventional photosensitive polymer. Also, the photosensitive polymer including a cyclic structure provides improved resistance with respect to a dry etch over a conventional photosensitive polymer. The third monomer included in a photosensitive polymer has a silicon-containing group that is preferably a bis(trimethylsilyl)propyl group. Since the silicon-containing group of the photosensitive polymer has a less bulkier structure than a conventional photoresist polymer, there is a decrease in the hydrophobicity of the photosensitive polymer. Further, the concentration of Si may be increased to improve resistance with respect to a dry etch of the photosensitive polymer. After the photosensitive polymer is exposed to light, the Si containing group is substituted with hydrogen, thereby forming a carboxyl group on the third monomer. Thus, the photosensitive polymer including the third monomer with a carboxyl group will readily dissolve in a developing solution. | A photosensitive polymer including silicon and a resist composition using the same are disclosed. The photosensitive polymer has the following formula 1.
In formula 1, R 1 of the first monomer and R 3 of the third monomer are an alkyl group. R 2 of the first monomer is hydrogen, alkyl, alkoxy, or carbonyl. The X of the first monomer is an integer selected from 1 to 4. Further, m/(m+n+p) is about 0.1 to about 0.4, n/(m+n+p) is about 0.1 to about 0.5, and p/(m+n+p) is about 0.1 to about 0.4. | 8 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates in general to pressing molds and in particular to a new and useful method and device for compacting bulk material into railroad ties. Fine plant parts are mixed with binders in a molding press, in which moveable wall pairs that can be moved against each other form between them the filling and pressing chamber. Pressing strokes are performed alternatingly and repeatedly after which the pressed molding is cured under the effect of heat while maintaining the pressure. Such a process is known from West German Patent No. 32,27,074. In the procedure described the moveable walls are located opposite each other and define the mold chamber. The moveable walls act on the mixture entered into the mold chamber in pairs consecutively and repeatedly. This has proved successful especially in the production of I sections, whose webs and legs have approximately equal thickness.
However, if beam-shaped moldings of substantially greater cross section are to be pressed from the fine plant parts mixed with binder, as would be the case, e.g., when pressing railroad ties, the prior-art technique is not sufficient for bringing about the pressing of the fine parts over the entire cross section. Even if the outer surface of the molding to be formed is subjected to the repeated and intense action of the moveable wall pairs, the pressure that is reasonably available is not sufficient for pressing the fine parts present in the middle zone of the molding with the required intensity. What is found, instead, in this central zone of the molding is a loose structure of fine parts, which therefore fails to share the strength of the entire molding. There is even a risk of formation of shrinkage cavities or other cavities.
SUMMARY OF THE INVENTION
Therefore, the basic task of the present invention is to provide a process, and a device suitable for carrying out the process, which makes it possible to press fine plant parts intensively over the entire cross section of a large-sized, beam-shaped molding and to avoid the above-mentioned disadvantages.
West German Patent No. DE-PS 32,27,074, describes a device for compressing compactable material. According to the present invention in that at the beginning of the pressing operating strokes, an additional amount of fine parts is pressed into a designated section of the mold chamber. The designated section is a section of the molding subject to tensile stress. As a result of which a compression zone of particularly pre-compacted fine parts, which exerts a reactive effect against the subsequent pressing pressure of the moveable wall pairs, is created.
A core of pre-compacted fine plant parts is formed by this method within the mold chamber. This core exerts a reactive effect in relation to the subsequent pressing strokes acting from different directions. Every individual press stroke of the moveable walls leads to compression of the compacted mixture in this pre-compacted central core zone. As a result this core zone in turn undergoes additional compaction and its reactive effect is intensified. It is recognizable from the cross section of the finished pressed molding how the fine parts filled loosely into the filling chamber appear in the form of layers. The layers form wave-shaped, curved or even intermeshing layers, which surround the core of pre-compacted fine parts like flow lines. In addition, considerably more strongly compacted layers, are recognizable in the peripheral zones of the molding. This causes particularly high strength in the edge zone of the molding.
It is also possible to have two or more additional amounts, arranged in a distributed pattern, act on the mixture of fine parts according to the present invention.
The present invention made it possible, to compact a molding of large cross section over its entire cross section very strongly and inexpensively. Thus creating the prerequisite for using the molding under particularly high loads, as occur, e.g., in railroad ties. The present invention is not limited to this field of application, but comprises all the applications of the moldings according to the present invention in a great variety of technical areas.
In an embodiment of the present invention, the pre-compacted core is formed in a very simple manner by pressing the additional amount from a channel-shaped chamber, which expands and extends over the entire length of the chamber, into the mixture mentioned in the mold chamber. The channel-shaped chamber is preferably formed by at least one setback moveable wall of a moveable wall series. After the channel-shaped chamber has been filled the setback moveable wall is first moved alone, and then together with the series of moveable walls. It is also possible first to move the moveable wall series and then to close the channel-shaped chamber. In this case the two movements can also be performed simultaneously.
EP-A 0,065,660 describes railroad ties as being pressed from fine plant parts mixed with binders by specially compacting the zone on which the rails of the track will come to lie. In EP-A 0,065,660 either plate-shaped parts are set into the surface of the railroad tie areas on which the rails of the track come to lie, or a heap of fine parts, which was formed on said support surfaces of the rails, is pressed together with the mixture filled into the mold. As a result of which a strip-shaped superficial compaction takes place.
It may be true that this strip-shaped compaction of the support surface for the rail prevents pressure exerted by the engine and the railroad cars traveling on the rail from pressing the rail into the railroad tie. However, one has obviously overlooked the fact that the overall strength of the railroad tie thus produced is much too low. The reason being it is not possible to produce a molding with high strength and bending resistance from fine plant parts by pressing the mass of fine parts in a mold in one direction only.
The present invention differs from this, in principle, by the fact that the additional amount introduced into the core zone of the mold chamber is intended to offer an opposing force to the pressing forces acting from different directions. The fine parts located between the moveable walls and the pre-compacted zone are compressed, and as a result of which the above described flow line structure of layers is formed. It is thus possible to produce a molding of large cross section with particularly high strength.
It has proved particularly advantageous within the framework of the present invention to add a certain percentage of long chips to the mixture of fine parts to be pressed. Introducing them into the mold chamber such that the long chips will be oriented in parallel to the longitudinal direction of the moldings. The long chips are prepared for the pressing process according to the present invention in a suitable manner. Using long chips of a size of circa 150 mm in length, 5-8 mm in width, and 0.4-0.8 mm in thickness has proved to be advantageous, but the present invention is not limited to these dimensions, and they are intended only to indicate generally the dimensions which the long chips are to have.
It is known from West German Patent No. DE-PS 33,46,469 how "pin chips" (i.e., small-sized, long chips can be introduced into a mold chamber oriented in the longitudinal direction in order to subsequently perform pre- pressing and to subsequently extrude the pre-pressed object. Even though extrusion cannot be considered in the present invention, it is nevertheless possible to use the prior-art measures to orient the long chips. Therefore, to disclose the present invention, we expressly refer to the teaching of the prior known document.
In accordance with one aspect of the invention moldings of particularly large cross section are best obtained by performing a pre-pressing in a first press and the final pressing of the molding in a subsequent, second press. It is important for the molding formed in the first press to be pushed, together with molding plates, which act against the side walls of the molding, out of the first molding press and to be introduced into the second molding press.
It is known from West German Offenlegungsschrift No. DE-OS 33,07,557 that the finished pressed molding can be pushed, together with the molding plates surrounding it, out of the press and introduced, while maintaining the pressing pressure, into a setting zone, in which the mixture will set under the effect of heat. The teaching shown in this document for guiding the molding plates can be used without problems in the present invention, but the moveable walls remain in the molding press and the molding is pushed off only with the molding plates.
A further object of the invention is to provide a device for pressing flexurally rigid beam shaped moldings which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects obtained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a cross section through a mold chamber after a lateral transverse pressing was performed;
FIG. 2 is a cross section according to FIG. 2 with representation of a pre-compacted compression zone brought about by two-step vertical pressing;
FIG. 3 is a schematic perspective partial view of a pre-pressed molding with lateral molding plates at the transition from one molding press into another;
FIGS. 4 through 7 are cross sections through a similar the pressing device of a second stage of molding shown in different positions of the press:
FIG. 8 shows a cross section through a furnished pressed molding; and
FIG. 9 is a sectional view of another embodiment of mold construction.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The example according to FIG. 1 shows the cross section of a first molding press in which a molding chamber 1 is filled with a mixture of plant parts and binders. Depending on the intended use, wood chips or particles of other plant fibers, e.g., straw and the like, can be used as particles. If moldings of particularly high strength and large cross section, e.g., railroad ties, are to be produced, it is recommended that long chips be used, which are introduced into the molding chamber 1 in an oriented position. It should be borne in mind in this connection that the long chips extend in the longitudinal direction of the molding.
Said molding chamber 1 is defined by the moveable walls 2, 3, 4, and 5. The lateral moveable walls 2 and 3 and the moveable walls 4 and 5 which are movable in the vertical direction form moveable wall pairs whose movement is controlled such that the moveable wall pairs act on the material filled into the molding chamber 1 one after another and repeatedly, as will be described later.
In the embodiment described, said lower moveable wall 5 consists of a series of individual moveable walls 6 and 7 arranged next to each other, the middle one 6 of which is set back and therefore forms a channel-shaped chamber 12 which expands said molding chamber 1 in the area where the material consisting of fine parts intended for forming the zone subject to tensile stress of the molding is located. The example in FIG. 2 shows the contour of a beam cross section in which the zone subject to tensile stress is located in the lower zone of said molding chamber 1.
It is assumed in FIG. 1 that said molding chamber 1 is filled in a suitable manner, and said upper moveable wall 4 can be assumed to be removed during the filling process. After completion of the filling process, said upper moveable wall 4 is returned into its starting position. This is followed by a first pressing stroke of the lateral moveable walls 2 and 3 along the arrows 10, and the pressing stroke of the lateral moveable walls 2 and 3 is transmitted via molding plates 8 to the mixture located in the molding chamber 1. Said molding plates 8 extend over the entire length of said mold chamber 1, and in the embodiment shown, they have a bent zone 9 which is intended to form a lateral upper bevel on the molding 15 to be formed. This is important, for example, when railroad ties are to be produced. Said molding plate 8 is profiled depending on the desired cross section of the moldings 15.
The representation in FIG. 1 corresponds to the position of said molding plates 9 after completion of the first pressing stroke along said arrows 10.
This is followed by the steps according to FIG. 2, which are important for the present invention and are carried out in that the middle moveable wall, 6, performs a pre-pressing stroke along arrow 11, thus pushing the additional amount of fine plant parts located in said channel-shaped chamber 12 into the already filled mold chamber 1, as a result of which a compression zone 28 consisting of compacted fine parts is formed. In the embodiment according to FIG. 2, said compression zone 28 is located in the lower zone of said mold chamber 1, because it is assumed that the zone subject to tensile stress of the molding is to be formed there.
If the intended use of the molding to be formed would require a zone subject to tensile stress elsewhere, it would be advisable to displace said compression zone 28 according to the intended purpose. It is decisive that said compression zone 28 be located in the same core zone of said filling chamber 1 where the greatest stress of the molding can be expected to occur. The pressing position of the molding does not always correspond to the position in which it will be used. Therefore, FIG. 1 represents only one of many possibilities. For the same reason, it is also possible to provide a plurality of such compression zones by designing the moveable walls appropriately.
The essential purpose of the compression zone 28 formed is to create a strength in the core zone of the molding 15 to be formed, which exerts a reactive effect to the pressing force of the moveable walls 2 through 5. If the compression zone 28 had not been formed, the pressing force of said moveable walls 2 through 5 would not be sufficient to press the middle zone of the molding to be formed with the required intensity.
The pre-pressing stroke along said arrow 11 leads to the formation of a flush pressing surface 14 on the end face of said moveable wall parts 6 and 7. From now on, said moveable wall parts 6 and 7 are moved jointly as a single moveable wall.
However, it is also possible to move forward first the moveable wall series 6 and 7 and to close said channel-shaped chamber 12 by an additional movement of said moveable wall 6 only thereafter. The two movements may also be performed simultaneously.
The position of said moveable walls 6 and 7 after the pressing stroke performed along the arrows 13 is shown in the embodiment according to FIG. 2. Said lateral moveable walls 2 and 3 with their molding plates 8 have maintained their position under pressure, whereas said upper and lower cheek plates 4 and 5 have been moved against each other.
These movements according to FIGS. 1 and 2 take place in a first molding press 18. The work in said first molding press 18 is completed with the pressing process according to FIG. 2. The pressed molding is subsequently pushed out of said first molding press 18 in the longitudinal direction along with said two molding plates 8, as is symbolically indicated by arrow 17 in FIG. 3. Said molding plates 8 now slide along said lateral moveable walls 2 and 3, which makes it necessary to ensure low-friction guiding. Corresponding suggestions can also be found in the state of the art mentioned in the introduction.
The embodiments according to FIGS. 4 through 7 show different press sections in a second molding press 19, into which the blank of the molding 15 has been pushed together with said molding plates 8 to form molding chamber 1'.
In said second molding press 19, the lateral side cheeks 2' and 3' with said molding plates 8 that are in contact with them are moved against each other in the direction of the arrows 20 during another pressing stroke. It should be ensured in this connection that said upper and lower molding plates 8 do not yet reach the plane of action of said upper and lower cheek plates 4' and 5'. This transverse pressing stroke according to FIG. 4 is followed by a vertical pressing stroke according to FIG. 5, after which said upper and lower moveable walls 4' and 5' are moved against each other along the arrows 21. Said moveable walls 4' and 5' thus almost reach their final pressing end positions.
This process is followed by another transverse pressing stroke according to FIG. 6, during which said molding plates 8 are moved forward into their final pressing end positions. The gap between said molding plates 8 and said upper and lower moveable walls 4' and 5' is thus compensated. This transverse movement takes place along the arrows 22.
FIG. 7 shows the absolute pressing end position, in which said upper and lower moveable walls 4' and 5' have been moved against each other along the arrows 23. It is seen that the pressing surface of said upper cheek plate 4' is now flush with the upper bend in the bent zone 9 of said molding plates 8, as a result of which a molding 15 according to FIG. 8, in which the bevel 16 is an imprint of said molding plates 8, has been formed. Said molding plates 8 have also formed the side walls 27 and bottom surface 25 of the molding 15 in the same way.
Said compression zone 28, shown symbolically, which generates forces of reaction according to the arrows 29 when a pressure acts on the outer surface of the molding 15 via the moveable walls 2 through 5 or 2' through 5', is represented in the middle section 24 of the molding 15. The fine parts being compacted now slide off on said compression zone 28, unless they remain directly in this zone in the compressed state, which leads to an arc-shaped deformed structure along the lines 30 in the molding 15. A particularly greatly compacted peripheral zone 34 is also formed on the molding 15 at the same time. The edge zones 35 are characterized by a particularly high degree of compaction. This explains why moldings 15 produced according to the present invention possess particularly great strength in the normally jeopardized edge zones.
Finally, the embodiment according to FIG. 9 shows a machine arrangement as an alternative to FIG. 1, in which said mold chamber 1 is filled independently of the position of said upper moveable wall 4. To achieve this, the machine is subdivided so that said moveable wall 4 is arranged in one machine part 31 and the other moveable walls 2, 3, and 5 with said molding plates 8 in another machine part 32. If said machine parts 31 and 32 are displaced transversely relative to one another, said mold chamber 1 can be filled regardless of the position of said upper moveable wall 4.
In an alternative, said lower moveable wall 5 may also be left in the position shown in FIG. 1, so that only said lateral moveable walls 2 and 3 with said molding plates 8 are to be moved to below the filling opening 36. This movement can be performed by proper selection of the stroke of the drives for said lateral moveable walls 2 and 3. | The present invention pertains to a process and devices for producing beam-shaped moldings from fine plant parts mixed with binders in molding presses. Based on the discovery that the degree of compaction of the core of such moldings decreases with increasing cross section of the moldings, it is suggested in the present invention that the core zone of the molding be formed by an additional amount of fine parts moved there and compacted deliberately, which amount of material acts reactively as a compression zone to the moveable walls surrounding it during the compaction of the molding. Compaction of the molding over its entire cross section and at the same time particularly great compaction of the peripheral zones of the molding are thus achieved. The strength and the bending resistance of such moldings are particularly high, and such moldings are therefore also suitable for forming railroad ties. | 1 |
FIELD OF THE INVENTION
The present invention relates generally to precast cantilevered retaining walls. More specifically, the present invention relates to a cantilevered concrete retaining wall having a base shear key and blockouts for receiving a material that substantially impedes the wing wall from sliding or other inadvertent movement.
BACKGROUND
Retaining walls are subject to various forces that may cause them to fail. Pressure at the toe of the footing is generally larger than pressure at the heel of the footing so retaining walls have an inherent tendency to tilt forward away from an embankment. Occasionally, the base soil is of a poor quality and when sufficient backfill is placed between the backface of the retaining wall and an embankment, for example, the approach fill at a bridge abutment, the backfill pressure produces a settlement with lateral effect into the zone beneath the heel so that the retaining wall may tilt back into the backfill and the embankment. Lateral forces generated by earth and water pressure may cause the base of the retaining wall to slide outward and fail. Retaining walls are generally designed to resist these lateral forces by creating friction between the bottom surface of the footing and the soil. Some soil types are more prone to shifting or erosion and may decrease the friction between the footing and soil. Different soil types exert different amounts of pressure on the retaining wall. Local soil conditions may require an increase in the width of the footing to achieve the required friction between the bottom surface of the retaining wall and the soil to counteract the lateral forces on the retaining wall. However, making the footing wider increases the amount of materials used, increases transportation costs, and requires increased excavation of soil to form a wider subgrade which increases cost and time required for site preparation and installation. In some cases, it may not be possible to increase the footing width based on site requirements. The depth of the footing cover can also be increased in some situations to provide additional resistance to lateral forces; however, this also increases the cost of site preparation because excavation must be deeper, and additional concrete is required which increases costs as well.
Concrete retaining walls that are cast-in-place at the job site are known to have a higher coefficient of friction between the footing and the soil compared to precast concrete retaining walls that are manufactured at a precast plant, transported to the job site, and placed on the soil. However, there are several shortcomings in the use of cast-in-place retaining walls compared to the use of precast concrete retaining walls. Creating forms for a retaining wall at a job site is time consuming and may require the presence of many employees at a remote location. The job site may not be as safe for employees as a precast plant due to open excavations, the presence of heavy equipment, and the natural environment. The forms may have to be custom made, increasing labor and material costs and making re-use of the forms unlikely. Placing and aligning reinforcing steel precisely at a job site may be more difficult than at a precast plant, potentially weakening the retaining wall. The concrete for the retaining walls may have to be transported long distances to the job site in individual truckloads increasing transportation and labor costs. Finally, the concrete is exposed to the environment while it is curing which can increase the curing time or adversely affect the strength characteristics of the retaining wall. Construction of the project may be delayed while waiting for the concrete to cure.
Due to the numerous limitations associated with cast-in-place retaining walls, there is an unmet need for a precast concrete retaining wall which has a coefficient of friction equivalent to a cast-in-place retaining wall of similar size.
SUMMARY OF THE INVENTION
In view of the limitations in prior art retaining walls and methods of using them, the present disclosure provides a new and useful precast cantilevered wing wall and a method of use thereof which is cost effective to fabricate, more versatile in use than known prior art retaining walls, and less susceptible to failure.
One aspect of the present disclosure is to provide a new precast cantilevered wing wall and method of use thereof that prevents the cantilevered wing wall from sliding or other inadvertent movement. Another aspect of the present disclosure is to provide a new precast cantilevered wing wall that has many novel features not offered by the prior art. One such feature is a base shear key or stem wall adapted to fit into a trench formed in the subgrade beneath the footing of the cantilevered wing wall. Another novel feature includes one or more blockouts formed through the footing. The precast cantilevered wing wall and base shear key are placed on the prepared subgrade and the base shear key is placed in the trench. A material that replicates the strength of compacted soil is poured or deposited through the blockouts to fill voids between the soil of the subgrade and the shear key to lock the cantilevered wing wall in place. The material may be any material that fills the voids and replicates the strength of compacted soil such as grout, cement, concrete, mortar, controlled density fill, adhesives, hydro compacted sand, or any combination thereof.
In one embodiment, the cantilevered wing wall may be assembled from individual precast concrete sections. In another embodiment, the cantilevered wing wall may be precast monolithically as one integral piece without any individual components, joints, or necessity to interconnect any components.
In one embodiment, a method of retaining an embankment with a precast cantilevered wing wall is disclosed, the method generally comprising (1) providing a precast cantilevered wing wall having a stem of a predetermined height, length, and thickness, a footing interconnected to the stem, the footing extending laterally from a front face of the stem to form a toe and the footing extending laterally from a back face of the stem to form a heel, the footing having a predetermined thickness, a base shear key extending downwardly a predetermined depth from a substantially horizontal plane defined by the footing, and a plurality of blockouts formed through the footing between the stem and the base shear key, wherein each of the plurality of blockouts have a sufficient dimension to receive a grout material; (2) excavating soil to form a subgrade of a determined width, length, and depth; (3) excavating soil to form a trench of a second determined width, length, and depth in the subgrade; (4) placing the cantilevered wing wall on the subgrade, wherein the base shear key of the cantilevered wing wall extends at least partially into the trench; and (5) filling the trench and at least one of the plurality of said blockouts at least partially with the grout material that fills the void between footing and the subgrade, wherein the grout material replicates the strength of compacted soil, wherein said grout material comprises at least one of a grout, a cement, a concrete material, a mortar, a controlled density fill, an adhesive, a hydro compacted sand, a controlled density fill, and an aggregate, or any combination thereof.
In one embodiment, the subgrade soil may optionally be compacted to a determined density. In another embodiment, at least one blockout may be formed through the footing between the stem and the toe. In yet another embodiment, the footing may be formed without the base shear key. In another embodiment, drain holes may be formed through the stem. In yet another embodiment, a drainage system may optionally be installed between the back face of the stem and the embankment. In still another aspect for further stabilization, one or more soil nails may optionally be installed through at least one of the plurality of said blockouts. In another embodiment, anchors may be embedded within the precast cantilevered wing wall so that the cantilevered wing wall can be lifted, transported, and placed in a position of use. The method may further optionally comprise placing infill material between the wall and the embankment to a determined height, placing second infill material in front of the stem above the footing to a final grade line, and compacting the infill material and the second infill material to a second determined density.
In another embodiment, a precast cantilevered wing wall is disclosed, the cantilevered wing wall comprising: a stem of a predetermined height, length, and thickness; a footing connected to the stem, the footing extending laterally from a front face of the stem to form a toe and the footing extending laterally from a back face of the stem to form a heel; and a plurality of blockouts formed through the footing, wherein each of the plurality of blockouts have a sufficient size to receive at least one of a grout material and a reinforcing bar. In an embodiment, the plurality of blockouts may optionally be comprised of two or more rows of blockouts. In another embodiment, at least one blockout is formed between stem and the toe. In yet another embodiment, the plurality of blockouts may optionally be formed through the footing to have an irregular spacing. In still another optional embodiment, the blockouts may have a shape resembling at least one of a parallelogram, a square, a rectangle, a circle, a triangle or any combination thereof. In one embodiment, a base shear key extends down a predetermined depth from a substantially horizontal plane defined by the footing. In another embodiment, the stem has a first predetermined height on a right side of the cantilevered wing wall and a second predetermined height on a left side of the cantilevered wing wall and the first predetermined height is optionally greater than the second predetermined height. In still another embodiment, the first predetermined height is optionally less than the second predetermined height. In yet another embodiment, the plurality of blockouts have an irregular spacing. In still another embodiment, the plurality of blockouts are formed through the footing between the stem and a rear portion of the heel. In another embodiment, at least one of the plurality of blockouts is formed between the stem and a forward-most portion of the toe. In yet another embodiment, the cantilevered wing wall further comprises anchors, the anchors having a first end at least partially embedded in the concrete and a second end adapted to be manipulated by lifting equipment to lift, transport, and/or place the cantilevered wing wall in a position of use.
In yet another embodiment, a method of manufacturing a monolithic precast concrete cantilevered retaining wall is disclosed and which generally comprises (1) creating a form which defines the geometry of the retaining wall wherein the form comprises a stem of a predetermined height, length, and thickness, a footing connected to the stem, the footing having a predetermined thickness and extending laterally a width from a front face of the stem to form a toe and extending laterally a width from a back face of the stem to form a heel, optionally a shear key extending down a predetermined depth from a substantially horizontal plane defined by the footing, and a plurality of blockouts through the footing; (2) placing reinforcing steel in the form; (3) pouring a predetermined volume of concrete into the form; and (4) removing the form after the concrete has cured, wherein the precast concrete cantilevered retaining wall can be lifted, transported, and place in a position of use. In one embodiment, the plurality of blockouts are formed between the stem and the heel to create a void adapted to receive reinforcing materials such as metal rebar and/or steel. In one optional embodiment, at least one blockout is formed between the stem and the toe. In still another embodiment, the plurality of blockouts may have an irregular size. In yet another embodiment, a shape of at least one of the plurality of blockouts differs from a second shape of a second of the plurality of blockouts. In yet another embodiment, anchors may be embedded within the precast cantilevered wing wall, the anchors having a first end at least partially embedded within the cantilevered wing wall and a second end adapted to be engaged by lifting hardware to lift, transport, and place the cantilevered wing wall in a position of use.
Additional features and advantages of embodiments of the present disclosure will become more readily apparent from the following discussion, particularly when taken together with the accompanying drawings.
References made herein to a “cantilevered wing wall” or aspects thereof should not necessarily be construed as limiting the present invention to a particular type of retaining structure. It will be recognized by one skilled in the art that the present invention may be used with other types of structures such as gravity walls, semi-gravity wall, conventional walls, non-gravity cantilevered wall, anchored walls, abutments, culverts, retaining walls, wing walls, and the like to retain an embankment. Accordingly, the term “cantilevered wing wall” is intended to cover all types of structures designed to retain an embankment of any type.
The terms “grout material” or “grout” as used herein refer to any material that replicates the strength of compacted soil. Such materials includes, but are not limited to, grout, cement, concrete, mortar, putty, plastic, polymer concrete, aggregate, controlled density fill, adhesives, hydro compacted sand, or any combination thereof, or similar binding materials that may be represented in a variety of types and composition mixes having various combinations of ingredients as will be recognized by one of skill in the art.
The phrase “material that replicates the strength of compacted soil” as used herein refers to any material such as grout, cement, concrete, mortar, controlled density fill, adhesives, concrete, hydro compacted sand, or any combination thereof used to fill voids and/or trenches beneath a footing of a cantilevered wing wall.
Although generally referred to herein a “precast” cantilevered wing wall, aspects of the present invention may be used with cast-in-place cantilevered wing walls as will be recognized by one of skill in the art.
The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.”
The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.
The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.
It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112 ( f ). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.
The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements or components. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate embodiments of the invention and together with the summary of the invention given above and the detailed description of the drawings given below serve to explain the principles of these embodiments. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. Additionally, it should be understood that the drawings are not necessarily to scale.
FIG. 1 is an isometric view of a cantilevered wing wall according to one embodiment;
FIG. 2 is a side view of a cantilevered wing wall according to an embodiment;
FIG. 3 is fragmentary side view of a cantilevered wing wall according to an embodiment;
FIG. 4 is a front view of multiple cantilevered wing walls positioned adjacent one another in series according to one embodiment of the present invention;
FIG. 5 is a top view of a cantilevered wing wall according to an alternate embodiment of the present invention;
FIG. 6 is a top view of a cantilevered wing wall according to yet another embodiment of the present invention;
FIG. 7A is a top plan view of multiple cantilevered wing walls positioned adjacent one another in a structure according to an embodiment;
FIG. 7B is a plan view of FIG. 7A on the line 7 B; and
FIG. 7C is a plan view of FIG. 7A on the line 7 C.
A component list of the various components shown in drawings is provided herein:
Number
Component
10
cantilevered wing wall
14
stem
18
stem height
19
stem length
20
stem thickness
22
footing
23
footing thickness
24
toe width
25
heel width
26
back face
30
front face
34
toe
38
heel
42
base shear key
43
depth
44
width
46
blockouts
46A
circular blockout
47
distance from heel
48
distance from edge
49
blockout width
50
blockout length
51
distance of separation
52
joint
54
embankment
58
subgrade
62
subgrade depth
66
footing cover
70
final grade
74
trench
78
grout
82
backfill
86
footing key
90
buttress
94
counterfort
98
vertical seam
102
right end
106
left end
DETAILED DESCRIPTION
Various embodiments of the present invention are described herein and as depicted in the drawings. The present disclosure has significant benefits across a broad spectrum of endeavors. It is the applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. It is expressly understood that although FIGS. 1-6 depict embodiments of precast cantilevered wing walls, the present invention is not limited to these embodiments and may be used in any form of application related to retaining walls or systems and methods to prevent the inadvertent movement of soil.
Referring now to FIG. 1 , an embodiment of a precast cantilevered wing wall 10 of the present invention is shown. In the example of FIG. 1 , the cantilevered wing wall 10 includes a stem 14 having a predetermined height 18 , length 19 , and thickness 20 . The stem 14 is connected to a footing 22 with a predetermined thickness 23 . The stem has a back face 26 and a front face 30 . The footing 22 may project laterally a predetermined width 24 from the front face 30 to form a toe 34 and/or from the back face 26 a predetermined width 25 to form a heel 38 . Optionally, a base shear key 42 extends down a predetermined depth 43 from the heel 38 of the footing 22 . The base shear key has a predetermined width 44 extending from the heel 38 in the direction of the toe 34 under the footing 22 . The stem height 18 , length 19 , and thickness 20 , footing thickness 23 , toe width 24 , heel width 25 , shear key depth 43 , and shear key width 44 may be any dimension required based on the design criteria of the installation. In one embodiment, as shown in FIG. 1 , it is anticipated that the shear key 42 may have a depth 43 of 12 inches and a width 44 of 12 inches. However, the base shear key 42 may have any depth 43 or width 44 required by the design criteria of the installation. For example, the base shear key could have a depth 43 of 24 inches and a width 44 of 12 inches. The base shear key 42 can be of any shape such as a tapered shape as illustrated in FIG. 2 .
Blockouts 46 are formed through the footing 22 between the stem wall 14 and the base shear key 42 . Although the blockouts 46 are shown as generally square shaped, it should be understood that they may be of any shape, including a circle, triangle, rectangle, or parallelogram, or one or more combinations thereof. Additionally, blockouts 46 of different shapes and sizes may be formed through the footing 22 . The blockouts 46 may be formed a distance 47 from the heel 38 and a distance 48 from the left and right edges of the footing 22 . The blockouts 46 may have a width 49 and a length 50 . Any number of blockouts 46 may be formed through the footing 22 . A distance 51 may separate each blockout 46 from an adjacent blockout 46 . Optionally, the distance 51 may be unequal wherein the blockouts 46 may be spaced irregularly through the footing 22 . In one embodiment, illustrated in FIG. 6 , the blockouts may be arranged in more than one row from the right end 102 to the left end 106 of the footing 22 . In one embodiment, as shown in FIG. 1 , the blockouts may be formed a distance 47 of 12 inches from the heel, may be equally spaced a distance 48 of 4 inches from the left and right edges of the footing 22 , may have a width 49 of 12 inches and a length 50 of 12 inches, and each blockout may be equally separated from an adjacent blockout by a distance 51 of 4 inches. As will be appreciated by one skilled in the art, the actual length 50 and width 49 of the blockouts and the distances 47 , 48 , and 51 may vary as required by design criteria for each particular installation. Various dimensions are provided in FIG. 1 to illustrate one exemplary embodiment and it is expressly contemplated that dimensions of the cantilevered wing wall, the base shear key, and the placement, dimensions, and spacing of the blockouts may be varied and still comport with the scope and spirit of the present disclosure. Although not shown, the precast cantilevered wing wall 10 may be reinforced with steel rebar or other materials with high rigidity to help impede movement of the wing wall after installation.
FIG. 2 illustrates another embodiment of a precast cantilevered wing wall 10 of the present invention. The stem 14 is connected to the footing 22 at a joint 52 using any material or method known in the art. For example, the stem 14 may be joined to the footing 22 using a key interlocking with a groove or depression. In one embodiment, the cantilevered wing wall 10 may be formed in one piece wherein the stem 14 and the footing 22 are formed together at the same time to form a monolithic precast structure. The back face 26 is generally designed to engage an embankment 54 comprised of soil or other material. The footing 22 is placed on a prepared subgrade 58 excavated to a depth 62 determined so that the footing 22 may be covered to a predetermined depth 66 below the final grade 70 . The base shear key 42 fits into a trench 74 dug in the subgrade 58 . In an alternate embodiment, after the retaining wall is placed on the subgrade 58 , a plurality of soil nails (not illustrated) of any type or size known in the art may optionally be emplaced through the blockouts 46 for further stabilization. As illustrated in FIG. 3 , grout 78 is poured through the blockouts 46 to fill the void between the subgrade and footing and the trench 74 . Pouring grout 78 into the trench 74 through the blockouts 46 increases the coefficient of friction between the footing and the subgrade 58 soil such that the coefficient of friction for the precast cantilevered wing wall is equivalent to the coefficient of friction of a cast-in-place cantilevered wing wall of a similar size.
Returning to FIG. 2 , after the grout material 78 cures, the footing 22 is covered and backfill 82 is placed between the embankment 54 and the back face 26 . Also shown in the embodiment of FIG. 2 , the footing 22 may optionally include a footing key 86 that extends down from the bottom of the footing 22 . Buttresses 90 may optionally be added to the front face 30 and counterforts 94 may optionally be added to the back face 26 based on design criteria. One or both of the back face 26 and the front face 30 may have a batter such that the stem 14 has a thickness 20 A near the footing 22 greater than a thickness 20 B at the top.
Referring to FIG. 4 , three cantilevered wing walls 10 A, 10 B, and 10 C of another embodiment of the present invention are illustrated. The individual wing walls 10 A-C are positioned adjacent one another or aligned at vertical seams 98 . Each wing wall 10 A-C has a stem 14 with a height 18 A greater on the right end 102 than a height 18 B on the left end 106 so that in this perspective the front face 30 of the stem 14 is higher on right end 102 . In another embodiment, the individual wing walls may be higher on the left end than on the right end providing a negative slope in this perspective. Individual cantilevered wing walls with a positive or negative slope may be positioned adjacent to each other and/or to individual cantilevered wing walls with a constant stem height to produce a profile of a varying height. In one embodiment, individual cantilevered wing walls may be positioned adjacent one another and then joined together using mechanical fasteners, by welding pre-placed joints, with a grout, or one or more other means.
FIG. 5 illustrates yet another embodiment of a cantilevered wing wall. The footing 22 extends away from the stem 14 further on the left end 106 than on the right end 102 giving the footing 22 a trapezoidal shape. Said another way, the heel projection 25 A on the left end 106 is larger than the heel projection 25 B on the right end 102 . Of course, as one skilled in the art will recognize, the right end 102 could extend further than the left end 106 . The footing 22 projecting laterally from the front face 30 may also have a trapezoidal or other shape. FIG. 5 also illustrates a circular blockout 46 A formed in conjunction with rectangular blockouts 46 .
FIG. 6 illustrates another embodiment of a cantilevered wing wall. The footing 22 extends away from the stem 14 an equal distance on the left end 106 and on the right end 102 . Two rows of blockouts 46 are formed through the footing 22 between the heel 38 and the stem 14 . The blockouts 46 have an irregular spacing. Optional blockouts 46 have been formed through the footing 22 between the toe 34 and the stem 14 .
FIG. 7A illustrates sections of cantilevered wing walls 10 D- 10 M of the present positioned adjacent one another. The cantilevered wing walls 10 D- 10 M are aligned with other precast concrete elements to form a structure. FIG. 7B illustrates a front view of cantilevered wing walls 10 D- 10 H of FIG. 7A . FIG. 7C illustrates a front view of cantilevered wing walls 10 I- 10 M of FIG. 7A . Various dimensions, angles, and alignments of cantilevered wing walls 10 D- 10 M are provided in FIGS. 7A-7C to illustrate exemplary embodiments of sizes, shapes, and alignments of individual cantilevered wing walls. It is expressly contemplated that sizes, shapes, and alignments of the cantilevered wing walls may be varied and still comport with the scope and spirit of the present disclosure.
Some embodiments of the present disclosure may be fabricated to optionally include a variety of simulated material patterns on the front face 30 , including but not limited, to simulated block, brick, stone, cut stone, stone block, flagstone, granite, sandstone, as well as other material and patterns known in the art. The invention may also embody a wide variety of different finishes, colors, and textures such as those commonly utilized in the architectural and stone industries to provide a high quality appearance compatible with any surrounding development.
In one embodiment, the cantilevered wing wall may be formed and cast on site, for example, using poured concrete. In some embodiments, other materials may be used including, but not limited to, plastic, polymer concrete, or similar materials that may be represented in a variety of types and composition mixes having various combinations of ingredients such as those found in the manufacture of concrete, plastics, polymers, cement, water, cementitious materials, and chemical and or mineral admixtures, coloring agents which, when combined, will create a concrete material. In one embodiment, blockouts may optionally be formed through the footing between the toe and the stem. In some embodiments, the cantilevered wing wall may optionally be formed without a base shear key or a footing key.
The present invention has many benefits compared to prior art cantilevered wing walls. Because the precast cantilevered wing wall of the present invention is more resistant to lateral forces than prior art precast retaining walls, the width of the footing and height of the stem can be reduced, decreasing the amount of material that must be excavated and reducing the amount of material used in the cantilevered wing wall. In addition, installation time may be reduced because if additional stability is required, soil nails may be installed through the blockouts without drilling through the footing. The precast cantilevered wing wall of the present invention is less expensive to manufacture and has a coefficient of friction equivalent to a cast-in-place retaining wall of similar size. The precast cantilevered wing wall of the present invention may also be manufactured in controlled conditions and under close observation resulting in a stronger, more reliable structure.
The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments described and shown in the figures were chosen and described in order to best explain the principles of the invention, the practical application, and to enable those of ordinary skill in the art to understand the invention.
While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. It is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. | The present invention relates generally to precast cantilevered retaining walls and methods of using and forming precast cantilevered retaining walls. More specifically, the present invention relates to a cantilevered concrete retaining wall having a base shear key and blockouts for receiving a material that substantially impedes the wing wall from sliding or other inadvertent movement, to a method of retaining a soil embankment with a cantilevered concrete retaining wall, and to a method of manufacturing a precast concrete cantilevered retaining wall. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to fungi and their symbiotic bacterial group for treating organic waste by decomposing, purifying and/or deodorizing it. The invention further relates to an effective uses thereof.
[0003] 2. Detailed Description of Prior Art
[0004] Many studies have been carried out in order to develop methods enabling the effective disposal of pollutants and waste materials which, unless disposed of properly, would have a grave adverse effect on the environment. Among them, biological waste disposal methods using microbes rapidly attract attention in recent years partly because they are free from the risk of invoking secondary environmental pollution in contrast with chemical waste disposal methods, and partly because according to those methods disposal of pollutants and waste materials proceeds as a natural process occurring in an ecological system consisting of symbiotic microbes.
[0005] Treatment of organic waste using microbes has long been employed as a common means for purifying liquid waste. However, no sufficient studies have yet been made as to the proper ecological system of microbes which grow by digesting organic waste, thereby purifyinq the waste. Indeed, bad smells and sludge residue which are generated during and subsequent to biological treatment of liquid waste, and considered to be a problem associated with the biological treatment have been resolved by adding two separate units to the sewage cleaning system, one for deodorizing the waste during its biological treatment and the other for further treating the remaining sludge in a separate tank.
[0006] Some studies have been published as to the microorganisms useful for decomposing or deodorizing organic waste. Aerobic bacterial species cited in those studies to be used for aerobic treatment include, for example, Zooglea, Achromobacter, Alcaligenes, Bacillus, Pseudomonas, etc. Anaerobic bacterial species to be used for anaerobic treatment include, for example, Desulfovibrio, Methanomonas, etc. Bacterial species to be used for decomposing odorous materials include, for example, Nitrobacter which decomposes ammonia, Chlorobium which decomposes sulfur-containing compounds, and Cl-compound assimilating bacteria such as those belonging to Genera Hyphomicrobium and Thiobacillus (Toshio OMORI, “Environmental Biotechnology” 2001, published in Japan).
[0007] However, ordinary aerobic treatment results in the production of a great amount of residual sludge. Moreover, in order to allow a system of deodorizing microbes as described above to completely decompose, by oxidation, ammonia and sulfur-containing compounds contained in waste into odorless, inorganic elements, it is necessary to exactly adjust the amount of oxygen supplied to the deodorizinq microbe group. The exact control of oxygen supply to a microbe group is so difficult that it is practically impossible to completely eliminate bad smells from waste using such a system. In addition, since ordinary anaerobic treatment consists of confining microbes together with waste in an anaerobic environment so that the microbes can digest the waste, the problem of producing a rich amount of odorous materials after treatment remains unsolved.
[0008] Some patents propose the adoption of bacterial species including new ones for treating or deodorizing organic waste. For example, the Japanese Patent Application Publication No. 2001-224365 proposes a microorganism-containing compound useful for eliminating slurry adherent to the toilet stool or kitchen sink, and its foul odor, which is obtained by adding sodium hydrogencarbonate, glucose and alum to microorganisms belonging to Genus Bacillus capable of producing amylase, protease and lipase. Further, Japanese PCT Patent Application Publication No. 2002-528113 discloses an invention in which microbes are separated from soil; among them those that are effective for treating sewage are identified (four Actinomyces species, and one belonging to Genus Bacillus); the microbes are used for treating and deodorizing sewage discharged from livestock pens; and the supernatant of treated sewage is used as a deodorizing agent or liquid fertilizer.
[0009] However, the majority of the microbes used both in the Japanese Patent Application Publication No. 2001-224365 and Japanese PCT Patent Application Publication No. 2002-528113 employ oxygen as an electron-acceptor, and thus to sustain their growth it is necessary to supply a huge amount of oxygen. Thus, the purification and deodorizing systems proposed in those patents share the same problems encountered with the above aerobic treatment. The Japanese Patent Application Publication No. 2001-224365 further discloses a method for accelerating the decomposition of organic waste, by adding thereto microbes appropriate for the kind of given organic waste. Therefore, it is necessary to sequentially add a series of microbe groups to organic waste during the course of its decomposition until the organic waste is completely decomposed. With regard to the bacterial species disclosed in the Japanese PCT Patent Application Publication No. 2002-528113, their decomposing and deodorizing activities are tested only on sewage from livestock pens, and feasibility of producing a fertilizer from decomposed and deodorized sewage is tested only on the same sewage. Namely, the invention in question does not mention at all as to what effects those microbes have in the treatment and odor-elimination of organic waste at large.
SUMMARY OF THE INVENTION
[0010] The present invention is to provide a method which comprises using a group of microbes (fungi and their symbiotic bacterial group) which are distinct from the species of microbes used in usual sewage purification systems, for decomposing and purifying organic waste, and deodorizing it by decomposing odorous materials. The fungi and their symbiotic bacterial group provided by the invention (microbe group of the invention) can digest organic waste which serves as a carbon source using inorganic salts as an electron-acceptor in an environment where the level of oxygen content is kept essentially at 1 ppm or less. In the concrete, the microbe group of the invention includes, to mention predominant ones, following organisms:
[0011] [0011] Mucor indicus (ATCC90364),
[0012] Myxococcus sp. (ATCC49305),
[0013] [0013] Flavobacterium johnsoniae (ATCC23107),
[0014] [0014] Pseudomonas alcaligenes (ATCC14909),
[0015] [0015] Klebsiella ornitinolytica (ATCC31898),
[0016] [0016] Bacillus licheniformis (ATCC14580),
[0017] [0017] Bosea thiooxidans (ATCC700366),
[0018] [0018] Methylosinus tricosporium (ATCC35070).
[0019] The aforementioned inorganic salt includes at least nitrate. The aforementioned carbon source is organic material containing cellulose compounds.
[0020] The present invention provides an agent comprising the aforementioned fungi and their symbiotic bacterial group for treating organic waste, and an agent for deodorizing organic waste.
[0021] Further, the present invention provides a method for treating organic waste which comprises adding the aforementioned fungi and their symbiotic bacterial group to organic waste for mixture, and allowing that microbe group to decompose and purify the organic waste.
[0022] And further, the present invention provides a method for deodorizing organic waste which comprises adding the aforementioned fungi and their symbiotic bacterial group to the organic waste and allowing that microbe group to deodorize the organic waste by decomposing odorous materials.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] The inventor of the present invention had long studied from a bacteriological viewpoint to seek a method for effectively treating liquid waste, and found that fungi and their symbiotic bacterial group appearing in sewage under certain conditions are quite effective not only for decomposing and purifying a wide variety of organic wastes, but also for deodorizing those wastes, and reached this invention. The fungi and their symbiotic bacterial group can grow cooperatively in the presence of a carbon source and an electron-accepter, in an environment where the level of oxygen is kept essentially at 1 ppm or less.
[0024] The fungi and their symbiotic bacterial group provided by the invention are effective not only for decomposing and purifying organic waste such as sewage from factories, sewage from common household, sewage from toilet, raw trash, fresh waste from toilet and latrine, plant waste or the like, but also for deodorizing such organic waste.
[0025] According to the invention, the allowable limit of oxygen concentration is essentially 1 ppm (1 mg/L) or lower. This is because, if the level of oxygen were above the aforementioned limit, aerobic species would be more activated which would lead to the conventional type of waste treatment based on the activation of sludge. The term “essentially” is used here to mean that the upper limit of oxygen concentration may fall around 1 ppm including a minute range above that limit over which the fungi and symbiotic bacterial group of the invention can safely grow. It is possible to supply the above level of oxygen to the microbe group of the invention, as follows. When purification of liquid waste is required, the amount of oxygen dissolved in the waste after the aeration treatment is adjusted properly. When the odor of waste from livestock pens must be eliminated, exposure of the waste to atmosphere is adjusted by, for example, covering the waste with a vinyl sheet.
[0026] In an environment where the level of oxygen is adjusted to the above level, the microbe group comprising the fungi and their symbiotic bacterial group of the invention respire using, as an electron-acceptor, oxygen which serves as an easily accessible energy source, and grow using organic materials as a nutritional source. When oxygen is used up (i.e., dissolved oxygen becomes exhausted, or the level of oxygen becomes zero), the microbe group respire using inorganic salts or another chemical constituent of the waste as an electron-acceptor. The inorganic salts include at least nitrate. In addition, they may include sulfate (containing thiosulfate), iron ingredient, manganese ingredient, fumarate, etc. Of those inorganic salts, at first nitrate is consumed according to its oxidation-reduction potential. Then, the other salts are also consumed being used as electron-acceptors (solution containing such inorganic salts will be called a controlled electron-acceptor solution hereinafter).
[0027] The electron-acceptor solution may contain, for example, nitrates at 6 ppm, sulfates at 12 ppm, and thiosulfates at 1 ppm. However, the contents of those inorganic salts in the controlled electron-acceptor solution are not limited to any specific ranges but may vary depending on the environment where an involved microbe group of the invention grows. Once the aforementioned inorganic salts which serve as electron-acceptors are added to waste to be treated, they will be then produced by the microbe group itself existent in the waste, and thus no additional supply of those salts will be necessary as long as the microbe group stably grow on the waste. The carbon source is a nutrient upon which the microbe group grows, and consists of organic materials comprising cellulose compounds such as cellulose, hemicellulose, and the like.
[0028] The microorganisms appearing in the above described environment were isolated, and the base sequence of DNA of each isolate was determined for identifying the isolate. As a consequence it was found that the microbe group of the invention predominantly comprises fungi accompanied with symbiotic bacteria as specified below:
[0029] 1 . Mucor indicus (ATCC90364);
[0030] 2. Myxococcus sp. (ATCC49305);
[0031] 3 . Flavobacterium johnsoniae (ATCC23107);
[0032] 4 . Pseudomonas alcaligenes (ATCC14909);
[0033] 5 . Klebsiella ornitinolytica (ATCC31898);
[0034] 6 . Bacillus licheniformis (ATCC14580);
[0035] 7 . Bosea thiooxidans (ATCC700366); and
[0036] 8 . Methylosinus tricosporium (ATCC35070).
[0037] ATCC cited above is an abbreviation of the American Type Culture Collection, and those microbes cited above are readily available from this organization.
[0038] The microbe group (the fungi and their symbiotic bacterial group) is obtained by transferring sewage containing organic materials into an aeration tank, aerating the sewage in such a manner as to allow the concentration of oxygen dissolved in the sewage to be 1 ppm or less, and extracting the supernatant. More preferably, the microbe group is obtained by separating (depositing) a sediment from the above aerating sewage liquid, aerating again the sediment in such a manner as to allow the concentration of oxygen dissolved in the sediment to be 1 ppm or less, and extracting the supernatant.
[0039] Individual microbes cited above are known. However, the microbe group of the invention where individual microbes are in symbiotic relations with each other in terms of catabolism is capable of decomposing organic materials, and decomposing odorous metabolites.
[0040] The microbe group of the invention where individual microbes are in symbiotic relations with each other in terms of catabolism grow on organic materials, so it is considered, via a sort of cascade processes: at an initial phase of catabolism certain organic materials are digested by one species of microbes into intermediates which are then digested by another species of microbes into further decomposed intermediates, and the process is repeated until the initial organic materials are reduced to basic inorganic elements. These cascade processes result in decomposition of odorous intermediates during this catabolic process. The fungi and their symbiotic bacterial group are basically weakly aerobic, and grow using, as a carbon and energy source, protein metabolites such as oligopeptides, amino acids, organic acids, etc. Or, they digest ammonia and hydrogen sulfate which are left by certain other organisms as end products, or the oxides of those compounds to gain energy therefrom. However, since the microbe group in question is mixed with other microbes growing on organic matters, finally the system digests organic matters in collaboration with other microbes which are also sustainable under the aforementioned condition.
[0041] The microbes identified by numbers 1, 2, 3 and 6 above (initially active group) secrete mucous fluid which contains amylase, protease, nuclease, lipase and cellulase which, when brought into contact with organic matter, digest it and leave by-products. The by-products attract another group of organisms including microbes 4 and 5 mentioned above (mid-term active group). The by-products are then decomposed further into inorganic elements which may be digested by a third group of microbes 7 and 8 (finally active group). For the most part, the mucous secret is composed of proteins. It is thought that the mid-term active group, when they consume the by-products or external supply of nutrients, will digest the proteins contained in the secret to maintain their life.
[0042] The aforementioned fungi and their symbiotic bacterial group can be used in the production not only of a treatment agent for decomposing/purifying organic waste but also of a deodorizing agent for deodorizing such organic waste. The treatment agent and/or deodorizing agent described above may be prepared by subjecting sewage to a renewed aeration in such a manner as to allow its oxygen content to be 1 ppm or less, extracting the supernatant (in a liquid) therefrom, applying the supernatant to a cellulose substrate consisting, for example, of rice-bran, saw dusts or straws which serves as a culture bed, to thereby inoculate the fungi and their symbiotic bacterial group to the culture bed, incubating the culture under a weakly aerobic condition (oxygen conc. being 1 ppm or less), and drying the resulting culture and pulverizing the solid into a powder using conventional methods.
[0043] When the treatment agent for organic waste prepared as above is applied to organic waste such as sewage, trash, fresh discharge from toilets and latrines or the like in an environment where the oxygen concentration is kept at 1 ppm or less, it is possible to decompose organic matters contained in the waste, to thereby purify the waste. Treatment of sewage consists of adding the treatment agent for organic waste to raw liquid waste, aerating the liquid waste such that the level of dissolved oxygen (DO) is kept essentially at 1 mg/L or less, allowing precipitates contained in the liquid waste to settle to form a sediment or sludge, separating the sludge from the supernatant which is treated conventionally, subjecting the sludge to a renewed aeration such that the level of dissolved oxygen (DO) is kept essentially at 1 mg/L or less, separating the supernatant from the sludge which is treated conventionally, and preparing a treatment agent from the supernatant or transferring the supernatant to raw liquid waste to use it as a treatment agent.
[0044] The deodorizing agent, when applied to organic matter emitting a foul odor, eliminates the foul odor by decomposing odorous constituents of the organic matter. This is in contrast with conventional deodorizing agents mainly comprising bacteria which are specialized in digesting fetid substances such as sulfates, methane gas, ammonia and the like. Namely, the deodorizing agent of the invention depends on the coordinated activity of a microbe group comprised mainly of fungi and their symbiotic bacteria group which can respire using oxygen and inorganic salts as their electron acceptors, and thus smoothly metabolize organic matter while scarcely producing malodorous intermediates during the course of metabolic activity.
[0045] Examples representing the invention will be described below. It should be understood, however, that the scope of the invention is not limited in any way to those examples.
EXAMPLES
[0046] Domestic sewage was aerated in an experimental tank in such a manner as to allow the level of dissolved oxygen to be kept at 1 ppm or less. Flora contained in the supernatant were sampled. They were placed in a medium, stirred and suspended. Then, they were diluted to an appropriate concentration, incubated on an LB medium, and separated into individual species for identification. The fungi were distinguished depending on the base sequence of ribosomal 18S RNA, while the bacteria based on the corresponding sequence of ribosomal 16S RNA. Myxococci were identified by microscopy. Properties of the organisms thus isolated and identified are listed in Table 1.
TABLE 1 Name of Electron Electron Excreted organisms acceptor donor enzymes Note Mucor indicus Oxygen Sugar, organic acid Flavobacterium Oxygen, Cellulose Cellulase Denitrification johnsoniae nitrate Pseudomonas Oxygen, Organic alcaligenes nitrate acid, amino acid Klebsiella Fumarate Organic acid Nitrification ornitionolytica (fermen- tation) Bacillus Oxygen, sugar Protease, Denitrification licheniformis nitrate cellulase, etc. Bosea Oxygen Organic Oxidation of thiooxidans acid, amino sulfides acid Methylosinus Oxygen Carbon Deodorizing, tricosporium (weakly compound, Assimilation of aerobic) hydrogen C 1 compounds Mixococcus sp. Oxygen Oligopeptide Protease, Secretion of lipase, protein-rich etc. mucus, & antibiotic substances
[0047] The fungi and their symbiotic bacterial group and controlled electron-acceptor solution were prepared as described above. They were transferred into experimental tanks containing domestic sewage, sewage from kitchen containing minced trash (kitchen sewage), sewage from pig pens (pig pen sewage), and sewage from food processing plants (food plant sewage). Each tank content was aerated in such a manner as to allow the content of dissolved oxygen to be 1 ppm or less. A sample was extracted from the supernatant of each tank content, and its physico-chemical properties were determined to evaluate the quality of treated water.
TABLE 2 (Treatment of domestic sewage) N-hexane Total Total pH BOD*1 COD*2 SS*3 extraction nitrogen phosphor Sewage 7.1 17 14 22 0.5> 22.7 1.1 Treated 6.4 5.7 3.3 6.2 0.5> 8.8 1.4 water
[0048] [0048] TABLE 3 (Treatment of kitchen sewage) N-hexane pH BOD SS extraction Total nitrogen Total phosphor Sewage 6.9 1886 1069 347 75 16 Treated 7.6 105 116 6.2 22.6 9.3 water
[0049] [0049] TABLE 4 (Treatment of pig pen sewage) pH BOD COD SS Total nitrogen Total phosphor Sewage 6.8 5100 1600 2700 560 100 Treated 8.1 70 430 76 150 25 water
[0050] [0050] TABLE 5 (Treatment of food plant sewage) N-hexane Total pH BOD COD SS extraction nitrogen Total phosphor Sewage 6.3 1100 360 230 11 10.6 3.9 Treated 7.6 28 34 19 0.5> 8.07 0.84 water
[0051] As shown in the tables, for all the sewage samples tested, the total contents of nitrogen- and phosphor-containing compounds were greatly reduced, suggesting the marked improvement of quality of the test sewage. The odor of the samples was eliminated after treatment, and their residual sludge was also greatly reduced. A microbe group of the invention suspended in a controlled electron-acceptor solution was mixed with a compost sample (consisting of raw trash and livestock manure) in an environment where the oxygen level is kept equal to 1 ppm or less. Then, it was found that the compost sample was decomposed highly effectively without emitting any notable odor.
[0052] Controlled electron-acceptor solutions each containing a microbe group of the invention were added to various fetid samples to evaluate the deodorizing activity of the microbe group. The results are shown in the table below.
TABLE 6 Odor Deodorizing Application Fetid matter classification activity method Domestic Sewage odor +++ Mixing sewage tank Pig manure Strong ++ Spraying ammoniac odor Fowl manure Fowl manure ++ Spraying odor Cattle manure Fermented ++ Spraying organic acid Raw trash Acidic odor ++ Spraying Pen, pet house Ammoniac odor +++ Spraying
[0053] As is obvious from inspection of the table, the microbe group of the invention exerted a marked deodorizing effect on all the fetid samples, suggesting the excellent deodorizing activity of the microbe group. The deodorizing activity of the test solution towards a fetid sample was quantified by the number of plus symbol (+): the higher the deodorizing activity of the test solution is to a given fetid sample, the more the number of plus symbol is attached to the sample.
[0054] As discussed above, the fungi and their symbiotic bacterial group of the invention can decompose/purify organic waste while decomposing foul odor from the waste during treatment, and thus the microbe group of the invention can be suitably used as a treatment and deodorizing agent for organic waste. Moreover, if the fungi and their symbiotic bacterial group of the invention are combined with a controlled electron-acceptor solution, and then the suspension is applied to organic waste, the microbe group will produce electron-acceptors by themselves as a result of their physiological action on the waste, which in turn accelerates their overall growth, thus obviating the need for additional supply of the microbe group, and simplifying works involved in the management of the sewage purification system. | Provided are fungi and their symbolic bacterial group suitable for decomposing/purifying organic waste and deodorizing a fetid source. The fungi and their symbiotic bacterial group are symbiotic flora which grow together in an environment where an oxygen concentration is kept essentially at 1 ppm or less, by metabolizing carbon sources utilizing inorganic salts as an electron-acceptor, and comprise, as predominant organisms, following microbes: Mucor indicus , Myxococcus sp., Flavobacterium johnsoniae, Pseudomonas alcaligenes, Klebsiella ornitinolytica, Bacillus licheniformis, Bosea thiooxidans , and Methylosinus tricosporium. | 2 |
FIELD OF THE INVENTION
The field of this invention relates to slip systems and an apparatus and method for release of such slips, particularly when used with retrievable packers.
BACKGROUND OF THE INVENTION
In the past, retrievable packers have been designed with opposing slips above and below the packing element. This provides a means for transferring packing element loads due to differential pressure directly through the slips and into the casing without applying this load as a high-tensile load on the mandrel or other parts. This feature has proven to be very desirable for high-performance packers. One feature of such designs, however, is the tendency of the pack-off force applied to the packing element to be "bulldogged" or trapped between the two sets of opposing slip cones, which are in turn jammed under the slips. In order to release this type of a retrievable packer, the upper slip must be pulled from a position of very high engagement force between the casing and the cone which is used to guide the slip outwardly into contact with the casing. Damage can result to the tool if the slip is literally pulled off the tool, which leaves the remainder of the tool hung up in the wellbore.
In the past, various combinations of slips and cones have been used for urging the slips outwardly into contact with the casing. One such slip actuation mechanism is shown in U.S. Pat. No. 4,711,326. This patent illustrates vertically shiftable slips carried in slots by the side edges which engage mating profiles formed in the slots. These slots form guideways for the slips for shifting the slips upwardly and outwardly relative to the body between a set position for engaging a conduit and an unset position. Various other designs have used an upward pull to release the slips. Such designs are illustrated in U.S. Pat. Nos. 5,044,433 and 5,044,441.
The shortcomings of the prior designs have been in the release sequence. The prior designs have emphasized a direct pull upwardly on the uppermost slip from a mandrel to make the slips ride along the cone and retract from contact with the surrounding casing. In the prior designs, the initial contact force between the slip and the casing has been so great that shifting the mandrel to apply direct force to the slip has resulted in failure at the connection between the mandrel and the slip, leaving the slip still engaged to the casing.
The desired objective in the past has been to find a way to undermine the support for the slip so as to avoid the hazard of having to apply unduly high forces to make the slip release while under load. The apparatus and method of the present invention addresses this need to release the upper slip with a design that provides for selective weakening of the structural support for the engaged slips by virtue of components in the cone so that release can be accomplished with a greatly reduced force.
SUMMARY OF THE INVENTION
A slip release system is disclosed which undermines support for slips by virtue of selective weakening of a structural element supporting the slips in a set position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective of the apparatus of the present invention, shown in the set position for the slips.
FIG. 2 is a sectional elevational view of the slips in the set position.
FIG. 3 is a sectional elevational view in the released position.
FIG. 3A is a sectional elevational view illustrating the key and cone in the released position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus A is shown in FIG. 1. There a series of slips 10 and 12 are illustrated. The slips 10 and are disposed preferably at 90° in an annularly shaped apparatus A which is suitable for downhole use when four slips are used. More or less slips can be used without departing from the spirit of the invention. Preferably, the slips 10 and 12 are identical in construction and in the preferred embodiment have opposed edges 18 and 20 which are guided by a cone 22. Cone 22 guides edges 18 and 20 in a manner so as to urge the slips 10 and 12 outwardly toward casing 28 as they move downwardly. When the slip, such as slip 10, advances along cone 22, it is outwardly ramped, as shown in FIG. 2, until the teeth 26 engage the casing 28, thereby suspending the mandrel 30. As previously stated, the assembly using slips can be used for a variety of downhole tools. One typical application is a packer assembly with the packing element secured above and below by slips, as illustrated in FIG. 1. At the top of each of the slips illustrated in FIG. 1 is a handle assembly 32, comprising of a pair of opposed recesses 34 and 36. Extending into recesses 34 and 36 to actuate the slip along edges 18 and 20 is sleeve 38, which is actuated for movement using mandrel 30. Upon downward movement of mandrel 30, sleeve 38 biases the edges 18 and 20 along cone 22.
FIG. 2 illustrates the slips in the set position. The walls of the cone 22 have disposed within cut-outs 40 a key 42 (as illustrated in FIG. 3A). Key 42 has a tapered upper end 44 whose position is fixed with respect to cone 22 by virtue of pin 46 extending transversely through bore 48 (see FIG. 3 and 3a). As will be explained below, when it is time to release the slips 10 and 12, the pin 46 is sheared with respect to bore 48 as key 42 is upwardly biased. As shown in FIGS. 2 and 3, mandrel 30 has a ring 50 secured in a groove 52. Keys 42 extend radially outwardly from cut-outs 40 such that upon upward movement of ring 50, the mandrel 30 exerts an upward force on keys 42. This is illustrated by comparing FIG. 3 to FIG. 2. As can be seen in FIGS. 3and 3A, when it is time to release the packer or tool employing the slips 10 and 12, the upper slips 10 and 12 are released by an upward pull on the mandrel 30. This upward pull brings up ring 50, which in turn via sleeve 54 pushes on lower end 56 of each of the keys 42. As keys 42 move up, pin 46, which extends through keys 42 and into cone 22, is sheared as illustrated in FIGS. 3 and 3A. Because the upper end of each of the keys 42 is tapered, the side walls 58 and 60 converge as they present themselves adjacent the top of cut-out 40 near bore 48. As a result, the circumferential support presented by cone 22 onto side walls 18 and 20 is undermined as edges 62 and 64 of cut-out 40 have the opportunity under load to flex toward each other. Once edges 62 and 64 are free to flex circumferentially toward each other, the side walls holding edges 18 and 20 can move away from each other reducing or eliminating the wedging force on slips 10 and 12, wherein an upward pull on handle 32 of the slips 10 and 12 easily dislodges teeth 26 from casing 28. Up until the time that pin 46 is sheared, the cone 22 has a rigid cylindrical structure and the slips 10 and 12 are firmly wedged along their edges 18 and 20 to the cone 22. However, with the keys 42 moved upwardly by movement of mandrel 30, the entire cone structure 22 is substantially weakened circumferentially so that the slips 10 and 12 may thereafter be easily pulled upwardly. Therefore, because of ramped guidance along edges 18 and 20, an upward pull from sleeve 38 after movement of keys 42 retracts the teeth 26 from casing 28.
The present design is a significant improvement over prior designs which have exhibited numerous problems in getting the upper slips to release. In prior designs, direct pulls on slips in the area of handle 32 in a situation where the slips are firmly wedged has frequently resulted in breakage of the handle 32. As a result, the entire top of the tool down to the slips and cones must be milled in order to be able to retrieve the tool from the wellbore and to allow the packing element (not shown) to release.
Those skilled in the art will appreciate that what has been illustrated is a specific mechanical embodiment which selectively weakens the elements used to wedge a slip in the set position. Other mechanical embodiments that weaken the cone structure so as to facilitate ultimate disengagement or defeat the wedging of the slips are also within the purview of the invention. One advantage of the design of the present invention is that the keys 42 may be reset and new pins 46 installed so that the cone 22 can be reused on another application. While a mechanical release mechanism has been illustrated, those skilled in the art will appreciate that hydraulic forces from the wellbore or from the surface alone or in combination with mechanical forces can also be used to initiate the release feature which weakens the cone structure, thereby facilitating removal of the slips in a condition where they are not mechanically or otherwise wedged against a casing 28. Other means of storing or applying a force to move keys 42 such as electrical or chemical can also be used. While a notch with a tapered wedge is illustrated as the preferred embodiment, other devices which weaken the cone wall and thus relieve, at least in part, a wedging force on the slips are within the scope of the invention.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention. | A slip release system is disclosed which undermines support for slips by virtue of selective weakening of a structural element supporting the slips in a set position. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional application of co-pending Ser. No. 732,937, filed Oct. 15, 1976, now U.S. Pat. No. 4,062,406.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a valve and lubricator assembly having particular utility on offshore locations in order to house a wire line or other tool while the shutoff valve and/or master or safety valve of the wellhead assembly are open. The present lubricator assembly when open functions as a pressure housing to permit a straight opening to the tubing therebelow or when closed, functions as a pressure barrier that allows installation of a wire line or other tools in a well in a safe manner.
2. Description of the Prior Art
During the completion, testing and/or workover of a subterranean well at an inland location, it may be necessary to run equipment such as a perforating gun or the like on a wire or electric line into the well when the well is under pressure. This is achieved by inserting the equipment into a length of production tubing above the christmas tree, the length of tubing being commonly referred to as a "lubricator". The lubricator section is isolated from the portion of the well therebelow by a valve or a series of readily accessable hand manipulated valves. On some inland locations, it may be necessary to extend the lubricator section as high as 60 feet into the air.
On offshore locations, where space is at a premium and valves are not readily accessable, an inland-type lubricator is not practical. For example, use of such an extended length of tubing may be hazardous when applied to an offshore well site utilizing a floating vessel thereabove. Relative motion between the floating vessel and the tubing string which is anchored in the well within the sea bed causes considerable difficutly in manipulation of manual valves.
Most offshore locations will utilize a riser pipe extending from the floating vessel to the ocean floor where it is connected to the uppermost portion of the blowout preventer stack. The riser functions as casing and provides a conduit for mud circulation and isolation of the well from the sea. Whenever the well is "live" or capable of flowing, there is usually tubing between the floating vessel and the blow out preventer stack. This tubing will be inside the riser, if a riser is used. This tubing section is available for use as a lubricator section for insertion therethrough of wire or electric line equipment if a valve is provided therebelow. Use of the riser pipe as the lubricator section will eliminate use of an extending lubricator section above the floating vessel and will thereby eliminate the hazards involved in such use.
In view of the fact that the lubricator assembly must contain the well pressure while the equipment is inserted therethrough for subsequent utilization in the well, it is necessary to control the well pressure below the lubricator assembly during this procedure. This is achieved by use of a valve assembly within the lubricator section. Some commercial and prior art lubricators contain normally open valve assemblies which permit the valve to automatically open if hydraulic control pressure is lost. Under certain conditions, if control pressure were lost, a blow out might result. Other lubricator valve assemblies contain normally closed valve assemblies which permit the valve to automatically close if hydraulic control pressure is lost. Normally, closed valves can close and sever the wire or other line if control pressure is lost, possibly damaging the valve and rendering it inoperable, thereby causing a blow out of the well. Moreover, each of these types of prior art valve assemblies are somewhat disadvantageous in that they are not fail-safe, that is, the open or closed position of the valve is not affected by loss of control pressure.
The present lubricator valve assembly overcomes many of the disadvantages of the prior art apparatuses by providing a mechanism which utilizes a combination of pressure means to activate the valve element. Additionally, the present lubricator assembly provides means for locking the valve manipulating mechanism when the valve element is in closed position. The present lubricator and valve assembly are not automatically manipulated when control pressure is lost, which results in a fail-safe valve assembly. Moreover, the present lubricator assembly also provides a means for both reducing metallic friction on the ball valve surfaces during the opening and closing manipulating steps as well as providing a metal-to-metal seal when pressuring above the ball valve element.
A necessary function of this tool is the requirement that the tubing be pressured from the surface to re-open the valve. Pressure above the tool must exceed pressure below the tool before it will open, thus assuring control of the well by a pressure source above the lubricator.
SUMMARY OF THE INVENTION
The present invention provides a lubricator and valve assembly designed primarily for use in conjunction with the drilling, completion and workover of subterranean oil and gas wells at offshore locations. The valve assembly preferably contains a reciprocatable ball valve mechanism which is held in open position by mechanical means and is insensitive to tubing pressure. Application of first fluid means in the fluid control line acting on an activating mandrel will raise the mandrel, and, in turn, rotate the valve element to closed position. The lubricator valve apparatus also has mechanical locking means which will maintain the activiating mandrel in a locked position after the valve has been shifted to closed position, the locking mechanism being initially activated by longitudinal upward movement of the valve control mandrel. Second fluid pressure means within the tubing also are provided in the lubricator assembly whereby the valve control mandrel is released from the mechanical lock mechanism and the valve is reciprocated to open position. Valve metallic friction reducing means are also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic longitudinal view showing an offshore well location and the lubricator valve assembly made up as a part of the tubing string within a riser pipe above the well blowout preventer stack.
FIGS. 2a, 2b, and 2c are elongated views, in series, of the present lubricator assembly with the valve element shown in fully opened position, FIG. 2b being a lower continuation of FIG. 2a, and FIG. 2c being a lower continuation of FIG. 2b.
FIG. 3 is a series of views of the valve element and its immediate activating components comprising a valve control strap housing (upper view), a valve control strap (middle view), and the ball element (lower view).
FIG. 4 is a cross-sectional detail taken along lines 4--4 of FIG. 2c, showing the ball element within the lubricator assembly in opened position and its interrelation with the valve activating mechanism.
FIG. 4a is a partial side view of the valve and its activating mechanism. The ball element is shown in open communication with flow passageways above and below the apparatus.
FIGS. 5a, 5b, and 5c are longitudinal views of the lubricator assembly with the ball element shown in closed position and the locking mechanism in activated state to prevent control line pressure activation of the ball element to open position, FIG. 5b being a lower continuation of FIG. 5a, and FIG. 5c being a lower continuation of FIG. 5b.
FIG. 6 is a cross-sectional view taken along lines 6--6 of FIG. 5c showing the ball element and its immediate operating mechanism, the valve element being shown in closed position.
FIG. 6a is a partial side view of the valve and its activating mechanism, similar to the view shown in FIG. 4a, the valve mechanism being in closed position in relation to flow passageways above and below the apparatus.
FIG. 7 is a complete cross sectional view of the lubricator assembly taken along lines 7--7 of FIG. 5b.
FIG. 8 is a longitudinal sectional view of the central section of the lubricator assembly showing the collet fingers of the lock mechanism sliding between companion locking surfaces on the valve control mandrel and the latch sleeve during relative longitudinal movement between the control mandrel and the latch sleeve.
FIG. 9 is a view similar to that of FIG. 8 showing the lock sleeve in position to unlock the control mandrel, with tubing pressure entering the lock piston chamber for activation of the lock sleeve.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The lubricator valve apparatus A has a ball valve element 1 which is shifted from an open position to a closed position by longitudinal manipulation of a control mandrel mechanism 2 operatively comprising a ball piston element 3, an elongated lock mandrel member 4 affixed thereto, a lock piston mandrel 5 affixed to the lock mandrel member 4, and a thrust carriage element 6 engaged below the lock piston mandrel 5.
The ball valve element 1 and its immediate operative components are depicted in FIG. 3. As shown, the ball element 1 has a flow passageway 1a therethrough to permit communication of well and other fluids as well as tools, such as perforating guns, and the like, not shown. The internal diameter of the ball element as represented by the flow passageway 1a is substantially equivalent to the internal diameter of the control mandrel elements 2 thereabove and the bottom sub member 7 therebelow to provide a full opening valve element. The ball element 1 is manipulatively affixed to a companion control ring 8 having in its center a control seat 9 for housing of an exteriorally protruding control pin 10 on the valve element 1. The control ring 8 is affixed to the inner surface 11 of a longitudinally extending valve control strap 12 having at its upper end 12a a series of lock members 13a and 13b to assist in manipulation of the valve element 1, and a solid valve rotation stop member 14 on the control strap lower end 12b immediate and just below the control ring 8. The valve rotation stop 14 has primary and secondary surfaces 14a and 14b on each side thereof for limitation of the rotation of the ball element 1 during reciprocation. The primary surface 14a of the valve stop element 14 will engage a companion shoulder stop element 15 extending from a travel grooveway 10a formed around the control pin 10 on each side of the ball element 1. When the ball element 1 is manipulated to its closed position, the control pin 10 will rotate within the control ring 8. The ball element grooveway 10a will rotate with respect to the valve stop element until the secondary surface 14b engages the protruding thrust abutment 16 on the valve element 1, thereby preventing further rotation and reciprocation of the ball element 1.
The ball element 1 is operatively engaged within the valve control strap 12 when the control pin 10 is within its companion control slot 9, the valve rotation stop member 14 being within the ball element grooveway 10a. Additionally, the valve control strap 12 is operatively engaged within an exterior valve control strap housing member 17 having therein an engrooved longitudinal control strap receptacle 18 for receipt of the valve control strap 12. Protruding outwardly from the inner diameter surface 17a of the valve control strap housing 17 is a valve manipulating pin 19 for travel engagement within its companion manipulating slot 20 on the exterior surface of the ball element 1. As the valve control strap 12 is caused to be raised or lowered, the ball element 1 is rotated by the force exerted on the manipulating pin 19 and over the outwardly extending surface 21 of the slot 20.
The ball element 1, valve control strap 12 and control strap housing 17 are, in turn, housed within the apparatus A in a circumferentially extending elongated valve housing member 22 connected at its lower end by threads 23 to the bottom sub member 7, which, in turn, has at its upper end an upwardly protruding head 24 with a plurality of portal members 25 providing pressure passageways from the interior of the apparatus A to a pressure passage 26 immediate the head portion 24 of the bottom sub 7 and the valve control strap housing 17, for permitting pressure communication within the apparatus A during the re-opening sequence of the ball element 1, as described below. The bottom sub 7 is connected at its lower end by thread members 27 to a tubing section 28 which continues the tubing string downwardly through the well W. O-rings 29 are provided within their respective grooveways 29a on the bottom sub 7 and the upper portion 30 of the tubing element 28 to prevent fluid communication between the tubing section 28 and the bottom sub 7, and the bottom sub 7 and the valve housing 22, respectively.
The upper and lower outwardly extending carriage lock elements 13a and 13b of the valve control strap 12 are functionally engageable within a companion grooveway 13a 1 within the thrust carriage 6 and above an outwardly and circumferentially extending abutment 13b 1 upon the valve control strap 12, respectively. The differential sleeve 31 has protruding exteriorally therearound a retainer ring element 32 encapsulating at its lower end an elastomeric elongated seal member 32a for smooth engagement upon the outer smooth surface 1b of the ball element 1. Within the retainer ring 32 is a grooveway 32b for receipt of an O-ring 32c to prevent fluid communication between the retainer ring 32 and the differential sleeve member 31. The differential sleeve 31, which is a free-floating device, except when the valve is in the fully closed position, is operatively engaged by the valve control strap 12 to the thrust carriage 6 immediately thereabove which, in turn, is engaged by threads 33 to the lock piston mandrel 5 having at its upper end a series of pressure ports 34 for communication of fluid within the interior of the apparatus A and within a releasing piston pressure chamber 35 formed between the lock piston mandrel 5 and a releasing piston 36 outwardly encircling the immediate upper end thereof. The lock piston mandrel 5 is connected by threads 37 to the lock mandrel member 4 which, in turn, provides a partial internal housing for the locking device described below. The lock mandrel 4 is engaged at its upper end by threads 37 to the ball piston 3 having a grooveway 38a for receipt of the circumferentially extending O-ring 38 around the upper end of the lock mandrel 4 to prevent fluid communication between the ball piston 3 and the lock mandrel 4. The lower portion of the ball piston 3 provides an exteriorally protruding retainer stop member 39 having engaged on the top thereof a spring seat 40 engaging the lower end of a spring element 41 encircling the lower portion of the ball piston 3, the spring element 41 being encapsulated at its upper end by a companion spring seat 42 encircularly affixed around the ball piston 3 and held in place against upward travel by an outwardly extending and downwardly facing shoulder 43 formed on a control pressure housing 44 described in further detail below.
Forming the uppermost portion of the ball piston 3 is a longitudinally extending piston head 45 having a grooveway 46a for receipt of an O-ring 46 at its upper and lower ends to prevent fluid communication between the piston head 45 and the control pressure housing 44. A similar grooveway 47a for receipt of companion O-ring 47 also is provided upon the piston head 45 to prevent fluid communication between the piston head 45 and a top sub 48 when the piston head 45 slides along the outer and exterior surfaces 49a and 49b of the top sub 48, and control pressure housing 44 respectively, during operation. The piston head 45 has at its upper end a central opening 50 entering into a pressure passageway 51 extending longitudinally throughout the piston head 45, the passageway 51 terminating at a corresponding opening 52 at the lower end of the piston head 45 and communicating with a pressure chamber 52a formed therebelow by the lower end of the piston head 45, the inner wall 44a of the control pressure housing 44, the outer wall 3a of the ball piston 3, and continuing lowerly between the outer housing 13 of the apparatus A and the control mandrel components 2 until pressure communication resistance is afforded by operation of the O-rings within the control pressure housing 44, the lock piston housing 54, the releasing piston 36, the lock piston mandrel 5, and the lock mandrel 4.
The piston head 45 and the passageway 51 therethrough communicate with an upper control pressure chamber 55 which, in turn, communicates with a control line duct 56 formed within the upper portion of the control pressure housing 44. A receiving groove 57 at the uppermost end of the control pressure housing 44 provides a means for engagement of the lower end 58 of a fluid control line 59 which extends upwardly and adjacent the exterior of the apparatus A to a control panel (not shown) on the ship deck, platform, or the like.
A reference vent line 60 extending from the control panel, of similar construction as the control line 59, is engaged within a companion receiving groove 61 therefor within the upper end of the control pressure housing 44 and at a point 90° from the receiving groove 57 for the control line 59. The reference vent line 60 communicates with a reference pressure duct 62 longitudinally and downwardly extending therefrom within the control pressure housing 44 and terminating at a lower port 62a which is in fluid communication with a reference pressure chamber 63 circumferentailly extending around the piston head 45 and within the upper portion of the control pressure housing 44. The reference pressure system as described above will be operationally depicted in sequence below.
When the ball element 1 is in open position such that the flow passage 1a therein communicates with the interior passageway P and P 1 above and below the ball valve element 1, the apparatus A and the ball valve element 1 will not be activated until such time as control pressure is increased, thus initiating the ball closure cycle.
In association with the ball closure cycle is the function and operation of the locking system which prevents downward longitudinal movement of the lock mandrel 4 and its interconnecting and associated parts until such time as tubing pressure causes deactiviation of the locking system. The locking system of the present apparatus basically is comprised of a longitudinally extending tubular-like locking sleeve 64, the releasing piston 36 and a collet lock apparatus 65. Interconnected by threads 66 to an upwardly and inwardly extending box 67 on the control pressure housing 44 is a circumferentially extending locking latch mechanism 68 having an adjustment passage 68a extending laterally through its uppermost portion. At a lower end of the locking latch mechanism 68 and forming a part thereof are a plurality of flexible finger-like collet members 65, each member 65 having an inwardly protruding spoon element 69 at the end thereof for securable engagement within a companion upset 70 along the lock mandrel 4.
Operationally interconnected with the locking latch mechanism 68 is the longitudinally extending tubular locking sleeve 64 open at its upper end 64a and receiving within its interior 64b the lock mandrel 4 and the locking latch mechanism 68. Along the inwardly facing interior surface 64b of the locking sleeve 64 and immediate the outwardly protruding upset 70 along the lock mandrel 4, when the ball element 1 is in its open position, is a slightly outwardly protruding shoulder 71 for cooperation with the upset 70 on the lock mandrel 4 to engage the outer surface 72 of the collet members 65 in order to resist downward longitudinal movement of the lock mandrel 4 after the ball element 1 has been reciprocated to its fully closed position. The lower section of the locking sleeve 64 serves as an outer housing for a spring 73, which is compressably encircled around the lower portion of the lock mandrel 4, the spring 73 urging the entire locking sleeve 64 in an upward direction, this force being resisted by an outwardly protruding shoulder 74 on the lock mandrel 4 which contacts a resistance block 75 extending from the locking sleeve 64 for engagement with the shoulder 74. A thrust bearing 76 is provided around and below the resistance block 75 for assembly of the spring 73.
As will be described in further detail below and in operational sequence, when the ball element 1 is to be reciprocated to closed position, the lock mandrel 4 will be caused to travel upwardly. The force contained within the compressed spring 73 within the locking sleeve 64 will cause the locking sleeve 64 to travel upwardly. As the inner smooth surface 78 along the spoon 69 of the collet 65 contacts and travels along the upwardly sliding upset 70 on the lock mandrel 4, the collet elements 65 will expand outwardly, and the outwardly and slightly downwardly angled outer surface 79 on the spoon 69 will engage the smooth surface or shoulder 71 along the locking sleeve 4. This position is shown in FIG. 8.
As the lock mandrel 4 continues its upward travel, the shoulder surface 71 on the locking sleeve 4 will momentarily engage the surface 79 on the spoon 69 which affords resistance to further upward travel of the locking sleeve 64. Although the sleeve 64 is thus stabilized against longitudinal movement, the lock mandrel 4 continues upward travel with upset 70 passing upwardly against the surface 78 on spoon 69, until the upset 70 is completely above the surface 78 at which time the collet 65 is urged inwardly to its normally retracted position by the force exerted thereon by shoulder 71 engaging its companion surface 79. The force exerted by the 71, 79 interface will cause the collet elements 65 to collapse and pass under the upset 70 while the upward travel of the lock mandrel 4 continues. The shoulder 71 on the locking sleeve 64 is permitted to force the collet 65 to pass under the upset 70 by means of the upward urging of the locking sleeve 64 afforded by expansion of the spring element 73 as the locking sleeve 64 follows the upward travel of the lock mandrel 4.
When the collet 65 is in its locked position, as shown in FIG. 5b, the ball element 1 will be rotated to its completely closed position and, because of the downward longitudinal resistance afforded by the action of the collet 65 in conjunction with the lock mandrel 4, the lock mandrel 4 will be unable to travel downwardly to reopen the ball element 1.
A series of pressure passages 82 are provided laterally through the locking sleeve 64 to permit transmission of control fluids throughout the control pressure housing 44 immediate the spring 73.
Operatively associated with the locking mechanism of the present apparatus, and as means to reopen the ball element 1 after the lock mandrel 4 has been placed in its fully locked position, a releasing piston mechanism is provided which is initially activiated by increasing well tubing pressure within the tubing string I and the interior A-1 of the apparatus A to provide a differential over the wall pressure within the pressure chamber areas of the apparatus A. Tubing pressure ports 34 circumferentially extend through the lock piston mandrel 5, which is attached by threads 37 to the lower end of the lock mandrel 4. A releasing piston 36 which is interconnected to the lower end of the locking sleeve 64 defines along its inner surface a piston pressure chamber 35 communicating with the ports 34. The releasing piston 36 being functionally interconnected with the locking sleeve 64, is limited in upward longitudinal travel by contact of the resistance block 75 with the outwardly protruding shoulder 74 along the inner surface of the lock mandrel 4, while resistance to downward longitudinal movement of the releasing piston 36 is afforded by an outwardly extending shoulder 80 thereon which may contact a companion shoulder 81 which extends outwardly along the lock piston housing 54.
As the pressure in the area P 1 is overcome by an increase in the pressure in the area P, differential pressure will cause the expansion of the piston chamber 35 immediate the releasing piston 36, and the releasing piston 36 with its interconnected locking sleeve 64 will be urged slightly downwardly, thus permitting the outwardly extending and upwardly facing shoulder 71 on the locking sleeve 64 to be disengaged from its companion surface 79 of the collet 65. In turn, the lock mandrel 4, which is urged downwardly by the operation of the ball spring element 41 circumferentially extending around the lower portion of the ball piston 3, is permitted to travel downwardly when the collet members 65 spring to their disengaged position and away from the upset 70 along the lock mandrel 4. With the collet elements 65 in disengaged position, the spring 41 surrounding the ball piston 3 will afford sufficient downward longitudinal movement to the lock mandrel 4 and its associated parts to rotate the ball element 1 to its fully open position.
The lubricator apparatus A of the present invention is made up such that it is an integrable part of the tubing string I with sections of tubing string I being connected to it by threaded or other means. The tubing string I is inserted within the riser pipe R and through the blowout preventor B-P, the tubing string I extending through the sea bed B into the well W. The control and reference vent lines 59 and 60 extend from their respective receiving grooves 57 and 61, within the lubricator valve assembly A to a control panel (not shown) on the drill ship, platform, or the like, and the control line pressure is applied to the control line 59 to the lubricator apparatus, as shown in FIGS. 2a, 2b and 2c. As pressure is increased in the control line, pressure will act on the piston head 45 to cause the ball piston 3, the lock mandrel 4 interconnected therewith, the lock piston mandrel 5 therebelow, the thrust carriage 6 and the valve control strap 12 to move upwardly causing the manipulating pin 19 on the exterior 17a of the valve control strap housing 17 to travel within its companion manipulating groove 20 causing rotation of the ball element 1 until the secondary surface 14b on the valve stop 14 engages the thrust abutment 16 of the ball element 1, at which point the ball element 1 is in its completely closed position. When the ball element 1 is in its fully closed position, the ball control strap 12 is not the upstop for the ball because the floating differential sleeve 31 rises until it contacts the lower portion 54a of the lock piston housing 54. The differential sleeve 31 prohibits further longitudinal travel of the ball element 1, thereby providing a metal-to-metal seal between the differential sleeve 31 and the ball element 1. Additionally, the reference vent line 60, will confirm that the ball piston 3 and its interconnected parts have travelled longitudinally upwardly within the lubricator apparatus A, thus indicating and confirming activiation of the tool to rotate the ball element 1 to its closed position.
When it is desired to insert production or completion equipment within the tubing string I to perform functions such as perforating and the like, the ball element 1 is rotated to closed position and the tools are inserted through the tubing string I and the lubricator valve assembly A on a wireline, electric line, or the production string (not shown). The ball element 1 is rotated to its closed position by increasing control pressure, which, in turn, permits the ball piston 3, the lock mandrel 4, the lock piston mandrel 5, the thrust carriage 6 and the valve control strap 12 to travel upwardly. Repeated variations in control pressure will not affect the closed and locked position of the valve.
As noted above, in conjunction with the step of manipulating the ball element 1 to its fully closed position, there is provided a locking mechanism to insure that the ball element 1 is maintained in a fully and sealingly closed position. When the control line 59 pressure is applied, the lock mandrel 4 will travel upwardly and the upset 70 thereon will cause slight outward expansion of the collet elements 65 on the locking latch 68. As the upward travel of the lock mandrel 4 and ball piston 3 continues, the inner surface of the collet elements 65 will travel across the outwardly protruding surface 70a of the upset 70, and the collet elements 65 will be urged into a slightly retracted and locked position when the outer surface 65a of the collet elements 65 engages the outwardly protruding shoulder 71 along the locking sleeve 64 which will lock the collet 65 below the upset 70 in a position which will prevent downward movement of the lock mandrel 4. The outwardly extending shoulder 71 on the locking sleeve 64 maintains upward force upon the collet element 65 in conunction with the lock mandrel 4 by the force of the spring 73 housed within the locking sleeve 64. The upset 70 on the lock mandrel 4 is urged into locking position with the collet 65 and the locking sleeve 64 due to the force of the spring 73. Control pressure may be bled off and the valve will remain closed.
With the ball element 1 of the lubricator assembly A being rotated to its completely closed position, the well W is shut off therebelow, thus permitting pressure to be bled off above the lubricator, thereby allowing completion or other equipment to be made up within the lubricator section of the tubing string I in the riser Pipe R. After the equipment is made up on a secondary, production string, wire line, or the like, it will be necessary to reciprocate the ball element 1 to fully open position to pass the equipment through the lubricator assembly A and into the well W therebelow. With the lock mandrel 4 and its corresponding and associated parts being in locked position, activation of the ball element 1 to open position can only be accomplished by increasing pressure within the tubing area P to an excess of well pressure within the tubing area P 1 , acting below the valve, thus providing differential pressure manipulation of the ball element l to open position. This assures well control because the tubing must be closed and pressure tight at the surface. Since the well pressure in area P will be greater than the tubing pressure acting within the area P 1 below the ball valve 1 during initial manipulation of the ball element 1 to open position, the differential sleeve 31 will be pressure activated into sealing engagement with the outer smooth surface 1b of the ball element l to permit the seat 31a of the sleeve 31 to engage the ball element l and surface 1b and establish a pressure seal. Once the ball opens, the metal-to-metal seal is no longer pressure activated and the differential sleeve 31 is no longer in contact with the ball element l. The differential sleeve 31 serves to prevent metallic friction between the surface 1b of the ball element 1 and the metallic surface at the end 31a of the differential sleeve 31 when the ball element l is being manipulated to open and closed positions. Additionally, the retainer ring 32 and elastomeric seal element 32a function in cooperation with the differential sleeve 31 to provide a rubber-to-metal seal when the well pressure in the area p 1 below the ball exceeds pressure above the ball element l in the area P.
In order to shift the ball element l from closed to open position, the tubing pressure in the area P is permitted to enter the releasing piston chamber 35 through the pressure ports 34 in the lock piston mandrel 5. As the pressure is increased over the static well pressure in the area P 1 the differential pressure in the releasing piston chamber 35 causes the releasing piston 36 and the locking sleeve 64 interconnected therewith to move longitudinally downwardly within the control pressure housing 44. As the locking sleeve 64 and the releasing piston 36 move downwardly, the spring 73 housed within the locking sleeve 64 is contracted and the outwardly protruding shoulder 71, which has engaged the collet member 65 to cooperate with the upset 70 to lockingly engage the mandrel 4, is caused to separate from its engaged surface 78 on the collet 65. As the locking sleeve 64 travels downwardly because of tubing pressure increase, the collet 65 will expand and the inner surface of its flexible elements will quickly travel over the outer longitudinal surface 70a of the upset member 70 on the lock mandrel 4. When the collet element 65 is disengaged from the upset member 72, the lock mandrel 4 and its companion activating elements will be urged downwardly by expansion of the spring 41 encircling the ball piston 3. The thrust carriage 6 which is affixed to the lock piston mandrel 5 urges the valve control strap 12 in a downward direction to, in turn, cause the manipulating pin 19 on the valve control strap housing 17 to travel within the manipulating groove 20 on the ball element l to rotate the ball element l to open position. Rotation of the ball element l continues automatically to the full open position because of the urging of the spring 41 until secondary surface 14a of the valve stop 14 engages the thrust abutment 16 on the surface 21 of the ball element l. The downstop 24a stops longitudinal movement of the ball element l and its companion activating elements. When the ball piston 3 and its correspondingly operational parts are manipulated to rotate the ball element l to open position, the control fluid level will rise somewhat as the ball piston head 45 travels downwardly and the ball piston chamber 55 decreases correspondingly. Thus, downward movement of the ball piston 3 can be detected at the drill ship or platform surface by a drop in pressure and fluid level in the indicators affixed to the reference vent line 60. Such a drop and decrease in fluid level and pressure would be indicative that the ball element l is in open position. Correspondingly, an increase in fluid level in the reference vent line 60 would signify that the ball piston 3 and its correspondingly interrelated components had been activated to rotate the ball element l to closed position.
From the above, it can be seen that a lubricator valve apparatus is provided which is placed into closed position by an increase in control line pressure. A decrease in control line pressure thereafter will not cause a reversal in the operational mode to reciprocate the ball element to open position. Additionally, closure of the ball element also activates a locking mechanism which will prevent manipulation of the ball element to open position by increasing control line pressure. In conjunction with each of the above features, there is provided a means for unlocking the ball element control mechanism and rotation of the ball element to open position by means of increasing tubing pressure within the apparatus. In conjunction with the utilization of tubing pressure to unlock and activate the ball element to open position, there is provided a friction reduction mechanism which provides a metal-to-metal seal upon increase of tubing pressure.
It can also be seen from the above that the lubricator apparatus of the present invention may be manipulated to open, closed, locked, and reopened positions without requirement of retrieval of the tool to the drill ship or platform for reactiviation. This feature is accomplished by utilizing control line pressure and tubing pressure in sequential combinations.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by 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. Accodingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | An improvement in a lubricator apparatus for use in installation of drilling, completion, workover tools, or parts thereof for subsequent use in a subterranean well and for control of fluids through said well, the lubricator having therein a valve assembly comprising a longitudinally shiftable carriage, a ported valve head rotatable on said valve seat means between closed and opened positions by said carriage to control flow of fluids through said well and through said lubricator apparatus. Improvement comprises a differential sleeve longitudinally movable immediate the valve assembly and is sealingly engageable upon the exterior of the ported valve head when the valve assembly is in closed position. The sleeve is sealingly disengageable from the ported valve head when the assembly is in opened position and is urgeable to sealing engagement upon the ported valve head in response to pressure differential across the valve assembly, with the sleeve being in frictionless relationship with the ported valve head in absence of pressure differential across the valve assembly. Reference pressure operated means in conduit communication with said valve assembly are provided for rendering the valve assembly insensitive to hydrostatic pressure at the depth of the operation of the valve assembly and further enabling control pressure to rotate the ported valve head operatively independent of well pressure. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to belt drive systems and more particularly to engine belt drive systems having automatic belt tension control. cl BACKGROUND OF THE INVENTION
[0002] Most engines used for automobiles and the like include a number of belt driven accessory systems that are necessary for the proper operation of the vehicle. The accessory systems may include an alternator, air conditioner compressor and power steering pump.
[0003] The accessory systems are generally mounted on a front surface of the engine. Each accessory having a pulley mounted on a shaft for receiving power from some form of belt drive. In early systems, each accessory was driven by a separate belt that ran between the accessory and the crankshaft. With improvements in belt technology, single serpentine belts were developed and are now used in most applications. Accessories are driven by a single serpentine belt routed among the various accessory components. The serpentine belt is driven by the engine crankshaft.
[0004] Since the serpentine belt must be routed to all accessories, it has generally become longer than its predecessors. To operate properly, the belt is installed with a pre-determined tension. As it operates, it may stretch slightly. This results in a decrease in belt tension, which may cause the belt to slip. Consequently, a belt tensioner is used to maintain the proper belt tension as the belt stretches during use. A belt tension may be controlled by movement of pulleys as well as through the use of tensioners.
[0005] Control systems are known which allow a user to adjust a belt tension during operation of the system. These systems generally use a cylinder or other mechanical device to adjust a drive wheel position. The control system may also adjust a belt tension in response to belt speed.
[0006] Representative of the art is Japanese Publication No. 2001-059555 to Denso which discloses a belt transmission system to control slipping of a belt by computing a slip factor from a detection value from a first and second tachometer, the first tachometer detecting an engine speed and the second tachometer detecting an auxiliary module speed.
[0007] Also representative of the art is U.S. Pat. No. 5,641,058 (1997) to Merten er al. which discloses a invention which employs pressure and displacement sensors for the automatic monitoring and adjustment of endless belts by movement of drive and return wheels.
[0008] The prior art does not allow active control of belt tension to reduce belt slip while increasing belt life by setting a low belt tension when low tension is all that is required, but increasing tension momentarily and temporarily when such is necessary during transient conditions to prevent belt slip and associated noise.
[0009] What is needed is a belt tension control system having sensors for detecting a. belt operating condition. What is needed is a belt tension control system having a control module for using belt operating condition signals to actively control an actuator. What is needed is a belt tension control system for increasing a belt life by actively controlling a belt tension. What is needed is a belt tension control system capable of anticipating and preventing a belt slip noise event. The present invention meets these needs.
SUMMARY OF THE INVENTION
[0010] The primary aspect of the invention is to provide a belt tension control system having an actuator controlled by a control module for moving a pivoted pulley to adjust a belt tension.
[0011] Another aspect of the invention is to provide a belt tension control system having sensors for detecting a belt operating condition.
[0012] Another aspect of the invention is to provide a belt tension control system having a control module for using belt operating condition signals to actively control an actuator.
[0013] Another aspect of the invention is to provide a belt tension control system for increasing a belt life by actively controlling a belt tension.
[0014] Another aspect of the invention is to provide a belt tension control system capable of anticipating and preventing a belt slip noise event.
[0015] Other aspects of the invention will be pointed out or made obvious by the following description of the invention and the accompanying drawings.
[0016] The invention comprises a belt drive system for automatically controlling a belt tension. The system comprises an actuator controlled by a control module. The actuator operates on a pivoted pulley. A belt is trained about the pivoted pulley as well as other pulleys driving various accessories. A series of sensors in the system detect a belt condition including a belt tension. Sensor signals are transmitted to the control module. The control module processes the signals and instructs the actuator to move the pivoted pulley, thereby increasing or decreasing a belt tension. A feedback loop from the sensors to the control module allows the belt tension to be continuously monitored and adjusted many times per second. The system may actively control a belt tension by anticipating a system condition to prevent a belt noise by comparing sensor signals to a system model stored in a control module memory.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate preferred embodiments of the present invention, and together with a description, serve to explain the principles of the invention.
[0018] [0018]FIG. 1 is a schematic view of the inventive system.
[0019] [0019]FIG. 2 is a schematic diagram of the closed loop control philosophy.
[0020] [0020]FIG. 3 is a control algorithm diagram for the inventive system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] [0021]FIG. 1 is a schematic view of the inventive system. The system anticipates and prevents belt slip in front end accessory drive systems thereby decreasing system noise and increasing belt life. The extent to which a belt may slip is dependent primarily on load and belt tension. A surface coefficient of friction on a belt and pulley(s) also plays a role. Belt slip is most readily identified by noise emitted by the belt during operation. Belt slip may also result in premature belt failure without causing noise, but as a result of increased belt temperature through friction between a belt and a pulley. Friction causes a belt temperature to rise to levels that are detrimental to long belt life. Belt slipping most often occurs during transients when system conditions are rapidly changing, for example engine accelerations and decelerations. To prevent this from occurring, the instant invention allows a belt operating condition, including a belt tension to be detected, analyzed and rapidly adjusted in order to prevent a belt slip condition.
[0022] The inventive system generally comprises a number of accessories being driven by an endless belt or drive member 6 . The accessories driven by the belt are mounted to a front surface or surfaces of a vehicle engine. The accessories and belt may also be mounted to a frame, wherein the frame with the belt and accessories is then mounted as a complete unit to an engine surface.
[0023] The accessories comprise an alternator 2 (ALT) and pulley 4 , idler 8 (Idr), power steering pump 10 (PS), air conditioner 12 (AC), water pump 14 (WP), and crankshaft pulley 16 (CRK), each accessory having a pulley engaged with the belt. The crankshaft pulley drives the belt in direction D, thereby driving the accessories. The pulley and belt may have any profile known in the art, including v-belt, multi-ribbed or toothed.
[0024] Alternator 2 comprises a frame that is pivotably mounted to an engine surface or base (not shown) at pivot 30 . Alternator 2 also comprises arm 38 that is engaged at one end by actuator 20 . Pivot 30 allows the alternator and thereby the pulley to be pivoted about pivot 30 by a movement of actuator 20 . A pivoting movement of alternator 2 allows a belt tension to be adjusted.
[0025] Control module 18 comprises a computer processor capable of receiving and processing sensor signals received from sensors 22 , 46 , 48 , and 58 . It also generates and transmits control signals for controlling an actuator 20 movement and relative position. Sensor 22 is a load cell for detecting a load caused by a belt tension acting on the alternator arm 38 . Sensor 46 detects a belt tension by detecting a load exerted on the idler 8 by a belt 6 . Sensor 48 detects a displacement of the actuator 20 . Sensor 58 detects a rotational speed of crankshaft pulley 16 , which also equates to engine speed. Each sensor may comprise an analog or digital configuration, depending on a users needs.
[0026] Control module 18 is connected to sensors 22 , 46 , 48 , 58 by wires 60 , 63 , 62 , and 64 respectively. It is also electrically connected to actuator 20 by wire 61 . The system may include sensors in addition to those described above. The additional sensors may provide other signals to the control module for adjusting a belt condition including ambient temperature and belt alignment. Each sensor may also comprise a RF transmitter with the control module comprising an RF receiver, thereby eliminating the need for physical connectors such as wires between the sensors and the control module.
[0027] Control signals are transmitted by control module 18 to actuator 20 through wire 61 . Actuator 20 may comprise an electric motor, solenoid, or hydraulic cylinder or other form of mechanism known in the art that is capable of effecting a displacement or movement of arm 38 upon receiving a control signal from the control module.
[0028] Control module 18 may be programmable by a user thereby allowing a user to adjust operating parameters. The control module may also be ‘hard-wired’ and therefore unprogrammable by a user in the field. In either case the control module must be initially programmable to allow an instruction set to be initially loaded by means known in the art.
[0029] In operation, belt 6 is entrained on the drive system pulleys as shown in FIG. 1. Sensors 22 , 46 , 48 , and 58 are installed at predetermined positions on the belt drive system. Sensor 46 detects a belt tension at idler 8 . This is referred to as the “tight” side of the belt with respect to the alternator. Sensor 22 detects a load that is a function of a belt tension acting upon alternator pulley 4 and through a moment arm having a length L extending from pivot 30 to a point on arm 38 . Sensor 48 detects a relative position of actuator 20 . Sensor 58 , which may comprise a tachometer, detects a crankshaft rotational speed.
[0030] [0030]FIG. 2 is a schematic diagram of the closed loop control philosophy. Each sensor 22 , 46 , 48 , and 58 transmits signals proportional to the load, tension, displacement or speed of the belt to the control module 18 . The signals received by the control module from each sensor are compared to measured and calculated operating parameters or to parameters stored in a control module memory, more particularly, certain parameter reference values. The control module 18 then generates a control signal in response to the comparison of the stored reference parameters to the signal parameters. The resultant control module signal is transmitted to actuator 20 which moves to vary an alternator pulley position by partially rotating the alternator arm 38 about pivot 30 . Movement of alternator 2 either increases or decreases a belt 6 tension. The change in a belt or engine operating condition, or increase or decrease in belt tension, is sensed by each sensor 22 , 46 , 48 , 58 which then causes the cycle to repeat. This closed-loop system allows the control module to quickly and accurately control a belt tension in response to a measured belt tension. This allows ‘real-time’ adjustment of belt tension based upon operational need.
[0031] This represents a significant improvement over the prior art by increasing a belt life by allowing a belt tension to be maintained at a nominal level for most operating conditions, but then allowing a belt tension to be temporarily changed to prevent a belt slip or noise from occurring during transient conditions.
[0032] The magnitude of the change in a belt tension is adjustable based upon the operating condition prevailing at the time. For example, it may be necessary to increase a belt tension by 200N in certain high transient load conditions, while in other cases an increase of only 100N may be sufficient to prevent a belt slip or belt slip noise from occurring. In either case, the control module analyses the sensor signals and signals the actuator to set an appropriate arm 38 position and thereby an appropriate belt tension. Once the transient condition has passed the actuator position and hence belt tension is changed back to a nominal operating value. Typically the transients correspond to engine accelerations/decelerations and have durations on the order of a few seconds.
[0033] Measurable characteristics of the engine and belt drive system which serve to anticipate and quantify transient events may be programmed into the control module. These may include differential loads on each sensor based upon their respective locations in the system. These parameters may also include engine acceleration, and ambient temperature. As the belt and engine parameters vary, they are measured and transmitted by the sensors and received by the control module processor. The processor processes these sensor signals and sends a control signal to activate the actuator to either increase or decrease a belt tension before a belt slip or noise generating event occurs.
[0034] By way of example, if a transient condition such as an engine acceleration is imminent, the control module may instruct the actuator to adjust a position to maintain or increase a belt tension before a belt slip occurs. For example, for an engine acceleration of 6000 RPM/sec, the acceleration duration is approximately 1 second. The required processing time for one complete cycle through the control loop in FIG. 3 is approximately 10-20 milliseconds. One cycle comprises the time required to sense the system condition, computate an appropriate actuator movement, move the actuator and then measure the changed system condition. One can readily appreciate this allows the system to operate at a rate of 50 to 100 adjustments per second, sufficient to control belt slip and belt tension. Consequently, a real-time, active control of a belt tension and thereby of a belt slip noise is realized by the instant invention.
[0035] To further enhance the active control feature of this invention the control module may be integrated with a vehicle central processing unit (CPU). In this embodiment the vehicle CPU is programmed to analyze engine and belt operating conditions that would be expected to cause belt noise. The engine operating conditions would comprise variables such as engine speed, engine acceleration, engine temperature, and ambient temperature. The vehicle CPU receives and processes signals for each variable noted above plus others including throttle position, transmission gear, electrical load, rotational speed of various accessory pulleys and so on. The system may also act to prevent a belt slip when a differential speed between the belt and an accessory pulley exceeds a predetermined value of any selected variable, including pulley speed. On receipt of a command signal from the vehicle CPU, through wire 70 , the control module 18 signals actuator 20 to move if the control algorithm required such movement, thereby increasing or decreasing a belt tension. This would occur concurrently with the control module's analysis of the sensor signals. The vehicle command signal is reconciled with the control module control signal to avoid conflicting signals being transmitted to the actuator. In this embodiment the control module would not have a separate presence, instead being integrated within the vehicle CPU, requiring only a small portion of the overall vehicle CPU processing and memory capacity.
[0036] In another embodiment, the control module receives a plurality of signals of the type noted above from the vehicle CPU through wire 70 . In this embodiment the control module is tasked with processing the vehicle CPU signals along with the sensor signals to generate a control signal. The control signal is transmitted to the actuator to adjust a belt tension.
[0037] In yet another embodiment the system may operate in an open loop mode whereby a control command is input to the control module. The control command may be pre-programmed, or such command can be input by an outside user, or received from another source such as the vehicle CPU. The control module processes the control command to generate a control signal that is transmitted to the actuator. No feedback is received from a separate sensor, so the system achieves an equilibrium state based on the changed position of the actuator. This embodiment allows a user to adjust a belt tension independently of the system operating parameters. The control module may also compare the control command to a known set of values stored in a memory in order to prevent overstressing the system causing premature belt failure.
[0038] [0038]FIG. 3 is a control algorithm diagram for the inventive system. The algorithm comprises a closed loop. Variables used in the diagram include “Ts” meaning alternator theoretical slack side tension required to prevent slip. Other variables are defined herein.
[0039] At 1001 , inputs to the control module include an alternator hubload from sensor 22 , an idler hubload from sensor 46 , and an engine speed from sensor 58 . These measured parameters are used to calculate an alternator torque, an alternator Tsm and alternator Ttm. “Hubload” refers the load imposed on a pulley by a belt tension.
[0040] The equations are:
T tm = F Idr 2 Sin ( θ Idr 2 ) and ,
T sm = H Alt L 1 + L 2 L 1 Sin ( θ Alt 2 ) - T tm and T Alt = R Alt ( T tm - T sm )
[0041] where,
[0042] Tsm=Alt slack side tension calculated from measured data
[0043] Ttm=Alt tight side tension calculated from measure data
[0044] F Idr =Force measured at the idler
[0045] H Alt =Alternator hubload
[0046] L 1 =Distance from pivot to Alt pulley center
[0047] L 2 =Distance from Alt pulley center to load cell
[0048] θ Idr =Idler pulley wrap
[0049] θ Alt =Alternator pulley wrap
[0050] R Alt =Pitch diameter of alternator pulley
[0051] T Alt =Alternator torque
[0052] At 1002 , the control module determines if the alternator is loaded or unloaded, based upon alternator Tsm and Ttm calculated at 1001 . The “alternator load” measurement comprises the electrical load imposed upon the alternator by operation of the vehicle of which it is a part.
[0053] If the alternator is loaded, at 1003 the control module calculates the required alternator Ts, or slack side tension, for a loaded system. In this case the loaded system includes a loaded power steering pump, air conditioner, water pump and alternator at the specific engine speed. At 1007 , the control module determines if the alternator Tsm from 1001 is less than the calculated alternator Ts at 1003 , for this condition. If the answer is “yes” then the control module will send a signal to increase the alternator hubload, see 1008 , by activating actuator 20 . If the answer is “no” the control module sends a signal to decrease the alternator hubload, see 1009 , by activating actuator 20 . Sensor 22 provides actuator position signals at 1010 in response to a movement of the actuator.
[0054] At 1010 a signal is received by the control module from sensor 48 to determine if the actuator has reached either of its travel limits. If the answer is “yes”, a warning signal will be generated to indicate either excessive belt stretch or breakage, see 1011 . If the answer is “no” then the loop repeats beginning with 1001 . Sensor 48 and the associated travel limits are set after the belt is installed and properly tensioned.
[0055] Returning to 1002 , if the alternator is not loaded, the control module determines whether or not the air conditioner is loaded, see 1004 . In this case “air conditioner load” refers to the air conditioner compressor being in service.
[0056] If the air conditioner is loaded, at 1005 the control module calculates the required alternator Ts for a loaded system. The loaded system in this case includes a loaded power steering pump, air conditioner, and water pump under load at the specific engine speed with the alternator unloaded. At 1007 , the control module determines if the alternator Tsm from 1001 is less than the calculated alternator Ts at 1005 , for this operating condition. If the answer is “yes” then the control module will send a signal to increase the alternator hubload, see 1008 , by activating actuator 20 . If the answer is “no” the control module sends a signal to decrease the alternator hubload, see 1009 , by activating actuator 20 . As described above, at 1010 a signal is received by the control module to determine if the actuator has reached either of its travel limits. If the answer is “yes”, a warning signal will be generated to indicate either excessive belt stretch or breakage, see 1011 . If the answer is “no” then the loop repeats beginning with 1001 .
[0057] Returning to 1004 , if the air conditioner is not loaded the control module calculates the required alternator Ts for the system with the loaded power steering and water pump loaded at the measured engine speed, see 1006 . At 1007 the control module determines if the measured alternator Tsm is less than the calculated alternator Ts for this condition. If the answer is “yes” then the control module will send a signal to increase the alternator hubload, see 1008 , by activating actuator 20 . If the answer is “no” the control module sends a signal to decrease the alternator. hubload, see 1009 , by activating actuator 20 . Sensor 22 provides actuator position signals at 1010 in response to a movement of the actuator. As described above, at 1010 a signal is received by the control module to determine if the actuator has reached either of its travel limits. If the answer is “yes”, a warning signal will be generated to indicate either excessive belt stretch or breakage, see 1011 . If the answer is “no” then the loop repeats beginning with 1001 .
[0058] One can appreciate that the system described herein can include additional belt driven accessories, including an air compressor or mechanical fuel pump. It may also include multiple belt trains, each driven by a crankshaft pulley and each comprising a pivoted pulley and actuator.
[0059] Although a single form of the invention has been described herein, it will be obvious to those skilled in the art that variations may be made in the construction and relation of parts without departing from the spirit and scope of the invention described herein. | The invention comprises a belt drive system for automatically controlling a belt tension. The system comprises an actuator controlled by a control module. The actuator operates on a pivoted pulley. A belt is trained about the pivoted pulley as well as other pulleys driving various accessories. A series of sensors in the system detect a belt condition including a belt tension. Sensor signals are transmitted to the control module. The control module processes the signals and instructs the actuator to move the pivoted pulley, thereby increasing or decreasing a belt tension. A feedback loop from the sensors to the control module allows the belt tension to be continuously monitored and adjusted many times per second. The system may actively control a belt tension by anticipating a system condition to prevent a belt noise by comparing sensor signals to instructions stored in a control module memory. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to semiconductor fabrication and more specifically to improvement of adhesion between microelectronic films.
BACKGROUND OF THE INVENTION
[0002] Adhesion between chemical vapor deposition (CVD) barrier dielectric layers, or via etch-stop layers, and silicate (SiO based materials) low-k films, or solution-gelation (SOL-GEL) processed films, is a major concern in microelectronics integration. Weak adhesion at this interface results in film delamination during subsequent processing. In current practice, such adhesion is very low, on the order of less than about 0.12 GPa/{square root}M (giga parcel/square root meter), which results in severe peeling.
[0003] U.S. Pat. No. 6,303,524 B1 to Sharangpani et al. describes low-k curing methods that affect adhesion.
[0004] U.S. Pat. No. 6,303,523 B2 to Cheung et al. describes a low-k film deposition process to improve adhesion.
[0005] U.S. Pat. No. 6,180,518 B1 to Layadi et al. describes a method of forming vias in a low-k dielectric material and discusses low-k layer adhesion problems.
[0006] U.S. Pat. No. 4,238,528 to Angelo et al. describes adhesion promoters for polyamides.
[0007] U.S. Pat. No. 5,965,202 to Taylor-Smith et al. describes coupling agents between low-k layers.
SUMMARY OF THE INVENTION
[0008] Accordingly, it is an object of one or more embodiments of the present invention to provide enhanced adhesion between dielectric films and silicate films.
[0009] It is another object of one or more embodiments of the present invention to provide enhanced adhesion between CVD dielectric films and spin-on low-k silicate films.
[0010] Other objects will appear hereinafter.
[0011] It has now been discovered that the above and other objects of the present invention may be accomplished in the following manner. Specifically, a structure having an overlying dielectric layer formed thereover is provided. An adhesion promoter layer is formed upon the dielectric layer. The adhesion promoter layer including adhesion promotion molecules. The dielectric layer and the adhesion promoter layer are treated to a low-temperature treatment to bind at least some of the adhesion promotion molecules to the dielectric layer. A silicate layer is formed upon the low-temperature treated adhesion promoter layer. The silicate layer and the low-temperature treated adhesion promoter layer are treated to a high-temperature treatment to bind at least some of the adhesion promotion molecules to the silicate layer whereby the silicate layer is adhered to the dielectric layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will be more clearly understood from the following description taken in conjunction with the accompanying drawings in which like reference numerals designate similar or corresponding elements, regions and portions and in which:
[0013] FIGS. 1 to 4 schematically illustrates a preferred embodiment of the present invention.
[0014] FIGS. 5 to 7 illustrate the first series of adhesion promotion molecules.
[0015] [0015]FIGS. 8A, 8B, 9 A and 9 B illustrate the second series of adhesion promotion molecules.
[0016] [0016]FIGS. 10 and 11 illustrate the third series of adhesion promotion molecules.
[0017] [0017]FIGS. 12A, 12B and 12 C illustrate the mechanism believed to enhance adhesion between the CVD dielectric layer and the spin-on low-k layer using a sample first series of adhesion promotion molecules.
[0018] [0018]FIGS. 13A, 13B and 13 C illustrate the mechanism believed to enhance adhesion between the CVD dielectric layer and the spin-on low-k layer using a sample second series of adhesion promotion molecules.
[0019] [0019]FIGS. 14A, 14B and 14 C illustrate the mechanism believed to enhance adhesion between the CVD dielectric layer and the spin-on low-k layer using a sample third series of adhesion promotion molecules.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Initial Structure
[0021] As shown in FIG. 1, structure 10 has an overlying layer 12 formed thereover. Layer 12 may function as, for example a barrier layer or a via etch-stop layer.
[0022] Structure 10 is preferably understood to possibly include a semiconductor wafer or substrate, active and passive devices formed within the wafer, conductive layers and dielectric layers (e.g., inter-poly oxide (IPO), intermetal dielectric (IMD), etc.) formed over the wafer surface. The term “semiconductor structure” is meant to include devices formed within a semiconductor wafer and the layers overlying the wafer. Structure 10 may be a silicon wafer or a silicon substrate.
[0023] Layer 12 may be a chemical vapor deposition (CVD) dielectric layer or a spin-on dielectric layer and is preferably comprised of silicon dioxide (SiO 2 ), silicon carbide (SiC), silicon oxynitride (SiON), carbon-doped silicon oxide (SiOC), silicon nitride (SiN) or silicon carbo-oxynitride (SiCNO). Layer 12 may also be a metal layer preferably such as copper (Cu), aluminum (Al), gold (Au) or silver (Ag).
[0024] It is noted that if layer 12 is a CVD dielectric layer, then layer 18 is a spin-on dielectric layer and if layer 12 is a spin-on dielectric layer, then layer 18 is a CVD dielectric layer.
[0025] Layer 12 has a thickness of preferably from about 300 to 5000 Å and more preferably from about 300 to 600 Å.
[0026] In one key step of the invention, an adhesion promoter layer 14 is then coated upon layer 12 to improve the adhesion between layer 12 and Adhesion promoter layer 14 has a thickness of preferably from about 20 to 300 Å and more preferably from about 50 to 150 Å.
[0027] Adhesion promoter layer 14 is comprised of adhesion promotion molecules selected from one of three series of adhesion promotion molecules such as (1) a first series: dihydroxyl-terminated molecules; (2) a second series: hydroxyl-/alkoxysilyl-terminated molecules; or (3) a third series: hydroxylvinyl or hydroxylacryl-terminated molecules. That is, for example:
[0028] 1. first series of adhesion promotion molecules as shown in FIGS. 5 to 7 , i.e.:
[0029] a) dihydroxyl terminated molecules as shown in FIG. 5;
[0030] b) alkoxysilyl hydroxyl terminated molecules as shown in FIG. 6; or
[0031] c) alkoxysilyl terminated molecules as shown in FIG. 7;
[0032] where R is —CH 2 —, —CH 2 —CH 2 —, —CH 2 —CH 2 —CH 2 —, etc.; and where R may further include an ether [—CH 2 —O—CH 2 —] or ester
[0033] linkage;
[0034] 2. second series of adhesion promotion molecules as shown in FIGS. 8A, 8B, 9 A and 9 B, i.e.:
[0035] a) alkoxysilyl vinyl terminated molecules as shown in FIG. 8A;
[0036] b) hydroxyl vinyl terminated molecules as shown in FIG. 8B;
[0037] c) alkoxysilyl acryl terminated molecules as shown in FIG. 9A; or
[0038] d) hydroxyl acryl terminated molecules as shown in FIG. 9B;
[0039] where R is —CH 2 —, —CH 2 —CH 2 —, —CH 2 —CH 2 —CH 2 —, etc.; and where R may further include an ether [—CH 2 —O—CH 2 —] or ester [—CH 2 —C—O—CH 2 —] linkage; or
[0040] 3. third series of adhesion promotion molecules as shown in FIGS. 10 and 11, i.e.:
[0041] a) (RO) x Si(OR′) 4-x as shown in FIG. 10; or
[0042] b) (RO) x Si(OR′) 3-x H as shown in FIG. 11
[0043] where R is methyl (—CH 3 ), ethyl (—CH 2 CH 3 ), propyl (—CH 2 CH 2 CH 3 ), etc. and
[0044] where R′ is —CH 2 —, —CH 2 —CH 2 —, —CH 2 —CH 2 —CH 2 —, etc.; and where R may further include an ether [—CH 2 —O—CH 2 —] or ester [—CH 2 —C—O—CH 2 —] linkage.
[0045] Of the three series of molecules, the first series (as a group) is more preferred. Of the molecules, the alkoxysilyl hydroxyl terminated molecules as shown in FIG. 6, the alkoxysilyl terminated molecules as shown in FIG. 7, the alkoxysilyl vinyl terminated molecules as shown in FIG. 8A and the alkoxysilyl acryl terminated molecules as shown in FIG. 9A are more preferred with the alkoxysilyl terminated molecules as shown in FIG. 7 being most preferred.
[0046] Low-Temperature Treatment 16
[0047] As shown in FIG. 2, the structure of FIG. 1 is subjected to a low-temperature treatment 16 to bind the adhesion promotion molecules of adhesion promoter layer 14 to layer 12 , forming low-temperature treated adhesion promoter layer 14 ′.
[0048] The low temperature treatment 16 is conducted under the following conditions for:
[0049] I. the first series of adhesion promotion molecules as shown in FIGS. 5 to 7 :
[0050] temperature: preferably from about 150 to 250° C. and more preferably from about 180 to 230° C.; and
[0051] time: preferably from about 3 to 10 minutes and more preferably from about 5 to 8 minutes; and
[0052] II. the second series of adhesion promotion molecules as shown in FIGS. 8A, 8B, 9 A and 9 B, and the third series of adhesion promotion molecules as shown in FIGS. 10 and 11:
[0053] temperature: preferably from about 150 to 250° C. and more preferably from about 180 to 230° C.; and
[0054] time: preferably from about 3 to 30 minutes and more preferably from about 10 to 20 minutes.
[0055] Formation of Spin-on Low-k Silicate Layer 18
[0056] As shown in FIG. 3, a layer 18 is formed over low-temperature treated adhesion promoter layer 14 ′ to a thickness of preferably from about 500 to 8000 Å and more preferably from about 3000 to 6000 Å. As noted above, if layer 12 is a CVD dielectric layer, then layer 18 is a spin-on dielectric layer and if layer 12 is a spin-on dielectric layer, then layer 18 is a CVD dielectric layer.
[0057] Preferably, layer 12 is a CVD dielectric layer and layer 18 is a spin-on low-k silicate/SiO based material as will be used for illustrative purposes hereafter.
[0058] Spin-on low-k silicate layer 18 is comprised of silicon (Si), oxygen (O) and carbon (C) atoms (also see the description of layer 12 ).
[0059] High-Temperature Treatment 20
[0060] As shown in FIG. 4, the structure of FIG. 3 is subjected to a high-temperature treatment 20 to bind the spin-on low-k silicate layer 18 to CVD dielectric layer 12 via the high-temperature treated adhesion promoter layer 14 ″.
[0061] The high temperature treatment 20 is conducted under the following conditions for the first, second and third series of adhesion promotion molecules:
[0062] temperature: preferably from about 300 to 450° C. and more preferably from about 350 to 420° C.; and
[0063] time: preferably from about 1 to 6 hours and more preferably from about 2 to 4 hours.
[0064] The high-temperature treatment 20 cures the double bonds of the second series of adhesion promotion molecules being either vinyl or acryl terminated molecules. Please see FIGS. 13A, 13B and 13 C.
[0065] The adhesion between the CVD dielectric layer 12 and the spin-on low-k silicate layer 18 using the adhesion promoter layer 14 in accordance with the method of the present invention is improved to preferably greater than about 0.30 GPa/{square root}M (giga parcel/square root meter) and more preferably greater than about 0.5 GPa/{square root}M so that subsequent chemical mechanical polishing processes do not delaminate the spin-on low-k silicate layer 18 from the CVD dielectric layer 12 .
[0066] Proposed Mechanisms of Adhesion Enhancement
[0067] [0067]FIGS. 12A, 12B and 12 C illustrate the mechanism believed by the inventors to enhance adhesion between the CVD dielectric layer and the spin-on low-k layer using a sample first series of adhesion promotion molecules; FIGS. 13A, 13B and 13 C illustrate the mechanism believed to enhance adhesion between the CVD dielectric layer and the spin-on low-k layer using a sample second series of adhesion promotion molecules and FIGS. 14A, 14B and 14 C illustrate the mechanism believed to enhance adhesion between the CVD dielectric layer and the spin-on low-k layer using a sample third series of adhesion promotion molecules.
[0068] Each series of FIGS. 12A, 13A and 14 A illustrate the upper surface of CVD dielectric layer 12 (with exposed —OH molecules) after being coated with adhesion promoter layer 14 comprising sample adhesion promotion molecules from the first, second and third series of adhesion promotion molecules, respectively.
[0069] Each series of FIGS. 12B, 13B and 14 B illustrate (1) the upper surface of CVD dielectric layer 12 after the low-temperature treatment 16 so that the upper surface of CVD dielectric layer 12 is bound to the sample adhesion promotion molecules from the first, second and third series of adhesion promotion molecules of the low-temperature treated adhesion promoter layer 14 ′, respectively, and (2) the spin-on low-k silicate layer 18 is formed over the low-temperature treated adhesion promoter layer 14 ′.
[0070] Each series of FIGS. 12C, 13C and 14 C illustrate (1) the lower surface of spin-on low-k silicate layer 18 after the high-temperature treatment 20 so that the lower surface of spin-on low-k silicate layer 18 is bound to the sample adhesion promotion molecules from the first, second and third series of adhesion promotion molecules of the high-temperature treated adhesion promoter layer 14 ″, respectively, and (2) the upper surface of CVD dielectric layer 12 bound to the sample adhesion promotion molecules from the first, second and third series of adhesion promotion molecules of the high-temperature treated adhesion promoter layer 14 ″, respectively.
[0071] It is noted that FIG. 13C also demonstrates double bond cross-linking that also may occur.
[0072] Advantages of the Present Invention
[0073] The advantages of one or more embodiments of the present invention include greatly improving the adhesion between CVD dielectric layers and spin-on silicate layers.
[0074] While particular embodiments of the present invention have been illustrated and described, it is not intended to limit the invention, except as defined by the following claims. | A method of adhering a silicate layer to dielectric layer comprising the following steps. A structure having an overlying dielectric layer formed thereover is provided. An adhesion promoter layer is formed upon the dielectric layer. The adhesion promoter layer including adhesion promotion molecules. The dielectric layer and the adhesion promoter layer are treated to a low-temperature treatment to bind at least some of the adhesion promotion molecules to the dielectric layer. A silicate layer is formed upon the low-temperature treated adhesion promoter layer. The silicate layer and the low-temperature treated adhesion promoter layer are treated to a high-temperature treatment to bind at least some of the adhesion promotion molecules to the silicate layer whereby the silicate layer is adhered to the dielectric layer. | 7 |
BACKGROUND AND SUMMARY
The present invention relates to the field of chip removing machining and particularly to a milling insert and a milling cutter tool in which the milling insert is mounted. The milling insert is shaped as a trigon shape having a number of cutting edges and is adapted to be mounted in a milling cutter body of the milling cutter tool.
Previously known trigon-shaped milling inserts are shaped to be mounted substantially radially in a milling cutter body, the axis of a centrally placed mounting hole being directed tangentially in relation to the milling cutter body. Such a mounting requires a considerable recess in the milling cutter body so that mounting of a milling insert could be accomplished, which in turn means that the milling cutter body at a certain radius only can receive a certain a number of milling inserts. Furthermore, radial mounting means that the strength of the milling insert to a certain extent depends on the extension thereof in the axial direction of the mounting hole.
Tangentially mounted milling inserts can be seen in, for instance, WO 2005/075135, U.S. Pat. No. 6,872,034 and U.S. Pat. No. 7,014,396.
It is desirable to provide an improved trigon-shaped milling insert, which can be mounted tangentially in the milling cutter body of a tool and which furthermore is provided with dedicated support surfaces for an improved abutment against a pocket of the milling cutter body.
It is also desirable that the support surfaces are placed on the milling insert as well as in the milling cutter body in such a way that the cutting forces in a milling operation contributes to an increased abutment against the pocket as well as to minimizing the torque to turn the milling insert radially out of the pocket.
It is also desirable to provide a milling cutter tool for such a milling insert.
An aspect of the invention relates to an indexable milling insert having a trigon shape, which milling insert comprises a mounting hole placed centrally in the milling insert, an upper side and a lower side, which sides are parallel with each other and act as an alternating first and second support surface. The milling insert is provided with major cutting edges, which are oriented perpendicularly to the axis of the mounting hole as well as arranged in such a way that a turning of the milling insert around the center of the mounting hole alternatively a flipping of the milling insert into an alternative cutting position provides an identical position of the major cutting edges in relation to a workpiece. In this connection, the major cutting edges of the milling insert are placed in the milling insert, when the same is tangentially mounted in a cutting body, in such a way that, in the shown top view, the shortest distance of the major cutting edges to the axis of the hole is smaller than the distance of a third support surface to the axis of the hole.
Furthermore, milling inserts may be shaped so that the distance in top view between each major cutting edge and an adjacent third support surface grows in the direction from an associated nose edge.
Furthermore, the milling insert may comprise three major cutting edges placed on the edge of the respective lower/upper side near a cutting corner.
The milling insert may be provided with third support surfaces placed along the sides of the milling insert at a right angle in relation to the imaginary extension of the first support surface.
The milling insert may be provided with additional third support surfaces placed along the sides of the milling insert at a right angle in relation to the imaginary extension of the second support surface.
The third support surfaces may be pair-wise arranged in direct connection with and on both sides of a cutting corner of the milling insert.
The milling insert may be provided with clearance surfaces placed in direct connection with the first support surface and the second support surface in the extension of the respective major cutting edges along the edge of the respective first and second support surface so that the clearance surfaces form an acute edge angle with the imaginary extension of the support surfaces.
The milling insert may be provided with corner surfaces placed at an angle to and in direct connection with the third support surfaces and at a right edge angle in relation to the imaginary extension of the first and the second support surface.
The milling insert may furthermore be shaped so that each corner surface and adjacent third support surface connect to each other under an angle β, where 10°<β<20°, preferably is 13°<β<17°. Furthermore, a milling insert may be shaped so that each major cutting edge forms an angle φ with the appurtenant third support surface, which angle φ is of the same size as the angle β±2°.
All support surfaces of the milling insert may be completely planar.
The major cutting edge of the milling insert may also transform directly into a nose edge.
The milling insert may furthermore comprise six minor cutting edges, each one having an extension from the first support surface toward the second support surface at a substantially parallel orientation with the symmetry axis of the mounting hole.
The milling insert may also be shaped so that each minor cutting edge is of the same size as the third support surface in a direction parallel with the axis of the hole. Each minor cutting edge may also connect directly to a nose edge.
Furthermore, all cutting edges connected to each other may be situated in the same plane.
An aspect of the invention also relates to a milling cutter tool comprising a milling cutter body having a plurality of insert pockets. Each insert pocket is intended to receive a milling insert shaped according to anyone of the above-mentioned milling inserts.
The insert pockets of the milling cutter tool may comprise a main support surface against which the milling insert is arranged to abut by the first/second support surface thereof.
The insert pocket of the milling cutter tool may also comprise a wedge-shaped support pocket having primary support surfaces arranged, in which support pocket the milling insert is mounted with abutment of the pair-wise arranged third support surfaces thereof against the primary support surfaces in order to, by means of arising cutting forces in a milling operation, provide an increased abutment force of the milling insert against the support pocket.
The support pocket of the milling cutter tool may furthermore be provided with a secondary support surface against which another one of the third support surfaces of the milling insert is arranged to abut.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described closer by means of embodiment examples, reference being made to the accompanying drawings, where
FIG. 1 shows a milling insert according to the present invention in top view,
FIG. 2 shows the milling insert in perspective view,
FIG. 3 shows a side view of the milling insert,
FIG. 4 shows a cross section of the milling insert according to line B-B in FIG. 1 and FIG. 3 ,
FIG. 5 shows a perspective view of a milling cutter body according to the present invention without any milling inserts mounted,
FIG. 6 shows a side view of the milling cutter body having mounted milling inserts in engagement with a workpiece.
DETAILED DESCRIPTION
With reference to FIGS. 1-4 , there are shown a double-sided or indexable milling insert according to the present invention, which has a trigon-shaped or hexagonal basic shape as well as is manufactured from directly pressed cemented carbide. With “cemented carbide”, reference is here made to WC, TiC, TaC, NbC, etc., in sintered combination with a binder metal such as, for instance, Co or Ni. The milling insert is preferably at least partly coated with layers of, e.g., Al2O3, TiN and/or TiCN. In certain cases, it may be justified that the cutting edges consist of or comprise soldered superhard materials such as CBN or PCD.
FIG. 1 shows a trigon-shaped milling insert 10 , by which is meant that the milling insert, in top view, is substantially triangular but that each side of the triangle is broken outward from the center of the triangle in order to form two sides of each one of the sides of the triangle, which means that the milling insert has obtained six corners, the tip angles of the triangle having been made more obtuse. The two sides form an angle between themselves in the interval of 25°-35°, preferably 28°-31°. Another way of describing a trigon-shaped milling insert is that an imaginary circle inscribed in the milling insert touches the periphery of the milling insert in six points. However, the present milling insert has every second of the six corners chamfered in order to form corner surfaces that are seen more clearly below. Thus, the milling insert comprises six sides S 1 , S 2 , S 3 , S 4 S 5 , S 6 , each one of which comprises a major cutting edge, H 1 , H 2 , H 3 , H 4 , H 5 , H 6 , three major cutting edges H 2 , H 4 , H 6 of which are shown in FIG. 1 in direct connection with an upper side constituting an upper first support surface 11 , while the other three major cutting edges H 1 , H 3 , H 5 are found on the lower side of the milling insert. For the mounting of the milling insert 10 in an insert pocket, a mounting hole 12 , including the axis 70 thereof, is provided centrally in the milling insert 10 . In direct connection with the upper support surface 11 of the milling insert, three clearance surfaces 21 , 23 , 25 are provided at the sides S 1 , S 3 , S 5 , which clearance surfaces form the angle α with the upper support surface 11 . Correspondingly, in direct connection with the opposite lower second support surface 13 of the milling insert, three additional clearance surfaces 22 , 24 , 26 (not visible in FIG. 1 ) are provided at the sides S 2 , S 4 , S 6 , which additional clearance surfaces also form the angle α with the second support surface 13 . The first support surface 11 and the second support surface 13 have substantially the shape of an equilateral triangle.
FIG. 2 shows in a perspective view the upper first support surface 11 of the milling insert, the first major cutting edge H 1 of the milling insert, the second major cutting edge H 2 of the milling insert, the third major cutting edge H 3 of the milling insert, the fourth major cutting edge H 4 of the milling insert, and the sixth major cutting edge H 6 of the milling insert. Furthermore, the figure shows that each major cutting edge H 1 -H 6 transforms into a nose cutting edge N 1 -N 6 , the first N 1 , the second N 2 , the third N 3 , the fourth N 4 and the sixth N 6 one of which nose cutting edges are shown in the figure. Furthermore, it is shown in the figure that each nose cutting edge N 1 -N 6 connects directly to a minor cutting edge B 1 -B 6 , the first B 1 , the second B 2 , the third B 3 , the fourth B 4 and the sixth B 6 one of which minor cutting edges are shown in the figure. The minor cutting edges form the three cutting corners SH of the milling insert. All edges are situated in the same plane. To each major cutting edge H 1 -H 6 and minor cutting edge B 1 -B 6 , a chip breaking countersunk recess U 1 -U 6 connects, the first U 1 , the second U 2 , the third U 3 and the sixth U 6 one of which recesses are shown in the figure. These in relation to the edges countersunk recesses, give the edges a positive rake angle so as to cut easily in a workpiece. The first 21 and the third one of the clearance surfaces 21 - 26 are also shown in the figure.
Furthermore, corner surfaces 31 - 36 are provided in direct connection with the respective clearance surfaces 21 - 26 and placed as additional sides of the milling insert so that the first 31 and the sixth 36 one of the corner surfaces are placed between the sides S 1 and S 6 . Correspondingly, the second 32 and the third 33 one of the corner surfaces are placed between the sides S 2 and S 3 , and the fourth 34 and the fifth 35 one of the corner surfaces are placed between the sides S 4 and S 5 , compare with FIG. 1 .
Furthermore, FIGS. 1 and 2 show third support surfaces 41 - 46 , which are situated on the six sides of the milling insert with an axial extension that is smaller or equal to half the thickness of the milling insert so that the first 41 one of the third support surfaces is situated on the first side S 1 of the milling insert, the second 42 one of the third support surfaces is situated on the second side S 2 of the milling insert, the third 43 one of the third support surfaces is situated on the third side S 3 of the milling insert, the fourth 44 one of the third support surfaces is situated on the fourth side S 4 of the milling insert, the fifth 45 one of the third support surfaces is situated on the fifth side S 5 of the milling insert, and the sixth 46 one of the third support surfaces is situated on the sixth side S 6 of the milling insert. All the third support surfaces may be planar and intended to absorb tangential forces on the milling insert. Also the clearance surfaces 21 - 26 may be planar.
The first 21 one of the clearance surfaces, the first 31 one of the corner surfaces and the first 41 one of the third support surfaces form a first group G 1 of surfaces, which, via the first 21 one of the clearance surfaces, connect to the upper first support surface 11 . As is seen in FIG. 1 and FIG. 2 , the corresponding groups G 3 and G 5 connect to the upper first support surface, and the groups G 2 , G 4 and G 6 to the opposite lower second support surface 13 .
The corner surfaces 31 - 36 and the third 41 - 46 support surfaces are perpendicular in relation to both the upper first 11 and the lower second 13 support surface, which means that the upper 11 and the lower 13 support surface are parallel with each other. However, the corner surfaces 31 - 36 and the third 41 - 46 support surfaces within each group connect to each other under an angle β, where 10°<β<20° and preferably is 13°<β<17°, see FIG. 1 . Thus, the corner surfaces and the third support surfaces, respectively, form the angle 90°+α with the clearance surface within each group G 1 -G 6 .
Furthermore, in FIG. 1 , an angle φ is indicated, which shows the angle between a major cutting edge H 1 -H 6 and an appurtenant third 41 - 46 support surface, which angle φ is of the same size as the angle β±2°.
FIG. 3 shows a side view of the milling insert where the upper support surface 11 is parallel with the lower support surface 13 . The figure also shows the first major cutting edge H 1 with the appurtenant first nose cutting edge N 1 and first minor cutting edge B 1 , as well as the sixth major cutting edge H 6 with the appurtenant sixth nose cutting edge N 6 and sixth minor cutting edge B 6 . Furthermore, the figure shows the first chip-breaking recess U 1 as well as the sixth chip-breaking recess U 6 diagonally situated in relation to the first chip-breaking recess U 1 in the shown view. The figure also shows the diametrical position of the group G 1 including the clearance surface 21 , the corner surface 31 and the support surface 41 in relation to the group G 6 including the surfaces 26 , 36 , 46 . The other two side views of the milling insert are arranged in a corresponding way as shown in FIG. 3 when the milling insert is rotated one third of a revolution at a time around the axis 70 of the mounting hole. The figure also shows that the two corner surfaces 31 , 36 are connected to each other by a waist 51 , which contributes to a distribution of possible stresses over the corner surfaces 31 , 36 . In a corresponding way, also other corner surfaces are pair-wise connected to each other by a corresponding waist.
It should also be noted that all clearance surfaces 21 , . . . , 26 end at a distance from the nose cutting edges in order to contribute to a strengthening of the milling insert in this portion. Compare also FIGS. 1 and 2 .
FIG. 4 shows a section B-B according to FIG. 3 and according to the dashed line in FIG. 1 through the mounting hole 12 but beside the axis 70 , the projection of which in the mounting hole 12 has been indicated by the numeral 71 . The figure shows the clearance surfaces 21 , 23 and 26 , which all form the angle α with the upper and lower support surface 11 , 13 , respectively, where 20°<α<45° preferably that 25°<α<40°. The third clearance surface 23 transforms into the third 43 one of the third support surfaces. The figure also shows the third chip-breaking recess U 3 and the third major cutting edge H 3 .
FIG. 5 shows a milling cutter body 81 , without any milling inserts mounted, for a milling cutter tool according to the invention. The milling cutter body is provided with a plurality of identically shaped insert pockets 82 , each one of which is provided with a main support surface 83 against which a milling insert is arranged to be mounted by a screw 84 , see FIG. 6 , being screwed-in through the mounting hole of the milling insert into a threaded fastening hole 85 in the insert pocket of the milling cutter body 81 . The insert pocket 82 is provided with two primary support surfaces 86 , 87 as well as with a secondary support surface 88 . Together, the primary support surfaces form a wedge-shaped support pocket 93 , against which the third support surfaces of the milling insert abut after an assembly, and against which the milling insert is pressed by the tangential cutting forces when the milling cutter tool machines a workpiece. The secondary support surface 88 does also contribute to a force absorption of cutting forces on the milling insert, but has above all the purpose of facilitating mounting of the milling insert in the insert pocket 82 .
FIG. 6 shows a milling cutter tool 91 , in the form of a cutting body 81 having a number of mounted milling inserts 10 , during machining of a workpiece 92 . The direction of rotation of the milling cutter tool 91 is shown by the arrow, the translation motion of the milling cutter tool upon milling being into the plane of the paper. In this connection, the milling insert 10 is mounted with one of the cutting corners SH thereof placed for abutment by the support surfaces thereof in the corresponding primary support surfaces 86 , 87 of the wedge-shaped support pocket 93 of the insert pocket. Between the abutment surfaces 86 , 87 , 88 of the insert pocket 82 , clearances 94 , 95 are provided to eliminate stresses between the surfaces as well as to eliminate point loads from the corner surfaces of the milling insert.
Thus, the present invention relates to an economically advantageous milling insert for milling, which allows a stable location of the milling insert in the milling cutter body for a milling cutter tool, as well as to a milling cutter tool for such a milling insert.
The milling cutter tool is intended to be used for end milling or for face milling.
The invention is not limited to the embodiment described above but may be varied within the scope of the subsequent claims.
The disclosures in Swedish patent application No. 0601388-2, from which this application claims priority, are incorporated herein by reference. | An indexable milling insert has a trigon shape and includes a mounting hole placed centrally in the milling insert, an upper side and a lower side, which sides are parallel with each other and act as an alternating first support surface and second support surface. The milling insert is furthermore provided with major cutting edges, which are oriented perpendicularly to the axis of the mounting hole as well as arranged in such a way that a turning of the milling insert around the center of the mounting hole into an alternative cutting position alternatively a flipping of the milling insert into an alternative cutting position provides an identical position of the major cutting edges in relation to a workpiece. The major cutting edges of the milling insert are furthermore placed in the milling insert, when the same is tangentially mounted in a cutting body, so that the shortest distance of the major cutting edges to the axis of the hole in top view is smaller than the distance of a third support surface to the axis of the hole. A milling cutter tool having such a milling insert mounted is also disclosed. | 8 |
FIGS. 7 and 8 of the patent or application are photographs. Copies of this patent or patent application publication with photographs will be provided by the Office upon request and payment of the necessary fee.
BACKGROUND OF THE INVENTION
The invention relates to a method for producing hemin proteins using plant cells, and in particular the hemin proteins capable of reversibly binding oxygen, for example hemoglobin and its derivatives, and myoglobin. It relates, in addition, to the proteins obtained using the method. The invention also relates to the genetically transformed cells and plants capable of producing these proteins, and to the nucleic acid constructs involved in the transformation. In addition, the invention relates to products, for example pharmaceutical or cosmetic products, containing these hemin proteins.
BACKGROUND OF THE INVENTION
Hemin proteins are complex molecules composed of one or more polypeptide chain(s) in association with one or more ferroporphyrin nucleus or nuclei. These nuclei are composed of four pyrrole rings, juxtaposed in a closed structure and linked by methene bridges, and containing an iron atom at the center of the molecule. Hemin proteins differ from one another in the nature and the number of the polypeptide chains and in the nature of the side chains carried by the eight β atoms of the pyrrole rings. An example of a ferroporphyrin nucleus is iron-containing protoporphyrin IX, also known by the name “protoheme” or simply “heme” (FIG. 1 ).
The hemin protein family comprises numerous substances which are important from the biological point of view in animals and in plants, particularly hemoglobin, myoglobin, cytochromes, peroxidases and catalases.
Hemoglobin is the main constituent of the red blood cells. Its essential function is to bind, transport and deliver the quantity of oxygen necessary for normal tissue function.
The hemoglobin molecule is composed of two types of globin chains or subunits, called α and β (of 141 and 146 amino acids respectively), and linked in pairs to form a α 2 β 2 tetramer. Each of these subunits contains, solidly attached in a hydrophobic sac, a heme molecule (that is to say protoporphyrin IX) containing, at the center, a divalant iron atom (Fe 2+ ) to which a molecule of oxygen reversibly binds. Each tetrameric hemoglobin molecule therefore contains 4 iron atoms and 4 oxygen molecules which it binds during its passage through the lungs. The molecular mass of the tetramer is 64,650 D. In man, the α and β chains are synthesized from two types of genes situated on chromosomes 16 and 11 respectively.
The term beta, or “nonalpha”, type chains covers not only the beta chains, but also the chains called epsilon, gamma or delta.
Normally, in adults, more than 95% of the hemoglobin consists of alpha 2 beta 2 tetramer, that is to say the association of two heterologous alpha-beta dimers, associated with the catalytic complex, heme. 2% to 3% of a hemoglobin consisting of alpha 2 delta 2 tetramers, and traces of fetal hemoglobin alpha 2 gamma 2 exist.
The tetrameric human hemoglobin molecule exists in two quaternary forms or structures depending on whether oxygen is bound or not to the iron atoms. In the presence of oxygen, hemoglobin is said to be in an R (for relaxed) state and its affinity for oxygen is high. In the absence of oxygen, hemoglobin is said to be in a T (for tense) state and its affinity for oxygen is 100 times lower (Perutz, 1970). The resultant affinity is linked to the equilibrium between the concentrations of R and T forms. The higher the concentration of hemoglobin in the T form at any level of oxygenation, the lower this affinity. The affinity of hemoglobin for oxygen is regulated by the cofactor-2,3-diphosphoglycerate (DPG), a small molecule derived from the metabolism of glucose and which binds to the β chains of tetrameric hemoglobin, reducing its affinity for oxygen.
The increase in the risks of infection by products derived from human blood (hepatitis, HIV) makes the development of an artificial oxygen carrier as substitute for blood transfusion necessary.
Techniques using recombinant DNAs have been proposed for producing the protein chains of globin.
The aim of the first techniques developed was essentially to cause the alpha and beta chains to be synthesized in E. coli separately (Naga{umlaut over (i )}and Thogen-Sen, 1987), involving cumbersome methods for separate expression of each of the chains. These methods could hardly be exploited on an industrial scale.
More recently, the expression of soluble and functional recombinant hemoglobin has been developed in E. coli (Hoffman et al., 1990, P.N.A.S., 87, 8521-8525) and Saccharomyces cerevisiae (Wagenbach et al., 1991, Biotechnology, 9, 57-61). Each of these systems has advantages and disadvantages. Indeed, the highest expression levels are obtained in E. coli which has, nevertheless, the disadvantage of producing endotoxins and of not cleaving the NH 2 terminal methionines contrary to Saccharomyces cerevisiae . In the yeast, the yields of synthesis of hemoglobin are low (3 to 5%), compared with the 10-15% obtained in E. coli . This currently limits the use of yeast in the context of an industrial development plan.
The use of animal cells in culture or of transgenic animals as hosts for production has also been achieved (Swanson et al., Bio/Technology, May 1992, 10, page 55). It appears that these techniques cannot currently be exploited because of low expression levels and the risks of contaminations by viruses and by prions.
The technical problem which the present invention proposes to solve is to produce hemin proteins, and in particular hemoglobin and its derivatives, in a large quantity at low costs, without the risk of viral or subviral contaminations. The inventors have provided a solution to this problem by using plant cells as host for the transformation and the production.
Various teams have already taken an interest in the production of mammalian recombinant proteins in plant cells or in transgenic plants. For example, the specific expression, in rapeseed, of leuenkephalin has been obtained with expression levels of about 0.1% (Vanderkerckhove et al., Biotechnology, 1989, 7, 929-932).
In 1990, Sijmons et al., (Biotechnology, 1990, 8, 217-221) transferred the gene for human serum albumin into tobacco and potato cells. Regardless of the origin of the signal peptides (human or plant), human serum albumin levels of the order of 0.02% of the total proteins were obtained in the potato leaves, stems and tubers.
Other mammalian recombinant proteins have also been produced in plants: hepatitis B surface antigen (Mason et al., P.N.A.S., 1992, 89, 11745-11749); human interferon (Edelbaum J. of Interferon Res., 1992, 12, 449-453); a mouse antibody to Streptococcus mutans , an agent for dental caries (Hiatt and Mass., FEBS, 1992, 307, 71-75); an anti-Herpes antibody (Russel, 1994) and hirudin (Moloney, 1994).
All these research studies show that the production of mammalian recombinant proteins in plant cells is possible and that the mechanisms of protein synthesis from the DNA sequences are similar in animal cells and plant cells.
On the other hand, little information is available on the subject of the iron-containing porphyrins in plants, particularly on their structures, their synthesis pathways and the assembly of the porphyrin nuclei and the protein chains to form the hemin proteins. The production of recombinant molecules having the capacity to reversibly bind oxygen, and requiring the assembly, in the cell, of heterologous proteins and of endogenous plant porphyrins has never been described.
SUMMARY OF THE INVENTION
The invention relates to a method for producing recombinant hemin proteins using plant cells. According to the method of the invention, the plant cell is genetically modified so as to be able to express the protein component of a hemin protein. The porphyrin nucleus is produced by the cell endogenously, the assembling of the protein and porphyrin components taking place spontaneously by virtue of their high affinity for each other.
More particularly, the invention relates to a method for producing hemin proteins comprising the following steps:
i) introducing, into plant cells, one or more nucleic acid molecule(s) each of which comprises at least one sequence encoding a protein component of a hemin protein of animal origin or a variant or a portion of this protein component, and optionally a sequence encoding a selection agent;
ii) selecting the cells which have integrated the nucleic acid encoding the protein component;
iii) propagating the transformed cells, either in culture or by regenerating whole transgenic or chimeric plants;
iv) recovering, and optionally purifying, a hemin protein comprising a complex of the protein or proteins encoded by the abovementioned nucleic acid with at least one iron-containing porphyrin nucleus, or a plurality of these complexes.
The invention preferably relates to a method for producing hemin proteins comprising the following steps:
i) introducing, into plant cells, one or more nucleic acid molecule(s) each of which comprises at least one sequence encoding a protein component of a hemin protein of animal origin preferably capable of reversibly binding oxygen or a variant or a portion of this protein component, and optionally a sequence encoding a selection agent;
ii) selecting the cells which contain the nucleic acid encoding the protein component of the hemin protein;
iii) optionally, propagating the transformed cells, either in culture or by regenerating whole transgenic or chimeric plants;
iv) recovering, and optionally purifying, a hemin protein comprising a complex consisting of the protein or proteins encoded by the abovementioned nucleic acid and at least one iron-containing porphyrin nucleus, or a plurality of these complexes.
In the context of the present invention, the term “hemin protein” means any protein having an iron-containing porphyrin nucleus as prosthetic group, and in particular protoporphyrin IX as exists in human myoglobin and hemoglobin (FIG. 1 ). The porphyrin nucleus may also be derivatives of heme from those of human heme. The side chains are preferably hydrophobic.
The hemin proteins of the invention include in particular the hemin proteins having, as main function, the reversible binding of oxygen, that is to say myoglobin and hemoglobin, as well as the cytochromes whose role is to transport electrons. The derivatives of these proteins conserving these functions are also included in the invention.
According to a preferred variant, the hemin protein of the invention is hemoglobin or a hemoglobin-type protein. In the context of the invention, the term “hemoglobin-type protein” includes all the hemin proteins having at the same time:
i) one or more α- and/or β-globin chain(s) or variants of these polypeptides, and
ii) one or more molecules of iron-containing protoporphyrin IX, or of protoporphyrins differing from protoporphyrin IX in the nature of the side chains,
iii) having a capacity to reversibly bind oxygen, preferably with an affinity of between 10 and 50 mm Hg at 37° C., pH7.4. More particularly, the affinity is between 20 and 30 mm Hg, by way of example, the P 50 of total blood at pH 7.2 is of 26±2 mm Hg.
In the text which follows, the term “hemoglobin-type molecule” will be used synonymously with the term “hemoglobin derivative”.
In this context, a “variant” of a protein component, and particularly of α- or β-globin, means an amino acid sequence which distinguishes itself in relation to the natural sequence by one or more amino acid substitution(s), deletion(s) or insertion(s). In general, the variant exhibits at least 90%, and preferably at least 95%, homology or identity with the natural sequence. In the context of the present invention, the percentage homology between two amino acid sequences is calculated as being the number of identical amino acids plus the number of similar amino acids in the alignment of the two sequences, divided by the length of the sequences between two given positions. If, between the two given positions, the two sequences do not have the same length, the percentage homology is the number of identical and similar amino acids, divided by the length of the longest sequence. The amino acids considered to be “similar” are known in the art, see for example R. F. Feng, M. S. Jobson and R. F. Doolittle; J. Mol. Evol.; 1985; 21; 112-115. They are normally considered to be those which, within a permutation matrix, have a positive coefficient of substitution.
The term “variant” also includes fragments of polypeptide chains, for example of α- or β-globin, normally having a length of at least 90% of the parent molecule. The variants can also be made longer than the parent molecule by adding nonfunctional sequences. Preferably, the variants conserve the biological and immunological properties of the parent molecule.
The first stage of the method of the invention consists in introducing, into plant cells, one or more nucleic acid molecule(s) comprising at least one sequence encoding a protein component of a mammalian hemin protein, or a variant of this component.
When the hemin protein is a single-chain protein, for example myoglobin or cytochrome, the nucleic acid introduced into the plant cells normally comprises a copy of the sequence encoding this protein.
On the other hand, when it is an oligomeric or a multimeric protein, such as hemoglobin or hemoglobin-type molecules, the sequences encoding the various protein units are introduced into the plant cell, either within the same nucleic acid molecule, or within separate nucleic acid molecules. Preferably, for the production of hemoglobin and its derivatives, the sequences encoding α- and β-globin, or their variants, are within the same vector, called co-expression vector. The vector may comprise one or more copy(ies) of each coding sequence.
Alternatively, the sequences encoding α- and β-globin, or their variants, may be present on separate nucleic acid molecules. According to this variant, the two molecules may be introduced into the same plant cell, provided that an appropriate selection system is available. Another technique consists in introducing one of the molecules into a first plant cell, and the other into a second plant cell. Each of the transformed cells is then regenerated into a whole plant, it then being possible for the plants thus obtained to be crossed in order to give a progeny capable of producing both the α and β chains. This approach can be used to optimize the yield of hemoglobin.
The nucleic acid molecules introduced into the plant cell during the first stage of the method are also part of the invention. Generally, these nucleic acids comprise:
i) one or more sequence(s) encoding a protein component of an animal hemin protein, and
ii) one or more sequence(s) encoding a targeting signal of plant origin, and/or sequences for regulation of transcription which are recognized by a plant cell.
More particularly, the nucleic acid of the invention comprises:
i) one or more sequence(s) encoding a protein component of an animal hemin protein, the said protein having the capacity to reversibly bind oxygen, and
ii) sequences for regulation of transcription which are recognized by a plant cell, comprising a promoter and sequences for regulation of termination, and
iii) one or more sequence(s) encoding a targeting signal of plant origin.
Preferably, the sequences encoding the protein component encode animal α- or β-globin, for example of human or bovine origin, or the variants thereof. In this manner, the properties of the molecule, and in particular the affinity for oxygen and the stability, can be optimized.
Among these modifications, it is possible, for example, to introduce into one or into both of the α- and β-globin chains, by site-directed mutagenesis, one or two sequence difference(s) in order to reduce the affinity for oxygen. These mutations may be chosen from examples of natural mutations (see Table I), or from the mutations indicated by examination of the three-dimensional model of natural hemoglobin A.
TABLE I
Some mutated human hemoglobins
(Int. Hemoglobin Center, 1995)
Normal residues and
Abnormal hemoglobin
positions
Replacement
α chain (SEQ ID NO: 31)
I
16
Lys
Glu
G Honolulu
30
Glu
Gln
Norfolk
57
Gly
Asp
M Boston
58
His
Tyr
G Philadelphia
68
Asn
Lys
O Indonesia
116
Glu
Lys
β chain (SEQ ID NO: 33)
C
6
Glu
Lys
S
6
Glu
Val
G San Jose
7
Glu
Gly
E
26
Glu
Lys
M Saskatoon
63
His
Tyr
Zurich
63
His
Arg
M Milwaukee
67
Val
Glu
D Punjab
121
Glu
Gln
Mequon
41
Phe
Tyr
Providence
82
Lys
Asp
In a very advantageous manner, the mutants whose functional properties correspond to the physiological conditions for oxygen transport will be used: reversible binding, cooperativity and low speed of autooxidation. Among the mutants, there will be preferably used the double mutants α 2 β 2 F41Y,K82D (that is to say a mutant whose β chain comprises the following modifications: Phe-41 is replaced by Tyr, and Lys-82 is replaced by Asp) or α 2 β 2 F41Y,K66T (that is to say a mutant whose β chain comprises the following modifications: Phe-41 is replaced by Tyr, and Lys-66 is replaced by Thr) which correspond to these functional characteristics.
The modification of the α and β chains may also be carried out in order to stabilize the molecule, that is to say to avoid the dissociation of the tetramer into small-sized dimers which are rapidly filtered by the kidneys and which limit the intravascular life of hemoglobin. Covalent bridging, with the aid of phosphate or diaspirin, has been demonstrated as being an effective technique for stabilizing the tetramer (Benesch and Kwong, 1994). The same result can be obtained through modifications of the amino acid chain. The α subunits are produced in an alpha—alpha dimeric form linked by a glycyl residue. In this form, they conserve their capacity to correctly assemble onto the beta partner subunits and onto heme in order to form a soluble hemoglobin. This hemoglobin can no longer dissociate into dimers because the tetrameric structure is stabilized by a covalent bond (peptide bond) between the alpha-beta dimers. This technique makes it possible to increase the intravascular half-life of the molecule.
Among the variants, it is also possible to use a hybrid protein composed of a portion of the alpha chain and a portion of the beta chain.
According to a preferred variant of the invention, the nucleic acid comprises, in addition to the sequences encoding α- or β-globin, sequences encoding targeting signals. Preferably, these signals are chloroplast or mitochondrial targeting signals. The expression and/or accumulation of the recombinant proteins in these organelles is particularly preferred because of the availability of endogenous iron-containing porphyrins which are found here. The yield of hemin proteins is therefore increased. In addition, the targeting of the proteins toward the chloroplasts and the mitochondria avoids glycosylation of the protein, which may be advantageous since the natural hemoglobin molecule is not glycosylated.
As an example of chloroplast targeting signals, there may be mentioned the sequence encoding the transit peptide of the precursor of the small subunit of ribulose 1,5-diphosphate carboxylase of Pisum sativum (see examples). As mitochondrial targeting signals, there may be mentioned the sequence encoding the transit peptide of the precursor of the beta subunit of mitochondrial ATP-aseF1 of Nicotiana plumbaginifolia (see examples).
These transit peptides, as well as the N-terminal methionine, are normally cleaved in the chloroplasts or the mitochondria. The expression of the proteins in the plastids therefore also has the advantage of producing a molecule lacking N-terminal methionine as natural molecule.
According to another variant, the targeting sequences may be sequences encoding an N-terminal signal peptide (“prepeptide”), optionally in association with a signal responsible for retaining the protein in the endoplasmic reticulum (KDEL-type signal), or a vacuolar targeting signal or “propeptide”. The presence of the N-terminal signal peptide or prepeptide allows the penetration of the nascent protein into the endoplasmic reticulum where a certain amount of post-translational processing occurs, particularly the cleaving of the signal peptide, the N-glycosylations, if the protein in question has N-glycosylation sites, and the formation of disulfide bridges. Among these various signals, the prepeptide responsible for the targeting of the protein into the endoplasmic reticulum, is dominant. It is normally a hydrophobic N-terminal signal peptide having between 10 and 40 amino acids and being of animal or plant origin. Preferably, it is a prepeptide of plant origin, for example that of sporamine, barley lectin, plant extensin, α-mating factor, pathogenesis protein 1 or 2.
Normally, the signal peptide is cleaved by a peptidase signal upon the co-translational introduction of the nascent polypeptide into the lumen of the RER. The mature protein no longer contains this N-terminal extension.
The targeting sequences can, besides the prepeptide, also comprise an endoplasmic retention signal, consisting of the KDEL, SEKDEL or HEKDEL peptides. These signals normally exist at the C-terminal end of the protein and remain on the mature protein. The presence of this signal tends to increase the recombinant protein yields.
The targeting signals may, besides the prepeptide, also comprise a vacuolar targeting signal or “propeptide”. In the presence of such a signal, after passing into the RER, the protein is targeted toward the vacuoles of the aqueous tissues, the leaves for example, as well as to the protein bodies of the storage tissues, for example the seeds, tubers and roots. The targeting of the protein toward the protein bodies of the seed is particularly advantageous because of the capacity of the seed to accumulate proteins, up to 40% of the proteins relative to the dry matter, in cellular organelles derived from the vacuoles, called protein bodies and because of the possibility of stocking, for several years, the seeds containing the recombinant proteins in the dehydrated state.
As propeptide, it is possible to use a signal of animal or plant origin, the plant signals being particularly preferred, for example prosporamine. The propeptide may be N-terminal (“N-terminal targeting peptide” or NTTP), or C terminal (CTTP) Since the propeptides are normally cleaved upon entry of the protein into the vacuole, it is not present in the mature protein.
The use of the signal peptide or prepeptide can lead to the glycosylation of the protein. Normally, globin has no N-glycosylation sites, but these may be introduced by mutagenesis. The α and β chains can also have O-glycosylation sites.
In the absence of any targeting signal, the protein is expressed in the cytoplasm.
The nucleic acid introduced into the plant cell may also comprise sequences for regulation of transcription which are recognized by the plant cell. The nucleic acid is in this case a “chimeric gene”. The regulatory sequences comprise one or more promoter(s) of plant or viral origin or obtained from Agrobacterium tumefaciens . They may be constitutive promoters, for example the CaMV 35S, the double 35S, the Nos or OCS promoters, or promoters specific for certain tissues such as the grain or specific for certain phases of development of the plant. As promoters specific for seeds, there may be mentioned the promoter of the gene for napin and for the acyl carrier protein (ACP) (EP-A-0,255,378), as well as the promoters of the AT2S genes of Arabidopsis thaliana , that is to say the PAT2S1, PAT2S2, PAT2S3 and PAT2S4 promoters (Krebbers et al., Plant Physiol., 1988, vol. 87, pages 859-866). It is particularly preferable to use the cruciferin or phaseolin promoter or pGEA1 and pGEA6 of Arabidopsis, promoters of genes of the “Em, Early Methionine labelled protein” type, which is strongly expressed during the phases of drying of the seed.
It is possible to envisage using “enhancers” to improve the efficiency of expression. When the transformation occurs directly in the chloroplast and mitochondrial genomes, gene promoters specific for these compartments can be used.
The sequences for regulation of transcription normally comprise sequences for termination of transcription which are of plant or of viral origin, for example 35S, or of bacterial origin
(Agrobacterium).
When the transforming nucleic acid does not comprise regulatory sequences, it is preferable to add onto each end of the nucleic acid a DNA sequence homologous to the genomic sequences which are adjacent to a specific insertion site in the genome. This allows the integration of the construct by homologous recombination, at a site where endogenous regulatory sequences can control the expression of the heterologous sequences.
The nucleic acids of the invention may also comprise one or more intron(s), preferably of plant origin. These introns, which are obtained from a plant gene, are introduced artificially so as to increase the efficiency of expression of the heterologous sequence.
Indeed, it has been demonstrated, particularly in monocotyledonous plants, that the insertion of an intron into the untranslated 5′ portion of a gene, that is to say between the site of initiation of transcription and the site of initiation of translation, leads to an improvement in the stability of the messenger, and consequently, to a better expression. The intron(s) used in this manner are obtained preferably from a monocotyledonous plant such as maize. This is preferably, but not necessarily, the first intron of the gene.
The nucleic acid sequence encoding α- and β- globin (SEQ ID NO: 30 and SEQ ID NO: 32, respectively) and its variants is normally cDNA. Appropriate sequences are illustrated in FIGS. 2 and 3, any degenerate sequence can also be used as well as the sequences of the variants as defined above.
The introduction of a nucleic acid molecule(s) into the plant cell can be carried out in a stable manner either by transformation of the nuclear genome, or by transformation of the chloroplast genome of the plant cell, or by transformation of the mitochondrial genome.
For the transformation of the nuclear genome, conventional techniques may be used. All known means for introducing foreign DNA into plant cells may be used, for example Agrobacterium, electroporation, protoplast fusion, particle gun bombardment, or penetration of DNA into cells such as pollen, microspore, seed and immature embryo. Viral vectors such as the Gemini viruses or the satellite viruses may also be used as introducing means. Agrobacterium tumefaciens and rhizogenes constitute the preferred means. In this case, the sequence of the invention is introduced into an appropriate vector with all the necessary regulatory sequences such as promoters, terminators and the like, as well as any sequence necessary for selecting the transformants which have integrated the heterologous sequences.
The transformation of the nuclear genome of the plant cell is often carried out using the targeting signals mentioned above and which determine the cellular compartment where the expression and/or accumulation of the protein will occur.
According to another variant of the invention, the introduction of the nucleic acid into the plant cell can be carried out by the transformation of the mitochondrial or chloroplast genomes (see for example Carrer et al., Mol. Gen. Genet., 1993, 241, 49-56).
Techniques for direct transformation of the chloroplasts or the mitochondria are known per se and may comprise the following steps:
i) introducing transformant DNA by the biolistic technique (Svab et al., P.N.A.S., 1990, 87, 8526-8530);
ii) integrating the transformant DNA by two homologous recombination events;
iii) selectively removing copies of the wild-type genome during repeated cell divisions on selective medium.
In order to allow the homologous recombination of the transformant DNA, two DNA fragments homologous to the genomic sequences, for example the rbcL and ORF 512 genes are added to each end of the DNA to be inserted into the genome.
The direct transformation of the chloroplasts or mitochondria has the advantage of substantially increasing the yield of hemoglobin but the N-terminal methionine is retained.
According to another variant of the invention, the heterologous nucleic acid can be introduced into the plant cell by means of a viral vector.
The method of the invention comprises a step of detecting the hemin proteins and in particular hemoglobin and its derivatives. This makes it possible to verify if the plant or the plant cell is capable, not only of expressing the heterologous proteins, but also of assembling them correctly with the porphyrin nucleus. For the hemoglobin in a complex environment containing other chromophores or molecules which scatter light, detection by time-resolved optical spectroscopy will be advantageously used. This technique is described in detail in the examples. Other detection techniques consist in using antibodies specific for the alpha or beta globin chains or their variants. The spectrometric and immunological techniques can be used in association with each other. The use of these techniques makes it possible to select the plants which are capable of producing hemoglobin and its derivatives according to the invention.
The method of the invention comprises, in addition, a step of recovering or extracting hemoglobin or its derivatives from plant tissues. The extraction is normally carried out by grinding the tissues, for example leaves or grains, in an appropriate buffer, filtering the ground product, precipitating the proteins in the supernatant, centrifuging and taking up the pellet in an appropriate buffer with dialysis. A partial purification step can also be carried out at this stage by chromatography on an anion-exchange column.
The tetramer of hemoglobin, or of its derivatives, is purified by two successive chromatographies on an ion-exchange resin followed by a step of concentrating and saturating the concentrate with carbon monoxide. These techniques are described in detail in the examples.
When the expression of hemoglobin and of its derivatives takes place under the control of a constitutive promoter, such as the 35S double promoter, an expression level of at least 1% hemoglobin compared with the total proteins may be obtained. The proteins represent about 10% of the dry mass of the leaf and a ton of dry tobacco leaves is harvested per hectare. It is therefore possible to obtain of the order of 100 grams of hemoglobin per hectare of tobacco cultivated, assuming that only 10% of the hemoglobin produced is purified.
The method of the invention therefore allows the production of hemoglobin at very low costs with a higher production capacity than that obtained using fermenters of the culture of bacteria or yeast.
Besides the method of transformation, the invention also includes vectors comprising one or more nucleic acid(s) or chimeric gene(s) defined above. As an example of vectors, there may be mentioned binary vectors or plasmids, viral vectors such as gemini viruses or the CaMVs.
The invention also relates to the plant cells transformed with the nucleic acid sequences of the invention. Preferably, they are transformed plant cells capable of producing one or more hemoglobin(s) or derivatives of hemoglobin according to the invention.
They may be plant cell cultures in vitro, for example in liquid medium. Various modes of culture (“batch”, “fed batch” or continuous) for this type of cells are currently under study. The “batch” cultures are comparable to those carried out in an Erlenmeyer flask since the medium is not changed, these cells thus have only a limited quantity of nutrient materials. The “fed batch” culture corresponds, for its part, to a “batch” culture with programmed supply of substrate. For a continuous culture, the cells are supplied continuously with nutrient medium. An equal volume of the biomass-medium mixture is removed in order to maintain the volume of the reactor constant. The quantities of plant biomass which can be envisaged with cultures in bioreactors are variable depending on the plant species, the mode of culture and the type of bioreactor. Under certain conditions, biomass densities of about 10 to 30 g of dry weight per liter of culture can be obtained for species such as Nicotiana tabacum, Vinca rosea and Catharanthus roseus.
The cells of the invention can also be immobilized, which makes it possible to obtain a constant and prolonged production of hemoglobin. The separation of the hemoglobin and the plant biomass is also facilitated. As immobilization method, there may be mentioned immobilization in alginate or agar beads, inside polyurethane foam, or alternatively inside hollow fibers.
The cells of the invention may also be root cultures. The roots cultivated in vitro, in a liquid medium, are called “Hairy roots”, they are roots transformed by the bacterium Agrobacterium rhizogenes.
Instead of producing the hemoglobin of the invention by culturing plant cells, it is possible to regenerate chimeric or transgenic plants from transformed explants, using techniques known per se.
As appropriate plants, there may be mentioned the Angiospermae comprising monocotyledonous and dicotyledonous plants. More particularly, there may be mentioned tobacco, species belonging to botanic families such as leguminous plants (for example beans, peas and the like), cruciferous plants (for example cabbage, raddish, rapeseed and the like), Solanaceae (for example tomatoes, potato and the like), Cucurbitaceae (for example melon), Chenopodiaceae (for example beetroot), Umbelliferae (for example carrots, celery and the like). There may also be mentioned cereals such as wheat, maize, barley, triticale and rice, oleaginous plants such as sunflower and soybean. Tobacco, potato, tomato and maize are particularly preferred. For potato, the expression takes place preferably in the tubers.
The invention also relates to the seeds of transgenic plants capable of producing hemoglobin as well as their progeny.
The invention also relates to the hemin proteins which may be obtained by the method of the invention, in particular the hemin proteins capable of reversibly binding oxygen, for example the hemoglobins and derivatives thereof.
The hemoglobins of the invention are capable of binding O 2 in a reversible manner with an affinity (P 50 ) preferably close to physiological values (37° C.), pH 7.40). The affinity of the molecule for O 2 is expressed as P 50 : that is to say the partial pressure of O 2 when hemoglobin or its derivatives is 50% saturated. The P 50 is measured according to the usual techniques, for example by means of an analyzer which measures the percentage O 2 saturation as a function of the O 2 pressure (Kister et al., 1987). Normally, the hemoglobins of the invention have an acceptable autooxidation rate in order to minimize the formation of methemoglobin which is unsuited to the transport of O 2 . This characteristic can be measured by the absorption spectrum.
Preferably, the hemoglobins of the invention are tetramers, preferably alpha 2 beta 2 , beta 4 , or optionally tetramers of chimeric α/β subunits (Dumoulin et al., 1994, Art. Cells, Blood Subst., and Immob. Biotech., 22, 733-738) or multiples of four subunits. The physical size of the complex should be at least that of the tetramer in order to avoid its filtration by the kidneys.
The hemin proteins of the invention can be used in numerous pharmaceutical, cosmetic or industrial applications. The invention relates in particular to pharmaceutical compositions comprising one or more hemin protein(s) according to any one of claims 15 to 23 , in association with a physiologically acceptable excipient.
In the pharmaceutical field, all the conditions requiring an improvement in the transport of oxygen can be treated with the hemoglobins of the invention, these conditions comprising the following:
acute or chronic hemorrhage,
states of shock,
coronary or sylvian angioplasties,
treatments of solid tumors, sensitization to gamma-therapy,
preservation of organs before transplant and during transport,
malignant hemopathies.
The hemoglobins of the invention are normally used in the form of an injection in solutions optionally stabilized as regards the tetrameric form of the complex (for example addition of pyridoxal phosphate or diaspirin) as regards autooxidation. It is also possible to use suspensions of hemoglobin grafted on a support in order to increase the lifetime in the bloodstream. The support may be any conventional support in this domain, for example polysaccharides.
BRIEF DESCRIPTION OF THE DRAWINGS
Various aspects of the invention are illustrated in the figures:
FIG. 1 : Iron-containing protoporphyrin III (IX),
FIG. 2 : cDNA sequence of human α-globin (423 base pairs; SEQ ID NO: 30), and corresponding protein, (SEQ ID NO: 31),
FIG. 3 : cDNA sequence of human β-globin (438 base pairs; SEQ ID NO: 32), and corresponding protein, (SEQ ID NO: 33)
FIG. 4 : Experimental device for flash photolysis. A pulsed laser serves for the photo-dissociation of the Hb ligands: (HbCO→Hb+CO). A second optical beam, oriented at 90°, detects changes in absorption as a function of time after dissociation.
FIG. 5 : Kinetics of bimolecular recombination of CO with hemoglobin in plant extract. The two phases correspond to the two allosteric states of Hb: R (rapid) and T (slow). Conditions: 0.1 atm CO, pH 6-6, 25° C., about 50% dissociation, 0-1, 1 and 10 μM Hb.
FIG. 6 : Kinetics of recombination of CO with hemoglobin as a function of the percentage dissociation (by variation of the laser energy). The kinetics are sensitive to the number of ligands dissociated (1 to 4). At a high level of dissociation, Hb (deoxy or mono-ligand containing) shifts toward the slow form “T”. At a low laser energy, the tetramers (mainly with three ligands) remain in the rapid form “R”.
FIG. 7 : Western-blot analysis of the extract of the seeds of the transgenic tobacco T26-22 transformed with the plasmid pBIOC59. The extracts of seeds (75 μg of proteins) of a nontransformed tobacco (1) and of a transgenic tobacco (T26-22) (2), molecular weight markers (3) and HbA (50 ng) (4) are separated by SDS-PAGE 17% electrophoresis under reducing conditions. The Western blotting is carried out under the conditions described in section X.a. The molecular weight markers and the α and β globins are indicated.
FIG. 8 : Western-blot analysis of the fractions obtained during partial purification. The proteins in the fractions eluted from Sephacryl S-100 (37 μg), from S-Sepharose (30 μg) which are obtained during purification from mixtures of control seeds [(2) and FE-Control (4) respectively] and of seeds accumulating rHb [(3) and FE-rHb (5) respectively], HbA (50 ng) (1) and molecular weight markers (6) were separated by SDS-PAGE 17% electrophoresis under reducing conditions. The Western blotting is carried out under the conditions described in section X.a. The molecular weight markers and the α and β globins are indicated.
FIG. 9 : Kinetics of recombination of CO with the FE-rHb fraction. The kinetics, following flash photolysis, is characteristic of the normal tetrameric Hb. The FE-Control fraction obtained from the control plants gives a signal of amplitude 1 mOD, that is to say about 50 times weaker than that observed for the FE-rHb fraction (48 mOD).
FIG. 10 : Kinetics of recombination of CO with the FE-rHb fraction at various laser intensity levels. Similar results are observed for HbA (FIG. 6 ).
FIG. 11 : Demonstration of the reversible binding of oxygen to the FE-rHb sample. Since the oxyhemoglobin samples give only weak signals, we used, for these measurements, the technique of mixing a CO atmosphere and O 2 . After photodissociation of CO, the rapid phase corresponds to the binding of oxygen. The oxygen is then replaced with CO which can again be photodissociated. The figure also shows the kinetics of recombination of the CO of the same sample equilibrated under 1 atm or 0.1 atm CO.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLES
I. CONSTRUCTION OF BASAL EXPRESSION BINARY PLASMIDS ALLOWING THE PRODUCTION OF RECOMBINANT PROTEINS IN TOBACCO LEAVES
The expression of genes in tobacco leaves requires the following regulatory sequences:
1) the constitutive double 35S promoter (pd35S) of CaMV (cauliflower mosaic virus). It corresponds to a duplication of the transcription-activating sequences situated upstream of the TATA element of the natural 35S promoter (Kay et al., 1987).
2) the sequence for termination of transcription, 35S polyA terminator, which corresponds to the noncoding 3′ region of the sequence of the circular double-stranded DNA cauliflower mosaic virus producing the 35S transcript (Franck et al., 1980).
The constructions of the various plasmids via the use of recombinant DNA techniques (Sambrook et al., 1989) are derived from pBIOC4. This binary plasmid is derived from pGA492 (An, 1986) which contains, between the right and left borders derived from the plasmid pTiT37 of Agrobacterium tumefaciens , on its transfer DNA, the following sequences:
the constitutive promoter of the nos gene encoding nopaline synthase (Depicker et al., 1982),
the coding sequence of the nptII gene encoding neomycin phosphotransferase II (Berg and Berg, 1983) deleted off the region of the first 8 codons including the ATG methionine initiation codon and fused to the sequence of the first 14 codons of the coding sequence of the nos gene (Depicker et al., 1982), the coding sequence of the nos gene lacking the region of the first 14 codons, the nos terminator (Depicker et al., 1982), a polylinker (HindIII-XbaI-SacI-HpaI-KpnI-ClaI-BglII) preceding the cat gene encoding chloramphenicol acetyltransferase (Close and Rodriguez, 1982) and the termination sequences of gene 6 of the plasmid pTiA6 of Agrobacterium tumefaciens (Liu et al., 1993).
To remove virtually the whole of the coding sequence of the cat gene, the plasmid pGA492 was doubly digested with SacI (restriction site of the polylinker) and with ScaI (restriction site present in the sequence of the cat gene) and then subjected to the action of the enzyme T4 DNA polymerase (New England Biolabs) according to the manufacturer's recommendations. The ligation of the modified plasmid (20 ng) was carried out in a reaction medium of 10 μl containing 1 μl of 10×T4 DNA ligase buffer (Amersham) and 2.5 U of T4 DNA ligase enzyme (Amersham) at 14° C. for 16 hours. The E. coli DH5α bacteria previously made competent were transformed (Hanahan, 1983).
The plasmid DNA of the clones obtained, selected on 12 μg/ml tetracycline, was extracted according to the alkaline lysis method (Birnboim and Doly, 1979) and analyzed by enzymatic digestion with restriction enzymes. Next, the HindIII restriction site of the plasmid DNA of the selected clone was modified at an EcoRI restriction site with the aid of a phosphorylated HindIII—EcoRI adaptor (Stratagene Cloning Systems). To carry out this modification, 500 ng of plasmid DNA of the selected clone were digested with HindIII, dephosphorylated with the enzyme calf intestinal alkaline phosphatase (Boehringer Mannheim) according to the manufacturer's recommendations and coprecipitated in the presence of 1500 ng of HindIII-EcoRI adaptor DNA, 1/10 volume of 3 M sodium acetate pH 4.8 and 2.5 volumes of absolute ethanol at −80° C. for 30 min. After centrifugation at 12000 g for 30 min. the precipitated DNA was washed with 70% ethanol, dried, taken up in 8 μl of water, heated at 65° C. for 10 min, and then ligated in the presence of 1 μl of 10×T4 DNA ligase buffer (Amersham) and 2.5 U of the enzyme T4 DNA ligase (Amersham) at 14° C. for 16 hours. After inactivation of the T4 DNA ligase at 65° C. for 10 min, the ligation reaction mixture was digested with EcoRI, purified by electrophoresis on a 0.8% agarose gel, electroeluted (Sambrook et al., 1989), precipitated in the presence of 1/10 volume of 3 M sodium acetate pH 4.8 and 2.5 volumes of absolute ethanol at −80° C. for 30 min, centrifuged at 12000 g for 30 min, washed with 70% ethanol and then dried. The E. coli DH5α bacteria previously made competent were transformed (Hanahan, 1983). The plasmid DNA of the clones obtained, selected on 12 μg/ml tetracyclin, was extracted according to the alkaline lysis method (Birnboim and Doly, 1979) and analyzed by enzymatic digestion with HindIII and EcoRI in particular. The resulting binary plasmid, which now possesses only the last 9 codons of the coding sequences of the cat gene and in which the EcoRI site is unique, was called pBIOC4.
a. CONSTRUCTION OF THE EXPRESSION BINARY PLASMID pBIOC21.
The expression cassette, consisting of the pd35S promoter and the 35S polyA terminator, was isolated from the plasmid pJIT163D. The plasmid pJIT163D is derived from the plasmid pJIT163 which is itself derived from the plasmid pJIT60 (Guerineau and Mullineaux, 1993). The plasmid pJIT163 possesses an ATG codon between the HindIII and SalI sites of the polylinker. To eliminate this ATG and to obtain the plasmid pJIT163D, the plasmid DNA pJIT163 was doubly digested with HindIII and SalI, purified by electrophoresis on a 0.8% agarose gel, electroeluted (Sambrook et al., 1989), precipitated in the presence of 1/10 volume of 3 M sodium acetate pH 4.8 and 2.5 volumes of absolute ethanol at −80° C. for 30 min, centrifuged at 12000 g for 30 min, washed with 70% ethanol, dried, subjected to the action of the Klenow enzyme (New England Biolabs) according to the manufacturer's recommendations, deproteinized by extraction with 1 volume of phenol:chloroform:isoamyl alcohol (25:24:1) and then 1 volume of chloroform:isoamyl alcohol (24:1), precipitated in the presence of 1/10 volume of 3 M sodium acetate pH 4.8 and 2.5 volumes of absolute ethanol at −80° C. for 30 min, centrifuged at 12000 g for 30 min, washed with 70% ethanol, dried and finally ligated in the presence of 1 μl of 10×T4 DNA ligase buffer (Amersham) and 2.5 U of T4 DNA ligase enzyme (Amersham) at 14° C. for 16 hours. The E. coli DH5α bacteria previously made competent, were transformed (Hanahan, 1983). The plasmid DNA of the clones obtained, selected on 50 μg/ml ampicillin, was extracted according to the alkaline lysis method (Birnboim and Doly, 1979) and analyzed by enzymatic digestion with restriction enzymes. To isolate the expression cassette consisting of the pd35S promoter and of the 35S polyA terminator (SacI-XhoI fragment), the plasmid DNA of the pJIT163D clone selected was digested with SacI and XhoI. The SacI-XhoI-fragment, carrying the expression cassette, was purified by electrophoresis on a 0.8% agarose gel, electroeluted (Sambrook et al., 1989), precipitated in the presence of 1/10 volume of 3 M sodium acetate pH 4.8 and 2.5 volumes of absolute ethanol at −80° C. for 30 min, centrifuged at 12000 g for 30 min, washed with 70% ethanol, dried and then subjected to the action of Mung Bean nuclease enzyme (New England Biolabs) according to the manufacturer's recommendations. This purified insert (200 ng) was cloned into the plasmid DNA of pBIOC4 (20 ng) digested with EcoRI, treated with the Mung Bean nuclease enzyme and dephosphorylated with the enzyme calf intestinal alkaline phosphatase (Boehringer Mannheim) according to the manufacturer's recommendations. The ligation reaction was carried out in 20 μl, in the presence of 2 μl of 10×T4 DNA ligase buffer (Amersham), 2 μl of 50% polyethylene glycol 8000 and 5 U of T4 DNA ligase enzyme (Amersham) at 14° C. for 16 hours. The E. coli DH5α bacteria previously made competent were transformed (Hanahan, 1983). The plasmid DNA of the clones obtained, selected on 12 μg/ml tetracyclin was extracted according to the alkaline lysis method (Birnboim and Doly, 1979) and analyzed by enzymatic digestion with restriction enzymes. The resulting plasmid was called pBIOC21.
b. CONSTRUCTION OF THE CO-EXPRESSION BINARY PLASMID pBIOC43.
The co-expression binary plasmid will allow expression of two genes in the same binary vector.
The co-expression binary plasmid is derived from pBIOC21. It contains two expression cassettes each consisting of a pd35S promoter and a 35S polyA terminator but differ in the polylinker separating the promoter from the terminator. One of the expression cassettes is that of pBIOC21 already described in paragraph I.a. The other expression cassette was obtained by replacing the HindIII-BamHI-SmaI-EcoRI polylinker of pJIT163D (described in paragraph I.a.) by a HindIII-EcoRI adaptor carrying the PacI, AscI, MluI and HpaI restriction sites. This adaptor was obtained by renaturation of the 2 oligodeoxynucleotides WD 11 (5′ AGC TGA TTA ATT AAG GCG CGC CAC GCG TTA AC 3′; SEQ ID NO: 1) and WD12 (5′ AAT TGT TAA CGC GTG GCG CGC CTT AAT TAA TC 3′; SEQ ID NO: 2) which are complementary for their 28 terminal 3′ nucleotides. One hundred μM of each of these two oligodeoxynucleotides were previously phosphorylated by the action of 10 U of T4 polynucleotide kinase enzyme (New England Biolabs) in a total reaction volume of 10 μl of 10×T4 polynucleotides kinase buffer (New England Biolabs) and 3 μl of ATP (95 mM). The two reaction mixtures were incubated at 37° C. for 1 hour, and then at 65° C. for 20 min. They were then combined and their volume of phenol;chloroform:isoamyl alcohol (25:24:1) and 1 volume of chloroform:isoamyl alcohol (24:1), 50 μl of 3M sodium acetate pH 6.0 were added. The reaction mixture was incubated at 80° C. for 10 min and then cooled slowly to room temperature. The DNA was then precipitated in the presence of 2.5 volumes of absolute ethanol at −80° C. for 30 min, centrifuged at 14000 g at 4° C. for 1 hour, washed with 70% ethanol, centrifuged at 14000 g at 4° C. for 10 min, dried, taken up in 10 μl of H2O. The HindIII-EcoRI DNA fragment was then cloned at the HindIII-EcoRI sites of the plasmid DNA pJIT163D previously dephosphorylated with the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation reaction was carried out in a reaction volume of 20 μl in the presence of 1 U of T4 DNA ligase (Gibco-BRL) for a total DNA concentration of 8.5 nM with a vector/insert molar ratio of 1 and of 4 μl of 5×T4 DNA ligase buffer (Gibco-BRL) at 25° C. for 16 hours. The E. coli DH5α bacteria previously made competent were transformed (Hanahan, 1985). The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC42. Its validity was verified by sequencing with the aid of the “Sequenase Version 2.0 DNA Sequencing” kit marketed by United States Biochemical (USB) according to the dideoxynucleotides method (Sanger et al., 1977). The reaction conditions follow the manufacturer's recommendations except for the denaturation and hybridization. The reaction medium containing the plasmid DNA (0.5 to 1 pmol), the oligonucleotide primer (2pmol), 10% DMSO and the 1× reaction buffer (USB), is incubated at 100° C. for 10 min, then suddenly cooled to −80° C. in dry ice.
From pBIOC42, the DNA fragment encoding the expression cassette consisting of the pd35S promoter and of the 35S polyA terminator was isolated by double digestion with SacI and XhoI. It was purified by electrophoresis on a 0.75% agarose gel, and then subjected to the action of the “Geneclean II” kit marketed by BIO101 according to the manufacturer's recommendations. Next, this DNA fragment was inserted at the SacI and XhoI sites of the plasmid pBCSK+ marketed by Stratagene and previously dephosphorylated with the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation was carried out in a reaction volume of 20 μl in the presence of 1 U of T4 DNA ligase (Gibco-BRL) for a total DNA concentration of 8.5 nM with a vector/insert molar ratio of 1 and of 4 μl of 5×T4 DNA ligase buffer (Gibco-BRL) at 25° C. for 16 hours. The E. coli DH5α bacteria previously made competent were transformed (Hanahan, 1985). The plasmid DNA of the clones obtained, selected on 30 μg/ml of chloramphenicol, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion with restriction enzymes. The resulting plasmid was called pBIOC75.
From pBIOC75, the DNA fragment carrying the expression cassette consisting of the pd35S promoter and the 35S polyA terminator was isolated by digestion with KpnI. It was purified by electrophoresis on a 0.75% agarose gel, and then subjected to the action of the “Geneclean II” kit marketed by BIO101 according to the manufacturer's recommendations. Next, this DNA fragment was ligated to the plasmid DNA of pBIOC21 digested with KpnI and dephosphorylated with the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation was carried out in a reaction volume of 20 μl in the presence of 1 U of T4 DNA ligase (Gibco-BRL) for a total DNA concentration of 8.5 nM with a vector/insert molar ratio of 1 and of 4 μl of 5×T4 DNA ligase buffer (Gibco-BRL) at 25° C. for 16 hours. The E. coli DH5α bacteria previously made competent were transformed (Hanahan, 1985). The plasmid DNA of the clones obtained, selected on 12 μg/ml of tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion with restriction enzymes. The resulting plasmid was called pBIOC43.
II. CONSTRUCTION OF THE CHIMERIC GENES ENCODING THE α AND β GLOBIN CHAINS ALLOWING EXPRESSION OF RECOMBINANT HUMAN HEMOGLOBIN IN THE CYTOPLASM OF TOBACCO LEAVES
The plasmid alpha1pJW101 contains the cDNA for the α globin chain, cloned into the plasmid pMB9 as described by Wilson et al. (1978).
The M13mp10 phage CIIIX beta contains the cDNA for the β globin chain, cloned into the M13 mp10 phage as described by Nagai et al. (1985). In this construction, the cDNA encoding β globin was inserted in 3′ of the coding sequence for the cII protein of the lambda phage, followed by that encoding the FX tetrapeptide, forming a fusion gene in which the initiator ATG codon of β globin has been deleted.
a. CONSTRUCTION OF THE PLASMID pBIOC44 CONTAINING THE cDNA ENCODING α GLOBIN FOR CYTOPLASMIC TARGETING.
To obtain cytoplasmic targeting of the α globin chain, the initiator methionine codon of the α globin chain was maintained.
The cDNA encoding the cytoplasmic targeting α globin chain was obtained in three stages. The first two stages made it possible to suppress the internal HindIII site (substitution of a T for a C) at position 276 of the coding sequence whereas the third stage combines the 2 cDNA fragments encoding the recombinant α globin chain.
The first stage consisted in the amplification of the first 95 codons of the mature α globin chain on the plasmid alpha1pJW101 with the aid of the 2 oligodeoxynucleotides, WD13 (5′ tacaagcttaaca ATG GTG CTG TCT CCg GCC GAC 3′; SEQ ID NO: 3) and AD27 (5′ CGG GTC CAC CCG GAG CTT GTG 3′; SEQ ID NO: 4). The WD13 primer provides the HindIII restriction site, the sequence aaca favoring the initiation of translation (Joshi, 1987) and preceding the initiator ATG codon followed by the first 6 condons of the mature a globin chain of which the fourth (CCT) is substituted for CCg (silent mutation) in order to create the EagI restriction site. The AD27 primer allows the suppression of the HindIII restriction site by substitution of nucleotide T for C (position 276 of the coding sequence). The PCR amplification was carried out in 100 μl of reaction medium containing 10 μl of 10×Taq DNA polymerase buffer (100 mM Tris-HCl pH 8.4, 500 mM KCl and 20 mM MgCl 2 ), 16 μl of the dNTP mixture (1.25 mM dATP, 1.25 mM dCTP, 1.25 mM dGTP and 1.25 mM dTTP), 10 μl of each of the primers described above at 10 μl, 10 μl of template DNA (alpha1pJW101) at 1 ng/μl and 0.5 μl of Taq DNA polymerase at 5 U/μl (Perkin Elmer). Thirty cycles each comprising 30 sec of denaturation at 97° C., 1 min hybridization at 55° C. and 2 min extension at 72° C. were carried out in the Appligène “Crocodile II” apparatus. The amplified DNA fragments were then purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit marketed by BIO101 according to the manufacturer's recommendations. The purified amplified DNA fragments are taken up in 20 μl.
The second stage consisted in the amplification of the last 54 codons of the mature a globin chain on the plasmid alpha1pJW101 with the aid of the 2 oligodeoxynucleotides, AD26 (5′ CAC AAG CTC CGG GTG GAC CCG 3′; SEQ ID NO: 5) and WD14 (5′ gcgaattc TCA ACG GTA TTT GGA GGT CAG CAC 3′; SEQ ID NO: 6). The WD14 primer provides the EcoRI restriction site situated just after the stop codon. The AD26 primer allows the suppression of the HindIII restriction site by substitution of nucleotide T for C (position 276 of the coding sequence). The PCR amplification was carried out as described in the first stage. The treatment of the amplified DNA fragments was carried out as described in the first stage.
The third stage was the PCR amplification of the complete cDNA encoding the α globin chain (142 codons including the initiator ATG). The two types of DNA fragments amplified in the first and second stages served as template DNA and the two primers used were WD13 and WD14. The PCR amplification was carried out as described in the first stage except that the hybridization temperature of the cycle is 60° C. The amplified DNA fragments were then extracted with H 2 O-saturated ether after having adjusted the volume to 500 μl with TE buffer (10 mM Tris-HCl pH 8.0, 1 mM EDTA). After extraction with 1 volume of phenol:chloroform:isoamyl alcohol (25:24:1) and 1 volume of chloroform:isoamyl alcohol (24:1), the DNA fragments were precipitated in the presence of 1/10 volume of 3 M sodium acetate pH 6.0 and 2 volumes of absolute ethanol at −80° C. for 30 min, centrifuged at 14000 g at 4° C. for 30 min, washed with 70% ethanol, centrifuged at 14000 g at 4° C. for 10 min, dried, taken up in 50 μl of H 2 O. Next, 25 μl of these DNA fragments were doubly digested with HindIII and EcoRI, purified by electrophoresis on 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) and cloned at the HindIII and EcoRI sites of the plasmid pNEB193 marketed by New England Biolabs, and previously dephosphorylated with the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC44. The nucleotide sequence of the cDNA encoding the recombinant α globin chain was verified by sequencing with the aid of the “Sequenase Version 2.0 DNA Sequencing” kit marketed by United States Biochemical (USB) as described in section I.b. The sequencing revealed two silent mutations situated at the forty-eighth nucleotide (C modified to T) and at the fifty-fourth (T modified to C) of the coding sequence for the α globin chain.
b. CONSTRUCTION OF THE PLASMID pBIOC45 CONTAINING THE cDNA ENCODING β GLOBIN FOR CYTOPLASMIC TARGETING.
To obtain cytoplasmic targeting of the β globin chain, the methionine codon was fused with the first codon of the mature β globin chain by maintaining the open reading frame since ATG had been deleted from the construct M13mp10 cIIFX beta.
The cDNA encoding the cytoplasmic targeting β globin chain was obtained by PCR amplification of the 146 codons constituting the mature β globin chain on the phage M13mp10 cIIFX beta with the aid of the 2 oligodeoxynucleotides WD15 (5′ gtcattaattaaca ATG GTG CAC CTG ACT CCT GAG GAG AAG TCg GCC GTT AC 3′) and WD16 (5′ aatgagctcgttaacgcgt TTA GTG ATA CTT GTG GGC CAG GGC 3′). The WD15 primer provides the PacI restriction site, the aaca sequence favoring the initiation of translation (Joshi, 1987) and the initiator ATG codon followed by the first 12 codons of the mature β globin chain of which the ninth (TCT) is substituted for TCg (silent mutation) in order to create the EagI restriction site. The WD16 primer provides the MluI, HpaI and SacI restriction sites placed after the stop codon. The PCR amplification and the treatment of the amplified DNA fragments were carried out as described in the third stage of section II.a. Next, 25 μl of these DNA fragments were doubly digested with PacI and SacI, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) and cloned at the PacI and SacI sites of the plasmid pNEB193 marketed by New England Biolabs, previously dephosphorylated by the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC45. The nucleotide sequence of the cDNA encoding the recombinant β globin chain was verified by sequencing as described in section I.b.
c. CONSTRUCTION OF THE EXPRESSION BINARY PLASMIDS PBIOC 46 AND pBIOC47, AND OF THE CO-EXPRESSION BINARY PLASMID pBIOC49 FOR CYTOPLASMIC TARGETING.
c.1. CONSTRUCTION OF THE BINARY PLASMID pBIOC46 CONTAINING cDNA ENCODING α GLOBIN FOR CYTOPLASMIC TARGETING.
Starting with pBIOC44, the HindIII-EcoRI fragment carrying the cDNA encoding the cytoplasmic targeting α globin chain was isolated by double enzymatic digestion with HindIII and EcoRI, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101). Next, this DNA fragment was ligated with the plasmid DNA of pBIOC21 doubly digested with HindIII and EcoRI, and dephosphorylated with the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracyline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC46. The nucleotide sequence of the cDNA encoding the recombinant α globin chain was verified by sequencing as described in section I.b. The plasmid DNA of the binary vector pBIOC46 was introduced by direct transformation into the Agrobacterium tumefaciens LBA4404 strain according to the method of Holsters et al. (1978). The validity of the clone selected was verified by enzymatic digestion of the plasmid DNA introduced.
c.2. CONSTRUCTION OF THE BINARY PLASMID pBIOC47 CONTAINING THE cDNA ENCODING β GLOBIN FOR CYTOPLASMIC TARGETING.
Starting with pBIOC45, the HindIII-EcoRI fragment carrying the cDNA encoding the cytoplasmic targeting β globin chain was isolated by double enzymatic digestion with HindIII (total digestion) and EcoRI (partial digestion) , purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101). Next, this DNA fragment was ligated with the plasmid DNA of pBIOC21 doubly digested with HindIII and EcoRI and dephosphorylated with the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation and the transformation were carried out as described in section I.b.
The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC47. The nucleotide sequence of the cDNA encoding the recombinant β globin chain was verified by sequencing as described in section I.b. The plasmid DNA of the binary vector pBIOC47 was introduced by direct transformation into the Agrobacterium tumefaciens LBA4404 strain according to the method of Holsters et al. (1978). The validity of the clone selected was verified by enzymatic digestion of the plasmid DNA introduced.
c.3. CONSTRUCTION OF THE CO-EXPRESSION BINARY PLASMID pBIOC49 CONTAINING THE cDNA ENCODING THE α AND β GLOBINS FOR CYTOPLASMIC TARGETING.
The HindIII-EcoRI fragment carrying the cDNA encoding the cytoplasmic targeting α globin chain was isolated from pBIOC44 described in section II.c.1., and ligated with the plasmid DNA of pBIOC43 doubly digested with HindIII and EcoRI, and previously dephosphorylated with the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 12 μg/ml tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC48.
The PacI-MluI fragment carrying the cDNA encoding the cytoplasmic targeting β globin chain was isolated from pBIOC45 described in section II.c.2., and ligated with the plasmid DNA of pBIOC48 doubly digested with PacI and MluI, and dephosphorylated by the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation and the transformation were carried out as described in section I.b., except that the E. coli Sure tet − strain was used in place of DH5α. The Sure tet − strain is derived from the Sure strain (Stratagene) made sensitive to tetracycline by the loss of the F′ episome. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC49.
The nucleotide sequence of the cDNAs encoding the recombinant α and β globin chains was verified by sequencing as described in section I.b. The plasmid DNA of the binary vector pBIOC49 was introduced by direct transformation into the Agrobacterium tumefaciens LBA4404 strain according to the method of Holsters et al. (1978). The validity of the clone selected was verified by enzymatic digestion of the plasmid DNA introduced.
III. CONSTRUCTION OF THE CHIMERIC GENES ENCODING THE α AND β GLOBIN CHAINS ALLOWING EXPRESSION OF RECOMBINANT HUMAN HEMOGLOBIN IN THE MITOCHONDRIA OF TOBACCO LEAVES
To obtain mitochondrial targeting, the sequence encoding the transit peptide of the Nicotiana plumbaginifolia mitochondrial ATPase-Fi β subunit precursor (ATG GCT TCT CGG AGG CTT CTC GCC TCT CTC CTC CGT CAA TCG GCT CAA CGT GGC GGC GGT CTA ATT TCC CGA TCG TTA GGA AAC TCC ATC CCT AAA TCC GCT TCA CGC GCC TCT TCA CGC GCA TCC CCT AAG GGA TTC CTC TTA AAC CGC GCC GTA CAG TAC; SEQ ID NO: 9) is fused with the first codon of the sequence encoding, on the one hand, the mature α globin chain (deletion of the initiator ATG) and, on the other hand, the mature β globin chain (deletion of the initiator ATG) while maintaining the open reading frames.
The sequence encoding the Nicotiana plumbaginifolia mitochondrial ATPase F1 β subunit is contained in the plasmid pTZ-catp2-1 provided by Boutry. This plasmid corresponds to the plasmid pTZ18R containing the cDNA (cNP10) as described by Boutry and Chua (1985).
The N-terminal transit peptide, composed of 54 amino acids as defined by Chaumont et al. (1994), was used during the carrying out of the constructions.
a. CONSTRUCTION OF THE PLASMID pBIOC50 CONTAINING THE cDNA ENCODING α GLOBIN FOR MITOCHONDRIAL TARGETING.
To obtain mitochondrial targeting of the α globin chain, the sequence encoding the transit peptide of the Nicotiana plumbaginifolia mitochondrial ATPase-F1 β subunit precursor was fused with the first codon of the sequence encoding the mature α globin chain while maintaining the open reading frame. The cleaving sequence between the sequences of the transit peptide and the mature α globin chain is Tyr-Val.
The sequence encoding the transit peptide of the mitochondrial ATPase-F1 β subunit precursor was amplified by PCR on the plasmid pTZ-catp2-1 with the aid of the 2 oligodeoxynucleotides, WD17 (5′ cgcaagcttaaca ATG GCT TCT CGG AGG CTT CTC 3′; SEQ ID NO: 10) and WD18 (5′ tag aat tC GGC cGG AGA CAG CAC GTA CTG TAC GGC GCG GTT TAA G 3′; SEQ ID NO: 11). The WD17 primer provides the HindIII restriction site, the aaca sequence promoting the initiation of translation (Joshi, 1987) and the first 7 codons of the transit peptide (including the initiator ATG). The WD18 primer provides the EcoRI restriction site, the first 5 codons of the sequence encoding the mature α globin chain (an EagI restriction site is created by silent mutation in the fourth codon (CCT modified to CCG) and the last 7 codons of the sequence of the transit peptide. PCR amplification and the treatment of the amplified DNA fragments were carried out as described in the third step of chapter II.a. Next, these DNA fragments were doubly digested with HindIII and EagI, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) and cloned at the HindIII and EagI sites of the plasmid pBIOC44 described in section II.a., previously purified by electrophoresis on a 0.75% agarose gel and using the “Geneclean II” kit. The plasmid pBIOC44 was dephosphorylated by the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC50. The nucleotide sequence of this chimeric gene resulting from the translational fusion between the sequence encoding the transit peptide and the cDNA encoding the mature α globin chain was verified by sequencing as described in section I.b. The sequencing revealed two silent mutations situated at the tenth nucleotide (C modified to A) and at the one hundred forty first (C modified to G) of the coding sequence for the transit peptide.
b. CONSTRUCTION OF THE PLASMID pBIOC51 CONTAINING THE cDNA ENCODING β GLOBIN FOR MITOCHONDRIAL TARGETING.
To obtain mitochondrial targeting of the β globin chain, the sequence encoding the transit peptide of the Nicotiana plumbaginifolia mitochondrial ATPase-F1 β subunit precursor was fused with the first codon of the sequence encoding the mature β globin chain while maintaining the open reading frame. The cleaving sequence between the sequences of the transit peptide and the mature β globin chain is Tyr-Val.
The sequence encoding the transit peptide of the mitochondrial ATPase-F1 β subunit precursor was amplified by PCR on the plasmid pTZ-catp2-1 with the aid of the 2 oligodeoxynucleotides, WD19 (5′ gtcattaattaaca ATG GCT TCT CGG AGG CTT CTC GCC TCT C 3′; SEQ ID NO: 12) and WD20 (5′aatgagct C GGC cGA CTT CTC CTC AGG AGT CAG GTG CAC GTA CTG TAC GGC GCG GTT TAA G 3′; SEQ ID NO: 13). The WD 19 primer provides the PacI restriction site, the aaca sequence promoting the initiation of translation (Joshi, 1987) and preceding the first 9 codons of the transit peptide (including the initiator ATG). The WD20 primer provides the SacI restriction site, the first 10 codons of the sequence encoding the mature β globin chain (an EagI restriction site is created by silent mutation in the ninth condon (TCT modified to TCg)) and the last 7 codons of the sequence of the transit peptide. The PCR amplification and the treatment of the amplified DNA fragments were carried out as described in the third stage of section Il.a. Next, these DNA fragments were doubly digested with PacI and EagI, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) and cloned at the PacI and EagI sites of the plasmid pBIOC45 described in section II.b., previously purified by electrophoresis on a 0.75% agarose gel and using the “Geneclean II” kit. The plasmid pBIOC45 was dephosphorylated by the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC5 1. The nucleotide sequence of this chimeric gene resulting from the translational fusion between the sequence encoding the transit peptide and the cDNA encoding the mature β globin chain was verified by sequencing as described in section I.b.
c. CONSTRUCTION OF THE CO-EXPRESSION BINARY PLASMID pBIOC53 CONTAINING THE cDNAs ENCODING THE α AND β GLOBINS, FOR MITOCHONDRIAL TARGETING.
The HindIII-EcoRI fragment carrying the cDNA encoding the mitochondrial targeting α globin chain was isolated from pBIOC50 described in section III.a., and ligated to the plasmid DNA of pBIOC43 doubly digested with HindIII and EcoRI, and dephosphorylated by the enzyme calf intestinal alkaline phosphatase (New England Biolabs) according to the manufacturer's recommendations. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC52.
The PacI-MluI fragment carrying the cDNA encoding the mitochondrial targeting β globin chain was isolated from pBIOC51 described in section III.b., and ligated to the plasmid DNA of pBIOC52 doubly digested with PacI and MluI, and dephosphorylated by the enzyme calf intestinal alkaline phosphatase (New England Biolabs). The ligation and the transformation were carried out as described in section II.c.3 using the E. coli Sure tet strain. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC53.
The nucleotide sequence of the cDNAs encoding the recombinant α and β globin chains allowing α mitochondrial targeting was verified by sequencing as described in section I.b. The plasmid DNA of the binary vector pBIOC53 was introduced by direct transformation into the Agrobacterium tumefaciens LBA4404 strain according to the method of Holsters et al. (1978). The validity of the clone obtained was verified by enzymatic digestion of the plasmid DNA introduced.
IV. CONSTRUCTION OF THE CHIMERIC GENES ENCODING THE α AND β GLOBIN CHAINS ALLOWING EXPRESSION OF RECOMBINANT HUMAN HEMOGLOBIN IN THE CHLOROPLASTS OF TOBACCO LEAVES
To obtain chloroplastic targeting, the sequence encoding the transit peptide of the precursor of the small subunit of ribulose 1,5-diphosphate carboxylase of Pisum sativum L. (ATG GCT TCT ATG ATA TCC TCT TCA GCT GTG ACT ACA GTC AGC CGT GCT TCT ACG GTG CAA TCG GCC GCG GTG GCT CCA TTC GGC GGC CTC AAA TCC ATG ACT GGA TTC CCA GTT AAG AAG GTC AAC ACT GAC ATT ACT TCC ATT ACA AGC AAT GGT GGA AGA GTA AAG TGC; SEQ ID NO: 14) is fused with the first codon of the sequence encoding, on the one hand, the mature α globin chain (deletion of the initiator ATG) and, on the other hand, the mature β globin chain (deletion of the initiator ATG) while maintaining the open reading frames.
This N-terminal transit peptide, composed of 57 amino acids, as defined by Anderson et al. (1986), was isolated from the plasmid pJIT117 (Guerineau et al., 1988) and used during the carrying out of the constructions.
a. CONSTRUCTION OF THE PLASMID pBIOC55 CONTAINING THE cDNA ENCODING α GLOBIN FOR CHLOROPLAST TARGETING.
To obtain chloroplast targeting of the α globin chain, the sequence encoding the transit peptide of the precursor of the small subunit of the ribulose 1,5-diphosphate carboxylase of Pisum sativum L. was fused with the first codon of the sequence encoding the mature α globin chain while maintaining the open reading frame. The cleaving sequence between the sequences of the transit peptide and of the mature α globin chain is Cys-Val.
The sequence of the transit peptide of the precursor of the small subunit of ribulose 1,5-diphosphate carboxylase was amplified by PCR on the plasmid pJIT117 with the aid of the 2 oligodeoxynucleotides, WD21 (5′ cgcaagcttaaca ATG GCT TCT ATG ATA TCC TCT TCA GC 3′; SEQ ID NO: 15) and WD22 (5′ tag aat tC GGC cGG AGA CAG CAC GCA CTT TAC TCT TCC ACC ATT GC 3′; SEQ ID NO: 16). The WD21 primer provides the HindIII restriction site, the aaca sequence promoting the initiation of translation (Joshi, 1987) and the first 8 codons of the transit peptide (including the initiator ATG). The WD22 primer provides the EcoRI restriction site, the first 5 codons of the sequence encoding the mature a globin chain (an EagI restriction site is created by silent mutation in the fourth codon (CCT modified to CCg)) and the last 7 codons of the sequence of the transit peptide. The PCR amplification and the treatment of the amplified DNA fragments were carried out as described in the third stage of section II.a.
Next, these DNA fragments were doubly digested with HindIII and EcoRI and cloned at the HindIII and EcoRI sites of the plasmid pNEB193 marketed by New England Biolabs. The plasmid pNEB193 was dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC54. The nucleotide sequence of this chimeric gene resulting from the translational fusion between the sequence encoding the transit peptide and the cDNA encoding the mature α globin chain was verified by sequencing as described in section I.b.
From the plasmid pBIOC54, the HindIII-EagI fragment, carrying the sequence encoding the transit peptide of the precursor of the small subunit of ribulose 1,5-diphosphate carboxylase and the first 4 codons of the mature α globin chain was isolated by double digestion, HindIII (total digestion) and EagI (partial digestion). This HindIII-EagI fragment, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) was cloned at the HindIII and EagI sites of the dephosphorylated plasmid pBIOC44 as described in section II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC55. The nucleotide sequence of this chimeric gene resulting from the translational fusion between the sequence encoding the transit peptide and the cDNA encoding the mature α globin chain was verified by sequencing as described in section I.b.
b. CONSTRUCTION OF THE PLASMID pBIOC57 CONTAINING THE cDNA ENCODING β GLOBIN FOR CHLOROPLAST TARGETING.
To obtain chloroplast targeting of the β globin chain, the sequence encoding the transit peptide of the Pisum sativum L. ribulose 1,5-diphosphate carboxylase small subunit precursor was fused with the first codon of the sequence encoding the mature β globin chain while maintaining the open reading frame. The cleaving sequence between the sequences of the transit peptide and the mature β globin chain is Cys—Val.
The sequence encoding transit peptide of the ribulose 1,5-diphosphate carboxylase small subunit precursor was amplified by PCR on the plasmid pJIT117 with the aid of the 2 oligodeoxynucleotides, WD23 (5′ gtcattaattaaca ATG GCT TCT ATG ATA TCC TCT TCA GCT GTG 3′; SEQ ID NO: 17) and WD24 (5′ aatgagct C GGC cGA CTT CTC CTC AGG AGT CAG GTG CAC GCA CTT TAC TCT TCC ACC 3′; SEQ ID NO: 18). The WD23 primer provides the PacI restriction site, the aaca sequence promoting the initiation of translation (Joshi, 1987) and preceding the first 10 codons of the transit peptide (including the initiator ATG). The WD24 primer provides the SacI restriction site, the first 10 codons of the sequence encoding the mature β globin chain (an EagI restriction site is created by silent mutation in the ninth codon (TCT modified to TCg)) and the last 6 codons of the sequence of the transit peptide. The PCR amplification and the treatment of the amplified DNA fragments were carried out as described in the third stage of section II.a. Next, these DNA fragments were doubly digested with PacI and SacI, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) and cloned at the PacI and SacI sites of the plasmid pNEB193 marketed by New England Biolabs. The plasmid pNEB193 was dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC56. The nucleotide sequence of this chimeric gene resulting from the translational fusion between the sequence encoding the transit peptide and the cDNA encoding the mature β globin chain was verified by sequencing as described in section I.b.
From the plasmid pBIOC56, the PacI-EagI fragment, carrying the sequence of the transit peptide of the ribulose 1,5-diphosphate carboxylase small subunit precursor and the first 9 codons of the sequence encoding the mature β globin chain, was isolated by double digestion, PacI (total digestion) and EagI (partial digestion). This PacI-EagI fragment, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101), was cloned at the PacI and EagI sites of the dephosphorylated plasmid pBIOC45 as described in section II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990), and analyzed by enzymatic digestion. The resulting clone was called pBIOC57. The nucleotide sequence of this chimeric gene resulting from the translational fusion between the sequence encoding the transit peptide and the cDNA encoding the mature β globin chain was verified by sequencing as described in section I.b.
c. CONSTRUCTION OF THE CO-EXPRESSION BINARY PLASMID pBIOC59 CONTAINING THE cDNAs ENCODING THE α AND β GLOBINS, FOR CHLOROPLAST TARGETING.
The HindIII-EcoRI fragment carrying the cDNA encoding the chloroplast targeting α globin chain was isolated from pBIOC55 described in section IV.a., and ligated to the plasmid DNA of pBIOC43 doubly digested with HindIII and EcoRI and dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC58.
The PacI-MluI fragment carrying the cDNA encoding the chloroplast targeting β globin chain was isolated from pBIOC57 described in section IV.b., and ligated to the plasmid DNA of pBIOC58 doubly digested with PacI and MluI, and dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section II.c.3 using the E. coli Sure tet − strain. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC59.
The nucleotide sequence of the cDNAs encoding the recombinant α and β globin chains allowing chloroplast targeting was verified by sequencing as described in section I.b. The plasmid DNA of the binary vector pBIOC59 was introduced by direct transformation into the Agrobacterium tumefaciens LBA4404 strain according to the method of Holsters et al. (1978). The validity of the clone selected was verified by enzymatic digestion of the plasmid DNA introduced.
V. CONSTRUCTION OF THE CHIMERIC GENES ENCODING THE α AND β GLOBIN CHAINS ALLOWING EXPRESSION OF THE RECOMBINANT HUMAN HEMOGLOBIN FOR SECRETION IN TOBACCO LEAVES
To obtain secretion, the sequence encoding the signal peptide (SP) of sporamine A of the tuberized roots of sweet potato (Murakami et al., 1986; Matsuoka and Nakamura, 1991) (ATG AAA GCC TTC ACA CTC GCT CTC TTC TTA GCT CTT TCC CTC TAT CTC CTG CCC AAT CCA GCC CAT TCC; SEQ ID NO: 19), is fused with the first codon of the sequence encoding, on the one hand, the mature α globin chain (deletion of the initiator ATG) and, on the other hand, the mature β globin chain (deletion of the initiator ATG) while maintaining the open reading frames. This signal peptide of 23 amino acids was isolated from the plasmid pMAT103 (Matuoka and Nakamura, 1991) and used during the carrying out of the constructions.
a. CONSTRUCTION OF THE PLASMID pBIOC60 CONTAINING THE cDNA ENCODING α GLOBIN FOR SECRETION.
To obtain the secretion of the α globin chain, the sequence encoding the signal peptide of sweet potato sporamine A was fused with the first codon of the mature α globin chain while maintaining the open reading frame. The cleaving sequence between the sequences of the signal peptide and the mature a globin chain is Ser-Val.
The sequence encoding the signal peptide (SP) of the sporamine A of the tuberized roots of sweet potato was amplified by PCR on the plasmid pMAT103 with the aid of 2 oligodeoxynucleotides, WD25 (5′ cgcaagcttaaca ATG AAA GCC TTC ACA CTC GC 3′; SEQ ID NO: 20) and WD26 (5′ tagaattC GGC cGG AGA CAG CAC GGA ATG GGC TGG ATT GGG CAG G 3′; SEQ ID NO: 21). The WD25 primer provides the HindIII restriction site, the aaca sequence promoting the initiation of translation (Joshi, 1987) and the first 6 codons of the signal peptide (including the initiator ATG). The WD26 primer provides the EcoRI restriction site, the first 5 codons of the sequence encoding the mature α globin chain (an EagI restriction site is created by silent mutation in the fourth codon (CCT modified to CCg)) and the last 7 codons of the sequence of the signal peptide. The PCR amplification and the treatment of the amplified DNA fragments were carried out as described in the third stage of section II.a. Next, these DNA fragments were doubly digested with Hindll and EagI, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) and cloned at the HindIII and EagI sites of the dephosphorylated plasmid pBIOC44 described in section II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC60. The nucleotide sequence of this chimeric gene resulting from the translational fusion between the sequence encoding the signal peptide and the cDNA encoding the mature a globin chain was verified by sequencing as described in section I.b.
b. CONSTRUCTION OF THE PLASMID pBIOC61 CONTAINING THE cDNA ENCODING THE β GLOBIN FOR SECRETION.
To obtain the secretion of the β globin chain, the sequence encoding the signal peptide of the sweet potato sporamine A was fused with the first codon of the mature β globin chain while maintaining the open reading frame. The cleaving sequence between the sequences of the signal peptide and the mature β globin chain is Ser-Val.
The sequence encoding the signal peptide (SP) of the sporamine A of the tuberized roots of sweet potato was amplified by PCR on the plasmid pMAT103 with the aid of the 2 oligodeoxynucleotides, WD27 (5′ gtcattaattaaca ATG AAA GCC TTC ACA CTC GC 3′; SEQ ID NO: 22) and WD28 (5′ aatgagct C GGC cGA CTT CTC CTC AGG AGT CAG GTG CAC GGA ATG GGC TGG ATT GGG CAG G 3′; SEQ ID NO: 23). The WD27 primer provides the PacI restriction site, the aaca sequence promoting the initiation of translation (Joshi, 1987) and the first 6 codons of the signal peptide (including the initiator ATG). The WD28 primer provides the SacI restriction site, the first 10 codons of the sequence encoding the mature β globin chain (an EagI site is created by silent mutation in the ninth codon (TCT modified to TCg)) and the last 7 codons of the sequence of the signal peptide. The PCR amplification and the treatment of the amplified DNA fragments were carried out as described in the third stage of section II.a. Next, these DNA fragments were doubly digested with PacI and EagI, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) and cloned at the PacI and EagI sites of the dephosphorylated plasmid pBIOC45 described in section II.b. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC61. The nucleotide sequence of this chimeric gene resulting from the translational fusion between the sequence encoding the signal peptide and the cDNA encoding the mature β globin chain was verified by sequencing as described in section I.b.
c. CONSTRUCTION OF THE CO-EXPRESSION BINARY PLASMID pBIOC63 CONTAINING THE cDNAs ENCODING THE α AND β GLOBINS FOR SECRETION.
The HindIII-EcoRI fragment carrying the cDNA encoding the α globin chain for secretion was isolated from pBIOC60 described in section V.a., and ligated to the plasmid DNA of pBIOC43 doubly digested with HindIII and EcoRI, and dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section II.c.3 using the E. coli Sure tet strain. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC62.
The PacI-MluI fragment carrying the cDNA encoding the β globin chain for secretion was isolated from pBIOC61 described in section V.b., and ligated to the plasmid DNA of pBIOC62 doubly digested with PacI and MluI, and dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracyclin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC63.
The nucleotide sequence of the cDNAs encoding the α and β globin chains for secretion was verified by sequencing as described in section I.b. The plasmid DNA of the binary vector pBIOC63 was introduced by direct transformation into the Agrobacterium tumefaciens LBA4404 strain according to the method of Holsters et al. (1978). The validity of the clone selected was verified by enzymatic digestion of the plasmid DNA introduced.
VI. CONSTRUCTION OF THE CHIMERIC GENES ENCODING THE α AND β GLOBIN CHAINS ALLOWING EXPRESSION OF RECOMBINANT HUMAN HEMOGLOBIN IN THE ENDOPLASMIC RETICULUM OF TOBACCO LEAVES
The sequence encoding the KDEL signal (Lys-Asp-Glu-Leu), placed at the C-terminal end of the α and β globin chains upstream of the stop codon combined with the presence of the sequence encoding the N-terminal signal peptide (SP) of sporamine A of the tuberized roots of sweet potato allows targeting in the endoplasmic reticulum.
a. CONSTRUCTION OF THE PLASMID pBIOC65 CONTAINING THE cDNA ENCODING THE α GLOBIN ALLOWING RETENTION IN THE ENDOPLASMIC RETICULUM.
To obtain retention in the endoplasmic reticulum, the sequence encoding the KDEL signal (5′ aaa gat gag cta 3′; SEQ ID NO: 24) was placed before the first stop codon (TGA) of the mature α globin chain while maintaining the open reading frame.
The plasmid containing the cDNA encoding the α globin chain which contains the sequence encoding the KDEL signal placed before its first stop codon was obtained by following the same steps as for the manufacture of the plasmid pBIOC44 described in II.a. except that the WD29 primer (5′ gcgaattc TCA tag ctc atc ttt ACG GTA TTT GGA GGT CAG CAC 3′; SEQ ID NO: 25) replaces the WD14 primer. The WD29 primer provides the EcoRi restriction site and the KDEL sequence situated respectively after and before the stop codon.
The resulting plasmid obtained was called pBIOC64. The nucleotide sequence of the chimeric gene between the cDNA encoding the α globin chain and the sequence encoding the α KDEL signal was verified by sequencing as described in section I.b.
Next, the plasmid pBIOC64 was modified as described in V.a. by translational fusion with the signal peptide of sporamine A of the tuberized roots of sweet potato to give the plasmid pBIOC65 allowing targeting in the endoplasmic reticulum. The nucleotide sequence of the chimeric gene between the sequence encoding the signal peptide, the cDNA encoding the mature α globin chain and the sequence encoding the KDEL signal was verified by sequencing as described in section I.b. The cleaving sequence between the sequences of the signal peptide and the mature α globin chain is Ser—Val.
b. CONSTRUCTION OF THE PLASMID pBIOC67 CONTAINING THE cDNA ENCODING THE β GLOBIN ALLOWING RETENTION IN THE ENDOPLASMIC RETICULUM.
To obtain retention in the endoplasmic reticulum, the sequence encoding the KDEL signal (5′ aaa gat gag cta 3′; SEQ ID NO: 24) was placed before the first stop codon (TAA) of the mature βglobin chain while maintaining the open reading frame.
The plasmid containing the cDNA encoding the β globin chain which contains the sequence encoding the KDEL signal before its first stop codon was obtained by following the same steps as for the manufacture of the plasmid pBIOC45 described in II.b., except that the WD30 primer (5′aatgagctcgttaacgcgt TTA tag ctc atc ttt GTG ATA CTT GTG GGC CAG GGC 3′; SEQ ID NO: 26) replaces the WD16 primer. The WD30 primer provides the MluI, HpaI and SacI restriction sites and the KDEL sequence placed respectively after and before the stop codon.
The resulting plasmid obtained was called pBIOC66. The nucleotide sequence of the chimeric gene between the cDNA encoding the β globin chain and the sequence encoding the KDEL signal was verified by sequencing as described in section I.b.
Next, the plasmid pBIOC66 was modified as described in V.b. by translational fusion with the signal peptide of the sporamine A of the tuberized roots of sweet potato to give the plasmid pBIOC67 allowing targeting in the endoplasmic reticulum. The nucleotide sequence of the chimeric gene between the sequence encoding the signal peptide, the cDNA encoding the mature β globin chain and the sequence encoding the KDEL signal was verified by sequencing as described in section I.b. The cleaving sequence between the sequences of the signal peptide and the mature β globin chain is Ser—Val.
c. CONSTRUCTION OF THE CO-EXPRESSION BINARY PLASMID pBIOC69 CONTAINING THE cDNAs ENCODING THE α AND β GLOBINS ALLOWING RETENTION IN THE ENDOPLASMIC RETICULUM.
The HindIII-EcoRI fragment carrying the cDNA encoding the α globin chain allowing retention in the endoplasmic reticulum was isolated from pBIOC65 described in section VI.a., and ligated to the plasmid DNA of pBIOC43 doubly digested with HindIII and EcoRI, and dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracyclin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC68.
The PacI-MluI fragment carrying the cDNA encoding the β globin chain allowing retention in the endoplasmic reticulum was isolated from pBIOC67 described in section VI.b., and ligated to the plasmid DNA of pBIOC68 doubly digested with PacI and MluI, and dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section II.c.3 using the E. coli Sure tet − strain. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracyclin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC69.
The nucleotide sequence of the cDNAs encoding the α and β globin chains allowing their retention in the endoplasmic reticulum was verified by sequencing as described in section I.b. The plasmid DNA of the binary vector pBIOC69 was introduced by direct transformation into the Agrobacterium tumefaciens LBA4404 strain according to the method of Holsters et al. (1978). The validity of the clone selected was verified by enzymatic digestion of the plasmid DNA introduced.
VII. CONSTRUCTION OF THE CHIMERIC GENES ENCODING THE α AND β GLOBIN CHAINS ALLOWING EXPRESSION OF THE RECOMBINANT HUMAN HEMOGLOBIN IN THE VACUOLES OF TOBACCO LEAVES
To allow vacuolar targeting, the sequence encoding the prepropeptide (PPS) of sporamine A of the tuberized roots of sweet potato (Murakami et al., 1986; Matsuoka and Nakamura, 1991), which corresponds to the signal peptide followed by the N-terminal sequence for vacuolar targeting (ATG AAA GCC TTC ACA CTC GCT CTC TTC TTA GCT CTT TCC CTC TAT CTC CTG CCC AAT CCA GCC CAT TCC AGG TTC AAT CCC ATC CGC CTC CCC ACC ACA CAC GAA CCC GCC; SEQ ID NO: 27), is fused with the first codon of the sequence encoding, on the one hand, the mature α globin chain (deletion of the initiator ATG) and, on the other hand, the mature β globin chain (deletion of the initiator ATG) while maintaining the open reading frames. This prepropeptide of 37 amino acids was isolated from the plasmid pMAT103 (Matuoka and Nakamura, 1991) and used during the carrying out of the constructions.
To obtain vacuolar targeting of the α globin chain, the sequence encoding the prepropeptide of sweet potato sporamine A was fused with the first codon of the mature α globin chain while maintaining the open reading frame. The cleaving sequence between the sequences of the signal peptide and the mature α globin chain is Ala—Val.
a. CONSTRUCTION OF THE PLASMID pBIOC70 CONTAINING THE cDNA ENCODING THE α GLOBIN ALLOWING VACUOLAR TARGETING.
The sequence encoding the N-terminal prepropeptide (PPS) of the sporamine A of the tuberized roots of sweet potato was amplified by PCR on the plasmid pMAT103 with the aid of the 2 oligodeoxynucleotides, WD25 (5′ cgcaagcttaaca ATG AAA GCC TTC ACA CTC GC 3′; SEQ ID NO: 20) described in V.a. and WD31 (5′ tagaattC GGC cGG AGA CAG CAC GGC GGG TTC GTG TGT GGT TG 3′; SEQ ID NO: 28). WD31 primer provides the EcoRI restriction site, the first 5 codons of the sequence encoding the mature α globin chain (an EagI site is created by silent mutation in the fourth codon (CCT modified to CCg)) and the last 6 codons of the sequence of the N-terminal prepropeptide. The PCR amplification and the treatment of the amplified DNA fragments were carried out as described in the third stage of section II.a. Next, these DNA fragments were doubly digested with HindIII and EagI, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) and cloned at the HindIII and EagI sites of the dephosphorylated plasmid pBIOC44 described in section II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC70. The nucleotide sequence of the chimeric gene between the sequence encoding the prepropeptide and the cDNA encoding the mature α globin chain was verified by sequencing as described in section I.b.
b. CONSTRUCTION OF THE PLASMID pBIOC71 CONTAINING THE cDNA ENCODING β GLOBIN ALLOWING VACUOLAR TARGETING.
To obtain vacuolar targeting of the β globin chain, the sequence encoding the prepropeptide of sporamine A of sweet potato was fused with the first codon of the mature β globin chain while maintaining the open reading frame. The cleaving sequence between the sequences of the signal peptide and the mature β globin chain is Ala—Val.
The sequence encoding the N-terminal prepropeptide (PPS) of sporamine A of the tuberized roots of sweet potato was amplified by PCR on the plasmid pMAT103 with the aid of the 2 oligodeoxynucleotides, WD27 (5′ gtcattaattaaca ATG AAA GCC TTC ACA CTC GC 3′; SEQ ID NO: 22) described in V.b. and WD32 (5′ aatgagct C GGC cGA CTT CTC CTC AGG AGT CAG GTG CAC GGC GGG TTC GTG TGT GGT TG 3′; SEQ ID NO: 29). The WD32 primer provides the SacI restriction site, the first 10 codons of the sequence encoding the mature β globin chain (an EagI restriction site is created by silent mutation in the ninth codon (TCT modified to TCg)) and the last 6 codons of the sequence of the N-terminal prepropeptide. The PCR amplification and the treatment of the amplified DNA fragments were carried out as described in the third stage of section II.a. Next, these DNA fragments were doubly digested with PacI and EagI, purified by electrophoresis on a 1.8% agarose gel and by the action of the “Geneclean II” kit (BIO101) and cloned at the PacI and EagI sites of the dephosphorylated plasmid pBIOC45 described in section II.b. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 100 μg/ml ampicillin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC71. The nucleotide sequence of the chimeric gene between the sequence encoding the prepropeptide and the cDNA encoding the mature β globin chain was verified by sequencing as described in section I.b.
c. CONSTRUCTION OF THE CO-EXPRESSION BINARY PLASMID pBIOC73 CONTAINING THE cDNAs ENCODING THE α AND β GLOBINS ALLOWING VACUOLAR TARGETING.
The HindIII-EcoRI fragment carrying the cDNA encoding the vacuolar targeting α globin chain was isolated from pBIOC70 described in section VII.a., and ligated to the plasmid DNA of pBIOC43 doubly digested with HindIII and EcoRI, and dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section I.b. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracyclin, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC72.
The PacI-MluI fragment carrying the cDNA encoding the vacuolar targeting β globin chain was isolated from pBIOC71 described in section VII.b., and ligated to the plasmid DNA of pBIOC72 doubly digested with PacI and MluI, and dephosphorylated as described in II.a. The ligation and the transformation were carried out as described in section II.c.3. using the E. coli Sure tet − strain. The plasmid DNA of the clones obtained, selected on 10 μg/ml tetracycline, was extracted according to the alkaline lysis method (Stephen et al., 1990) and analyzed by enzymatic digestion. The resulting clone was called pBIOC73.
The nucleotide sequence of the cDNAs encoding the vacuolar targeting α and β globin chains was verified by sequencing as described in section I.b. The plasmid DNA of the binary vector pBIOC73 was introduced by direct transformation into the Agrobacterium tumefaciens LBA4404 strain according to the method of Holsters et al. (1978). The validity of the clone selected was verified by enzymatic digestion of the plasmid DNA introduced.
VIII: PRODUCTION OF TRANSGENIC TOBACCO PLANTS
The tobacco plants used for the transformation experiments ( Nicotiana tabacum var. PBD6) are cultured in vitro on Murashige and Skoog basic medium (1962) supplemented with Gamborg et al. vitamins (1968, Sigma reference M0404), sucrose at 20 g/l and agar (Merck) at 8 g/l. The pH of the medium is adjusted to 5.8 with a solution of potassium hydroxide before autoclaving at 120° C. for 20 min. The tobacco plantlets are transplanted by taking internode cuttings every 30 days on this MS20 propagation medium.
All the in vitro cultures are carried out in an air-conditioned chamber under the conditions defined below:
Light intensity of 30 μE.m −2 . S −1 ; photoperiod of 16 h;
Thermoperiod of 26° C. by day, 24° C. by night.
The transformation technique used is derived from that of Horsch et al. (1985).
A preculture of Agrobacterium tumefaciens LBA4404 strain containing the plasmids pBIOC46 or pBIOC47 or pBIOC49 or pBIOC53 or pBIOC59 is carried out for 48 h at 28° C., with stirring, in LB medium supplemented with appropriate antibiotics (rifampicin and tetracycline). The preculture is then diluted 50-fold in the same medium and cultured under the same conditions. After one night, the culture is centrifuged (10 min, 3000 g), the bacteria are taken up in an equivalent volume of liquid MS30 medium (30 g/l sucrose) and this suspension is diluted 10-fold.
Explants of about 1 cm 2 are cut from the leaves of the plantlets described above. They are then brought into contact with the bacterial suspension for 1 h, and then dried rapidly on filter paper and placed on a coculture medium (solid MS30).
After 2 days, the explants are transferred to Petri dishes on MS30 regeneration medium containing a selective agent, kanamycin (200 mg/l), a bacteriostatic, augmentin (400 mg/l) and the hormones necessary for the induction of buds (BAP, 1 mg/l and NAA, 0.1 mg/l) . A transplantation of the explants is carried out on the same medium after 2 weeks of culture. After a further 2 weeks, the buds are transplanted into Petri dishes on the development medium composed of the MS20 medium supplemented with kanamycin and augmentin. After 15 days, the buds are transplanted into pots on the same medium whose kanamycin concentration has been decreased by one half. The rooting takes about 20 days, at the end of which the plantlets can be cloned using internode cuttings in vitro or taken out to the greenhouse.
IX: PARTIAL EXTRACTION AND PARTIAL PURIFICATION OF RECOMBINANT PROTEINS FROM TOBACCO LEAVES
Fifty grams of transformed tobacco leaves (fresh weight) are ground in liquid nitrogen and then left stirring for 15 min at 4° C. in 300 ml of 50 mM tris-HCl buffer pH 8 supplemented with 1 mM EDTA, 1 mM β-mercaptoethanol and polyvinylpyrrolidone (PVP, 10 g/300 ml). The ground product is filtered on miracloth and then centrifuged for 20 min at 4° C. at 10000 g. The supernatant is again filtered on miracloth. The proteins are then precipitated for 12 h at 4° C. with a solution of ammonium sulfate at saturation. After centrifuging for 20 min at 10000 g, the pellet is taken up in 50 mM tris-HCl buffer pH 8 supplemented with 1 mM DTT and 1 mM EDTA and dialyzed twice 12 hours against this same buffer. After dialysis, the retentate is centrifuged and then filtered on miracloth. An assay of proteins is also carried out according to the Bradford technique (1976).
First purification step: Equilibration in 10 mM phosphate buffer pH 6.7-1 mM EDTA by passing over a Sephadex G25 resin and then loading onto an ion-exchange resin (CM cellulose) equilibrated in 10 mM phosphate buffer pH 6.7, 1 mM EDTA. Washing with 4 volumes of this same buffer and then eluting with a linear gradient from 10 mM Na 2 HPO 4 pH 6.7, 1 mM EDTA to 100 mM Na 2 HPO 4 pH 6.7, 1 mM EDTA.
Second purification step: Equilibration in 10 mM Tris-HCl buffer pH 8.4-1 mM EDTA by passing over a Sephadex G25 resin and then loading onto an ion-exchange resin DEAE-Sephacel equilibrated in 10 mM Tris-HCl buffer pH 8.4, 1 mM EDTA. Washing with 4 volumes of this same buffer and then eluting with a 20 mM KH 2 PO 4 buffer pH 7.4. The pH and ionic strength conditions can be modified according to the nature of the hemoglobin variant.
Detection of hemoglobin
Hemoglobin (Hb) is detected by virtue of its chromophore, heme, which gives it its characteristic color. At low concentration and in the presence of another chromophore or molecule which scatters light, the signal due to Hb may be masked. This problem can be overcome using a dynamic technique which makes it possible to detect the presence of Hb in a complex system.
This method is based on differential spectra corresponding to a transition between two forms of Hb and on the photodissociation properties of ligands such as O 2 and CO (Gibson, 1956; Mardenet et al., 1994). The probability of dissociation being higher for CO, this ligand is therefore preferably used. The preparation of the samples is carried out under anaerobic conditions.
The experimental equipment is composed of two sources of light: the first is a pulsed source (laser) which dissociates the ligands, and the second is a continuous lamp which makes it possible to observe the recombination of the ligands by virtue of a change in the intensity of light transmitted (FIGS. 4, 5 and 6 ). The photodissociation is efficient in the entire visible spectral domain; our system consists of a YAG laser whose pulses have a duration of 10 ns at 532 mm. The detection is more sensitive in the Soret band (416 nm); we chose 436 nm close to the maximum absorption of the deoxy form. The changes in transmitted intensity occur first of all in a time of the order of the nanosecond (geminate phase) and then continue in a few milliseconds (bimolecular phase). We are particularly interested in this second phase which reflects the allosteric transitions of Hb (FIGS. 5 and 6 ). Rapid and reversible kinetic studies make it possible to obtain numerous data and therefore a reliable indication of the state of Hb as regards its normal, physiological function.
The preparation of the samples is carried out as described below. The tobacco leaves (20 g) are ground in liquid nitrogen and then the ground product is mixed with 60 ml of the extraction solution (25 mM Tris-HCl pH 7.5, 10 mM β-mercaptoethanol, 1 mM EDTA). The homogenate is centrifuged at 10000 g at 4° C. for 15 minutes. The supernatant containing the soluble proteins is collected. The assay of the proteins is carried out according to the Bradford technique (1976). To 1 ml of plant protein extract (1 mg/ml) are added 32 μl and 3.2 μl of a concentrated human hemoglobin solution (3.13 mg/ml) in order to obtain solutions containing 100%, 10% and 1% hemoglobin, respectively, relative to the total proteins.
The results obtained are the following:
The kinetics of the samples equilibrated under 0.1 atm CO for three Hb concentrations: 100%, 10% and 1% of the total proteins present in the extract in an amount of 1 mg/ml were measured. The curves are biphasic, similar to those of Hb alone, and exhibit a normal speed (of the order of 1000/s) for the rapid phase (FIG. 5 ). The kinetics are similar for the two concentrations, with the exception of the increase in noise (signal) predictable at low concentration. No signal was observed for the plant extract in the absence of Hb, under the same conditions. We can conclude that the kinetics of recombination of CO with HbA in an extract of tobacco leaves is normal.
X: EXTRACTION AND PARTIAL PURIFICATION OF RECOMBINANT HEMOGLOBIN FROM TOBACCO SEEDS
In this section, the techniques used for the detection by Western blotting, the extraction and partial purification and the demonstration of the functionality of the recombinant hemoglobin produced in the seeds of transgenic tobacco plants (rHb), are described. The latter are obtained by transformation of the coexpression plasmid PBIOC 59 containing the cDNAs encoding the α and β globins allowing targeting in the chloroplast.
a. WESTERN-BLOT DETECTION OF THE RECOMBINANT HEMOGLOBIN ACCUMULATED IN TOBACCO SEEDS
Seventy-five milligrams of tobacco seeds (fresh weight) are ground in liquid nitrogen and then in 600 μl of 25 mM ice-cold Tris-HCl buffer pH 8 supplemented with 1 mM EDTA, 1 mM DTT and 1 mM PMSF. The ground product is transferred into an Eppendorf tube and centrifuged at 4° C. at 10000 g for 10 min. The supernatant is then concentrated by ultrafiltration with the aid of the micropure 0.45 and microcon 10 devices (Amicon). The assay of the proteins is carried out according to the Bradford technique (1976) using bovine serum albumin (fraction V) as standard.
The proteins are separated according to their apparent molecular mass by polyacrylamide gel electrophoresis in the presence of SDS according to the Laemmli method (Laemmli, 1970) under reducing conditions. The apparatus used is the Mini-protean II (Bio-Rad). The gel consists of a concentration gel (5% acrylamide, 0.17% bis-acrylamide, 63 mM Tris-HCl pH 6.8, 0.1% SDS) and a separating gel (17% acrylamide) 0.56% bis-acrylamide, 375 mM Tris-HCl pH 8.8, 0.1% SDS). The protein samples are previously diluted with 0.25 volume of loading solution (200 mM Tris-HCl pH 6.8, 400 mM DTT, 40% glycerol, 8% SDS, 0.2% bromophenol blue), then treated at 100° C. for 5 min and finally loaded onto the gel. The electrophoresis is carried out in Tris-glycine-SDS buffer (25 mM Tris, 250 mM glycine, 1% SDS) at 25 mA.
After electrophoresis, the proteins are transferred onto a nitrocellulose membrane (BA 85, Schleicher & Schuell) by electrotransfer according to the Towbin et al. technique (1979). The transfer is carried out with the aid of the “mini trans blot module” apparatus (Bio-Rad) at 150 V for 90 min in the presence of the transfer solution (25 mM Tris, 192 mM glycine, 20% methanol). The membrane is rinsed for 5 min at room temperature in 1×PBS (10.4 mM Na 2 HPO 4 , 3.2 mM KH 2 PO 4 , 116 mM NaCl) buffer and then dried.
The presence of the globin chains on the Western-blots is detected using, as primary antibody, a rabbit anti-human hemoglobin immune serum (ref: H-4890, Sigma) and, as secondary antibody, an anti-rabbit IgG monoclonal antibody coupled to alkaline phosphatase (A-8025, Sigma). The revealing is performed using the chromogenic substrate [5-bromo-4-chloro-3-indoyl phosphate/nitro blue tetrazolium (BCIP/NBT)].
The membrane is incubated, with stirring, for 5 min in a TBST buffer solution (10 mM Tris-HCl pH 7.5, 150 mM NaCl, 0.05% Tween 20), and then for at least 30 min in the same solution supplemented with 5% skimmed milk powder (Regilait). The latter solution is replaced, 1/5000 of the volume of anti-hemoglobin immune serum is added and the membrane is incubated for at least 2 hours. It is rinsed 3 times 5 min with TBST solution. The incubation with the secondary antibody is carried out for 1 hour with the anti-rabbit IgG monoclonal antibody diluted 1/10000 in the TBST solution. Next, the membrane is again rinsed 3 times. The alkaline phosphatase activity is revealed by incubating the membrane in the revealing solution (100 mM Tris-HCl pH 9.5, 100 mM NaCl, 5 MM MgCl 2 , 330 μg/ml BCIP, 165 μg/ml NBT). The reaction is stopped by rinsing with water.
FIG. 7 represents the Western-blot analysis of the protein composition of the extracts of seeds of tobacco plants transformed or otherwise with the plasmid pBIOC59. The polyclonal antibody recognizes the two normal adult hemoglobin (HbA) globin chains separated during the SDS-PAGE electrophoresis. It is observed that the protein extract of the seeds of the transgenic plant T26-22 differs from that of the control plant in the presence of two polypeptides whose apparent molecular mass is similar to that of the globin chains of HbA and which are recognized by the antibody. Furthermore, they appear to be represented in an equimolar manner. It can therefore be said that in the seeds, the transgenes encoding the fusion proteins transit peptide-α globins and transit peptide-β globin are expressed; the cleaving of the transit peptide would be correctly performed, such that the α and β globins accumulate. In the seeds of 11 plants, of the 20 tobacco plants transformed independently with the plasmid pBIOC59, the presence of the globins is detected. Expressed as equivalents of HbA, the maximum level of about 0.05% rHb relative to the total soluble proteins extracted is observed for the plant T26-22. It was possible to assess this by comparative Western-blot analysis of HbA concentration ranges in the protein extract of control plant seeds.
b. EXTRACTION AND PARTIAL PURIFICATION OF RECOMBINANT HEMOGLOBIN FROM TOBACCO SEEDS.
The partial purification was carried out using as starting material a mixture of the seeds of transgenic tobacco plants transformed with the plasmid pBIOC59 and expressing the rHb.
Fifteen grams of tobacco seeds (fresh weight) are ground in liquid nitrogen and then in 100 ml of 25 mM ice-cold Tris-HCl buffer pH 8 supplemented with 1 mM EDTA, 1 mM DTT and 1 mM PMSF. The ground product is filtered on miracloth® and then the filtrate is centrifuged at 4° C. at 10000 g for 10 min. The supernatant is first saturated with carbon monoxide (CO) and then filtered with a 0.22 μm filter and finally concentrated by ultrafiltration with the aid of centriprep 10 devices (Amicon). The concentrate is saturated with CO. Two successive chromatographic steps are carried out (4° C.) while monitoring the absorbance values at 280 nm (proteins) and 415 nm (hemoproteins). (i) The concentrate is previously filtered with a 0.22 μm filter and then loaded onto a Sephacryl-S100 column (Pharmacia) (2.1 cm×90 cm) equilibrated with buffer D (9.12 mM Na 2 HPO 4 , 20.88 mM NaH 2 PO 4 , 1 mM DTT, 1 mM EDTA, pH 6.5). The fraction containing the rHb is collected, filtered through a 0.22 μm filter and then saturated with CO and finally concentrated as above. Sixty-five percent of the proteins are removed at this stage. (ii) This concentrate is loaded onto the second column, a fast-flow S-sepharose (Pharmacia) (1.1 cm×10 cm) equilibrated with buffer D. After washing with 8 volumes of buffer D, an ionic strength gradient is applied (buffer D to buffer D containing 500 mM NaCl). The hemoglobin is eluted as one peak. The fractions containing this peak are combined and the proteins are concentrated as described above. Before and after concentrating, the samples are saturated with CO. This concentrate constitutes the rHb-enriched fraction called FE-rHb. Only 3% of the proteins of the extract now remain in this fraction. To obtain a control for subsequent analyzes, this purification scheme was applied under the same conditions to an extract obtained from 15 g of tobacco seeds not expressing rHb, leading to the production of the fraction called FE-Control.
The presence of the α and β globins in these fractions was tested for using the Western-blot technique under the conditions described in paragraph X.a. The FE-rHb fraction indeed contains rHb, these two polypeptides being detected (FIG. 8 ).
c. DEMONSTRATION OF THE FUNCTIONALITY OF THE RECOMBINANT HEMOGLOBIN BY FLASH PHOTOLYSIS.
The demonstration of the functionality was performed using, as starting material, the rHb-enriched fraction called FE-rHb, using, as control, the equivalent control fraction FE-Control and HbA.
The control experiments where 1 F HbA was added to the plant extract showed biphasic recombination kinetics and variations of the slow fraction depending on the energy of the flash of laser light. These results demonstrate that the function of HbA is not altered by the solvent conditions used.
After photodissociation of the ligands from Hb, bimolecular recombination occurs within a time scale of μs-ms (k-on speed) . Although the natural physiological ligand is oxygen, the studies described were performed with carbon monoxide (CO) which gives a photo-dissociation signal which is much greater than that obtained with O 2 because the yield is higher. Likewise, the difference in the speeds of recombination for the two conformations of Hb (R and T corresponding to tetramers with and without ligand) is also higher. Experimentally, the samples are equilibrated under 0.1 atm CO which gives the best conditions of observation of the two phases. As the reaction is reversible, the photodissociation (γ) of the same sample can be repeated in order to accumulate several curves, which greatly improves the signal/noise ratio.
γ
HbCO→Hb+CO
k-on —CO
The observation of a variation of the amplitude of slow recombination as a function of the dissociation fraction (by modification of the laser energy) demonstrates the presence of a functional hemoglobin.
The transgenic plants receive genetic information only for the synthesis of globin and not for heme. Consequently, if functional Hb (globins+heme) is expressed in the plants, it means that it has captured the heme in situ. Other hemoproteins present in plants can give an optical signal after flash photolysis. These hemoproteins will not give a signal if the hemin iron is in the ferric form which does not bind the CO and O 2 ligands. CO and O 2 bind reversibly only if the iron atom is in the ferrous form. It is consequently important to demonstrate the existence of kinetic processes for the two phases and the variation in the relative contributions of the two phases due to factors known to influence the function of hemoglobin.
The enriched sample FE-rHb shows a CO photodissociation signal of 48 mOD (optical density) and makes it possible to carry out certain experiments at different levels of dissociation; these experiments are carried out in the absence of sodium dithionite in order to avoid any parasitic contribution due to the presence of hemoproteins. The same experiment, carried out with the FE-Control fraction showed a signal of 1 mOD (FIG. 9 ).
The results recorded at various levels of laser light energy are shown in FIG. 10 . The curves are similar to that of HbA and shows the existence of a characteristic property of hemoglobin, namely the lower fraction of slow speed when the light intensity is decreased so as to obtain a lower dissociation.
The sample was then equilibrated under a CO atmosphere. As expected, the recombination kinetics are thereafter more rapid. For hemoglobin in solution, the slow fraction is usually lower at high CO concentration since there is less time available to make the R→T transition after dissociation. The FE-rHb sample does not exhibit this effect (FIG. 11 ).
Another method can be used to study the speeds of association and of dissociation of oxygen. The principle of this method is based on the following fact: although CO has an affinity about 200 times higher than that of oxygen, the speed of association of CO with the ligand-containing Hb (R state) is about 10 times lower than for oxygen. A sample equilibrated with an equal mixture of CO and O 2 will be essentially in the HbCO form. It is then possible to photodissociate the CO (with a high yield), which allows the study of the recombination of O 2 . A slow terminal phase of the order of 1 s due to the replacement of oxygen by CO provides information on the speed of dissociation (k-off). Only the FE-rHb sample reveals a signal for binding of oxygen (FIG. 11 ).
The studies of the FE-rHb fraction by flash photolysis have shown:
a biphasic recombination of CO with rapid and slow speeds similar to those observed in tetrameric Hb A;
a decrease in the slow fraction at low laser energy as for Hb A;
an increase in speed for higher CO concentrations as for normal Hb;
a reversible binding of oxygen with on and off speeds similar to those of normal Hb A;
It can be concluded that the recombinant hemoglobin produced in tobacco seeds possesses the properties of tetrameric Hb A in all the functional tests carried out.
XI: CONSTRUCTION OF CHIMERIC GENES ENCODING THE α AND β CHAINS OF HUMAN HEMOGLOBIN AND ALLOWING EXPRESSION IN MAIZE SEEDS. CONSTRUCTION OF THE PLASMIDS CONTAINING ONE OF THE α OR β CHAINS OF HUMAN HEMOGLOBIN AND ALLOWING CONSTITUTIVE EXPRESSION OR EXPRESSION IN THE ALBUMIN IN MAIZE SEEDS
The constitutive or albumin-specific expression, in maize seeds, of the sequences of the α and β chains of human hemoglobin required the following regulatory sequences: one of the three promoters allowing a constitutive expression:
rice actin promoter followed by the rice actin intron (pAR-IAR) contained in the plasmid pAct1-F4 described by McElroy et al. (1991);
35S double constitutive promoter (pd35S) of CaMV (cauliflower mosaic virus). It corresponds to a duplication of the sequences activating transcription, situated upstream of the TATA element of the natural 35S promoter (Kay et al., 1987);
the promoter of the maize γzein gene (pγzein) contained in the plasmid pγ63 (Reina et al., 1990). The plasmid pγ63 results from the cloning of pγzein at the HindIII and XbaI sites of a plasmid pUC18 containing, between its HindIII and EcoRI sites, the expression cassette “p35S-gus-tNOS” of pBI221 marketed by Clontech. It allows expression in the albumin maize seeds. Combined with the rice actin intron, this promoter confers expression is of constitutive type; one of the two terminators:
the sequence for termination of transcription, 35S polyA terminator, which corresponds to the noncoding 3′ region of the sequence of the circular double-stranded DNA cauliflower mosaic virus producing the 35S transcript (Franck et al., 1980);
the sequence for termination of transcription, NOS polyA terminator, which corresponds to the noncoding 3′ region of the nopaline synthase gene of the Ti plasmid of nopaline-containing strain of Agrobacterium tumefaciens (Depicker et al., 1982).
The type of vector used is derived from pBSIISK+ (Stratagene). Each vector comprises an expression cassette, namely one of the promoters, one of the α or β chains of human hemoglobin and one of the terminators. Vectors comprising the two cassettes for expression of each of the α and β chains of human hemoglobin were also constructed. The clonings were carried out according to the customary methods.
Bibliographic references:
Benesch & Kwong. Hemoglobin 1994, 18, 185-192.
Birnboim & Doly. Nucleic Acids Res. 1979, 7, 1513-
Boutry & Chua. EMBO J. 1985, 4, 2159-2165.
Bradford. Anal. Biochem. 1976, 72, 248-254.
Carrer et al. Mol. Gen. Genet. 1993, 241, 49-56.
Chaumont et al. Plant Mol. Biol. 1994, 24, 631-641.
Gamborg et al. Exp. Cell Res. 1968, 50, 151-158.
Guerineau et al. Nucleic Acid Res. 1988, 16, 11380.
Gibson. J. Physiol. 1956, 134, 123.
Edelbaum. J. Interferon Res. 1992, 12, 449-453.
Hanahan. J. Mol. Biol. 1983, 166, 557-
Hanahan. In “DNA cloning volume I, a practical approach” (Ed: Glover D. M.) IRL Press, 1985, pp 109-135.
Hiatt & Ma. FEBS Let. 1992, 307, 71-75.
Hoffman et al. Proc. Natl. Acad. Sci. USA 1990, 87: 8521-8525.
Horsch et al. Science 1985, 227, 1229-1231.
International Hemoglobin Information Center (1995) Hemoglobin, 19, 37-124.
Jessen et al. Meth Enzymol, 1994, 231, 347-364.
Joshi. Nucleic Acid Res. 1987, 15, 6643-6653.
Kister et al. J. Biol. Chem. 1987, 262, 12085-12091.
Krebbers et al. Plant Physiol. 1988, 87, 859-866.
Marden et al. Meth Enzymol. 1994, 232 71-86.
Mason et al. Proc. Natl. Acad. Sci. USA 1992, 89, 11745-11749.
Moloney. Int. Meeting of Production of Recombinant Proteins in Plants, Leicester 1994, page 36-38
Murashige & Skoog. Physiol. Plantarum 1962, 15, 473-497.
Nagai & Thogersen. Meth. Enzymol. 1987, 153, 461-481.
Nagai et al. Proc. Natl. Acad. Sci. USA 1985, 82, 7252-7255.
Perutz. Nature 1970, 228, 726-739.
Russel. Int. Meeting of Production of Recombinant Proteins in Plants, Leicester 1994, page 43
Sambrook et al. Molecular Cloning: A Laboratory Manual. Second Edition. Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1989).
Sanger et al. Proc. Natl. Acad. Sci. USA 1977, 74, 5463-5467
Stephen et al. Nucleic Acid Res. 1990, 18, 7463-7464.
Svab et al. Proc. Natl. Acad. Sci. USA 1990, 87, 8526-8530.
Swanson et al. Bio/Technology 1991, 9, 57-61.
Symons et al. Bio/Technology 1990, 8, 217-221.
Vanderkerckhove et al. Bio/Technology 1989, 7, 929-932.
Wagenbach et al. Biotechnology 1991, 9: 57-61.
Wilson et al. Nucleic Acid Res. 1978, 5, 563-581.
Kay R. et al., Science, 1987, 236: 1299.
Franck A. et al., Cell, 1980, 21: 285.
Depicker A. et al., J. Mol. Appl. Genet., 1982, 1: 561.
Mc Elroy et al., Mol. Gen. Genet., 1991, 231: 150.
Reina et al., N.A.R., 1990, 18: 6426.
Dumoulin et al., Prot. Sci., 1996, 5: 114-120.
Feng et al., J. Mol. Evol., 1985, 21: 112-115.
Dumoulin et al., Art. Cells Blood Subs. Immob. Biotech., 1994, 22: 733-738.
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33
1
32
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
pBIOC21
1
agctgattaa ttaaggcgcg ccacgcgtta ac 32
2
32
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
pBIOC21
2
aattgttaac gcgtggcgcg ccttaattaa tc 32
3
34
DNA
Artificial Sequence
Description of Artificial Sequence Homo
sapiens
3
tacaagctta acaatggtgc tgtctccggc cgac 34
4
21
DNA
Artificial Sequence
Description of Artificial Sequence Homo
sapiens
4
cgggtccacc cggagcttgt g 21
5
21
DNA
Artificial Sequence
Description of Artificial Sequence Homo
sapiens
5
cacaagctcc gggtggaccc g 21
6
24
DNA
Artificial Sequence
Description of Artificial Sequence Homo
sapiens
6
tcaacggtat ttggaggtca gcac 24
7
52
DNA
Artificial Sequence
Description of Artificial Sequence Homo
sapiens
7
gtcattaatt aacaatggtg cacctgactc ctgaggagaa gtcggccgtt ac 52
8
43
DNA
Artificial Sequence
Description of Artificial Sequence Homo
sapiens
8
aatgagctcg ttaacgcgtt tagtgatact tgtgggccag ggc 43
9
162
DNA
Nicotiana plumbaginifolia
9
atggcttctc ggaggcttct cgcctctctc ctccgtcaat cggctcaacg tggcggcggt 60
ctaatttccc gatcgttagg aaactccatc cctaaatccg cttcacgcgc ctcttcacgc 120
gcatccccta agggattcct cttaaaccgc gccgtacagt ac 162
10
34
DNA
Artificial Sequence
Description of Artificial Sequence Nicotiana
plumbaginifolia
10
cgcaagctta acaatggctt ctcggaggct tctc 34
11
45
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
Nicotiana plumbaginifolia and Homo sapiens
11
tagaattcgg ccggagacag cacgtactgt acggcgcggt ttaag 45
12
42
DNA
Artificial Sequence
Description of Artificial Sequence Nicotiana
plumbaginifolia
12
gtcattaatt aacaatggct tctcggaggc ttctcgcctc tc 42
13
61
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
Nicotiana plumbaginifolia and Homo sapiens
13
aatgagctcg gccgacttct cctcaggagt caggtgcacg tactgtacgg cgcggtttaa 60
g 61
14
171
DNA
Pisum sativum
14
atggcttcta tgatatcctc ttcagctgtg actacagtca gccgtgcttc tacggtgcaa 60
tcggccgcgg tggctccatt cggcggcctc aaatccatga ctggattccc agttaagaag 120
gtcaacactg acattacttc cattacaagc aatggtggaa gagtaaagtg c 171
15
39
DNA
Artificial Sequence
Description of Artificial Sequence Pisum
sativum
15
cgcaagctta acaatggctt ctatgatatc ctcttcagc 39
16
46
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
Pisum sativum and Homo sapiens
16
tagaattcgg ccggagacag cacgcacttt actcttccac cattgc 46
17
44
DNA
Artificial Sequence
Description of Artificial Sequence Pisum
sativum
17
gtcattaatt aacaatggct tctatgatat cctcttcagc tgtg 44
18
57
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
Pisum sativum and Homo sapiens
18
aatgagctcg gccgacttct cctcaggagt caggtgcacg cactttactc ttccacc 57
19
69
DNA
Ipomoea batatas
19
atgaaagcct tcacactcgc tctcttctta gctctttccc tctatctcct gcccaatcca 60
gcccattcc 69
20
33
DNA
Artificial Sequence
Description of Artificial Sequence Ipomoea
batatas
20
cgcaagctta acaatgaaag ccttcacact cgc 33
21
45
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
Ipomoea batatas and Homo sapiens
21
tagaattcgg ccggagacag cacggaatgg gctggattgg gcagg 45
22
34
DNA
Artificial Sequence
Description of Artificial Sequence Ipomoea
batatas
22
gtcattaatt aacaatgaaa gccttcacac tcgc 34
23
61
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
Ipomoea batatas and Homo sapiens
23
aatgagctcg gccgacttct cctcaggagt caggtgcacg gaatgggctg gattgggcag 60
g 61
24
12
DNA
Artificial Sequence
Description of Artificial Sequence Homo
sapiens
24
aaagatgagc ta 12
25
44
DNA
Artificial Sequence
Description of Artificial Sequence Homo
sapiens
25
gcgaattctc atagctcatc tttacggtat ttggaggtca gcac 44
26
55
DNA
Artificial Sequence
Description of Artificial Sequence Homo
sapiens
26
aatgagctcg ttaacgcgtt tatagctcat ctttgtgata cttgtgggcc agggc 55
27
111
DNA
Ipomoea batatas
27
atgaaagcct tcacactcgc tctcttctta gctctttccc tctatctcct gcccaatcca 60
gcccattcca ggttcaatcc catccgcctc cccaccacac acgaacccgc c 111
28
43
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
Ipomea batatas and Homo sapiens
28
tagaattcgg ccggagacag cacggcgggt tcgtgtgtgg ttg 43
29
59
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
Ipomea batatas and Homo sapiens
29
aatgagctcg gccgacttct cctcaggagt caggtgcacg gcgggttcgt gtgtggttg 59
30
423
DNA
Homo sapiens
30
gtgctgtctc ctgccgacaa gaccaacgtc aaggccgcct ggggcaaggt tggcgcgcac 60
gctggcgagt atggtgcgga ggccctggag aggatgttcc tgtccttccc caccaccaag 120
acctacttcc cgcacttcga cctgagccac ggctctgccc aggttaaggg ccacggcaag 180
aaggtggccg acgcgctgac caacgccgtg gcgcacgtgg acgacatgcc caacgcgctg 240
tccgccctga gcgacctgca cgcgcacaag cttcgggtgg acccggtcaa cttcaagctc 300
ctaagccact gcctgctggt gaccctggcc gcccacctcc ccgccgagtt cacccctgcg 360
gtgcacgcct ccctggacaa gttcctggct tctgtgagca ccgtgctgac ctccaaatac 420
cgt 423
31
141
PRT
Homo sapiens
31
Val Leu Ser Pro Ala Asp Lys Thr Asn Val Lys Ala Ala Trp Gly Lys
1 5 10 15
Val Gly Ala His Ala Gly Glu Tyr Gly Ala Glu Ala Leu Glu Arg Met
20 25 30
Phe Leu Ser Phe Pro Thr Thr Lys Thr Tyr Phe Pro His Phe Asp Leu
35 40 45
Ser His Gly Ser Ala Gln Val Lys Gly His Gly Lys Lys Val Ala Asp
50 55 60
Ala Leu Thr Asn Ala Val Ala His Val Asp Asp Met Pro Asn Ala Leu
65 70 75 80
Ser Ala Leu Ser Asp Leu His Ala His Lys Leu Arg Val Asp Pro Val
85 90 95
Asn Phe Lys Leu Leu Ser His Cys Leu Leu Val Thr Leu Ala Ala His
100 105 110
Leu Pro Ala Glu Phe Thr Pro Ala Val His Ala Ser Leu Asp Lys Phe
115 120 125
Leu Ala Ser Val Ser Thr Val Leu Thr Ser Lys Tyr Arg
130 135 140
32
438
DNA
Homo sapiens
32
gtgcacctga ctcctgagga gaagtctgcc gttactgccc tgtggggcaa ggtgaacgtg 60
gatgaagttg gtggtgaggc cctgggcagg ctgctggttg tctacccttg gacccagagg 120
ttctttgagt cctttgggga tctgtccact cctgatgctg ttatgggcaa ccctaaggtg 180
aaggctcatg gcaagaaagt gctcggtgcc tttagtgatg gcctggctca cctggacaac 240
ctcaagggca cctttgccac actgagtgag ctgcactgtg acaagctgca cgtggatcct 300
gagaacttca ggctcctggg caacgtgctg gtctgtgtgc tggcccatca ctttggcaaa 360
gaattcaccc caccagtgca ggctgcctat cagaaagtgg tggctggtgt ggctaatgcc 420
ctagcccaca agtatcac 438
33
146
PRT
Homo sapiens
33
Val His Leu Thr Pro Glu Glu Lys Ser Ala Val Thr Ala Leu Trp Gly
1 5 10 15
Lys Val Asn Val Asp Glu Val Gly Gly Glu Ala Leu Gly Arg Leu Leu
20 25 30
Val Val Tyr Pro Trp Thr Gln Arg Phe Phe Glu Ser Phe Gly Asp Leu
35 40 45
Ser Thr Pro Asp Ala Val Met Gly Asn Pro Lys Val Lys Ala His Gly
50 55 60
Lys Lys Val Leu Gly Ala Phe Ser Asp Gly Leu Ala His Leu Asp Asn
65 70 75 80
Leu Lys Gly Thr Phe Ala Thr Leu Ser Glu Leu His Cys Asp Lys Leu
85 90 95
His Val Asp Pro Glu Asn Phe Arg Leu Leu Gly Asn Val Leu Val Cys
100 105 110
Val Leu Ala His His Phe Gly Lys Glu Phe Thr Pro Pro Val Gln Ala
115 120 125
Ala Tyr Gln Lys Val Val Ala Gly Val Ala Asn Ala Leu Ala His Lys
130 135 140
Tyr His
145 | A method for producing human hemoglobin proteins by (i) inserting into plant cells one or more nucleic acid molecules that each comprise at least one sequence coding for a protein component of a human hemoglobin protein capable of reversibly binding oxygen, and optionally a sequence coding for a selection agent; (ii) selecting cells containing nucleic acid coding for the protein component of the human hemoglobin protein; (iii) optionally propagating the transformed cells either in a culture or by regenerating whole transgenic or chimeric plants; and (iv) recovering and optionally purifying the human hemoglobin protein that includes a complex consisting of the protein or proteins coded for by the nucleic acid and at least one iron-containing polphyritic nucleus, or a plurality of such complexes. | 0 |
FIELD OF THE INVENTION
[0001] The present invention pertains generally to incubators such as infant incubators used for premature and newborn patients to provide a suitable microclimate in the interior space and more particularly the invention relates to a hoodless incubator.
BACKGROUND OF THE INVENTION
[0002] The incubators known so far for premature and newborn patients provide a suitable microclimate in the interior space, which is closed off by a bed and a generally transparent hood belonging to it. The heat losses of the immature patient can thus be compensated and the patient in question can be treated under thermally neutral conditions. However, these prior-art incubators have the drawback that the access to the patient by the care personnel and by the parents is greatly limited because of the closed incubator hood.
[0003] Even though so-called open care devices, which have a radiant heater as well as a mattress heater, which is optionally present in order to maintain the small patient under thermally neutral conditions, are also known as an alternative to the incubators closed by means of a hood, the ambient humidity is nonphysiological for the immature prematurely born patient. This leads to very high transepidermal losses of water and to dehydration of the patient, which cannot be compensated by the only limited availability of infusions. The high radiant output necessary leads to high skin temperatures and to the steady risk for overheating or even burn. Nevertheless, open care devices are preferably used despite the said drawbacks because of the good access to the patient when a prematurely born patient is not yet stable physiologically and requires intensive care measures. Due to the irreconcilable conflict between the desired microclimate in the closed incubator with the greatly limited access to the patient, on the one hand, and, on the other hand, the desired unhindered access to the patient in open care devices, which is, however, associated with heat supply from one side, where one cannot speak of a comfortable microclimate, attempts have already been made at resolving the conflict with a so-called hybrid device.
[0004] In U.S. Pat. No. 6,213,935 B1, the top side of the hood of an incubator is raised by means of an elevator when needed, so that the open care can be performed with the radiant heater integrated in the top side of the hood. When the top side of the hood is lowered, the radiant heater is switched off, so that a usual incubator with convection function is made available when the top side of the hood is lowered.
[0005] U.S. Pat. No. 5,817,002 shows an open care unit with a bed, which has air outlet channels on three sides and is to generate a microclimate above the patient's bed. A hood with a radiant heater likewise offers the possibility of providing as an alternative a closed incubator.
[0006] These prior-art concepts shall embody two types of device in one, where there is a switch-over between the different operating states, so that the heat supply by warm air convection prevails in the closed incubator, and the heat supply by heat radiation by means of a radiant heater prevails in the open care device. One drawback of these prior-art concepts arises from the switch-over between the different paths of heat transfer, because there is no heat equilibrium for the patient during the switch-over time and beyond because the heat sources require a finite time to heat up. This means that the patient cools down during each switch-over and it may take more than an hour each time for the patient to reach his original body temperature again.
SUMMARY OF THE INVENTION
[0007] Accordingly, the object of the present invention is to provide an incubator that supplies both a good microclimate and guarantees good access to the patient at the same time and continuously.
[0008] According to the invention, a hoodless incubator is provided including a bed and an air jet unit arranged above the bed and directed toward the bed. The air jet unit discharges a jacketed impinging jet, comprising an inner, air-conditioned core jet and a non-air-conditioned jacket jet jacketing the core jet. The bed is surrounded by a channel-like edge area, which is in flow connection via a first feed channel with a first fan arranged therein and with a heating and humidifying means likewise arranged therein with an air jet unit in order to form the air-conditioned core jet.
[0009] An essential advantage of the present invention arises from the fact that no switch-over between different operating states is necessary and cooling of the patient is thus prevented from occurring, but, on the other hand, both good conditioning in terms of the air temperature and humidity is available for the patient and the patient is readily accessible.
[0010] The jacket jet may advantageously consist essentially of ambient air, which is fed to the air jet unit via a second feed channel with a second fan.
[0011] The velocities of the core jet and the jacket jet during the discharge from the air jet unit may advantageously be between 0.2 m and 1 m per sec. The ratio of the velocity of the core jet to the velocity of the jacket jet may advantageously be approx. 3:1.
[0012] The air volume flow discharged from the air jet unit may advantageously be 300 to 900 L per minute for the core jet and 600 L to 1,800 L per minute for the jacket jet.
[0013] The air jet unit may advantageously be arranged pivotably above one of the front surfaces of the bed, so that the impinging jet discharged from the air jet unit, which is composed of the core and jacket jets, forms an angle of less than 90° and preferably 20° to 70° with the bed.
[0014] An additional radiant heater may advantageously be present for the bed.
[0015] An air outlet to the environment, which is preferably located between the first fan and the heating and humidifying means may advantageously be provided in the first feed channel.
[0016] The heating and humidifying means may advantageously be controlled as a function of the temperature and the humidity of the ambient air such that a preset temperature and a preset humidity are obtained in the area above the bed.
[0017] The core jet may advantageously have a relative humidity between 35% and 85% and a temperature between 28° C. and 39° C. The relative humidity and the temperature of the jacket jet discharged from the air jet unit may advantageously correspond to those of the ambient air.
[0018] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a schematic view showing a vertical section along the bed for an arrangement of the present invention;
[0020] [0020]FIG. 2 is a schematic view showing a vertical section along the bed for a second arrangement of the present invention;
[0021] [0021]FIG. 3 is a schematic view showing a vertical section along the bed for a modified arrangement according to FIG. 2;
[0022] [0022]FIG. 4 is a vertical sectional view through a first embodiment of a hoodless incubator; and
[0023] [0023]FIG. 5 is a vertical sectional view through a second embodiment of a hoodless incubator; and
[0024] [0024]FIG. 6 is a flow diagram of the control process of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to the drawings in particular, identical components are designated by identical reference numbers.
[0026] The arrangement of a hoodless incubator according to the present invention is shown schematically in FIG. 1 in a vertical section along the bed 1 for the patient.
[0027] An air jet unit 6 , from which specifically processed air is discharged as an air jet in the form of a plurality of parallel air flows with different temperatures and humidity levels, is arranged above the bed 1 . This air jet is a jacketed impinging jet, which comprises, e.g., an inner, air-conditioned core jet 4 , which supplies the warm and humid air for the air conditioning of the bed 1 and consequently for the microclimate of the patient, and has a jacket jet 5 of cooler and drier air on the outside, which is drawn off laterally at all four side channels 2 limiting the bed 1 as a cold edge jet 3 . The cooler edge jet 3 counteracts the thermal buoyancy and holds the warm and humid air of the core jet 4 together. As a result, a desired stable microclimate develops on the bed 1 . The velocities, temperatures and humidity levels of the composite air jet are coordinated with one another such that the entire flow field above the bed 1 is stable: The air velocities of the core jet 4 and of the jacket jet 5 are in the range of 0.2 and 1 m per sec during the discharge from the air jet unit 6 , and the ratio of the velocity of the core jet 4 to the velocity of the jacket jet 5 is preferably approximately 3:1.
[0028] The effective discharge areas during the discharge from the air jet unit 6 are, e.g., 400 square cm for the core jet 4 and 1,000 square cm for the jacket jet 5 .
[0029] The temperature and the humidity of the core jet 4 correspond to the desired microclimate, namely, to an air temperature selectable between 28° C. and 39° C. and a relative humidity between 35% and 85%. The temperature and humidity of the jacket jet 5 are, in general, at the values of the ambient air, but the temperature may also be below the ambient air temperature. As a result, the flow velocities directly on the bed 1 are approx. 0.06 to 0.18 m per sec. The quasi stationary microclimate is disturbed only slightly even in the case of minor disturbances in the jacketed air jet, e.g., during care procedures at the patient. This also applies to draft phenomena in the room, when, e.g., a person is walking by the incubator or the door or a window is briefly opened. As a variant of the arrangement according to FIG. 1, the air jet unit 6 may also be inclined pivotably obliquely above the bed 1 in the direction of a front surface, so that it is arranged according to FIG. 2 above the other, opposite front surface. This variant has the advantage that the air jet unit 6 does not interfere with the X-raying of the patient, i.e., it is located outside the schematically outlined ray path 8 of an X-ray apparatus. This variant also allows the use of a radiant heater 7 , which can supply the patient with additional heat output when the pure convective heat is not sufficient to keep the patient in a thermal equilibrium. The additional radiant heater 7 may be necessary, e.g., in the case of cool and air-conditioned rooms and especially in the case of small premature babies during the first days of life when their transepidermal water losses are still very high because of the yet undeveloped, immature stratum corneum.
[0030] The air jet unit 6 may also be pivoted by up to 90° from the bed 1 according to FIG. 3, and it is located at one of the front sides of the incubator or the bed 1 in this case. The entire bed 1 is accessible in this case from three sides without hindrance for care procedures, for X-raying, for the additional radiant heater 7 or for a phototherapy means.
[0031] [0031]FIG. 4 shows the air circulation of the hoodless incubator: The bed 1 proper for accommodating the patient is located in the bed housing 100 .
[0032] Essentially only the air-conditioned air, which is located above the bed 1 , is drawn off in the channel-like edge area 9 directly around the bed 1 . The air-conditioned air is drawn in by a first fan 11 via a first intermediate housing 10 , and heated and humidified by means of a heating and humidifying means 12 . The air thus air-conditioned is then fed centrally to the air jet unit 6 via a first feed channel 13 in order to form the core jet 4 there. The feed channel 13 may be heated and/or insulated in order to prevent the air-conditioned air from condensing. The heating along part or along the entire feed channel 13 may optionally replace the heating of the heating and humidifying means 12 . The cooler jacket jet 5 passes over into the edge jet 3 shown in FIGS. 1 and 3 and is drawn off extensively in the side channels 2 surrounding the bed 1 by a second fan 15 and united in a second intermediate housing 14 . This relatively cool and relatively dry air is fed to the air jet unit 6 via a second feed channel 16 . It is split there uniformly circumferentially such that it forms the jacket jet 5 around the core jet 4 and is returned to the bed 1 in a directed manner. Both the core jet 4 and the jacket jet 5 may be further subdivided into a plurality of parallel air flows with different discharge velocities in order to improve the action of the jacketing and to make it more stable. Both the air of the core jet 4 and that of the jacket jet 5 are extensively circulated in the example and are enriched with ambient air only partially.
[0033] [0033]FIG. 5 shows the air circulation of a second hoodless incubator: The bed 1 proper for accommodating the patient is located in the bed housing 100 .
[0034] Essentially only the air-conditioned air of the core jet 4 and only part of the jacket jet 5 are drawn off together in the channel-like edge area 9 of the bed 1 . The air is drawn in by the first fan 11 via the intermediate housing 10 , and heated and humidified by means of the heating and humidifying means 12 . A partial flow of the air drawn in is removed downstream as an excess into the environment after the first fan 11 through an air outlet 19 . The second fan 15 draws in fresh air from the environment and leads it into the air jet unit 6 , where it is directed as a jacket jet 5 toward the bed 1 in order to stabilize the core jet 4 . Other variants of the present invention are possible.
[0035] The heating and humidifying means 12 may be controlled as a function of the temperature and the humidity of the ambient air as shown in FIG. 6. The heating and humidifying means 12 is connected to a control processor 22 which is connected to a temperature/humidity sensor or temperature/humidity sensor arrangement 20 . The temperature sensor arrangement 20 is positioned in area above the bed 1 . Based on the sensed temperature and humidity at sensor arrangement 20 , the control processor 22 controls the heating and humidifying means 12 such that a preset temperature and a preset humidity are obtained in the area above the bed 1 .
[0036] The bed 1 may be provided with low side walls with a height of about 10 cm to 25 cm within the framework of the present invention in order to prevent the patient from falling out of the bed 1 . When raised, the side walls can additionally stabilize the flow of the microclimate. The bed 1 may optionally also be provided with a mattress heater to compensate increased heat losses of the patient.
[0037] In general, prior-art bacteria or sterilizing filters are located in the feed channel 13 for the circulated air-conditioned air in order to rule out the infestation of the air-conditioned air with microorganisms with certainty.
[0038] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | A hoodless incubator is provided, which supplies both a good microclimate in the area of the patient surface ( 1 ) and guarantees good access to the patient at the same time and continuously. The incubator includes a bed ( 1 ) and an air jet unit ( 6 ) arranged above the bed ( 1 ) and directed toward the bed ( 1 ). The air jet unit ( 6 ) discharges a jacketed impinging jet, formed of an inner, air-conditioned core jet ( 4 ) and a non-air-conditioned jacket jet ( 5 ) surrounding the core jet ( 4 ). The bed ( 1 ) is surrounded by a channel-like edge area ( 9 ), which is in flow connection with the air jet unit ( 6 ) via a first feed channel ( 13 ) with a first fan ( 11 ) arranged therein and with a heating and humidifying device ( 12 ) likewise arranged therein in order to form the air-conditioned core jet ( 4 ). | 0 |
TECHNICAL FIELD
The present invention relates to an activator of peroxisome proliferator activated receptor δ.
PRIOR ART
The peroxisome is a small organ present in cells of animals and plants, and its matrix contains various enzymes such as catalases. Various compounds such as fibrates, herbicides, and phthalic acid plasticizers are known as peroxisome proliferators which induce proliferation of peroxisomes.
Isseman, et al. have identified a nuclear receptor which is activated by peroxisome proliferator and called it peroxisome proliferator activated receptor (PPAR).—Nature, 347, p 645-650, 1990.
Three subtypes such as PPARα, PPARγ and PPARδ have been identified.—Proc. Natl. Acad. Sci. USA, 91, p 7335-7359, 1994.
The above-mentioned fibrates used as the serum triglyceride (TG) lowering drug can modulates PPARδ activity. Further, thiazolidine compounds (Troglitazone, Rosiglitazone, Pioglitazone) useful in the treatment of diabetes are also known as ligands of PPARγ.
It is reported that several compounds such as GW-2433 (Glaxo Wellcome), L-165041 (Merck), and YM-16638 (Yamanouchi Pharmaceutical) activate PPARδ. Each formula is as follows:
WO 92/10468 describes that GW-2433 can be employable for prevention and treatment of atherosclerosis.
WO 97/28115 describes that L-165041 can be employable for treatment of diabetes and suppression of obesity.
WO 99/04815 describes that YM-16638 shows effects for reducing serum cholesterol and reducing LDL cholesterol.
Recently, JBC, 272(6), p 3406-3410, 1997 and Cell, 99, p 335-345, 1999 describe proposal for application of PPAR δ ligand as an anti-cancer agent and an anti-inflammatory agent.
European Patent 558 062 describes the following compound A which has a structure similar to that of the general formula (I) [mentioned below] representing a compound of the invention:
J. Immunol. Methods, 207(1), 23-31, 1997 describes a compound B having the following formula:
All of the compounds identified by the compound A, compound B and the general formula (I) of the invention may be described as compounds of phenoxyacetic acid type. However, there are clear structural differences between the compounds A, B and the compound of the invention. For example, the phenoxy group of the compounds A, B has the propyl group substituted with the oxazolyl group or the ethoxy group substituted with the oxazolyl group, while the compound of the invention has the propionyl group substituted with the oxazolyl group or the like. Further, the oxazole ring of the compounds A, B has only one of the ethyl group or the phenyl group, while the compound of the invention may have both of the groups.
In addition, while the above-mentioned EP 558 062 teaches that the compound A is of value for treatment of hyperthrombinemia and as blood pressure depressant, no mention is given with respect to an effect as PPARδ ligand.
Further, while the J. Immunol. Methods teaches the use of the compound B as blood pressure depressant, there is no concrete description to teach that the compound is effective as PPARδ ligand.
Recently, WO 01/40207 describes a substituted oxa(thia)zole derivative showing an agonist action for PPARα, and WO 01/16120 describes an oxa(thia)zole derivative substituted with a biaryl group which is employable as a PPAR controlling agent.
In comparison with the compounds of the invention, the compound of WO 01/40207 has C(═O)NH as X and an alkylene chain bond as Y, and the compound of WO 01/16120 has an alkylene chain as X and O, X or the like as Y. Accordingly, the structural difference is clear.
Proc. Natl. Acad. Sci. U.S.A. 2001, Apr. 24; 98(9): 5306-11, and WO01/00603 describe that the following compound GW-501516 has a highly selective agonist action for PPARα.
There is a clear structural difference between the GW-501516 and the compound of the invention, that is, GW-501516 has the methyl group as X of the present invention, and S as Y.
Further, each of WO 02/14291 (Nippon Chemiphar Co., Ltd.) and WO 02/50048 (GLAXO) discloses a compound having an agonist action of peroxisome proliferator activated receptor. WO 02/50048 describes synthetic intermediates such as ethyl[2-methyl-4-(3-(4-methyl-2-[4-(trifluoromethyl)phenyl]-1,3-thiazol-5-yl)propanoyl)phenoxy]acetic acid, ethyl[2-methyl-4-((4-methyl-2-[4-(trifluoromethyl)phenyl]-1,3-thiazol-5-yl)acetyl)phenoxy]acetic acid, ethyl[4-(1-hydroxy-3-(4-methyl-2-[4-(trifluoromethyl)phenyl]-1,3-thiazol-5-yl)propyl)-2-methylphenoxy]acetic acid, ethyl[4-(1-hydroxy-2-(4-methyl-2-[4-(trifluoromethyl)phenyl]-1,3-thiazol-5-yl)ethyl)-2-methylphenoxy]acetic acid.
The present invention provides a compound having the below-mentioned general formula (I) and a salt thereof, which has an agonist action (action as activator of peroxisome proliferator activated receptor δ.
DISCLOSURE OF INVENTION
The invention resides in a compound having the following general formula (I) or a salt thereof:
(wherein R 1 is phenyl, naphthyl, pyridyl, thienyl, furyl, quinolyl or benzothienyl, any of which can have substituents selected from the group consisting of C 1-8 alkyl, C 1-8 alkyl having halogen, C 1-8 alkoxy, C 1-8 alkoxy having halogen, C 2-8 alkenyl, C 2-8 alkynyl, halogen, C 2-7 acyl, benzoyl, hydroxyl, nitro, amino, phenyl and pyridyl;
R 2 is C 1-8 alkyl, C 1-8 alkyl having halogen, C 2-8 alkenyl, C 2-8 alkynyl, 3-7 membered cycloalkyl, C 1-8 alkyl having 3-7 membered cycloalkyl, or C 1-6 alkyl substituted with phenyl, naphthyl or pyridyl, any of which can have substituents selected from the group consisting of C 1-8 alkyl, C 1-8 alkyl having halogen, C 1-8 alkoxy, C 1-8 alkoxy having halogen, C 2-8 alkenyl, C 2-8 alkynyl, halogen, C 2-7 acyl, benzoyl, hydroxyl, nitro, amino, phenyl and pyridyl;
A is oxygen, sulfur or NR 9 in which R 9 is hydrogen or C 1-8 alkyl;
X is a C 1-8 alkylene chain which can have substituents selected from the group consisting of C 1-8 alkyl, C 1-8 alkoxy and hydroxyl and which can contain a double bond;
Y is C(═O), C(═N—OR 10 ), CH(OR 11 ), CH═CH, C≡C, or C(═CH 2 ) in which each of R 10 and R 11 is hydrogen or C 1-8 alkyl;
each of R 3 , R 4 and R 5 is hydrogen, C 1-8 alkyl, C 1-8 alkyl having halogen, C 1-8 alkoxy, C 1-8 alkoxy having halogen, C 2-8 alkenyl, C 2-8 alkynyl, halogen, C 2-7 acyl, benzoyl, hydroxyl, nitro, amino, phenyl, or pyridyl;
B is CH or nitrogen;
Z is oxygen or sulfur;
each of R 6 and R 7 is hydrogen, C 1-8 alkyl, C 1-8 alkyl having halogen; and
R 8 is hydrogen or C 1-8 alkyl;
provided that at least one of R 3 , R 4 and R 5 is not hydrogen.
The invention also provides an activator of peroxisome proliferator activated receptor δ, which contains as an effective component a compound of the formula (I) or a salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
In the formula (I), examples of the alkyl groups having 1-8 carbon atoms include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl and pentyl.
Examples of the alkyl groups having 1-8 carbon atoms and a halogen substituent include methyl, ethyl, propyl, isopropyl, butyl, and t-butyl which are substituted with 1-3 halogens such as fluorine, chlorine, and bromine. Preferred are trifluoromethyl, chloromethyl, 2-chloroethyl, 2-bromoethyl and 2-fluoroethyl.
Examples of the alkoxy groups having 1-8 carbon atoms include methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, t-butoxy and pentyloxy.
Examples of the alkoxy groups having 1-8 carbon atoms and a halogen substituent include methoxy, ethoxy, propoxy, isopropoxy, butoxy and t-butoxy groups substituted with 1-3 halogen atoms such as fluorine atom, chlorine atom or bromine atom. Trifluoromethoxy, chloromethoxy, 2-chloroethoxy, 2-bromoethoxy and 2-fluoroethoxy are preferred.
Examples of the alkenyl groups having 2-8 carbon atoms include vinyl and allyl.
Examples of the alkynyl groups having 2-8 carbon atoms include propargyl.
Examples of the 3-7 membered cycloalkyl groups include cyclohexyl and cyclopentyl.
Examples of the alkyl groups having 1-8 carbon atoms and a 3-7 membered cycloalkyl substituent include cyclohexylmethyl and cyclopentylmethyl.
(1) A preferred compound of the invention is a compound of the formula (I) or salt thereof, in which R 1 is phenyl which can have substituents selected from the group consisting of C 1-8 alkyl, C 1-8 alkyl having 1-3 halogen atoms, C 1-8 alkoxy, C 1-8 alkoxy having 1-3 halogen atoms, C 2-8 alkenyl, C 2-8 alkynyl, halogen, C 2-7 acyl, benzoyl, hydroxyl, nitro, amino, phenyl and pyridyl.
(2) Another preferred compound of the invention is a compound of the formula (I), a salt thereof or (1), in which R 2 is C 2-8 alkyl.
(3) A further preferred compound of the invention is a compound of the formula (I), a salt thereof, (1) or (2), in which R 1 is attached to the 2nd position. In the case that R 1 is attached to the 2nd position, R 4 is attached to the 4th position and —X—Y— is attached to the 5th position, or R 4 is attached to the 5th position and —X—Y— is attached to the 4th position.
(4) A furthermore preferred compound of the invention is a compound of the formula (I), a salt thereof, (1), (2) or (3), in which A is oxygen or sulfur.
(5) A still further preferred compound of the invention is a compound of the formula (I), a salt thereof, (1), (2), (3) or (4), in which X is a C 1-8 alkylene chain.
(6) A still further preferred compound of the invention is a compound of the formula (I), a salt thereof, (1), (2), (3), (4) or (5), in which Y is C(═O).
(7) A still further preferred compound of the invention is a compound of the formula (I), a salt thereof, (1), (2), (3), (4), (5) or (6), in which each of R 3 , R 4 and R 5 is hydrogen, C 1-8 alkyl or C 1-8 alkyl having halogen.
(8) A still further preferred compound of the invention is a compound of the formula (I), a salt thereof, (1), (2), (3), (4), (5), (6) or (7), in which B is CH.
(9) A still further preferred compound of the invention is a compound of the formula (I), a salt thereof, (1), (2), (3), (4), (5), (6), (7) or (8), in which Z is oxygen.
(10) A still further preferred compound of the invention is a compound of the formula (I), a salt thereof, (1), (2), (3), (4), (5), (6), (7), (8) or (9), in which each of R 6 and R 7 is hydrogen or C 1-4 alkyl.
(11) A still further preferred compound of the invention is a compound of the formula (I), a salt thereof, (1), (2), (3), (4), (5), (6), (7), (8) or (9), in which R 8 is hydrogen.
(12) A still further preferred compound of the invention is a compound of the formula (I) or a salt thereof, in which R 1 is phenyl or naphthyl, each of which can have substituents selected from the group consisting of C 1-8 alkyl, C 1-8 alkyl having halogen, C 1-8 alkoxy, C 1-8 alkoxy having halogen, C 2-8 alkenyl, C 2-8 alkynyl, halogen, C 2-7 acyl, benzoyl, hydroxyl, nitro, amino, phenyl and pyridyl;
R 2 is C 2-8 alkyl;
A is oxygen or sulfur;
X is a C 1-8 alkylene chain which can have a C 1-8 alkyl substituent and which can contain a double bond;
Y is C(═O), CH═CH, or C(═CH 2 );
each of R 3 , R 4 and R 5 is hydrogen, C 1-8 alkyl, C 1-8 alkyl having halogen, C 1-8 alkoxy, C 1-8 alkoxy having halogen, C 2-8 alkenyl, C 2-8 alkynyl, halogen, C 2-7 acyl, benzoyl, hydroxyl, nitro, amino, phenyl, or pyridyl;
B is CH;
Z is oxygen or sulfur;
each of R 6 and R 7 is hydrogen or C 1-8 alkyl; and
R 8 is hydrogen or C 1-8 alkyl.
(13) A still further preferred compound of the invention is a compound of (12), in which X is a C 1-8 alkylene chain.
(14) A still further preferred compound of the invention is a compound of (12) or (13), in which R 1 is attached to the 2nd position.
(15) A still further preferred compound of the invention is a compound of (12), (13) or (14), in which R 8 is hydrogen.
(16) A still further preferred compound of the invention is a compound of (12), (13), (14) or (15), in which the substituents of R 3 , R 4 and R 5 other than hydrogens are placed at ortho-positions with respect to -Z-CR 6 R 7 CO 2 R 8 .
The compound of the formula (I) can be present in the form of geometrical isomers such as cis and trans and optical isomers. These isomers are included in the compounds of the invention.
Further, the compounds of the invention can be in the form of pharmaceutically acceptable salts such as alkali metal salts, e.g., sodium salt and potassium salt.
The processes for preparing the compound of the formula (I) according to the invention are described below.
[Synthetic Process 1]
[in the formulas, Q is a releasing group such as tosyloxy or halogen (e.g., bromine), and R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , A, X, Y, B and Z are those described hereinbefore.
In the above-described process, the compound of the formula (I) according to the invention can be prepared by reacting a phenol or thiophenol compound of the general formula (a) with an acetic acid derivative of the general formula (b). The reaction can be carried out in a solvent such as methyl ethyl ketone in the presence of a base such as potassium carbonate.
The starting compound of the formula (a), can be prepared by a process similar to the below-mentioned synthetic scheme.
[Synthesis Example 1 for Starting Compound in which Y is CO, Z is O]
[in the formulas, n is an integer of 1 to 7, Bn is benzyl, and R 1 , R 2 , R 3 , R 4 , R 5 , A and B are those described hereinbefore.]
[Synthesis Example 2 for Starting Compound in which Z is S]
[in the formulas, R 1 , R 2 , R 3 , R 4 , R 5 , A, B, X and Y are those described hereinbefore.]
The phenol compound is treated with dimethylthiocarbamoyl chloride in the presence of a base such as triethylamine to obtain a dimethylthiocarbamoyloxy compound. The dimethylthiocarbamoyloxy compound is heated in n-tetradecane or no solvent to obtain a dimethylcarbamoylsulfanyl compound as a rearranged compound. The dimethylcarbamoyl group is treated with NaOH or MeONa to be converted to a thiophenol compound.
[Synthesis Example 3 for Starting Compound in which Y is CO, Z is O]
[in the formulas, m is an integer of 0 to 6, and R 1 , R 2 , R 3 , R 4 , R 5 , A, B and Bn are those described hereinbefore.]
The acetophenone compound and the aldehyde compound synthesized according to a conventional method are condensed with hydration using a base such as NaOH, KOH, MeONa, EtONa, piperidine in a solvent such as methanol, ethanol, anhydrous benzene to obtain a α,β-unsaturated ketone compound. The α,β-unsaturated ketone compound is treated, for example subjected to a hydride contact reduction to conduct reduction of the olefin and the debenzylation to obtain the subject compound.
[Synthesis Example 4 for Starting Compound in which Y is CO, Z is O]
[in the formulas, R 1 , R 2 , R 3 , R 4 , R 5 , A, B, n and Bn are those described hereinbefore.]
The benzaldehyde compound is treated with a Grignard reagent obtained according to a conventional method in the presence of a solvent such as a ether or THF under the condition of a low temperature to obtain an alcohol compound. The alcohol compound can be converted into a ketone compound by using a Jones reagent (chromium(VI) oxide-sulfuric acid-acetone) or chromium(VI)-pyridine complex (e.g., pyridinium chlorochromate, pyridinium dichromate). The alcohol compound can also be converted into the ketone body in the same manner by using DMSO oxidation. Finally, the ketone body is subjected to debenzylation to be converted into the subject phenol compound.
[Synthesis Example 5 for Starting Compound in which Z is O]
[in the formulas, R a is hydrogen atom or an alkyl group having 1 to 5 carbon atoms, and R 1 , R 2 , A, X, Y and B are those described hereinbefore.]
The phenol compound is subjected to an allylation according to a conventional method, and heated (at 150° C. or higher) with no solvent or in a solvent such as quinoline to obtain a compound having the rearranged allyl group at the ortho-position.
[Synthesis Example 6 for Starting Compound in which Z is O]
[in the formulas, R b is an alkyl group having 1 to 6 carbon atoms, and R 1 , R 2 , A, X, Y and B are those described hereinbefore.]
The phenol compound is subjected to an acylation according to a conventional method, and heated in the presence of a Lewis acid catalyst to obtain a compound having the rearranged acyl group at the ortho-position.
[Synthesis Example 7 for Starting Compound in which Y is CH═CH]
[in the formulas, R 1 , R 2 , R 3 , R 4 , R 5 , A, B, n and Bn are those described hereinbefore.]
The phenol compound obtained in the Synthesis example 1 for starting compound is treated with a reducing agent such as lithium aluminum hydride, sodium boron hydride to obtain an alcohol compound. The alcohol compound is subjected to dehydration using a halogenation agent, a sulfonation agent or a dehydration agent to obtain an olefin compound.
[Synthetic Process 2 (wherein R 8 is H)]
[in the formulas, R c is an alkyl group having 1 to 8 carbon atoms, and R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , A, X, Y, B and Z are those described hereinbefore.]
In the above-illustrated process for preparation, a compound of the formula (I) (R 8 ═H) according to the invention can be obtained by the ester compound of the formula (c) is hydrolyzed in a solvent such as aqueous ethanol in the presence of a base such as sodium hydroxide, potassium hydroxide or lithium hydroxide.
[Synthetic Process 3 (wherein Y is C(═N—OH)]
[in the formulas, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , A, X, B and Z are those described hereinbefore].
In the above-illustrated process, a compound of the formula (I) (Y is C(═N—OH)) according to the invention can be obtained by reacting the ketone compound of the formula (d) with hydroxylamine.
[Synthetic Process 4 (wherein Y is C(═CH 2 ))
[in the formulas, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , A, B, Z and n are those described hereinbefore].
The ketone compound (Y is C(═O)) can be treated with methyl triphenyl phosphonium bromide in the presence of a base such as t-BuOK, n-BuLi, sec-BuLi, EtONa in a solvent such as a dry ether or THF (according to Wittig reaction) to introduce a methylene chain into the compound.
[Synthetic Process 5 (wherein Y is C(═CH 2 ))
[in the formulas, R 10 is an alkyl group having 1 to 10 carbon atoms, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , A, B, Z and n are those described hereinbefore].
The ketone compound (Y is C(═O)) can be treated with alkyl halide such as iodomethane in the presence of a base such as t-BuOK, BuLi, EtONa, NaH in a solvent such as a dry ether or THF to introduce an alkyl chain into the compound at the α-position of the carbonyl group.
The representative compounds of the invention are described below.
(1) Compounds of the Following Formula
Compounds of the formula (I) in which R 5 is H, B is CH, R 8 is H, and R 1 , R 2 , R 3 , R 4 , R 6 , R 7 , A, X, Y and Z are shown in Tables 1 to 4.
TABLE 1
A
R 1
R 2
R 3
R 4
R 6
R 7
X
Y
Z
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
H
H
CH 2
CH═CH(4)
O
S
(4-CF 3 )Ph
Hexyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Hexyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
Me
Me
CH 2
CH═CH(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(3)
H
H
H
CH 2 CH 2
C═O(4)
O
14 S
(4-CF 3 )Ph
Isopropyl
Me(3)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Pr(2)
H
H
H
CH 2 CH 2
C═O(4)
O
18 S
(4-CF 3 )Ph
Isopropyl
Allyl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
24 S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
H
H
CH═CH
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
Me
Me
CH═CH
C═O(4)
O
S
(4-OMe)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(3,5-F)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(3,5-F)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
2-Naphthyl
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
2-Naphthyl
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-Bu)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-Bu)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
23 S
(4-CF 3 )Ph
Isopropyl
Cl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Cl(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(5)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(5)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
Me
H
CH 2 CH 2
C═O(4)
O
Remark: Numeral in ( ) means a position of the group.
TABLE 2
A
R 1
R 2
R 3
R 4
R 6
R 7
X
Y
Z
S
(4-CF 3 )Ph
Hexyl
Me(2)
H
Me
Me
CH 2
CH═CH(4)
O
S
(4-CF 3 )Ph
Hexyl
Me(2)
H
Me
Me
CH 2
CH 2 CH 2 (4)
O
S
(4-CF 3 )Ph
Hexyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(5)
O
S
(4-CF 3 )Ph
Ethyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Ethyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-Me)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-Me)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
S
S
(4-Et)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-iPr)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-t-Bu)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-Cl)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-F)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-NO 2 )Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-NMe 2 )Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
S
S
(4-Et)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-iPr)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-t-Bu)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-Cl)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-F)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-NO 2 )Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-NMe 2 )Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-Cl)Ph
Isopropyl
Allyl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
Remark: Numeral in ( ) means a position of the group.
TABLE 3
A
R 1
R 2
R 3
R 4
R 6
R 7
X
Y
Z
O
(2-OH,4-Cl)Ph
Isopropyl
Allyl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
O
(2-OH,4-Cl)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
CH═CH(3)
O
O
(4-Me)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
S
O
(2,4-Me)Ph
Isopropyl
Pr(2)
H
Me
Me
CH(Me)CH 2
C═O(4)
O
S
(2-OH,4-Me)Ph
Bu
Benzyl(2)
H
H
H
CH 2 CH 2
C═O(3)
O
NH
(2-OH,4-CF 3 )Ph
Pr
Acetyl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
N-Me
(2-OH,4-Cl)Ph
Hexyl
Cl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(2,4-Me)Ph
Et
Br(2)
H
H
H
CH 2 CH 2
C═O(4)
S
S
(3,4-Cl)Ph
Bu
CF 3 (2)
H
Me
Et
CH 2 CH 2
C═O(4)
O
S
(2,4-Me)Ph
Hexyl
Me(2)
Me(6)
Me
Me
CH(Me)CH 2
C═O(4)
O
S
(2,4-Cl)Ph
Bu
Me(2)
Me(3)
H
H
CH 2 CH 2
C═O(4)
O
S
(2-OH,3,4-Me)Ph
Pr
Cl(2)
Cl(6)
H
H
CH 2 CH 2
CH═CH(4)
O
S
(2,4-F)Ph
Hexyl
Me(2)
H
Me
Me
CH 2 CH 2
CH═CH(4)
O
O
(3,4,5-Me)Ph
Et
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
S
O
(2-OH,3,4-Me)Ph
Bu
Me(3)
H
Me
Me
CH 2 CH 2
C═O(4)
O
O
(2-OH,4-CF 3 )Ph
Phenylethyl
Me(2,6)
H
H
H
CH 2 CH 2
C═O(3)
O
O
(4-OMe)Ph
Isopropyl
Me(2)
Me(6)
H
H
CH 2 CH 2
C═O(4)
O
S
(2-Cl,4-OPh)Ph
Isopropyl
Acetyl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
NH
1-Naphthyl
Isopropyl
Cl(3)
H
H
H
CH 2
CH═CH(4)
S
N-Me
2-Naphthyl
Isopropyl
Br(3)
H
Me
Et
CH(Me)CH 2
C═O(4)
O
S
2-Quinolyl
Isopropyl
CF 3 (2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
NH
8-Quinolyl
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
N-Me
3-Quinolyl
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
2-Pyrimidyl
Isopropyl
Allyl(3)
H
H
H
CH 2 CH 2
C═O(4)
O
Remark: Numeral in ( ) means a position of the group.
TABLE 4 A R 1 R 2 R 3 R 4 R 6 R 7 X Y Z S 2-Thyenyl Isopropyl Me(2) H H H CH 2 CH═CH(4) S S 2-Pyridyl Isopropyl Me(2) H H H CH 2 CH 2 C═O(4) O S 4-Pyridyl Isopropyl Me(2) H H H CH 2 CH 2 C═O(4) O S 5-Et-2-Pyridyl Isopropyl Me(2) H H H CH 2 CH 2 C═O(4) O S 5-Me-2-Pyridyl Isopropyl Me(2) H H H CH 2 CH 2 C═O(4) O S 5-Et-2-Pyridyl Isopropyl Me(2) H Me Me CH 2 CH 2 C═O(4) O S 2-Furanyl Isopropyl Me(2) H H H CH 2 CH 2 C═O(4) O S 2-Imidazolyl Isopropyl Me(2) H Me Et CH 2 CH 2 C═O(4) O O 2-Indolyl Isopropyl Pr(2) H Me Me CH 2 CH 2 C═O(4) O O 2-Benzofuranyl Isopropyl Benzyl(2) H Me Me CH 2 CH 2 C═O(4) O O 2-Benzothienyl Isopropyl Acetyl(2) H Me Me CH 2 CH 2 C═O(4) S O 2-Benzoimidazolyl Isopropyl Cl(2) Cl(6) Me Me CH 2 CH 2 C═O(4) S S (4-CF 3 )Ph sec-Bu Me(2) H H H CH 2 CH 2 C═O(4) O S (4-CF 3 )Ph sec-Bu Me(2) H Me Me CH 2 CH 2 C═O(4) O S (4-CF 3 )Ph Isobutyl Me(2) H H H CH 2 CH 2 C═O(4) O S (4-CF 3 )Ph Phenylethyl Me(2) H H H CH 2 CH 2 C═O(4) O S (4-CF 3 )Ph Isopropyl CF 3 (2) H H H CH 2 CH 2 C═O(4) O S (4-CF 3 )Ph Isopropyl CHF 2 (2) H H H CH 2 CH 2 C═O(4) O S (4-CF 3 )Ph Isopropyl Me(2) H H H CH 2 CH 2 C═CH 2 (4) O Remark: Numeral in ( ) means a position of the group.
(2) Compounds of the Following Formula
Compounds of the formula (I) in which R 4 is H, R 5 is H, B is CH, R 8 is H, and R 1 , R 2 , R 3 , R 6 , R 7 , A, X, Y and Z are shown in Tables 5 and 6.
TABLE 5
A
R 1
R 2
R 3
R 4
R 6
R 7
X
Y
Z
O
(2,4-Cl)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
O
(2,4-Cl)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
O
(2,4-Cl)Ph
Isopropyl
Allyl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
O
(2-OH,4-Cl)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
O
(2-OH,4-Cl)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
O
(2,4-Cl)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
S
O
(2,4-Cl)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
CH═CH(4)
O
O
(2,4-Cl)Ph
Isopropyl
Me(3)
H
H
H
CH 2 CH 2
C═O(4)
O
O
(2,4-Cl)Ph
Isopropyl
Me(3)
H
Me
Me
CH 2 CH 2
C═O(4)
O
O
(2,4-Cl)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═CH 2 (4)
O
O
(2,4-Cl)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═CH 2 (4)
O
O
(2,4-Cl)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH(Me)
C═O(4)
O
O
(2,4-Cl)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH(Me)
C═O(4)
O
O
(2,4-Cl)Ph
Isopropyl
Cl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
O
(2,4-Cl)Ph
Isopropyl
Cl(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(4-CF 3 )Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
S
(2,4-Cl)Ph
Isopropyl
Me(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(2,4-Cl)Ph
Isopropyl
Me(2)
H
Me
Me
CH 2 CH 2
C═O(4)
O
O
(2,4-Me)Ph
Isopropyl
Pr(3)
H
Me
Me
CH(Me)CH 2
C═O(4)
O
S
(2-OH,4-Me)Ph
Bu
Benzyl(2)
H
H
H
CH 2 CH 2
C═O(3)
O
NH
(2-OH,4-CF 3 )Ph
Pr
Acetyl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
N-Me
(2-OH,4-Cl)Ph
Hexyl
Cl(2)
H
H
H
CH 2 CH 2
C═O(4)
O
S
(2,4-Me)Ph
Et
Br(2)
H
H
H
CH 2 CH 2
C═O(4)
S
O
(3,4-Cl)Ph
Bu
CF 3 (3)
H
Me
Et
CH 2 CH 2
C═O(4)
O
Remark: Numeral in ( ) means a position of the group.
TABLE 6 A R 1 R 2 R 3 R 4 R 6 R 7 X Y Z O (2,4-Me)Ph Hexyl Me(2) Me(6) Me Me CH(Me)CH 2 C═O(4) O O (2,4-Cl)Ph Bu Me(2) Me(3) H H CH 2 CH 2 C═O(4) O O (2-OH,3,4-Me)Ph Pr Allyl(2) H H H CH 2 CH 2 CH═CH(4) O S (2,4-F)Ph Hexyl Ph(2) H Me Me CH 2 CH 2 CH═CH(4) O NH (3,4,5-Me)Ph Et Me(2) H H H CH 2 CH 2 C═O(4) S N-Me (2-OH,3,4-Me)Ph Bu Me(3) H Me Me CH 2 CH 2 C═O(4) O S (2-OH,4-CF 3 )Ph Isopropyl Me(2) Me(6) H H CH 2 CH 2 C═O(3) O O (2-Cl,4-OMe)Ph Isopropyl Me(2) Me(6) H H CH 2 CH 2 C═O(4) O O (2-Cl,4-OPh)Ph Isopropyl Acetyl(2) H H H CH 2 CH 2 C═O(4) O O 1-Naphthyl Isopropyl Cl(2) H H H CH 2 CH═CH(4) S O 2-Naphthyl Isopropyl Br(2) H Me Et CH(Me)CH 2 C═O(4) O S 2-Quinolyl Isopropyl CF 3 (2) H Me Me CH 2 CH 2 C═O(4) O NH 8-Quinolyl Isopropyl Me(2) H Me Me CH 2 CH 2 C═O(4) O N-Me 3-Quinolyl Isopropyl Me(2) H H H CH 2 CH 2 C═O(4) O S 2-Pyrimidyl Isopropyl Allyl(2) H H H CH 2 CH 2 C═O(4) O O 2-Thienyl Isopropyl Me(2) H H H CH 2 CH═CH(4) S O 2-Furanyl Isopropyl Me(2) H H H CH 2 CH 2 C═O(4) O O 2-Imidazolyl Isopropyl Me(2) H Me Et CH 2 CH 2 C═O(4) O O 2-Indolyl Isopropyl Pr(2) H Me Me CH 2 CH 2 C═O(4) O O 2-Benzofuranyl Isopropyl Benzyl(2) H Me Me CH 2 CH 2 C═O(4) O S 2-Benzothienyl Isopropyl Acetyl(2) H Me Me CH 2 CH 2 C═O(4) S S 2-Benzimidazolyl Isopropyl Cl(2) Cl(6) Me Me CH 2 CH 2 C═O(4) S Remark: Numeral in ( ) means a position of the group.
(3) Compounds of the Following Formula
Compounds of the formula (I) in which R 5 is H, B is CH, R 8 is H, and R 1 , R 2 , R 3 , R 4 , R 6 , R 7 , A, X, Y and Z are shown in Table 7.
TABLE 7
A
R 1
R 2
R 3
R 4
R 6
R 7
X
Y
Z
O
(2,4-Me)Ph
Hexyl
Me(2)
Me(6)
Me
Me
C═O(4)
CH(Me)CH 2
O
O
(2,4-Cl)Ph
Bu
Me(2)
Me(3)
H
H
C═O(4)
CH 2 CH 2
O
S
(2-OH,4-CF 3 )Ph
Isopr
Me(2)
Me(6)
H
H
C═O(3)
CH 2 CH 2
O
O
(2-Cl,4-OMe)Ph
Isopr
Me(2)
Me(6)
H
H
C═O(4)
CH 2 CH 2
O
S
2-Benzimidazolyl
Isopr
Cl(2)
Cl(6)
Me
Me
C═O(4)
CH 2 CH 2
S
Remark: Numeral in ( ) means a position of the group.
The pharmacological effects of the invention are described below.
The PPARδ activating effect of the compound of the invention was determined by the following method:
A chimeric receptor expression plasmid (GAL4-hPPARδ LBD), a reporter plasmid (UASx4-TK-LUC) and β-galactosidase (β-GAL) are transfected into CV-1 cells by utilizing a lipofection reagent DMRIE-C (Life Technologies). Subsequently, it is incubated for 40 hours in the presence of a compound of the invention or a compound for comparison (L-165041), and then the luciferase activity and β-GAL activity are measured on the soluble cells.
The luciferase activity is calibrated by the β-GAL activity, and a relative ligand activity is calculated under the condition that the luciferase activity of the cells treated by L-165041 is set to 100%). In the same manner, relative ligand activities to PPARδ and γ transactivation activities are calculated (see the below-mentioned Examples 51, 52).
As seen from Tables 8, 9, the compounds of the invention (Examples 1-50) show an excellent PPARδ activating effect.
As also seen from Example 53 (Table 10), the compounds of the invention (Examples 4 and 10) show an excellent effect of increasing HDL cholesterol.
Apparently, the compounds of the invention having the general formula (I) show excellent PPARδ activating effect. Accordingly, these compounds are expected to serve as remedy for prevention and treatment of the following diseases: hyperglycemia, hyperlipidemia, obesity, syndrome X, hyperchloresterolemia, hyperlipopreoteinemia, other dysbolismic diseases, hiperlipemia, arterial sclerosis, diseases of cardiovascular systems, hyperphagia, ischemic diseases, malignant tumors such as lung cancer, mammary cancer, colonic cancer, cancer of great intestine, and ovary cancer, Alzheimer's disease, inflammatory disease, osteoporosis (Mano H. et al., (2000) J. Biol. Chem., 175:8126-8132), Basedow's disease, and adrenal cortical dystrophy.
The compound of the invention can be administered to human beings by ordinary administration methods such as oral administration or parenteral administration.
The compound can be granulated in ordinary manners for the preparation of pharmaceuticals. For instance, the compound can be processed to give pellets, granule, powder, capsule, suspension, injection, suppository, and the like.
For the preparation of these pharmaceuticals, ordinary additives such as vehicles, disintegrators, binders, lubricants, dyes, and diluents. As the vehicles, lactose, D-mannitol, crystalline cellulose and glucose can be mentioned. Further, there can be mentioned starch and carboxymethylcellulose calcium (CMC-Ca) as the disintegrators, magnesium stearate and talc as the lubricants, and hydroxypropylcellulose (HPC), gelatin and polyvinylpirrolidone (PVP) as the binders.
The compound of the invention can be administered to an adult generally in an amount of 0.1 mg to 100 mg a day by parenteral administration and 1 mg to 2,000 mg a day by oral administration. The dosage can be adjusted in consideration of age and conditions of the patient.
The invention is further described by the following non-limiting examples.
EXAMPLES
Example 1
2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) 3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one
To an ice-cold THF (5 mL) was added 60% sodium hydride (97 mg, 2.42 mmol). Subsequently, a solution of ethyl 2-[(3-methyl-4-benzyloxy)benzoyl]acetate (757 mg, 2.42 mmol) in THF (4 mL) was dropwise added for 30 minutes. The mixture was allowed to room temperature, and then stirred for 30 minutes. To the mixture was added 4-iodomethyl-5-isopropyl-2-(2,4-dichlorophenyl)oxazole (960 mg, 2.42 mmol). The resulting mixture was refluxed for 20 hours under nitrogen atmosphere, and allowed to room temperature. THF was removed under reduced pressure. To the residue was added acetic acid (6.4 mL)-conc. hydrochloric acid (1.6 mL), and the mixture was refluxed for 10 hours, and allowed to room temperature. The reaction mixture was poured into ice water. Ethyl acetate was added to the mixture. The organic layer was washed with a saturated aqueous sodium hydrogen carbonate solution, water, and a saline, dried over anhydrous sodium sulfate. Ethyl acetate was removed under reduced pressure, and the residue was purified by column chromatography on silica gel with hexane/ethyl acetate (3/1) to give the desired compound (706 mg) as pale yellowish white crystalline (yield 70%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 2.26 (s, 3H), 2.95 (t, 2H, J=7 Hz), 3.19 (dq, 1H, J=7 Hz, J=7 Hz), 3.30 (t, 2H, J=7 Hz), 5.75 (s, 1H), 6.75 (d, 1H, J=8 Hz), 7.30 (dd, 1H, J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.70 (dd, 1H, J=2, 8 Hz), 7.76 (d, 1H, J=2 Hz), 7.88 (d, 1H, J=8 Hz).
(2) Ethyl 2-[4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
In methyl ethyl ketone (10 mL) were suspended the obtained 3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one (209 mg, 0.50 mmol), ethyl 2-bromo-2-methylpropionate (489 mg, 2.50 mmol), and potassium carbonate (346 mg, 2.50 mmol). The suspension was refluxed for 40 hours. The suspension was then allowed to room temperature, filtered to remove insolubles, and washed with methyl ethyl ketone. The solvent was distilled off. The residue was purified by column chromatography on silica gel with hexane/ethyl acetate (7/1) to give the desired compound (272 mg) as colorless oil (quantitative yield).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.26 (t, 3H, J=7 Hz), 1.29 (d, 6H, J=7 Hz), 1.64 (s, 6H), 2.25 (s, 3H), 2.95 (t, 2H, J=7 Hz), 3.18 (dq, 1H, J=7 Hz, J=7 Hz), 3.32 (t, 2H, J=7 Hz), 4.21 (q, 2H, J=7 Hz), 6.60 (d, 1H, J=8 Hz), 7.30 (dd, 1H, J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.71 (dd, 1H, J=2, 8 Hz), 7.80 (d, 1H, J=2 Hz), 7.89 (d, 1H, J=8 Hz).
(3) 2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
In a mixture of ethanol (6 mL) and water (3 mL) was dissolved the obtained ester compound (270 mg, 0.51 mmol), and then lithium hydroxide monohydrate (65 mg) was added. The mixture was refluxed for 48 hours, and allowed to room temperature. Ice water was added to the reaction mixture. The mixture was neutralized by addition of 3N hydrochloric acid. Precipitated crystals were filtered, washed with water, dried in air over night, and further dried under reduced pressure (60° C.) to give 170 mg of the desired compound (yield 68%).
White powder (mp: 100-105° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 1.66 (s, 6H), 2.24 (s, 3H), 2.94 (t, 2H, J=7 Hz), 3.21 (dq, 1H, J=7 Hz, J=7 Hz), 3.26 (t, 2H, J=7 Hz), 6.71 (d, 1H, J=8 Hz), 7.29 (dd, 1H, J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.56 (dd, 1H, J=2, 8 Hz), 7.79 (d, 1H, J=2 Hz), 7.84 (d, 1H, J=8 Hz).
Example 2
[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]acetate
The synthetic intermediate of Example 1, namely 3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one (105 mg, 0.25 mmol) and potassium carbonate (103 mg, 0.75 mmol) were suspended in acetone (3 mL). Ethyl bromoacetate (0.08 mL, 0.75 mmol) was added to the suspension while cooling with ice. The suspension was allowed to room temperature, and refluxed while heating for 6 hours. Insolubles were filtered, and washed with acetone. Subsequently, the solvent was distilled off. The residue was purified by column chromatography on silica gel with hexane/ethyl acetate (7/1-4/1) to give the subject compound (117 mg) as colorless oil (yield 92%)
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.26 (t, 3H, J=7 Hz), 1.30 (d, 6H, J=7 Hz), 2.31 (s, 3H), 2.75 (t, 2H, J=7 Hz), 3.18 (dq, 1H, J=7 Hz, J=7 Hz), 3.33 (t, 2H, J=7 Hz), 4.26 (q, 2H, J=7 Hz), 4.69 (s, 2H), 6.69 (d, 1H, J=8 Hz), 7.30 (dd, 1H, J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.8-7.85 (m, 2H), 7.89 (d, 1H, J=8 Hz).
Example 3
[4-[3-[2-(4-Trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) 3-[2-(4-Trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one
To an ice-cold THF (5 mL) was added 60% sodium hydride (27 mg, 0.67 mmol). Subsequently, a solution of ethyl 2-[(3-methyl-4-benzyloxy)benzoyl]acetate (190 mg, 0.61 mmol) in THF (3 mL) was dropwise added for 30 minutes. The mixture was allowed to room temperature, and then stirred for 30 minutes. To the mixture was added 5-iodomethyl-4-isopropyl-2-(4-trifluoromethyl)phenylthiazole (250 mg, 0.61 mmol). The resulting mixture was refluxed for 20 hours under nitrogen atmosphere, and allowed to room temperature. THF was removed under reduced pressure. To the residue was added acetic acid (3.2 mL)-conc. hydrochloric acid (0.8 mL), and the mixture was refluxed for 10 hours under heating, and allowed to room temperature. The reaction mixture was poured into ice water. The mixture was extracted with ethyl acetate. The organic layer was washed with a saturated aqueous sodium hydrogen carbonate solution, water, and a saline, dried over anhydrous sodium sulfate. Ethyl acetate was removed under reduced pressure, and the residue was purified by column chromatography on silica gel with hexane/ethyl acetate (3/1) to give the desired compound (195 mg) as pale yellowish white crystal (yield 73%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.33 (d, 6H, J=7 Hz), 2.29 (s, 3H), 3.14 (dq, 1H, J=7 Hz, J=7 Hz), 3.2-3.3 (m, 4H), 5.35 (s, 1H), 6.80 (d, 1H, J=8 Hz), 7.63 (d, 2H, J=8 Hz), 7.74 (dd, 1H, J=2, 8 Hz), 7.79 (d, 1H, J=2 Hz), 7.89 (d, 2H, J=8 Hz).
(2) Ethyl [4-[3-[2-(4-Trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2 (yield 80%).
Colorless oil
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 2.33 (s, 3H), 3.15 (dq, 1H, J=7 Hz, J=7 Hz), 3.2-3.3 (m, 4H), 4.27 (q, 2H, J=7 Hz), 4.71 (s, 2H), 6.71 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.75 (dd, 1H, J=2, 8 Hz), 7.81 (d, 1H, J=2 Hz), 8.00 (d, 2H, J=8 Hz).
(3) [4-[3-[2-(4-Trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2 using the obtained ester compound (yield 88%).
White powder (mp: 145-155° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.33 (d, 6H, J=7 Hz), 2.32 (s, 3H), 3.15 (dq, 1H, J=7 Hz, J=7 Hz), 3.2-3.3 (m, 4H), 4.76 (s, 2H), 6.75 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.81 (dd, 1H, J=2, 8 Hz), 7.82 (d, 1H, J=2 Hz), 8.00 (d, 2H, J=8 Hz).
Example 4
2-[4-[3-[2-(4-Trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[2-(4-Trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1 using the synthetic intermediate of Example 3, namely 3-[2-(4-trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one (yield 74%).
Colorless oil
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.21 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 1.65 (s, 6H), 2.27 (s, 3H), 3.15 (dq, 1H, J=7 Hz, J=7 Hz), 3.2-3.3 (m, 4H), 4.22 (q, 2H, J=7 Hz), 6.62 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.70 (dd, 1H, J=2, 8 Hz), 7.80 (d, 1H, J=2 Hz), 8.00 (d, 2H, J=8 Hz).
(2) 2-[4-[3-[2-(4-Trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1 using the obtained ester compound (yield 90%).
Pale yellow amorphous
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.33 (d, 6H, J=7 Hz), 1.67 (s, 6H), 2.27 (s, 3H), 3.14 (dq, 1H, J=7 Hz, J=7 Hz), 3.2-3.3 (m, 4H), 6.75 (d, 1H, J=8 Hz), 7.63 (d, 2H, J=8 Hz), 7.72 (dd, 1H, J=2, 8 Hz), 7.80 (d, 1H, J=2 Hz), 7.99 (d, 2H, J=8 Hz).
Example 5
[2-Allyl-4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]phenoxy]acetic acid
(1) 3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(4-hydroxyphenyl)propan-1-one
To an ice-cold THF (15 mL) was added 60% sodium hydride (120 mg, 3.00 mmol). Subsequently, a solution of ethyl 2-[(4-benzyloxy)benzoyl]acetate (900 mg, 3.02 mmol) in THF (15 mL) was dropwise added for 30 minutes. The mixture was allowed to room temperature, and then stirred for 30 minutes. To the mixture was added 4-iodomethyl-5-isopropyl-2-(2,4-dichlorophenyl)oxazole (1.20 g, 3.00 mmol). The resulting mixture was refluxed for 20 hours under nitrogen atmosphere, and allowed to room temperature. THF was removed under reduced pressure. To the residue was added acetic acid (7.5 mL)-conc. hydrochloric acid (2.0 mL), and the mixture was refluxed for 5 hours, and allowed to room temperature. The reaction mixture was poured into ice water, and extracted with ethyl acetate. The organic layer was washed with a saturated aqueous sodium hydrogen carbonate solution, water, and a saline, dried over anhydrous sodium sulfate. Ethyl acetate was removed under reduced pressure, and the residue was purified by column chromatography on silica gel with hexane/ethyl acetate (3/1) to give the desired compound (650 mg) as pale yellowish white crystal (yield 53%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.32 (d, 6H, J=7 Hz), 2.96 (t. 2H, J=7 Hz), 3.22 (dq, 1H, J=7 Hz, J=7 Hz), 3.25 (t, 2H, J=7 Hz), 6.77 (d, 2H, J=8 Hz), 7.29 (dd, 1H. J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.60 (s, 1H), 7.76 (d, 2H, J=8 Hz), 7.84 (d, 1H, J=8 Hz).
(2) 3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(4-allyloxyphenyl)propan-1-one
In acetone (5 mL), 3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(4-hydroxyphenyl)propan-1-one (202 mg, 0.50 mmol) and potassium carbonate (103 mg, 0.75 mmol) were suspended. Allyl bromide (91 mg, 0.75 mmol) was added to the suspension while cooling with ice. The suspension was stirred at room temperature for 20 hours. The reaction mixture was poured into water, and extracted with ethyl acetate. The organic layer was washed with water, and a saline, dried over anhydrous sodium sulfate. Ethyl acetate was removed under reduced pressure to give the subject compound (205 mg) as pale yellow solid residue (yield 92%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 2.96 (t, 2H. J=7 Hz), 3.18 (dq, 1H. J=7 Hz, J=7 Hz), 3.34 (t, 2H, J=7 Hz), 4.59 (dt, 2H, J=2, 5 Hz), 5.25-5.35 (m, 1H), 5.40-5.45 (m, 1H), 5.95-6.10 (m, 1H), 6.93 (d, 2H, J=9 Hz), 7.29 (dd, 1H, J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.89 (d, 1H, J=8 Hz), 7.96 (d, 2H, J=9 Hz).
(3) 3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-allyl-4-hydroxyphenyl)propan-1-one
At 180° C., 3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(4-allyloxyphenyl)propan-1-one (200 mg, 0.45 mmol) was heated for 5 hours. The compound was allowed to room temperature, the resulting compound was purified by column chromatography on silica gel with hexane/ethyl acetate (3/1) to give the desired compound (36 mg) as pale yellow oil (yield 18%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 2.96 (t, 2H, J=7 Hz), 3.18 (dq, 1H, J=7 Hz, J=7 Hz), 3.33 (t, 2H, J=7 Hz), 3.43 (d, 2H, J=6 Hz), 5.1-5.2 (m, 2H), 5.51 (s, 1H), 5.85-6.1 (m, 1H), 6.82 (d, 1H, J=8 Hz), 7.29 (dd, 1H, J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.79 (d, 1H, d, J=2 Hz), 7.80 (dd, 1H, J=2, 8 Hz), 7.88 (d, 1H, J=8 Hz).
(4) [2-Allyl-4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]phenoxy]ethyl acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2 (yield 84%).
Colorless oil
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.29 (t, 3H, J=7 Hz), 1.30 (d, 6H, J=7 Hz), 2.96 (t, 2H, J=7 Hz), 3.18 (dq, 1H, J=7 Hz, J=7 Hz), 3.33 (t, 2H, J=7 Hz), 3.47 (d, 2H, J=6 Hz), 4.26 (q, 2H, J=7 Hz), 4.69 (s, 2H), 5.05-5.15 (m, 2H), 5.95-6.10 (m, 1H), 6.73 (d, 1H, J=8 Hz), 7.30 (dd, 1H, J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.83 (d, 1H, J=2 Hz), 7.84 (dd, 1H, J=2, 8 Hz), 7.88 (d, 1H, J=8 Hz).
(5) [2-Allyl-4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]phenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2 (yield 81%).
White powder (mp: 145-150° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 2.96 (t, 2H, J=7 Hz), 3.19 (dq, 1H, J=7 Hz, J=7 Hz), 3.32 (t, 2H, J=7 Hz), 3.46 (d, 2H, J=6 Hz), 4.71 (s, 2H), 5.05-5.15 (m, 2H), 5.95-6.10 (m, 1H), 6.95 (d, 1H, J=8 Hz), 7.30 (dd, 1H, J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.81 (dd, 1H, J=2, 8 Hz), 7.83 (d, 1H, J=2 Hz), 7.86 (d, 1H, J=8 Hz).
Example 6
[4-[3-[2-(2-Hydroxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) 3-[2-(2-Methoxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one
To an ice-cold THF (50 mL) was added 60% sodium hydride (204 mg, 5.10 mmol). Subsequently, a solution of ethyl 2-[(3-methyl-4-benzyloxy)benzoyl]acetate (1.6 g, 5.12 mmol) in THF (25 mL) was dropwise added for 30 minutes. The mixture was allowed to room temperature, and then stirred for 30 minutes. To the mixture was added 4-iodomethyl-5-isopropyl-2-(2-methoxy-4-chlorophenyl)oxazole (2.00 g, 5.11 mmol). The resulting mixture was refluxed for 20 hours under nitrogen atmosphere, and allowed to room temperature. THF was removed under reduced pressure. To the residue was added acetic acid (16 mL)-conc. hydrochloric acid (4 mL), and the mixture was refluxed for 10 hours under heating. The mixture was allowed to room temperature, and poured into ice water. Ethyl acetate was added to the mixture. The organic layer was washed with a saturated aqueous sodium hydrogen carbonate solution, water, and a saline, dried over anhydrous sodium sulfate. Ethyl acetate was removed under reduced pressure, and the obtained residue was filtered, washed with an ether, and hexane to give the desired compound as white powder. Subsequently, the washings was concentrated, and the residue was filtered, washed with an ether, and hexane in the same manner as is mentioned above. The obtained powder was mixed with the previously obtained powder, and the mixed powder was dried under reduced pressure to give the desired compound (1.8 g) as pale yellowish white crystal (yield 70%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.32 (d, 6H, J=7 Hz), 2.18 (s, 3H), 2.91 (t, 2H, J=7 Hz), 3.06 (t, 2H, J=7 Hz), 3.18 (dq, 1H, J=7 Hz, J=7 Hz), 3.87 (s, 3H), 6.70 (d, 1H, J=8 Hz), 6.99 (d, 1H, J=2 Hz), 7.03 (dd, 1H, J=2, 8 Hz), 7.41 (dd, 1H, J=2, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.83 (d, 1H, J=8 Hz), 8.94 (s, 1H)
(2) 3-[2-(2-Hydroxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one]
The obtained 3-[2-(2-methoxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one (621 mg, 1.50 mmol) was suspended in methylene chloride (30 mL) and cooled with ice. To the suspension, a 1M methylene chloride solution of boron trichloride (BCl 3 ) (3.0 mL, 3.00 mmol) was dropwise added for 1 minute. The mixture was allowed to room temperature, stirred for 72 hours, and poured into ice water. Chloroform and saturated sodium hydrogen carbonate were added to the mixture. The organic layer was washed with water, and a saline, dried over anhydrous sodium sulfate. The chloroform was removed under reduced pressure. The residue was purified by column chromatography on silica gel with hexane/ethyl acetate (3/1) to give the desired compound (385 mg) as colorless oil (yield 64%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 2.27 (s, 3H), 2.94 (t, 2H, J=7 Hz), 3.19 (dq, 1H, J=7 Hz, J=7 Hz), 3.29 (t, 2H, J=7 Hz), 5.22 (s, 1H), 6.79 (d, 1H, J=8 Hz), 6.90 (dd, 1H, J=2, 8 Hz), 7.04 (d, 1H, J=2 Hz), 7.68 (d, 1H, J=8 Hz), 7.74 (dd, 1H, J=2, 8 Hz), 7.78 (d, 1H, J=2 Hz), 11.50 (s, 1H).
(3) [4-[3-[2-(2-Hydroxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]ethyl acetate
The obtained 3-[2-(2-hydroxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one (378 mg, 0.95 mmol) was dissolved in acetone (20 mL). To the solution, potassium carbonate (158 mg, 0.95 mmol) and ethyl bromoacetate (158 mg, 0.95 mmol) were added while cooling with ice. The mixture was allowed to room temperature, and stirred for 20 hours. After insoluble was filtered off, the mixture was washed with acetone to remove the solvent. The residue was purified by column chromatography on silica gel with hexane/ethyl acetate (4/1) to give the desired compound (315 mg) as white solid (yield 69%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.29 (t, 3H, J=7 Hz), 1.31 (d, 6H, J=7 Hz), 2.31 (s, 3H), 2.94 (t, 2H, J=7 Hz), 3.20 (dq, 1H, J=7 Hz, J=7 Hz), 3.30 (t, 2H, J=7 Hz), 4.26 (q, 2H, J=7 Hz), 4.69 (s, 2H), 6.70 (d, 1H, J=8 Hz), 6.90 (dd, 1H, J=2, 8 Hz), 7.04 (d, 1H, J=2 Hz), 7.68 (d, 1H, J=8 Hz), 7.75-7.85 (m, 2H), 11.48 (s, 1H).
(4) [4-[3-[2-(2-Hydroxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2 (yield 87%).
White powder (mp: 159-161° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 2.31 (s, 3H), 2.94 (t, 2H, J=7 Hz), 3.19 (dq, 1H, J=7 Hz, J=7 Hz), 3.30 (t, 2H, J=7 Hz), 4.76 (s, 2H), 6.74 (d, 1H, J=8 Hz), 6.90 (dd, 1H, J=2, 8 Hz), 7.04 (d, 1H, J=2 Hz), 7.68 (d, 1H, J=8 Hz), 7.80-7.85 (m, 2H).
Example 7
[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenylsulfanyl]acetic acid
(1) 3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-[3-methyl-4-(dimethylthiocarbamoyloxy)phenyl]propan-1-one
In dry dioxane (5 mL), 3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one (417 mg, 1.00 mmol) obtained in (1) of Example 1, 4-dimethylaminopyridine (12 mg, 0.10 mmol) and triethylamine (0.28 mL, 2.00 mmol). To the solution, dimethylthiocarbamoyl chloride (148 mg, 1.20 mmol) was added while cooling with ice. The reaction temperature was increased, and refluxed over night. The mixture was allowed to room temperature. To the mixture, 4-dimethylaminopyridine (12 mg, 0.10 mmol) and dimethylthiocarbamoyl chloride (148 mg, 1.20 mmol) were again added. The mixture was refluxed for 20 hours. The reaction mixture was allowed to room temperature, and poured into ice water. Ethyl acetate was added to the mixture. The organic layer was washed with water, and a saline, dried over anhydrous sodium sulfate. Ethyl acetate was removed under reduced pressure. The residue was purified by column chromatography on silica gel with hexane/ethyl acetate (3/1), and chloroform/methanol (100/1) to give the desired compound (170 mg) as a mixture with the starting materials.
(2) 3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-[3-methyl-4-(dimethylcarbamoylsulfanyl)phenyl]propan-1-one
The obtained crude thiocarbamoyl compound (160 mg) was dissolved in n-tetradecane (10 mL). The solution was refluxed at the internal temperature of 250° C. for 8 hours. The mixture was allowed to room temperature. The reaction mixture was directly purified by column chromatography on silica gel with hexane/ethyl acetate (3/1) to give the desired compound (120 mg) as a pale yellow oil (two steps yield 24%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 2.45 (s, 3H), 2.97 (t, 2H, J=7 Hz), 3.0-3.2 (br, 6H), 3.19 (dq, 1H, J=7 Hz, J=7 Hz), 3.38 (t, 2H, J=7 Hz), 7.30 (dd, 1H, J=2, 8 Hz), 7.48 (d, 1H, J=2 Hz), 7.57 (d, 1H, J=8 Hz), 7.78 (dd, 1H, J=2, 8 Hz), 7.88 (d, 1H, J=2 Hz), 7.89 (d, 1H, J=8 Hz).
(3) 3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-mercaptophenyl)propan-1-one
The obtained carbamoyl compound (110 mg, 0.22 mmol) was dissolved in dry methanol (5 mL). To the solution, 0.5N MeONa (0.66 mL, 0.33 mmol) was added. The mixture was refluxed for 20 hours, and allowed to room temperature. The mixture was poured into ice water. The mixture was neutralized with 3N hydrochloric acid. Ethyl acetate was added to the mixture. The organic layer was washed with water, and a saline, dried over anhydrous sodium sulfate. Ethyl acetate was removed under reduced pressure to obtain the desired compound (80 mg) as pale yellow oil (yield 84%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 2.34 (s, 3H), 2.96 (t, 2H, J=7 Hz), 3.18 (dq, 1H, J=7 Hz, J=7 Hz), 3.34 (t, 2H, J=7 Hz), 3.51 (s, 1H), 7.2-7.3 (m, 2H), 7.49 (d, 1H, J=2 Hz), 7.66 (dd, 1H, J=2, 8 Hz), 7.75 (d, 1H, J=2 Hz), 7.88 (d, 1H, J=8 Hz).
(4) Ethyl [4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenylsulfanyl]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2 (yield 89%).
Colorless oil
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.25 (t, 3H, J=7 Hz), 1.30 (d, 6H, J=7 Hz), 2.39 (s, 3H), 2.96 (t, 2H, J=7 Hz), 3.18 (dq, 1H, J=7 Hz, J=7 Hz), 3.35 (t, 2H, J=7 Hz), 3.73 (s, 2H), 4.20 (q, 2H, J=7 Hz), 7.2-7.35 (m, 2H), 7.49 (d, 1H, J=2 Hz), 7.7-7.8 (m, 2H), 7.88 (d, 1H, J=8 Hz).
(5) [4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenylsulfanyl]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2 using the obtained ester compound (yield 71%).
White powder (mp: 140-145° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 2.39 (s, 3H), 2.96 (t, 2H. J=7 Hz), 3.19 (dq, 1H. J=7 Hz, J=7 Hz), 3.32 (t, 2H, J=7 Hz), 3.77 (s, 2H), 7.2-7.35 (m, 2H), 7.49 (d, 1H, J=2 Hz), 7.7-7.8 (m, 2H), 7.87 (d, 1H, J=8 Hz).
Example 8
2-[4-[3-[2-(2-Hydroxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[2-(2-hydroxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
In methyl ethyl ketone (10 mL), 3-[2-(2-hydroxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one (150 mg, 0.38 mmol), ethyl 2-bromo-2-methylpropionate (146 mg, 0.75 mmol) and potassium carbonate (103 mg, 0.75 mmol) were suspended. The suspension was refluxed for 20 hours, and allowed to room temperature. After insoluble was filtered off, the mixture was washed with methyl ethyl ketone to removed the solvent. The residue was purified by column chromatography on silica gel with hexane/ethyl acetate (8/1) to give the desired compound (83 mg) as colorless oil (yield 43%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.21 (t, 3H, J=7 Hz), 1.31 (d, 6H, J=7 Hz), 1.64 (s, 6H), 2.25 (s, 3H), 2.93 (t, 2H, J=7 Hz), 3.19 (dq, 1H, J=7 Hz, J=7 Hz), 3.28 (t, 2H, J=7 Hz), 4.22 (q, 2H, J=7 Hz), 6.60 (d, 1H, J=9 Hz), 6.90 (dd, 1H, J=2, 9 Hz), 7.04 (d, 1H, J=2 Hz), 7.68 (d, 1H, J=9 Hz), 7.70 (dd, 1H, J=2, 9 Hz), 7.78 (d, 1H, J=2 Hz), 11.48 (s, 1H).
(2) 2-[4-[3-[2-(2-Hydroxy-4-chlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 2 using the obtained ester compound (yield 33%).
Pale white amorphous
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 1.68 (s, 6H), 2.27 (s, 3H), 2.94 (t, 2H, J=7 Hz), 3.20 (dq, 1H, J=7 Hz, J=7 Hz), 3.29 (t, 2H, J=7 Hz), 6.77 (d, 1H, J=9 Hz), 6.90 (dd, 1H, J=2, 9 Hz), 7.04 (d, 1H, J=2 Hz), 7.68 (d, 1H, J=9 Hz), 7.74 (dd, 1H, J=2, 9 Hz), 7.80 (d, 1H, J=2 Hz).
Example 9
[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-propenyl]-2-methylphenoxy]acetic acid
(1) 4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyloxazol-4-yl]-1-hydroxypropyl]-2-methylphenol
To a solution of lithium aluminum hydride (92 mg, 2.42 mmol) in dry THF (20 mL), 3-[2-(2,4-dichlorophenyl)-5-isopropyloxazol-4-yl]-1-(4-hydroxy-3-methylphenyl)propan-1-one (1.01 g, 2.41 mmol) was gradually added while cooling with ice. The mixture was stirred for 1 hour, and further stirred at room temperature. The reaction mixture was again cooled with ice. To the mixture, a saturated aqueous sodium sulfate solution was dropwise added. After insoluble materials were filtered out, the solvent was removed under reduced pressure. The residue was extracted with ethyl acetate, washed with water (15 mL) containing a small amount of a 1M aqueous solution of hydrochloric acid, and dried over anhydrous sodium sulfate. The solvent was removed under reduced pressure to obtain the desired compound (997 mg) as ocher yellow crystal (yield 98%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 3H, J=7 Hz), 1.31 (d, 3H, J=7 Hz), 2.07 (dt, 2H, J=7 Hz, 7 Hz), 2.24 (s, 3H), 2.67 (dt, 2H, J=2 Hz, 7 Hz), 3.07 (m, 1H), 3.65 (brs, 1H), 4.72 (t, 2H, J=7 Hz), 5.06 (s, 1H), 6.71 (d, 1H, J=8 Hz), 7.06 (dd, 1H, J=2 Hz, 8 Hz), 7.15 (d, 1H, J=2 Hz), 7.30 (dd, 1H, J=2 Hz, 8 Hz), 7.50 (d, 1H, J=2 Hz), 7.91 (d, 1H, J=8 Hz).
(2) 4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyloxazol-4-yl]-1-propenyl]-2-methylphenol
To the obtained phenol compound (840 mg, 2.00 mmol), DMSO (8 mL) was added. The mixture was stirred at 150° C. for 2 hours, and allowed to room temperature. Ethyl acetate (20 mL) was added to the mixture. The mixture was washed with water (20 mL), and then a saturated saline (20 mL). After the mixture was dried over anhydrous sodium sulfate, the solvent was removed under reduced pressure. The residue was recrystallized with ethyl acetate/hexane=1/10 (6.6 mL) to give the desired compound (58 mg) as pale yellow crystal (total yield 81%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 2.22 (s, 3H), 3.13 (m, 1H), 3.45 (dd, 2H, J=1 Hz, 6 Hz), 4.72 (brs, 1H), 6.19 (dt, 1H, J=6 Hz, 16 Hz), 6.37 (d, 1H, J=16 Hz), 6.69 (d, 1H, J=8 Hz), 7.06 (d, 1H, J=8 Hz), 7.12 (s, 1H), 7.30 (dd, 1H, J=2 Hz, 8 Hz), 7.50 (d, 1H, J=2 Hz), 7.93 (d, 1H, J=8 Hz).
(3) Ethyl [4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-propenyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.29 (t, 3H, J=7 Hz), 1.31 (d, 6H, J=7 Hz), 2.27 (s, 3H), 3.12 (m, 1H), 3.46 (dd, 2H, J=1 Hz, 6 Hz), 4.25 (q, 2H, J=7 Hz), 4.61 (s, 2H), 6.22 (dt, 1H, J=6 Hz, 16 Hz), 6.39 (d, 1H, J=16 Hz), 6.63 (d, 1H, J=8 Hz), 7.10 (dd, 1H, J=2 Hz, 8 Hz), 7.18 (d, 1H, J=2 Hz), 7.30 (dd, 1H, J=2 Hz, 8 Hz), 7.50 (d, 1H, J=2 Hz), 7.94 (d, 1H, J=8 Hz).
(4) [4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-propenyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Pale yellow crystal (mp: 143-144° C.) 1 H-NMR (DMSO-d 6 , 400 MHz) δ: 1.27 (d, 6H, J=7 Hz), 2.17 (s, 3H), 3.22 (m, 1H), 3.43 (d, 2H, J=6 Hz), 4.66 (s, 2H), 6.21 (dt, 1H, J=6 Hz, 16 Hz), 6.39 (d, 1H, J=16 Hz), 6.74 (d, 1H, J=8 Hz), 7.14 (dd, 1H, J=2 Hz, 8 Hz), 7.22 (d, 1H, J=2 Hz), 7.56 (dd, 1H, J=2 Hz, 8 Hz), 7.78 (d, 1H, J=2 Hz), 7.98 (d, 1H, J=8 Hz). IR (KBr) cm −1 : 2968, 2931, 1734, 1564, 1502, 1458, 1387, 1242, 1203, 1138, 1119, 966, 804.
Example 10
[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]-1-propenyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]-1-propenyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in Example 9.
1 H-NMR (CDCl 3 , 400 MHZ) δ: 1.29 (t, 3H, J=7 Hz), 1.34 (d, 6H, J=7 Hz), 2.28 (s, 3H), 3.12 (m, 1H), 3.67 (dd, 2H, J=1 Hz, 6 Hz), 4.26 (q, 2H, J=7 Hz), 4.62 (s, 2H), 6.17 (dt, 1H, J=6 Hz, 16 Hz), 6.40 (d, 1H, J=16 Hz), 6.65 (d, 1H, J=8 Hz), 7.11 (dd, 1H, J=2 Hz, 8 Hz), 7.19 (d, 1H, J=2 Hz), 7.64 (d, 2H, J=8 Hz), 8.01 (d, 2H, J=8 Hz).
(2) [4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]-1-propenyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Pale yellow powder (mp: 125-128° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.34 (d, 6H, J=7 Hz), 2.28 (s, 3H), 3.13 (m, 1H), 3.68 (dd, 2H, J=1 Hz, 6 Hz), 4.68 (s, 2H), 6.19 (dt, 1H, J=6 Hz, 16 Hz), 6.40 (d, 1H, J=16 Hz), 6.69 (d, 1H, J=8 Hz), 7.13 (dd, 1H, J=2 Hz, 8 Hz), 7.20 (d, 1H, J=2 Hz), 7.64 (d, 2H, J=8 Hz), 8.01 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2974, 1751, 1506, 1325, 1252, 1225, 1169, 1136, 1122, 1119, 1066, 843.
Example 11
[4-[3-[4-Hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[4-hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.89 (t, 3H, J=7 Hz), 1.29 (t, 3H, J=7 Hz), 1.3-1.5 (m, 6H), 1.7-1.8 (m, 2H), 2.33 (s, 3H), 2.75 (t, 2H, J=8 Hz), 3.2-3.3 (m, 4H), 4.27 (q, 2H, J=7 Hz), 4.71 (s, 2H), 6.72 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.8-7.9 (m, 2H), 7.97 (dd, 2H, J=1 Hz, 8 Hz).
(2) [4-[3-[4-Hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Yellow amorphous
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.88 (t, 3H, J=7 Hz), 1.3-1.5 (m, 6H), 1.7-1.8 (m, 2H), 2.32 (s, 3H), 2.75 (t, 2H, J=8 Hz), 3.2-3.3 (m, 4H), 4.76 (s, 2H), 6.75 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.7-7.9 (m, 2H), 7.97 (dd, 2H, J=1 Hz, 8 Hz). IR (KBr) cm −1 : 2954, 2929, 2858, 1724, 1676, 1603, 1500, 1441, 1327, 1284, 1219, 1169, 1142, 1111, 1068.
Example 12
2-[4-[3-[4-Hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[4-hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.89 (t, 3H, J=7 Hz), 1.21 (t, 3H, J=7 Hz), 1.2-1.5 (m, 6H), 1.65 (s, 6H), 1.7-1.8 (m, 2H), 2.27 (s, 3H), 2.74 (t, 2H, J=8 Hz), 3.2-3.3 (m, 4H), 4.22 (q, 2H, J=7 Hz), 6.62 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.70 (dd, 1H, J=2 Hz, 8 Hz), 7.80 (d, 1H, J=2 Hz), 7.98 (d, 2H, J=8 Hz).
(2) 2-[4-[3-[4-Hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Yellow oil
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.88 (t, 3H, J=7 Hz), 1.3-1.5 (m, 6H), 1.6-1.8 (m, 2H), 1.69 (s, 6H), 2.27 (s, 3H), 2.74 (t, 2H, J=8 Hz), 3.2-3.3 (m, 4H), 6.75 (d, 1H, J=8 Hz), 7.63 (d, 2H, J=8 Hz), 7.72 (dd, 1H, J=2 Hz, 8 Hz), 7.80 (d, 1H, J=2 Hz), 7.97 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2956, 2927, 2858, 1741, 1678, 1601, 1500, 1325, 1261, 1169, 1124, 1066, 845.
Example 13
2-[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]-1-propenyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]-1-propenyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.25 (t, 3H, J=7 Hz), 1.34 (d, 6H, J=7 Hz), 1.55 (s, 6H), 2.21 (s, 3H), 3.12 (m, 1H), 3.67 (dd, 2H, J=1 Hz, 6 Hz), 4.24 (q, 2H, J=7 Hz), 6.17 (dt, 1H, J=6 Hz, 16 Hz), 6.38 (d, 1H, J=16 Hz), 6.60 (d, 1H, J=8 Hz), 7.03 (dd, 1H, J=2 Hz, 8 Hz), 7.16 (d, 1H, J=2 Hz), 7.64 (d, 2H, J=8 Hz), 8.01 (d, 2H, J=8 Hz).
(2) 2-[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]-1-propenyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Yellow oil
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.34 (d, 6H, J=7 Hz), 1.61 (s, 6H), 2.23 (s, 3H), 3.13 (m, 1H), 3.68 (dd, 2H, J=1 Hz, 6 Hz), 6.20 (dt, 1H, J=6 Hz, 16 Hz), 6.40 (d, 1H, J=16 Hz), 6.77 (d, 1H, J=8 Hz), 7.09 (dd, 1H, J=2 Hz, 8 Hz), 7.19 (d, 1H, J=2 Hz), 7.64 (d, 2H, J=8 Hz), 8.01 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2970, 2929, 2872, 1716, 1616, 1500, 1325, 1167, 1126, 1066, 964, 845.
Example 14
[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-3-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-3-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 2.56 (s, 3H), 3.15 (m, 1H), 3.23 (s, 4H), 4.28 (q, 2H, J=7 Hz), 4.65 (s, 2H), 6.75 (dd, 1H, J=2 Hz, 9 Hz), 6.78 (d, 1H, J=2 Hz), 7.64 (d, 2H, J=9 Hz), 7.70 (d, 1H, J=9 Hz), 8.00 (d, 2H, J=9 Hz).
(2) [4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-3-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
White crystal (mp: 136-142° C.)
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.33 (d, 6H, J=7 Hz), 2.56 (s, 3H), 3.15 (m, 1H), 3.23 (s, 4H), 4.72 (s, 2H), 6.7-6.8 (m, 2H), 7.64 (d, 2H, J=8 Hz), 7.71 (d, 1H, J=9 Hz), 8.00 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2962, 1741, 1672, 1603, 1574, 1450, 1325, 1260, 1236, 1211, 1168, 1126, 1066, 976, 849, 698, 611.
Example 15
[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-3-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-3-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (t, 3H, J=7 Hz), 1.30 (d, 6H, J=7 Hz), 2.53 (s, 3H), 2.94 (t, 2H, J=7 Hz), 3.19 (m, 1H), 3.29 (t, 2H, J=7 Hz), 4.27 (q, 2H, J=7 Hz), 4.64 (s, 2H), 6.72 (dd, 1H, J=2 Hz, 8 Hz), 6.76 (d, 1H, J=2 Hz), 7.30 (dd, 1H, J=2, 9 Hz), 7.49 (d, 1H, J=2 Hz), 7.76 (d, 1H, J=9 Hz), 7.88 (d, 1H, J=8 Hz).
(2) [4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-3-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
White crystal (mp: 97-102° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 2.51 (s, 3H), 2.93 (t, 2H, J=7 Hz), 3.19 (m, 1H), 3.26 (t, 2H, J=7 Hz), 4.65 (s, 2H), 6.71 (dd, 1H, J=2 Hz, 8 Hz), 6.75 (d, 1H, J=2 Hz), 7.29 (dd, 1H, J=2 Hz, 8 Hz), 7.48 (d, 1H, J=2 Hz), 7.72 (d, 1H, J=8 Hz), 7.85 (d, 1H, J=8 Hz). IR (KBr) cm −1 : 3454, 2976, 1730, 1682, 1637, 1605, 1564, 1460, 1383, 1363, 1317, 1242, 1201, 1178, 1120, 1072, 1051, 978, 868, 818, 741.
Example 16
[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-3-methylphenoxy]-2-methylpropionic acid
(1) Ethyl [4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-3-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.22 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 1.63 (s, 6H), 2.52 (s, 3H), 3.14 (m, 1H), 3.22 (s, 4H), 4.22 (q, 2H, J=7 Hz), 6.63 (dd, 1H, J=2 Hz, 9 Hz), 6.90 (d, 1H, J=2 Hz), 7.64 (d, 1H, J=9 Hz), 7.64 (d, 2H, J=9 Hz), 8.00 (d, 2H, J=9 Hz).
(2) [4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-3-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Yellow amorphous
1 H-NMR (CDCl 3 400 MHz) δ: 1.33 (d, 6H, J=7 Hz), 1.66 (s, 6H), 2.53 (s, 3H), 3.14 (m, 1H), 3.23 (s, 4H), 6.74 (dd, 1H, J=2 Hz, 8 Hz), 6.78 (d, 1H, J=2 Hz), 7.64 (d, 2H, J=8 Hz), 7.66 (d, 1H, J=8 Hz), 8.00 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 3456, 2968, 2929, 2873, 1740, 1736, 1678, 1603, 1325, 1248, 1167, 1126, 1066.
Example 17
2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-3-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-3-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.22 (t, 3H, J=7 Hz), 1.30 (d, 6H, J=7 Hz), 1.63 (s, 6H), 2.49 (s, 3H), 2.93 (t, 2H, J=7 Hz), 3.18 (m, 1H), 3.28 (t, 2H, J=7 Hz), 4.23 (q, 2H, J=7 Hz), 6.61 (dd, 1H, J=2 Hz, 9 Hz), 6.67 (d, 1H, J=2 Hz), 7.30 (dd, 1H, J=2 Hz, 9 Hz), 7.49 (d, 1H, J=2 Hz), 7.70 (d, 1H, J=9 Hz), 7.88 (d, 1H, J=9 Hz)
(2) 2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-3-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
White crystal (mp: 98-100° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 1.63 (s, 6H), 2.47 (s, 3H), 2.92 (t, 2H, J=7 Hz), 3.1-3.3 (m, 3H), 6.66 (dd, 1H, J=2 Hz, 9 Hz), 6.73 (d, 1H, J=2 Hz), 7.27 (dd, 1H, J=2 Hz, 8 Hz), 7.48 (d, 1H, J=2 Hz), 7.55 (d, 1H, J=9 Hz), 7.83 (d, 1H, J=8 Hz). IR (KBr) cm −1 : 2980, 2940, 1720, 1680, 1600, 1560, 1460, 1250, 1145, 1125.
Example 18
[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-propylphenoxy]acetic acid
(1) Ethyl 2-allyl-4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]phenoxyacetate
The desired compound was obtained in an analogous manner as in (2), (3) and (4) of Example 5.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.29 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 3.15 (m, 1H), 3.2-3.3 (m, 4H), 3.48 (d, 2H, J=7 Hz), 4.26 (q, 2H, J=7 Hz), 4.71 (s, 2H), 5.1-5.2 (m, 2H), 5.9-6.1 (m, 1H), 6.75 (d, 1H, J=9 Hz), 7.64 (d, 2H, J=8 Hz), 7.8-7.9 (m, 2H), 8.00 (d, 2H, J=8 Hz).
(2) Ethyl [4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-propylphenoxy]acetate
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.95 (t, 3H, J=7 Hz), 1.28 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 1.6-1.8 (m, 2H), 2.68 (t, 2H, J=7 Hz), 3.15 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 4.26 (q, 2H, J=7 Hz), 4.70 (s, 2H), 6.72 (d, 1H, J=9 Hz), 7.64 (d, 2H, J=8 Hz), 7.7-7.9 (m, 2H), 8.00 (d, 2H, J=8 Hz).
(3) [4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-propylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Pale white crystal (mp: 145-150° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 0.96 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 1.6-1.8 (m, 2H), 2.68 (t, 2H, J=7 Hz), 3.15 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 4.77 (s, 2H), 6.76 (d, 1H, J=9 Hz), 7.64 (d, 2H, J=8 Hz), 7.7-7.9 (m, 2H), 8.00 (d, 2H, J=8 Hz).
Example 19
2-Allyl-4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]phenoxyacetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Pale yellow crystal (mp: 165-175° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.33 (d, 6H, J=7 Hz), 3.15 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.4 (m, 4H), 3.48 (d, 2H, J=7 Hz), 4.76 (s, 2H), 5.0-5.1 (m, 2H), 5.9-6.1 (m, 1H), 6.79 (d, 1H, J=9 Hz), 7.64 (d, 2H, J=8 Hz), 7.8-7.9 (m, 2H), 8.00 (d, 2H, J=8 Hz)
Example 20
[4-[4-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-buten-2-yl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[4-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-buten-2-yl]-2-methylphenoxy]acetate
In a dry ether (2 mL), potassium t-butoxide (120 mg, 1.07 mmol) was suspended. Methyl triphenyl phosphonium bromide (350 mg, 0.98 mmol) was added to the suspension. The mixture was stirred for 2 hours at room temperature. [4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]ethyl acetate (450 mg, 0.89 mmol) and a dry ether (1.5 mL) were added to the mixture. The resulting mixture was stirred for 16 hours at room temperature. Methyl triphenyl phosphonium bromide (175 mg, 0.49 mmol), a dry ether (5 mL) and potassium t-butoxide (60 mg, 0.53 mmol) were added to the reaction mixture. The resulting mixture was stirred for 30 minutes at room temperature. The mixture was refluxed for 4 hours, and allowed to room temperature. Ethyl acetate (10 mL) was added to the reaction mixture. The mixture was washed with water (10 mL), and a saturated saline (10 mL), and dried over anhydrous sodium sulfate. The solvent was removed under reduced pressure. The residue was purified by column chromatography on silica gel with ethyl acetate/hexane (1/9) to give the desired compound (131 g) as colorless oil (yield 29%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.24 (d, 6H, J=7 Hz), 1.30 (t, 3H, J=7 Hz), 2.29 (s, 3H), 2.6-2.7 (m, 2H), 2.8-3.0 (m, 3H), 3.27 (q, 2H, J=7 Hz), 4.63 (s, 2H), 5.00 (d, 1H, J=1 Hz), 5.23 (d, 1H, J=1 Hz), 7.66 (d, 1H, J=8 Hz), 8.21 (dd, 1H, J=2 Hz, 8 Hz), 7.26 (d, 1H, J=2 Hz), 7.31 (dd, 1H, J=2 Hz, 8 Hz), 7.50 (d, 1H, J=2 Hz), 7.92 (d, 1H, J=8 Hz).
(2) [4-[4-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-buten-2-yl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Pale yellow oil
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.25 (d, 6H, J=7 Hz), 2.29 (s, 3H), 2.6-2.7 (m, 2H), 2.8-2.9 (m, 2H), 2.93 (m, 1H), 4.65 (s, 2H), 5.01 (d, 1H, J=1 Hz), 5.23 (d, 1H, J=1 Hz), 6.69 (d, 1H, J=8 Hz), 7.22 (dd, 1H, J=2 Hz, 8 Hz), 7.26 (d, 1H, J=2 Hz), 7.32 (dd, 1H, J=2 Hz, 8 Hz), 7.50 (d, 1H, J=2 Hz), 7.91 (d, 1H, J=8 Hz). IR (KBr) cm −1 : 3088, 2968, 2927, 2872, 1736, 1605, 1564, 1504, 1460, 1225, 1142, 1107.
Example 21
2-[4-[4-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-buten-2-yl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[4-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-buten-2-yl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.23 (d, 6H, J=7 Hz), 1.26 (t, 3H, J=7 Hz), 1.59 (s, 6H), 2.30 (s, 3H), 2.6-2.7 (m, 2H), 2.8-3.0 (m, 3H), 3.25 (q, 2H, J=7 Hz), 4.99 (d, 1H, J=1 Hz), 5.23 (d, 1H, J=1 Hz), 6.62 (d, 1H, J=8 Hz), 7.13 (dd, 2H, J=1 Hz, 8 Hz), 7.24 (d, 1H, J=2 Hz), 7.31 (dd, 1H, J=2 Hz, 8 Hz), 7.50 (d, 1H, J=2 Hz), 7.92 (d, 1H, J=8 Hz).
(2) 2-[4-[4-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-1-buten-2-yl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Brown oil
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.24 (d, 6H, J=7 Hz), 1.61 (s, 6H), 2.24 (s, 3H), 2.6-2.7 (m, 2H), 2.8-2.9 (m, 2H), 2.91 (m, 1H), 5.03 (d, 1H, J=1 Hz), 5.25 (d, 1H, J=1 Hz), 6.79 (d, 1H, J=8 Hz), 7.18 (dd, 1H, J=2 Hz, 8 Hz), 7.26 (m, 1H), 7.31 (dd, 1H, J=2 Hz, 8 Hz), 7.50 (d, 1H, J=2 Hz), 7.91 (d, 1H, J=8 Hz). IR (KBr) cm −1 : 2972, 2935, 2873, 1716, 1603, 1564, 1500, 1464, 1385, 1250, 1151, 1107.
Example 22
[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-2-methylpropionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-2-methylpropionyl]-2-methylphenoxy]acetate
Ethyl [4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-methylphenoxy]acetate (450 mg, 0.89 mmol) was dissolved in dry THF (4 mL). Sodium hydride (40 mg, 1.00 mmol) was gradually added to the solution. The mixture was stirred for 30 minutes at room temperature.
Methyl iodide (0.07 mL, 1.12 mmol) was dropwise added to the mixture. The resulting mixture was stirred for 27 hours at room temperature. Sodium hydride (10 mg, 0.25 mmol) and methyl iodide (0.02 mL, 0.32 mmol) were further added to the mixture. The resulting mixture was stirred for 19 hours 30 minutes at room temperature. The solvent was removed under reduced pressure. Ethyl acetate (5 mL) was added to the residue. The residue was washed with a saturated saline (2 mL), and dried over anhydrous sodium sulfate. The solvent was removed under reduced pressure. The residue was purified by column chromatography on silica gel with ethyl acetate/hexane (1/9) to give the desired compound (218 mg) as colorless oil (purity 97%, yield 29%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.18 (d, 3H, J=7 Hz), 1.22 (d, 3H, J=7 Hz), 1.28 (d, 3H, J=7 Hz), 1.29 (t, 3H, J=7 Hz), 2.29 (s, 3H), 2.63 (dd, 1H, J=7 Hz, 14 Hz), 3.00 (dd, 1H, J=7 Hz, 14 Hz), 3.10 (m, 1H), 4.00 (m, 1H), 4.26 (q, 2H, J=7 Hz), 4.68 (s, 2H), 6.67 (d, 1H, J=8 Hz), 7.30 (dd, 1H, J=2 Hz, 8 Hz), 7.48 (d, 1H, J=2 Hz), 7.8-7.9 (m, 2H), 7.85 (d, 1H, J=8 Hz).
(2) [4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-2-methylpropionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
White amorphous
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.18 (d, 3H, J=7 Hz), 1.22 (d, 3H, J=7 Hz), 1.28 (d, 3H, J=7 Hz), 2.28 (s, 3H), 2.64 (dd, 1H, J=7, 14 Hz), 2.98 (dd, 1H, J=7 Hz, 14 Hz), 3.13 (m, 1H), 3.95 (m, 1H), 4.64 (s, 2H), 6.66 (d, 1H, J=8 Hz), 7.30 (dd, 1H, J=2 Hz, 8 Hz), 7.48 (d, 1H, J=2 Hz), 7.76 (dd, 1H, J=2 Hz, 8 Hz), 7.81 (m, 1H), 7.82 (d, 1H, J=8 Hz). IR (KBr) cm −1 : 3427, 2970, 2931, 2873, 1740, 1672, 1599, 1564, 1502, 1456, 1383, 1271, 1230, 1120.
Example 23
2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-2-methylpropionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]-2-methylpropionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.20 (d, 3H, J=7 Hz), 1.22 (d, 3H, J=7 Hz), 1.27 (d, 3H, J=7 Hz), 1.63 (s, 3H), 1.63 (s, 3H), 2.23 (s, 3H), 2.62 (dd, 1H, J=7 Hz, 14 Hz), 2.99 (dd, 1H, J=7 Hz, 14 Hz), 3.10 (m, 1H), 3.99 (m, 1H), 4.20 (q, 2H, J=7 Hz), 6.58 (d, 1H, J=8 Hz), 7.30 (dd, 1H, J=2 Hz, 8 Hz), 7.48 (d, 1H, J=2 Hz), 7.73 (dd, 1H, J=2 Hz, 8 Hz), 7.80 (d, 1H, J=2 Hz), 7.85 (d, 1H, J=8 Hz).
(2) 2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]-2-methylpropionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
White amorphous
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.16 (d, 3H, J=7 Hz), 1.21 (d, 3H, J=7 Hz), 1.27 (d, 3H, J=7 Hz), 1.65 (s, 3H), 1.66 (s, 3H), 2.23 (s, 3H), 2.63 (dd, 1H, J=7 Hz, 14 Hz), 2.97 (dd, 1H, J=7 Hz, 14 Hz), 3.13 (m, 1H), 3.94 (m, 1H), 6.71 (d, 1H, J=8 Hz), 7.26 (m, 1H), 7.46 (d, 1H, J=2 Hz), 7.61 (dd, 1H, J=2 Hz, 8 Hz), 7.7-7.9 (m, 2H). IR (KBr) cm −1 : 3456, 3431, 2972, 2933, 2873, 1740, 1674, 1599, 1564, 1498, 1462, 1385, 1257, 1142, 1119.
Example 24
[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propenoyl]-2-methylphenoxy]acetic acid
(1) 3-[4-Isopropyl-2-(4-trifluoromethylphenyl)thiazol-5-yl]-1-(4-methoxymethoxy-3-methylphenyl)propenone
To a mixture of dry MeOH (3 mL) and dry THF (3 mL), 4-isopropyl-2-(4-trifluoromethylphenyl)thiazol-5-carboxyl aldehyde (803 mg, 2.68 mmol), 1-(4-methoxymethoxy-3-methylphenyl)ethanone (521 mg, 2.68 mmol) and sodium methoxide (9 mg, 0.13 mmol) were added. The resulting mixture was stirred for 14 hours at room temperature. Sodium methoxide (36 mg, 0.53 mmol) and dry MeOH (3 mL) were added again to the mixture. The resulting mixture was stirred for 26 hours at room temperature. The solvent was removed under reduced pressure. Ethyl acetate (30 mL) was added to the residue. The residue was washed with water (40 mL). The aqueous layer was extracted with ethyl acetate (30 mL, 20 mL). The organic layer was added to the aqueous layer. The mixture was washed with a saturated saline (20 mL), dried over anhydrous sodium sulfate. The solvent was removed under reduced pressure. The residue was purified by column chromatography on silica gel with ethyl acetate/hexane (1/9) to give the desired compound (1.04 g) as a yellow crystal (yield 81%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.39 (d, 6H, J=7 Hz), 2.33 (s, 3H), 3.43 (m, 1H), 3.51 (s, 3H), 5.30 (s, 2H), 7.14 (d, 1H, J=8 Hz), 7.30 (d, 1H, J=15 Hz), 7.71 (d, 2H, J=8 Hz), 7.8-7.9 (m, 2H), 8.04 (d, 1H, J=15 Hz), 8.11 (d, 2H, J=8 Hz).
(2) 1-(4-Hydroxy-3-methylphenyl)-3-[4-isopropyl-2-(4-trifluoromethylphenyl)thiazol-5-yl]propenone
In a mixture of isopropanol (4 mL) and THF (16 mL), 3-[4-isopropyl-2-(4-trifluoromethylphenyl)thiazol-5-yl]-1-(4-methoxymethoxy-3-methylphenyl)propenone (1.049 g, purity 99.6%, 2.18 mmol) was dissolved. To the mixture, a 1M aqueous solution of hydrochloric acid (2.6 mL) was added. The resulting mixture was stirred for 4 hours at room temperature, and for 19 hours and 30 minutes at 65° C. The solvent was removed under reduced pressure. The residue was suspended in a mixture of ethanol (6 mL) and hexane (2 mL). The crystals were filtered, washed with a mixture of ethanol (2 mL) and hexane (2 mL), and with hexane (2 mL), and dried for 30 minutes at room temperature under reduced pressure to give the desired compound (908 mg) as a yellow crystal (yield 97%).
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.39 (d, 6H, J=7 Hz), 2.32 (s, 3H), 3.44 (m, 1H), 6.85 (d, 1H, J=8 Hz), 7.31 (d, 1H, J=15 Hz), 7.71 (d, 2H, J=8 Hz), 7.81 (dd, 1H, J=2 Hz, 8 Hz), 7.81 (bs, 1H), 8.03 (d, 1H, J=15 Hz), 8.11 (d, 2H, J=8 Hz).
(3) Ethyl [4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propenoyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (t, 3H, J=7 Hz), 1.39 (d, 6H, J=7 Hz), 2.38 (s, 3H), 3.44 (m, 1H), 4.29 (q, 2H, J=7 Hz), 4.74 (s, 2H), 6.77 (d, 1H, J=8 Hz), 7.29 (d, 1H, J=15 Hz), 7.71 (d, 2H, J=8 Hz), 7.86 (dd, 1H, J=2 Hz, 8 Hz), 7.88 (bs, 1H), 8.03 (d, 1H, J=15 Hz), 8.11 (d, 2H, J=8 Hz).
(4) [4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propenoyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Yellow crystal (mp: 203-205° C. (dec.)) 1 H-NMR (CD 3 OD/CDCl 3 =1/20, 400 MHz) δ: 1.39 (d, 6H, J=7 Hz), 2.37 (s, 3H), 3.44 (m, 1H), 4.71 (s, 2H), 6.82 (d, 1H, J=8 Hz), 7.30 (d, 1H, J=15 Hz), 7.72 (d, 2H, J=8 Hz), 7.8-7.9 (m, 2H), 8.03 (d, 1H, J=15 Hz), 8.11 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2964, 2870, 1761, 1741, 1601, 1581, 1329, 1269, 1230, 1188, 1171, 1132, 1109, 1168, 823.
Example 25
2-[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propenoyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazole]propenoyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.23 (t, 3H, J=7 Hz), 1.38 (d, 6H, J=7 Hz), 1.68 (s, 6H), 2.32 (s, 3H), 3.44 (m, 1H), 4.24 (q, 2H, J=7 Hz), 6.68 (d, 1H, J=8 Hz), 7.29 (d, 1H, J=15 Hz), 7.71 (d, 2H, J=8 Hz), 7.78 (dd, 1H, J=2 Hz, 8 Hz), 7.87 (d, 1H, J=2 Hz), 8.02 (d, 1H, J=15 Hz), 8.11 (d, 2H, J=8 Hz).
(2) 2-[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazole]propenoyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Yellow crystal (mp: 187-189° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.38 (d, 6H, J=7 Hz), 1.72 (s, 6H), 2.33 (s, 3H), 3.46 (m, 1H), 6.82 (d, 1H, J=8 Hz), 7.28 (d, 1H, J=15 Hz), 7.71 (d, 2H, J=8 Hz), 7.82 (dd, 1H, J=2 Hz, 8 Hz), 7.88 (d, 1H, J=2 Hz), 8.04 (d, 1H, J=15 Hz), 8.10 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 3466, 2972, 1740, 1657, 1655, 1639, 1603, 1500, 1327, 1325, 1273, 1169, 1128, 1068.
Example 26
[4-[3-[4-Isopropyl-2-(4-methoxyphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]propionic acid
(1) Ethyl [4-[3-[4-isopropyl-2-(4-methoxyphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]propionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.29 (t, 3H, J=7 Hz), 1.32 (d, 6H, J=7 Hz), 2.32 (s, 3H), 3.11 (dq, 1H, J=7 Hz, 7 Hz), 3.1-3.3 (m, 4H), 3.84 (s, 3H), 4.27 (q, 2H, J=7 Hz), 4.70 (s, 2H), 6.71 (d, 1H, J=8 Hz), 6.8-7.0 (m, 2H), 7.7-7.9 (m, 4H).
(2) [4-[3-[4-Isopropyl-2-(4-methoxyphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]propionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Pale yellow crystal (mp: 170-172° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 2.32 (3H, s), 3.11 (dq, 1H, J=7 Hz, 7 Hz), 3.1-3.3 (m, 4H), 3.84 (s, 3H), 4.76 (s, 2H), 6.74 (d, 1H, J=8 Hz), 6.91 (d, 2H, J=9 Hz), 7.7-7.9 (m, 4H). IR (KBr) cm −1 : 2970, 1726, 1672, 1605, 1517, 1456, 1367, 1304, 1302, 1300, 1282, 1261, 1209, 1176, 1130, 1065, 1034, 1018, 995, 843, 824.
Example 27
[4-[3-[2-(3,5-Difluorophenyl)-4-isopropylthiazol-5-yl]propionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[2-(3,5-difluorophenyl)-4-isopropylthiazol-5-yl]propionyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.28 (t, 3H, J=7 Hz), 1.32 (d, 6H, J=7 Hz), 2.33 (s, 3H), 3.14 (m, 1H), 3.2-3.3 (m, 4H), 4.27 (q, 2H, J=7 Hz), 4.71 (s, 2H), 6.71 (d, 1H, J=8 Hz), 6.7-6.9 (m, 1H), 7.4-7.5 (m, 2H), 7.7-7.8 (m, 2H).
(2) [4-[3-[2-(3,5-Difluorophenyl)-4-isopropylthiazol-5-yl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Pale yellow crystal (mp: 125-128° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 2.32 (s, 3H), 3.13 (m, 1H), 3.2-3.3 (m, 4H), 4.75 (s, 2H), 6.7-6.8 (m, 2H), 7.4-7.5 (m, 2H), 7.7-7.9 (m, 2H). IR (KBr) cm −1 : 3446, 2970, 2929, 2376, 1749, 1743, 1676, 1620, 1599, 1533, 1504, 1502, 1458, 1439, 1363, 1321, 1271, 1230, 1176, 1136, 1134, 1132, 1072, 1053, 987, 879, 847, 808, 677.
Example 28
2-[4-[3-[2-(3,5-Difluorophenyl)-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[2-(3,5-difluorophenyl)-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.21 (t, 3H, J=7 Hz), 1.31 (d, 6H, J=7 Hz), 1.65 (s, 6H), 2.27 (3H, s), 3.13 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 4.22 (q, 2H, J=7 Hz), 6.62 (d, 1H, J=9 Hz), 6.79 (dt, 1H, J=2 Hz, 9 Hz), 7.4-7.5 (m, 2H), 7.69 (dd, 1H, J=2 Hz, 9 Hz), 7.79 (d, 1H, J=2 Hz).
(2) 2-[4-[3-[2-(3,5-Difluorophenyl)-4-isopropylthiazol-5-yl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
White crystal (mp: 132-133° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 1.69 (s, 6H), 2.28 (s, 3H), 3.13 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 6.77 (d, 1H, J=9 Hz), 6.7-6.8 (m, 1H), 7.4-7.5 (m, 2H), 7.73 (dd, 1H, J=2 Hz, 9 Hz), 7.81 (d, 1H, J=2 Hz). IR (KBr) cm −1 : 2974, 2927, 1741, 1652, 1620, 1605, 1535, 1506, 1502, 1458, 1363, 1327, 1321, 1284, 1263, 1147, 1122, 1068, 987, 876, 850, 675.
Example 29
[4-[3-[4-Isopropyl-2-(2-naphthyl)-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[4-isopropyl-2-(2-naphthyl)-5-thiazolyl]propionyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.28 (3H, t, J=7 Hz), 1.37 (6H, d, J=7 Hz), 2.33 (3H, s), 3.18 (1H, m), 3.2-3.3 (4H, m), 4.25 (2H, q, J=7 Hz), 4.69 (2H, s), 6.71 (1H, d, J=8 Hz), 6.4-6.5 (2H, m), 7.7-7.9 (5H, m), 8.04 (1H, dd, J=2 Hz, 8 Hz), 8.34 (1H, s)
(2) [4-[3-[4-Isopropyl-2-(2-naphthyl)-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Pale yellow crystal (mp: 97-100° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.37 (6H, d, J=7 Hz), 2.32 (3H, s), 3.18 (1H, m), 3.2-3.3 (4H, m), 4.76 (2H, s), 6.74 (1H, d, J=8 Hz), 7.4-7.5 (2H, m), 7.7-7.9 (5H, m), 8.03 (1H, dd, J=2 Hz, 8 Hz), 8.33 (1H, s). IR (KBr) cm −1 : 3845, 3745, 3429, 2962, 2929, 2368, 2345, 1749, 1676, 1601, 1506, 1502, 1362, 1255, 1228, 1132, 1068, 858, 813, 748, 476, 420
Example 30
2-[4-[3-[4-Isopropyl-2-(2-naphthyl)-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
White crystal (mp: 164-166° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.36 (d, 6H, J=7 Hz), 1.68 (s, 6H), 2.28 (s, 3H), 3.16 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.4 (m, 4H), 6.76 (d, 1H, J=8 Hz), 7.4-7.5 (m, 2H), 7.73 (dd, 1H, J=2 Hz, 8 Hz), 7.8-7.9 (m, 3H), 7.82 (d, 1H, J=2 Hz), 8.03 (dd, 1H, J=2 Hz, 9 Hz), 8.34 (s, 1H). IR (KBr) cm −1 : 2966, 1741, 1655, 1620, 1605, 1365, 1284, 1263, 1180, 1147, 1146, 808, 750.
Example 31
[4-[3-[2-(4-Butylphenyl)-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[2-(4-butylphenyl)-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.92 (3H, t, J=7 Hz), 1.29 (3H, t, J=7 Hz), 1.32 (6H, d, J=7 Hz), 1.3-1.4 (2H, m), 1.5-1.6 (2H, m), 2.32 (3H, s), 2.62 (2H, t, J=8 Hz), 3.15 (1H, m), 3.2-3.3 (4H, m), 4.26 (2H, q, J=7 Hz), 4.70 (2H, s), 6.71 (1H, d, J=8 Hz), 7.19 (2H, d, J=8 Hz), 7.7-7.8 (4H, m).
(2) [4-[3-[2-(4-Butylphenyl)-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Pale yellow amorphous
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.92 (3H, t, J=7 Hz), 1.31 (6H, d, J=7 Hz), 1.3-1.4 (2H, m), 1.5-1.7 (2H, m), 2.31 (3H, s), 2.62 (2H, t, J=8 Hz), 3.12 (1H, m), 3.1-3.3 (4H, m), 4.74 (2H, s), 6.72 (1H, d, J=8 Hz), 7.19 (2H, d, J=8 Hz), 7.7-7.8 (4H, m). IR (KBr) cm −1 : 3435, 2960, 2929, 2870, 2860, 2368, 1741, 1676, 1601, 1502, 1456, 1414, 1360, 1319, 1275, 1230, 1176, 1138, 1065, 985, 885, 837, 812, 627.
Example 32
2-[4-[3-[2-(4-Butylphenyl)-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[2-(4-butylphenyl)-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.92 (t, 3H, J=7 Hz), 1.21 (t, 3H, J=7 Hz), 1.32 (d, 6H, J=7 Hz), 1.3-1.4 (m, 2H), 1.5-1.7 (m, 2H), 1.65 (s, 6H), 2.26 (s, 3H), 2.62 (t, 2H, J=8 Hz), 3.11 (dq, 1H, J=7 Hz, 7 Hz) 3.2-3.3 (m, 4H), 4.22 (q, 2H, J=7 Hz), 6.61 (d, 1H, J=9 Hz), 7.19 (d, 2H, J=8 Hz), 7.70 (dd, 1H, J=2 Hz, 9 Hz), 7.79 (d, 2H, J=8 Hz), 7.79 (d, 1H, J=2 Hz)
(2) 2-[4-[3-[2-(4-Butylphenyl)-4-isopropyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
White crystal (mp: 121-122° C.) 1 H-NMR (CDCl 3 , 400 MHz) d: 0.92 (t, 3H, J=7 Hz), 1.31 (d, 6H, J=7 Hz), 1.3-1.4 (m, 2H), 1.5-1.7 (m, 2H), 1.68 (s, 6H), 2.27 (s, 3H), 2.62 (t, 2H, J=8 Hz), 3.11 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 6.76 (ld, 1H, J=9 Hz), 7.19 (d, 2H, J=8 Hz), 7.72 (dd, 1H, J=2 Hz, 9 Hz), 7.78 (d, 2H, J=8 Hz), 7.80 (d, 1H, J=2 Hz).
Example 33
[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-chlorophenoxy]acetic acid
(1) Ethyl [4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-chlorophenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H NMR (CDCl 3 , 400 MHz) δ: 1.29 (t, 3H, J=7 Hz), 1.34 (d, 6H, J=7 Hz), 3.15 (m, 1H), 3.26 (s, 4H), 4.27 (q, 2H, J=7 Hz), 4.77 (s, 2H), 6.85 (d, 1H, J=9 Hz), 7.64 (d, 2H, J=8 Hz), 7.84 (dd, 1H, J=2 Hz, 9 Hz), 8.00 (d, 2H, J=8 Hz), 8.03 (d, 1H, J=2 Hz).
(2) [4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-chlorophenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
White crystal (mp: 149-151° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.34 (d, 6H, J=7 Hz), 3.15 (m, 1H), 3.26 (s, 4H), 4.82 (s, 2H), 6.90 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.87 (dd, 1H, J=2 Hz, 8 Hz), 8.00 (d, 2H, J=8 Hz), 8.04 (d, 1H, J=2 Hz). IR (KBr) cm −1 : 1724, 1684, 1616, 1595, 1496, 1406, 1360, 1329, 1281, 1232, 1203, 1157, 1117, 1016, 839, 773.
Example 34
[4-[3-[2-(4-Trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]propionyl]-2-chlorophenoxy]-2-methylpropionic acid
(1) Ethyl [4-[3-[2-(4-trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]propionyl]-2-chlorophenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.23 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 1.68 (s, 6H), 3.14 (m, 1H), 3.25 (s, 4H), 4.23 (q, 2H, J=7 Hz), 6.82 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.75 (dd, 1H, J=2 Hz, 8 Hz), 8.00 (d, 2H, J=8 Hz), 8.01 (d, 1H, J=2 Hz).
(2) [4-[3-[2-(4-Trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]propionyl]-2-chlorophenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Pale yellow amorphous
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.33 (d, 6H, J=7 Hz), 1.71 (s, 6H), 3.14 (m, 1H), 3.26 (s, 4H), 7.02 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.80 (dd, 1H, J=2 Hz, 8 Hz), 8.00 (d, 2H, J=8 Hz), 8.03 (d, 1H, J=2 Hz).
Example 35)
[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-chlorophenoxy]acetic acid
(1) Ethyl [4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-chlorophenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 3.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.28 (t, 3H, J=7 Hz), 1.30 (d, 6H, J=7 Hz), 2.96 (t, 2H, J=7 Hz), 3.17 (m, 1H), 3.33 (t, 2H, J=7 Hz), 4.27 (q, 2H, J=7 Hz), 4.76 (s, 2H), 6.83 (d, 1H, J=8 Hz), 7.30 (dd, 1H, J=2 Hz, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.8-7.9 (m, 2H), 8.05 (d, 1H, J=8 Hz).
(2) [4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-chlorophenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
White crystal (mp: 134-137° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 2.96 (t, 2H, J=7 Hz), 3.19 (m, 1H), 3.30 (t, 2H, J=7 Hz), 4.78 (s, 2H), 6.84 (d, 1H, J=8 Hz), 7.31 (dd, 1H, J=2 Hz, 8 Hz), 7.49 (d, 1H, J=2 Hz), 7.81 (dd, 1H, J=2 Hz, 8 Hz), 7.84 (d, 1H, J=8 Hz), 8.03 (d, 1H, J=2 Hz). IR (KBr) cm −1 : 3437, 1720, 1687, 1593, 1562, 1497, 1458, 1406, 1221, 1203, 1088, 1038, 833, 808, 744, 692.
Example 36
2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-chlorophenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-chlorophenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.23 (t, 3H, J=7 Hz), 1.30 (d, 6H, J=7 Hz), 1.67 (s, 6H), 2.95 (t, 2H, J=7 Hz), 3.17 (m, 1H), 3.31 (t, 2H, J=7 Hz), 4.23 (q, 2H, J=7 Hz), 6.80 (d, 1H, J=9 Hz), 7.30 (dd, 1H, J=2 Hz, 9 Hz), 7.49 (d, 1H, J=2 Hz), 7.77 (dd, 1H, J=2 Hz, 9 Hz), 7.88 (d, 1H, J=9 Hz), 8.03 (d, 1H, J=2 Hz).
(2) 2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-oxazolyl]propionyl]-2-chlorophenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (2) of Example 1.
White crystal (mp: 76-79° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (d, 6H, J=7 Hz), 1.68 (s, 6H), 2.95 (t, 2H, J=7 Hz), 319 (m, 1H), 3.29 (t, 2H, J=7 Hz), 6.97 (d, 1H, J=9 Hz), 7.29 (dd, 1H, J=2 Hz, 9 Hz), 7.48 (d, 1H, J=2 Hz), 7.72 (dd, 1H, J=2 Hz, 8 Hz), 7.84 (d, 1H, J=8 Hz), 8.02 (d, 1H, J=2 Hz). IR (KBr) cm −1 : 2968, 1720, 1686, 1593, 1562, 1493, 1460, 1402, 1385, 1306, 1259, 1200, 1180, 1146, 1059, 968, 902, 879, 822, 777, 739, 700, 571.
Example 37
[4-[3-[5-Isopropyl-2-(4-trifluoromethyl)phenyl-4-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) [4-[3-[5-Isopropyl-2-(4-trifluoromethyl)phenyl-4-thiazolyl]propionyl]-2-methylphenoxy]ethyl acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.29 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 2.31 (s, 3H), 3.14 (t, 2H, J=7 Hz), 3.37 (m, 1H), 3.43 (t, 2H, J=7 Hz), 4.26 (q, 2H, J=7 Hz), 4.70 (s, 2H), 6.70 (d, 1H, J=9 Hz), 7.63 (d, 2H, J=8 Hz), 7.8-7.9 (m, 2H), 7.95 (d, 2H, J=8 Hz).
(2) [4-[3-[2-(4-Trifluoromethyl)phenyl-5-isopropyl-4-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (1) of Example 2.
White crystal (mp: 125-132° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.33 (d, 6H, J=7 Hz), 2.30 (s, 3H), 3.14 (t, 2H, J=7 Hz), 3.37 (m, 1H), 3.42 (t, 2H, J=7 Hz), 4.74 (s, 2H), 6.73 (d, 1H, J=9 Hz), 7.63 (d, 2H, J=8 Hz), 7.8-7.9 (m, 2H), 7.94 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 3425, 2964, 1751, 1686, 1603, 1581, 1504, 1433, 1410, 1365, 1329, 1252, 1173, 1132, 1111, 1068, 1018, 989, 841, 815, 675, 611.
Example 38
2-[4-[3-[5-Isopropyl-2-(4-trifluoromethyl)phenyl-4-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl [4-[3-[5-isopropyl-2-(4-trifluoromethyl)phenyl-4-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.21 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 1.64 (s, 6H), 2.25 (s, 3H), 3.14 (t, 2H, J=7 Hz), 3.36 (m, 1H), 3.41 (t, 2H, J=7 Hz), 4.21 (q, 2H, J=7 Hz), 6.61 (d, 1H, J=8 Hz), 7.63 (d, 2H, J=8 Hz), 7.74 (dd, 1H, J=2, 8 Hz), 7.81 (bs, 1H), 7.95 (d, 2H, J=8 Hz).
(2) 2-[4-[3-[5-Isopropyl-2-(4-trifluoromethyl)phenyl-4-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
White crystal (mp: 89-93° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.34 (d, 6H, J=7 Hz), 1.67 (s, 6H), 2.25 (s, 3H), 3.14 (t, 2H, J=7 Hz), 3.38 (m, 1H), 3.40 (t, 2H, J=7 Hz), 6.75 (d, 1H, J=8 Hz), 7.63 (d, 2H, J=8 Hz), 7.72 (dd, 1H, J=2 Hz, 8 Hz), 7.82 (d, 1H, J=2 Hz), 7.93 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2964, 1720, 1678, 1601, 1498, 1458, 1410, 1365, 1325, 1257, 1169, 1135, 1068, 1016, 972, 847, 771, 606.
Example 39
[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) [4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
White crystal (mp: 158-161° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.34 (d, 6H, J=7 Hz), 2.29 (s, 3H), 3.15 (t, 2H, J=7 Hz), 3.37 (m, 1H), 3.40 (t, 2H, J=7 Hz), 4.73 (s, 2H), 6.71 (d, 1H, J=8 Hz), 7.2-7.3 (m, 1H), 7.47 (d, 1H, J=2 Hz), 7.7-7.9 (m, 2H), 8.03 (d, 1H, J=8 Hz). IR (KBr) cm −1 : 2953, 1740, 1664, 1602, 1583, 1551, 1504, 1475, 1429, 1363, 1317, 1277, 1254, 1244, 1176.1132, 1103, 1063, 989, 887, 862, 821, 777, 683.
Example 40
2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[2-(2,4-dichlorophenyl)-5-isopropyl-4-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.21 (t, 3H, J=7 Hz), 1.34 (d, 6H, J=7 Hz), 1.62 (s, 6H), 2.25 (s, 3H), 3.14 (t, 2H, J=7 Hz), 3.36 (m, 1H), 3.40 (t, 2H, J=7 Hz), 4.22 (q, 2H, J=7 Hz), 6.60 (d, 1H, J=9 Hz), 7.27 (dd, 1H, J=2, 9 Hz), 7.47 (d, 1H, J=2 Hz), 7.73 (dd, 1H, J=2 Hz, 8 Hz), 7.81 (bs, 1H), 8.07 (d, 1H, J=8 Hz).
(2) 2-[4-[3-[2-(2,4-Dichlorophenyl)-5-isopropyl-4-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (2) of Example 1.
White amorphous
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.34 (d, 6H, J=7 Hz), 1.66 (s, 6H), 2.25 (s, 3H), 3.14 (t, 2H, J=7 Hz), 3.38 (m, 1H), 3.39 (t, 2H, J=7 Hz), 6.73 (d, 1H, J=8 Hz), 7.26 (dd, 1H, J=2 Hz, 9 Hz), 7.46 (d, 1H, J=2 Hz), 7.70 (dd, 1H, J=2 Hz, 8 Hz), 7.81 (d, 1H, J=2 Hz), 8.02 (d, 1H, J=8 Hz).
Example 41
[5-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [5-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 2.35 (s, 3H), 3.14 (m, 1H), 3.2-3.3 (m, 4H), 4.26 (q, 2H, J=7 Hz), 4.71 (s, 2H), 7.24 (d, 1H, J=7 Hz), 7.35 (d, 1H, J=2 Hz), 7.49 (dd, 1H, J=2 Hz, 7 Hz), 7.64 (d, 2H, J=8 Hz), 8.00 (d, 2H, J=8 Hz).
(2) [5-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
Pale yellow crystal (mp: 130-133° C.) 1 H-NMR (DMSO-d 6 , 400 MHz) δ: 1.28 (d, 6H, J=7 Hz), 2.26 (s, 3H), 3.1-3.3 (m, 3H), 3.38 (t, 2H, J=7 Hz), 4.77 (s, 2H), 7.30 (d, 1H, J=8 Hz), 7.35 (s, 1H), 7.55 (d, 1H, J=8 Hz), 7.81 (d, 2H, J=8 Hz), 8.05 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2968, 2931, 2872, 1767, 1741, 1678, 1618, 1616, 1579, 1533, 1506, 1450, 1412, 1362, 1327, 1294, 1242, 1167, 1126, 1124, 1122, 1068, 1016, 978, 874, 847, 777, 609.
Example 42
2-[5-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[5-[3-[4-isopropyl-2-(4-trifluoromethylphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.26 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 1.63 (s, 6H), 2.29 (s, 3H), 3.14 (m, 1H), 3.2-3.4 (m, 4H), 4.26 (q, 2H, J=7 Hz), 7.22 (d, 1H, J=8 Hz), 7.31 (d, 1H, J=2 Hz), 7.47 (dd, 1H, J=2 Hz, 8 Hz), 7.64 (d, 2H, J=8 Hz), 8.00 (d, 2H, J=8 Hz)
(2) 2-[5-[3-[4-Isopropyl-2-(4-trifluoromethylphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
White crystal (mp: 124-126° C.) 1 H-NMR (DMSO-d 6 , 400 MHz) δ: 1.27 (d, 6H, J=7 Hz), 1.54 (s, 6H), 2.22 (s, 3H), 3.1-3.4 (m, 5H), 7.30 (s, 1H), 7.31 (d, 1H, J=8 Hz), 7.56 (d, 1H, J=8 Hz), 7.81 (d, 2H, J=8 Hz), 8.05 (d, 2H, J=8 Hz), 13.12 (bs, 1H) IR (KBr) cm −1 : 2972, 1736, 1684, 1618, 1616, 1498, 1452, 1412, 1327, 1259, 1167, 1130, 1068, 1016, 972, 845, 777.
Example 43
2-[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]propionic acid
(1) Ethyl 2-[4-[3-[4-isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]propionate
Intermediate of Example 3, namely 3-[2-(4-trifluoromethyl)phenyl-4-isopropyl-5-thiazolyl]-1-(3-methyl-4-hydroxyphenyl)propan-1-one (433 mg, 1.00 mmol) and potassium carbonate (166 mg, 1.20 mmol) was suspended in acetone (10 mL). To the suspension, ethyl 2-bromopropionate (216 mg, 1.20 mmol) was added while cooling with ice. The mixture was stirred for 20 hours at room temperature. The reaction mixture was poured into ice water, and extracted with ethyl acetate. The organic layer was washed with water (20 mL) and a saturated saline (20 mL), dried over anhydrous sodium sulfate. The solvent was removed under reduced pressure. The residue was purified by column chromatography on silica gel with hexane/ethyl acetate (5/1) to give the desired compound (534 mg) as a colorless oil (quantitative yield).
1 H NMR (CDCl 3 , 400 MHz) δ: 1.24 (t, 3H, J=7 Hz), 1.33 (d, 6H, J=7 Hz), 1.66 (d, 3H, J=7 Hz), 2.31 (s, 3H), 3.15 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 4.20 (q, 2H, J=7 Hz), 4.82 (q, 1H, J=7 Hz), 6.68 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.76 (dd, 1H, J=2 Hz, 8 Hz), 7.80 (d, 1H, J=2 Hz), 8.00 (d, 2H, J=8 Hz).
(2) 2-[4-[3-[4-Isopropyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]propionic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
White crystal (mp: 120-123° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.33 (d, 6H, J=7 Hz), 1.70 (d, 3H, J=7 Hz), 2.31 (s, 3H), 3.15 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 4.88 (q, 1H, J=7 Hz), 6.73 (d, 1H, J=9 Hz), 7.63 (d, 2H, J=8 Hz), 7.77 (dd, 1H, J=2, 9 Hz), 7.80 (d, 1H, J=2 Hz), 7.99 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2950, 1740, 1670, 1600, 1500, 1450, 1320, 1300, 1275, 1250, 1190, 1160, 1130, 1060, 845.
Example 44
4-[3-[4-Methyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[4-methyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.29 (t, 3H, J=7 Hz), 2.31 (s, 3H), 2.46 (s, 3H), 3.2-3.3 (m, 4H), 4.26 (q, 2H, J=7 Hz), 4.70 (s, 2H), 6.71 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.76 (dd, 1H, J=2 Hz, 8 Hz), 7.80 (d, 1H, J=2 Hz), 7.97 (d, 2H, J=8 Hz).
(2) [4-[3-[4-Methyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (1) of Example 2.
White crystal (mp: 194-195° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 2.32 (s, 3H), 2.45 (s, 3H), 3.2-3.3 (m, 4H), 4.75 (s, 2H), 6.74 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.7-7.9 (m, 2H), 7.96 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 3500, 2900, 1780, 1730, 1680, 1610, 1500, 1410, 1370, 1330, 1240, 1180, 1080, 850.
Example 45
2-[4-[3-[4-Hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]-1-propenyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[4-hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]-1-propenyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.88 (t, 3H, J=7 Hz), 1.25 (t, 3H, J=7 Hz), 1.3-1.5 (m, 6H), 1.58 (s, 6H), 1.7-1.8 (m, 2H), 2.22 (s, 3H), 2.74 (t, 2H, J=7 Hz), 3.65 (d, 2H, J=6 Hz), 4.24 (q, 2H, J=7 Hz), 6.16 (dt, 1H, J=6 Hz, 16 Hz), 6.40 (d, 1H, J=16 Hz), 6.60 (d, 1H, J=8 Hz), 7.04 (dd, 1H, J=2, 8 Hz), 7.16 (d, 1H, J=2 Hz), 7.64 (d, 2H, J=8 Hz), 7.99 (d, 2H, J=8 Hz)
(2) 2-[4-[3-[4-Hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]-1-propenyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Pale brown powder (mp: 152-155° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 0.88 (t, 3H, J=7 Hz), 1.2-1.5 (m, 6H), 1.61 (s, 6H), 1.7-1.8 (m, 2H), 2.23 (s, 3H), 2.74 (t, 2H, J=7 Hz), 3.66 (d, 2H, J=6 Hz), 6.20 (dt, 1H, J=6 Hz, 16 Hz), 6.41 (d, 1H, J=16 Hz), 6.78 (d, 1H, J=8 Hz), 7.09 (dd, 1H, J=2 Hz, 8 Hz), 7.19 (d, 1H, J=2 Hz), 7.64 (d, 2H, J=8 Hz), 7.99 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2920, 1700, 1610, 1500, 1445, 1320, 1250, 1160, 1120, 1060, 900, 840.
Example 46
2-[5-[3-[4-Hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[5-[3-[4-hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.89 (t, 3H, J=7 Hz), 1.26 (t, 3H, J=7 Hz), 1.3-1.4 (m, 6H), 1.54 (s, 6H), 1.7-1.8 (m, 2H), 2.29 (s, 3H), 2.74 (t, 2H, J=8 Hz), 3.2-3.3 (m, 4H), 4.26 (q, 2H, J=7 Hz), 7.22 (d, 1H, J=8 Hz), 7.31 (d, 2H, J=8 Hz), 7.47 (dd, 1H, J=2 Hz, 8 Hz), 7.64 (d, 1H, J=2 Hz), 7.98 (d, 2H, J=8 Hz).
(2) 2-[5-[3-[4-Hexyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Yellow oil
1 H-NMR (CDCl 3 , 400 MHz) δ: 0.88 (t, 3H, J=7 Hz), 1.2-1.4 (m, 6H), 1.64 (s, 6H), 1.7-1.8 (m, 2H), 2.29 (s, 3H), 2.73 (t, 2H, J=7 Hz), 3.2-3.3 (m, 4H), 7.25 (d, 1H, J=8 Hz), 7.43 (s, 1H), 7.50 (d, 1H, J=8 Hz), 7.62 (d, 2H, J=8 Hz), 7.96 (d, 2H, J=8 Hz)
Example 47
[4-[3-[4-Ethyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[4-ethyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.30 (t, 3H, J=7 Hz), 1.32 (t, 3H, J=7 Hz), 2.33 (s, 3H), 2.79 (q, 2H, J=7 Hz), 3.2-3.3 (m, 4H), 4.27 (q, 2H, J=7 Hz), 4.71 (s, 2H), 6.71 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.8-7.9 (m, 2H), 7.99 (d, 2H, J=8 Hz).
(2) [4-[3-[4-Ethyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
White crystal (mp: 165-167° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (t, 3H, J=7 Hz), 2.32 (s, 3H), 2.79 (q, 2H, J=7 Hz), 3.2-3.3 (m, 4H), 4.76 (s, 2H), 6.74 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.80 (dd, 1H, J=2, 8 Hz), 7.81 (d, 1H, J=2 Hz), 7.97 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2975, 1760, 1740, 1670, 1610, 1600, 1580, 1500, 1440, 1360, 1320, 1260, 1220, 1160, 1130, 1110, 1960, 840, 820.
Example 48
2-[4-[3-[4-Ethyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[4-ethyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.21 (t, 3H, J=7 Hz), 1.32 (t, 3H, J=7 Hz), 1.55 (s, 6H), 2.27 (s, 3H), 2.79 (q, 2H, J=7 Hz), 3.2-3.3 (m, 4H), 4.22 (q, 2H, J=7 Hz), 6.62 (d, 1H, J=8 Hz), 7.64 (d, 2H, J=8 Hz), 7.69 (dd, 1H, J=2, 8 Hz), 7.79 (d, 1H, J=2 Hz), 7.99 (d, 2H, J=8 Hz).
(2) 2-[4-[3-[4-Ethyl-2-(4-trifluoromethyl)phenyl-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
White crystal (mp: 168-170° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (t, 3H, J=7 Hz), 1.69 (s, 6H), 2.27 (s, 3H), 2.78 (q, 2H, J=7 Hz), 3.2-3.3 (m, 4H), 6.75 (d, 1H, J=8 Hz), 7.63 (d, 2H, J=8 Hz), 7.72 (dd, 1H, J=2, 8 Hz), 7.80 (d, 1H, J=2 Hz), 7.97 (d, 2H, J=8 Hz). IR (KBr) cm −1 : 2950, 1720, 1680, 1660, 1580, 1540, 1440, 1400, 1360, 1320, 1260, 1160, 1120, 1060, 960, 840, 820.
Example 49
[4-[3-[4-Isopropyl-2-(4-methylphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
(1) Ethyl [4-[3-[4-isopropyl-2-(4-methylphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]acetate
The desired compound was obtained in an analogous manner as in (1) of Example 2.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.29 (t, 3H, J=7 Hz), 1.31 (d, 6H, J=7 Hz), 2.32 (s, 3H), 2.37 (s, 3H), 3.12 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 4.27 (q, 2H, J=7 Hz), 4.70 (s, 2H), 6.71 (d, 1H, J=8 Hz), 7.19 (d, 2H, J=8 Hz), 7.7-7.8 (m, 4H).
(2) [4-[3-[4-Isopropyl-2-(4-methylphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]acetic acid
The desired compound was obtained in an analogous manner as in (2) of Example 2.
White crystal (mp: 188-190° C.) 1 H-NMR (CDCl 3 , 400 MHz) δ: 1.32 (d, 6H, J=7 Hz), 2.32 (s, 3H), 2.37 (s, 3H), 3.12 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 4.75 (s, 2H), 6.73 (d, 1H, J=8 Hz), 7.18 (d, 2H, J=8 Hz), 7.7-7.8 (m, 4H). IR (KBr) cm −1 : 2950, 1720, 1670, 1600, 1580, 1500, 1440, 1360, 1310, 1280, 1210, 1180, 1120, 1060, 820.
Example 50
2-[4-[3-[4-Isopropyl-2-(4-methylphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
(1) Ethyl 2-[4-[3-[4-isopropyl-2-(4-methylphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionate
The desired compound was obtained in an analogous manner as in (2) of Example 1.
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.21 (t, 3H, J=7 Hz), 1.32 (d, 6H, J=7 Hz), 1.65 (s, 6H), 2.26 (s, 3H), 2.37 (s, 3H), 3.11 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 4.22 (q, 2H, J=7 Hz), 6.61 (d, 1H, J=8 Hz), 7.19 (d, 2H, J=8 Hz), 7.69 (dd, 1H, J=2, 8 Hz), 7.7-7.8 (m, 3H).
(2) 2-[4-[3-[4-Isopropyl-2-(4-methylphenyl)-5-thiazolyl]propionyl]-2-methylphenoxy]-2-methylpropionic acid
The desired compound was obtained in an analogous manner as in (3) of Example 1.
Yellow amorphous
1 H-NMR (CDCl 3 , 400 MHz) δ: 1.31 (d, 6H, J=7 Hz), 1.67 (s, 6H), 2.27 (s, 3H), 2.36 (s, 3H), 3.11 (dq, 1H, J=7 Hz, 7 Hz), 3.2-3.3 (m, 4H), 6.72 (d, 1H, J=8 Hz), 7.18 (d, 2H, J=8 Hz), 7.70 (d, 1H, J=8 Hz), 7.72 (d, 2H, J=8 Hz), 7.79 (s, 1H).
Example 51
Pharmacological Experiment 1
I. Method
(1) Measurement of PPARα, γ, δ Transactivation Activity
PPARα, γ, δ transactivation activity of each compound [Examples 1-8 and known PPARδ agonist (L-16504: Berger, J., et al. (1999), J. Biol. Chem., 274:6718-6725)] was measured in the manner described below.
1) Material
CV-1 cells were obtained from Tohoku University Aging Medical Laboratory, Medical Cell Collection Center. All test compounds were dissolved in dimethylsulfoxide (DMSO). Final concentration of DMSO was 0.1%.
2) Plasmid
Receptor expression plasmid (GAL4-hPPARα, LBD GAL4-hPPARγ LBD, GAL4-hPPARδ LBD), Reporter plasmid (UASx-4-TK-LUC), and β-galactosidase expression plasmid (βGAL) similar to Kliewer, S. A., et al., ((1992) Nature, 358:771-774) were used.
3) Transfection
CV-1 cells were seeded in 24 well culture plates at 2×10 5 cells per well, and cultured for 24 hours OPTI-MEM I Reduced Serum Medium (Life Technologies, 500 μL/well) containing 4%-fetal bovine serum (FBS). After washing with OPTI-MEM, transfection mixture (250 μL/well) containing 0.03 μg of GAL4-hPPARδ LBD, 0.25 μg of UASx-4-TK-LUC, 0.35 μg of βGAL, and 2 μL of lipofection reagent, DMRIE-C (Life Technologies) were added. The cells were incubated for 5 hours at 37° C.
4) Cell Treatment by Addition of Test Compound
The cells were washed and incubated for 40 hours in the presence of the test compound (final concentration was 10 −7 M or 10 −6 M)
5) Measurement of the Level of Reporter Gene Expression
The culture medium was removed and the cells were washed with PBS twice. A solubilizing buffer (100 μL/well) containing 25 mM Tris-PO 4 (pH 7.8), 15% v/v glycerol, 2% CHAPS, 1% Lecithin, 1% BSA, 4 mM EGTA (pH 8.0), 8 mM MgCl 2 , 1 mM DTT was added. After the incubation for 10 minutes at room temperature, a portion (20 μL) of the solution was transferred into a 96-well plate. Subsequently, 100 μL of luciferase substrate solution (Piccagene: available from Nippon Gene Co., Ltd.) was added, and a luminous intensity per one second (luciferase activity) was measured using a microluminoreader (Type MLR-100, Corona Electrics Co., Ltd.). Each luciferase activity was corrected by the transfection efficiency which was calculated from β-galactosidase activity. The assay method of β-galactosidase activity was as follows: A portion (50 μL) of the solubilized sample was transferred into another 96-well plate; 100 μL of ONPG (2-nitrophenyl-β-galactopyranoside) solution was added and incubated for 5 minutes at room temperature. 50 μL of a reaction stopping solution (1M sodium carbonate solution) was added. Then the absorbance at 414 nm was measured.
A relative PPAR activity was calculated as follows: 0% (luciferase activity of cells treated with DMSO (0.1%) alone), 100% (luciferase activity of cells treated with a control (PPARα: 10 −4 M WY-165041, PPARγ: 10 −5 M Rosiglitazone, PPARδ: 10 −4 M L-165041)
II. Results
The results are shown in Table 8.
TABLE 8
α
γ
δ
Example 1
76
10
84
Example 2
0
2
61
Example 3
0
5
101
Example 4
11
12
86
Example 5
1
6
75
Example 6
0
6
73
Example 7
0
3
61
Example 8
0
4
48
GW-2433
64
7
52
GW-501516
0
1
90
Relative activities for PPAR transactivation were shown.
Each value represents as % of control. Cells were cultured in the presence of compounds at 10 −7 M except Example 1 (10 −6 M).
Positive Control:
α: 10 −4 M WY-14643
γ: 10 −5 M Rosiglitazone
δ: 10 −4 M L-165041
It is clear that the compounds of Examples have PPARδ transactivation activity similar to or more potent than L-165041.
Example 52
Pharmacological Tests 2
PPAR transactivation activities of the compounds of Examples 9-50 were assayed in the same manner as described in Example 51. The results are shown in Table 9.
TABLE 9
Test compound
α
γ
δ
Example 9
(0)
(4)
(84)
Example 10
0
1
67
Example 11
0
1
56
Example 12
75
31
45
Example 13
63
17
62
Example 14
0
0
42
Example 15
(NT)
(NT)
(58)
Example 16
62
3
57
Example 17
NT
NT
(90)
Example 18
0
1
70
Example 19
0
2
86
Example 20
NT
NT
(72)
Example 21
NT
NT
(62)
Example 22
0
0
52
Example 23
NT
NT
(93)
Example 24
0
0
75
Example 25
NT
NT
61
Example 26
NT
NT
18
Example 27
NT
NT
37
Example 28
0
NT
21
Example 29
NT
NT
27
Example 30
(85)
(47)
(76)
Example 31
NT
NT
51
Example 32
1
NT
14
Example 33
0
1
44
Example 34
5
3
66
Example 35
(0)
(1)
(71)
Example 36
(14)
(5)
(92)
Example 37
NT
NT
(71)
Example 38
(3)
(9)
(69)
Example 39
NT
NT
(65)
Example 40
(22)
(3)
(72)
Example 41
(5)
(60)
NT
Example 42
(68)
(55)
NT
Example 43
3
5
42
Example 44
(0)
(0)
(38)
Example 45
90
20
49
Example 46
(78)
(69)
(46)
Example 47
0
0
57
Example 48
(84)
(13)
(51)
Example 49
0
2
56
Example 50
104
50
30
Relative activities for PPAR transactivation were shown.
Each value represents as % of control. Cells were cultured in the presence of compounds at 10 −7 M except the compounds that the values are given in parentheses (for example, Example 44 etc.). Those compounds were assayed at 10 −6 M.
NT or (NT) means “not tested”.
Positive Control:
α: 10 −4 M WY-14643
γ: 10 −5 M Rosiglitazone
δ: 10 −4 M L-165041
It is clear from Table 9 that the compounds of Examples 9-50 have potent PPARδ transactivation activities. It is also clear from Tables 8 & 9 that the compound of the formula (I) wherein R 2 is methyl (Example 44) is inferior in the PPARδ transactivation activity to the other compounds of the formula (I) wherein R 2 is ethyl (Example 47 etc.), isopropyl (Example 3 etc.), or hexyl (Example 11 etc.). Therefore, the alkyl group of R 2 preferably has two or more carbon atoms.
Example 53
Pharmacological Experiment 2
HDL Cholesterol Elevating Effect
I. Method
HDL cholesterol elevating effect was measured by using db/db mice, which are hereditary obesity mice. The db/db mice (10 weeks old) were divided into groups based on serum HDL cholesterol levels. Each of the compounds of the present invention (compounds synthesized in Examples 4 and 10) and GW-501516 was orally administered for one week twice daily. Mice of the control group (to which no agent was administered) were orally given 1% methyl cellulose solution. After 16 hours from the final administration, blood sample was collected, and serum HDL cholesterol level was measured. HDL cholesterol was separated by electrophoresis on agarose gels (Chol/Trig Combo, Helena Laboratories). Serum total cholesterol levels were measured enzymatically using a kit (Pure Auto, Daiichi Chemicals) by an automatic analyzer (7060E type, Hitachi Ltd.). HDL cholesterol levels were calculated from total cholesterol levels and HDL cholesterol/total cholesterol ratios.
II. Results
Serum HDL cholesterol levels of experiments groups are shown in Table 10. Each value represents as % of the control group.
TABLE 10
Dose
Ratio of increasing HDL
Test compound
(mg/kg/b.i.d.)
cholesterol (% to control)
Example 4
10
176
Example 10
10
134
GW-501516
10
149
As shown in Table 10, compounds of the present invention raised serum HDL cholesterol significantly. It is clear that they have potent HDL cholesterol elevating effect.
Therefore, the compounds of the invention are useful for the treatment of dyslipidemia. | A compound represented by the following general formula (I):
(wherein R 1 represents phenyl, etc. which can have substituents selected from the group consisting of C 1-8 alkyl, C 1-8 alkyl having halogen, halogen, hydroxyl, etc.; R 2 represents C 1-8 alkyl, etc.; A represents oxygen, sulfur, etc.; X represents C 1-8 alkylene chain, etc.; Y represents C(═O), CH═CH, etc.; R 3 , R 4 , and R 5 each represents hydrogen, C 1-8 alkyl, etc.; B represents CH or nitrogen; Z represents oxygen or sulfur; R 6 and R 7 each represents hydrogen, C 1-8 alkyl, etc.; and R 8 represents hydrogen or C 1-8 alkyl; provided that at least one of R 3 , R 4 , and R 5 is not hydrogen) or a salt of the compound; and a PPAR-δ activator which contains the compound or salt as the active ingredient. | 2 |
FIELD OF THE INVENTION
The present invention relates to a vehicle.
BACKGROUND INFORMATION
It is common knowledge that vehicles can be driven by means of a drive wheel. A forklift additionally has a lifting axle for raising or lowering a load. However, the lifting axle requires a drive unit.
SUMMARY
Therefore, the present invention is based on the objective of further refining a vehicle in a more compact and easily producible manner.
Features of the present invention in the vehicle are that the vehicle has two chassis components, which are connected by a sloping plane, especially by a guide and/or plain bearing along a sloping plane, a first drive wheel being situated on at least one of the chassis components, and one wheel on the other chassis component, a rotational speed differential between the rotational speed of the drive wheel and the rotational speed of the wheel being able to be brought about by a device.
This has the advantage that a height adjustment can be undertaken during a time period in which the two wheels have different rotational speeds. Equivalent thereto is a relative angle differential value between the angular value of the wheel and the drive wheel. According to the present invention, no supplementary element, such as an electric motor, is required for generating the lifting movement, but merely an influencing of the front wheels.
In one advantageous development, the chassis components are situated so as to be guided along the sloping plane, using a guidance device. This has the advantage that the chassis components can execute the movement only along the sloping plane.
In one advantageous development, a locking means is provided, which is able to block or enable the relative movement of the chassis components along the sloping plane. This has the advantage that irregularities during the maneuvering do not cause any height adjustment.
In one advantageous development, the device is a brake device, which acts on the wheel, in particular, the wheel being a fixed roller or a swivel roller, in particular. This has the advantage that only a single drive unit is required and the wheel situated on the other chassis component is able to be adjusted to a different rotational speed with the aid of a brake device.
In one advantageous development, the device has a controlled or regulated electric motor, which can be used to drive the wheel, especially at a predefined setpoint speed, which is the same as the rotational speed of the first drive during normal driving, i.e., especially driving without a lifting movement, and which differs when the lifting movement is executed. This has the advantage that a lifting movement is able to be performed in an uncomplicated manner. In particular, the lift is already possible during driving, the drives being operated differently. No separate lifting gear drive is necessary.
In one advantageous development, the drive wheel has a controlled or regulated electric motor, which can be used to drive the wheel, especially at a predefined setpoint speed, which is the same as the setpoint rotational speed of the wheel in standard driving without lifting movement and which differs when the lifting movement is executed. This has the advantage that the lifting movement is able to be brought about via wheels of the chassis components provided for maneuvering.
In one advantageous development, the direction of the normal of the sloped plane has a non-vanishing angular amount in relation to the direction of the normal of the maneuvering plane. This has the advantage that the sloping plane is not parallel with the maneuvering plane.
In one advantageous development, the drive wheel or the wheel is connected to the first or second chassis component via a linear guidance. This has the advantage that the drive wheel or wheel does not lose traction with the ground during the lifting movement.
In one advantageous development, swivel rollers or fixed rollers are situated on one or both chassis component(s). This has the advantage that the weight force can be introduced into the maneuvering surface via these rollers.
In one advantageous development, the control unit transmits control signals and/or control information, especially the setpoint rotational speed or the setpoint torque, to the converter and/or the device. This has the advantage of allowing a control of the lifting movement, in that the relative rotational speed difference is appropriately predefined for a time interval, i.e., a relative angular adjustment value of the wheels of the vehicle.
In one advantageous development, the drive wheel is pressed against the maneuvering plane with the aid of a spring element, which is braced on the chassis component, or a linear actuator. This is advantageous insofar as a clamping force of sufficient magnitude is able to be applied, so that the drive wheel will not lose contact with the ground.
The present invention is not restricted to the feature combination of the claims. Those skilled in the art will discover additional meaningful combination possibilities of claims and/or individual claim features and/or features of the specification and/or of the figures, that arise from the stated objective and/or the objective resulting from a comparison with the related art, in particular.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic illustration of a vehicle, especially a transport vehicle, for which standard driving is depicted.
FIG. 2 illustrates the manner in which a lift 5 is realized in the vehicle.
FIG. 3 shows normal driving for another vehicle according to the present invention, the vehicle having only one pair of drive wheels 30 .
FIG. 4 depicts the manner in which a lift is realized in the vehicle according to FIG. 3 .
DETAILED DESCRIPTION
As illustrated in FIGS. 1 and 2 , the chassis of the vehicle features a sloping plane. That is to say, a first chassis component 1 and a second chassis component 2 are connected via a sloping plane, so that in a relative approach of the two chassis components ( 1 , 2 ), one of chassis components 1 , which is chassis component 1 in the example, is elevated. The top side of first chassis component 1 thus is able to be fitted with an object to be lifted.
In this way the vehicle according to the present invention is able to replace a forklift. A load picked up at a first height is therefore able to be transported to a different position at a different level.
First chassis component 1 is linked to a first drive wheel 3 via a linear guidance 6 , which is able to be driven by an electric motor.
Linear guidance 6 makes it possible for the first drive wheel to stay in contact with the maneuvering surface during the lifting movement. In the course of the lifting movement, first chassis component 1 is raised and guided by linear guidance 6 .
Second chassis component 2 likewise has a drive wheel 4 , and this second drive wheel 4 is likewise able to be driven by an electric motor.
Instead of the individual wheels shown in the figures, multiple wheels can be used, which have drives that are operated in synchrony, especially electric motors.
As illustrated in FIG. 2 , the lifting movement is produced by a relative movement toward each other, since the chassis components ( 1 , 2 ) connected via the sloping plane, which may be developed to include a plain bearing or an antifriction bearing, for instance, are then moved toward each other and first chassis component 1 must therefore be raised, since the second chassis component has a second drive wheel 4 that is immovable in the lifting direction.
Second drive wheel 4 is supported on second chassis component 2 by means of a bearing. A bearing supports first drive wheel 3 on linear guidance 6 , which in turn is connected to second chassis component 2 .
The electric motors are supplied by a converter and preferably include sensors for recording the angular position of the rotor shaft of the individual electric motor or the particular drive wheel ( 3 , 4 ). As a result, the angular positions of drive wheels ( 3 , 4 ) are able to be regulated or controlled in a precise manner, especially when the electric motors are developed as synchronous motors. The height is thereby precisely controllable as well.
Instead of the bilateral movement of both drive wheels ( 3 , 4 ) toward each other as shown in FIG. 2 , it is also possible to move one of the wheels more slowly than the other. As a result, the load is already able to be lifted while the vehicle is driving. Braking of one of the drive wheels ( 3 , 4 ) and a simultaneous movement of the other one of the drive wheels ( 3 , 4 ) induces a lifting movement as well.
As illustrated in FIG. 3 and FIG. 4 , a lifting movement is able to be executed also when using only a single drive wheel 30 or only one type of drive wheels 30 operated in synchrony.
For if one or each of the two chassis component(s) ( 1 , 2 ) is maneuverable on the maneuvering surface via fixed rollers 31 , as illustrated in FIG. 3 and FIG. 4 , a height adjustment by the relative movement of the two chassis components ( 3 , 4 ) is also possible by decelerating one of the chassis components, in the example, first chassis component 1 . A brake is disposed on this chassis component 1 for that purpose, or a brake 32 is situated on fixed roller 31 connected to first chassis component 1 .
If the brake force is controllable, then the lift may already be executed in the course of driving, by appropriate braking of fixed roller 31 .
Swivel rollers or also other wheels are usable as fixed rollers. The weight force is introduced into the maneuvering surface essentially via fixed rollers 31 . Drive wheel 30 can be driven with the aid of the electric motor to which it is connected, which in turn is supplied from a converter. The drive wheel is preferably pressed against the maneuvering surface such that it does not lose traction. It is therefore not necessary to transmit the entire weight of the chassis component via drive roller 30 .
Drive wheels 30 are preferably disposed so as to be steerable. That is to say, the wheel axle of drive wheels 30 is rotatable parallel to the maneuvering plane. To do so, the drive wheel is linked to second chassis component 2 via a pivot bearing.
The lift direction has been marked by reference numeral 5 in FIGS. 2 and 4 and takes place in the gravitational direction or counter thereto.
In one further exemplary embodiment according to the present invention, the sloping plane is lockable, so that no unintentional lifting of the load occurs when driving without a height adjustment.
In another exemplary embodiment according to the present invention, the two chassis components ( 3 , 4 ) are guided along the sloping plane. As a result, only a relative displacement of the two chassis components ( 3 , 4 ) toward each other along the sloping plane is possible.
In one further exemplary embodiment of the present invention, the vehicle is developed as a rail-guided vehicle. The principle of the present invention can easily be transferred to such vehicles as well. In such a case, rail wheels are used instead of the fixed rollers, and the drive wheels ( 2 , 4 , 30 ) are likewise realizable as rail wheels.
LIST OF REFERENCE NUMERALS
1 first chassis component
2 second chassis component
3 first drive wheel, in particular first drive roller
4 second drive wheel, in particular second drive roller
5 lift
6 linear guidance
30 drive wheel
31 fixed roller, especially a swivel roller
32 braked fixed roller 31 | A vehicle having two chassis components, which are connected by a sloping plane, especially by a guidance device and/or sliding bearing along a sloping plane, a first drive wheel being situated on at least one of the chassis components, and one wheel on the other chassis component, a rotational speed differential between the rotational speed of the drive wheel and the rotational speed of the wheel being able to be induced by a device. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to the detachment of fluid-transferring devices and connections from a corresponding hub, and especially when transferring fluid in a medical setting. The invention may find particular use in detaching a fluid transfer device such as a syringe, or other fluid transfer connection, from a hub that is connected to a living subject to/from whom fluid is being transferred.
BACKGROUND OF THE INVENTION
[0002] In a medical setting it may be necessary or desirable to transfer fluid to/from a subject for a variety of reasons. For example, a hub connected to a needle or other cannula may be used to draw blood from a vein or to infuse fluid substances i.e., intravenous (IV) therapy. A drip is one type of IV therapy. IV therapy may be used to correct electrolyte imbalances, to deliver medications or nutrition, for blood transfusion or as fluid replacement to correct dehydration. IV therapy can also be used for chemotherapy of cancer patients. Fluid-transferring devices such as syringes may also be attached to a hub that connects a cannula for the addition or removal of fluid to/from a variety of bodily cavities, organs, or vessels. For instance, the hub may be part of an entity providing a catheter to drain urine from the bladder or kidney, to remove fluid from an abscess, to extract liquid from joints or cysts, or to administer breathing gases through a tracheal tube. A typical endotracheal tube may include a cuff inflation tube with a hub for attachment of a syringe to enable inflation to seal the trachea and bronchial tree against air leakage and aspiration of fluids. A tracheostomy tube or urinary tract catheter might also use a cuff system with a hub for connection of a syringe or other device to inject fluid to inflate a cup or balloon that holds it in place. However fluid injections using a syringe connected to a needle are one of the most common health care procedures in the world.
[0003] When transferring fluids to/from a subject, the hub with its needle, catheter or other cannula inserted in the patient is often left in-situ while the fluid-transferring device may be removed and replaced, e.g., to empty/re-fill a syringe or to change over the IV therapy. Where two medical devices that carry small fluid volumes must be connected, a standard Luer fitting is the most common means of achieving a leak-free junction. One type of Luer fitting, commonly called a “Luer lock/lok”, uses an internally threaded collar surrounding a “Luer slip” friction fit (see below) tapered male tip of a syringe or the like. The projecting tip can be inserted into a corresponding female hub with an external thread, or other suitable protrusion for cooperating with the collar, and the collar screwed down on the hub to lock the connection. Such Luer lock fittings have the advantage of providing a secure connection that cannot easily come loose, but two hands are needed to hold the hub while screwing the device in/out. A more rapid form of attachment may be preferred in some circumstances, for example in an emergency situation. Another type of Luer fitting, commonly called a “Luer slip”, simply uses a friction fit between a female hub and corresponding tapered male tip of a device without a threaded collar. A standard friction fit may be achieved by a 6% taper. A Luer slip attachment is common for infusing less viscous fluids, such as vaccinations, and transferring fluids where high pressures are not involved, for example when drawing blood.
[0004] A problem observed with both Luer lock and Luer slip connections is the risk of injury when detaching the fluid-transferring device from a hub on a cannula that is still connected to a patient. Although a medical practitioner might take care to hold the hub and avoid injury when unscrewing a Luer lock connection, there is a temptation with a Luer slip connection to try to pull the device from the hub e.g., with one hand. However this can easily result in the hub being tugged away from the body and causing tissue damage. Often the device may not be pulled in a straight line with the cannula connected to the hub, but rotated, and this can twist the components. The tape used to hold the hub e.g., IV port in position is often loosened from the skin and its cannula e.g., needle may even be accidentally extracted. When emptying fluid from a body cavity, for example, keeping the needle hub still when detaching the syringe can be essential to avoid diffuse cutting inside the cavity or damage of the cavity wall. In addition there is a risk of unacknowledged contamination of both the hub and the Luer tip (not only the user) when holding the very small hub with the thumb and index fingers while pulling away the male tip, the tip sliding past the user's fingers as it is released.
[0005] Moreover tugging with a single hand does not usually apply enough force even to pull the device out of a friction fitting (such as a Luer slip) and, depending on the force used when connecting the Luer slip tip to the hub, the practitioner usually needs to hold or push the hub while also pulling the device so that it becomes detached. Typically the device will be rotated simultaneously while pulling away from the hub. This jerking can result in unwanted extraction of the needle or other component connected to the hub. The connection will often be pressurised by fluid. For example, a cuff connected to a tracheostomy tube, endotracheal tube or urinary catheter often has a tight connection of the male Luer tip with two-handed operation being required to loosen the connection while the sprung piston in the female Luer hub blocks the outflow of fluid (air or liquid) from the cuff.
[0006] Several medical procedures involve targeted introduction of an empty syringe connected to a cannula or other catheter. Such procedures require careful insertion of the cannula or catheter and also careful removal of the syringe if the catheter or cannula is left in situ. The process typically involves applying negative pressure in the syringe by pulling the plunger/piston back during the inward insertion movement of the cannula or catheter towards a target inside the patient. The objective is to verify that the correct target has been reached by drawing a body liquid, e.g., blood, cerebrospinal fluid, synovial fluid from joints, bile, or urine into the syringe barrel where it can be observed. When the appropriate liquid is seen in the barrel, the user can be sure that the catheter tip is in the correct position. Some procedures involve the use of additional guiding tools, e.g., ultrasound guided cannula insertion. During such procedures the user must hold onto the ultrasound probe in addition to the syringe, and monitor the position of the cannula or catheter on a screen. After reaching the target with the tip, the operator typically needs to detach the syringe from the catheter hub. Using conventional methods this can inadvertently cause the tip to dislocate from its intended targeted original position as two handed operation is required to remove the hub. Furthermore during such ultrasound-guided techniques for catheter tip placement, the ultrasound probe is typically put aside/inactivated before the disconnection and therefore the user loses the ability to accurately monitor the position of the tip.
[0007] Ease of disconnection can be a problem not only when detaching a device from a hub connected to a patient but also when it is desired to fill/empty a device such as a syringe via a fluid hub in a quick and convenient manner. For example, when filling a syringe using a needle inserted in a vial, each time that the syringe is removed it requires two hands to firmly grasp the needle hub and the syringe to separate them while the needle remains in the vial. As mentioned above, there is again a risk of contamination as the user grasps the hub and the tip comes into contact with the fingers holding the hub.
[0008] Another situation where a user might come into contact with a needle hub is when using a blood collection tube. The blood tubes are evacuated plastic or glass containers sealed with an elastomeric septum that is piercable by a double-ended needle to draw venous blood. Due to the piercing force and pressure differential, a secure connection to the needle assembly is required and therefore a threaded Luer lock connection is normally used rather than a Luer slip. U.S. Pat. No. 5,201,716 proposes an alternative blood specimen collection system that does not require the needle assembly to be grasped and twisted during disconnection. In this system a needle assembly is mounted with an interference fit rather than a threaded connection. A pivotally mounted lever assembly is spring-biased to hold the needle assembly in position, i.e., to provide an additional level of security over the friction fit. If the lever is actuated against its spring bias then there is only an interference fit holding the needle assembly in place. The lever can be pivoted to simultaneously release the spring bias and to apply a forward ejection force to the needle assembly.
[0009] In any situation where one hand is holding a needle hub while pulling a device away there is a risk of needlestick injury and contamination. Needle caps frequently being mislaid or forgotten can exacerbate this. This also applies when separating a needle or other contaminated component from a syringe or similar device for disposal purposes, with many needlestick injuries occurring when trying to remove sharps to throw into a bin. Usually the person handling a syringe will try to cover a contaminated needle with a cap after use, before grasping the hub to separate the needle from the syringe barrel for disposal. However, when mounting a needle cap onto the contaminated needle a person will use the large muscle groups in the arms and shoulders that work less precisely and, combined with poor depth of vision, this often results in a needlestick injury to the fingers holding the needle cap. It would be better if a needle hub could be safely released without needing to cap the needle or handle the connection.
[0010] There are various fluid transfer procedures in the medical setting that may require a very secure connection between a fluid transfer tip (e.g., provided by a syringe) and a corresponding hub. The hub may be connected to a needle or catheter inserted into an artery, vein, cavity or organ of a patient. In the field of cardiology, angiography and angioplasty procedures may inject fluids (liquid and/or air) into narrow channels at high pressure. Manual syringes and manifold sets are used for percutaneous coronary interventions and coronary diagnostic procedures such as angiography. A cardiac angiographic kit typically may include a catheter hub for connection, a catheter body of chosen size, length and stiffness, and a tip with a single end-hole to eject fluids. The catheter body is inserted into the coronary vessels, ventricles and/or peripheral vasculature. A syringe may be connected to the catheter hub to inject contrast agents or saline at pressures ranging between 250 and 800 psi, and even up to 1000 or 1200 psi (84 bar). The catheter hub has an external thread to provide a standard Luer lock connection.
[0011] Luer lock connectors have become universal, not only for joining syringes to hubs, but also for connecting small-bore medical tubing and hoses for liquids and/or gases. Luer lock connections are commonly used for vascular IV lines but also find use in other medical treatment or diagnostic systems. Tubing and hoses may use a Luer lock connection for cuff inflation systems, feeding tubes, catheters, and hoses for vascular, enteral, respiratory, neuraxial and urethral/urinary systems.
[0012] The screw connection of a Luer lock hub is often considered necessary to withstand high pressures. However a syringe, hose, or other fluid transfer device must be rotated to connect, and disconnect, its Luer lock collar to/from the hub. This can take time and requires a two-handed operation. Furthermore, when a user grips the hub to unscrew the connection there is a risk of contamination, especially where the hub may include a needle that may carry blood on its shaft. It would improve the efficiency and workflow of medical procedures if a fluid transfer device could be disconnected from a Luer lock hub more easily.
[0013] There are various devices known in the art to assist in the removal of a Luer slip hub from a fluid transfer device. Many of these devices utilise a lever member capable of pushing the hub away from the tip of the fluid transfer device. In such embodiments the positioning of the lever member on the fluid transfer device can lead to accidental release of the hub, as the lever typically requires a small amount of force to be applied to it in order to remove the hub. This accidental release could be dangerous in instances where a needle is attached to the hub as this could result in a needlestick injury.
[0014] Arrangements for removing a Luer slip hub may also be used to remove a Luer-lock hub from a fluid transfer device. Some examples of this are taught in WO2014/020090. These fluid transfer devices typically may include a threaded collar attached to a lever member. Such a lever member is capable of moving the threaded collar away from the Luer-lock hub allowing it to be released. However The Applicant has now appreciated the potential for improvement of the arrangements taught in the above-mentioned application. In particular it has been recognised that in some circumstances there might be a tendency with such devices when screwing the Luer-lock hub to the device for the lever member to pull forward and away from the fluid transfer tip. This could cause the threaded collar to move away from the fluid transfer tip and so result in a poor connection between the hub and transfer tip which could lead to the loss of fluid during use of the fluid transfer device.
SUMMARY OF THE INVENTION
[0015] The present invention seeks to address or mitigate this problem. When viewed from a first aspect the present invention provides a fluid transfer device including:
a body member; a fluid transfer tip, the fluid transfer tip comprising a tapered friction fitting for a corresponding hub; a disconnecting member having a front portion and a rear portion; and engagement features operating between the disconnecting member and the body member which engage with one another to inhibit the front portion of the disconnecting member from moving relative to the fluid transfer tip; the device being arranged such that upon application of a force to the rear portion of the disconnecting member, the disconnecting member deforms so that the engagement features are no longer in engagement with one another, thereby allowing the front portion of the disconnecting member to move relative to the fluid transfer tip and subsequently release the hub from the friction fitting.
[0021] Thus it will be seen by those skilled in the art that a fluid transfer device provides a novel mechanism for reducing the risk of accidental release of the hub from the fluid transfer tip. The engagement features ensure that the hub is only removed when a sufficient force is applied to the rear portion of the disconnecting member. The engagement features help to reduce the risk that if a user should inadvertently apply pressure to the disconnecting member, this will accidentally release the hub.
[0022] In a set of embodiments the disconnecting member is provided by a lever member. An advantage of using a lever member to disconnect the tip from a corresponding hub is that it can amplify an input force to provide a greater output force, i.e., providing leverage to push a hub away from the tip. In a set of embodiments the lever member is pivotally mounted relative to the fluid transfer tip. The mechanical advantage of a lever member can increase the force applied so that the device can be released without necessarily holding the hub, thereby enabling single-handed operation. This carries several advantages—for example the ability to maintain sterility during procedures. In the case of catheter insertion procedures, such as those previously described, it advantageously allows a user easily to detach the hub when the tip is correctly positioned without disturbing its position. In ultrasound-guided procedures it also allows the entire procedure up to and including detachment of the hub to be conducted without looking away from the ultrasound monitor.
[0023] Advantageously the disconnecting member is designed such that any potential user can apply an appropriate force to overcome the engagement features. The disconnecting member could be formed integrally with the body member—e.g., using a living hinge. In another set of embodiments the disconnecting member is a separate part from the body member.
[0024] Any suitable form of engagement features may be used. For example complementary mutually engaging coarse surfaces could be provided on the disconnecting member and body member. In a set of embodiments however the engagement features may include at least one protrusion and at least one complementary recess. Protrusions and recesses are considered advantageous as they may provide a positive indication to the user when they are in a locked position. For example when a user applies a force to the disconnecting member it will be evident if the features are locked together as the disconnecting member will not be moved when a smaller force is applied.
[0025] The protrusion may, for example, be located on the body member of the fluid transfer device or on an adapter fitted thereto. The recess may be located on the disconnecting member. However it will be appreciated that the arrangement of engagement features could be the other way around or indeed any combination thereof could be provided—e.g., with some protrusions on one part and other protrusions on the other part. It will be appreciated that there may be any number of engagement features depending on the application of the device. For example the device may be provided with more engagement features to increase the force necessary to move the connecting member.
[0026] In a set of embodiments the engagement features are designed such that there is a smooth transition from engagement to non-engagement. This may be achieved through chamfered or rounded edges on the engagement features. Such a smooth transition may be advantageous in some circumstances to prevent an excessive force being applied to the hub.
[0027] In a set of embodiments the engagement features are visible to the user. Such embodiments may be advantageous in ensuring the user is aware of the state of the lever member when connecting a hub to the fluid transfer device. The disconnecting member may be clear or translucent thus enabling the user to see through the surface of the disconnecting member to determine whether the engagement features are in engagement with one another. Alternatively the engagement features may extend through an external surface of the disconnecting member. For example a protrusion on the body member having a non-circular cross-section could extend through a corresponding aperture on the disconnecting member enabling it to be seen by the user.
[0028] In a set of embodiments in which the disconnecting member may include a lever member, the engagement parts are positioned behind a point at which the lever member pivots. This ensures that the force applied to the lever initially goes towards deforming the lever member and separating the engagement features instead of causing the lever member to become detached from its pivot points.
[0029] In accordance with the invention the hub may be retained on the tip purely by the friction fit. In a set of embodiments however the disconnecting member may include locking means for holding the hub. This may help the hub to be held onto the tip more securely.
[0030] In a set of embodiments the locking means is provided by a latch or other positive connection. For example, a suitable positive connection may be achieved by engaging a pair of male/female parts. This ensures that there is a strong positive connection with the hub and only allows removal of the hub when the lever is depressed. Some non-limiting examples of a latch may include a single protrusion, a series of protrusions or a saw-tooth profile.
[0031] In a further set of embodiments the locking means may include a screw thread provided on a lever member providing the disconnecting member. This provides a mechanism for locking a suitably configured hub, e.g., a standard Luer lock hub, onto the device. The hub may be connected by relative rotation between it and the body member, as is conventional, to ensure a tight screw connection. Such a Luer lock connection may be suited to high pressure fluid transfer procedures.
[0032] In such arrangements the lever member may be arranged such that movement of the front portion of the lever member relative to the body member causes the screw thread to pivot away and release the screw fit so that a hub can be disconnected from the device without an unscrewing action. The usual two-handed operation of unscrewing can thus be replaced by a simple one-handed operation of the lever member.
[0033] It is not essential that the hub also carries a screw thread. For example if the screw thread on the lever member does not extend all the way around the hub, the hub may be engaged though a simple annular flange, such as is found on a standard Luer slip hub, with the screw thread engaging the flange to provide a positive connection in addition to the friction fitting. Other hub designs may also be positively engaged by the screw thread, as is explained further below.
[0034] The Applicant has appreciated that locking the lever member in position, by means of the engagement features, is also beneficial when using threaded or flanged hubs with a threaded collar on the lever member. When screwing a screw threaded hub or hub with a flange onto a device without the lever member locked in position, there may be a tendency for the lever member to be pulled forward, due to the threaded hub pulling on the collar, in such a way that the collar might slip off the thread or flange. In this case when screwing the hub in further it would not be possible to obtain a desirably tight connection between the hub and male connector tip. With the engagement features of the present invention this problem may be overcome. The engagement features may prevent the lever member from moving in reaction to the pulling force referred to above. Consequently as the hub is screwed onto the collar the lever member is kept in an engaged position, with the threaded collar held close to the male connector tip, and a tight fit can be made with the male connector tip. Furthermore, when the disconnecting member is in the locked position, and the engagement features are in engagement with one another, a pulling force provided by the collar as the hub is screwed in to the collar, pulls the sidewalls of the disconnecting member inwards, and further tightens the engagement of the engagement features thus preventing the disconnecting member from moving.
[0035] The screw thread mounted on the lever member can be considered a kind of latch, as pivoting the lever member releases the latch so that the screw thread is separated from a corresponding thread on an outer surface of the connected hub. This leaves the hub connected by the friction fitting alone. Simply releasing the screw fit is not enough to disconnect the hub from the fluid transfer tip; the hub cannot fall away from the tip under gravity due to the friction fitting. The lever member of preferred embodiments of the invention has the additional function of also releasing the hub from the friction fitting. This may be achieved in a single smooth action by the lever member, for example a front surface of the front portion moving relative to the fluid transfer tip to push away the hub and release the friction fitting. In a preferred set of embodiments the lever member is pivotally connected to the body member of the device with one end, such as a front surface, moveable between first and second positions relative to the fluid transfer tip.
[0036] As is mentioned above, a hub may be connected to the fluid transfer device by pushing and rotating the hub, thus engaging the thread on the hub with the threaded collar. For example, a standard Luer lock hub may be rotated by up to 270° to ensure connection of its outer screw thread with the screw thread mounted on the lever member. During this process the lever member may remain locked in its engaged position while the hub is being connected. However, the Applicant has recognised that the time and/or manual dexterity required to rotate a hub to form the screw fit may not always be desirable. In accordance with embodiments of the invention however, an over-threshold force can be applied to the rear portion of the lever member to pivot the screw thread or other locking means provided on the front portion of the lever member away from the tip. A hub can then be pushed onto the male connector tip. A final, short rotation of the hub may then allow the screw thread to engage. This may provide an improvement over standard Luer lock connections as it may only require a turn through 90° (or less), rather than 180° or 270°, to complete the screw fit connection.
[0037] In a set of embodiments the screw thread on the lever member is only partial. For example the screw thread may be an internal thread carried by a partial or hemi-cylindrical collar. As such a collar only extends around one side of the fluid transfer tip, e.g., up to 180° around the circumference of the fluid transfer tip, the screw fit may be released simply by pivoting the lever member to move the collar away from the fluid transfer tip and hub connected thereto.
[0038] More generally, it is preferable that the screw thread provided on the lever member takes the form of an internally threaded collar. Such a collar may be provided on the lever member to at least partially surround the fluid transfer tip. In order to ensure a secure Luer lock connection, the internally threaded collar may extend substantially 360° around the circumference of the fluid transfer tip. However a 360° collar can make it more difficult for the lever member to operate to release the screw fit, as the collar must be moved away from the fluid transfer tip on all sides. The internally threaded collar may be separable into multiple segments that are arranged to be moved apart by pivoting the lever member to disengage the engagement features and thereby release the screw fit with the hub.
[0039] Such a fluid transfer connection benefits from the screw fit of a standard Luer lock connection, which is trusted to withstand pressurised fluid transfer procedures, the quality of the connection is ensured as the lever member is locked in position. The connection also enables the Luer lock connection to be released by operating the lever member instead of unscrewing the tip from a corresponding hub. This can be a simple one-handed gesture rather than a two-handed twisting movement. The separable collar allows the lever-operated disconnection mechanism to cooperate with a standard Luer lock hub.
[0040] In a set of embodiments the locking means is carried by a collar provided on the disconnecting member such that the hub can be mounted to the tip by initially applying a force to the disconnecting member to disengage the engagement features and move the collar away from the tip, and when the hub has been pushed onto the friction tip, the disconnecting member can be returned to a position whereby the locking means on the collar engages with the hub. Such an embodiment is advantageous as it allows the user to easily mount the hub on the device without having to overcome the locking means when attaching the hub. This is particularly advantageous when the locking means is provided by a latch which might require significant force to push the hub past the latch.
[0041] A potential problem with pushing a hub away from a tip is that it may be forcibly disconnected. If the hub is carrying a needle or other sharp object then this could pose an injury risk. In a set of embodiments therefore the device further may include a catch means arranged to catch the hub after it has been released from the friction fitting. Further movement of the disconnecting member (e.g., against a resilient bias) may cause the catch means to catch the hub. In this way the hub may be caught as it becomes disconnected but then controllably separated from the device. The catch means be may be subsequently released by resiliently biased movement of the disconnecting member, e.g., back to its resting state.
[0042] In a set of embodiments the disconnecting member is moveable between two positions: a first position wherein the front portion proximal to the male connector tip is close to the base of the tip and a second position wherein the front portion moves towards a distal end of the male connector tip. In a further set of embodiments the disconnecting member is resiliently biased such that it returns to its first position when no force is applied to the disconnecting member. This may be advantageous as it means that the device may always be in a state whereby a hub can be attached.
[0043] In a further set of embodiments the resilient bias is provided by the disconnecting member itself. This is advantageous as the lever member can be designed such that the deformation of the lever member, required to separate the engagement parts, acts to resiliently bias the disconnecting member back to its first, locked, positioned. In a set of embodiments the disconnecting member is made from an elastically deformable material. In a preferred set of embodiments the disconnecting member is made from plastic which can provide an inexpensive, sterile, and disposable product for single use in a medical setting.
[0044] Although the disconnecting member may take many different forms, preferably the disconnecting member may include a front surface that is substantially transverse to the axis of the tip and the front surface is arranged to move along the tip from a first position to a second position when force to disengage the engagement features is applied to the disconnecting member. In order for the disconnecting member to transfer force efficiently, it is preferable for it to be relatively stiff. The disconnecting member may be stiffened by forming it as a three-dimensional shell—i.e., with a shape that extends significantly in all three dimensions.
[0045] In a set of embodiments the disconnecting member may include a front surface that is substantially transverse to the axis of the tip and one or more side surfaces that extend in a direction substantially parallel to the axis of the tip. The surfaces may form a shroud extending at least partly around an axis defined by the tip—e.g., by at least 90 degrees. The shroud preferably extends back from the front surface, away from the fluid transfer tip. The three-dimensional extent of the member can help to ensure that it is stiff even if formed of a plastics material yet is still deformable to allow the engagement features to separate. In such embodiments, when a force is applied to the disconnecting member it causes the side surfaces of the disconnecting member to expand, thus disengaging the engagement features and allowing the disconnecting member to move relative to the body member.
[0046] In a further set of embodiments separate resilient means are provided between the disconnecting member and the body member. This may be in the form of a spring or any piece of elastically deformable material. This may be advantageous to ensure that the disconnecting member returns to its original, locked position to ensure the screw thread connection is secure, irrespective of any resilience of the disconnecting member itself.
[0047] The body member comprising at least one of the engagement features may be integral with or separate from the fluid transfer tip. In one set of embodiments the body member may include an integral mounting arrangement for the disconnecting member. In embodiments where the body member is integral with the fluid transfer tip, it may be positioned behind the fluid transfer tip, for example carried by a fluid chamber that is integrated with the tip.
[0048] In one set of embodiments the fluid transfer device may include a fluid chamber in communication with the fluid transfer tip and the body member is integrated with the fluid chamber. For example, the body member may include an axle integrated with the fluid chamber for pivotally mounting a disconnecting member in the form of a lever member. In a set of embodiments one of the engagement features is integrated with the fluid chamber. In such examples, the fluid transfer device may include a syringe and the syringe barrel may have an axle moulded on its outer surface to pivotally mount the lever member along with an engagement feature moulded on its outer surface to engage the corresponding feature on the lever member. The fluid chamber, such as the barrel of a syringe, may therefore be designed to mount a disconnecting member so that the device can be supplied with the disconnecting member pre-mounted ready for use.
[0049] In another set of embodiments the disconnecting member could even be integrated with the body member, for example as a lever member pivotally mounted by an integral hinge and held in a locked position by means of complementary engagement features on the body member and the lever member respectively. The lever member and body member could, for example, be formed as a single plastics moulding, e.g., with the lever member pivotally mounted by a living hinge or the like.
[0050] However, in another set of embodiments it may be desirable to retrofit a disconnecting member to an existing fluid transfer device or connection. For example, it may be desirable to mount a lever member to a standard syringe or other device/connection—via a suitable body member which may grip the syringe etc.—so as to enjoy various of the benefits outlined above but without changing the design of the device/connection. In such embodiments it is preferable that the disconnecting member is mounted by a separate body member. The body member may be attached to a fluid transfer device or connection by any suitable means. So as to avoid interference with the fluid transfer tip, the body member may be attached to the aft end of the tip, or behind the tip, e.g., by an attachment collar which grips the body. In a set of embodiments the body member may include means for gripping a barrel, hose, or other suitable portion of a fluid transfer device. The gripping means, could, for example, include one or more elastically compliant fingers made from a high friction material such as synthetic rubber.
[0051] When viewed from a second aspect the invention provides a connector for a fluid transfer device comprising a fluid transfer tip including a tapered friction fitting for a corresponding hub, the connector providing:
a body member; a disconnecting member having a front portion and a rear portion; and engagement features operating between the disconnecting member and the body member which engage with one another to inhibit the front portion of the disconnecting member moving relative to the body member; the device being arranged such that upon application of a force to the rear portion of the disconnecting member, the disconnecting member deforms so that the engagement features are no longer in engagement with one another, thereby allowing the front portion of the disconnecting member to move relative to the fluid transfer tip and subsequently release the hub from the friction fitting.
[0056] It will be understood that such a retrofitting adapter may be attached around the fluid transfer tip or any other part of a fluid transfer connection or device, such as a syringe, in any situation where operation of the lever member may assist in locking and subsequently disconnecting a hub to/from the tip. The adapter may be attached before or after inserting the tip into a hub. Such an adapter could be optionally attached to a fluid transfer device or connection by a user when it is determined that the friction fitting is too tight to be easily disconnected by pulling the tip away from the hub, or at least not without risking damage or injury. The mechanism could also be optionally attached where the fluid transfer device (or connection) is connected to a hub carrying a needle and protection from needle spike is desired.
[0057] In one set of embodiments of either aspect of the invention the disconnecting member is removably mounted to the body member. This means that a user may remove and discard the disconnecting member if it is not required or if it is preferable to operate the device (or connection) without any interference from the disconnecting member.
[0058] The fluid transfer device may include any type of device used to transfer fluid—liquid and/or gas—either to or from a fluid receptacle. The fluid receptacle may be inanimate or it may be part of a living subject, for example a bodily cavity, organ, or vessel, such as a vein or artery. The present invention may find a wide range of uses, for example it could be employed for containers of dangerous or hazardous liquids—e.g., glue—where it is desirable to be able to detach a cap whilst avoiding contact with a user's hand. In a preferred set of embodiments however the fluid transfer device is a medical device. The fluid transfer device may include one or more devices such as a syringe, pre-filled syringe, IV delivery device e.g., “drip”, transfusion device, fluid pump, stopcock, aspirator, suction device, container for a blood collection tube or hose. Alternatively the fluid transfer device could include a luer lock/luer slip male/female “bridge extension”, which would enable the one-hand use functionality described herein to be added to an existing device. The device may be made to meet the relevant medical standard(s), for example ISO 7886 for sterile hypodermic syringes.
[0059] These and other features and improvements of the present application and the resultant patent will become apparent to one of ordinary skill in the art upon review of the following detailed description when taken in conjunction with the several drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0060] Some embodiments of the present invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:
[0061] FIG. 1 is an exploded view of a fluid transfer device embodying the invention;
[0062] FIG. 2 is an enlarged view of the adapter of FIG. 1 ;
[0063] FIG. 3 shows the fluid transfer device in typical use;
[0064] FIG. 4 is a pair of cross-sectional views on line A-A of FIG. 3 showing the lever member and corresponding adapter in both locked and unlocked positions;
[0065] FIG. 5 is a close-up view of a lever member in accordance with another embodiment of the invention;
[0066] FIG. 6 shows a lever member similar to that of FIG. 5 without the catch;
[0067] FIG. 7 shows another embodiment of a fluid transfer device wherein the axle and engagement features are integral;
[0068] FIG. 8 is a sectional view of the fluid transfer device of FIG. 7 with a lever member and hub attached;
[0069] FIG. 9 is a perspective view of the fluid transfer device of FIG. 8 ;
[0070] FIG. 10 shows another embodiment of the lever member with a threaded collar and catch integrally provided;
[0071] FIG. 11 shows the hub being screwed onto a fluid transfer device including the lever member of FIG. 10 ;
[0072] FIG. 12 is a sectional view of the embodiment of FIG. 11 with the hub in the locked position on the fluid transfer device;
[0073] FIG. 13 shows the lever member being depressed in order to release he engagement features and release the hub;
[0074] FIG. 14 shows the lever member being returned to its original position and the hub being released from the device;
[0075] FIG. 15 is an enlarged sectional view of the hub being held in the locked position by the threaded collar;
[0076] FIG. 16 shows the hub attached to the fluid transfer device in the locked position;
[0077] FIG. 17 is a cross sectional view of a fluid transfer device in accordance with the invention with the lever member in the locked position;
[0078] FIG. 18 is an enlarged view of the side walls of the lever member and body member of FIG. 17 when the lever member is in the locked position;
[0079] FIG. 19 is a view of the fluid transfer device when the lever member has been depressed;
[0080] FIG. 20 is a cross sectional view of the fluid transfer device when the lever member has been depressed and he side walls of the lever member have expanded;
[0081] FIG. 21 is an enlarged view of the side walls of the lever member and fluid transfer device when the lever member is in the un-locked position;
[0082] FIG. 22 is view similar to FIG. 2 of a further embodiment of an adapter in accordance with the invention; and
[0083] FIG. 23 is an enlarged view of the gripping features of FIG. 22 .
DETAILED DESCRIPTION
[0084] There may be seen in FIG. 1 an embodiment of a disconnecting mechanism for a fluid transfer device taking the form of a syringe 2 . The syringe 2 generally may include a fluid barrel 4 in communication with a male tip 6 . The tip 6 is tapered from its aft end, proximal to the barrel 4 , to its forward end according to the standard Luer slip design i.e., a 6% taper (equivalent to around 3.43°). Fluid in the barrel 4 can be transferred through the tip 4 by pushing or pulling a plunger 8 inserted in the barrel 4 . However, although a syringe 2 is shown in each of the embodiments for simplicity, such a Luer slip tip could equally be part of another fluid transfer device such as a drip, a hose connector or an “extension bridge” connector, as mentioned earlier.
[0085] FIG. 1 demonstrates how the syringe 2 can be connected with a body member in the form of an adapter 10 , a lever member 12 , and a female hub 14 . In this embodiment the lever member 12 is attached to the adapter 10 . This adapter can then be positioned on the syringe 2 . The male connector tip 6 may be connected to a corresponding female hub 14 in order to transfer fluid to a needle 16 or other cannula mounted on the hub 14 . Although not shown, the needle 16 might already be inserted into a living subject, for example for IV therapy with the hub 14 providing an IV port for the injection and/or removal of various fluids.
[0086] The tapered tip 6 is inserted into the hub 14 and forms a friction fit that is fluid-tight. In each of the embodiments, a lever member 12 is provided that can be manually operated to move relative to the male tip 6 between a first position, proximal to the syringe barrel and a second position spaced from the first position towards the distal end of the male tip 6 so as to push against the hub 14 . Operation of the lever member 12 therefore acts to disconnect the syringe hub 14 from the tip 6 without a user needing to pull or tug the syringe hub 14 to release the friction fit of the Luer slip connection.
[0087] In the embodiment of FIG. 1 the lever member 12 is pivotally mounted to the adapter 10 which is attached to the syringe barrel 4 . The adapter 10 can be held on the syringe 2 by any suitable means. This may be a friction fit or there may be locking features that hold the adapter on the syringe barrel 4 . Alternatively the adapter 10 may include an internal thread and the syringe 2 may include an external thread to allow the adapter 10 to be screwed onto the syringe 2 .
[0088] The lever member 12 may include a front surface 18 and rearwardly extending surface. The rearwardly extending surface may include a top surface 20 and side surfaces 22 . In the embodiment shown in FIG. 1 the lever member further may include a screw threaded collar 24 and a catch 26 . The purpose of the threaded collar 24 is to engage with the hub 14 to lock it in position and the catch 26 is present to catch the hub 14 once it has been released from the male tip 6 by the lever member 12 .
[0089] There is shown in FIG. 2 an enlarged view of the adapter 10 . The adapter 10 has the general form of an annular band 28 enabling it to be fitted onto the syringe 2 . The band 28 has a smooth inner surface 30 . This inner surface 30 could be tapered or stepped to allow the adapter 10 to be fitted on to syringe barrels or other devices which have different diameters. In this embodiment the adapter is held on due to the frictional force between the adapter 10 and the outer surface of the syringe barrel 4 .
[0090] The adapter may include two axle portions 32 integrally moulded at its forward end. These mount the lever member 12 to the adapter so that it can pivot about an axis defined by the axle portions 32 . The adapter 10 further may include protrusions 34 extending from a rear part thereof. The protrusions 34 have chamfered edges 36 which ensure that they pass smoothly into and out of corresponding recesses on the lever member 12 as will be explained hereinbelow.
[0091] FIG. 3 shows the fluid transfer device 2 , adapter 10 , lever member 12 , and female hub 14 in normal use. The adapter 10 is positioned on the device 2 and the lever member 12 is pivotally mounted to the adapter 10 in such a way that pivotal movement is inhibited as is shown more clearly on the left hand side of FIG. 4 . The female hub 14 can be screwed onto the male connector 6 tip by screwing it through the thread on the threaded collar 24 . This is made possible as the hub 14 may include an annular flange 40 . As the collar 24 is hemi-cylindrical in the embodiment shown, it is not necessary for the hub 14 to have a threaded section, an annular flange is sufficient to allow it to engage with the half screw thread 24 . In different embodiments if the collar extends substantially around the male connector tip 6 then it may be necessary for the hub 14 to be threaded. The catch 26 on the lever member 12 prevents the hub 14 from being dangerously ejected from the device as will be explained later.
[0092] As seen in FIGS. 1 and 3 , the lever member 12 is formed in a shroud shape which extends rearwardly and partially surrounds the adapter 10 and syringe barrel 4 through an angle of approximately 270°. Internal sockets (not shown) receive the axle portions 32 when the lever is clipped onto the adapter 10 to allow for pivotal movement between them. As shown in the left hand portion of FIG. 4 however, such pivotal movement is inhibited by the protrusions 34 on the adapter 10 being received in complementary recesses 38 on the inner surface of the side portions 22 of the lever 12 . This can therefore be considered to be a locked position.
[0093] The right hand side of FIG. 4 shows what happens when a user applies a force to the rear part 20 of the lever member. Pivotal movement is inhibited by the engagement between the protrusions 34 and recesses 38 , but because the lever member 12 is moulded from a flexible plastic material the force applied to the rear part 20 of the lever causes the side surfaces 22 of the lever member to deform and bow out. As a result the recesses 38 are disengaged from the protrusions 34 and so the lever member 12 can then be pivoted about the axle portions 32 .
[0094] In the embodiments shown the protrusions 34 and recesses 38 are positioned centrally about the axis of the fluid transfer device 2 , however it will be appreciated that depending on the application they could be positioned away from the centre axis and further towards the top or the bottom of the adapter 10 .
[0095] FIG. 4 illustrates that the shape of the lever member 12 can provide a resilient bias. Here the top portion 20 of the lever member is narrower in horizontal extent than the lower section. When the lower sections 22 are made to bow out by an applied force as in the right hand part of FIG. 4 , when the force is subsequently removed, the deformed sides 22 tend to return to their original shape. As the top portion 20 is narrower than the lower portion 22 , this pulls the lever member upwards 12 and thus causes the protrusions 34 and recesses 34 to become re-engaged, thus locking the lever member 12 in place once more.
[0096] Because the lever member 12 is locked into position unless pressure is applied to the rear portion 20 , when the hub 14 is screwed into the threaded collar 24 , the collar (which is an integral part of the lever member) resists the tendency to be drawn up by the hub 14 which would otherwise give rise to a tendency to slip off the flange 40 and so reduced the connection strength.
[0097] FIG. 5 shows a different embodiment of the lever member 12 ′. The lever member 12 ′ still has a shroud shape with a hemi-cylindrical collar 24 ′ and a catch 26 . However in this embodiment the collar 24 ′ also may include split sections 41 which extend away from the collar 24 ′ in a conical shape. This effectively increases the size of the opening of the collar 24 ′ and makes it easier for the user to locate the female hub onto the device. FIG. 6 shows a similar embodiment except there is no catch provided.
[0098] FIG. 7 shows a further embodiment. In this embodiment instead of the annular adapter there is provided an adapter 42 that can be fitted directly to a hose or other fluid transfer device rather than a syringe. In this embodiment it can be seen that the aft end of the adapter 42 may include a nozzle 44 which can be connected to another device. This has a cylindrical section 46 with an enlarged frusto-conical end portion 48 . This allows a hose or other device to be slid easily onto the end of the device and be held in place. In other embodiments (not shown) a similar adapter could be provided which forms a Luer lock/Luer slip male/female “bridge extension” which is able to connect to other devices which Luer lock/luer slip compatible—e.g., by including in the adapter a hub-like structure able to receive a standard male tip and a tip-like structure able to receive the hub bearing the needle.
[0099] The adapter 42 also may include an integral male connector tip 6 ′ and the adapter 42 shown in FIG. 7 also may include axle portions 32 ′ for enabling a lever member 12 , 12 ′ to be mounted to the adapter 42 . Also seen on the side of the adapter 42 is one of two protrusions 34 ′ which engage in complementary recess in the lever member to lock it into position as previously described. A reinforcing ring 50 of material ensures that when pressure is applied to the lever member it does not deform into the void space around the adapter and instead expands to disengage the protrusions 34 ′.
[0100] Also shown is a base plate 52 on the opposite side of the adapter 42 to the axle portions 32 ′. This has a curved rear portion 54 . The base plate 52 is provided to allow the user to grip the adapter 42 securely. This assists both when positioning the female hub 14 on the male tip 6 ′ and when releasing the hub 14 .
[0101] FIG. 8 shows an assembled implementation of the adapter 42 of FIG. 7 , in which the female hub 14 mas been placed on the male tip 6 ′. It can be seen that the flanged portion 40 of the hub is held in place by the internally threaded collar 24 on the lever member 12 .
[0102] FIG. 9 is another view of the same embodiment whereby the lever member 12 ′ and hub 14 are shown. This figure shows where the user can grip both the lever member rear portion 20 and the base plate 52 . In this figure the benefit provided by the split diverging portion 41 of the collar 24 can be seen since it effectively increases the aperture size of the collar, making guiding the hub 14 into the internally threaded collar 24 easier.
[0103] FIG. 10 shows he lever member 12 of FIG. 1 . The threaded collar 24 may include half a turn of internal thread 56 which enables the user easily to screw the hub onto the device as it requires turning the hub (not shown) through a small angle to attach it.
[0104] FIGS. 11-14 show the sequence of events when a hub is attached to the device and later removed. As seen in FIG. 11 the device may include an adapter 10 carrying a lever member 12 attached to a syringe 2 as previously described, e.g., with reference to FIG. 1 . The hub 14 bearing a needle 16 is attached to the syringe 2 by first by placing the hub 14 onto the male connector tip 6 and screwing it into position. During this the flange 40 on the hub engages with the internal thread on the collar 24 . Throughout the attachment of the hub, the lever member 12 remains in the locked position whereby the protrusions 34 and recesses 38 are in engagement. This ensures that when the hub 14 is screwed on, the lever member 12 is not pulled towards the distal end of the male connector tip 6 , thus ensuring a good connection between the hub 14 and male tip 6 . Thus as the hub 14 is screwed on, the connection with the male tip 6 is improved and a better fluid-tight fit is achieved.
[0105] Once the hub 14 is fully screwed into position it is in a locked position. It is held in place by the friction fit provided by the male tip 6 and the threaded collar 24 . This locked position can be seen in FIG. 12 . In this state the user can apply pressure to the plunger 8 which will result in fluid being transferred through the male tip 6 and out of the needle 16 .
[0106] When the user has finished using the device and wishes to remove the female hub 14 , they simply apply pressure to the top surface 20 of the lever member 12 . This process can be seen in FIG. 13 . The applied pressure causes the side surfaces 22 of the lever member 12 to deform and thus the recesses 38 disengage from the protrusions 34 . As soon as the recesses 38 are free from the protrusions 34 , the force applied to the lever 12 causes it to rotate about the axle portions 32 . This causes the threaded collar 24 to move away from the flange 40 on the hub 14 and the front surface of the lever member 12 to move towards a distal end of the male connector tip 6 pushing away the female hub 14 . This acts to release the hub 14 from the friction fit. The catch 26 also moves towards the hub 14 to arrest its free movement and prevent it from being ejected dangerously from the device. At this stage, as shown in FIG. 13 , the hub 14 is still loosely over the male tip 6 , however it is held only by the catch 14 .
[0107] When the user wishes to remove the female hub 14 completely for safe disposal, they can release the applied pressure to the lever member 12 . This process is illustrated in FIG. 14 . After the force being applied to the lever member 12 is released, the lever member 12 returns to its un-deformed state and so to its locked position as previously described with reference to FIG. 4 . The hub 14 is thereby freed from the catch 26 and can be discarded appropriately in a sharps bin or other suitable place.
[0108] FIG. 15 shows an enlarged view of the hub 14 when screwed onto the adapter and held in position by the threaded collar 24 . The internal thread 56 grips the flange 40 on the hub 14 . It is clear from this view that in this embodiment there is a minimal amount of thread 56 on the collar 24 . This allows a quick and easy attachment of the hub 14 to the device since it is only necessary to turn it through a small angle. In situations where a stronger connection is required, for example where the pressures involved are higher, the collar 24 may be provided with more turns of thread 56 .
[0109] FIG. 16 shows another view of all the components of FIG. 1 together in a locked position. It can be seen that the adapter 10 has been slid onto the chamber 4 of the syringe 2 . FIG. 17 is a sectional view on line A-A of FIG. 16 . It is possible to see how the axle portions 32 engage with sockets 60 on the lever member 12 providing a pivot axis. Also the protrusions 34 and recesses 38 , which form the locking mechanism, can be seen.
[0110] FIG. 18 is an enlarged view the circled area of FIG. 17 showing the protrusions 34 on the adapter 10 engaging with the recesses 38 on the side walls 22 of the lever member 12 . It may be seen that the protrusion 34 is a relatively loose fit in the recess 38 to ensure that the protrusion 34 is reliably received in the recess 38 without becoming caught on the edge thereof. The small amount of play this permits is not sufficient to dislodge the hub 14 . The Applicant has appreciated that several variations in the shape of the protrusion, and a tight/loose fit in the corresponding recess enable adjusting the design to an optimal function.
[0111] FIGS. 19 to 21 correspond to FIGS. 16-18 for the case where the lever rear portion 20 is pressed down to release the lever 12 . FIG. 19 shows the hub 14 disengaged and pushed away from its friction fit with the tip and so partially disconnected from the device as described above with reference to FIG. 13 .
[0112] FIG. 20 shows how the side surfaces 22 of lever member 12 expand to disengage the engagement means. Applying a force to the top surface 20 of the lever member 12 it causes the protrusions 34 to press against the sides of the recesses 38 . The force being applied therefore goes towards expanding the side surfaces 22 causing the lever member 12 to deform. This causes the sides 22 to bow out so that the recesses 38 separate away from the protrusions 34 . Once the protrusions 34 and recesses 38 are out of engagement, the lever member 12 is free to rotate further.
[0113] Also visible in FIG. 20 are sockets 60 on the lever member 12 in the form of elongated slots. The slots 60 receive the axle portions 32 on the adapter 10 . The slots 60 are elongated so as to accommodate the relative movement between the lever member 12 and the adapter 10 when the lever is depressed without the axles portions 32 becoming disengaged from the slots 60 .
[0114] FIG. 21 shows an enlarged cross sectional view of the protrusions 34 and recesses 38 when the lever member 12 is in the unlocked position. It is clear that the sidewalls 22 of the lever member have expanded and the lever member 12 is free to pivot about the axle portions 32 . As the lever member 12 pivots, the protrusions 34 move along the inside surface of the side walls 22 . Although in the embodiment described the protrusions 34 pass along the inside surface, a groove may be provided on the inside surface of the sidewalls 22 to assist in directing the motion of the protrusion 34 and thus the lever member 12 .
[0115] As described above, the hub 14 is typically attached to the device by pushing it onto the tip 6 whilst at the same time screwing it into the threaded collar 24 . As an alternative method it is also possible first to depress the lever member rear portion 20 , which disengages the protrusions 34 and recesses 38 and causes the lever member to pivot. The threaded collar 24 is pivoted away from the tip. The hub 14 can then be pushed onto the tip 6 and the lever member 12 can be released. The resilience of the lever member 12 causes it to return to its original locked position. The threaded collar 24 also returns to engage the flange 40 of the hub. The hub 14 can then be rotated a small amount to screw it into its final position. This method is advantageous as it requires minimal turning of the hub which may be difficult in instances where the hub is attached to a needle, or in instances where the hub is already attached to a living subject.
[0116] FIG. 22 shows an alternative embodiment of an adapter 10 ′. This embodiment provides extra gripping means 62 on the adapter 10 ′ to reduce the risk of the adapter being made to slip on the barrel 4 when a hub 14 is screwed onto the device. It can be seen that there are four high-friction gripping fingers 62 provided around the circumference of the adapter 10 ′, however the number of and placement of these may vary depending on the application. The gripping fingers 62 are moulded as part of the adapter 10 ′ and decrease its effective internal diameter to make a tighter fit. There also have clip sections 64 which may provide further grip or may lock into corresponding grooves on the barrel 4 of the device 2 . The adapter 10 ′ also may include a lipped section 66 which abuts against the front surface of the fluid transfer device 2 when it is fully on the device.
[0117] Also shown in FIG. 22 is an alternative form of protrusion 34 ″. It can be seen that the protrusion 34 ″ has a fin-like shape with a tapered edge 70 tapering towards the bottom of the adapter 10 ′ and a horizontal edge 72 . Such a protrusion 34 ″ is advantageous as the horizontal edge 72 ensures that the lever cannot be pivoted downwards when the hub is being screwed on. It is only possible to dislodge the lever member 12 from the edge 72 when there is a significant force applied to the top surface 22 of the lever member 12 . Furthermore the tapered face 70 ensures that when the pressure to the lever member 12 is removed, the recess on the lever member 12 can easily slide over the protrusion 34 ″ and return to its locked position. This ensures that the device is always in a locked position when no force is being applied to the lever member 12 .
[0118] FIG. 23 shows an enlarged view of the additional gripping fingers 62 provided on the adapter 10 ′. It is seen that the gripping fingers 62 are provided on the lipped section 66 at the end of the adapter. The adapter 10 ′ is typically made from plastic, this allows the gripping means 62 to flex towards the wall of the adapter 10 ′ during attachment to a device. This flexibility ensures that a strong grip is achieved with the fluid transfer device 2 , and it also allows the adapter 10 ′ to be used with devices that have slightly varying diameters
[0119] In the embodiments shown the protrusions and axles are located on the adapter or fluid transfer device. However it is appreciated the both the axles and/or protrusions may be provided on the lever member and corresponding recesses may be provided on the adapter or fluid transfer device. Indeed there are many other possible ways in which engagement features could be provided to inhibit movement between the lever member and adapter.
[0120] It will be appreciated that it is not essential for an adapter to be provided—the invention could be implemented using a specially designed fluid transfer device. Moreover it is not essential to use a pivoting lever member—other forms of disconnecting member are contemplated such as a linearly sliding disconnecting member.
[0121] It should be apparent that the foregoing relates only to certain embodiments of the present application and the resultant patent. Numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the invention as defined by the following claims and the equivalents thereof. | A fluid transfer device may include a body member and a fluid transfer tip, wherein the fluid transfer tip may include a tapered friction fitting for a corresponding hub. The fluid transfer device also may include a disconnecting member having a front portion and a rear portion and engagement features operating between the disconnecting member and the body member. The engagement features engage with one another to inhibit the front portion of the disconnecting member from moving relative to the fluid transfer tip. The fluid transfer device is arranged such that upon application of a force to the rear portion of the disconnecting member, the disconnecting member deforms so that the engagement features are no longer in engagement with one another. This allows the front portion of the disconnecting member to move relative to the fluid transfer tip and subsequently release the hub from the friction fitting. | 0 |
TECHNICAL FIELD
The invention relates to a superconducting switching element and a method for its intentional switching.
THE PRIOR ART
Superconducting switching elements, which can be selectively switched in a very short time from a superconducting state into a normal state, can be used in high power electronics for a large number of devices, in particular, if the electric strength of semiconductor elements is not sufficient or the time constants of conventional switches are too high. Examples of such devices, the function of which can be improved by superconducting power switches, are current limiters, rectifiers, inverted rectifiers, high field magnets and magnetic energy storages.
Superconducting switches have already been described on the basis of classic metallic superconductors like niobate etc. However, since these classical superconductors are also very good normal conductors having a very low resistance, the height of the increase of the resistance during switching is very low. Accordingly, a lot of material must be used, for example in the form of a long wire wound to a coil to obtain a significant increase of the resistance in the electric circuit. The amount of the required material, however, leads to a very high thermal inertia and the switch requires a long recooling time (several ten seconds up to minutes) until it can be operated again.
High temperature superconductors are in contrast thereto poor conductors in the normal state. In the form of thin films on a carrying substrate, the thermal time constant is lower by orders of magnitude (in the range of milliseconds). For this reason resistive switches on the basis of thin HTS layers are of high interest for the above described applications.
Superconducting switching elements consist typically of a conductor of high temperature superconducting material which is deposited onto a carrying substrate by means of thin film techniques and which is structured into suitable conducting paths by means of photolithography. Such a conductor is electrically contacted at its ends and inserted into an electric circuit. The superconductor is cooled to a temperature below its critical transition temperature so that the nominal current can flow through the superconductor without ohmic losses. If the transported current exceeds the nominal current, for example in case of a short in the circuit, or if the current carrying capability is artificially reduced by an external influence, the superconductor switches from the superconducting state over to the normal conducting state, since the superconductor loses its superconducting property, if the critical current is exceeded. Due to the arising high resistance, the short circuit current is limited or can be directed into a parallel branch in the electric circuit. This switching process occurs within fractions of a millisecond up to a few milliseconds.
If the switching element is added in series to an electric circuit, it can be used as a resistive current limiter. Such current limiters are known from the DE 198 27 225 and the DE 198 32 273. Due to its short response time and the limitation of the maximal current, all other operating means, which are arranged in the electric circuit, are substantially less loaded. The switch acts as a self-triggering fuse. After the short circuit has been removed by means of conventional switches, the superconductor can recool and is available for a new switching process.
If the switch can be selectively triggered, the suddenly occurring resistance can also be used for switching the current flow into a parallel line of a lower ohmic resistance. The switch acts in this case not as a fuse but as switchable points. Due to the fast response time and the low thermal inertia of the thin film conductor, these points can also be used to periodically switch an alternating current of low frequency, as for example the 50 or 60 Hz net frequency.
Also in the case of a resistive current limiter switching on its own according to the above described principle and not requiring an active control, such a control is nevertheless desirable. The reason is that the superconductor changes only under ideal circumstances simultaneously over its complete length into the normal conducting state. In practice, the switching process always starts at the weakest point caused by the imhomogenity of the material. Since the complete dissipated energy arises instantaneously locally in this narrowly limited area, a so-called “hot spot” can form by local overheating. Due to a positive feedback, the area continues to heat up until the material is destroyed by heating. For this reason measures are taken in known current limiters to prevent the “hot spot”-formation. One example for these measures is to deposit a metallic parallel conductor (“shunt”) onto the superconductor. Such arrangements are described in the DE 198 56 425 and the above mentioned patents. A major disadvantage of this “shunt”-layer, however, is that the resistance in the normal conducting state is in the case of triggering the switch no longer exclusively determined by the superconductor but essentially by the metallic “shunt”-layer, whereby the maximally switchable power (the product of current prior to switching and voltage drop after switching) is drastically reduced. If it is possible to simultaneously switch the superconductor in a large area, the “hot spot”-problem is no longer present and there is no need for the shunt-layer.
It is known that the superconductor can be heated above its critical temperature by a heater arranged on the substrate using a current pulse so that the switching process can be triggered. Resistively heated thin metallic layers, for example made out of constantan, can be used. However, it is a disadvantage of this method that considerably high heating powers are necessary. In the case of a high temperature superconductor, the operating temperature is typically above 40 K, preferably close to the boiling temperature of liquid nitrogen at approximately 77 K. In this temperature region heat is distributed through the substrate by diffusion, i.e. the heating pulse must at first fill the—compared to the superconducting film—huge heat capacity of the substrate. The necessary heater power is therefore considerably higher than necessary for triggering the superconductor alone. Furthermore, the added heat increases the recooling time of the switch into the superconducting state. Therefore, this way of triggering is not suitable for fast periodic switching processes.
Further it is known that the critical current can be suppressed in classical metallic superconductors by applying a magnetic field so that the switching process can be triggered. This method, however, is not practicable in the case of epitactically grown high temperature superconductor layers due to the necessary high critical field strength.
It is therefore the problem of the present invention to actively control the switching process and to simultaneously trigger it in a large area in a way that the described disadvantages of the prior art are overcome. This allows on the one hand to solve the problem of local overheating, on the other hand there are completely new fields of application for such a switching element due to the fast, selective triggering.
SUMMARY OF THE INVENTION
This problem is solved by a switching element with a high temperature superconductor and an irradiating assembly for irradiating electromagnetic energy onto the high temperature semiconductor. Another aspect of the invention is directed to a method of switching a high temperature superconductor that includes providing the high temperature superconductor in a superconducting state and irradiating the high temperature superconductor with electromagnetic energy until the high temperature superconductor switches into a normal conducting state.
According to the invention, the triggering of the switching process in a current-carrying superconductor is made possible by irradiation of electromagnetic high frequency having preferably a comparatively low power. The quickly changing field can directly couple to the superconductor and induces a resistance in the superconducting layer which is further amplified by the transport current, until the superconductor becomes normally conductive.
Preferably, the field is irradiated in the form of high frequent pulses of a fixed frequency. The same effects, however, can be obtained with fields consisting of different frequencies. Accordingly, the triggering is not limited to pure high frequent sinusoidal oscillations but can be generally obtained by signals changing in time having high frequent Fourier components which are equivalent to the stimulating frequencies described below. The time length of the high frequency irradiation is only relevant insofar that it must be long enough to trigger the switching process.
Further preferred embodiments and applications of the switching element according to the invention as well as of the corresponding method are the subject-matter of further dependent claims.
SHORT DESCRIPTION OF THE DRAWING
In the following the typical construction for a controlled triggering of superconducting switching elements is exemplary presented. The following drawings serve for illustration:
FIG. 1 : Schematic assembly of a controllable switching element. The switching element consists of a superconducting strip conductor 1 deposited onto a substrate. This element is inserted in series into an electric circuit and carries a current I. The source of the current 2 can be a direct currency source, an alternating currency source or any other current source. The oscillating circuit 3 for creating the high frequency consists of the capacitors 4 and 5 and the coil 6 which is positioned close to the superconductor. By means of a pulsed HF-generator 7 the high frequency is coupled via the capacitor 4 into the oscillating circuit. The coupling of the high frequency can also be achieved by other methods common in the art. The time length of the pulse can be adjusted at the generator 7 . Instead of a generator, also a self stimulating circuit can be used.
FIGS. 2 a-e : Different possible embodiments of flat coils 6 for coupling the magnetic field into the superconductor 1 . The number of windings of the coil varies depending on the size of the area to be switched or the inductivity necessary for the oscillating circuit 3 .
FIG. 3 : Time dependency of current and voltage over the superconducting switch operated as a resistive current limiter. At first an initial current of approximately 36 A was applied to the superconductor. Subsequently, the superconductor was subjected to a high frequency pulse of 23 MHz with an output power of 11 W of 5 ms. Thus, a switching process was triggered and the current limited to approximately 15% of the initial current.
FIG. 4 : Schematic construction for triggering a stack of superconducting switching elements 1 . The single superconducting elements are connected to each other via contacting lines 11 . (a) Between a pair of plates there is a respective coil 6 of the oscillating circuit triggering the two adjacent plates. (b) In case of a sufficiently high HF-power, a complete stack of several superconducting elements 1 can be triggered.
FIG. 5 : Arrangement for the fast decoupling of energy from a magnetic energy storage. The storage consists of the high field coil 20 which is shorted via the switching element 1 and in which a permanent current circulates. A consumer can be connected to the contacts 2 which is during normal operation supplied by the mains supply. In case of a short interruption of the mains supply which would substantially interfere with the consumer, the switching element 1 is triggered and the current is available at the contacts for smoothing the interference of the mains supply. In general such an arrangement can be used for creating high power, direct currency pulses.
FIG. 6 : Two switching elements 1 and 1 ′ are arranged in an electric circuit each in parallel to a consumer 30 , which can be a magnetic coil or any other ohmic consumer. At a parallel circuit current can be coupled into from the outside via a transformer 40 . In case of the consumer being a superconducting magnet this arrangement can be operated as a flow pump. In case of another consumer this is called a controlled rectifier.
FIGS. 7 a, b : Relation between irradiated power and switching time for different high frequencies in the MHz-range.
DETAILED DESCRIPTION
The superconducting switching element consists according to FIG. 1 of a thin high temperature superconductor film on a substrate structured into a strip conductor 1 and contacted at its ends. It is inserted in series into an electric circuit. Close to the superconductor 1 a coil 6 is arranged having preferably a planar shape, which is isolated from the superconductor for example by a thin Kapton film. For cooling the assembly, it can be arranged for example in a PVC-reservoir filled with liquid nitrogen.
Different embodiments of the coupling coil are exemplary shown in FIG. 2 . The coil can be wound as a flat coil out of copper, silver-plated copper wire or silver wire or a high frequency stranded wire, it can be structured in layer technique onto the backside of a substrate or be manufactured from the copper coated conductor plate (Pertinax, epoxy resin-fiber glass laminate).
In a particular preferred embodiment a 35 μm thick conductor coil made out of copper is used. It is structured by means of photolithography from a 1.4 mm thick conductor path on epoxy resin fiber glass laminate FR4. Exemplary dimensions of the coil are in the range of 10 mm×40 mm.
Preferably, the coil can also consist of superconducting material in order to obtain a high Q of the oscillating circuit and thus a low switching power. The coil is either directly supplied via a pulsed high frequency generator or it is, as shown in the example of FIG. 1 , part of an oscillating circuit 3 , which is fed from a frequency generator 7 with high frequency pulses (time length 1 μs to 1 s), or it oscillates on its own. The coupling into the oscillating circuit can be achieved, as shown, via a capacitor 5 or any other common ways, for example inductively. In the case of the shown arrangement of an oscillating circuit, the overall capacity is tuned to the desired resonance frequency of the oscillating circuit.
The used frequencies are preferably in the MHz-range and should preferably not exceed 200 MHz, since the major part of the power is at higher frequencies released as electromagnetic waves and not available for switching which requires high output powers at the frequency generators.
The high frequency power P into fed into the oscillating circuit versus the switching time at different frequencies is shown for two different measurements in the FIGS. 7 a and 7 b . These measurements were performed with the same sample (switching currency I s =34 A), however, using different initial currents of 26 A ( FIG. 7 a ) and 22 A ( FIG. 7 b ) (voltage source: Battery). The smallest switching times are achieved at a frequency of approximately 10 MHz. At higher powers P into the switching time of the different frequencies approach each other more and more. Prior measurements up to 800 MHz confirm that a switching with higher frequency requires a longer pulse length or a higher power, as already indicated up to 80 MHz. Frequencies above 100 MHz are therefore not to be reasonably used as switching frequencies. This also seems to apply for frequencies below 10 MHz. In general an essentially exponential relation between the power and the switching time is found.
There are two operating modes for the superconducting switching element:
1. The switch is heated after triggering by the current flowing through, the superconductor remains in the resistive state until the flow of current is interrupted somewhere else and the superconductor can cool down. 2. The switch is triggered by the HF-power coupled into, however, the dissipated energy caused by the current flowing through is less than the cooling power of the carrying-off of heat. The flow of current is not sufficient to keep the superconductor in the resistive state. Once the HF-signal is turned off, the switch cools down and becomes superconducting again. This operating mode may for example be present, if there is a low ohmic conductor parallel to the switch.
EXAMPLES
Example 1
The actively triggered superconducting switching element 1 consists of a 4 cm long and 1 cm wide YBCO-film (YBa 2 Cu 3 O 7-δ ) having a thickness of 300 nm, which is epitactically deposited onto a sapphire substrate. The superconducting ridge is subjected to an initial current of 36 A. The coupling coil 6 for the high frequency consists of a flat coil according to FIG. 2 b with 11 windings and an inductivity of 1.5 μH. It covers the ridge almost completely. The switching process can be recognized in FIG. 3 by a voltage increase and a current drop. The current is limited to approx. 15% of the initial current.
Example 2
The actively triggered superconducting current limiter 1 is inserted in series into an electric circuit. If a strong current increase exceeding the nominal current—for example due to a short circuit—is detected, the short circuit current can be limited by the active triggering of all superconducting elements without the occurrence of a hot spot. The limitation to approximately the nominal current takes place within a few milliseconds. The HF coil 6 must not necessarily cover the complete superconductor 1 but can be limited to parts of preferably a few millimeter length. If such a macroscopic area has switched, a hot spot can no longer form and the quench is distributed over the conductor with speeds between 10 and 100 m/s. The switching length depends on the maximal voltage of the outer circuit.
Example 3
A superconducting magnetic energy storage (SMES) consists of a superconducting coil 20 creating a high magnetic field which is shorted according to FIG. 5 via a superconducting switch 1 of the above construction. In order to decouple energy from the system, the superconducting element 1 is switched by means of the high frequency pulse into the normal conducting state. The superconducting switching element 1 acts as points for the current. During the time period of the HF-pulse the stored energy is available at the contacts 2 , that is, for an external consumer for a time period of typically a few milliseconds. When the HF-pulse is turned off, the superconductor 1 falls back into the superconducting state and the energy storage is shorted again. This arrangement serves to buffer short voltage fluctuations in the external electric circuit, which is very important for the operation of sensitive systems, for example in the semiconductor or paper production.
Example 4
Two or more actively triggered superconducting switches 1 , 1 ′ are used for operating a flow pump by switching in antiphase (cf. FIG. 6 ). Such flow pumps serve for loading a great inductivity with a high current. The alternating current fed via the transformer 40 into the superconducting circuit is switched by the alternating opening and closing of the switches 1 and 1 ′ so that as a net result the current in the magnet 30 is stepwise increased. For a pumping frequency of 20 Hz at first a closing time of the switch of 15 ms is necessary which can easily be achieved with the switching element 1 , 1 ′ according to the invention.
Example 5
Two or more actively triggered superconducting switches 1 , 1 ′ are used for rectifying an alternating current by switching in antiphase. An exemplary circuit is shown in FIG. 6 and can be operated in the same manner as the flow pump (example 4). However, instead of the magnetic coil 30 there is a consumer 30 for direct current provided.
Example 6
If in Example 5 or FIG. 6 the functions of consumer and current source are exchange, the assembly can be used as an inverted rectifier. A direct voltage fed into the system at the position 30 is transformed into alternating voltage at the output 40 by a periodic switching of the switches 1 and 1 ′ in antiphase.
The examples 4 to 6 have in common that the primary circuit with an alternating current is only inductively coupled to the superconducting, that is, cooled secondary circuit. Thus, both circuits can be easily thermally decoupled so that there is no undesired heat flow via the contacts into the cooled area. | The invention relates to a switching element for modifying the electric resistance with at least one high temperature superconductor ( 1 ) and means ( 3 ) for irradiating electromagnetic high frequency onto the at least one high temperature superconductor ( 1 ). The invention further relates to a method for switching a high temperature superconductor ( 1 ) comprising the steps of providing a high temperature superconductor ( 1 ) in the superconducting state and irradiating an electromagnetic high frequency until the high temperature superconductor ( 1 ) changes over into a normally conducting state. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to detector assemblies for use principally, but not exclusively, in well logging.
BACKGROUND OF THE INVENTION
[0002] The latest hydrocarbon production methods require that the production section of the well has a maximum possible length in the oil-bearing stratum. Since most oil-bearing production zones are substantially horizontal, this results in the final section of the well becoming appropriately horizontal. Although the general location of an oil-bearing stratum may be known prior to the drilling of a production well to tap the oil-bearing stratum, the position (in all dimensions) of the production zone is not initially known with sufficient accuracy to ensure that the well can be bored directly to the production zone. Accordingly, geological formation data are collected as the well is drilled, and the collected data are suitably analysed to derive the exact direction (in all three dimensions) along which the well is to be extended, particularly to ensure that the final (and usually horizontal) section of the well is in the best position for the recovery of oil. The procedure is known as “geosteering”.
[0003] Geological formation data are commonly gathered by gamma logging, i.e. by a procedure in which the intensity of detected gamma radiation is utilised to deduce geological properties. (While the source of gamma radiation may be naturally occurring radioisotopes more or less distributed throughout surrounding geological formations, a more usual source of gamma radiation is a manufactured gamma source (e.g., a compact mass of cobalt-60) emplaced at a fixed or controllably variable depth in an adjacent well such that the gamma source radiators through the geological formations between the gamma source radiates through the geological formations between the gamma source and a gamma detector in the production well being drilled).
[0004] In order to geosteer, directional logging is necessary. For example, the intensity of detected gamma radiation above the bore of the well being drilled may be compared with the intensity of detected gamma radiation below the bore in order to decide the direction and extent by which to deviate the inclination of the next section of well to be drilled.
[0005] A gamma radiation detector typically comprises an assembly of a gamma-sensitive crystal (which emits a visible photon in response to the impact of a gamma photon), a photomultiplier (which outputs an electrical pulse count proportional to the light output of the gamma-sensitive crystal which, in turn, is proportional to the intensity of incident gamma radiation), and a pulse counter to accumulate a count, over a fixed interval, of electrical pulses from the photomultiplier.
[0006] The gamma radiation detector can be made directionally sensitive by surrounding the gamma-sensitive crystal with a gamma radiation shield (e.g., a tungsten shroud), the shield having an aperture or window through which gamma radiation can reach the gamma-sensitive crystal but only from one direction.
[0007] In order to carry out directional gamma logging of the well, it is necessary to orient the shield window to a selected angle with respect to a notional vertical plane through the well bore, and obtain a series of gamma intensity readings at various such angles, thereby to obtain a polar survey of geological formations surrounding the location of the detector.
[0008] In prior art well-drilling operations, the gamma radiation detector was incorporated into a bottom-hole drilling assembly. Directional gamma logging required that normal rotation of the drill string had to be stopped, and the drill string manipulated to orient the window to the required series of angles. The prior art directional logging procedure was therefore time-consuming, and prevented drilling during logging. (Transmission to the surface of logging data was also time-consuming, being usually undertaken by inducing pressure pulses in the drilling mud).
[0009] There is therefore a requirement for a means of conducting well logging operations such as gamma logging during drilling.
[0010] As will be discussed below, gamma logging during drilling requires the establishment of the angular orientation of a downhole assembly about the borehole axis. There are other situations in which knowledge of this angular orientation is desirable, for example in operation of the controllable stabiliser described in EP-A-1024245. The present invention aims to provide a convenient means of doing so.
SUMMARY OF THE INVENTION
[0011] According to one aspect of the present invention, there is provided a rotary assembly comprising a rotatable shaft; a sleeve journalled on the shaft and adapted to be stationary during rotation of the shaft; an earth vector sensor mounted for rotation with the shaft, the earth vector sensor being responsive to a given physical parameter in a direction substantially radial to the shaft; and an orientation signal generator which comprises means for generating a pulse train representing rotation of the shaft relative to the sleeve as a predetermined number of pulses per revolution, and means for deriving from the pulse train and the output of the earth vector sensor the angle between the earth vector and a given position on the sleeve.
[0012] Preferably, the rotary assembly is a downhole assembly adapted to form part of a drill string, and the earth vector is the component transverse to the drill string axis in the vicinity of the assembly of the earth's local magnetic field or gravitational field.
[0013] The means for generating a pulse train preferably comprises a directional sensor arranged radially of the shaft and cooperating with a plurality of elements equispaced around the circumference of the sleeve. In a preferred embodiment, said elements are ferromagnetic segments, and the sensor is a coil; the ferromagnetic elements may suitably be 24 in number.
[0014] Said deriving means preferably operates to integrate the earth vector sensor output over each of a number of successive part-revolutions, for example quarter revolutions, of the shaft to provide a series of simultaneous equations, and solving these equations to provide an orientation angle for each of said plurality of elements with respect to the earth vector.
[0015] From another aspect, the invention provides a method of sensing the angular position of a rotary assembly which comprises a rotatable shaft and a sleeve journalled on the shaft and adapted to be stationary during rotation of the shaft; the method comprising sensing an earth vector along an axis transverse to and rotating with the shaft, generating a pulse train representing rotation of the shaft relative to the sleeve as a predetermined number of pulses per revolution, and deriving from the pulse train and the earth vector the angle between the earth vector and a given position on the sleeve
DESCRIPTION OF PREFERRED EMBODIMENT
[0016] One embodiment of the first aspect of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0017] [0017]FIG. 1 is a schematic cross-section of part of a downhole rotary assembly; and
[0018] [0018]FIG. 2 shows a pulse train produced in the assembly of FIG. 1.
[0019] Referring to FIG. 1, a shaft 10 forms part of a downhole assembly. A sleeve 12 is rotatable with respect to the shaft 10 . In use, the sleeve 12 engages with a well bore and is rotationally stationary, with the shaft 10 rotating within it.
[0020] The assembly determines orientation by reference to an earth vector E, which is that component of the local earth magnetic field or local earth gravity acting at right angles to the shaft axis.
[0021] The assembly includes an earth vector sensor 14 mounted on the shaft for rotation therewith. The earth vector sensor 14 is a sensor for measuring the amplitude of the earth magnetic field or gravity along a rotating axis OX radial to the shaft.
[0022] The sleeve 12 is provided with a number (in this embodiment twenty four) of equally circumferentially spaced ferromagnetic segments 16 , which cooperate with a pick-off coil 18 mounted on the shaft 10 .
[0023] The pick-off coil 18 is arranged, in this embodiment, to detect along the same axis OX as the vector sensor 14 but could be arranged on a different radius of the shaft 10 as long as the angle between the two detector axes is known.
[0024] The pick-off coil 18 produces a pulse train P0 - P24 as illustrated in FIG. 2. The outputs of the earth vector sensor 14 and the pick-off coil 18 are processed as will now be discussed. It will be apparent to those in the art that the signal processing to be described can be effected by readily available electronic circuits or computers.
EARTH VECTOR SENSOR OUTPUT
[0025] If the (constant) angular velocity of the rotating shaft is W then
W=d(S)/dt
[0026] If time=0 when (OX) is aligned with the Earth Vector Reference Direction (OE), then the Shaft Orientation Angle at any subsequent time t is given by
S = ∫ 0 t W · t = W · t
[0027] and the Segment n Orientation Angle Sn=W.tn
[0028] If the period of rotation of the drill sting is T then
T=2π/W
[0029] With reference to FIG. 1, the magnitude of the sensed vector along the sensing axis direction (OX) at time t can be written as
Ex ( t )= E. cos( W ( t ))+ Ek
[0030] where E is the magnitude of the Earth Reference Vector {E} and Ek is a constant term provided that W is constant.
[0031] Thus, the sensing transducer output at time t can be written as
Vx ( t )= V .cos( W.t )+ Vk
[0032] where Vk is a constant term combining the transducer bias and the term Ek. V=SF.E where SF is the transducer scale factor (volts/g).
EARTH VECTOR SENSOR OUTPUT INTEGRATIONS
[0033] If Pulse P 0 of FIG. 1 is an arbitrarily chosen pulse at some time to the repeated pulses P 0 , P 6 , P 12 and P 18 associated with times t 0 , t 0 +T/4, t 0 +T/2, t 0 +3T/4 respectively are used to control the integration of the sensing transducer output Vx(t) over 4 successive quarter periods of rotation starting at time t 0 .
[0034] Consider the Integration of Vx(t) from any initial time t i to t i +T/4
Q = ∫ t i t i + T4 V · cos ( W · t ) · t + ∫ t i t i + T / 4 Vk · t Thus ,
Q = [ ( V / W ) · sin ( W · t ) ] t i + T / 4 t i + Vk · T / 4
[0035] or
Q= ( V/W ).[sin( W.t i +W.T/ 4)−sin( W.t i )]+ K
[0036] or
Q= ( V/W ).[sin( W.t i +π/2)−sin( W.t i )]+ K
[0037] or
Q= ( V/W ).[cos( W.t i )−sin( W.ti )]+ K (i)
[0038] Where K is a constant=Vk.T/4
[0039] Using equation (i), the integration of Vx(t) from time t 0 to time t 0 +T/4 yields
Q 1=( V/W ).[cos( W.t 0 −sin( W.t 0 ]+K (ii)
[0040] Using equation (i), the integration of Vx(t) from time t 0 +T/4 to time t 0 +T/2 yields
Q 2=( V/W ).[cos( W.t 0 +W.T/ 4)]−sin( W.t 0 +W.T/ 4)]+ K
[0041] or
Q 2=( V/W ).[cos( W.t 0 +π/2)−sin( W.t 0 +π/2)]+ K
[0042] or
Q 2=( V/W ).[−sin( W.t 0 )−cos( W.t 0 )]+ K (iii)
[0043] Using equation (i), the integration of Vx(t) from time t 0 +T/2 to time to+3T/4 yields
Q 3=( V/W ).[cos( W.t 0 +W.T/ 2)−sin( W.t 0 +W.T/ 2)]+ K
[0044] or
Q 3=( V/W ).[cos( W.t 0 +π)−sin( W.t 0 +π)]+ K
[0045] or
Q 3 ( V/W ).[−cos ( W.t 0 )+sin( W.t 0 )]+ K (iv)
[0046] Using equation (i), the integration of Vx(t) from time t 0 +3T/4 to time t 0 +T yields
Q 4 ( V/W ).[cos( W.t 0 )+ W. 3T/4)−sin( W.t 0 +W. 3T/4)]+ K
[0047] or
Q 4=( V/W ).[cos( W.t 0 +3π/2)−sin( W.t 0 +3π/2)+ K
[0048] or
Q 4=( V/W ).(sin( W.t 0 )+cos( W.t 0 )]+ K (v)
[0049] Writing K1=V/W and α=W.t 0 then equations (ii) through (v) yield for the four successive integrations of Vx(t)
Q 1=− K 1.sinα+ K 1.cosα+ K (vi)
Q 2 =−K 1.sinα+ K 1.cosα+ K (vii)
Q 3 =K 1.sinα K 1.cosα+ K (viii)
Q 4 =K 1.sinα+ K 1.cosα+ K (ix)
ROTATION ANGLES
[0050] Equations (vi) through (ix) can be solved to yield angle α; there is a degree of redundancy in the possible solutions but, for example,
Q 1 −Q 2=2 K 1.cosα
[0051] and
Q 3− Q 2=2 K 1.cosα
[0052] or
sinα/cosα=( Q 3 −Q 2)/( Q 1− Q 2) (x)
[0053] Since α=W.t 0 then α is the angle S 0 between (OE) and the radius through the segment which activates pulse P 0 , or the angle between (OX) and (OE) at the time t 0 when P 0 occurs, it follows that when Pulse P n occurs at time t 0 the angle between (OX) and (OE) is
Sn=α+n. 2π/24 (xi)
[0054] Thus, the segment orientation angles Sn for each segment are known and the corresponding pulses can be used to control events at known 15 degree (2π/24) rotating shaft orientation angles.
[0055] The foregoing embodiment may be incorporated in a controllable stabiliser apparatus as described in EP-A-1024245 to provide an orientation reference. In such use, the embodiment described may have an additional function. In EP-A-1024245 a controlled eccentricity is produced between the shaft 10 and the sleeve 12 . By examining not only the timing but also the amplitude of the pulses P0 - P24, the amount of eccentricity at any time can be determined.
[0056] The present invention in another aspect provides a well-logging procedure comprising the steps of providing a directional well-logging means in a bottom-hole assembly, the directionality of the logging means being substantially synchronous with rotation of the bottom-hole assembly, providing direction sensing means in the bottom-hole assembly for sensing the instantaneous direction of the bottom-hole assembly and hence of the well-logging means, providing a respective logging data reception means for each direction for which well logging is to take place, and switching the output of the well-logging means between appropriate ones of the logging data reception means according to the instantaneously sensed direction of the bottom-hole assembly whereby to accumulate directional logging data during rotation of the bottom-hole assembly.
[0057] The well-logging procedure may comprise the further step of subsequently transmitting accumulated directional logging data to the surface by utilising a data transmission means that does not require cessation of rotation of the bottom-hole assembly.
[0058] The invention in this further aspect may also be defined in terms of well-logging equipment comprising a rotatable bottom-hole assembly including a directional well-logging means whose directionality is substantially synchronous with rotation of the bottom-hole assembly, direction sensing means for sensing the instantaneous direction of the bottom-hole assembly and hence of the well-logging means, a respective logging data reception means for each direction for which well logging is to take place, and switching means for switching the output of the well-logging means between appropriate ones of the logging data reception means according to the instantaneously sensed direction of the bottom-hole assembly.
[0059] The bottom-hole assembly may further comprise data transmission means capable of selectively transmitting accumulated directional logging data to the surface, the data transmission means preferably not requiring cessation of rotation of the bottom-hole assembly.
[0060] The directional well-logging means may comprise a directionally sensitive gamma logger which is mounted within the bottom-hole assembly and is mounted non-rotatably with respect thereto. The gamma logger may be rendered directionally sensitive by being shrouded by a gamma radiation shield having a gamma radiation transmitting aperture therein.
[0061] The direction sensing means may comprise a geomagnetically sensitive magnetometer means operable to provide substantially instantaneous values for the bearing and azimuth of the bottom-hole assembly.
[0062] The well-logging equipment according to the second aspect of the present invention may be incorporated into a directionally-controlled eccentric as described in EP.A.1024245, preferably as part of the directionally-sensitive control system 18 of the exemplary embodiment as described with reference to FIG. 1 of EP.A.1024245.
[0063] Modifications and improvements of the above-described embodiments can be adopted without departing from the scope of the invention. | The rotational position of a shaft ( 10 ) with respect to a sleeve ( 12 ) is determined by using a sensor ( 14 ) rotating with the shaft ( 10 ) to detect an earth vector such as magnetic or gravitational field, using a coil ( 18 ) on the shaft in conjunction with a plurality of ferromagnetic elements ( 16 ) on the sleeve to monitor relative rotation, and calculating the rotational position from these parameters. Applicable to downhole use, particularly gamma ray measurements. | 4 |
BACKGROUND
[0001] 1. Field of the Disclosure
[0002] The disclosure relates to a device for carrying out chemical and/or biological reactions.
[0003] 2. Discussion of the Background Art
[0004] With such devices tissue sections, cells, cell organelles, cell constituents, genomic or plasmid DNA, cDNA, RNA, e.g. mRNA, siRNA, microRNA as well as DNA or RNA analogs, such as PNA, LNA, proteins, in particular antibodies, peptides, polysaccharides, saccharides, metabolites as well as educts and products of chemical or physiological reactions and other molecules are examined. In this connection, the molecules, cell constituents, organelles, cells or tissues to be analyzed are placed either directly or indirectly via linking molecules or gel carriers onto the surface of an object carrier, normally a glass object carrier, and mounted there via covalent, coordinate or hydrogen bridge bonds to the surface. Placing of molecules can also be obtained by synthesizing on the surface, in particular of polymers, and previous mounting of one or a plurality of synthetic elements, or by mounting after synthesizing. Alternatively, molecules, cell constituents, organelles, cells or tissues can be placed onto the carrier surface and mounted there, the former interacting with the molecules, cell constituents, organelles or cells to be analyzed by covalent, coordinate, hydrogen bridge bonds, dipole-dipole-interactions or by van der Waals forces.
[0005] Detection of the molecules, cell constituents, organelles, cells or tissues to be analyzed can be effected by a reaction with a color or by bonding of a color. Detection can also be effected by chemical or enzymatic reactions, such as oxidation of silver ions e.g. by thiol groups, conversion of a substrate into a color, chemiluminescence or a polymerase chain reaction. Further, indirect detection via specifically binding molecules, such as antibodies, biotin and streptavidin, complementary DNA or RNA which, on their part, can be detected e.g. by applying the aforementioned methods, is also possible. Further, detection with the aid of physical method, such as detection of the radioactive decay of radioisotope-marked molecules, conductivity, light refraction, light absorption or changed surface properties is possible. Also, bound molecules, cell constituents, organelles, cells or tissues can be analyzed on the surface or in a condition as removed from the surface with the aid of different analyzing techniques, such as fluorescence-activated cell sorting (FACS), electrophoresis, mass spectroscopy, elementary analysis, NMR spectroscopy or IR spectroscopy.
[0006] The methods described can be applied for the purpose of examination including detection, quantification and characterization of molecules, cell constituents, organelles or cells. For example, the presence, quantity or properties of various molecules, such as synthetic products, saccharides or polysaccharides, metabolites, active substances of medicines, peptide or protein quantities, changes to or of peptides or proteins, post-translational modifications of proteins, e.g. phosphorylation and/or dephosphorylation, methylation and/or demethylation, glycosylation and/or deglycosylation, the specificity and affinity of antibodies, genomic changes, such as loss or multiplication of alleles, chromosomes or chromosome segments, changed gene sequences or other sequences, alternative splice variants of genes, changes of gene activities, changes or modifications of cell surfaces, or the presence, quantity or type of bacteria, viruses, fungi or other pathogens as well as the correspondingly formed antibodies, can be analyzed and detected.
[0007] Such examination of chemical and/or biological samples can serve, for example, for characterization of reactions or molecules, research of metabolic processes, regulatory mechanisms, or characterization or diagnosis of diseases and/or check of therapies.
[0008] The device described hereunder serves for improving the interaction of the subject molecules, cell constituents, organelles, cells or tissues with the molecules, cell constituents, organelles or cells in solution, as well as the reactions by optimized distribution and more uniform temperature control.
[0009] Hereunder the examination of the gene expression with the aid of DNA microarrays is exemplified.
[0010] For this purpose, for example, DNA is placed onto the surface of an object carrier. Placing of the DNA may occur in all ways known in the art including dripping with the aid of a robot. Thus, the position of the individual DNA pieces on the object carrier is known. The DNA pieces combine with the surface of the object carrier and adhere thereto such that their positions do not change in the subsequent analyzing process.
[0011] In the next step, RNA is taken, for example, from a tumor to be analyzed. With the aid of enzymes, the RNA is transformed into DNA and subsequently marked with suitable markers, particularly fluorescent color markers.
[0012] Additionally, a comparative sample with healthy tissue is produced. The healthy DNA is also marked with a suitable marker. Preferably, the marker is a fluorescent marker of another color such that the healthy tissue is marked with a greenly fluorescent marker and the tissue to be analyzed taken from the tumor, for example, with a red color marker.
[0013] Subsequently, both samples are placed onto the entire object carrier. The DNA strands included in the two samples bond via hydrogen bridge bonds (base pairing) with the complementary DNA strands (hybridization) on the surface of the object carrier. Bonding of the DNA included in the samples with the DNA pieces adhering to the object carrier is effected in a hybridization process. Subsequently, the object carrier is washed such that only firmly adhering DNA pieces and hybridized DNA from the two samples are present on the object carrier.
[0014] After the object carrier has been dried, it is subjected to a detecting process. In this process, the individual positions of the object carrier to which DNA pieces adhere are analyzed using a suitable microscope. In doing so, the fluorescent markers coupled to the DNA are stimulated by laser light, for example, such that the fluorescent markers fluoresce in the corresponding color. If a certain position to which a DNA piece adheres appears as a red spot, for example, it can be concluded that this gene was active in the tumor tissue but not in the healthy tissue. If a spot fluoresces greenly, it can be concluded that this gene was only active in the healthy tissue. When a yellow fluorescence occurs, the corresponding gene was active in both tissues. With the aid of the above method, it can be diagnosed which genes are active in a tumor, for example. From this, conclusions as to the kind of tissue change and the like can be drawn.
[0015] For preventing drying and for realizing a uniform distribution of the DNA molecules, it is known to close the object carrier by a lid, for example, such that a sample chamber is formed between the object carrier and the lid. Then, the sample chamber is vibrated by a vibration means to effect a movement of the two samples. This movement helps the corresponding sample components to find the suitable counterparts with which they then combine. Providing a vibration means has the disadvantage that stationary waves are produced and thus only a limited movement of the sample occurs.
[0016] The problems described in the example above also exist in other analyses of chemical and/or biological samples in which one sample, for example, firmly adheres to a base portion at the object carrier and another sample is to react on it.
[0017] Further, from PCT/EP02/02900 an analyzing device comprising a base portion and a head portion or a lid is known. The base portion and the head portion form a sample chamber. The base portion may be a flat object carrier, for example, made of thin glass. Likewise, the object carrier or another sample carrier may be placed upon the base portion such that the sample carrier is arranged within the sample chamber. Further, this device comprises a moving means for moving the sample in the sample chamber. According to the disclosure, the device comprises a conveying means as a moving means. With the aid of the moving means, at least part of the sample is drawn off the sample chamber and subsequently returned to the sample chamber. Moving of part of the sample can be effected by moving the sample to and fro in that part of the sample is drawn off the sample chamber and returned in opposite direction to the sample chamber. For this purpose, at least one channel is preferably connected with the sample chamber, which channel is connected with a pump or another conveying means for moving the sample to and fro. Another possibility for moving the sample in the sample chamber is to circulate the sample. In this case at least part of the sample is drawn off via a discharge channel and returned to the sample chamber via a supply channel. In this case the sample is conveyed in the same direction.
[0018] By providing a moving means for the sample, occurrence of stationary waves is prevented. Drawing off and supplying at least part of the sample ensures that the entire sample quantity present in the sample chamber is moved. This is ensured in the case of both moving at least part of the sample to and fro and circulating at least part of the sample.
[0019] When the device described in PCT/EP02/02900 is used, an undesired cooling of the sample, in particular the conveyed part of the sample, may occur. This phenomenon occurs in particular in the analysis of chemical and/or biological samples which must have, for example, a temperature of up to 75° C. in the sample chamber. Further, it was noted that heating of the sample chamber, in particular through components made of glass, leads to a delay in the temperature control and possibly to inexact sample temperatures. This is in particular due to the poor heat conductivity of glass. Further, it was noted that it is not possible to make the base portion and/or the head portion from steel, high-grade steel, aluminum, copper or compounds/alloys therefrom, e.g. anodized aluminum, brass. Although these materials have good heat conductivity, they are attacked by numerous samples.
[0020] It is an object of the disclosure to provide device for examining chemical and/or biological samples, wherein the sample temperature is adjustable.
SUMMARY OF THE DISCLOSURE
[0021] The device according to the disclosure comprises a sample chamber formed by a first portion and a second (head) portion. For changing the temperature of the sample, according to the disclosure a heating and cooling element is connected with the second (head) portion. According to the disclosure, a side of the second (head) portion defining the sample chamber is made from a material with high resistance to the sample and good temperature conductivity. This allows the sample temperature to be maintained within a narrow specified temperature range via the heating and cooling element connected with the sample portion. The temperature variation preferably lies in a range of ±1° C. Further, provision of a sample-resistant material according to the disclosure ensures that, for example, the analysis results are not falsified by part of the sample being separated from or washed out of the second (head) portion.
[0022] Preferably, the material is resistant to deionized or distilled water. Preferably, the material is resistant to aqueous solutions, preferably saline solutions up to the solubility limit, preferably haloides, carbonates, sulfates, nitrates, hydroxides, borates, silicates, amines, amides, phosphates, hydrogen phosphates and dihydrogen phosphates, preferably of the alkali and alkaline earth metals, e.g., but not limited to, NaCl, CaCl 2 , MgCl 2 , NaOH, ethylenediaminetetraacetate (EDTA), tetraethylammonium chloride.
[0023] Preferably, the material is resistant to organic acids and bases as well as their salts, e.g., but not limited to, formic acid, acetic acid, citric acid, sodium citrate, ammonium acetate.
[0024] Preferably, the material is resistant to water-soluble polymers, e.g., but not limited to, sodium dextransulfate, poly(ethylene glycol), polyacrylamide.
[0025] Preferably, the material is resistant to detergents, preferably ionic detergents, e.g., but not limited to, sodium dodecylsulfate (SDS) or Tween.
[0026] Preferably, the material is resistant to organic solvents, e.g., but not limited to, chloroform, preferably polar solvents, e.g., but not limited to, dimethylformamide (DMF), formamide, dimethyl sulfoxide (DMSO), dimethylsulfide (DMS), ketones, e.g., but not limited to, acetone, alcohols, preferably methanol, ethanol, propanol, isopropanol, butanol, isobutanol, phenol, polyalcohols, preferably glycol, glycerol.
[0027] The resistance exists preferably in a temperature range from −196° C. to 500° C., preferably from −80° C. to 200° C., preferably from −20° C. to 150° C., preferably from 4-100° C.
[0028] Preferably, the resistance lasts for at least 12 hours, preferably, the resistance allows repeated use of the head portion.
[0029] Preferably, the material is characterized by a loss of weight of less than 10 mg/m 2 per hour. In additions, the concentration of ions dissolved from the material, for example. by pitting/corrosion, should not affect the reaction in the chamber or the movement of the sample. This would happen if there is a reaction with one of the components in the chamber (e.g. denaturation of proteins or strand breaks of DNA), changing the pH of the buffer composition or inhibition of reaction or binding.
[0030] Preferably, materials having a mechanical load-bearing capacity are used. Preferably, hard materials having a Vickers hardness [HV] of at least 10, preferably more than 20, preferably more than 50, preferably more than 100, preferably more than 500 are used. Preferably, the material has a yield strength 0.2 % of at least 10 MPa, preferably more than 100 MPa, preferably more than 200 MPa, preferably more than 500 MPa, preferably more than 1000 MPa. Preferably, the material has a bending strength of at least 10 MPa, preferably at least 50 MPa, preferably at least 100 MPa, preferably at least 500 MPa, preferably at least 1000 MPa.
[0031] Preferably, the material has a good heat conductivity. Preferably, the heat conductivity exceeds 10 W/mK. Preferably, the heat conductivity exceeds 100 W/mK.
[0032] Preferably, the material, from which in particular the overall second (head) portion is made, is selected such that it offers good dimensional accuracy. Thus it can be ensured that the volume of the sample chamber is defined and constant. Preferably, the manufacturing tolerances of the surface defining the sample chamber are smaller than 20 μm, preferably smaller than 10 μm, preferably smaller than 5 μm and preferably less than twenty percent of the smallest inner dimension of the chamber. Preferably, the mean linear thermal expansion coefficient α 30-1000 lies in the range from 1-10*10 −6 /K, or in the range of 10 −3 /K-10 −9 /K, or in the range of 10 −4 /K-10 −8 /K, or in the range of 10 −5 /K-10 −7 /K.
[0033] Further, the material used is preferably selected such that little or no interaction occurs between the sample and the material. Preferably, the surfaces do not comprise any reactive groups which form a covalent or coordinate bond with amine groups, thiol groups or hydroxyl groups. Preferably, the surface is uncharged. Preferably, the surface does not comprise any groups which may form hydrogen bridge bonds (hydroxyl groups, amine groups or thiol groups).
[0034] Preferred materials from which at least one side of the second (head) portion defining the sample chamber, and preferably the overall head portion are made include: heat-conductive plastic materials, preferably CoolPoly E1501 polypropylene (Cool Polymers, Inc.), graphite, diamond, ceramic, metals, preferably aluminum or copper, alloys, preferably brass. Graphite, metals or alloys are preferably used in combination with a protective layer. Preferred protective layers are silicate coatings, parylene, diamond-like carbon, Teflon, silicon carbide, silicon nitride or boron nitride.
[0035] Particularly preferred is the use of ceramic, in particular non-oxide ceramics, in particular borides, carbides, nitrides and silicides (e.g. TiC, TaC, WC, TiN, TaN, TiB 2 , MoSi 2 ), in particular aluminum nitride, boron nitride, boron carbide, silicon nitride, silicon carbide, further hard-material mixed crystals (e.g. TiC—WC, TiC—TaC—WC, TiC—TiN) as well as double carbides and complex carbides (e.g. CO 3 W 3 C, Ni 3 W 3 C).
[0036] Preferably, the second (head) portion preferably comprises a flat surface extending in the direction of the sample chamber. Since in a particularly preferred embodiment the first portion is also flat and arranged in parallel to the inside of the second (head) portion, it is ensured that inside the sample chamber the sample has a uniform thickness and/or height.
[0037] In a particularly preferred embodiment, the second (head) portion is connected via an intermediate element with the temperature-control element. The intermediate element is made from a material with good heat conductivity, in particular from metal, and in a particularly preferred variant from aluminum. In a particularly preferred embodiment, the preferably provided channels for conveying and/or circulating the sample pass through the intermediate element. Due to the good heat conductivity of the intermediate element, the intermediate element serves as a heat accumulator such that the sample temperature is also equalized in the channels arranged in the intermediate element. To prevent interaction between the sample and the material of the intermediate element, preferably flexible conduits made of a suitable material are arranged in the channel. Also, the channels of the intermediate element may coated with a sample-resistant material.
[0038] The second (head) portion preferably comprises at least one channel through which sample liquid can be supplied to the sample chamber and/or discharged from the sample chamber. In a particularly preferred variant, the second (head) portion comprises on the side facing the sample chamber elements and/or a mechanically molded surface, e.g. grooves, and/or a chemically molded surface, e.g. differently hydrophobic zones, which provide for a uniform overflow, intermixing, homogenization and/or distribution of the liquid in the sample chamber. Preferably, the supply and/or discharge channels comprise a transverse channel connected with the respective channel, wherein the transverse channel is preferably configured as a slot or a groove and is open over its overall length in the direction of the sample chamber. This configuration allows for better movement and homogenization of the sample.
[0039] Preferably the aspect ratio of the thickness of the chamber to the width of the chamber is between 19:60 and 21:71, and more preferably 21:63.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] Hereinafter, the disclosure will be explained in detail with respect to a preferred embodiment with reference to the accompanying drawings in which:
[0041] FIG. 1 shows a schematic top view of a preferred embodiment of the receiving device with several inserted base portions,
[0042] FIG. 2 shows a schematic sectional view of a first preferred embodiment taken along the line II-II of FIG. 1 , the head portion not illustrated in FIG. 1 , an intermediate element and a temperature-control element being additionally illustrated,
[0043] FIG. 3 shows a schematic sectional view of a second preferred embodiment in principle corresponding to the embodiment shown in FIG. 1 ,
[0044] FIG. 4 shows a schematic top view of a preferred embodiment of the head portion on the side facing the sample chamber,
[0045] FIG. 5 shows a schematic sectional view taken along the line V-V of FIG. 4 ,
[0046] FIG. 6 shows a schematic sectional view of a preferred embodiment of the head portion in connection with the intermediate element and the temperature-control element, and
[0047] FIG. 7 shows a schematic sectional view along line VII-VII of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0048] A receiving device 10 for several object carriers 12 comprises a portion 14 . The portion 14 is connected with centering elements 16 , 18 , 20 . In the illustrated embodiment, the centering elements 16 , 18 , 20 are arranged such that four rectangular receiving areas 22 are formed in each of which an object carrier 12 can be arranged. The centering elements 16 , 18 , 20 have two opposing shorter side walls 16 and two likewise opposing longer side walls 18 arranged between the side walls 16 . In the illustrated embodiment, three partition walls 20 arranged in parallel to the shorter side walls 18 are provided between the side walls 18 .
[0049] On the lower sides 24 of the centering elements 16 , 18 , 20 , the bottom portion 14 configured as a diaphragm is mounted. The receiving areas 22 hence have a flexible diaphragm as a bottom on which one object carrier 12 each is supported. Thus, it is possible to press from below against the diaphragm, as shown in FIG. 2 , in order to horizontally align the object carrier, for example.
[0050] On their insides 23 , i.e. on the sides facing the receiving areas 22 , the centering elements 16 , 18 , 20 are chamfered. Thereby, the opening pointing upwards in FIG. 2 of the individual receiving areas is upwardly enlarged. This facilitates the insertion of the object carriers 12 into the receiving areas 22 .
[0051] A head portion 26 according to the disclosure is configured such in a first embodiment ( FIG. 2 ) that it projects into the individual receiving areas 22 formed between the centering elements 16 , 18 , 20 . To this end, the lid 26 comprises four projections 28 in the illustrated embodiment, which have a substantially rectangular cross-section. The side walls 30 of the projections 28 abut on the inner walls of the web-shaped centering elements 16 , 20 . Likewise, side walls of the projection 28 not illustrated in FIG. 2 abut on the web-shaped centering elements 18 . On the underside of the lid 26 facing the base portion or sample carrier 12 , for each receiving area 22 frame-shaped projections 32 are provided or formed by an additional component. The frame-shaped projection is configured as a circumferential projection. On an underside 34 of the frame-shaped projection 32 , a seal 36 is provided which is also configured a circumferential seal. The seal 36 rests on an outer edge of the sample carrier 12 und seals the sample carrier towards the lid 26 . Due to the frame-shaped projection 32 , a sample chamber 38 is formed between an inner side of the lid 36 and the sample carrier 12 within the frame-shaped projection 32 . In an alternative configuration the base portion is on top and the head portion.
[0052] The head portion 26 , is below the base portion preferably made from ceramic material, is connected, on its side facing away from the sample chambers 38 with an intermediate element 27 . The intermediate element 27 is made from a material with good heat conductivity, in particular from aluminum. On the upper side facing away from the head portion 26 of the intermediate element 27 a temperature-control element 29 , such as a Peltier element, is arranged. Preferably, the temperature-control element 29 substantially extends over the overall surface of the intermediate element 27 such that the intermediate element 27 is uniformly heated. The intermediate element 27 transfers the heat to the head portion 26 which also has a good heat conductivity.
[0053] For moving samples provided in the sample chamber 38 , two channels 40 , 42 connected with the sample chamber 38 are provided in the lid 26 . The channel 40 , for example, is connected via a flexible conduit 44 to a pump 46 . Correspondingly, the channel 42 is connected via a flexible conduit 48 with a pump 50 . The two pumps 46 , 50 are controlled by a preferably common control unit. The pumps 46 , 50 alternately draw part of the sample located in the sample chamber into the channel 40 and 42 , respectively, and subsequently return it into the sample chamber 38 . Thereby, movement of the sample in the sample chamber 38 is realized such that, for example when the device is used for analyzing DNA molecules, the probability of an interaction and thus the bonding of marked DNA strands with the surface-bound DNA strands is increased.
[0054] The flexible conduits 44 , 48 connected with the channels 40 , 42 pass through the intermediate element 27 and through the temperature-control element 29 . Provision of a flexible conduit which passes through the intermediate element 27 ensures that no interaction occurs between the material of the intermediate element 27 and the sample. Further, it is ensured that the sample is also heated inside the flexible conduit, if possible. If necessary, the flexible conduits 44 , 48 may, in the exposed area, be surrounded and/or jacketed by an insulation and/or a heat-conductive layer connected with the temperature-control element 29 .
[0055] Further, two receiving chambers 52 , 54 are provided within the head portion 26 . The receiving chamber 52 is connected with the channel 40 , and the receiving chamber 54 is connected with the channel 42 . Due to the size of the receiving chambers 52 , 54 , the sample quantity taken from the sample chamber 38 can be collected. It is also possible that the two pumps 46 , 50 are directly connected with the receiving chambers 52 , 54 and are possibly arranged within the lid 26 or on the upper side thereof.
[0056] For supplying a sample to the sample chamber 38 , a further channel 56 connected with the sample chamber 38 is provided in the lid 26 , which channel 56 may also pass through the intermediate element 27 and the temperature-control element 29 , but preferably bypasses these elements. After the lid 26 has already been set upon the receiving device 10 , samples can be supplied through this channel 56 into the sample chamber 38 which is already tightly sealed. Likewise, the sample can be supplied through one of the two channels 40 , 42 , which is possibly branched for this purpose.
[0057] For improving the movement in the sample chamber 38 , the channels 40 , 42 may be branched such that a plurality of channels 40 , 42 are connected with the sample chamber 38 . Further, it is possible to provide a plurality of channels 40 , 42 per sample chamber 38 in the lid 26 . Preferably, half of the channels are connected with the same pump.
[0058] The lid 26 and the sample carriers 12 are held in respective holding devices not shown. In FIG. 2 , one and/or both holding devices can be vertically, transversely or arcuately moved. Because of the movement of one and/or both holding devices together with the lid and the sample carriers 12 , respectively, an automatic fitting of the lid 26 into the receiving areas of the receiving device 10 and/or an automatic fitting of the receiving areas of the receiving device 10 relative to the lid 26 is possible.
[0059] In this case, the seal 36 provided at the frame-shaped projections 32 is pressed upon an edge portion of the sample carriers 12 , and the sample chamber 38 is formed. Since the sample carriers 12 are supported on an elastic planar bottom portion 14 or a diaphragm serving as bottom portion 14 , damaging the sample carriers by lowering the lid 26 is prevented. Further, the elastic support or the elastic diaphragm 14 , respectively, serves for ensuring a tight sealing between the lid 26 and the sample carriers 12 .
[0060] The sample chamber 38 which, in the illustrated embodiment, substantially extends over the overall sample carrier 12 may be divided into a plurality of individual sample chambers. For this purpose, webs subdividing the sample chamber 38 are arranged on the lower side of the lid 26 . On the side of the webs facing the sample carrier 12 preferably seals corresponding to the seals 36 for sealing the individual sample chambers produced are provided. Each individual sample chamber produced is, as described above, preferably provided with channels 40 , 52 , 56 and has the corresponding preferred configuration. Each individual sample sub-chamber into which the sample chamber 38 is subdivided can thus be filled with hybridization liquid independent of adjacent sample chambers, and handled as described above. Due to the subdivision of the sample chamber 38 into a plurality of sample sub-chambers different samples can be analyzed in different ways using a standard object carrier 12 . In particular, identical samples taken e.g. from the bodies of different patients can be analyzed using the same hybridization liquids, or identical samples taken from the body of a patient can be analyzed using different hybridization liquids. In this connection it is particularly advantageous that commercial object carriers can be used as sample carriers 12 .
[0061] A second preferred embodiment ( FIG. 3 ) comprises a lower area identical with that described with reference to FIG. 2 . The lid or head portion 57 as well as both the intermediate element 76 and the temperature-control element 58 are of different configuration in this embodiment. Identical or similar components of the device are designated with the same reference numerals in FIG. 3 .
[0062] The head portion 57 comprises a supply channel 60 connected with the sample chamber 38 and a discharge channel 62 connected with the sample chamber 38 , said channels 60 , 62 bypassing the intermediate element 76 and the temperature-control element 58 . The channel 62 is connected via a valve 64 and a channel 66 with a pump 68 . The pump 68 is connected with the supply channel 66 . The valve 64 is further connected with a drain 70 . The channel 66 is connected via another channel 72 with a medium reservoir 74 . The arrangement of the pump 68 , the valve 64 , the medium reservoir 74 , including the connecting channel 72 , as well as the sample chamber 38 in the circuit comprising the sample chamber 38 , the valve 64 , the pump 68 and the channels 60 , 62 and 66 may be varied according to requirement.
[0063] The position of the valve 64 can be e.g. selected such that the sample in the sample chamber 38 is circulated. The sample is thus drawn off the chamber 38 via the discharge channel 62 , supplied via the channel 66 to the pump 68 and then supplied via the channel 66 back to the sample chamber 38 .
[0064] The position of the valve 64 may, for example, be selected such that the sample contained in the sample chamber 38 is circulated. The sample is thus drawn off the chamber 38 via the discharge channel 62 , supplied via the channel 66 to the pump 68 , and then returned via the channel 66 to the sample chamber 68 .
[0065] For discharging a portion of the sample via the drain 70 , the valve 64 may be arranged in an intermediate position such that a portion of the sample fed via the channel 62 to the valve 64 is supplied to the channel 70 , and another portion is supplied to the cannel 66 .
[0066] Further, it is possible to set the valve 64 such that the channel 66 is closed and the entire sample is supplied towards the drain 70 . For this purpose, new sample liquid is supplied with the aid of the pump 68 from the reservoir 74 to the sample chamber 38 , and the sample contained therein is pressed out of the sample chamber 38 . To allow the entire sample to be exchanged, the channel 66 must also be emptied. For this purpose, the valve 64 is switched over after evacuation of the sample from the sample chamber 38 such that the sample remaining in the channel 66 is pressed at least up to and into the channel 70 . Subsequently, the valve 64 is opened again and the sample contained in the channel 66 of the sample chamber 38 and the channel 62 is pressed into the drain 70 .
[0067] With the aid of the temperature-control element 58 , preferably a Peltier element, the temperature of the sample contained in the sample chamber 38 can be equalized via the intermediate element 76 and the head portion 57 . This is effected as described above with reference to FIG. 2 .
[0068] Preferably, a separate pump 68 is provided for each of the four sample chambers 38 of the illustrated embodiment. Preferably, only one medium reservoir is provided for a plurality of, in particular for all sample chambers 38 . For a separate sample exchange in the individual sample chambers 38 correspondingly controllable valves are provided in the channels.
[0069] An particularly preferred embodiment of a ceramic head portion 80 , which is suitable for defining a single sample chamber, is shown in FIGS. 4 and 5 . The head portions 26 and 57 , respectively, may be configured analogously to the head portion 80 .
[0070] The head portion 80 is of substantially rectangular configuration and comprises two through-going channels 82 , 84 . The channels 82 , 84 have, for example, the function of the channels 40 and 42 described with reference to FIG. 2 , or the function of the channels 60 , 62 described with reference to FIG. 3 . On a side 86 of the head portion 80 facing the sample, i.e. at a side wall of the sample chamber 38 , two transverse channels 88 are provided in the head portion 80 , said transverse channels 88 being connected with a through-going channel 82 and 84 , respectively. The transverse channels 88 are designed for a uniform flow through the sample chamber 38 and a better intermixing, homogenization and/or distribution of the sample.
[0071] On the side of the head portion 80 opposite the transverse channels the channels 82 , 84 have an enlarged diameter. The cylindrical expansion of the channels 82 , 84 serve for receiving the flexible conduits 44 , 48 ( FIG. 2) and 66 ( FIG. 3 ), respectively, connected with the pumps and possibly the valves. The flexible conduits arranged in these receiving openings 90 preferably bypass the intermediate element 27 and 76 , respectively, as well as the temperature-control element 29 and 58 , respectively.
[0072] Further, in the illustrated embodiment, the head portion 80 comprises a supporting element 92 configured as a circumferential projection. Due to the exact construction of the supporting element 92 the height of the sample chamber 38 can be defined with high accuracy. The distance between the head portion 80 and 26 , 57 , respectively, ( FIG. 2 and FIG. 3 ) and the object carrier 12 is set by a frame with a defined height. This frame can further be connected with the sealing element 36 shown in FIG. 2 and FIG. 3 . Alternatively, the circumferential projection can be configured as a raised portion, as shown in FIG. 2 and FIG. 3 , which directly defines the distance between the head portion 80 and 26 , 57 , respectively ( FIG. 2 and FIG. 3 ), and the object carrier 12 .
[0073] In another preferred embodiment ( FIGS. 6 and 7 ), the head portion 80 corresponds to the head portion described with reference to FIGS. 4 and 5 . The head portion 80 has connected thereto an intermediate element 94 preferably made of aluminum. An upper side of the intermediate element 94 facing away from the head portion 80 has connected thereto a temperature-control element 96 .
[0074] In contrast to the embodiments described above, the channels and/or flexible conduits do not extend substantially vertically through the intermediate elements 76 and 27 , respectively, as well as the temperature-control elements 58 and 29 , respectively. Rather, in this preferred embodiment, channels and/or bores 98 , 100 , 102 , 104 are provided in the intermediate element 94 . Here, the bores, as shown in FIGS. 6 and 7 , are arranged such that a flexible conduit 106 disposed inside the bores passes substantially horizontally over a long distance through the intermediate element 94 . This offers the advantage that the sample contained in the flexible conduit is kept at a constant temperature by the intermediate element 94 .
[0075] According to the embodiment involved ( FIG. 2 or FIG. 3 ), the pumps and valves are arranged laterally next to the intermediate element 94 and/or connected with the lateral outlet openings 108 and 110 .
[0076] In the embodiments described above, the base (first) portion ca be located above the second (head) portion. | A device for carrying out chemical and/or biological reactions comprises a sample chamber ( 38 ) formed by a first portion ( 12 ) and a second portion ( 26 ) and designed for holding the sample. With the aid of a moving means ( 46,50 ) the sample can be moved in the sample chamber ( 38 ). The second portion ( 26 ) is connected via an intermediate element ( 27 ) with a heating and cooling-control element ( 29 ) for heating and cooling the sample. For ensuring good temperature conductivity and resistance to the sample of the second portion ( 26 ), in a preferred embodiment, the second portion ( 26 ) is made of ceramic. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional application No. 61/464,017 filed Feb. 28, 2011 entitled “METHODS FOR IMPROVED FINANCIAL TRANSACTIONS”, the entire disclosure of which is incorporated herein.
TECHNICAL FIELD
[0002] The present invention relates to the field of financial transactional methods or processing and manners of changing such a financial transaction that is being processed. Methods of the present invention, in particular, relate to methods including the ability to use fixed or variable data, as such data is sent to a financial transaction processor, in order to modify the transaction, and thus changing the financial transaction that is being processed or the method of processing the financial transaction.
BACKGROUND OF THE PRESENT INVENTION
[0003] Problems that are associated with using financial cards to conduct financial transactions are numerous and well known. Financial cards are connected with financial accounts, which cards typically include the owner's name, account number, expiration date and 3 digit CVV code on its front and/or back card faces. With this data and even less, it is possible for non-card owners who have pirated the information or who have stolen such a card to buy store front goods, order goods using the internet or phone, pay bills, convert goods to cash all using someone else's money and good name. The cost and time to fix financial accounts and repair one's reputation can be extreme. Problems are also caused by the theft of data by raiding corporate databases, by simply recording the data while handling a buyer's financial card, by pilfering the data during a phone or internet use of the financial card, or by simply conning a card holder out of the data during a spoofed call or internet message from the alleged financial card company. Banks that issue the cards continue to use antiquated methods of conducting the transactions where losses are not discovered for 24 hours or more based on batched translations at night allowing a criminal plenty of time to act. The banks most often suffer the monetary loss, but the individual card holder may also need to restore their reputation and bank accounts, perhaps taking months of time. The banks profit in transaction fees so that their losses are covered while an individual card holder suffers.
[0004] While ways have been developed to attempt to stop this problem, both banks and merchants that accept financial transaction cards have issues with changing the system. There is reluctance within this business of conducting financial transaction to spend the time and/or money to implement an improved financial transaction system that will not otherwise benefit a business's bottom line or improve the efficiency of the transaction process. Use of PIN (personal identification number) numbers that are known only by the card holder for every transaction, fingerprint identification of the card holder, and similar concepts could solve a vast majority of the problems. However, such solutions cost a great deal to implement and add time to every transaction. For example, it is common for a merchant to simply tell a buyer when using an automated system to press a button for a credit transaction when using a debit card rather than as a debit card, even though their transaction costs are higher in order to speed up the transaction. There is no unified cry by the public to change the system because most have not lost money nor had the pain of clearing their name.
[0005] What is needed is a financial transaction system that costs banks and merchants little or nothing to implement, that works as quickly and smoothly as the current system, that does not add to or change the already in place infrastructure of financial card processing equipment, and that eliminates the ability of the criminals to obtain the card data to rob accounts. Additionally, a reduction in financial loses and potential savings in producing less financial cards would be a desirable benefit. It has been reported by Gartner, Inc. that approximately 7.5 percent of U.S. adults have lost money as a result of some sort of financial fraud in 2008 in large part because of data breaches.
[0006] Buyers presently enjoy tremendous capability to purchase goods and services, i.e., conduct financial transactions, almost anywhere in the world. The US Banking system, in particular, facilitates this activity, through conventional means such as wire-transfers, checks and funds-transfers through the automated clearing house network (ACH—operated by The Electronic Payments Association, NACHA), and through regional networks such as Star and Mac, or national and international networks such as MasterCard, Visa, Amex, and the like. Often, traditional bank accounts are connected to these various networks by an issuing bank, and the buyer is given a card (debit or credit), which they present at a point of sale, or they simply enter the account number on the card into a web page for an online purchase. The purchase, then, initiates a transfer of funds from the card/account holder's bank account to the merchant's account in exchange for goods and services. The issuing bank typically is the bank that holds the buyer's account, and also is a member of the network(s) indicated on the particular card. From the network provider's perspective (e.g., Visa), the bank that caused the card to be issued is the “issuing bank.”
[0007] Identifying those networks that are connected to a given account can often be accomplished by looking at the reverse side of a card, where the logos of the various networks, often called “bugs,” are printed. These various networks, when they are not specific to a particular merchant or venue, are called “open-loop” in the payments industry. Visa, MasterCard, Amex, Discover, and Star are examples of networks that, when associated with a card and account, make the card “open-loop.” It is noted that it is not necessarily a “card” that is open or closed-loop, but it is rather the nature of the account “behind” the card. As such, open loop account numbers can be just as easily associated with, e.g., cell phones, a key, or a voucher.
[0008] Merchants today often try to increase their market share and drive business by offering programs such as loyalty programs, merchandise discounts, extended payments, increased services and the like. In order to offer these features in an easy to use, efficient manner, a merchant would benefit from tools that are not currently available. Such merchants have only a limited means of marketing the services offered to targeted audiences and implementing the services in a user-friendly cost effective manner. As one example, Veritec Inc., of Golden Valley, Minn., sells products and services that control methods of using a buyer's mobile phone as a means of marketing using coupons, ticketing, gift cards, loyalty programs, and the like, and, at the same time, that can also be a provider of financial account data for securely conducting financial transactions. The means, according to the Veritec system, of electronically transmitting the data is by using a 2D code that can be displayed on the phone screen. With this system, a merchant has a method of targeting a specific audience in real time and the ability to introduce services and programs to buyers via their mobile phone while at the same time allowing the transaction of business along with these unique offerings and by using the same mobile phone.
[0009] An issue for non-financial card transactions is implementing phone code financial accounts and phone code coupons such that minimum support in a merchant's POS (point of sale) computers or devices is required. Today if phone codes were implemented, there likely would be problems with both supplying hardware and software to POS devices at merchant POS sites. Without a reader that is enabled to read any specific 2D barcode, for example, that is displayed on the phone at the point of sale, there would be no capability of conducting a phone code transaction other than by manually entering data that is represented and encoded within the 2D barcode. Although some merchants may have 2D code readers at the point of sale, they might also be required to have other or additional firmware to read other specific 2D barcodes, for example, such as the VeriCode™ phone code also available from Veritec Inc., assuming a reader has a capability to read phone displayed codes that are under glass with high glare. To consistently read phone displayed codes, a device specifically made for this task should be utilized. Most all PUS devices are programmed to work using fixed firmware that is under the control of a financial card processor with minimal interest in migrating business to a competitive processor that is enabled to work with financial phone codes. If reading of phone codes requires changes to the firmware on POS devices, most likely the POS device would require replacement with a new POS device that is enabled with new firmware. The installed base of typical POS devices is so large that any such change would also be very expensive.
[0010] Under normal circumstances, a card based financial transaction includes at least three elements; the data that identifies the payee and associated financial institution, the data that identifies the payer and associated financial institution and the monetary amount of the transaction. Payer data is normally found on the first two tracks of a conventional financial card magnetic stripe (according to the accepted conventional standard), which payer data is normally transmitted into a financial transaction by swiping of the card in a reader. Payee data is normally preloaded into a POS device or held in memory in whatever processing method is being employed (POS Computer). A monetary amount is either hand entered into the POS device or generated by a POS computer. These three elements are typically uploaded through various means to processing centers that will authenticate a transaction, debit and credit the payee and payer accounts as well as dispersing transactional fees to those companies handling the transaction (Legacy Financial card Transaction). Any additional, varied, modifications to the transaction such as discounts, loyalty credits or debits, coupons, gift cards and the like are typically handled separately either by manual calculations or in the POS Computer. A payer must exercise a great deal of care at the point of sale to be sure that all available discounts or credits have been applied to the transaction. This process could be made more reliable and faster if the financial transaction processor could handle some portion of the modifications to a financial transaction.
[0011] Payer financial card magnetic stripe data conventionally contains a payer name, a payer account number, a card expiration date and discretionary data such as a PIN number, the CVV code and similar data. Most often, a magnetic stripe includes redundant data for values that are numbers. All data on conventional magnetic stripes falls into the ASCII range of characters. Track 1 of a conventional stripe uses (64) different characters and track 2 uses (16) different characters. Both track 1 and track 2 have null, unused characters in the discretionary data field that can be filled with data conveying instructions to a financial transaction processor.
SUMMARY OF THE PRESENT INVENTION
[0012] Processes are described herein that solve one or more of the afore-mentioned problems, without adding significant or any costs or increased transaction burdens to banks or merchants, that will also benefit both banks and merchants, and that reduce the risk of identity theft for a card holder. The premise of the invention is to reduce the availability of buyer data to others in order to provide greater security during a financial transaction. This can be accomplished in a variety of ways by modify the transaction process, including aspects of the transfer of data between, a buyer, a merchant, and a transaction processing party and at a variety of different stages.
[0000] Terms used hereinafter within this disclosure:
1. Financial Card—A typically plastic card used by an individual to conduct Financial Transactions tied to a Financial Account held by the individual, that is issued by a Bank, and minimally contains textual data including the individual's name, the Financial Account number, the expiration date of the Financial Card, a 3 digit security code called the CVV and a magnetic stripe with the same data that can be electronically read. 2. Financial Account—The Financial Card, Financial Account instrument, or any Financial Account authorized by a Bank or Bank agents, whereby an individual contracts with a Bank to provide the service of authorizing and making monetary transactional payments to Merchants on behalf of the individual and to settle all costs associated with the transaction. 3. Financial Account Holder—The Financial Card, Financial Account Holder is the individual that has contracted with a Bank to purchase goods or services from and make monetary payments to a Merchant using a Financial Card, Financial Account means to conduct a Financial Transaction. The Financial Account Holder, within this disclosure, will be known as the Buyer. 4. PAN—The Legacy Financial Card, Primary Account Number 16 digit to 19 digit number is known as the PAN which includes numbers identifying the Bank holding the Financial Account (BIN) and the Financial Account number. 5. Financial Transaction—The process by where a Buyer purchases goods or services from a Merchant and uses the Financial Account in order to pay for goods or services. 6. Merchant—A Merchant is any provider of goods or services that will receive monetary compensation, from a Buyer's Financial Account, for the goods or services provided to a Buyer. 7. Bank—A Bank is the legal entity that issues a Financial Account and Financial Card to a Buyer and is responsible for settling the monetary value of the transaction with a Merchant and the costs of the transaction with the service providers that facilitate the transaction. 8. Processor—A service provider that often handles under contract, for the Bank, the processing of a Financial Transaction by receiving an electronic transferred request from the Merchant including the Merchants data, the Buyer's Financial Card account data and the monetary value of the transaction and then facilitates the debiting and crediting of the Buyer's and Merchant's Financial Accounts as well as those of the service providers handling the transaction. A Bank may provide this service themselves. 9. POS Systems—The hardware and software used by Merchants to conduct a Financial Transaction that utilizes a Financial Card or minimally the 16 digit Financial Card PAN number and expiration data to implement a Financial Transaction. 10. Processor or Bank/Processor—The term Processor or Bank/Processor implies a relationship between the Bank and Processor that has shared functions with the Bank having authority. The Processor can have a minor role increasing to the Bank only holding funds and the Processor controlling all aspects of a Financial Transaction. A Bank may provide all of the services of the Processor themselves. 11. Innovative New Financial Transaction—The innovative process and inventions described in this disclosure concerning Financial Accounts and Financial Transactions. 12. Bank/Processor Membership Number—The Bank/Processor will typically have a legal agreement between themselves and Buyer and the Merchant providing financial services as described herein. The contracts are identified by a Bank/Processor Membership Number which at a minimum will be a 16 digit number, functionally much like current Financial Card PAN numbers and perhaps a second shorter number to protect the 16 digit number from public disclosure. It should also be noted that the Legacy Financial Account number, provided to the Merchant by a Bank or Processor for the acceptance of Financial Cards through a POS system, can be used to replace the Bank/Processor Membership Number within the scope of this invention. 13. Mobile Phone—Any of a number of mobile electronic devices that can display data and graphics on a screen and has a wireless communication means. 14. 2D Code—A graphic matrix symbology that has data encoded in the matrix pattern. 15. Account Data String—The data, commonly found on a Financial Card's magnetic stripe that identifies the Financial Account, the issuing financial institution and Financial Transaction Processor, the account holder, expiration data and security means to authenticate both the Financial Account and card holder. 16. Modified Account Data String—Any Account Data sent to a Processor that has data in the string such that the that data can effect changes to a Financial Transaction being processed or the method of processing the transaction not incorporated in a Legacy Financial Transaction.
[0029] Today a Buyer will acquire goods and services from a Merchant and use their Legacy Financial Card to pay for those goods and services. Legacy as used throughout this application as a modifier means the conventionally accepted system or systems as are used today in standardized transaction systems for financial transactions. A Buyer may present the Financial Card to the Merchant directly in a face-to-face transaction using the Merchants POS system or provide the card data remotely for a phone or internet purchase. In either case, a Merchant or others who may be illegally recording card data mayl have access to the four critical Financial Card data components; Buyer's name, Buyer's account number, expiration date and 3 digit CVV code. It is possible for a Merchant employees, for example, to obtain this data from a transaction receipt and memorizing the other details or for a phone or online operator to simply walk off with the data or a criminal that intercepts data being transferred electronically from a computer. The innovative Financial Transaction process of the present invention will prevent the disclosure of Buyer's personal and Financial Account data to the Merchant. It will also prevent personal or Financial Account data from being transmitted electronically or verbally over the internet of phone.
[0030] A process of the present invention starts with a Bank/Processor contracting with the Merchant and/or Buyer to provide this innovative new service. For example, once the new Financial Transaction system is in place, the Merchant can send a Bank/Processor a request, using a standard POS system and a Financial Card with an account number that triggers the new process. The data sent can include the Merchant's data and the monetary values of the transaction. The Processor can then send back to the Merchant a receipt, using the same method as the Legacy POS system, which has the Merchant data, the monetary data and a code with 2 to 5 digit number that represents the Financial Transaction. The Merchant can then present the receipt or just the code to the Buyer. The Buyer may run an application, such as has been provided by the Bank/Processor, on their Mobile Phone that wirelessly connects the Buyer's phone to the Processor. The application will preferably then ask the Buyer to choose which Financial Account for the transaction (if more than one is available), if the Buyer would like to provide a tip for a service and to enter the 2 to 5 digit number. The Processor can then immediately return to the Buyer's phone the details of the Financial Transaction represented by the 2 to 5 digit number including the goods or services cost, tips if included and taxes, the Financial Account chosen, and the Merchant information. If the Buyer accepts the sent data they can then also acknowledge the transaction by pressing a key on the phone or entering a PIN which may also enact an electronic signature for the transaction. The Processor can then send an acknowledging receipt to the Merchant's Legacy POS system for their records and the same receipt to the Buyer's phone.
[0031] A similar method in accordance with aspects of the present invention would have a Buyer furnishing a Merchant a membership number in the Bank/Processor system that the Merchant would send to a Processor along with Merchant data and the total costs for goods, services and taxes. This method would allow a Processor to directly contact a Buyer's phone and proceed, such as described just above, with a Financial Transaction without the use of the 2 to 5 digit Financial Transaction number but using a Buyer's Bank/Processor membership number to identify the Buyer's Financial Account.
[0032] A third similar method also in accordance with aspects of the present invention would have a Merchant providing a Buyer with a Bank/Processor membership number that is specific to them, the total costs for goods, services and taxes, and a 2 digit (for example) transaction number. The Buyer could then run a Bank/Processor application on their Mobile Phone, and upon being prompted could enter the Merchant Bank/Processor membership number, the total costs for goods, services and taxes, a Financial Account to use for the transaction, and the 2 digit transaction number and a tip if desired. The phone would preferably forward this data to a Processor along with the Buyer's Bank/Processor membership number. The Processor would preferably then immediately return to the Buyer's phone certain details of the Financial Transaction represented by the 2 digit number furnished by the Merchant including the goods or services cost, tips if included and taxes, a Financial Account chosen, and Merchant information. If the Buyer accepts the sent data they can then acknowledge the transaction by pressing a key on the phone, for example, or entering a PIN, as another example, which can then enact an electronic signature for the transaction. The Processor can also send an acknowledging receipt to the Merchant's Legacy POS system, including the 2 digit transaction number, for their records and the same receipt to the Buyer's phone. Note that any data transferred by the Buyer's Mobile Phone could preferably be encrypted for security.
[0033] A Financial Transaction method in accordance with the present invention also has other benefits for a Merchant and Buyer. While there is no Financial or personal data required to be transferred as part of a Financial Transaction in accordance with methods of the present invention, a Merchant can also offer a Buyer incentives to participate in Merchant marketing programs. These programs could include loyalty points to be exchanged for discounts on future purchases based on Buyer's use of the Merchants offerings. For example, a Mobile Phone coupon campaign can be implemented where the discounted goods or services are offered by the Merchant are sent to a Buyer's Mobile Phone. In each case the Buyer can remain anonymous to the Merchant, where a Processor can handle the tracking of a Buyer's purchases, loyalty discounts or discounting of coupon merchandise or services.
[0034] Having a Bank/Processor application running on a Buyer's phone offers many additional opportunities for a Bank, Merchant, Buyer and Processor. As part of a Bank/Processor agreement with a Buyer, a Bank could offer or require additional service offerings to the Buyer. A Buyer's Mobile Phone could be a new account manager for the Buyer's Bank accounts providing instant access to all or less of Banking services and transactions and cutting down on paper documents sent to the Buyer. This instant notification method could help sell Banking services as well as stopping overdrafts of Financial Accounts because real time data is not currently available with prior art methods and systems. A Merchant would not be subjected to charge backs based on Legacy fraud in accepting Financial Cards. Electronic Gift Cards for a Buyer could be managed through a Processor for discounting purchases from a Merchant. A Merchant, through a Processor could also design marketing campaigns based on demographic data that the Processor would filter for the Merchant. A Buyer would be protected from identity theft, could be notified of every transaction on all accounts at the Bank, take advantage of loyalty points and discounts without any overt action, conduct diverse Financial Transactions such as account to account transfers, toggling an account on and off, checking balances, paying bills and the like, anytime and anywhere. A Processor would be able to offer additional services which, as implemented in software, can also be highly profitable.
[0035] The advantages for the innovative Financial Process are numerous. For example, to a Bank, advantages can include the following. Processes in accordance with aspects of the present invention may no longer require a name brand Financial Card such as Visa, Master Card, Discover, America Express and the like to assure to Merchants that they will be paid. Fees that are normally paid for using name brand cards can now be spread among other participating parties or used to reduce Merchant fees. There would no longer be a requirement for a plastic Financial Card to be issued, which is often a Bank expense. If 7.5% of Buyers are experiencing fraud and Banks most often take responsibility for the monetary loss of fraud, the lack of criminals ability to steal Buyer's identity will reduce Bank loss. A Bank can sell also provide or sell additional services and provide superior service to a Buyer using a Bank/Processor application running on a Buyer's Mobile Phone.
[0036] Advantages to a Merchant can include the following, for example. A Merchant would not be required to change their Legacy hardware driven POS system. For those Merchants using a software driven POS method the only difference may be software changes to their current POS application that reflect how credit receipts are reported through there accounting system. A Merchant can offer loyalty and coupon marketing that are directed specifically at the Buyer's purchasing habits. Monetary loss from bad Financial Card Transactions and lost reputation from employees stealing Buyer identities could be a thing of the past.
[0037] For service Merchants a multiple action Legacy Financial Card Transaction, such as for restaurant services, is normally done based upon the follow steps. First, the service Merchant presents a Buyer with their bill for services. Then, the Merchant picks up the Buyer's Financial Card, runs the Buyer's Financial Card through the POS system, takes a receipt and card back to the Buyer, potentially gets the Buyer to add a tip and sign the receipt, takes the receipt back to the POS system, finds the transaction and rerun the transaction with the tip. This process could be changed by processes of the present invention by simply furnishing the Buyer a 2 to 5 digit, for example, transactional code or getting the Buyer's Bank/Processor membership number or providing a Buyer with a Merchant Bank/Processor membership number, along with the total costs for goods, services and taxes, and a 2 digit transaction number. This could all be done within a single action. It is contemplated that a Merchant might also be able to procure a reduction in Financial Transaction processing fees based upon the use of processes and systems in accordance with the present invention.
[0038] Advantages to a Buyer are also potentially numerous including the following. A Buyer is potentially the best served member of the Bank/Processor group in that they can gain a great deal of control over their financial lives while saving time, money and frustration. Advantages include the prevention of identity theft, as a Buyer's personal data would not be exposed to unknown persons, such as during a transaction. Loyalty points and discounted deals can be provided to Buyers without having to remember to do anything or exposing personal data to a Merchant. Buyers would have real time account and transaction data available to them and could conduct banking transactions anywhere and at anytime. Secure transactions could be conducted whether at a brick and mortar retail location, by phone, or in conducting internet transactions. There could also be an elimination of paper transaction receipts since both a Buyer's Mobile Phone and a Processor would have such data for future use that could also be downloaded to a application running on a Buyer's computer. There is additionally a potential for reduced Financial Transaction service fees based on lower fraud losses, lower Bank cost for maintaining the Buyer's Financial Account and the higher value of a Buyer to a Merchant.
[0039] For a Processor, specific advantages can also include the following. A Processor is a business that has fixed costs with a lower level of operating expenses. Any service that the Processor can add to their portfolio of services will have a cost of implementation but once implemented can yield high profits to the Processor as add on business. The add on business potential for the Processor include innovative Financial Transaction business based upon the present invention. Programs can include Loyalty programs for the Merchant and Bank, direct marketing programs for the Merchant and Bank, non-personal Buyer demographic data for the Merchants and the Bank, and enhanced electronic-banking programs for the Bank, as examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] FIG. 1 is a graphical illustration of potential communications between a buyer and merchants of different varieties along with a bank/processor in the performance of a financial transaction related to the purchase of a product or services;
[0041] FIG. 2 is a graphical illustration showing potential communications between a buyer, a merchant and bank/processor with a point of sale device and with alternative methods according to the present invention;
[0042] FIG. 3 is a graphical illustration of lines of data communication according to methods of the present invention;
[0043] FIG. 4 is a graphical illustration of lines of data communication according to alternative methods of the present invention;
[0044] FIG. 5 is a graphical illustration of lines of data communication according to other alternative methods of the present invention;
[0045] FIG. 6 is a graphical illustration of lines of data communication according to yet other alternative methods of the present invention;
[0046] FIG. 7 illustrates tracks of a magnetic stripe of a transactional card including data in accordance with the present invention;
[0047] FIG. 8 shows a personal communication device as being modified with variable data illustrated as a 2 dimensional bar code; and
[0048] FIG. 9 illustrates a processing track for financial transactions.
DETAILED DESCRIPTION
[0049] The following detailed description of aspects of the present invention includes graphic illustrations to provide clarity to the understanding of the present invention. The provided graphic illustrations are for illustrative purposes only and not to be considered as limitations for the present invention.
[0050] A Buyer in the past did not communicate with the Bank/Processor during a Legacy Financial Card, Financial Transaction. Only the Merchant had direct communications with the Bank/Processor. Under Financial Transaction processes of the present invention, a Buyer can now have a direct connection to the Bank/Processor. As shown in FIG. 1 , a Buyer 10 can communicate directly with a Bank Processor 12 , as illustrated by the two directional arrow 14 . While the discussion here-to-for has noted a Mobile Phone 20 (see FIG. 2 ) as an exemplary means of communication between a Buyer 10 and a Bank/Processor 12 , a Buyer's personal computer, Wi-Fi connected PDA or any other electronic means of communication between the Buyer and the Bank/Processor could be utilized. The arrow paths 16 and 18 represent communications paths between a Buyer 10 and a Merchant, the Merchant being represented as either a brick and mortar store 22 or a phone or internet business 24 . These paths 16 and 18 are fundamentally the same paths for a Legacy Financial Card and a Financial Transaction in accordance with Financial Transactions of the present invention that can preferably utilize the same infrastructure of POS System hardware that is in place today. The arrow paths 26 and 28 represent the potential communication paths between the Bank/Processor 12 and the Merchants 22 or 24 , which communications are also fundamentally the same paths for the Legacy Financial Card transaction as they are for Financial Transactions of the present invention that preferably can also utilize the same infrastructure of POS System hardware in place today. Because POS systems are widely diverse, it is likely that some POS Systems will require minor updated software to utilize Financial Transaction methods of the present invention along with many improved features, as detailed greater below.
[0051] In accordance with the present invention, there are multiple methods that will be described below for initializing an Innovative New Financial Transaction with reference to FIG. 2 . While each method described and illustrated provides an exemplary method, other methods could be utilized within the scope of this invention. The assumption of a financial transaction, in general, is that a Buyer 10 wishes to purchase goods or services from either a brick and mortar Merchant 22 or from a phone or internet Merchant 24 and that a Financial Transaction is to be conducted for payment from the Buyer 10 to the Merchant 22 or 24 for the good and/or services.
[0052] One method of the present invention is as follows. Within this exemplary method, multiple variations are also contemplated depending of the POS System that is currently being employed by a Merchant.
[0053] Small Merchant who does not use a computerized POS System—A Merchant 26 can calculate a Buyer's invoice using hand techniques or a computer that is not attached to a POS System 28 . The total monetary value of the invoice (Payment) will be calculated. The Merchant 26 can swipe a Bank/Processor Merchant card in the POS terminal, then enter the total payment into the POS terminal, and hit the send key, which are the same actions as those typical for initializing a Legacy Financial Card transaction. The firmware in the POS terminal can then preferably electronically send data onto the Financial Card Payment Network and be routed to the Bank/Processor. From a magnetic stripe of a card, the Bank/Processor can receive, at a minimum, the Merchant's name, a 16 digit account number, and Payment data. A second Merchant's Bank/Processor Identification Number could be received as well as additional data contained on the magnetic stripe and general data included by the POS hardware, firmware. Using this data, the Bank/Processor's software application can recognize the Financial Transaction as an Innovative New Financial Transaction and proceed as controlled by the Bank/Processor's software program. The Bank/Processor can then return to the Merchants POS System an intermediate receipt that at a minimum contains a 2 to 5 digit number that will represent a control number for this Financial Transaction along with Payment data. The control number can be varied in any number of ways.
[0054] Large Merchants who use a computerized POS System—The Merchant can enter a Buyer's purchases into the computerized POS System. The computer will calculate the total monetary value of the invoice (Payment). The Merchant can verify the data and hit the send key which is the same action as initializing a Legacy Financial Card transaction. The software in the computer will preferably electronically send the data onto the Financial Card Payment Network and be routed to the Bank/Processor. From the data generated by the computerized POS System, a Bank/Processor can preferably receive, at a minimum, the Merchant's name and/or a 16 digit account number, and Payment data. A second Merchant's Bank/Processor Identification Number could also be received as well as additional general data that is included by the computer. Using this data, the Bank/Processor's software application can recognize the Financial Transaction as an Innovative New Financial Transaction and proceed as controlled by the Bank/Processor's software program. The Bank/Processor can return to the Merchants POS System an intermediate receipt that at a minimum contains a 2 to 5 digit number that will also preferably represent a control number for this Financial Transaction along with Payment data. The control number can be varied in any number of ways.
[0055] Another exemplary method of the present invention is as follows. According to this method a Buyer can communicate to the Merchant a Buyer's Bank/Processor Membership Number. Methods of performing this communication could be via a Financial Card like design that contains a 16 digit Buyer's Bank/Processor Membership Number. This data could be printed in text on the card, be encoded on the magnetic stripe or both. Additional graphics or text and magnetic stripe data could all be included on the card. The Buyer could send the same data to the Merchant via a Blue Tooth, WiFi or cellular communication means as well as other such means such as writing the number on a piece of paper. Next a Merchant would send data to a Bank/Processor. Legacy Merchant Financial Account Number would be sent by the Merchant to the Bank/Processor using the POS Hardware or the POS Computerized System. This data could include minimally the Merchant's Legacy Financial Account number (normally sent when processing a Financial Card transaction) generated by the POS hardware or the POS Computer System, the Buyer's 16 digit Buyer's Bank/Processor Membership Number, and the Payment data. Alternatively, using a Bank/Processor Merchant Membership Number, a Merchant could instead send both a 16 digit Bank/Processor Merchant Membership Number and a Bank/Processor Buyer Membership Number along with Payment data to the Bank/Processor. In this regard, it is contemplated that it may be required to modify software of the POS Hardware, or firmware or the POS System computer software. The magnetic stripe on a Financial Card has room for discretionary data and both the POS Hardware, firmware and the POS System computer software could be modified to incorporate, either a 16 digit Bank/Processor Merchant Membership Number or the Bank/Processor Buyer Membership Number in the data stream from the magnetic stripe in the place of discretionary data. Although a 16 digit number is contemplated to be compatible with conventional current usages, other size numbers including other type characters are also contemplated in accordance with the present invention.
[0056] Yet another New Innovative Financial Transaction Initialization is also illustrated. A Merchant can communicate to the Buyer a 2 digit (for example, other size numbers are contemplated) Financial Transaction number along with either a 16 Digit or a shorter Bank/Processor Membership Number could be sent or a Merchant's Legacy Financial Account number (normally sent when processing a Financial Card transaction). The payment data would also be included as well as other pertinent data if required. The methods of this communication could be via a Blue Tooth, WiFi or cellular communication means as well as other such means such as a printed intermediate receipt. Under this method, a Buyer could send to the Bank/Processor, using the Bank/Processor application running on the Buyer's Phone, data including minimally a Merchant's Bank/Processor Membership Number or Legacy Financial Account number (normally sent when processing a Financial Card transaction), a Buyer's 16 digit Buyer's Bank/Processor Membership Number, the 2 digit Financial Transaction code and the Payment data.
[0057] For processing a financial transaction in accordance with methods of the present invention a first assumption is, that in all cases, a Bank/Processor will have received a notification that a Bank/Processor membership Financial Transaction is in progress. In accordance with the first method discussed above, a Bank/Processor has sent the Merchant a transaction identification 2 to 5 digit number and payment data, representing a current Financial Transaction with a Bank/Processor Buyer member. In accordance with the second method described above, a Bank/Processor has received from the Merchant a Merchant Financial Account Number (Legacy or Bank/Processor Membership number), the Buyer's Bank/Processor Membership number and the payment data. In accordance with the third described method described above, a Buyer has sent the Bank/Processor the Merchant's Financial Account Number (Legacy or Bank/Processor Membership number), the Buyer's Bank/Processor Membership number, the 2 digit Financial Transaction code and the Payment data. It is noted that in the first method, the Bank/Processor does not have the identification of the Buyer but has assigned a transaction identification 2 to 5 digit number. For the other methods, the Bank/Processor has all the required information to complete the Financial Transaction, excepting the Buyer's authorization and perhaps a gratuity if applicable.
[0058] Financial Transaction Processing in accordance with preferred methods of the present invention are described as follows and initially with reference to FIG. 3 .
[0059] According to a first exemplary method, Financial Transaction Processing does not expose any personal or Financial Account data about the Buyer to the Merchant, only to the Bank/Processor.
[0060] In this case, a Merchant has received from the Bank/Processor an intermediate receipt that has the payment and a 2 to 5 digit transaction number. For smaller Merchants this data will be routed through their POS Hardware and printed on the receipt printer. Larger Merchants will receive the data in their POS Computer System and can print the payment and a 2 to 5 digit transaction number or add the detailed transaction data and print an invoice as shown above. This printed invoice, or an electronically transmitted invoice, or any other chosen means can be used to provide the invoice to a Buyer.
[0061] A Buyer can start the Bank/Processor application on their Mobile Phone and, as shown in FIG. 3 , press “3”, for example, to open Bill Pay. The application will next prompt for the 2 to 5 digit transaction number which the Buyer will enter using the appropriate keys on the Mobile Phone and press “#”, for example, to send via the cellular network or a Wi-Fi connection if so enabled. The data sent can include the 2 to 5 digit transaction number, the Buyer's Bank/Processor Membership number and any other appropriate data such as found in an Account Data String, and authentication data that the signal is coming from the Buyer's Mobile Phone, PIN authentication and the like.
[0062] The Bank/Processor will preferably then receive the entered data, the Buyer's Bank/Processor Membership number and any other appropriate data, such as found in an Account Data String, and authentication data that the signal is coming from the Buyer's Mobile Phone, PIN authentication and the like. The Bank/Processor can then match the 2 to 5 digit transaction number provided to the Merchant and format a message that has the Merchants name, the payment data supplied by the Merchant and send said data to the Bank/Processor application running on the Buyer's Mobile Phone.
[0063] The Buyer will preferably then receive the Merchant's invoice, add a Tip in a Popup Window if desired and press “Y”, for example, to accept the transaction or “N”, for example, to decline the transaction. By pressing “Y” the Buyer can also be assigning an electronic signature to the Financial Transaction. The Bank/Processor application will send the Tip data, if any and the Y or N to the Bank/Processor via the cellular network or a Wi-Fi connection if so enabled.
[0064] If the Transaction is accepted the Bank/Processor can use standard Legacy Financial Card processing methods to authorize the Financial Transaction and facilitate the debiting and crediting of accounts for various parties participating in the Financial Transaction. Assuming that the transaction is authorized, the Bank/Processor can also send a receipt for the Financial Transaction to the Merchant's POS Hardware or the POS Computer System and to the Buyer's Mobile Phone as shown above.
[0065] In the case that a Financial Transaction is rejected by the Buyer, not authorized by the Bank/Processor or the 2 to 5 digit transaction number is not send to the Bank/Processor by the Buyer within a time limit, the Bank/Processor can return a message to the Merchant with information describing the reason for the transaction rejection using Financial Card Legacy rejection methods. If the Buyer rejected or was not authorized, The Bank/Processor can send a message to the Buyer's Mobile Phone with information describing the reason for the transaction rejection.
[0066] To conduct methods of the invention as described above, it would be preferable to consider the following. Preferably, the Buyer's Mobile Phone transmissions can be prioritized so that the communications between the Buyer and the Bank/Processor are conducted in no more than a few seconds. A Bank/Processor can recycle the 2 to 5 digit transaction number when the transaction closes or when the time limit runs out. The used 2 to 5 digit transaction number can be placed in the bottom of the queue and recycled when at the top. Like any Financial Transaction between a Buyer and a Merchant, a Merchant will need to exercise care in assuring that the transaction is complete before the Buyer leaves the premises. A Buyer's Mobile Phone may run out of battery, cease to work, get lost or otherwise be unavailable. As such, a Bank/Processor may also issue a regular, Legacy, Financial Card that can be processed using Legacy methods for such occasions. These described and suggested methods of the present invention would provide a faster, simpler method for restaurants and similar service Merchants compared to Legacy Financial Card methods since often a waiter will make 3 or more trips to a table, often waiting each time, to complete a transaction. The innovative Financial Transaction process described here within only requires a single trip to the table by the waiter.
[0067] Another method for Financial Transaction Processing in accordance with the present invention is described as follows and with reference to FIG. 4 . According to this exemplary method, a Financial Transaction processing step exposes a Buyer's Financial Account number to a Merchant. This can be the only data exposed and is unlikely to be problematic since the Merchant's or any other fraudulent attempt to use that number will be stopped by the Buyer rejecting the attempt or the Bank/Processor stopping the transaction based on a non-authenticated phone or PIN, as described.
[0068] In this example, a Bank/Processor will have already received a Buyer's Bank/Processor Membership number, a Merchant's Bank/Processor Membership number, or a Merchant Legacy Financial Account number, each as described above, along with the payment totals or payment details and totals and other data pertinent to the transaction. The Bank/Processor will match the Buyer's Bank/Processor Membership number, provided to the Merchant, to Buyer information in their database and format a message that has the Merchants name, the payment data supplied by the Merchant and send this data to the Bank/Processor application on the Buyer's Mobile Phone. It would be preferable that a Buyer's Mobile Phone's operating system would allow for launching an application based on incoming data. If not, a Buyer would need to have started the Bank/Processor application.
[0069] Preferably, the Buyer will receive the Merchant's invoice, add a Tip in a Popup Window, if desired, and press “Y”, for example, to accept the transaction or “N”, for example, to decline the transaction. By pressing “Y” the Buyer can also be assigning an electronic signature to the Financial Transaction. The Bank/Processor application can then send the Tip data, if any and the Y or N to the Bank/Processor via the cellular network or a Wi-Fi connection if so enabled.
[0070] If the Transaction is accepted, the Bank/Processor can use standard Legacy Financial Card processing methods to authorize the Financial Transaction and facilitate the debiting and crediting of accounts for various parties participating in the Financial Transaction. Assuming that the transaction is authorized, the Bank/Processor can send a receipt for the Financial Transaction to the Merchant's POS Hardware or the POS Computer System and to the Buyer's Mobile Phone as shown above. In the case that the Financial Transaction is rejected by the Buyer or not authorized by the Bank/Processor, the Bank/Processor can return a message to the Merchant with information describing the reason for the transaction rejection using Financial Card Legacy rejection methods. The Bank/Processor can also send a message to the Buyer's Mobile Phone with information describing the reason for the transaction rejection.
[0071] Methods in accordance with the above-described aspects of the present invention would provide a faster, simpler method for all types of Merchants compared to Legacy Financial Card methods. The innovative Financial Transaction process described here within only requires a single trip to the table by the waiter and a single card swipe and press the “Y” key on a Mobile Phone for Brick and Mortar retailers. While the issue remains of sending two Financial Account numbers Buyer and Merchant, the many ways of solving the problem should easily overcome any reluctance for a minor change to PUS Hardware firmware or POS computer system software.
[0072] Yet another example of methods in accordance with aspects of the present invention are described below with reference to FIG. 5 . In the case where a Merchant has already sent to the Buyer an invoice, the invoice could include the Merchant's Bank/Processor Membership number or a Merchant Legacy Financial Account number and payment data as a total payment or a detailed list of goods and services purchased plus tax as shown above. A Buyer can start the Bank/Processor application on their Mobile Phone and, as shown in FIG. 4 , press “3”, for example, to open Bill Pay. The application will preferably next prompt for the Merchant's Bank/Processor Membership number or a Merchant Legacy Financial Account number including a 2 digit transaction code and the payment data, which the Buyer will enter using the appropriate keys on the Mobile Phone and press “#”, for example, to send via the cellular network or a Wi-Fi connection if so enabled. The data sent can include the entered data noted above, the Buyer's Bank/Processor Membership number plus any other appropriate data, such as found in an Account Data String, and authentication data that the signal is coming from the Buyer's Mobile Phone, PIN authentication and the like.
[0073] A Bank/Processor can then receive the entered payment data, the Merchant's Bank/Processor Membership number or a Merchant's Legacy Financial Account number, the 2 digit transaction number and any other appropriate data, such as found in an Account Data String, and authentication data that the signal is coming from the Buyer's Mobile Phone, PIN authentication and the like. The Bank/Processor will preferably match the Buyer's Bank/Processor Membership number and the Merchant/Processor Membership number or Legacy Financial Account number, to information in their database and format a message that has the Merchants name, the payment data supplied, the 2 digit transaction number and then can send this data to the Bank/Processor application on the Buyer's Mobile Phone.
[0074] A Buyer can then receive the Merchant's invoice, add a Tip in a Popup Window if desired and press “Y”, for example, to accept the transaction or “N”, for example, to decline the transaction. By pressing “Y” the Buyer can also be assigning an electronic signature to the Financial Transaction. The Bank/Processor application can then send the Tip data, if any and the Y or N to the Bank/Processor via the cellular network or a Wi-Fi connection if so enabled.
[0075] If the Transaction is accepted, a Bank/Processor can use standard Legacy Financial Card processing methods to authorize the Financial Transaction and facilitate the debiting and crediting of accounts for various parties participating in the Financial Transaction. Assuming that the transaction is authorized, the Bank/Processor can send a receipt for the Financial Transaction to the Merchant's POS Hardware or the POS Computer System and to the Buyer's Mobile Phone as shown above. In the case where the Financial Transaction is rejected by the Buyer or not authorized by the Bank/Processor, the Bank/Processor can return a message to the Merchant along with information describing the reason for the transaction rejection using Financial Card Legacy rejection methods. The Bank/Processor may also send a message to the Buyer's Mobile Phone with information describing the reason for the transaction rejection.
[0076] Methods of the present invention as described above would provide a safe method for the Buyer to complete the transaction but at the cost of entering more data at least one time. A 16 digit Merchant's Bank/Processor Membership number or a Merchant's Legacy Financial Account number and 2 digit transaction would require hand entering 18 digits. The Bank/Processor application on the Buyer's Mobile Phone would preferably save the Merchant's Name, the Merchant's Bank/Processor Membership number or a Merchant's Legacy Financial Account number in a file with other Merchant data so that this information would only need to be entered once. The Buyer could enter payment data and the 2 digit transaction number every time. The Merchant would wait until they received a payment receipt before matching the 2 digit transaction number to an open invoice for the same payment or payment plus Tip. The Financial Transaction process described herein would only requires a single trip to the table by the Merchant's waiter, for example.
[0077] While the methods described and suggested above are all improved and effective methods of processing a Financial Transaction and have benefit for both the Merchant and the Buyer, yet another alternative method is contemplated that is a compromise between the Legacy Financial Card method and the New Innovative Financial Transaction Methods discussed above. Bank/Processors, ISOs and other Financial Card Market participants are part of an industry the issues Financial Cards. The Financial Transaction for those cards normally involves a Bank or Processor to conduct and settle the monetary portion of the transaction. The Bank/Processor typically has a software application that runs on secured computer servers and data networks that normally connect to Merchant POS systems including brick and mortar, phone and internet sales. For the vast majority of Financial Transactions, this process is automated and does not require human intervention. It is the Bank/Processor that writes or has written the Software that provides this service. Of course the software and system involved must be approved by relevant agencies to participate in this industry.
[0078] The methods described above require some changes to the Bank/Processor software application in order to provide the features and benefits noted in the discussion including the additional services surrounding new Merchant marketing potential. There are also potential minor changes to POS Hardware firmware and POS Computer System software required for some of the noted methods. The following alternative Financial Transaction process will not require any changes on the part of the Merchant or the Merchant's POS Hardware firmware or the POS Computer System software. An alternative method is described below with reference to FIG. 6 .
[0079] According to this alternative method, a Legacy Financial Card can be used in a method for initiating a Financial Transaction. A standard plastic credit, debit, prepaid or gift card's magnetic stripe can be used for this method. A card Financial Account number will have been issued by a Bank/Processor running a software program that has implemented the features of the following method. A 16 digit Legacy Financial Account PAN number can be in a class of cards where all the cards in the class will use this method and such number can include features or a single card's 16 digit Legacy Financial Account PAN number can be tagged in the Bank/Processor database to use this method's features. This method may expose a Buyer's personal (Name) and account information to a Merchant or other potential identity thieves if a credit, debit or named prepaid card is used. The risk, however, is low since any Financial Transaction using a card protected by this method of transaction will not be completed without a communication from a card holder's Mobile Phone agreeing to the transaction.
[0080] A Merchant would prepare an invoice for the Buyer denoting the goods and services purchased with the tax included and provide this invoice or minimally provide the total required payment to the Buyer. A Buyer, using a Bank/Processor issued Financial Card, could provide the card to the Merchant for swiping in their POS hardware or swiping the card themselves. The Merchant POS Hardware or POS Computer System would initialize a traditional Financial Card transaction. The firmware in the POS terminal or the software in the POS Computer System would then preferably electronically send the data onto the Financial Card Payment Network and be routed to the Bank/Processor. From the magnetic stripe, the Bank/Processor will receive, at a minimum, the Merchant's name and account data, the Buyer's 16 digit card Financial Account number, the expiration data, the CVV code and the Payment data. Additional data contained on the magnetic stripe and general data included by the POS hardware, firmware could also be sent. Using this data, the Bank/Processor's software application can recognize the Financial Transaction as an Innovative New Financial Transaction and proceed as controlled by the Bank/Processor's software program. The Bank/Processor can then match the Buyer's Bank/Processor 16 digit Financial Account card number to information in their database and then format a message that has the Merchants name, the payment data supplied by the Merchant and preferably send this data to the Bank/Processor application on the Buyer's Mobile Phone.
[0081] A Buyer can receive the Merchant's invoice, add a Tip in a Popup Window if desired and press “Y”, for example, to accept the transaction or “N”, for example, to decline the transaction. By pressing “Y” the Buyer can also be assigning an electronic signature to the Financial Transaction. The Bank/Processor application will preferably send the Tip data, if any and the Y or N to the Bank/Processor via the cellular network or a Wi-Fi connection if so enabled. If the Transaction is accepted, the Bank/Processor can use standard Legacy Financial Card processing methods to authorize the Financial Transaction and facilitate the debiting and crediting of accounts for various parties participating in the Financial Transaction. Assuming that the transaction is authorized, the Bank/Processor can send a receipt for the Financial Transaction to the Merchant's POS Hardware or the POS Computer System and to the Buyer's Mobile Phone as shown in FIG. 6 . In the case where the Financial Transaction is rejected by the Buyer or not authorized by the Bank/Processor, the Bank/Processor can return a message to the Merchant with information describing the reason for the transaction rejection using Financial Card Legacy rejection methods. The Bank/Processor can also send a message to the Buyer's Mobile Phone with information describing the reason for the transaction rejection.
[0082] This method is advantageous by providing a safe method for the Buyer to complete the transaction but the transaction can be accepted by any Merchant that process Financial Cards. The Merchant not only does not need a membership with the Bank/Processor or be required to update POS Hardware, firmware or POS Computer System software; they don't even need to know that the Financial Transaction processing is non-standard. The innovative Financial Transaction process described here within only requires a single trip or other effective communication to the Buyer by the Merchant's service provider.
[0083] According to another aspect of the present invention, the power and attraction of open-loop cards or Mobile Phones can be more effectively utilized. This aspect of the present invention utilizes open loop networks and preferably utilizes a Mobile Phone in place of a card. A problem with using a Mobile Phone in the current card swiper environment is that a Mobile Phone does not have a magnetic stripe that can be read to initiate the transaction. The data located in the magnetic stripe of a card and added by the Merchant should identify the Buyer, the Merchant, an open loop network, a Processor of said transaction, a Bank of the Merchant and a Bank account of the Buyer from which the funds will be used to pay for the transaction. The magnetic stripe on the card is “swiped” or read by a point of sale device and the information and Merchant data is passed through the open loop network to the Banks for payment. The company that is responsible for the transmission of this data is called a “Processor.” This aspect of the present invention addresses a Buyer point of sale transaction or “front end” and the Merchant processing transaction or “back end” of such a transaction.
[0084] As describe above in the Background section, Financial Cards are expensive to produce, easy to defraud and contribute to identity theft. Since most people have many different Financial Accounts they need to carry multiple cards, which is burdensome and increases the risk of losing a purse or billfold. One solution is to include Financial Account information within and to be displayed on a screen of a Mobile Phone and to use secure electronic data transfer steps to transfer the account and personal information. It is preferable in accordance with the present invention to provide variable data that can be uploaded with the Financial Transaction that would trigger modifications to the Financial Transaction. Also, it would be beneficial for a Merchant that uses a POS Computer System to be able to modify the magnetic stripe data before uploading the Financial Transaction and/or for a Mobile Phone to modify the data before uploading the Financial Transaction. Manners of achieving these desired results are described below.
[0085] According to this aspect of the present invention, desired solutions to present problems are addressed by adding features to standard Financial Transaction system methods, hardware, software and transactional capability. This process will reduce the cost and increase the speed of implementation, add Financial Transaction beneficial features that would otherwise not be available and be more transparent in the entire process.
[0086] It should also be noted that the end result of this process is a modified Financial Transaction in some of the process steps. A Buyer can buy an article or service and receive some sort of consideration for that purchase. The consideration may be a reduction in cost, a reduction in cost on a later purchase, loyalty rewards, payment options or other means of modifying the Financial Transaction that is beneficial to the Buyer. In the past the Merchant would need a means of implementing the Financial Transaction modification. For example, a Buyer would present a coupon, ticket or gift card, the POS clerk would scan or hand enter data on the coupon, ticket or gift card into the POS system, the Buyer could be asked to sign or provide other means of identity, the clerk hopefully would do all that is required to fulfill the modified transaction. The Buyer, if alert, would check the receipt to be sure the transaction was correct. This all takes time for both the clerk and Buyer and has a real chance of failure.
[0087] The aspect of the process of the present invention is within a conducting of a Financial Transaction including modified Financial Transactions, not at the point of sale, but at the financial Processor. The financial Processor could discount purchases, redeem gift cards or tickets, debit or credit loyalty points, record future discounts and the like, all of which will take place in the processing of a Mobile Phone Financial Transaction (hereafter Phone Transaction) and change the processing method and actions taken based data received from the Merchant and Buyer.
[0088] In order to implement the core inventive Financial Transaction process, a first step is to assure that the process is implemented at the point of sale. An assumption is that the Financial Transaction is routed to a Processor that has a modified Financial Transactions processing software enabled. A 16 digit PAN Financial Account number controls the routing of the Financial Transaction to the Processor and other parties. There are multiple methods of accomplishing the routing of the required data including those noted as follows.
[0089] For Financial Transactions that take place using a Legacy Financial Card with a Legacy PAN Financial Account and account data, a POS Computer System could be used to modify the Account Data String being sent to the Processor as a Modified Account Data String. Since the Legacy account data would be only that required for a Legacy Financial Transaction, the POS Computer System could make the changes to the Account Data String being uploaded to the Processor. Note that even if the transaction is a phone transaction, the account data can be modified to process additional features before being uploaded to the financial Processor.
[0090] For smaller Merchants where there is no connected POS Computer System and the Financial Transaction is entered via a POS device such as a VeriFone VX series POS device, as is currently commercially available from Verifone Systems Inc. of San Jose, Calif., the VX series can be enabled to read a Mobile Phone displayed 2D code that contains the Modified Account Data String or any other means that allows the electronic transfer of data to the POS Hardware. For example, the reader device for electronically readable data is connected to the RS232 port on the Verifone VX series reader and enters the account data into the VX device no differently than having swiped a Financial Card. No additional software (firmware) or hardware modifications at the point of sale are required to implement this method.
[0091] A method that could also be conducted and effective is the sending the Merchant number, Financial Account and the transaction modification variable data directly from the Mobile Phone to the Processor. This option is discussed in more detail below.
[0092] The next step is the modification of an Account Data String. While there are many schemes that would work inside of processes of the present invention, an exemplary method would be to use a scheme that verified the Merchant, identified the program/s that are to be applied to the transaction and added variable program data such as percentage off, monetary value of the discount, points to be awarded of debited, expiration dates and the like. An Account Data String for a magnetic stripe is illustrated in FIG. 7 as including a track 1 and a track 2. For example track 1 of the Account Data String could include in addition to the Legacy financial account data: the following: (3) 6 bit characters that identify the Merchant; and (6) 6 bit characters that identify the program/s for a particular Merchant. Track 2 could include: (9) 4 bit characters that would contain the variable data for the particular Merchant programs. Track 3 could include: up to (104) 4 bit characters. The character strings would be positioned in order to identify correct values for each program control.
[0093] According to the illustrated magnetic stripe tracks 1 & 2 sample data string, the “Z”s denote variable transaction modification data. Account data can be modified either in the POS computer or on the Buyer's Mobile Phone within the scope of this invention.
[0094] A third step is as follows. A first procedure for Mobile Phone transactions would be a step of downloading transaction modification programs to the Mobile Phone. Phone applications on the Mobile Phone, specific to the Merchant, a group of Merchants or all holders of a given type of Financial Account, for example, would process the transaction modification programs. The phone application/s would preferably manage any marketing collateral such as coupons, discounts, loyalty promotions and the like from the Merchant's or account provider. The phone application software could be downloaded through various common means and loaded into the phone as an application. Certainly the phone application could have other features that are outside the scope of this application. A big advantage to the Buyer is that they no longer need to cut out and have coupons on hand, VIP cards, specials for the newspaper or TV or any other cost savings method that requires an activity on their part. Any transaction modification program cost reduction or other benefit, on their phone or in conjunction with the card Processor and Merchant, can automatically be applied to the sale during the transaction at the Processor.
[0095] The next step is the transfer of data from a Mobile Phone to a POS Computer or the PUS device at the point of sale. The scope of the present invention includes any means of transfer where data on the phone is electronically sent to the POS Computer or the POS device at the point of sale such as the use of Bluetooth, WiFi, Audio, infrared, 2D Code reader and the like. An exemplary means is the use of a 2D code such as is illustrated in FIG. 8 . Veritec phone reader, FM200, as commercially available from Veritec Inc. of Golden Vallery, Minn., for example, is an ideal, low cost choice for a 2D code reader device that can be directly connected to the POS Computer or the POS device at the point of sale without the addition of software or changes to hardware.
[0096] Note that another step of the present invention is to send account data with the transactional modification variable data or a 2D code containing the data directly to the Processor from the Buyer's Mobile Phone using a Merchant number assigned by the Merchant phone application. As above, a Merchant could send data to the Processor but without the Buyer's Bank/Processor Membership Number. The difference is the Modified Account Data String that will effect changes to a Financial Transaction being processed or the method of processing the transaction.
[0097] A process of the present invention can include the following steps. First, a Merchant could send, via electronic means, a Merchant number and an itemized bill or summary of the bill to a Processor. The Processor would reply to the Merchant, such as via electronic means, with a 2 to 5 digit code, for example, that would be the identification number for the transaction. Then, the Merchant could provide the Buyer an itemized receipt with the 2 to 5 digit code or any other means that would provide the Buyer the 2 to 5 digit code. After that, the Buyer would preferably enter the 2 to 5 digit code into an application running on their phone that would send the 2 to 5 digit code, such as via electronic means, the Buyer's Financial Account data, the Modified Account Data String transactional modification variable data if any such offerings are on the phone for a particular Merchant or group of Merchants and a key enabled data point for a tip if desired to the Processor. Then, the Processor could match the 4 digit number to the data received from the Merchant and, if a match is found, modify the transaction according the modification variable data from either the Merchant or Buyer, and send, via electronic means, the Buyer details of the transaction to the Buyer's Mobile Phone application allowing the Buyer to refuse or accept the transaction by sending or not sending an acceptance or refusal to the Processor via the Buyer's Mobile Phone. Based on an acceptance, send, via electronic means, the Merchant the transaction completion data and the Buyer a receipt to the Buyer's Mobile Phone or based on a refusal a refusal message to both the Merchant and the Buyer's Mobile Phone. The Merchant could also issue a paper receipt and provide said receipt to the Buyer including the requirement for a signature after receiving the transaction completion data.
[0098] Alternatively, a linear barcode or a 2D barcode, containing Merchant identification number, can be printed on a placard or electronically displayed at the point of sale or on a printed receipt supplied to the Buyer. The Buyer can initiate a transaction by reading the Merchant code, such as using the phone's camera, with a barcode reading application loaded on the phone. The Merchant's identification code and the Buyer's Modified Account Data String or Account Data String can then be sent to the Bank/Processor, via the Buyer's Mobile Phone where the Merchant and Buyer are identified by the Processor and the account of the Buyer from which the funds will be used to pay for the transaction. A unique purchasing phone code can be generated and sent to back to the Buyer's cell phone. This unique purchasing code preferably contains a preauthorization for the transaction. Items to be purchased can then be tabulated on the Merchant's cash register and the POS code reader can be prompted to receive authorization for payment. The Mobile Phone display may then be placed on the reader and the transaction is authorized or the Merchant can manually read the purchasing code from the phone display.
[0099] Yet another alternative is for the Merchant to produce a 2D code or other electronically readable data method that contains the Merchant identification, the itemized or summary bill, transactional modification variable data and any other pertinent data which is then shown on a POS device display or printed on a Buyer receipt. The Buyer can initiate a transaction by reading the Merchant code, such as using the phone's camera, with an application loaded on the phone. The application adds to the Merchant data the Buyer's Modified Account Data String data or Account Data String, the transactional modification variable data if any such offerings are on the phone for a particular Merchant or group of Merchants and a key enabled data point for a tip if desired which is all sent to the Processor via electronic means. The Processor would preferably process the data and modify the transaction according the modification data from either the Merchant or Buyer, send the Buyer details of the transaction to the Buyer's Mobile Phone allowing the Buyer to refuse or accept the transaction by sending or not sending an acceptance or refusal to the Processor via the Buyer's Mobile Phone. Based on an acceptance, send the Merchant, via electronic means, the transaction completion data and the Buyer a receipt to the Buyer's Mobile Phone or based on a refusal a refusal message to both the Merchant and the Buyer's Mobile Phone. The Merchant could also issue a paper receipt and provide said receipt to the Buyer including the requirement for a signature after receiving the transaction completion data.
[0100] Note that the same steps and actions in the alternatives could occur using a computer rather than a Mobile Phone for transactions where the Buyer is or is not present at the Merchants location and the Buyer receives the 2 to 5 digit code or other data via his computer and sends his required Financial Account data to the Processor via his computer and receives data back from the Processor via his computer. The same is true for a Buyer not present where the Buyer receives the 2 to 5 digit number or other data including a 2D Code via voice on their phone or a phone text message and completes the transaction as above using their Mobile Phone.
[0101] Also note that transaction completion data could take the same form as a traditional Financial Card transaction where data is returned to a POS device or to the Merchant's computer where software in the computer completes the transaction details or any method that supplies the Merchant the data required to complete the transaction. Also note that the alternatives can be combined is such ways that the novel aspects are maintained in the inventive method and individual steps inside the alternative methods can be eliminated while still maintaining the other steps as inventive steps
[0102] A further step is the upgrading of a processing center to house all of the software required to implement the transaction from transactional modification variable data. The transaction will be handled like a restaurant transaction where an authorization hold is placed on funds until the Buyer has a chance to verify the transaction and modify the transaction if required (the Merchant will also have a chance to verify the final transaction value). The processing center application will next direct returned data to the Merchant's POS and the Buyer's Mobile Phone for verification and approval or modifications. When the Buyer and Merchant are satisfied, then a second transaction is registered that completes the finalized transaction. The Processor can send receipt data to the Buyer's Mobile Phone and the Merchants POS computer or device. Any additional checks, such as being sure the transactional modification variable data has not expired or has already been used, the account holder has funds in the account to complete the transaction, because of the large value of the transaction additional card holder identification is required or any other requirements for the transaction completion are fulfilled.
[0103] The transactional modification variable data can determine which program will be called in the Merchant phone application and additional variable data may also be applied to determine the values of a transaction modification. A Merchant sale transaction can be completed with adjustments as dictated by the transaction modification program. For phone tickets or phone gift cards the Processor fulfillment will behave as if the transaction is a stored value card and the debiting and crediting of accounts will be handled the same as if it were a stored value card. Loyalty or other such programs would be handled as prescribed by the phone application software and variable transaction modification data debiting and crediting points or monetary values. There is nothing in the process of the present invention that will stop a normal Financial Card or phone transaction from being completed without the use or availability of transactional modification variable data at an upgraded processing center.
[0104] Within the scope of the invention are other transactions such as extended payments, future value such as any amount off the next transaction with the Merchant, medical payments such as co-pay and variable prescribed drug costs and automated deductions such as a percentage for senior citizens. The number of transactional and service possibilities is numerous.
[0105] In FIG. 9 , a Legacy Financial Card Transaction is illustrated. As shown, the terms Acquirer and Issuer have the functions of the Bank/Processor in this disclosure. This Legacy Financial Transaction method has only the steps shown with no modification allowed to either the monetary or other real value of the or Financial Transaction or the method of processing the Financial Transaction. The Financial Transaction methods of the present invention would allow either the Acquirer or the Issuer to act as the Bank/Processor and make modifications to the Financial Transaction being processed or the method of processing the Financial Transaction based on the Modified Account Data Strings sent to a Bank/Processor.
[0106] Steps of using such a card include, the cardholder presenting the merchant with a credit card for payment. A merchant POS terminal reads the account number and other data encoded on the card's magnetic stripe or chip. The merchant terminal transmits the card information and transaction amount to the acquirer. Then, the acquirer combines the transaction information into an authorization request message and transmits to an open loop network provider. They then route the authorization request to the issuer for review. The issuer send an authorization response back to the open network either approving or denying the transaction. This message is routed back to the acquirer, and the acquirer transmits the result of the authorization request to the merchant terminal.
[0107] A magnetic stripe card is a type of card capable of storing data by modifying the magnetism of tiny iron-based magnetic particles on a band of magnetic material on the card. The magnetic stripe, sometimes called swipe card or magstripe, is read by physical contact and swiping past a magnetic reading head. A number of International Organization for Standardization standards, ISO/IEC 7810, ISO/IEC 7811, ISO/IEC 7812, ISO/IEC 7813, ISO 8583, and ISO/IEC 4909, define the physical properties of the card, including size, flexibility, location of the magstripe, magnetic characteristics, and data formats. The magnetic stripe contains three tracks, each 0.110 inches (2.79 mm) wide under conventional standards. Point-of-sale card readers almost always read track 1, or track 2, in the case that one track or the other is unreadable. The tracks of a magnetic stripe as including aspects that are used in accordance with the present invention are comprised as follows.
[0108] Track 1, Format B: 7-bit alphanumeric characters—210 bits per inch
Start sentinel—one character (generally ‘%’) Format code=“B”—one character (alpha only) Primary account number (PAN)—up to 19 characters. Usually, but not always, matches the credit card number printed on the front of the card. Field Separator—one character (generally ‘̂’) Name—two to 26 characters Field Separator—one character (generally ‘̂’) Expiration date—four characters in the form YYMM. Service code—three characters Discretionary data—may include Pin Verification Key Indicator (PVKI, 1 character), PIN Verification Value (PVV, 4 characters), Card Verification Value or Card Verification Code (CVV or CVK, 3 characters) End sentinel—one character (generally ‘?’) Longitudinal redundancy check (LRC)
Track 2: 5-bit scheme (4 data bits+1 parity), 0-9, plus the six characters : ; <=>?
Start sentinel—one character (generally ‘;’) Primary account number (PAN)—up to 19 characters. Usually, but not always, matches the credit card number printed on the front of the card. Separator—one char (generally ‘=’) Expiration date—four characters in the form YYMM. Service code—three digits. The first digit specifies the interchange rules, the second specifies authorization processing and the third specifies the range of services Discretionary data—as in track one End sentinel—one character (generally ‘?’) Longitudinal redundancy check (LRC)—it is one character and a validity character calculated from other data on the track. Most reader devices do not return this value when the card is swiped to the presentation layer, and use it only to verify the input internally to the reader.
Track 3: Track 3 can be encoded with at 210 bits per inch equaling 107 digits of the numbers 0-9, plus the six characters : ; < >?.
[0128] While the detailed drawings, specific examples, and particular formulations given here within described exemplary embodiments, they serve the purpose of illustration only. It should be understood that various alternatives to the embodiments of the invention described maybe employed in practicing the invention. It is intended that the following claims define the scope of the invention and that structures within the scope of these claims and their equivalents be covered thereby. The materials, constructions, methods and configurations shown and described may differ depending on the chosen performance characteristics and physical characteristics of the transactional modification variable data program and its use. For example, the types of materials, constructions, security features, electronically readable data methods used may differ. The descriptions here within are not limited to the precise details and conditions disclosed. Method steps provided may not be limited to the order in which they are listed but may be ordered any way as to carry out the inventive process without departing from the scope of the invention. Furthermore, other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangements of the exemplary embodiments without departing from the scope of the invention as expressed in the appended claims. | Disclosed are methods and processing techniques for modifying or changing a financial transaction that is being processed, such as for the purchase of goods or services. Methods of the present invention, in particular, relate to methods including the ability to use fixed or variable data, as such data is sent to a financial transaction processor, in order to modify the transaction, and thus changing the financial transaction that is being processed or the method of processing the financial transaction. The modifications that are made to the transaction enhance security to the buyer by disclosing less data during the transaction for others to potentially gain access. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application incorporates by reference and claims priority to U.S. Provisional Patent Application No. 61/333,881 filed May 12, 2010.
BACKGROUND OF THE INVENTION
The present subject matter relates generally to shelving system. More specifically, the present invention relates to a multi-element, multi-position shelving system.
Shelves and shelving units are ubiquitous staples in commercial and residential design and space management. Shelves may serve aesthetic and functional purposes promoted by the materials, the geometry, the configuration, the ornamentation, etc.
Shelves often occupy wall space and/or floor space. In many environments, wall space is a prime location for visual art. In addition, floor space is often a desirable feature. To the extent a shelving unit may be adaptable to serve aesthetic and utilitarian purposes, optimizing the use of wall space between visual art and storage/function while optimizing the floor space for functionality, it may be a functional improvement over the numerous existing shelves and shelving units.
Accordingly, a need exists for a shelving system that is adaptable to serve aesthetic and utilitarian purposes, optimizing the use of wall space between visual art and storage/function while optimizing the floor space for functionality.
BRIEF SUMMARY OF THE INVENTION
The shelving system disclosed herein is adaptable to serve aesthetic and utilitarian purposes, optimizing the use of wall space between visual art and storage/function while optimizing the floor space for functionality.
In one example, a shelving system includes a plurality of pivoting shelves, each independently adapted to be positioned in a horizontal or vertical position. The shelves are pivotally mounted to one or more rails that are anchored to a wall or similar approximately vertical element. The shelving system may be adapted to include visual art independently displayed on each shelf when each shelf is placed in the approximately vertical position. Alternatively, a plurality of shelves may be grouped to display a composite piece when two or more of the shelves are placed in the approximately vertical position. The shelves can be grouped horizontally, vertically or otherwise arranged to form an approximately two or three dimensional composite form. Various shelf designs may be employed and visual art may be adapted to be displayed via the shelves using numerous techniques.
In another example, one or more shelves in the shelving system may be adapted to provide approximately horizontal and/or vertical work surfaces for a user. For example, shelves may provide approximately horizontal work surfaces for supporting items, such as computers, etc. In another example, shelves may provide approximately vertical work surfaces, such as dry-erase boards, corkboards, etc. It is understood that the shelving system may be adapted for use as a workspace in any number of environments, including, but not limited to as a kiosk for inputting golf scores in a club house, data entry in an office space, or for a registry in retail environment. Other examples of uses for the shelving system are in a library to resource books or in a work space where a group may plug in their laptop computer and view work together. The shelving system may be useful anywhere temporary or ad-hoc workspaces or storage may be desired.
Various mechanisms may be provided to secure the shelves in either the approximately horizontal or vertical position and further to secure the shelves to the rails. Moreover, various mechanism may be provided to secure items to the shelves, both the approximately vertical surfaces (e.g., visual art, work surfaces, etc.) and the approximately horizontal surfaces (e.g., items displayed on the shelves, such as electronics, jewelry, 3D artwork, etc.). Further, accommodations for cord management may be incorporated in the shelving system to better facilitate the use of the shelving system with electronic equipment. A modular shelving system includes: a rail including a plurality of mounting holes; a plurality of shelves, each shelf including a pair of pivot pins; a plurality of pivots removably secured to the rail, wherein each pivot receives at least one pivot pin such that each of the shelves are rotatably supported on the rail between a corresponding pair of pivots; and a plurality of covers covering the rail and spanning the distance between each corresponding pair of pivots. The shelves each include a portion of a piece of visual art, such that when each of the shelves is positioned approximately vertically, the portion of the visual art is displayed and further such that when all of the plurality of shelves are positioned in the approximately vertical position, the entirety of the visual art is displayed.
An advantage of the shelving system is visual art may be displayed when one or more shelves are in the vertical position.
Another advantage of the shelving system is floor space may be conserved when one or more shelves are in the vertical position.
A further advantage of the shelving system is in providing an adaptable composite visual aesthetic.
Yet another advantage of the shelving system is in providing temporary and/or ad hoc workspace.
Still another advantage of the shelving system is in providing a visually appealing functional solution for commercial and residential space management.
Additional objects, advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The objects and advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.
FIG. 1 is a perspective view of an example of a shelving system as disclosed herein.
FIG. 2 is a perspective view of the shelving system shown in FIG. 1 , wherein several of the shelves are positioned horizontally to hold items thereon and other shelves are positioned vertically.
FIG. 3 is an exploded view of another shelving system as disclosed herein.
FIG. 4 is an exploded view of a rail and pivot attachments of the shelving system shown in FIG. 3 .
FIG. 5 is a cross-sectional side view of a rail and cover attachment from the shelving system shown in FIG. 3 .
FIG. 6 is an exploded perspective view of a shelf of a shelving system as disclosed herein.
FIG. 7 is an exploded perspective view of another shelf of a shelving system as disclosed herein.
FIG. 8 is a cross-sectional side view of the shelf shown in FIG. 7 .
FIG. 9 is a perspective view of another shelf of a shelving system as disclosed herein.
FIG. 10 is a side view of another shelving system as disclosed herein.
FIGS. 11 and 12 are perspective views illustrating how the shelf shown in FIG. 10 mounts within the shelving system.
FIGS. 13A and 13B are perspective views of another shelf of a shelving system as disclosed herein.
FIG. 14 is a perspective view of another shelf of a shelving system as disclosed herein.
FIG. 15 is a perspective view of another shelf of a shelving system as disclosed herein.
FIG. 16 is a perspective view of another shelf of a shelving system as disclosed herein.
FIGS. 17-19 are cross-sectional side views of various locking mechanisms for use in shelving systems as disclosed herein.
FIGS. 20-21 are perspective views of a preferred embodiment of the shelving system.
DETAILED DESCRIPTION OF THE INVENTION
The shelving system 10 shown in FIG. 1 includes a plurality of shelves 12 . In the example shown in FIG. 1 , the shelving system 10 includes twenty shelves 12 , each shown in a vertical orientation. As shown, the each of the shelves 12 cooperates to display a visual image, wherein each shelf 12 contributes to the overall composition.
FIG. 2 illustrates the shelving system 10 shown in FIG. 1 , with four of the shelves 12 shown in a horizontal orientation. As shown, the horizontally oriented shelves 12 are configured to support items, while the remaining vertically oriented shelves 12 cooperate to display a portion of the visual image. As shown, any number of the shelves 12 in the shelving system 10 may be oriented vertically or horizontally.
FIG. 3 illustrates another example of a shelving system 10 . In the example shown in FIG. 3 , the shelving system 10 includes: a plurality of shelves 12 ; a plurality of rails 14 , including mounting holes 16 ; a plurality of anchor bolts 18 securing the rails into the wall; a plurality of middle pivot supports 20 ; a plurality of end pivot supports 22 ; set screws 24 attaching the pivot supports 20 and 22 to the rails 14 ; and a plurality of covers 26 . Some of the elements of the shelving system 10 are shown in a closer view in FIG. 4 .
In the example shown in FIGS. 3 and 4 , there are four rails 14 anchored to the wall. Each of the rails 14 supports a group of four shelves 12 . However, it is understood that any number of rails 14 can support any number of shelves 12 . In addition, the rails 14 may be configured in number and geometry to form various shapes and proportions. Further, the shelves 12 may be provided in varying sizes and shapes such that the combination of shelves 12 may be used to provide various configurations and visual effects.
As shown in FIGS. 3 and 4 , the pivot supports 20 and 22 are configured as middle pivot supports 20 and end pivot supports 22 . In the example shown, the middle pivot supports 20 are approximately twice as wide as the end pivot supports 22 in order to support two shelves 12 with each middle pivot support 20 . However, it is understood that in certain embodiments, the pivot supports 20 and 22 may be identically designed.
The pivot supports 20 and 22 may be securely attached to the shelving system 10 using clips, screws or a locking mechanism to help prevent dislocating during seismic activity, user collision or theft.
The covers 26 shown in FIGS. 3 and 4 are used to provide an aesthetic cover to the rail 14 when the shelving system 10 is assembled. In addition, the covers 26 may protect the accidental or intentional tampering with the anchor bolts 18 holding the rail 14 to the wall. It is understood the cover 26 may increase the durability and the attractiveness of the shelving system 10 . However, alternate examples of the shelving system 10 may or may not include covers 26 .
In the examples shown in FIGS. 3 and 4 , the cover 26 serves the functional purpose of limiting the rotation of the shelves 12 . When the shelf 12 is rotated to the approximately horizontal position, the top surface of the shelf 12 comes into contact with the cover 26 , which prevents further rotation of the shelf 12 and maintains the shelf 12 in the horizontal position. It is contemplated that in other embodiments of the shelving system 10 , the rotation of the shelf may be limited by the rail 14 or by other mechanisms.
The shelves 12 shown in FIG. 3 include pivot pins 28 which pivotally attach the shelves 12 to the pivot supports 20 and 22 , as described further herein.
The example of the shelving system 10 shown in FIGS. 3 and 4 is substantially formed from extruded aluminum. For example, the rails 14 and the shelves 12 may be formed from extruded aluminum. However, it is understood that the shelving system 10 may be formed from any number of materials and combination of materials. For example, the shelves 12 may be made from sheet aluminum or sheet steel. Alternatively, the shelves 12 may be made from formed aluminum. Additionally, the shelves 12 and/or rail 14 may be formed from wood. It is further understood that the shelving system 10 may incorporate elements made from polymers, composites, carbon fiber, etc.
FIG. 5 is a cross-sectional view of a shelving system 10 where a middle pivot support 20 attaches to a rail 14 . As shown in FIG. 5 , the pivot support 20 provides a channel 30 within which the pivot pins 28 of the shelves 12 may be supported. As shown, the width of the channel 30 at the top of the channel 30 may be narrower than the width deeper into the channel 30 . The narrowest width of the channel 30 may be approximately the same dimension as or slightly narrower than the diameter of the pivot pins 28 . Accordingly, the channel 30 may secure the pivot pins 28 in a snap-fit mechanism. The materials used to construct the pivot supports 20 and 22 and/or pivot pins 28 may further effect the snap-fit attachment.
Although shown as a snap-fit attachment between pivot supports 20 and 22 and pivot pins 28 , it is contemplated that the shelves 12 may be supported in any number of ways that enable the shelves 12 to pivot between an approximately horizontal and an approximately vertical orientation.
It is contemplated that the shelving system 10 may be implemented in environments where the “vertical” wall is not actually vertical. In these environments, the pivot supports 20 and 22 may be configured to allow the shelves 12 to pivot between vertical and horizontal. Alternatively, the pivot supports 20 and 22 may be adapted to allow the shelves 12 to pivot between parallel to the wall surface and horizontal, to support items on the shelves 12 , whether the angle between the two is less than or greater than ninety degrees. It is further understood that the shelves 12 may be adapted to pivot between additional positions and orientations.
FIG. 6 illustrates and exploded view of a shelf 12 made from the combination of an extruded aluminum base 32 and a shelf body 34 formed from sheet aluminum. Additionally, the shelf 12 shown in FIG. 6 includes adhesive vinyl artwork 36 to be attached to the shelf 12 . FIG. 6 is merely one example of a shelf 12 that may be incorporated into the shelving system 10 and merely one example of attaching artwork to a shelf 12 . For example, the artwork may be etched into the shelf 12 or otherwise incorporated into the shelf 12 itself.
FIGS. 7 and 8 illustrate another example of how artwork may be attached to a shelf 12 . In the example shown in FIGS. 7 and 8 , the shelf assembly includes an artwork sheet 38 that is secured to the shelf 12 by a formed clear acrylic protective sleeve 40 . The assembly shown in FIGS. 7 and 8 is an example of a shelf 12 that may facilitate interchanging of artwork sheets 38 .
FIG. 9 illustrates another example of how artwork may be attached to a shelf 12 . In the example shown in FIG. 9 , the shelf assembly includes an artwork sheet 38 that is secured to the shelf 12 by a formed clear protective sheet 42 . The protective sheet 42 slides into the shelf 12 in channels 44 to secure the artwork 38 sheet therein. The assembly shown in FIG. 9 is another example of a shelf 12 that may facilitate interchanging of artwork sheets 38 .
The protective sleeve 40 and the protective sheet 42 are merely two examples of protective covers for protecting artwork from physical and/or from UV degradation. It is further contemplated that other configurations of protective covers may be employed in the shelving system 10 . Alternative embodiments may be clear, may be translucent and/or colored, or may be the artwork themselves.
FIG. 10 illustrates an example of a shelving system 10 in which a magnet 46 is used to secure the shelf 12 in the vertical orientation. The shelf 12 shown in FIG. 10 is formed from steel or other ferromagnetic material. The use of a magnet 46 and a ferromagnetic shelf 12 enable the shelf 12 to be secured in an upright position without it accidentally moving out of the upright position. A further advantage of using a ferromagnetic shelf 12 is that the shelf 12 may be used with magnetic artwork, signage, tiles, panels, etc. It is further contemplated that other securing mechanisms may be employed to secure the shelf 12 in one or more orientations.
FIGS. 11 and 12 illustrate how a shelf 12 mounts within the channel 30 of an end pivot support 22 . As described above, the pivot pin 28 of the shelf 12 may be lowered into the channel 30 and snapped into place. The shelf 12 may then rotate freely between a vertical and a horizontal orientation, with the magnet 46 securing the shelf 12 in the vertical orientation.
FIGS. 13A and 13B illustrate one example of a security bracket 48 that may be secured to the shelving system 10 , for example, by bolting the security bracket 48 to the cover 26 with a security bolt 50 . In the example shown in FIGS. 13A and 13B , the security bolt 50 passes through the rail 14 and anchors into the wall. The security bracket 48 enables valuable items to be secured to the shelving system 10 , such as, for example, such as electronics, jewelry, 3D artwork, etc.
FIG. 14 illustrates an example of how a shelving system 10 may be adapted for use with electronic equipment. In the example shown in FIG. 14 , a slot 52 is provided where the shelf 12 abuts the cover 26 such that an electronic cord 54 may be neatly passed through the shelf 12 . In other contemplated examples, the cord 54 may be passed within the cover 26 , within a covered channel (not shown) or other adapted cord management system.
FIG. 15 illustrates an example of a shelving system 10 adapted for use in a hot desking environment. As shown in FIG. 15 , the shelving system 10 includes various sizes of shelves 12 , including a wide shelf 12 for use as a horizontally oriented workspace. In addition, the shelving system 10 includes a white board 56 and a corkboard 58 , each of which provides a vertically oriented workspace. The remaining shelves 12 include artwork to form composite visual art. The shelving system 10 shown in FIG. 15 may be particularly advantageous in environments in which temporary desks or workspaces may be needed.
FIG. 16 is an example of a shelving system 10 that may be of particular use in a retail environment. As shown in FIG. 16 , the shelves 12 may incorporate an opening 60 from which hangers may be suspended. Accordingly, a unique configuration of hanging clothes may be arranged within visual art. The shelving system 10 shown in FIG. 16 may also be advantageously used in a hotel room where the shelving system 10 provides visual art and functional shelving and hangers for hanging clothing.
FIGS. 17-19 illustrate examples of locking mechanisms 62 that may be employed to assist in holding the pivot pin 28 within the channel 30 of the pivot support 20 or 22 . The examples shown demonstrate that various configurations of locking mechanisms may be employed, for example, to resist seismic events. In the example shown in FIG. 19 , the pivot support 20 or 22 includes a slot 64 for receiving a slide in locking mechanism 62 . As shown, any number of locking mechanisms 62 may be employed to secure the pivot pin 28 in the channel 30 .
In the embodiments of the shelving system 10 shown in FIGS. 1-19 , the pivot supports 20 and 22 and the shelves 12 may be provided in fixed positions or may be slidable along the rail 14 to be arranged in various configurations. If slidable, the pivot supports 20 and 22 and the shelves 12 may be locked into place, for example, using anchors, locks, etc. The slidable shelves 12 make the shelving system 10 modular and/or mobile, while being attached to a wall.
It is further contemplated that various portions or combinations of the shelving system 10 described herein as separate elements, for example the rail 14 and the pivot supports 20 and 22 , may be formed as unitary elements.
A preferred embodiment of the shelving system 10 is shown in FIGS. 20 and 21 . As shown in FIGS. 20 and 21 , the shelving system 10 includes a plurality of shelves 12 ; a plurality of rails 14 , including mounting holes 16 ; a plurality of anchor bolts 18 securing the rails into the wall; a plurality of middle pivot supports 20 ; a plurality of end pivot supports 22 ; set screws 24 attaching the pivot supports 20 and 22 to the rails 14 ; and a plurality of covers 26 .
The example shown in FIGS. 20 and 21 , the pivot supports 20 and 22 include receiving holes 66 for receiving the pivot pins 28 , rather than the channels 30 shown in other illustrated embodiments of pivot supports 20 and 22 . As shown, the receiving holes 66 surround the pivot pins 28 and allow the shelves 12 to pivot freely within the pivot pins 20 and 22 . The receiving holes 66 allow axial rotation while preventing translation of the pivot pins 28 out of the pivot supports 20 and 22 .
As shown in FIG. 21 , the pivot supports 20 and 22 include set screws 68 threaded through the lower surface of the pivot supports 20 and 22 into the receiving holes 66 for interaction with the pivot pins 28 . The middle pivot supports 22 may include a pair of set screws 68 , one for each pivot pin 28 and the end pivot supports 22 may include a single set screw 68 for the single pivot pin 28 located therein.
In use, the pivot pins 28 may be located into the receiving holes 66 . Then, the corresponding set screws 68 may be tightened against the pivot pins 28 to create resistance to rotation. The tighter the set screws 68 are tightened, the more resistance there is to rotational movement of the shelves 12 . The set screws 66 may be tightened such that the shelves 12 are essentially “locked” into a given position.
Although described above with reference to numerous examples and variations, it is contemplated that there are nearly limitless configurations into which the inventive subject matter described herein may be incorporated. For example, the shelves 12 may be provided as frames into which a plurality of video screens (e.g., LCD screens) forming a composite display. The video screens may be adapted such that they are switched on when placed in the upright “viewing” position and off when positioned in the horizontal position. In another example, the shelves 12 may include an inductive charging station such that when the shelf 12 is in the vertical position the station is switched off and when the shelf 12 is in the horizontal position it may be used to inductively charge electronic devices placed thereon. Many additional examples will be apparent to those skilled in the art based on the disclosure provided herein.
It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. | A modular shelving system includes: a rail including a plurality of mounting holes; a plurality of shelves, each shelf including a pair of pivot pins; a plurality of pivots removably secured to the rail, wherein each pivot receives at least one pivot pin such that each of the shelves are rotatably supported on the rail between a corresponding pair of pivots; and a plurality of covers covering the rail and spanning the distance between each corresponding pair of pivots. The shelves each include a portion of a piece of visual art, such that when each of the shelves is positioned approximately vertically, the portion of the visual art is displayed and further such that when all of the plurality of shelves are positioned in the approximately vertical position, the entirety of the visual art is displayed. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus and method that provide positive mechanical control from the surface of a well, or from a drill ship or platform, of the release of plugs used during a cementing operation of a subterranean well.
2. Description of the Prior Art
As a step in the completion operation of a subterranean well, casing is run into the well and the annular area exterior of the casing and within the open bore thereafter is cemented to secure the casing within the well. Cementing plugs are utilized in the cementing operation and are run ahead of the cement slurry in order to wipe mud off the walls of the casing and to prevent cement from being contaminated with the drilling fluid previously circulated within the casing and the well. Such plugs are oftentimes run into the well within the casing and behind a cement slurry in order to close off check valves, open stage collars, and reclose stage collars during multi-stage cementing operations.
When subsea wells are completed utilizing drill ships or floating platforms, it is difficult to tie back the casing string to the surface of the platform or drill ship because of the motion between the platform or drill ship and the subsea well head. Typically, cementing operations under such conditions have incorporated cementing plugs which have been affixed to the bottom of the drill string by shear pins, collet releasing mechanisms, or the like. After the drill string is landed in the well head, the cement plugs are released from engaged position on the drill string by dropping or pumping balls, darts, and the like, to hydraulically activate the release of the plugs. The drill pipe containing the secured cementing plugs is run on a drill pipe having a conventional expansion joint to longitudinally compensate for the movement of the drill ship on the ocean, and the drill pipe is tied back to the well head. Now, because the drill pipe is tied back, a full size cementing plug cannot be pumped or inserted through the drill pipe.
Regardless of whether the cementing operation is performed on an off-shore or inland well, most prior art plug dropping mechanisms are not completely reliable for efficient sequential release of the plugs, because of the use of hydraulic activation means to disengage the plug from its secured position, prior to pumping the plug downhole.
The present invention provides an apparatus and method for release of plugs without the use of auxiliary pumpable means, such as balls, darts, shear pins and the like. The present invention incorporates an apparatus which sequentially releases the plugs from their respective heads in a sequential, highly reliable, operation which is dependent only upon rotational manipulation of the drill pipe or other conduit to release the plugs from the engaged position relative to the pipe or conduit. When utilized above an off-shore well, the apparatus provides means for release of the plugs above the ocean floor and above the well head, and thus further provides a more reliable means of releasing plugs.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for holding and selectively mechanically releasing one or more plug devices which are used in cementing a subterranean well, preferably an off-shore well which is completed from a floating platform or drill ship. The apparatus is securable on a rotationally manipulatable conduit communicating with the well. The apparatus comprises an elongated cylindrical housing and control head means which are positioned within the housing and preferably having a flow passageway therethrough. The control head means is rotatably shiftable in response to manipulation of the conduit from closed position, whereby the plug device is prevented from passing through the control head means, to open position, whereby the plug device is permitted to pass through the control head means. Means are provided on the apparatus for transferring manipulation of the conduit to the control head means to selectively shift the control head means between open and closed positions. When plural plug devices are desired for use in the cementing operation, companion plural control head means are provided which are sequentially shifted from closed to open positions. Subsequent to opening of a given control head means, fluid is transmitted in auxiliary fluid passage means to pump the released plug downwardly through the apparatus and into the casing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is schematic illustration of a typical subsea well head installation, and illustrating the plug dropping or releasing apparatus of the present invention positioned within a blow out preventer stack above the well head, the lower end of the apparatus being disposed within the interior of the uppermost end of a casing hanger.
FIG. 2 is an enlarged longitudinal partially sectioned view of the actuator mechanism, off-set 90° from the view of FIG. 1.
FIG. 3 is a schematic view, off-set 90° from the view of FIG. 2, illustrating the exterior of the actuator component and upper plug dropping head of the apparatus.
FIG. 4 is a longitudinally extending exterior illustration of the plug dropping heads of the apparatus and the actuator sleeves, each of the heads being in closed position.
FIG. 5 is a view similar to that of FIG. 4, and off-set 90° from the view shown in FIG. 4.
FIGS. 6A, 6B, 6C and 6D are sequential exterior side schematic views of the apparatus, illustrating the position of the actuator sleeve and the respective plug dropping heads as each plug dropping head is manipulated from closed to open position: FIG. 6A showing the lowermost plug dropping head in open position; FIG. 6B showing the two lowermost plug dropping heads in open position; FIG. 6C illustrating the first, second and third plug dropping heads being in open position; and FIG. 6D illustrating the positioning of the camway sleeve when all of the plug dropping heads are manipulated to open position.
FIG. 7A is a cross-sectional view taken along line 7A--7A of FIG. 6A, illustrating a typical plug dropping head of the present invention in closed position.
FIG. 7B is a view similar to that of FIG. 7A and taken along line 7B--7B of FIG. 6B and showing a typical plug dropping head of the present invention in open position.
FIG. 8A is a perspective, dimensionalized illustration of a plug dropping head assembly when manipulated to closed position, a typical cementing plug being shown thereabove, and parallel cement flow tubes being circumferentially extended around the exterior of the plug dropping head.
FIG. 8B is a view similar to that of FIG. 8A, showing the plug dropping head manipulated to open position and a plug being pumped therethrough and positioned within the interior of the apparatus below the plug dropping head.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, the apparatus 10 is positioned within a blow out preventer stack R having its lowermost end resting upon the ocean floor F, arms R1, R2 and R3 extending interiorly within the stack R and being sequentially and longitudinally separated from one another to centrally secure the apparatus 10 within the stack R.
The apparatus 10 is run on the lower end of a drill string DS (FIG. 2) and is set within a conduit RC, the uppermost end of the apparatus 10 being located within the lowermost portion of a blow out preventer BOP, the lowermost end of the apparatus 10 extending to the uppermost end of a casing hanger CH having a shoulder CH1 for receipt of the apparatus 10. A string of casing C extends within the well through the well head WH below the ocean floor F. An anchoring shoulder WH1 on the well head WH positions the conduit RC in the well head WH. An elastomer seal S is provided to seal within the interior of the conduit RC.
Now referring to FIG. 2, the apparatus 10 has a longitudinally extending drive mandrel 12 which is affixed by conventional means, such as threads, to the lowermost end of drill or work string DS extending from the drill ship or floating platform. A radially and circumferentially extending guide element 11 is defined on the drive mandrel 12 which prevents the apparatus 10 from binding within the conduit RC as the apparatus 10 is rotatably manipulated to sequentially release the cementing plugs. A drive nut housing 14 is secured at threads 16 to a longitudinally extending actuator housing 58. An upper bearing assembly 17, in conjunction with a lower bearing assembly 54, permits rotation of the drive mandrel 12 in one direction relative to the actuator housing 58 during rotation of the drill string DS to manipulate the plug dropping heads from closed to open position. A bearing retainer member 15 extends circumferentially around the exterior of the drive nut housing 14 to secure it between the drive mandrel 12 and the actuator housing 58.
A transverse passageway 18 is defined through the drive mandrel 12 below the upper bearing assembly 17 and communicates with an interior passageway 13 longitudinally extending through the apparatus 10 and communicating to the drill string DS, the interior passageway 13 transmitting fluid mud and cement from the drill string DS to the well. The transverse passageway 18 is provided to permit pressure within the drill string DS to hydrostatically balance the component parts within the actuator housing 58 above a circumferentially extending elastomeric O-ring seal element 18a to assure that there are no axial forces transmitted to the drill string DS.
A profiled ratchet drive extension 20 circumferentially extends around a portion of the actuator housing 58 to receive a ratchet 19 urged interiorly by means of a compressed biasing spring element 20a to transmit rotation of the drill string DS in one direction, such as right-hand rotation, through the drive mandrel 12 and into the actuator housing 58 such that the apparatus 10 will rotate as a unit when the drill string DS is rotated in one direction for remedial actions involving securing the seal S between the riser conduit RC and the casing C, or the like.
A series of longitudinally extending circularly slanting drive thread elements 21 are provided circumferentially around the exterior of the drive mandrel 12 for receipt of companion threads on a drive nut element 22 which, in turn, carries, by means of a bolt or other securing means 23 a drive arm assembly having an uppermost drive arm member 24 for manipulating control pins within camway slots provided on the drive arm assembly to sequentially manipulate each of the plug dropping heads from closed to open position for dropping of the plugs during the cementing operation. As the drill string DS and the drive mandrel 12 affixed thereto are rotated in one direction, the drive nut 22 will move longitudinally upwardly within a drive slot 58a profiled within the actuator housing 58 and the drive nut 22 will travel along the threads 21 carrying the drive arm assembly for manipulation of the plug dropping heads.
As best shown in FIGS. 3 and 4, the drive arm assembly is, as stated above, secured at its uppermost end to the drive nut 22 by a bolt 23 received through the uppermost end of a first or upper drive arm member 24 which, in turn, is connected to a downwardly extending drive arm member 26 by means of a bolt 25. Similar bolts 27, 29, 31, 33, 35 and 37 secure companion downwardly extending arm members 28, 30, 32, 34, 36 and 38, one to another, respectively. The drive arm assembly provides a series of four camways 39a, 39b, 39c and 39d adjacent one side of the plug dropping head assemblies 44a, 44b, 44c and 44d, respectively. The camways define a running slot 40a, 40b, 40c and 40d for respective receipt of control pins 43a, 43b, 43c and 43d mounted on one side of the control heads 45a, 45b, 45c and 45d.
It will be noted that the running slot 40a on the uppermost, or fourth, control head 45a is longer than the running slot 40b on the control head 45b of the next, or third, plug dropping head 44b, the running slot 40b being somewhat longer than the running slot 40c of the second plug dropping head 44c, the running slot 40d of the lowermost, or first, plug dropping head 44d having the shortest length. Such a configuration is provided to enable shifting of the first control pin 43d on to an angularly off-set rotation slot 41d to rotate the first or lower control head 45d from closed to open position prior to any of the fourth, third and second control pins 43a, 43b and 43c, from being shifted into their respective rotation slots 41a, 41b and 41c. Likewise, the running slot 40c is somewhat shorter than the running slot 40b, to permit the second control pin 43 c to enter into its rotation slot 41c to manipulate the control head 45c to open position, before movement occurs between the control pin 43b and the control head 45b, as well as between the uppermost control pin 43a and the control head 45a. Finally, the running slot 40b in the third plug dropping head assembly 44b is somewhat longer than the running slot 40a of the uppermost or fourth plug dropping head 44a to permit shifting of the third control pin 43b into its rotation slot 41b prior to manipulation of the uppermost plug dropping head 44a from closed to open position.
After each of the control pins 43a 43b, 43c and 43d travel along their respective rotation slot and the particular control head is manipulated from closed to open position, the pin will be shifted into its respective longitudinally extending sequential dropping slot 42a, 42b, 42c and 42d during the next rotation of the drill string DS to drop the next plug. Thus, the fourth or uppermost plug dropping head 44a is functional with the shortest sequential dropping slot 42a on its camway 39a. The sequential dropping slot 42b immediate the third or next plug dropping head 44b is somewhat longer to permit travel of the third control pin 43b as the fourth or upper control pin 43a is manipulated within the running slot 40a and the rotation slot 41a. Continuing, the second plug dropping head 44c has the sequential dropping slot 42c on its camway 39c proportionately elongated relative to the third head 44b to permit travel of the second control pin 43c as the third control pin 43b travels within the running slot 40b and into the rotation slot 41b. Finally, the sequential dropping slot 42d of the lowermost, or first, plug dropping head 44d, and on the camway 39d, is the longest of all of the sequential dropping slots to permit the first control pin 43d to travel therein, as the second, third and fourth control pins, 43d 43b and 43a are manipulated from their respective running slot to the particular rotation slot.
Now referring to FIGS. 8A and 8B, the second plug dropping head assembly 44c is shown in dimensionalized views. It will be understood that each of the plug dropping heads 44a, 44b, 44c and 44d are of substantially identical design. The plug dropping head assembly 44c is mounted by means of its housing 44c' to the control housing 57. A rotatable control head member 45c is carried within the housing 44c' with a control pin 43c mounted on one side thereof and received within the running slot 40c of the camway 39c on the drive arm member 34. A flow passageway 46c having substantially the same internal diameter as the internal diameter of the casing C is provided through the control head 45c. A solid bridge 47c is provided on the control head 45c on each side which, when the control head 45c is in the position as illustrated in FIG. 8A, has one end across the interior passageway 13 of the apparatus 10 to provide a barrier against downward movement of a plug P, located immediately above the control head 45c.
Now referring to FIG. 8B, when the control head 45c is manipulated to the open position, the bridge 47c moves to each side of the plug dropping head assembly 44c and the passageway 46c is completely in alignment with the interior of the housing 44c', and is in full communication with the interior passage 13 of the apparatus 10 to permit the plug P to pass through the plug dropping head assembly 44c.
A series of four cementing plugs P, of conventional and known design, are positioned just above the control heads 45a, 45b, 45c and 45d. Each plug P has a longitudinal body P-4 carrying longitudinally spaced, circumferentially extending wiper flaps P1, P2 and P3 which will wipe against the interior of the control housing 57 of the apparatus 10 and the interior of the casing C as the plug P is moved therethrough.
Now referring to FIGS. 1, 2 and 8A, a series of four parallel flow conduits 49, 50, 51 and 52 are carried by the apparatus 10 and are sequentially spaced around the circumferential exterior of the plug dropping head housing 57, each of the plugs communicating within the actuator housing 58 with the interior passageway 13 and the interior of the drill string DS for transmission of mud and cement from the drill ship or floating platform through the well during the cementing operation. Although it is not necessary to provide four parallel flow conduits, it is desirable to provide multiple conduits whose total areas will substantially equal the areas of the interior passageway 13 and that of the drill string DS to afford maximum flow capacity through the flow conduits and into the interior of the casing C. The flow conduits 49, 50, 51 and 52 permit fluid to be transmitted downwardly of each of the plug dropping heads 44a, 44b and 44c so that fluid can be transmitted into the well as each of these plug dropping heads are bypassed when the control heads 45a-d are manipulated to closed position.
The parallel flow conduits 49-51 respectively begin through flow passageway ports 55a, 55b, 55c and 55d defined within the actuator housing 58 for communication with the interior passageway 13. As shown in FIG. 4, the conduits 49-51 pass through the uppermost end of each of the plug dropping heads 44a-d and pass out of the lowermost end thereof. Each flow conduit 49-51 has an adjustable pup connection 53 for securing lengths of each flow conduit between each of the plug dropping heads 44a-44d.
The parallel flow conduits 49-51 terminate exterior of the control housing 57 within the lowermost control head 45d in the lower plug dropping head 44d and communicates therebelow with the interior passageway 13 in the apparatus 10, and into the interior of the casing C just above the ocean floor F within the casing hanger CH.
Now referring to FIGS. 7A, 7B, 8A and 8B, the parallel flow conduits 49-51 are secured to the uppermost end of each of the housings, such as 44c', each housing having bored parallel flow passageway extensions 48c', 48c" 48c"' and 48c"" therethrough for continuing the parallel flow conduits through each of the plug dropping heads, such as 44c. As particularly shown in FIG. 7A, each flow passageway 48c'-48c"" is bored 160° through the housing 44c'. Therefore, when the control head, such as 45c shown in FIG. 8A, is manipulated to the closed position, such that the bridge 47c prevents the plug P from passing therethrough, fluid transmission through the parallel flow conduits 49-51 will pass through the flow passageways, such as 48c'-48c"", and lowerly thereof into the parallel flow conduit members therebelow. Also, because the passageway, such as 46c, is within the radial area of 180° opposite the 180° bored portion of the flow passageways through the housing 44c', fluid also will be transmitted through the passageway, such as 46c, and downwardly of the plug dropping head, such as 44c, thence through the interior passageway 13, and pressure will be exerted upon the uppermost flap P1 of the next and lower plug P.
When a control head of a plug dropping head assembly, such as control head 45c of the assembly 44c shown in FIG. 8B, is manipulated to the open position for dropping of the plug P therethrough, the passageway 46c will become completely aligned with the interior of the housing 44c and the interior passageway 13, as shown in FIG. 7B. Now, the complete radius of the flow passageways 48c'-48c"" is traversed 180°, and fluid cannot enter into the interior passageway 13 within each plug dropping head, such as 44c. Fluid now will bypass the interior portion of the plug assembly, but may be communicated downwardly within each of the respective parallel flow conduits.
OPERATION
Prior to running of the apparatus 10 on the drill string DS, it is necessary to properly locate each of the plugs P within their respective plug dropping heads 44a-d, just slightly above the respective control heads 45a-d. Accordingly, the drive arm assembly is disengaged from the drive mandrel 12 by disengaging the drive arm member 24 from the drive nut 22 by removing the bolt 23. Thereafter, the drive arm assembly is manually manipulated so that all of the control pins 43a-d are shifted to their lowermost position within their respective sequential dropping slots 42a-d, and the control heads 45a-d are manipulated to the fully open position such that each passageway 46a-d is in conformity with its housing 44a'-c'. In order to insert the plugs P through the plug dropping head housing 57 for respective location within the plug dropping heads, the drive nut housing 14, bearing retainer 15, drive mandrel 12 and lower bearing assembly 54 are removed from the actuator housing 58. Now, each of the four plugs P are manually inserted at the uppermost end of the drive mandrel 12 and through the interior passageway 13 for location within each of the respective plug dropping heads 44a-d and just above the uppermost end of the respective control head assembly 45a-d. The drive arm assembly thereafter is manually manipulated longitudinally downwardly, moving each control pin 43a-d from the lowermost end of the sequential dropping slot 42a-d into the rotation slot 41a-d and thence to the uppermost end of the running slot 40a-d. As the pin 43a moves relatively from the sequential dropping slot 42a-d into the rotation slot 41a-d, each control head assembly 45a-d is manipulated from the open position shown in FIG. 8B to the closed position shown in FIG. 8A.
The lower bearing assembly 54 is reinstalled in place within the actuator housing 58. Thereafter the upper bearing assembly 17, bearing retainer 15 and drive nut housing 14 are secured in place and the drive mandrel 12 run within the actuator housing and secured to the drive nut 22. The upper drive arm member 24 is secured again to the drive nut 22 by means of insertion of the bolt 23.
Subsequent to running the casing C within the well below the ocean floor F, the casing hanger CH is secured thereto and landed within the well head WH. The casing C is sealed with respect to the well head WH by means of a pack-off assembly for driving into place the seal S. The apparatus 10 is lowered on the end of the drill string DS and landed within the blow out preventer stack BOP and on to the shoulder CH-1 of the casing hanger CH. The rams (not shown) of the stack BOP may be closed around the upper portion of the drive mandrel 12 above the guide 11, if desired.
Mud now may be circulated down the drill string DS through the interior passageway 13 of the apparatus 10 and through the parallel flow conduits 49, 50, 51 and 52, thence within the interior passageway 13 below the lowermost plug dropping head 44d and into the interior of the casing C. The mud will pass from within the interior passageway 13 through each of the parallel flow conduits 49-51 at the passageways 55a, 55b, 55c and 55d within the actuator housing 58. The mud is circulated within the well to condition the hole.
It should be noted that when fluid is so transmitted, any pressure differential is equalized across each of the plug dropping head assemblies 44a-d because fluid pressure is passed above and below each such head, and each such head is filled with mud to keep cement from entering the interior in order to prevent clogging of component parts. The mud is permitted to pass interiorly within each of the plug dropping head assemblies 44a-d through the passageway 46a-d traversing the bored flow passageways, such as 48c'-48c"", within the control heads 45a-d.
After the well has been conditioned with mud, the surface flow lines (not shown) are moved from the mud pit to the cement pumping assembly. The drill string DS is rotated a predetermined number of turns to the left at the drill ship, or floating platform, by application of a pipe wrench or power tongs to the string DS. The drill string DS should be permitted to move freely, even though the apparatus 10 is secured within the blow out preventer BOP and the conduit RC, because of the guide 11 preventing binding between the apparatus 10 and the interior of the conduit RC.
As shown in FIG. 6A, as the drill string is rotated, the drive nut 22 progresses up the helical spiral relative to the drive mandrel 12, carrying the drive arm assembly upwardly with it. The drive arm member 38 will move upwardly, such that the first or lowermost control pin 43d on the lowermost plug dropping head assembly 44d will move relatively downwardly within the running slot 40d and angularly shift into the rotation slot 41d to rotationally manipulate the control head 45d from the closed position to the open position. Now, flow of fluid is blocked below the lowermost control head 45d and within the interior of the control housing 57. However, flow of fluid will pass within the second plug dropping head assembly 44c through the passageway 46c and within the interior of the control housing 57 to act upon the uppermost flap P1 of the plug P initially secured just slightly above the lowermost control head 45d within the lowermost or first plug dropping head assembly 44d. As fluid pressure is exerted upon the uppermost flap P1 of the plug P, located within the lowermost plug dropping head 44d, it is pumped through the open passageway 46d and through the control housing 57 therebelow and within the casing C. The plug, being above the last of the mud and below the cementing column, will wipe and clean the interior of the casing C ahead of the cementing column.
After displacement of cement and prior to recirculation of mud, the drill string DS again is rotated a predetermined number of turns in the same direction, i.e., the left, at the drill ship or floating platform. As shown in FIG. 6B, the rotation moves the drive nut 22 upwardly along the threads 21 of the drive mandrel 12 to shift the drive arm assembly further upwardly. Now, the second control pin 43c has been shifted from its initial position within the running slot 40c and into the rotation slot 41c to shift the control head 45c from the closed position to the open position, as shown in FIG. 8B. Now, fluid flow through the central housing 57 below the second plug dropping head assembly 44c is prevented, but fluid may pass within the control housing 57 through the passage 46b in the third plug dropping head assembly 44b, just upwardly of the second plug dropping head assembly 44c. As mud is pumped through the drill string DS and within the parallel flow conduits 49-51, it will enter within the interior of the control housing 57 within the plug dropping head assembly 44b to act upon the uppermost flap P1 of the plug P positioned within the second plug dropping head assembly 44c to pump it through the open control head 45c. Now, cement is pumped through the drill string DS and the parallel flow conduits 49-51 and the two cement plugs released from the first and second plug dropping head assemblies 44d and 44c are transmitted within the casing C to the bottom of the well.
The lowermost plug will be located within the well and a pressure indicated reflected at the surface of the well will signal that cement is starting to be transmitted exterior of the casing within the annular area between the well bore and the casing. Pressure now is increased such that the flaps P1, P2 and P3 of this plug P will fold so that cement can be circulated through the exterior of the casing. When the second plug P is landed within the bottom of the well, it will seal off the well bore.
The second stage cementing operation may be effected by rotating the drill string DS a predetermined number of turns in the same direction, i.e., to the left, to cause the drive nut 22 again to move upwardly on the threads 21 of the drive mandrel 12 within the actuator housing 58 of the apparatus 10 to carry the drive arm assembly correspondingly upwardly to move the third control pin 43b from its uppermost position within the running slot 40b into the rotation slot 40b into the rotation slot 41b in the camway 39b of the third plug dropping head assembly 44b. Now, the control head 45b is rotatably manipulated from the closed position to the open position and the plug P housed initially thereabove is permitted to be pumped therethrough. This position is shown in FIG. 6C.
This third plug P generally is utilized to cause a stage collar (not shown) located within the well on the casing C to be shifted openly for transmission of fluids therethrough and within the annular area between the well bore and the casing C thereabove. The well bore normally will be conditioned with mud by circulating it therethrough. Thereafter, cement will be circulated within the drill string DS, through the interior passageway 13 and through the parallel flow tubes 49-51.
After the cementing operation has been completed, and prior to circulating additional mud within the drill string DS, the drill string DS again is rotated a predetermined number of turns, i.e., to the left, to move the drive nut 22 on the drive threads 21 of the drive mandrel 12 to the final and uppermost position to carry the drive arm assembly correspondingly upwardly, such that the fourth control pin 43a moves within its running slot 40a and into its rotation slot 41a to shift the uppermost control head 45a in the fourth and uppermost plug dropping head assembly 44a from the closed position to the open position to permit the uppermost plug P to be freely passed through the uppermost control head 45a. This position is as shown in FIG. 6D. As the plug P passes through the apparatus 10 and into the casing C it will rest upon the stage collar (not shown) to reclose it. The cementing operation now is complete.
In order to pack-off the casing, the rams in the blow out preventer BOP are opened, if they were previously closed, and the drill string DS is rotated in the opposite direction, i.e., to the right. Now, such rotation will cause the ratchet 19 to become secured on the ratchet drive 20, such that continued right-hand rotation will carry the drive mandrel 12, the actuator housing 58 and the head housing 57 together as one unit. Now, the pack-off assembly within the casing hanger containing the seal S will elastomerically pack-off the casing C within the well head WH.
The casing hanger running tool (not shown) is disconnected from the casing pack-off assembly. The drill string DS is pulled upwardly such that the apparatus 10 is retrieved from the interior of the conduit RC.
Cleaning and redressing of the apparatus 10 may be effected simply by removing the drive nut housing 14, bearing retainer 15, upper bearing assembly 17, lower bearing assembly 54 and the drive mandrel 12 from within the actuator housing 58.
Additionally, it should be noted that each of the members of the drive arm assembly may be easily disconnected one from another for convenient cleaning and dislodging of cured cement. The control heads may be easily removed from within the plug dropping head assemblies for easy cleaning.
Several variations in the assembly can be made, depending upon the particular application and individual preference. For example, the bolts 25, 27, 29, 31 33, 35 and 37 may be replaced with T-slot and T-element configurations on the drive arm assembly members to afford easier redressing of the apparatus 10 subsequent to the cementing operation. Additionally, ball valve elements may be utilized instead of plug valve elements. In a ball valve design modification, the external parallel flow conduits 49-51 may not be necessary, because circulation ports can be defined in an annular area between the body of the ball valve element and the body of the plug dropping head assembly. Instead of the use of parallel exterior flow conduits 49-51 liners are defined within outer housings, the liners having a milled slot down their length for transmission of fluid therethrough.
Utilization of a ball valve design would permit cementing of a comparatively large casing inside a comparatively smaller diameter blow out preventer stack. For example, 13 inch casing could be cemented inside of a 163/4 blow out preventer stack, because the ball valve design inherently will have a very narrow wall section.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by 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. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | An apparatus and method are provided for holding and selectively mechanically releasing at least one plug device utilized in cementing a subterranean well, preferably a subsea well. The apparatus is securable and carryable on a manipulatable conduit, such as a drill string, communicating with the well. The apparatus comprises a cylindrical housing control head means positioned within the housing, shiftable in response to manipulation of the conduit from closed position, whereby the plug device is prevented from passing through the control head means, to open position, whereby the plug device is permitted to pass through the control head means. Means are provided for transferring at least one of longitudinal and rotational manipulation of the conduit to the control head means to selectively shift the control head means between closed and open positions. Subsequent to shifting of the control head means to open position, the plug device may be pumped through the control head means. When plural plugs are desired, companion plural control head means are selectively and sequentially manipulatable to open position. | 4 |
FIELD OF THE INVENTION
The present invention relates generally to transform systems, and more particularly to an autotransfusion apparatus for employing a patient's blood as a source for providing a transfusion.
The apparatus is intended to be used per- and postoperatively, for example in intensive-care wards after major operations or for direct use during operations where major hemorrhages may occur, such as, in connection with vascular surgery, liver operations, orthopedic operations such as hip-joint operations, and the like.
BACKGROUND OF THE INVENTION
In the past, the apparatus which have been commercially available for effecting autotransfusion include those marketed under the name of Haemonetics Cell Saver, IBM Cell Washer and Dideco, all of which employ centrifuging apparatus. Thus, after a careful wash, these devices yield a final product containing only red blood cells in a salt solution. These apparatus are also relatively expensive, owing to the centrifuges included An example of a system of this type can be found in the article "Autotransfusion and Emergency Surgery; Preliminary Report on an Improved Technique" in The International Journal of Artificial Organs, Vol. 8, No. 4, 1985, P. 221-224.
Simpler systems also exist, however, including those which are sold under the name of Sorenson and Solcotrans. These systems consist quite simply of a plastic canister which is prefilled with a certain amount of ACD-solution, and which is provided with a built-in filter. When the canister has thus been filled with blood it is simply turned upside down, so that the blood can be retransfused through the filter. These types of simplified systems, however, are not sufficiently effective in the case of more severe hemorrhages. Moreover, in view of the nature of these systems, the returned blood frequently also contains washing liquids, anticoagulants and other additives.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a simple apparatus which can now render it possible to return wholly or partly cleaned whole blood, including its plasma as well as other valuable substances, such as coagulation factors and the like. It is also an important objective hereof to concentrate the whole blood to a suitable hematocrit value, by filtering off superfluous salt solution and anticoagulant solution.
In accordance with the present invention, these and other objects have now been realized by the discovery of autotransfusion apparatus for employing a patient's blood as a source for providing a transfusion which comprises collecting means for collecting the patient's blood; treatment means comprising filter means for filtering the collected blood so as to separate a filtrate from the blood and remove undesired portions thereof; a blood retention vessel for retaining the treated blood; and return means for returning the treated blood from the blood retention vessel to the patient.
In accordance with a preferred embodiment of the autotransfusion apparatus of the present invention, the filter means includes a blood inlet, a blood outlet, and a filtrate outlet; the blood retention vessel includes an inlet and an outlet; and the filter means and the blood retention vessel comprise a recirculation circuit including conduit means for connecting the blood outlet of the filter means to the inlet of the blood retention vessel and the outlet of the blood retention vessel to the blood inlet for the filter means. Preferably, the recirculation circuit further includes a peristaltic pump for recirculating the blood therein.
In accordance with another embodiment of the autotransfusion apparatus of the present invention, the apparatus further includes a filtrate receptacle coupled to the filtrate outlet so that filtrate can be collected without contact with the ambient atmosphere. Preferably, the blood retention vessel includes a blood return outlet, and the return means comprises a blood return conduit coupled to the blood return outlet, including control means for controlling the flow of the blood in the blood return conduit. The blood retention vessel can also preferably include suspension means for suspending the blood retention vessel so that blood may flow therefrom by means of gravity.
In accordance with a preferred embodiment of the autotransfusion apparatus of the present invention, the collecting means includes diluting means for supplying a diluting solution to the blood, and intermediate blood storage means for storing the blood. Preferably, the intermediate blood storage means comprises a cardiotomy reservoir including blood filter means. The diluting means is preferably connected to the intermediate blood storage means so that the diluting means can supply the diluting solution to the intermediate blood storage means.
In accordance with the embodiment of the autotransfusion apparatus of the present invention, the collecting means further includes suction means for drawing the patient's blood, and anticoagulant supply means for supplying anticoagulant to the patient's blood. The suction means preferably includes first duct means for connecting the suction means for transporting the blood drawn by the suction means, and second duct means for connecting to the anticoagulant supply means. The anticoagulant supply means preferably includes anticoagulant control means for controlling the supply of the anticoagulant, and the diluting means includes diluting solution control means for controlling the supply of the diluting solution. Further, the apparatus preferably comprises uncoupling means for uncoupling the collecting means from the treatment means.
By including the filter in a recirculation circuit comprising the peristaltic pump, it is possible to utilize a filter possessing a limited capacity, and which therefore can be relatively inexpensive, and thereby suitable for a single use. The peristaltic pump also facilitates utilization of the apparatus of the present invention; since, the pump is adapted to work on a conventional pump segment, whereby the pump does not come into direct contact with the blood. The collecting vessel of the present invention permits continuous treatment of the blood, and also continuous return of the blood, even when the blood is supplied intermittently to the apparatus. Further, the blood may be returned to the patient solely by means of gravity. By coupling the filter to a filtrate bag for collection of the filtrate without exposure to the ambient atmosphere, the risk of contamination is diminished. Thus, it is possible to use an expendable filter for a longer period then if it were connected to an open drain. The cardiotomy reservoir provided with a filter permits the treatment of blood to be deferred until the amount thereof collected is sufficient to warrant such activity.
BRIEF DESCRIPTION OF THE DRAWING
The sole figure is a schematic drawing of a preferred embodiment of the invention.
DETAILED DESCRIPTION
The preferred embodiment of the present invention shown in the sole figure comprises a suction device 1 with a hand-operated device 2 and a suction tip 3 which preferably is designed as a filter basket in order to prevent lumps or the like from being drawn up thereby. Although not shown in the drawings, the suction device 1 is preferably provided with two ducts, one of which is adapted to be used for drawing up the blood, whereas the other is adapted for the supply of an anticoagulant, which is supplied from a source 6 which can be a bottle containing ACD (Acid-Citrate-Dextrose) through duct 4 which includes a monitoring device 5. However, the means for collecting blood can be connected to a catheter for directly drawing of the blood from the site of the operation, particularly when used postoperatively. Monitoring device 5 controls the flow of anticoagulant, and may comprise a simple drip chamber. The blood drawn up by means of the suction device 1 passes through duct 7 to an intermediate storage vessel 8, which in the present embodiment preferably comprises a conventional cardiotomy reservoir provided with a filter 9 for filtering the blood. An intermediate storage vessel is particularly appropriate in the event of minor hemorrhages. With this vessel, treatment of the blood may be deferred until a sufficient amount of blood has been collected. In postoperative use it may be appropriate to prefill this intermediate storage vessel with diluent and/or anticoagulant. The cardiotomy reservoir 8 is connected via a duct 10 to a vacuum source, which is not shown in the drawing. The apparatus of the present invention can be divided by a coupling 11 into a suction part on the left side of the broken line 12, and a treatment part on the right side thereof. However, if the duct 7 is connected directly to a draw-off catheter connected to the site of the operation, such as in postoperative applications, the suction part of the apparatus is not required.
A duct 13 is connected to the cardiotomy reservoir 8 for conveying diluting fluid, such as a physiological salt solution from a source 15 for such a solution through a monitoring device 14. Monitoring device 14 controls the flow of the diluent, and may comprise a simple drip chamber. This solution is then mixed with the blood in reservoir 8. The salt solution protects the red blood corpuscles, provides a certain amount of washing, and can be removed with the help of a filter prior to return of the blood to a patient. Even without diluting fluid, the blood may have to be concentrated prior to return in order to remove excess anticoagulant or rinse fluid conveyed to the site of an operation. From the reservoir 8 the mixture is conducted through a duct 16 and a further coupling 17, which is shown schematically in the figure, to a recirculation circuit, which in its entirety is designated by reference numeral 18. The overall system can thus also be divided by means of coupling 17 along broken line 19, the parts to the left of which are intended primarily for collection and dilution of the blood, whereas the parts to the right of same are intended for concentration and return of the blood to the patient. Coupling 17 facilitates the assembly and disassembly of the apparatus downstream of the intermediate storage vessel. In this fashion, the apparatus can be divided into two expendable portions, one comprising the intermediate storage vessel and elements arranged upstream therefrom, and the other comprising elements downstream therefrom. In recirculation circuit 18 the blood is pumped by means of a peristaltic pump 20 through a filter 21 to a collecting vessel 22. Since the filter 21 is included in the recirculation circuit 18 which also comprises the pump 20, it is possible to select a filter which has a limited capacity and which, therefore, can be relatively inexpensive, so that it can be used only once. The peristaltic pump also facilitates treatment involving only a single use, since the pump can be adapted to work on a conventional pump segment without making direct contact with the blood. This is accomplished by means of ducts 23 and 24 and shunt duct 25. The collecting vessel permits continuous treatment of the blood and continuous return of the blood, even if blood is supplied only intermittently to the apparatus. The outlet 26 for the filtrate is connected through duct 27 to a flexible filtrate bag 28 for the collection of the filtrate without exposure to the surrounding atmosphere. Accordingly, the risk of contamination is diminished. It is therefore possible to use ar expendable filter for a longer period of time than would be possible if it were connected to an open drain. When treatment of the blood is finished, that is to say when the appropriate hematocrit value has been attained, the blood is then passed through duct 29, with a monitoring device 30, to a retransfusion duct 31, whose tip 32 is intended to symbolize an injection cannula. The monitoring device 30 controls the flow of retransfusion blood, and may comprise a simple drip chamber. Collecting vessel 22 is provided with means for its suspension. These means have been designated in the Figure by reference numeral 33, and in the example shown consist of a handle and two suspension eyes. In this fashion, the blood can be returned to the patient solely by means of gravity. Filter 21 comprises a filter of the type normally used for hemofiltration. If a more rapid concentration is desired, as in connection with the continuing treatment of a patient where there is a risk of heavy bleeding, it is possible to use a filter of the type normally used for plasmapheresis. Examples of membrane material intended for hemofiltration are found, for example, in EP 0 046 816 and EP 0 098 392. Similarly, examples of membranes suitable for use in plasmapheresis are found in EP 0 044 958 and EP 0 095554.
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. | Autotransfusion apparatus is disclosed for employing a patient's blood as a source for providing a transfusion, and which can also supply anticoagulant and diluting solution to the blood collected from a patient. The apparatus including a cardiotomy reservoir for collecting the patient's blood, a blood filter for separating a filtrate from the blood, a blood retention bag for retaining the treated blood and from which the blood can be returned to the patient by gravity. | 0 |
FIELD OF THE INVENTION
The present invention relates generally to speech recognition for Internet video search and navigation using TV-centric systems.
BACKGROUND OF THE INVENTION
The present invention recognizes that it can be difficult for a viewer to input textual information into a television using a remote control for various purposes. For example, if a user of an Internet-enabled TV would like to search the Internet for video related to “Subject A” so that the video can be played on the TV, there is no easy way to give the TV this information, unlike a computer which has a keyboard that can be used. A keyboard can be provided with a TV, but as understood herein this is not fully consistent with the relaxed user experience that is typically associated with watching television.
As also recognized herein, another option for allowing user input is to use a “soft keyboard” that appears on the screen, and that requires the user to use cursor keys on the remote control to select individual characters of the desired search subject. As also understood herein, however, such a way to input text is tedious.
SUMMARY OF THE INVENTION
A system includes a TV communicating with the Internet and a remote control device wirelessly communicating with the TV. A microphone is on the remote control device and the remote control device digitizes speech signals representing a desired video site or video subject from the microphone, sending the signals to the TV. A processor implements speech recognition on received speech signals representing a desired video site or video subject to generate recognized speech. This speech recognition is performed in the context of a grammer constructed from information within Internet video sites as well as information in the user's context of having viewed the TV content i.e. closed captioned text. This recognized speech is an index. A database containing at least one index correlating speech with Internet addresses can be accessed by the processor using the recognized speech to return an Internet address of an Internet site.
In one implementation, the processor and database are located at an Internet server. In another implementation, the processor and database are located in the TV. In this latter implementation, the database can include an index derived from closed captioned text received by the TV, EPG (electronic program guide) information, and/or text input by a user, for a predetermined time (e.g., only information received for a most recent predetermined time period) or for a predetermined data amount (e.g., only the most recent “X” amount of information received, wherein “X” is a predetermined data amount.) The database may also include information representing items that are initial, manufacturer-defined grammar.
In another aspect, a method for returning an Internet address of an Internet site storing a desired video includes digitizing speech input to a TV remote. The speech is related to the video. The speech is sent to a TV, and at least phonemes in the speech are recognized. Using the phonemes as entering argument, a database is accessed to retrieve the Internet address.
In still another aspect, a computer program product has a computer-readable medium that bears means for recognizing digitized speech representing a video and generating recognized speech in response. The speech is initially detected by a TV remote control. The computer program product also has means for accessing a data structure correlating speech representing video to Internet addresses of sites storing the video, and means retrieving, from the data structure, at least one Internet address correlated to a match.
The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a first non-limiting embodiment of the present system;
FIG. 2 is a flow chart showing a non-limiting logic that can be used by the system of FIG. 1 ; and
FIG. 3 is a flow chart showing an alternate non-limiting logic that can be used.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1 , a system is shown, generally designated 10 , that includes a wireless hand-held TV remote control device 12 that can control a TV 14 in accordance with remote control principles known in the art. In the non-limiting embodiment shown, among other components such as a remote control keypad, the remote 12 has a microphone 16 for receiving voice commands from a person and a remote control microprocessor 18 for digitizing the signals from the microphone 16 . The signals if desired can be stored in memory 20 such as random access memory (RAM) and can be sent to the TV 14 by a RF or IR transmitter 22 in the remote 12 , for reception of the signals by a receiver 24 in the TV 14 .
The TV 14 can also include a TV processor 26 that can access a non-volatile TV memory 28 (NV RAM and/or hard disk drive/optical disk drive), and the TV processor 26 can be operably associated with a TV display 30 such as a flat panel display or cathode ray tube for displaying video thereon.
In the embodiment shown, the TV 14 can communicate with an Internet server 32 over a wired or wireless wide area network link 33 or other link in accordance with network principles known in the art. The server 32 includes a speech recognition module 34 which can recognize phonemes/words/phrases in digitized speech. The server 32 also includes a query processor 36 and a Web indexer/crawler 38 that can access the rest of the Internet 40 for purposes to be shortly disclosed to populate a text indices and video site links database 42 that is associated with the Internet server 32 .
More specifically, the web crawler/indexer 38 navigates the Internet and generates reference indices that may be used to refer to videos. Non-limiting examples of the sources for words/phonemes in the indices of the database include (1) closed captioned text that appear with videos, (2) digitized voice “soundtracks” that accompany the video, which is analyzed for phonemes and then indexed, (3) descriptive text that appears with the video, and (4) actual image recognition on the video itself. These indices, together with the location (Internet site) of the corresponding videos, are stored in the database 42 .
With the above system architecture in mind, attention is drawn to FIG. 2 to understand one non-limiting method of the present invention. Commencing at block 44 , speech is detected and digitized at the remote 12 . The digitized speech is sent to the TV 14 at block 46 using the remote transmitter 22 and TV receiver 24 , so that the TV processor 26 can relay the digitized speech at block 48 to the server 32 for recognition thereof by the speech recognition module 34 . In accordance with one aspect of the invention, the speech discussed above is the title of a video, subject of a video, or location of a video on the Internet. The speech recognition module 34 can recognize the video subject or video site using methods known in the field of speech recognition, such as, e.g., matching and analyzing phonemes for the digitized speech and contents of the database 42 .
As understood herein, speech recognition requires a context (grammar) to be accurate, and this grammar is provided by the information in the database 42 . Accordingly, after speech recognition at block 48 , the logic moves to block 50 to use the recognized phonemes to retrieve matching contents in the database 42 . More specifically, at block 50 the recognized phonemes from block 48 are matched to phonemes/words in the indices of the database 42 and then the corresponding video site links are returned to the TV 14 where they can be displayed on the monitor 30 for selection of a link by the user by means of the remote 12 , in order to retrieve the actual video content from the selected site. It is to be understood that the indices in the database may also be based on video speech “soundtrack” or the phonemes of video speech soundtracks as detected by the remote 12 .
The speech recognition may occur using a further limited grammer, where the grammer is based on audio corresponding with video viewed by the user, or metadata corresponding to video viewed by the user. FIG. 3 shows an alternate logic that can be used and that is wholly contained within the home (TV 14 and remote control 12 ) without resort to accessing the server 32 . At block 52 a limited grammar is maintained in the memory 28 of the television 14 , so that memory and processing requirements to process this grammar are manageable within the confines of typical TV processors and storages. In one implementation, the limited grammar database may if desired include indices derived from the closed captioned text and metadata received by the TV, as well as text that the user might have downloaded from the Internet and other sources (e.g. QAM broadcast, IPTV, etc.) for a limited time or data amount, e.g., for the past “X” bytes or “Y” hours. The grammar may also include items that are input (trained) by the viewer and a limited, initial, manufacturer-defined grammar that is considered relevant to TV content selection that is permanently part of the memory 28 .
Moving to block 54 , speech is detected and digitized at the remote 12 . The digitized speech is sent to the TV 14 at block 56 using the remote transmitter 22 and TV receiver 24 , so that the TV processor 26 can execute speech recognition thereof by a speech recognition module accessible to the TV processor 26 . After speech recognition at block 56 , the logic moves to block 58 to use the recognized phonemes to retrieve matching contents in the TV memory 28 , so that the corresponding video site links can be displayed on the monitor 30 for selection of a link by the user by means of the remote 12 , in order to retrieve the actual video content from the selected site. The matching contents in this implementation may be larger sequences of words and phrases within EPG, metadata, and closed captioned text that contain the recognized speech, and may be passed to an Internet search engine to return addresses of web pages with contents that match the recognized speech. This speech recognition may occur entirely within the RC, or TV, or devices connected to the TV, or it different parts of the speech recognition may occur within all such devices.
The effect of the method of FIG. 3 is that the speech recognition will work reliably if the user speaks a phrase that has occurred during the broadcast in the past few hours, or if it has occurred in any web page in the past few days.
While the particular SPEECH RECOGNITION FOR INTERNET VIDEO SEARCH AND NAVIGATION is herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims. | Speech representing a desired video site or video subject is detected and digitized at a TV remote, and then sent to a TV. The TV or in some embodiments an Internet server communicating with the TV use speech recognition principles to recognize the speech, enter a database using the recognized speech as entering argument, and return a link to an Internet site hosting the desired video. The link can be displayed on the TV for selection thereof by a user to retrieve the video. | 7 |
This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 60/954,118 filed Aug. 6, 2007.
FIELD OF THE INVENTION
The invention relates to a device and a use for storage and provision of medicament wafers, i.e. of medicaments in laminar form, in particular for contraception or for hormone replacement therapy.
PRIOR ART
Medicament wafers are film-shaped articles containing pharmaceutical active substances held in an active substance carrier. The active substances in the wafers can, for example, be administered by the transmucosal route, i.e. via the oral mucosa, by means of the wafers being placed on or under the tongue, after which the active substance carrier dissolves and in so doing releases the active substances. The wafers provided are enclosed in film pouches. According to DE 101 59 746 B4, these pouches can be composed of at least one support film and at least one cover film, in which case at least the film with the larger surface area has two parallel side edges, and the film-like or laminar material (wafer) is enclosed in a gas-tight and liquid-tight manner between the support film and the cover film. Devices for storage and provision of medicament wafers can contain film pouches stacked therein.
The device described in DE 101 59 746 B4 for storage and provision of wafers comprises a housing which is partitioned at least once and on whose lateral inner faces the side edges of the stacked film pouches bear, while the edge of a support film protruding beyond the edge of an associated cover film bears on a front inner face, and in which the stacked film pouches are pressed with spring-loading against the upper inner face of the housing. The front, upper area of the housing has two slits for separate ejection of the support film and cover film, the wafer being able to be provided with the support film or with the cover film. A separating tool for separating the support film from the cover film is arranged between the slits, on which separating tool the uppermost support film bears via its area lying in front of the front edge of the cover film. A transport element, which is rotatable about an axis of rotation, transports the medicament pouches out of the housing.
This device has the disadvantage that a user has no possibility of monitoring whether a wafer intended to be taken at a certain time has already been taken or not. As a result, two wafers can easily be taken instead of one, or the user completely forgets to take the wafer.
However, this possibility of monitoring is known for medicaments in blister packs, i.e. articles for storage of tablets, coated pills or the like, in which the tablets, coated pills or the like are contained in pockets embossed in a first film, and the film is connected to a second film that seals the pockets and can be torn off.
In EP 0 166 763 B1, for example, a blister pack is provided with a row of pockets for the tablets, where the pockets correspond in an unambiguous manner to the days of at least one calendar month and where, in addition, consecutive integer indicia are arranged in proximity to the pockets in such a way that each pocket can be visually identified with one and only one calendar day of the calendar month, and where consecutive integer indicia are arranged in proximity to tear-off zones in the second film in such a way that they are visible from the rear face of the second film, and where each zone can be visually identified with one and only one calendar day of the calendar month. Each pocket can therefore be visually identified, both from the front face and also from the rear face, with one and only one calendar day. Taking the tablets on a daily basis and monitoring user compliance is facilitated in this way.
Moreover, EP 0 511 726 B1 describes an arrangement which is used to receive tablets in an array and comprises the following: a blister pack with a predetermined surface area within which are located a plurality of tablets configured in a chosen array, a container for receiving the blister pack, and a day calendar which can be oriented with respect to the array of tablets in the blister pack, the day calendar being movable in order to position a selected start day on a first tablet in the array of tablets, and with pointers being provided on the container, and the blister pack has a locating notch near its edge and in proximity to a first tablet, such that the first tablet to be taken is indicated.
Furthermore, DE 10 2005 032 015 A discloses a case which receives a blister pack and comprises a first case half and a second case half hinged thereon. The first case half is designed as a pocket for receiving the blister pack and has an outer part and an inner viewing part and also first apertures in the viewing part and second apertures in the outer part, the first apertures being aligned with the second apertures, specifically at least where the receptacles for the tablets are located in the blister pack after it is received in the pocket. The second case half has a compartment for receiving a display means displaying days of the week, and windows for displaying the days of the week in an inner viewing surface of the second case half in the area of the compartment, the windows being arranged in such a way that they are assigned to the columns of the receptacles of a blister pack received in the pocket.
These embodiments of devices for storage and provision of medicament units relate to tablets in blister packs, however, and not to medicament wafers in medicament pouches.
It is therefore an object of the present invention to make available a device for storage and provision of medicament wafers.
Another object of the present invention is to ensure that the wafers are reliably removed from the device in a predetermined rhythm, i.e. that the device allows the user to monitor whether a medicament wafer has been taken as planned at a predetermined time.
A further object of the present invention is to make available a device for storage and provision of medicament wafers which is suitable for everyday use, has the required mechanical stability and can be produced easily and simply and therefore inexpensively.
A further object of the present invention is to provide a safe means of storing the medicament wafers.
SUMMARY OF THE INVENTION
These and other objects are achieved by the present invention.
A medicament pouch in the device according to the invention is typically composed of a base film and of a cover film. The cover film can be connected, for example glued, to the base film via a preferably strip-shaped join that extends along the side edges of the cover film. Moreover, in a particularly preferred embodiment, the base film and the cover film, on at least one side edge, each have protruding flaps that are not connected to each other. This makes it much easier to tear apart and thus open the medicament pouch in order to remove the wafer contained therein, because the two films can be easily gripped. A medicament wafer is enclosed between the base film and the cover film inside an area formed by the join.
The device according to the invention, which is used for storage and provision of medicament wafers, comprises medicament pouches which are arranged as a stack of pouches and contain medicament wafers. In the device, a support is arranged substantially parallel to an edge of the medicament pouches. To afford the user the possibility of monitoring whether a medicament has already been taken at a predetermined time, date indicators are arranged on the support, and a marking is arranged on each medicament pouch, such that markings arranged on successive medicament pouches in the stack of pouches are each in alignment with successive date indicators on the support.
By virtue of the fact that the medicament pouches in the device are arranged as a stack of pouches and are provided with mutually offset markings, and that display means for indicating the time at which the wafers are taken are arranged preferably on a support, substantially parallel to an edge of the medicament pouches, a user is at all times able to monitor if a wafer has already been taken at the actual intended time or if this is not the case.
DETAILED DESCRIPTION OF THE INVENTION
To secure the medicament pouches, with the wafers contained in them, in the device, the medicament pouches can be connected to the support preferably along the edge.
In a preferred embodiment of the invention, the support is formed by stub leaves which are arranged as a stack of leaves. These stub leaves are connected to one another at least in the area of a respective first leaf edge. Moreover, in this case, each medicament pouch is connected to one of the stub leaves via a respective second leaf edge opposite the first leaf edge, this also including the stub leaves being each formed in one piece with the medicament pouches, i.e. the medicament pouches being made wider at one edge thereof and forming the stub leaves at this widened edge. In this embodiment, the date indicators are arranged on a top stub leaf of the stack of leaves, along the second leaf edge thereof, or on a flap covering the top stub leaf.
Alternatively, the support can also be arranged adjacent to a first edge of the medicament pouches which lies opposite a second edge of the medicament pouches where the medicament pouches are connected to stub leaves via a respective second leaf edge lying opposite a first leaf edge of the stub leaves.
By means of the chosen structure of the device, the medicament pouches, with the wafers contained in them, are stacked together as in a notepad or book and can be removed one after another, preferably from the top. When the pouch lying at the top is removed in order to administer a wafer for a first time, the pouch lying below it in the stack becomes visible. This pouch lying underneath can then be removed during a subsequent second time of administration. The other pouches with the wafers can be removed according to the sequence of pouches in the stack. The pouches are each connected to stub leaves and are held by these in the stack. For removal, in one embodiment, a pouch can in each case be severed from the stub leaf to which it is connected. In an alternative embodiment, each pouch can be removed from the stack together with the connected stub leaf, for example by tearing it off or unstapling it.
By virtue of the fact that date indicators are arranged on a support, for example along the second leaf edge of a top stub leaf in the stack of leaves, and a marking is arranged on each of the medicament pouches in such a way that the markings arranged on the medicament pouches are each in alignment with the date indicators, the user can at all times tell if a pouch with a wafer has already been removed from the stack at the actual intended time, and the wafer has thus also been taken, or if this is not the case. It is possible to establish this from the fact that the marking located on the pouch is aligned with a defined date indicator on the adjacent support, preferably on the top stub leaf. In this way, the user can tell if the actual time falls within the period of time indicated by the date indicator of if this is not the case. Since the markings on successive pouches in the stack of pouches are in alignment with successive date indicators, removal of a top pouch from the stack of pouches reveals a marking on the pouch underneath, which is staggered by one unit of the date indicators, such that the time for the next administration is displayed. With this assignment of individual pouches to the date indicators on the stub leaves, it is easy to ensure reliable compliance with the administration schedule, since the user can tell from the marking on the top pouch, and from the date indicators on the support or along the leaf edge, whether a wafer has in fact to be removed and taken.
In a first embodiment in which the support is formed by a stack of leaves, and in which each pouch is removed from the attached stub leaf by being separated from the stack, date indicators are located only on a top stub leaf, since only this top stub leaf remains visible at all times. In a second embodiment in which the support is formed by a stack of leaves, and in which each pouch is removed from the stack together with the attached stub leaf, it is not only the top stub leaf, but every stub leaf connected to a pouch, that has to be provided with the date indicators, since the stub leaves are each removed at the same time as the pouches are removed. In this case, the support is formed by the respective top stub leaf together with all the stub leaves lying below it. However, since the date indicators in the latter case have to be arranged on all the stub leaves, the first embodiment is preferred over the second embodiment.
In a preferred further embodiment of the invention, each medicament pouch is connected separably to one of the stub leaves, for example by a perforation. In this way, the pouches can be easily removed from the stack, for example by being torn out. Each of the pouches can be produced in one unit together with an associated stub leaf, for example by means of the component parts of the pouches (base film, cover film) being made wider on one side. This part formed by the widening corresponds to the stub leaf.
If the wafers are to be taken daily, the date indicators, in a preferred embodiment, indicate days of the week or days of the calendar, the latter shown by the numbering of the days of a month. Compared to the indication of calendar days, indicators showing days of the week have the advantage of a more frequent rate of repetition. This permits an easier arrangement of date indicators on the support or on a top stub leaf, since for the first day only the matching day of the week has to be chosen from all seven days of the week, whereas, in the case of calendar days being indicated, the matching calendar day has to be chosen from 28, 29, 30 or 31 calendar days. Moreover, in the case of calendar days being indicated, at least as many calendar day indicators have to be arranged on the support or top stub leaf (at most 28, 29, 30 or 31 indications depending on the month) as there are pouches contained in the stack, since a repetition of the calendar day indicators takes place only at the start of a new month. In addition, it must be noted that the length of the month can be 28, 29, 30 or 31 days. This can easily lead to the device being used incorrectly. For this reason, the date indicators preferably indicate days of the week. In this case, it is preferable for seven days of the week to be indicated, preferably on the top stub leaf of the stack of leaves.
The days of the week, calendar days or other date indicators are preferably arranged on the support, preferably the top stub leaf, at the start of the period of administration of the wafers. For this purpose, the user arranges the date indicators on the support, preferably along the leaf edge, such that the date indicator for the first administration, for example for the first day of administration, lies either at the very top or at the very bottom, depending on the sequence of the markings on the successive medicament pouches, and the subsequent date indicators, for example days of the week, follow on above this or below this, in which process the pattern of markings on the medicament pouches has to be observed of course when applying the date indicators, such that the date indicators are in alignment with the markings.
The date indicators are preferably arranged on the support, in particular along the second leaf edge, by applying to the support a display means that comprises the date indicators. For example, a display strip containing the date indicators can be applied by slipping it into a holder on the support or by affixing it to the support. For example, the holder can be a slit in the support which, in the area of the date indicators arranged on the inserted display strip, has windows which permit viewing of the date indicators and permit assignment to an aligned marking on the top medicament pouch.
A display strip of this kind can, for example, initially have about twice as many successive date indicators as can be accommodated on the leaf edge, so as to be able to suitably prepare the display strip for application to the support. After determining when a wafer is to be taken for the first time, the associated date indicator on the display strip is assigned to the upper or lower position on the support, and the length of the display strip is then reduced to the length area corresponding to the available length on the support. For example, the display strip can be bent aside or cut off for application to the support above or below the date indicator for the first administration. Protruding parts of the display strip at the top or bottom can likewise be bent aside or cut off. The prepared display strip is then secured in the holder on the support, for example pushed into it or clamped there, or affixed to the support, such that the date indicators are in alignment with the markings on the medicament pouches.
Of course, the date indicators can also be applied in handwriting to the support.
The stub leaves are preferably connected to one another by clipping, gluing or stapling or by a ring binding or spiral binding. In principle, other types of connection are of course also conceivable. The stub leaves can for example be connected to one another by planar connection, for example by being glued to one another, in the area of their edge. An intimate and secure join of the individual stub leaves is achieved in this way. In another embodiment, the stub leaves can be hinged on one another. The latter is achieved by the stub leaves being connected to one another exclusively or mainly across the margins of the first leaf edge. In a particularly preferred embodiment, the stub leaves are connected or hinged to one another by a ring binding or a spiral binding, for example as in a notebook.
Moreover, an additional cover can be secured on at least one side of the stack of pouches in order to provide protection against mechanical or other effects, for example on the support or on the side of the stack of pouches opposite the support. In the closed state, this cover can bear on the outside of the stack of pouches. In one embodiment, the cover can be secured, particularly preferably hinged, on the support, and, in another embodiment, on that side of the stack of pouches opposite the support. The cover can be provided in particular for protection of the medicament pouches. The cover is made preferably of a stable material, for example card or plastic. The cover can be provided with an inscription or a logo or with some other arrangement that does not exclusively have functional purposes but also aesthetic purposes.
Moreover, in the area of the support, a cover can be connected thereto on one side of the stack of pouches and engage across both sides of the stack of pouches by being folded back at a side edge of the medicament pouches that lies opposite the support. For example, such a cover can be folded or bent from a sheet of card or plastic. The cover can be connected via one of its edges to the support and, at a distance therefrom and preferably parallel thereto, can have a fold that permits the folding back across the stack of pouches. The cover can thus completely cover both the front face and also the rear face of the stack of pouches and effectively protect the latter. The fold in the cover is preferably of such a width that it comfortably engages the thickness of the stack of pouches. In the closed state of the cover, the top pouch is protected by the free, folded-back front area of the cover, while the rear part of the cover connected to the support protects the rear face of the stack of pouches. Moreover, in the area in which it is connected to the support, the cover can be folded forwards over the connection site and across the stack of leaves and cover the latter. Thus, in this case, the support is formed by the stack of leaves and by the cover folded around. The stack of leaves is in this way also protected against mechanical damage. Therefore, instead of being arranged on the stack of leaves, the date indicators according to the present invention can be arranged on a flap on the stack of leaves, which flap is created by the cover being folded about the stack of leaves. In this case, the stack of leaves and the flap together form the support. Such configurations are known from booklets of matches, for example. Their production is simple and efficient.
Alternatively, the cover engaging across both sides of the device can also be secured on the device at the side of the stack of pouches lying opposite the stack of leaves, and it can be folded back across the side on which the stack of leaves is arranged. In this case, the support can be arranged, for example, on the side of the stack of pouches lying opposite the stack of leaves, and the folding of the cover forms for example the support.
The device according to the invention can preferably contain 120 medicament pouches for receiving medicament wafers in a stack of pouches. For contraception, it has hitherto been customary for one administration unit, i.e. one wafer, to be taken within 21 days, this administration phase being followed by a medication-free phase of 7 days. In the case of modern contraceptives, however, administration cycles are used that last longer than 21 days, for example up to 120 days. This longer administration phase is then followed by a medication-free phase of 4 days. To be able to provide wafers in sufficient number for such a case, it is possible to provide 120 medicament pouches in the device.
The figures and examples described below will provide a more detailed explanation of the invention. Of course, the embodiments shown in the figures and examples are provided only by way of illustration. This illustration does not limit the scope of the invention. Rather, the description below will reveal to a person skilled in the art not only the particular variants of the invention that are shown here, but also undisclosed variants according to the invention that he will easily be able to arrive at.
FIG. 1 shows a perspective view of a first embodiment of the invention;
FIG. 2 shows a perspective view of a second embodiment of the invention in the state when opened;
FIG. 3 shows a perspective view of the second embodiment of the invention in the state when closed;
FIG. 4 shows a perspective view of a third embodiment of the invention.
The same reference numbers in the figures designate the same features.
A device according to the invention, for storage and provision of wafers, is shown in FIG. 1 . The device comprises a cover 2 , for example of plastic, and a plurality of medicament pouches 1 in which the wafers are enclosed (not shown). The reverse of the device can be provided with another cover (not shown) which protects the medicament pouches 1 from mechanical damage. Each of the medicament pouches 1 has at its side a stub leaf 3 which, at a second leaf edge 3 ′′, is separated from the medicament pouch 1 only by a perforation 4 . The perforation 4 is used for tearing a medicament pouch 1 from the stub leaf 3 when needed, in order to be able to remove this pouch 1 from the device. The stub leaf 3 remains behind. This is shown in FIG. 1 : the top medicament pouch 1 . 1 has already been removed from the top stub leaf 3 . 1 by being torn off, and a bound medicament pouch 1 . 2 underneath it has become visible, which is still connected to the associated stub leaf (not visible) via the perforation 4 . It is possible for the device to contain, for example, 120 medicament pouches 1 . The cover 2 has an inscription which serves, for example, to provide directions for use and to identify the medicament and the manufacturer.
The medicament pouches 1 , with the stub leaves 3 attached to them, and the cover 2 are connected to one another in the manner of a booklet bound by a ring binding. For this purpose, first holes 6 are provided in a first leaf edge 3 ′ of the stub leaves 3 on each medicament pouch 1 , and one of the edges 7 ′ of the cover is provided with second holes 7 through which rings 5 of the ring binding engage.
The stub leaves 3 form a stack of leaves that forms a support 9 for date indicators. For this purpose, the top stub leaf 3 . 1 has date indicators that are arranged on a days-of-the-week strip 10 . The date indicators in this case show days of the week, here represented by the letters “M” (Monday), “T” (Tuesday), “W” (Wednesday), “T” (Thursday), “F” (Friday), “S” (Saturday), “S” (Sunday). This days-of-the-week strip is in the present case affixed to the top stub leaf 3 . 1 . The day indicator “M” for Monday is arranged at the very bottom, and the other days of the week are indicated in chronological order upwards from this. The day indicator “S” for Sunday is the last in this series. Choosing this arrangement of the day indicators on the days-of-the-week strip 10 makes clear that the first wafer is intended to be taken on a Monday. If, for example, the first wafer was to have been taken on a Thursday (corresponding to “T”), the days-of-the-week strip 10 would have had to be affixed in another format on the top stub leaf 3 . 1 , namely in the sequence (from below): T, F, S, S, M, T, W. The same applies to other schedules for taking the medicament. It is therefore preferable, before the start of treatment, to provide a user with a days-of-the-week strip 10 which can be used to prepare the device and on which all the days of the week are printed in sequence about twice, such that the user can prepare the display strip 10 with the 7 date indicators arranged in a sequence beginning with the day of the week chosen for the start of treatment. The end parts of the days-of-the-week strip 10 that are not needed are then cut off (or, if appropriate, are folded back if the strip 10 is secured in a holder or is pushed into a slit).
Markings 20 are also arranged on the medicament pouches 1 . The first medicament pouch 1 . 1 has a first marking 21 , which is in alignment with the day of the week indicator “M”=Monday on the days-of-the-week strip 10 . Thus, the wafer contained in this pouch is intended to be taken on a Monday. The medicament pouch 1 . 2 , which is located underneath and becomes visible when the top medicament pouch 1 . 1 is torn off, has a second marking 22 , which is in alignment with the day of the week indicator “T” for Tuesday on the days-of-the-week strip 10 . The wafer in this second pouch 1 . 2 is therefore to be taken on a Tuesday. Further markings 23 , 24 , 25 , 26 , 27 are only indicated symbolically here, since they are hidden in the indicated sequence on the subsequent medicament pouches 1 . Each of these markings 23 , 24 , 25 , 26 , 27 is in alignment with one of the days of the week indicators “W” for Wednesday, “T” for Thursday, “F” for Friday, “S” for Saturday and “S” for Sunday (in the stated sequence). The wafers contained in the medicament pouches located below are therefore to be taken on the corresponding days of the week. It is thus immediately clear to the user if a wafer has already been taken on a particular day or if this is not the case.
FIG. 2 shows a second embodiment of the invention. The device once again has a cover 2 , for example of board, and medicament pouches 1 . The cover 2 in this case also has an inscription that can be used to provide directions for use or to identify the medicament and the manufacturer. The cover 2 can be connected to a stack of leaves by gluing. This stack of leaves comprises a plurality of stub leaves 3 , which are glued to one another. These stub leaves 3 are separated from the medicament pouches 1 by a perforation 4 . To produce a medicament pouch 1 with a stub leaf 3 , the necessary base film and cover film are suitably prepared so as to form not only the medicament pouch 1 but also at the same time the adjoining stub leaf 3 . For this purpose, said base and/or cover films are to be made suitably larger than is needed to receive the wafers. After production of the pouches 1 , with the wafers located in them, and formation of the perforation that is used to separate each of the medicament pouches 1 from the associated stub leaf 3 , the medicament pouches 1 are stacked together with the stub leaves 3 in order to produce the device, and the stub leaves 3 are glued exclusively in the area of the stub leaves 3 . The stack of leaves resulting from the gluing of the stub leaves 3 can be connected to the cover 2 by adhesive bonding.
In the lower area of the device, the cover 2 is folded back towards the stack of pouches in order to form a flap 15 . The support 9 for the date indicators is formed in this way. Above the stack of leaves, the cover 1 forms an upper fold 11 , such that the cover 2 can be folded back across the front face of the stack of pouches.
A days-of-the-week strip 10 showing the day indicators “M”, “T”, “W”, “T”, “F”, “S”, “S” is affixed to the support 9 . The strip is prepared as in the example in FIG. 1 , such that the start date appears on the far left of the strip 10 , and is affixed to the support 9 . The medicament pouches 1 are also provided with markings 20 , which are in alignment with the day indicators on the days-of-the-week strip 10 . A marking 21 in alignment with the day indicator “M” is arranged on the top medicament pouch 1 . 1 , and a second marking 22 in alignment with the day indicator “T” is arranged on the medicament pouch 1 . 2 underneath. This second marking 22 is only shown symbolically here. Further markings are not shown, because they are concealed by the medicament pouches 1 lying in front of them.
FIG. 3 shows the second embodiment of the device according to the invention in the state when closed. An inscription and logos can be arranged on the outside of the cover 2 .
FIG. 4 shows a third embodiment of the device according to the invention. This device is formed like a booklet of matches. The inside face of the cover 2 is provided with an inscription, for example directions for use including the name of the medicament and the name of the manufacturer. In the lowermost area of the device, the cover 2 forms a flap 15 by way of a lower fold, by means of the cover 2 being guided round a stack of stub leaves 3 and secured there. The cover 2 does not cover the stub leaves 3 completely, however. It will be seen in FIG. 4 that the stack of leaves protrudes partially relative to the flap 15 . The support 9 is formed by the flap 15 and the stack of leaves. The cover 2 protects the rear face of the stack of pouches and is kinked at an upper fold 11 onto the front face of the device, such that it can also protect the front face of the stack of pouches against mechanical damage.
The stub leaves 3 are connected to the associated medicament pouches 1 via a perforation 4 . As in the case of the device according to FIG. 2 , the medicament pouches 1 can be produced in one piece with the associated stub leaves 3 . The two parts can be separated from each other with the aid of the perforation 4 .
A days-of-the-week strip 10 showing the day indicators “M”, “T”, “W”, “T”, “F”, “S”, “S” is once again arranged on the support 9 . The medicament pouches 1 have markings 20 , which are in alignment with the associated day indicators. In the example shown, the series of days of the week begins with “M” for Monday and ends with “S” for Sunday. A first medicament pouch 1 . 1 lying at the top is torn off from the support 3 with the aid of the perforation 4 . Part of the top stub leaf 3 . 1 is visible. The detached pouch 1 . 1 has a first marking 21 in alignment with “M” for Monday. A medicament pouch 1 . 2 lying underneath is visible. This second pouch 1 . 2 has a second marking 22 aligned with the day indicator “T” for Tuesday. By means of the markings 20 assigned to the day indicators, it is possible for the user to tell if a wafer has already been taken at the planned time, or if this is not the case.
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
In the foregoing and in the examples, all temperatures are set forth uncorrected in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.
The entire disclosures of all applications, patents and publications, cited herein and of corresponding German application No. 10 2007 037 374.2, filed Aug. 6, 2007, are incorporated by reference herein.
The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. | To monitor the intake of medicaments present in wafer form, a device is made available which is suitable for storage and provision of such forms of administration. This device comprises medicament pouches, which are arranged as a stack of pouches and contain medicament wafers, and it has the following features: a) the device has a support 9 which extends parallel to an edge of the medicament pouches 1 and on which date indicators are arranged, b) a marking 20 is arranged on each of the medicament pouches 1 in such a way that markings 20 arranged on successive medicament pouches 1 in the stack of pouches are each in alignment with successive date indicators. This ensures monitoring of the intake of the wafers. | 0 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/754,603 filed Dec. 30, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates to communication systems for user compliance and monitoring. More particularly, the present invention relates to interactive communication systems for the compliance and monitoring health. The present invention further relates to a method of generating revenue for an interactive communication system for compliance and monitoring health.
BACKGROUND OF THE INVENTION
[0003] For patients suffering from chronic illness, monitoring of their condition and ensuring compliance of health regimes is vital to their long term health. Often patients are not successful at keeping proper records of health statistics related to their condition. Logbooks, PDAs and computers adapted to monitor their conditions often become a burden, furthering their suffering instead of being a tool to assist them in effectively dealing with their condition.
[0004] In general, the ability to ensure the monitoring and response to changing physiological conditions in real time gives the patient the ability to react to their condition before an emergency occurs. The improved care through direct patient management means reduced costs associated with chronic conditions: less physician visits, less hospital visits and fewer sick days. It is documented that patient are up to 90% more compliant in reporting data using electronic diaries (eDiaries) versus paper based systems.
[0005] Diabetes is an example of a particularly difficult chronic condition requiring constant monitoring and attention by the patient. Diabetes is associated with an increased risk for a number of serious, often life-threatening complications and certain groups may experience an even greater threat. There are currently approximately 20 million people in North America alone suffering from Diabetes; this number is estimated to climb to 45 million by 2010. Good diabetes management can help reduce risk. However, approximately 70% of Diabetics do not manage their disease. In recent report issued by the American Association of Clinical Endocrinologists (AACE) entitled the “State of Diabetes in America”, blood sugar control across the United States was examined. The findings revealed that approximately two out of three Americans with type 2 diabetes analyzed in the study did not reach the AACE-recommended target blood sugar goal in 2003 and 2004.
[0006] Further, studies in the United States and abroad have found that improved glycemic control benefits people with either type 1 or type 2 Diabetes. In fact, after a 17 year federal study, the New England Journal of Medicine reported in the Dec. 22, 2005 issue that “intense control of blood sugar prevents heart attacks and strokes by nearly 50%”. According to the American Diabetes Association, every percentage point drop in A1C blood test results (e.g., from 8.0% to 7.0%) reduces the risk of microvascular complications (eye, kidney, and nerve diseases) by 40%.
[0007] In addition to glucose monitoring and control, blood pressure control reduces the risk of cardiovascular disease (heart disease or stroke) among persons with diabetes by 33% to 50%, and the risk of microvascular complications (eye, kidney, and nerve diseases) by approximately 33% [American Diabetes Association]. In general, for every 10 mm Hg reduction in systolic blood pressure, the risk for any complication related to diabetes is reduced by 12%. The control of blood lipids also is important, with studies showing that improved control of cholesterol or blood lipids (for example, HDL, LDL, and triglycerides) can reduce cardiovascular complications by 20% to 50%.
[0008] In addition to those suffering from chronic disease, preventative medicine often requires the monitoring of specific health-related statistics. For example, the monitoring of blood pressure and cholesterol is necessary for many people, especially those with a family history of cardiac problems. Moreover, so-called “pre-diabetics” are advised to keep close watch on their glucose level as a preventative measure in avoiding the full blown disease.
[0009] There have been various systems proposed for health monitoring. For example, U.S. Pat. No. 6,656,114 to Poalsen et al. discloses a specific method of self treating a disease, such as diabetes, wherein data is collected and processed to provide a number of alternative treatment options based on the analysis. The method and system is dependent on the diabetic patient to input the relevant data for analysis and treatment options. Specialized hardware is disclosed, namely a functional master module, providing a displaying means and input means, and includes a doser with transmitting and receiving capabilities.
[0010] U.S. Patent Application No. 2004/0059599 to McIvor discloses a health system and method to facilitate monitoring and management by a healthcare provider. The patient is prompted for various health-related data, which is then forwarded to the healthcare provider. The system is an acute health management system, requiring a response to an “alert” from the patient and subsequently provides options for alternative treatments.
[0011] U.S. Pat. No. 6,728,341 to Puchek et al. discloses a response and alert system supervised by a caregiver wherein the caregiver monitors the acute responses of the supervised person.
[0012] U.S. Patent Application No. 2004/0054263 to Moerman et al. discloses a specific diabetic monitoring and treatment system of a patient requiring a counselling centre, a glucometer, and a communication device adaptive thereof. The counselling centre requires a healthcare professional to provide advice, treatment options and coaching.
[0013] Although there are many alert type systems that have been developed, a major issue is the compliance element in being able to determine or enable greater compliance by ensuring that patients are acting in compliance with their respective health regimes. Although this may include measurements such as glucose levels or blood pressure, it may also require the taking of one or more medications, as well as elements such as exercise, discomfort levels or simply how the individual is feeling.
[0014] On the basis of the foregoing, there is a need for an interactive lifestyle monitoring system that is mobile and has a self-management aspect. There is a further need for an interactive lifestyle compliance and monitoring system that is simple, cost-effective, flexible, and requires no specialized hardware. There is yet a further need for an interactive lifestyle monitoring system that does not require third party intervention.
SUMMARY OF THE INVENTION
[0015] The present invention is a remote interactive method, system and computer program product for self-managing a person's regular lifestyle needs and attributes through a controlled notification and feedback system that monitors and ensures compliance.
[0016] In one embodiment, the system includes an input device comprising a communication means, a set-up means, a set-up notification means, an approval means, and a notification and data analysis means. The system furthermore comprises a user and administrator back-end means which includes a compliance measurement means.
[0017] The system provides for feedback and measurement for healthcare provides to ensure that those under their care are complying with notifications and respective regimes.
[0018] In that regard, the invention involves three compliance related elements: (i) relating to the direct management with a user; (ii) monitoring such compliance; and (iii) on the business model, creating an incentive for the user to use the invention over and above health concerns.
[0019] The system and method provides a simple, cost effective, and flexible self-management that does not require a third party intervention or treatment options on an immediate response or alert based system. The system provides for a long term management, compliance and analysis for the benefit of the individual. In implementing this method in a healthcare environment, the individual will gain a better understanding of managing their lifestyle and behaviour and allow for healthcare managers to measure compliance of certain activities (if required). Further, employing already existing and available low cost technology improves the rate of patient data capture.
[0020] Whereas the prior art has involved the intervention of a third party in the monitoring process (whether a healthcare provider, family member or otherwise), the present invention provides for self-management. Self-management provides a reinforcement mechanism that allows the patient to remain proactive and positive in relation to their condition.
[0021] Users are responsible for tailoring the setup to their particular needs. Notifications (such as a reminder or an alert) are provided on a regularly basis, prompting users to take necessary quantitative or qualitative measurements, medication, or to record particular activities or conditions. These notifications can be tailored in a number of ways, in accordance with the present invention. For example, the users can choose to monitor the particular attribute or attributes that are relevant to their condition, including glucose level, temperature, blood pressure, heart rate, weight, medication intake, pain characteristics, etc. The user is able to choose the number of notifications, and schedule them appropriately. The system confirms the input from the user, resulting in a reduction in the possibility of error. Such input in monitored, allowing the ability to ensure compliance or to determine the extent of compliance of the user.
[0022] The present invention utilizes SMS (“Short Message Service”) and MMS (“Multimedia Message Service”) technology with ordinary cellular phones or other personal communication devices. The present invention is advantageous in this respect, since it relies on existing SMS/MMS telecommunication technology and technology owned by the user, and not specialized hardware. However, the phone is not the only means of data entry; information can be entered into the system via an Internet portal. The system comprises two separate interfaces in this respect: (i) a consumer interface; and (ii) a system administrator interface.
[0023] The user is prompted for information, e.g., notification attributes, and the information is submitted back to the server. Based on disease-specific protocols determined by the user, the data can be analyzed immediately to identify trends, especially the detection of worsening conditions. Based on user-configured rules, family and other care-givers can be notified immediately of any adverse trends.
[0024] Users and their healthcare network can access more detailed information regarding the data collected through a web interface. The raw input data, basic trends and charts show the patients' most recent information as well as historical information which can all be printed out. Analytical tools can also be created and linked with the database. In addition, the healthcare provider and/or caregiver can also, based on the information, ‘push’ key messages via the present invention to a user or group of users depending on the circumstances.
[0025] The present invention also contemplates the pairing of other hardware, apart from personal communication devices, with the notification and feedback means. For example, patients can link “smart” BLUETOOTH™ enabled glucometers directly with the system or similar ‘smart’ monitors relating to measurements such as blood pressure, heart rate or even distance run. Furthermore, a global positioning device could be linked with the system or within the communication device to provide an advantageous feature if patient location monitoring is desired or analytics as to past or future location related behaviour. Hardware can also be adapted within the communication device such as biometric sensors to allow for quantitative measurements of the various attributes.
[0026] The present invention is preferably employed to provide monitoring and compliance systems for patients suffering from Diabetes, with the input data being related to glucose levels and/or blood pressure information. The present invention contemplates the monitoring of a plurality of measurements as opposed to just a single measurement. For example, Diabetes-related monitoring can consist of glucose levels, blood pressure values, heart rate, temperature, etc., or compliance issues such as whether medication has been taken and whether a user has exercised as may be required. It is to be expressly understood that monitoring of Diabetes-related conditions is only an example of an implementation, and the present invention contemplates various other applications, as discussed herein.
[0027] In an aspect of the present invention, the monitoring system is employed to monitor the blood pressure data of a user. In a further aspect of the present invention, the monitoring system can be used to track multiple measurements for patients who have undergone organ transplant. The present invention can also be employed to monitor a patient's thyroid condition, or to track Alzheimer's sufferers, or used to determine the mobility status of Arthritis sufferers, or as a means to record and monitor the medication intake and compliance for anyone on a specific medication regiment. The present invention is also well-suited for both diet management and related analysis, and exercise management and related analysis.
[0028] Further, the present invention is also operable to prompt the user for specific non-quantitative health or lifestyle related information related to any of the applications discussed herein.
[0029] In further aspects of the present invention, the monitoring system can be utilized for specific non-health related purposes, including but not limited to the following: maintaining contact with children; maintaining conduct with adults requiring supervision, such as with prison inmates, people involved in extreme-style sports such as skiing or cross country running, walkers, joggers, bike riders, etc.; meeting notification; reminder notification; travel or location updates (i.e. for people keeping track of travelers, such as children); fleet attributes such as gas consumption (input of fuel used and distance traveled); any type of location/trend analysis, including trend analysis involving a combination of location/activity and other data (e.g., tracking activity with glucose level or blood pressure); general remote input of an activity on a regular basis and analyzed for access by user and approved user(s); and/or general notification reminder system based on pre-determined parameters.
[0030] In yet a further aspect of the present invention, the present invention is adaptable to a business model whereby revenue is generated from the collection of service fees.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] A detailed description of the preferred embodiments is provided herein below by way of example only and with reference to the following drawings, in which:
[0032] FIG. 1A is a system diagram of the present invention, in one particular embodiment thereof.
[0033] FIG. 1B is a system diagram of the present invention, in another embodiment thereof.
[0034] FIG. 2A is a flowchart illustrating the overall method of the present invention.
[0035] FIG. 2B is a flowchart illustrating aspects of the method illustrated in FIG. 2A , namely the user's set-up, and the user's notification set-up.
[0036] FIG. 2C is a flowchart illustrating aspects of the method illustrated in FIG. 2A , namely system/admin approval.
[0037] FIG. 3 is a flowchart illustrating a further aspect of the method illustrated in FIG. 2A , namely an active interface.
[0038] FIG. 4 is a flowchart illustrating a further aspect of the method illustrated in FIG. 2A , namely access to a database.
[0039] FIG. 5A is a flowchart illustrating a further aspect of the method illustrated in FIG. 2A , namely a system administrator interface.
[0040] FIG. 5B is a flowchart illustrating a further aspect of the method illustrated in FIG. 2A , namely administrator user compliance review.
[0041] FIG. 6 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely a user login and registration system.
[0042] FIG. 7 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely database schema requirements for the user login and registration system depicted in FIG. 6 .
[0043] FIG. 8 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely a registered user web interface.
[0044] FIG. 9 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely a blood sugar report management system.
[0045] FIG. 10 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely database schema requirements for the blood sugar report management system depicted in FIG. 9 .
[0046] FIG. 11 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely a mobile reporting system.
[0047] FIG. 12 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely database schema requirements for the mobile reporting system depicted in FIG. 11 .
[0048] FIG. 13 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely an administration interface.
[0049] FIG. 14 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely database schema requirements for the administration interface depicted in FIG. 13 .
[0050] FIG. 15 is a flowchart illustrating an embodiment of a method of generating revenue in accordance with the present invention.
[0051] FIG. 16 is a flowchart illustrating another embodiment of a method of generating revenue in accordance with the present invention.
[0052] FIG. 17 is a flowchart illustrating a further embodiment of a method of generating revenue in accordance with the present invention.
[0053] In the drawings, one embodiment of the invention is illustrated by way of example. It is to be expressly understood that the description and drawings are only for the purpose of illustration and as an aid to understanding, and are not intended as a definition of the limits of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0054] Note that the term “Life:WIRE” is used herein for a method and system in accordance with the present invention.
[0055] With reference to FIG. 1A , the system of the present invention is best understood as a server ( 10 ) (referred to as the intermediary server computer) or group of interconnected servers and associated utilities. The server ( 10 ) in one particular embodiment of the present invention includes a web server ( 12 ) connected to the Internet ( 14 ), and operable to provide a series of web pages (not shown) further described below. The server ( 10 ) is also connected to a database ( 18 ).
[0056] In an embodiment of the present invention, the personal communication device ( 22 ) consists of a cellular phone, as illustrated in FIG. 1A , in which case the telephony server ( 20 ) of the present invention is further operable to support a connection between the communication device ( 22 ) and the server ( 10 ).
[0057] Alternatively, it should be understood that the telephony server ( 20 ) can support the connection between the communication device ( 22 ) and the server ( 10 ) via the Internet ( 14 ) through a wireless gateway ( 16 ). This embodiment is illustrated in FIG. 1B .
[0058] A server application ( 24 ) is linked to the server ( 10 ) of the present invention. The server application ( 24 ) consists of one or more software utilities that enables the described processing steps and supports the described functions, in accordance with the present invention. The computer program of the present invention is therefore best understood as the server application ( 24 ) linked to server ( 10 ). It should be understood that one of the aspects of the present invention is that there is no requirement for any specific programming on the communication device ( 22 ).
[0059] Suitable communication interfaces (not shown) are provided to the various components of server ( 10 ) in a manner that is known to enable the various communications there between.
[0060] The overall method of the present invention is illustrated in FIG. 2A . In summary, the method of the present invention consists of: (A) a user using an input device as a communication means; (B) the user sets-up an account and specifies a lifestyle notification scheme; (C) the account is approved by an administrator; (D) notifications (a notification can be an alert or a reminder, for example, depending on the implementation) are provided to user in accordance with their setup and user provides information to the system; (E) users' response data is analysed. The present invention further comprises both a user and administrator interfaces.
[0061] In a particular implementation of the present invention, related set-up functions and routines are initiated from one or more personal computers ( 28 ) that communicate with the web server ( 12 ) via the Internet ( 14 ). A user, using a personal computer ( 28 ), is first required to sign up to a website associated with the web server ( 12 ) and to perform certain set-up functions related to the operation of the present invention. The user sets up an account that is password protected. The user then determines the number of daily notification reminders, which can range from one to six, for example. Although the description herein discusses the frequency of notifications as within one to six per day, it should be understood that the present invention is not limited in this regard. The optimal number of notifications for any given user will vary, and may be greater than six per day or less than one per day.
[0062] The user also determines whether they want SMS notification to be sent to their cellular phone, for example, or alternatively the user can select strictly “active” interaction, meaning that the system of will anticipate Internet-only input and there is no requirement for SMS notification.
[0063] The input to the cellular phone ( 22 ) can be via simple text entry using the keypad, or the device can be configured to operate in a voice-activated manner. If voice-activated, the notifications would have an additional confirmation step whereby it would confirm the accuracy of the information entered by the user. The present invention contemplates the use of personal communication devices that provide technological means to measure and health or lifestyle related information of the user and subsequently communicate the information. As an example, “smart glucometers” can be employed by the user to reply to notifications by communicating glucose levels in accordance with the present invention. Other advanced personal communication devices can be employed having the capabilities to take a user's temperature, measure blood pressure, heart rate, etc. Furthermore, sensors can be embedded into the personal communication device such as a cell phone that can quantitively measure attributes such as temperature, heart rate, etc.
[0064] The user selects the interval time period to which the trend analysis is conducted by the system. As a default, trend analysis is conducted for every ten measurements, for example. The user also determines and selects the parameters for the trends in terms of when to issue notifications. The user specifies who, if anyone, should be sent an alert or notification when said notification parameters are met.
[0065] FIG. 2B depicts further aspects of the present invention. The user uses one or more of the input devices to provide the required information to accomplish the application set-up. The application set-up involves inputting information relating to the user. Included in the application set-up arc attribute parameters, if desired, which are elements that would allow Life:WIRE to better assign questions/notifications worded in a matter most likely preferable to the user. It would also Life:WIRE to group the user with similar attributes for chats, support, etc. The user thus establishes the notification scheme based on their own interactive lifestyle monitoring needs.
[0066] The notifications are also set-up, and there is a plurality of notification or alert types, as depicted. The notifications can be set-up in a plurality of ways, for example, single query, multiple query with no immediate response required, or multiple query with a response dependent on input. The user may determine the nature of the one or more elements measured or may be pre-determined by a third party administrator for the user. In addition, a user may desire notifications for multiple events (e.g., glucose, blood pressure, etc.). A user may also specify that the wish to response via alternate means than used to remind (e.g., SMS notification but a response via computer). The parameters for analysis for triggering the notification (i.e. a reminder or an alert) can be established either by the user or by a third party administrator.
[0067] Further, there is a system approval aspect as shown in FIG. 2C . In the approval process, the user submits all relevant and required information to a system administrator or manager for approval, and they determine whether an account is activated.
[0068] The user uses the input means the user provides information to the system via the active interface, an example of which is illustrated in FIG. 3 . The active interface governs the relationship between the user and the system, including the responses provided by the user in response to a notification, and analysis that the system conducts.
[0069] All information is accessible to the user and authorized third parties by accessing the database ( 18 ). As illustrated in FIG. 4 , access to the database ( 18 ) is preferably protected in some way, e.g., by a HASH algorithm. This along with one or more other security techniques ensures that the information remains secure.
[0070] Once the required parameters are specified, the user submits the info for approval through the Internet ( 14 ). The administrator receives the request for approval. If the request is not approved, the administrator deletes the request and user cannot go any further. If approved, the user is sent an e-mail for confirmation. When an e-mail sent, the user is also sent phone confirmation via SMS. Once the user replies, the system notifications are set.
[0071] In a particular implementation of the present invention, once the notification scheme is established, the system provides notifications to the user. The user responds to a notification, and the system assumes that any response prior to the next notification pertains to the preceding notification. The system performs trend analysis based on parameters selected by the user. The system determines whether response is within or outside such parameters. If it is within parameters, the system sends an SMS confirmation of the specific response. If outside the parameters, the system sends a confirmation of the specific response and provides additional notification that the user is outside its parameters. The system also sends an e-mail notification to addresses as indicated and approved by the user in the application setup. These third parties (e.g., a family member or a caregiver) may access the user's database of information provided they have been given permission and the login and password information from the user.
[0072] In the event that the user does not respond for a specified period (with an example default setting being two days), the system will send an e-mail to the user notifying them of non-response and allowing them to review the account database to make required updates and/or to contact administrators/support.
[0073] In a further aspect of a particular implementation of the present invention, the user may access their database ( 18 ) via the website using their login/password and have the following options: (i) non-wireless input, namely the user has the option at any time to input information directly into database via a computer with Internet access; (ii) charted information, namely viewing of their raw data in date order (as chosen by user) or for specific date period (as chosen by user), or user may view their data on an animated bar chart in date order (as chosen by user) or for specific period (as chosen by user); (iii) the user can update or revise information, including the information at initial set-up, e.g., SMS number, password or e-mail address; (iv) the user may activate or deactivate any notifications at any time; and (v) the user may print-out the database information from the web interface.
[0074] The administration interface of the present invention provides access to administrators to certain functions linked to the server ( 10 ). In a particular implementation of the present invention, these functions/resources are accessed via a series of web pages linked to the web server ( 12 ). The administration interface comprises a main page that prompts the user for login and password information. As an example, a flowchart illustrating a system administrator interface is provided in FIG. 5A . It should be understood that alternate means for authentication are also contemplated by the present invention. These web pages, for example, enable administrators to approve all requests for activation, review and access of all accounts (and respective databases), review usage of system via logs, etc., and provide an analysis of usage of system, accounts, etc. The administrator user compliance review is shown in FIG. 5B .
[0075] It should be understood that other functions/resources can be associated with the server ( 10 ) and made accessible via selection from possible options via user commands described in the present invention.
[0076] The present invention also provides for a plurality of notification types. In a particular implementation of the present invention, the notifications are provided by the server to the cellular phone in the form of enhanced test messaging. For example, the text notification can be a simple question, or multiple questions. In a further aspect, notifications can be multiple questions wherein each subsequent question is dependent on the previous response. The present invention also contemplates multiple notification options, including audio alerts, including musical alerts, voice alerts, and/or simple tones or ringing.
[0077] These audio notifications can be sent via MMS, and can be in mp3 or other suitable formats. A visual alert can be provided where such visual notifications are supported by the personal communication device ( 22 ). As mentioned herein, the notification can also be a direct alert linking to a third party, for example a family member or caregiver, as selected by the user. It should be understood that any notification or alert type mentioned herein can be implemented alone or in combination with other alert types, in accordance with the users' selection(s).
[0078] As mentioned, in yet a further aspect of the present invention musical notifications or alerts can be provided to the user through their personal communication device. In this regard, it is possible to correlate the particular musical piece to the various specific levels of notification or alert for the user. As an example, a notification comprising the song “Sugar, Sugar” can correspond to mild levels, whereas an notification comprising the song “No Sugar Tonight” can correspond to more serious levels. The parameter of these types of notifications can be set by the user and changed from time to time, in accordance with the present invention.
[0079] In a further aspect of the present invention, the content of notifications can comprise specific information based on database analysis. For example, the notification content can be tailored (by the user) in relation to the database analysis relevant to, e.g., dietary requirements, exercise requirements, medical condition, individual reading or measurement, and/or support requirements.
[0080] In another aspect of the present invention, the data collected by the database ( 18 ) can be linked and provided to third party systems for further processing. For example, the data can be utilized for the purpose of patient record management or processing of insurance claims, subject to privacy issues.
[0081] In one specific example of the implementation of this aspect of the present invention, the Life:WIRE system can be utilized by a pain management health provider. According to this implementation, data that is collected (by the Life:WIRE system) concerning pain levels and medication use is provided to a patient record management system to improve the data available to the patient record management system.
[0082] The specific architecture to support this example implementation can be arranged as follows. A user can be fitted with a personal monitoring device that is operable to provide pain level and medication data (e.g., using BLUETOOTH™) to a personal communication device (e.g., a BLACKBERRY™). The personal communication device then provides this data to the Life:WIRE system, which acts as a communication broker with the pain management health provider. The pain management health provider provides for data normalization, data aggregation and secure storage, and is operable to interface with other services providers (e.g., emergency personnel, dentists, laboratory, pharmacy, etc.). Health records maintained by the pain management health provider can be directed to the particular user through their personal communication device, whether via the Life:WIRE system or directly.
[0083] In yet further aspects of the present invention, notifications can comprise yet further information and content for the user. For example, a notification can take the form of a video of a caregiver, or even of the user themselves, giving a quick lecture about the current status, corresponding to the notification level. The notification can also provide links to sites, phone numbers, and suppliers relevant to the level. Alternatively, the notification can directly provide a tie-in, via text, cell, e-mail, web, camera, etc., to the particular caregiver or support individuals, as customized by the user. The present invention contemplates each one of these possible notifications/alerts, and any combination thereof, with the type of notification and any corresponding trend analysis customizable by the user.
[0084] The information requested by each notification is dependent on the individual needs of the user. For example, for users interested in monitoring Diabetes-related attributes, the notifications will prompt the user for specific values, including, e.g., glucose levels, blood pressure data, heart rate, weight, temperature, etc. The present invention is capable of interactively monitoring a plurality of measurements.
[0085] Tailoring the content of notifications may further improve the user's success at achieving adherence/compliance to a particular health regime. In this regard, the notifications can be changed on a regular basis, and can incorporate effects or entertainment elements to make them more interesting and engaging, for example through the use of comedy.
[0086] Further, the present invention is not limited to quantitative information but is also operable to prompt the user for specific non-quantitative health or lifestyle related information related to any of the applications discussed herein. For example, the notification can consist of a simple question, such as “How do you feel?”, “Do you feel alert?”, and “Do you feel tired?”, etc. This in turn can result in additional questions to where these qualitative questions can further yield helpful information from the user and can be correlated to other data via the data analysis aspect of the present invention. Such non-quantitative health or lifestyle related areas include dietary issues, mental health such as anxiety and exercise, to name a few.
EXAMPLE
[0087] The operation of the present invention is best understood by reference to the example below. In this particular implementation of the present invention, the Life:WIRE system is used to record glucose measurements for Diabetics. The system server notifies the patient to take his or her glucose readings from their glucometer. The patient then inputs the information and the database responds with both a confirmation of the level and notification if the levels on average are rising or falling. In the event that the level remain high or low for a determined period of time, the patient-designated individuals (caregiver, parent, physician or other) is emailed a notification to that effect.
[0088] It is to be expressly understood that monitoring of Diabetes-related conditions is only an example of the present invention in operation. The present invention comprises a plurality of applications, as detailed in the foregoing.
[0089] More particular aspects of the example are described below and are further illustrated by reference to the Figures. Specifically: (A) FIG. 6 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely a user login and registration system; (B) FIG. 7 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely database schema requirements for the user login and registration system depicted in FIG. 6 ; (C) FIG. 8 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely a registered user web interface; (D) FIG. 9 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely a blood sugar report management system; (E) FIG. 10 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely database schema requirements for the blood sugar report management system depicted in FIG. 9 ; (F) FIG. 11 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely a mobile reporting system; (G) FIG. 12 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely database schema requirements for the mobile reporting system depicted in FIG. 11 ; (H) FIG. 13 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely an administration interface; and (I) FIG. 14 is a flowchart illustrating a further aspect of one particular embodiment of the present invention, namely database schema requirements for the administration interface depicted in FIG. 13 .
1. User Login and Registration System
[0090] In an embodiment of the present invention, every new and registered user accessing the Life:WIRE system will require a username (which can be an e-mail address) and password. This system is illustrated in FIG. 6 ; the database schema requirements for this are illustrated in FIG. 7 .
[0091] (a) Login Screen
[0092] In one particular implementation of the present invention, the login screen will be the default page seen by any user attempting to access the site that is not logged in. The page will allow the user to enter their username (e-mail address) and password and then click a login button to confirm that their credentials are valid. Should the user information provided prove valid, the user will proceed to the “History Overview” page which is covered under the “Registered User Web Interface”. Should the credentials the user supplied be invalid, the user will be sent to the “Login Error” page that is detailed below.
[0093] This login screen will also include a link labelled “Forgot Password?”. This link will lead to a webpage that will allow a user to receive a new password via e-mail.
[0094] There will also be a link labelled “Create New Account”. When a new user arrives at the site they would use this like to begin the account creation process.
[0095] Users will be assigned to specific roles within the system. These roles include administrators, alpha testers, beta testers and general users. The user roles are set in the tbl_userGroup table and can be adjusted as needed. The roles control what functionality the users have access to within the system.
[0096] (b) Login Error
[0097] Should the user's credentials be invalid, they will be directed to this page. They will be notified that there has been a problem with the information they supplied and provided options to proceed.
[0098] The user will be able to use a link to return to the “Login Screen”. There will also be a link to the “Forgot Password?” system.
[0099] Finally, there will be the option to “Create a new account” that will link the user to the “User Registration Form”.
[0100] (c) User Registration Form
[0101] In this embodiment of the present invention, the user registration form is the first step in creating a new account. The user must provide his/her first and last name, a valid e-mail address that will also act as their username, the cell number they wish use, and a password. The password field will be masked so users will be required to enter it twice to ensure that they do not make a mistake. Once the user has completed the registration form they will click the “Next” button to continue to the “Reminder Schedule” page. During the submission process, the data that the user entered will be verified and, should a field have been left blank or was filled-in incorrectly, the browser will return to the “User Registration Form” with the errors highlighted at the top of the page.
[0102] (d) Reporting Schedule
[0103] Once a user has completed the “User Registration Form”, they will be asked to fill in the “Reporting Schedule”. The user will be presented with the option to input as many notifications, which in this case are reminders, as they choose and at which time they would like to have the reminder sent. They will also have the option to determine the nature of the reminders such as requiring the input of glucose levels or confirmation of having taken medication. The user will be able to change these times, and nature of reminders and they will also have the ability to turn any or all of the reminders off. They will also have the option of setting a reporting time but not having that time send out an SMS reminder.
[0104] Under the reminder time area will be three blank text boxes where the user can enter in e-mail addresses. These three e-mail addresses will be copied on any notifications that are sent the user's cell phone. The e-mail fields can be left blank.
[0105] In addition, the user will set their personal settings which allows the user to create the parameters under which the invention analyses the respective data trends. For example, in the measurement of glucose levels, it will allow for the user to determine the upper and lower limits and the number of measurements to use for such analysis. If the data trends go above or below such parameters, the invention will send a notification of that event to the pre-determined above
[0106] When the user has completed the form, they will click on the next button to continue. The page will check the times to make sure that they do not overlap.
[0107] Once the process has been completed, the page will display a thank you message and a note stating that a confirmation e-mail has been sent. The confirmation e-mail will contain a link that will have to be clicked on to verify the validity of the account. More information on the e-mail can be found below.
[0108] The scheduled reminders will be stored in the tbl_userRemindersSchedule table, as illustrated in FIG. 7 . This table is designed to be scalable so that the number of reminders is scalable as the system is further developed. For this example, users will be limited to and prompted to use up to six reminders, however this is a soft requirement based on the forms and not the data structure.
[0109] (e) E-mail: Confirmation Link
[0110] Once the user has completed the various web forms that are required to create an account they will receive an e-mail. This e-mail contains a link that returns the user to the website and confirms that the e-mail account that is associated with the new account is in fact accessible to the user. The link will send the user to the “Confirmation Received/Cell Phone Activation Instructions”.
[0111] (f) Confirmation Received/Cell Phone Activation Instructions
[0112] When a user clicks on the link supplied to them in the “E-mail: Confirmation Link”, they will be sent to this page. The page will confirm that the user's web account will be activated once an administrator approves the account. The page will also inform the user that a SMS message has been sent to their cell phone. “SMS: Cell Phone Confirmation” section has more information on the details of the message. This page will also contain a link back to the “Login Screen” and the text for that link should read “Back to User Login”.
[0113] (g) Forgot Password
[0114] Should a user have forgotten their password, they will be able to use the “Forgot Password” page to retrieve it. The user will be asked to enter the e-mail address they used to create their account and then hit a “Send Password” button. The page will then create a random password for the user's account and send that password to the user in an e-mail. More information on the e-mail can be found under the heading “E-mail: Random Password”. Should the e-mail address entered not be registered with the Life:WIRE system, the page will inform the user that the e-mail is not recognized.
[0115] (h) E-mail: Random Password
[0116] Should the user forget their password, they can request that the site create a new one and e-mail it to them. They will then receive an email that contains a new randomly generated password.
2. Registered User Web Interface
[0117] According to a particular implementation of the present invention, when a user wishes to review their blood sugar report history or make changes to their user account information, they will be able to do so via the “Registered User Web Interface”. This interface is illustrated in FIG. 8 . A user will need to have an account registered with the system and be logged in.
[0118] (a) Navigation System
[0119] A universal navigation system will be present on every page that is part of the web-based interface that a user interacts with while logged in. The navigation system will include links to the following locations: “History Overview”; “Blood Sugar Report Form”; “Blood Sugar Report Management”; “Change Reporting Schedule”; “Change User Information”; “Cell Phone Activation” (only appears if cell not active); and “Logout”.
[0120] (b) History Overview
[0121] When the user logs into the web site, they have the option to come to this page. The page is meant to summarize the most recent data based on the user's reporting. The user will be presented with a bar chart of their average blood sugar level on a weekly basis.
[0122] They will also see a graph of their reporting history displayed with each row containing a full day of reports.
[0123] The user will be able to adjust both the total time frame of the blood sugar chart displays (1 month, 2 months, 3 months, etc.) as well as the time each bar represents (daily, weekly etc.). Should a user's account not contain enough data to fill the requested time frame, the bars that do not have data will be set to zero.
[0124] The graph of reported data will adjust to the number of reporting times the user has set-up. For example, if the user has opted to only report their blood sugar 3 times per day, each day will only show 3 reports. The chart will display reports from newest to oldest. The user will also have the option to view a print-friendly version of this page that they can take with them to their 3-month check up.
[0125] (c) Print-Friendly View (History Overview)
[0126] Should a user wish to print a version of the “History Overview”, they will click on the “Print-Friendly” link on that page. They will be presented with a page containing only the historical data (both chart and graph) that is formatted to fit within the margins of a standard 8″×11″ sheet. There will be a link on this page that will return the user to the “History Overview”.
[0127] (d) Change Reporting Schedule Form
[0128] Through the use of the Life:WIRE system a user may decide that their original reporting schedule is not working. They will be able to use the “Change Reporting Schedule Form” to make changes to these settings. The page will work very much like the “Reporting Schedule”, barring a few exceptions. The first is that rather than a blank form appearing, the page will automatically fill in all fields with the current user's information. The second variation is that once the user has submitted the form they will be sent to the “Reporting Change Summary”. The form will be verified against the same criteria as the “Reporting Schedule”.
[0129] (e) Reporting Change Summary
[0130] Once the user has submitted the changes they would like to see to their reporting schedule they will be sent to this page. The page will contain a summary of their new information and verification that the changes have been made. A link at the end of the summary will lead the user back the “History Overview” page.
[0131] (f) User Info Change Form
[0132] If the user needs to make a change to their account information they will be able to do so via this form. This form is very much like the “User Registration Form” with a few exceptions, namely the form will be filled-in with the current user's account information when it load, and the user will not be able to change their e-mail address. Once the user has completed the form and the data has been verified as properly entered the user will be sent to the “User Info Update Summary”.
[0133] (g) User Info Update Summary
[0134] Once a user has updated their user information they will be sent to this page. The page will display their updated user information and confirm that the database has been changed. Should the user have changed the cell number that is associated with their account, the summary page will send out a “SMS: Cell Phone Confirmation” message, as the new number will need to be confirmed before it is used. The page will also have a link back to the “History Overview” page.
[0135] (h) User Info Update Summary
[0136] Once a user has updated their user information they will be sent to this page. The page will display their updated user information and confirm that the database has been changed. Should the user have changed the cell number that is associated with their account the summary page will send out a “SMS: Cell Phone Confirmation” message, as the new number will need to be confirmed before it is used. The page will also have a link back to the “History Overview” page.
[0137] (i) Blood Sugar Report Summary
[0138] Once an online blood sugar report is successfully entered into the system, the user will be sent to this page where they will see a confirmation of their submission and be presented with a link back to the “Historical Overview”. Should the user's average blood sugar be outside of the recommended range over the past 10 reports, the system will show a warning message on this page and send out an “Email: Notification” to requested recipients. This will occur unless the report entered is more than one day old.
[0139] (j) Cell Phone Activation Instructions
[0140] Should the user have ignored or deleted the original “SMS: Cell Phone Confirmation” that was sent to them during the account creation process, they will be able to use this system to confirm their cell phone number at anytime. This page will give the user instructions on the confirmation process followed by a link to the “Confirmation that the SMS was sent” page.
[0141] (k) Confirmation that the SMS Was Sent
[0142] The user will be notified that an SMS message has been sent to their cell number and that they should reply to it in order to confirm their cell number. The user will then follow a link at the bottom of the page back to the “History Overview” page. The rest of the process is covered under the “Mobile Reporting” section of this document.
3. Blood Sugar Report Management System
[0143] In a further aspect of the particular implementation of the present invention, a user may want or be required to change or delete blood sugar reports. This may be due to errors made during the reporting process. The “Blood Sugar Report Management System” is an interface that will allow user to manage their blood sugar reports. This system is illustrated in FIG. 9 ; the database schema requirements are illustrated in FIG. 10 .
[0144] (a) Report List
[0145] This page will show a list of reports. The reports will be in the form of a table and the user will have several options to alter the view. Each record will have links associated with them that will allow the user to either edit or delete the record.
[0146] Due to the potential number of records that could be displayed, the page will only show 20 records at a time. The user will be allowed to scroll through the reports 20 records at a time.
[0147] The user will also be able to refine the number of records shown by restricting the time frame. The user will be able to set a start date and end date and any records that where entered during the specified period will be displayed.
[0148] The reports will be displayed in a chart. “Edit” and “Delete” found in the command column will be links to the “Edit Form” and “Deletion Confirmation” pages, respectively. They will allow the user to perform either operation on the specific report with which they are associated. The page will also have a link to the “Print-Friendly View (Report List)” page.
[0149] (b) Print-Friendly View (Report List)
[0150] Should a user wish to print out a version of the “Report List”, they will click on the “Print-Friendly” link on that page. They will be presented with a page only containing all the reports in the selected time frame formatted to fit within the margins of a standard 8″×11″ sheet. There will be a link on this page that will return the user to the “Report List” page.
[0151] (c) Edit Form
[0152] The user can select to edit a blood sugar report from the “Report List”, which will lead them to this page. The user will be able to change the date, time, and blood sugar level associated with the record. Once the user has made the necessary adjustments they can submit their changes, at which point any error will be reported. If the record is acceptable the user will be sent to the “Edit Summary” page. Any alteration will not trigger a warning to be sent out.
[0153] (d) Edit Summary
[0154] Once a blood sugar record has been updated the user will be shown a summary of the changes they have made on this page. The user will then be presented with a link back to the “Report List” page.
[0155] (e) Deletion Confirmation
[0156] Should a user select to delete a record from the “Record List”, they will be sent to this page. They will be asked to confirm the deletion request. If they click on ‘Yes’ the user will be sent to the “Deletion Confirmed” page. If they select ‘No’ the user will return to the “Report List” page.
[0157] (f) Deletion Confirmed
[0158] The user will be sent to this page once they have confirmed that they would like to delete a specific record. The page will confirm that the record has in fact been removed from the database. The user will then be able to take a link back to the “Report List”.
4. Mobile Reporting
[0159] According to an embodiment of the present invention, most of the day-to-day interaction with the Life:WIRE system will be conducted via the cell phone rather than on the web.
[0160] One aspect of this mobile reporting is the reporting window. Should a user register six reporting times in one day, they have created six windows during which time they must submit their reports. For example, a user has set their first reporting time to start at 9 am and the next to start at 12 pm. Any message sent in between these two times will be considered a valid first window report and will show up on their report chart under the heading 1. Should the system receive two reports during one of these windows, only the first report will be considered valid.
[0161] An issue facing the mobile portion of the Life:WIRE system is what to do when a user leaves a cell area or turns off their cell for long periods of time. The SMS system will be required to identify that a user is not receiving messages and stop sending in order to avoid messages piling up and reduce any sending cost that may be incurred. The server will need to be able to recognize when the user has reconnected and resume sending messages at that point.
[0162] The mobile reporting system is illustrated in FIG. 11 ; the database schema requirements are illustrated in FIG. 12 .
[0163] (a) SMS: Cell Phone Confirmation
[0164] At various times a user will need to confirm that they have access to the cell phone number they have provided. The confirmation process will start with this message being received by the user's cell phone. The message will instruct the user to simply reply to the message with the letter “Y” to confirm that they wish their cell phone to receive messages from the Life:WIRE system.
[0165] (b) SMS: Phone Verification Received
[0166] Once a user replies to the “SMS: Cell Phone Confirmation” and the server has successfully received their confirmation message, the user will be sent a follow-up message informing the user that their phone will now receive reminders.
[0167] (c) SMS: Reminder Received by User
[0168] The server will send out a reminder to the user's cell phone at specified times requested by the user. This message will inform the user that they should check their glucose levels and reply to the message with the result. The user should then reply to the message to report their blood sugar level. Any report the user sends back prior to the next reporting window commencing will be considered a successful response to this message.
[0169] (d) SMS: New SMS Report Sent to Life: WIRE Number
[0170] In some instances a user may request not to be sent a reminder yet still wish to report their blood sugar. They would be able to do so by sending a message to the Life:WIRE number and reporting their glucose level.
[0171] (e) Enter Glucose Level
[0172] The user will be required to enter in their blood sugar level as reported by their glucometer into a text message and send it to the Life:WIRE SMS number. This process will require the user to be able to enter in numbers and decimal places via their cell phone.
[0173] When a user enters their blood sugar, the system will assume that they are entering in a number with at least one decimal place. Should the user enter a decimal point into their blood sugar level they submit, the system will accept the message as it is sent. Should the user not put in a decimal point, the system will assume that the last digit is after the decimal place. For example, 112 would be converted to 11.2.
[0174] (f) SMS: Confirm Receipt of Report
[0175] The server will send the user a confirmation that their blood sugar report was received and display how their report was interpreted by the system. This message will only be sent out if the user's blood sugar level does not trigger a warning.
[0176] (g) SMS: Send Warning to User
[0177] If a user's average blood sugar is outside of recommended bounds over the last 10 reports, the user will be sent a warning message that displays their current average blood sugar level and inform them that it is to high or low and that the user should take action in order to correct the variance. In addition, should a user's blood sugar have been well maintained during this period, a message will be sent stating that they have stayed within their desired range on average over the last ten reports.
[0178] (h) E-mail: Send Warning to Alternative Contacts
[0179] Should a user's report indicate that their average blood sugar level over the last 10 reports is out of the recommended range, all the alternative e-mail addresses registered to their account will receive and e-mail copy of the warning.
5. Administration Interface
[0180] According to an embodiment of the present invention, Life: WIRE administrators will require an interface that will allow them to perform administrative tasks on the system and view usage statistics. This portion of the system will not be accessible to the public and will require an administrator (admin) to login with a special username and password.
[0181] The administration interface is illustrated in FIG. 13 ; the database schema requirements are illustrated in FIG. 14 .
[0182] (a) Admin Login
[0183] An administrator (or “admin”) wishing to access the administration interface will go to a special web address that will bring them to the administrator login screen; at which point they will be required to enter in a username and password. Should the administrator enter in a valid username and password they will proceed to the “Pending New User Approvals” page. Should the login criteria the user supplied prove invalid, they will return to the login screen which will display an error message.
[0184] (b) Admin Navigation System
[0185] An admin navigation system will be present on every page that is part of the admin interface and that is accessible while logged in. The navigation system will include links to the following locations: “Pending New User Approvals”; “User Management”; “Usage Report”; “Event Log”; and “Logout”.
[0186] (c) Pending New User Approvals
[0187] Once an administrator has successfully logged in, they will be presented with a list of new user accounts that are awaiting approval. The list will only show accounts that have never been approved before.
[0188] User information is listed in a chart. The first field will show the user's name, the second will show their email address. A field marked “E-mail Conf” will show weather the user has confirmed their e-mail address with the system. Similarly, the “Cell Conf” field shows whether the user has successfully registered their cell with the system. The last column contains a link called “Approve” should an admin click on the approve button the users account will be activated and the admin will be sent to the “User Approval Confirmation” page. The admin will also have the option to delete the new account which will send the admin to the “Verify User Deletion” page.
[0189] (d) User Approval Confirmation
[0190] Once an admin has approved a new user, the admin will arrive at this page where they will see a notice that the user has been successfully approved and that the “E-mail: Account Approved” has been sent to the user notifying them of the activation of their account. The page will include a link back to the “Pending New User Approvals” page.
[0191] (e) E-mail: Account Approved
[0192] Once an admin has approved a user's account, the system sends the user a copy of this e-mail. They will be notified that they may now log into the system.
[0193] (f) User Management
[0194] Throughout the course of the normal operation of the Life:WIRE system, admins may be required to aid users with system problems or perhaps delete accounts that are no longer in use. The “User Management” page will allow the admin to view all the current approved accounts in the system. The chart therein is very similar to the one described under the “Pending New User Approvals” section, however, it has one key difference. Under the command column, there is a link labelled “Login”. Should the admin wish to investigate issues with a particular user's account, they can click this link to login as that user. This function is important as it allows an admin to help a user without the user having to reveal their password to the admin.
[0195] As the list of users may grow quite long, each page will only show 20 records at a time and the admin will be able to page through them 20 records at a time. They will also have the option of entering in part or a user's entire name to search for a specific account. Any accounts that match the criteria will be displayed so that partial names can be entered.
[0196] (g) Verify User Deletion
[0197] Should an admin decide that it is necessary to delete an account from the Life:WIRE system, they will arrive at this page where they will be asked to confirm the decision. They will be presented with two links, the first will be labelled “Yes” which will send them to the “Deletion Confirmation” page. The link will return them back to the “User Management” page or the “Pending New User Approvals” page depending on where they initially clicked the delete link.
[0198] (h) Deletion Confirmation
[0199] Once an admin has confirmed that they do, in fact, wish to delete an account, they will see this page that will confirm that the user account has been deleted and provided them with a link back the either the “User Management” page or the “Pending New User Approvals” page depending on the status of the record that was deleted. A deleted account will not actually be purged from the database but rather flagged as deleted and ignored by the system. This is important for potential data recovery.
[0200] (i) Usage Report
[0201] As the main goal of this system is to prove its own validity, the usage statistics will be a very important part of the admin interface. The usage report will display the following statistics: “Total Number of Approved Accounts”; “Total Number of Approved Accounts with Activated Cell Phones”; “Total Number of SMS Messages Sent”; “Total Number of SMS Messages Received”; “Average Number of Reminders Responded To”; “Average Number of Reminders Ignored”; “Average Number of Report Windows Filled”; “Average Number of Report Windows Empty”; “Average Blood Sugar Level 3 Months Ago”; “Average Blood Sugar Level 2 Months Ago”; “Average Blood Sugar Level 1 Month Ago”; “Total Number of Users that Report 80-100% As Expected”; “Total Number of Users that Report 60-80% As Expected”; “Total Number of Users that Report 40-60% As Expected”; “Total Number of Users that Report 0-40% As Expected”; “Average Blood Sugar Level of Users with 80-100% Reporting”; “Average Blood Sugar Level of Users with 60-80% Reporting”; “Average Blood Sugar Level of Users with 40-60% Reporting”; and “Average Blood Sugar Level of Users with 0-40% Reporting”.
[0202] An admin will also be able to produce a print-friendly version of the usage reports by clicking on the “Print-Friendly” Link.
[0203] (j) Print-Friendly Version (Usage Report)
[0204] Should a user wish to print a version of the “Usage Report” they will click on the “Print-Friendly” link on that page. They will be presented with a page containing only the usage statistics that are formatted to fit within the margins of a standard 8″×11″ sheet. There will be a link on this page that will return the user to the Usage Report.
[0205] (k) Event Log
[0206] The event log is a simple chart of all the events that have occurred through the invention. The chart will have to fields: “Event Type” and “Message”. There are four types of events that can occur: “User”, “Admin”, “System”, and “Error”. An admin will be able to view these logs 50 events at a time and will have the option to scroll through them. They will also be able to select a time frame to reduce the total number of records shown. The exact messages that will accompany each event will be determined during the production of the system. It is through the “Event Log” that administrators can monitor compliance of any element of the invention. The “Event Log” displays all activities such as time that an reminder was triggered, to which user it relates (which has a unique identifier), when a reminder was sent (which has a unique identifier relating to each unique user), when a response was received and what response was provided by the user.
BUSINESS MODEL
[0207] In yet another aspect of the present invention, a business model is proposed wherein revenue is generated from services fees. In this regard, Life:WIRE is a hosted service where hospital groups, private clinics and corporations can purchase subscriptions for their patients and employees in order to enhance their health care service or improve the effectiveness of their health plans. A white label hosted solution will give public health care services, insurance companies, HMO's, public sector insurers, pharmaceutical companies and medical measurement devices firms a branded application to complement their other health management initiatives and raise awareness and reduce customer switching for their products. A branded installed solution for telcos can increase SMS revenues, add a subscription service to their offering and convert cell phone to an affinity medical device, thereby reducing customer chum. Additionally, companies currently offering PC-based disease management solutions can add a branded mobile interface to their application utilizing the present invention. These companies can begin generating recurring revenue for the service rather than one-time software licensing fees. For example and without limiting the foregoing, the service providers can opt to charge users on a fee per use basis (e.g., $0.10 per message), or, alternatively, on a monthly fee per user basis (e.g., $7.95 per month) which provides for a set number of messages (e.g., 100) and then a set charge for any message exceeding that amount.
[0208] An embodiment for the revenue generation method of the present invention is provided in FIG. 15 . In this embodiment, the healthcare service providers, including pharmaceutical companies, HMO's, governmental and private health plans, or others directly provide the Life:WIRE service to their client base, charging a monthly fee. This is advantageous because the service is provided to an already existing customer base. Alternatively, the fees and the service can be controlled through the telco, as illustrated in FIG. 16 . In a further alternative embodiment, the revenue generation method comprises the telco and the healthcare partners working together to provide the service and collect fees (as shown in FIG. 17 ).
[0209] It should be understood that this revenue generation means contemplates the creation of relationships with sponsors of the service, such as, for example, an insurance company or other commercial sponsor. The relationship created with the sponsors may include certain “incentives” provided to the end users, including, for example, on a per notification basis. For example, for each notification a retail sponsor might provide a cash incentive or an incentive by allocating a certain number of loyalty points to the end user. Retail operations, for example, now market branded wireless services. The present invention, in one particular aspect thereof, provides a way in which to add value to the wireless services provided, and to cross-sell other products or services. For example, a response to a notification carried on a retail company's wireless service would result in allocation of a predetermined number of loyalty points redeemable for groceries sold by the retail company.
[0210] In particular, such incentives or rewards could come from the healthcare providers/client with whom the user is involved and entails passing on a portion of the savings realized on long term proper management. For example, as the estimated actuarial healthcare cost for an individual is reduced through the use of Life:WIRE, an insurer may offer a reduced insurance rate (e.g., if the insurer has a reduction of 40%, as per ADA studies, they may pass on 15% of such savings for those clients using Life:WIRE). Another example may be with the volume of use of Life:WIRE a telco may offer volume reductions in service charges or provide free minutes.
[0211] In general, the types of such incentives can be categorized as follows:
free estimates, samples or analyses; products or services for no extra cost; product or service discounts; product or service time extensions; phone free extra minutes or services; extended or life memberships; exclusive or charter memberships; group discounts; extended warranties; draws for prizes; free music, video or movie downloads; and/or reduced costs or free service on peripheral items or services.
[0224] What all this does for the revenue generation side is to increase use and compliance by users through these incentives and rewards, which in turn keeps their satisfaction and use high, meaning they remain subscribed on the service. With such use and compliance, the client (e.g., an HMO) realizes the benefit of reduction in costs of healthcare management thus encouraging them to direct more of their patients to use Life:WIRE. | A remote interactive method, system and computer program product is provided for self-managing a person's regular lifestyle needs through controlled notification and feedback. The invention provides a simple, cost effective and flexible self-management and compliance scheme that does not require third party intervention or treatment options typical with immediate-response or alert-based systems. The invention also provides for long term management and analysis for the benefit of the individual. In implementing the invention in a healthcare environment, the individual will gain a better understanding of managing their lifestyle and behaviour. A related business model is also disclosed. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 12/120,503 filed May 14, 2008, now U.S. Pat. No. 8,051,615, which claims the benefit of U.S. Provisional Patent Application No. 60/938,366 filed May 16, 2007, both of which are hereby incorporated by reference.
STATEMENT CONCERNING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
FIELD OF THE INVENTION
This invention relates to an apparatus for anchoring the end of a cable to a structure such as a concrete pillar, post, or the like.
BACKGROUND OF THE INVENTION
This invention relates to cable anchors of the type disclosed in U.S. Pat. No. 4,899,499, the disclosure of which is hereby incorporated by reference. The anchor disclosed has a body with a wedge-shaped (conical) internal bore surface, cable grippers with wedge-shaped (conical) external surfaces received in the bore, a cable gripped by the grippers and extending from one end of the body, a cap at the opposite end attached to the body through which a stem extends outside of the body and the stem having a head that is captured against a facing surface of the cap. The stem is threaded into an insert that is embedded in a concrete structure. The facing surfaces of the cap and head are generally flat such that in this structure it is desirable that the axis of the stem and the axis of the cable be aligned. While that is ideal, that is not always the case in practice. In practice, there are often at least slight deviations between the axis of the cable and the axis of the stem, which stress the components of the connection. In addition, as the cables that are anchored oftentimes form barriers, even if the cable is initially aligned, at least generally, with the stem, an impact to the cable can result in significant stresses and deviations from aligned axes, which, even if temporary, can damage or even break the assembly. Corrosion inside the anchor, for example between the grippers and the body, the cable and the grippers and the cap and the stem, exacerbates the problem.
SUMMARY OF THE INVENTION
The invention provides an apparatus for anchoring the end of a cable to a structure with the head of the stem and the facing surface of the cap being shaped to allow articulation between the head of the stem and the cap while maintaining surface contact. Preferably, the mating surfaces of the head and cap are frusto-spherical in shape. Thereby, an anchor of the invention can accommodate misalignments between the axis of the cable and the axis of the stem, either upon initial construction, impact to the cable, or other changes that may occur during the life of the structure, such as vibrations and settling.
The foregoing and other objects and advantages of the invention will appear in the detailed description which follows. In the description, reference is made to the accompanying drawings which illustrate a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an anchor of the invention installed in an insert embedded in a concrete structure and gripping the end of a cable;
FIG. 2 is an exploded perspective view of an anchor of the invention;
FIG. 3 is a perspective view of the cap of FIG. 2 viewed in the opposite direction of FIG. 2 ; and
FIG. 4 is a detail cross-sectional view illustrating the mating surfaces between the stem and cap.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , an anchor 10 of the invention is illustrated including a chuck body 12 , a stem 14 , a cap 16 attached to the chuck body and capturing the head 18 of the stem, grippers 20 securing the end of a cable 22 in the bore of the chuck body, and a spring 24 in the bore of the chuck body urging the grippers 20 into engagement with the cable 22 . Also illustrated in FIG. 1 is an insert 26 embedded in a concrete structure 28 into which a shank 15 of the stem 14 is threadedly fastened.
Referring to FIGS. 2 and 3 , the head 18 of the stem 14 has a frusto-spherical surface 30 that mates with a frusto-spherical surface 32 of the cap 16 . The mating frusto-spherical surfaces 30 and 32 permit articulation for 360° about the axis of the stem 14 relative to the cap 16 . The range of articulation permitted from the aligned position illustrated is sufficient to accommodate typical impacts, vibrations and construction imperfections. Thereby, the anchor 10 can accommodate misalignments between the axis of the cable 22 and the axis of the stem 14 that may result from many different causes.
While it is preferred that frusto-spherical surfaces be formed on both of the head 18 and the cap 16 , it may be possible to accomplish the advantages of the invention with other combinations of surfaces, for example, with just a frusto-spherical surface on the head 18 and a frusto-conical surface on the cap 16 , or just line contact at the end of a circular bore of the cap 16 .
The stem 14 also has a neck section 38 that extends through bore 40 of the cap 16 and is significantly smaller in diameter than the bore 40 so as to provide clearance to accommodate articulating motions of the stem 14 relative to the cap 16 . This clearance is what determines the range of articulation permitted by the construction. In addition, preferably, where the stem 14 exits the cap 16 and is exposed, the stem 14 has flats 44 that can be engaged by a wrench to turn the stem 14 so as to threadedly engage the shank 15 with the insert 26 . It is noted that the shank 15 as illustrated is externally threaded, but could alternatively be internally threaded.
The cable grippers 20 are conventional, for example, a set of two or three wedge-shaped jaws. Typically, the interior surface of the grippers 20 is formed with teeth, which may be formed by a thread cutting operation, and the exterior is a frusto-conical surface or a portion of a frusto-conical surface. The bore of the body 12 is a mating frusto-conical surface such that when the grippers 20 are urged leftwardly as viewed in FIG. 1 , they clamp down on the end of the cable 22 and bite into it to firmly grip it. The spring 24 biases the grippers 20 in this direction to aid in initial gripping of the cable 22 .
Preferably, the mating surfaces 30 and 32 are lubricated so as to reduce friction therebetween to take full advantage of the invention. Particularly when so lubricated, an anchor of the invention can accommodate and absorb even small misalignments between the cable 22 and the stem 14 , such as may be caused by vibrations, to prevent vibrations from being transmitted either to or from the cable to the stem 14 . Lubrication also reduces the stress on the assembly which may be caused by larger articulations, for example, from an impact, from the building settling, or during initial installation.
To assure adequate corrosion protection to protect the wedges 20 , housing 12 and strand 22 interface, which is the most vulnerable area for corrosion to start, and also to lubricate and protect against corrosion of the mating surfaces of the head and cap, a grease zerc fitting 50 ( FIG. 1 ) is preferably provided in the body 12 , through which grease or another corrosion inhibitor may be introduced into the body 12 . This also helps lubricate the surfaces 30 and 32 as discussed above.
A preferred embodiment of the invention has been described in considerable detail. Many modifications and variations to the preferred embodiment described will be apparent to a person of ordinary skill in the art. Therefore, the invention should not be limited to the embodiment described, but should be defined by the claims that follow. | A cable anchor has ball surfaces that permit misalignment between the cable and a stem of the anchor, and a fitting that permits the introduction of a corrosion inhibitor to the interior of the anchor. | 5 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/757,865, filed Apr. 9, 2010, entitled “Apparatus and Method for the Detection and Treatment of Atrial Fibrillation” which is a continuation of U.S. patent application Ser. No. 12/427,733, filed Apr. 21, 2009, entitled “Apparatus and Method for the Detection and Treatment of Atrial Fibrillation”, now U.S. Pat. No. 8,644,927, issuing on Feb. 4, 2014. The aforementioned priority applications being hereby incorporated by reference in their entirety for all purposes.
FIELD OF THE INVENTION
[0002] Embodiments described herein relate to an apparatus and method for detection and treatment of atrial fibrillation. More specifically, embodiments described herein relate to an apparatus and method for detection and treatment of atrial fibrillation using distributed bipolar electrodes placed on the surface of the heart to detect the earliest onset of fibrillation.
BACKGROUND
[0003] The heart has four chambers, the right and left atria and the right and left ventricles. The atria serve as primer pumps to the ventricles which in turn pump blood to the lungs (the right ventricle) or the aorta and the remainder of the body (the left ventricle). The heart is essentially and electromechanical pump, which contracts and pumps blood by means of a wave of depolarization that spreads from the atria to the ventricles in a timed fashion through a series of conduction pathways. Cardiac arrhythmia is a condition afflicting the heart and is characterized by abnormal conduction patterns which in turn can affect the pumping efficiency in one of more chambers of the heart. It can occur in either the atria, ventricles or both. Particular types of Atrial arrhythmia can cause a condition known as atria fibrillation (AF) in which the pumping efficiency of the atria are compromised. Instead of contracting in a coordinated fashion, the left or right atria flutter with little or no pumping efficiency.
[0004] During an episode of AF, the normal electrical impulses that are generated by the sin θ-atrial node (the SA node), the natural pacemaker of the heart are overwhelmed by disorganized electrical impulses, known as ectopic foci that may originate in the atria or pulmonary veins, leading to conduction of irregular impulses to the atria and the ventricles. This can result in an irregular heartbeat, known as an arrhythmia which may occur in episodes lasting from minutes to weeks, or years. Left unchecked, AF often progresses to become a chronic condition.
[0005] Atrial fibrillation is often asymptomatic, and while not immediately life-threatening, may result in palpitations, fainting, chest pain (angina), or congestive heart failure. Patients with AF have a significantly increased risk of stroke and pulmonary embolism due to the tendency of blood to pool and form clots or emboli in the poorly contracting atria which are then sent to the lungs in the case of the right atria causing pulmonary embolism, or the brain causing stroke.
[0006] Atrial fibrillation may be treated with medications, implanted ventricular defibrillators or surgical procedures. The current medications used either slow the heart rate or revert the heart rhythm back to normal. However patients must remain on medication for life and many patients cannot be successfully treated with medication. Implanted ventricular defibrillators may be used to deliver a series of high voltage electric shocks to convert AF to a normal heart rhythm in a technique known as synchronized electrical cardioversion. However, these shocks are extremely painful and may cause the patient to pass or literally be knocked to the ground from the shock. Surgical and catheter-based therapies may also be used to ablate or destroy portions of the atria and pulmonary veins containing the ectopic and other foci responsible for the generation of arrhythmias causing AF; however these require open heart surgery, cardiac catheterization or both and have met with limited success. Thus, there is a need for improved methods and devices for the treatment of atrial fibrillation.
BRIEF DESCRIPTION
[0007] Embodiments of the invention provide apparatus, systems and methods for the detection and treatment of atrial fibrillation and related conditions. Many embodiments provide a system including a pacemaker coupled to endocardial and/or epicardial leads having a distributed pattern of bipolar electrodes for the early detection and treatment of atrial fibrillation.
[0008] In a first aspect, the invention provides an endocardial lead having multiple bipolar electrodes that attach to the endocardial surface of the right atria in a distributed pattern for the early detection and treatment of fibrillation in the right atria. Preferably, the electrodes are arranged in a circular or other pattern on the endocardial surface of the right atria to define an area for detecting the location of a foci of aberrant electrical activity causing onset (including earlier onset) of atrial fibrillation. In specific embodiments, the foci can be detected by an algorithm in the pacemaker which identifies the location on the endocardial surface (by the nearest electrode pair) having the earliest activation (i.e., depolarization) during an episode of AF.
[0009] Once a foci is detected, the electrodes nearest the foci can then be used to send a pacing signal at that site to prevent the site from causing atrial fibrillation. In some embodiments, that site of early activation can be paced continuously. The lead is coupled to a pacemaker to send sensed signals from each electrode pair back to the pacemaker electronics for analysis to determine the onset of atrial fibrillation or a signal predictive or the onset of atrial fibrillation. The lead can be positioned by in the right atria by introduction and advancement from the jugular vein using cardiac catheterization techniques known in the art.
[0010] In particular embodiments, the electrodes can be positioned in a circular, oval or related pattern around the SA node. The electrode pairs can be positioned on a circular or oval shaped patch that is attached to the endocardial surface using mechanical attachment element such as a helical screw, barbed needle or other attachment means such as a biocornpatible adhesive. The adhesive can comprise a thermally activated adhesive that is activated by heat from the body or resistive heating from signals sent to the electrode pair. The patch can comprise a PTFE, polyester or other biocornpatible material known in the art and is desirably configured to bend and flex with the motion of the heart wall. It may also include one or more nonthrombogenic coatings including coatings impregnated with various elutable drugs known in the art such as TAXOL to prevent thrombus, platelet and other cell adhesion. The electrodes can comprise a radio-opaque or echogenic material for visualizing a location of the electrodes in the heart under flouroscopy, ultrasound or other medical imaging modality. Also the patch can include a section made out of such materials to serves as a marker for visualizing the location of the electrodes in the heart.
[0011] In a related aspect, the invention provides an epicardial lead having multiple bipolar electrodes that attach to the epicardial surface of the left atria in a distributed pattern for the early detection and treatment of fibrillation in the left atria. Preferably, the electrodes are arranged in a pattern on the epicardial surface of the left atria to electrically map the atria so as detect the location of a foci of aberrant electrical activity causing early onset of atrial fibrillation in the left atria. The pattern includes placement of one or more electrodes adjacent one or more of the pulmonary veins so as to detect foci in these locations. Additionally, in left atria lead embodiments, the lead can also be coupled to a 3 -axis accelerometer placed on the epicardial wall of the atria to sense atrial wall motion predictive of atrial fibrillation and normal sinus rhythm. The signal from the accelerometer may be used as a sole indication of AF, or it may be used to supplement the electrical signals from the bipolar leads positioned on the left atria to increase the predictive power of various algorithms used by the pacemaker for the detection of AF. Additionally, sensory inputs from the accelerometer can also be used to assess the effectiveness of atrial pacing signal in preventing AF and/or returning the heart to normal sinus rhythm.
[0012] In another aspect, the invention provides an apparatus, system and method for performing low voltage distributed cardioversion for converting the atria from a fibrillative state back to normal sinus rhythm. In these and related embodiments, the pacemaker can simultaneously send a higher voltage pacing signal (in the range of 8 to 10 volts) to all pairs of electrodes (e.g., on the particular atrial lead) to stimulate a large enough area of the atria to eliminate the arrhythmia. By using voltages lower than those typically used during external or internal cardioversion (which can be in the hundreds of volts for internal conversion to the thousands for external conversion) the pain experienced by the patient can be greatly reduced. The other benefit of this approach is that by using bipolar electrodes at each site, the electrical energy delivered to the heart can be contained in a very small region so that the risk of stimulating the ventricles (an unwanted effect in this case) is very small.
[0013] Further details of these and other embodiments and aspects of the invention are described more fully below, with reference to the attached drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a lateral view showing an embodiment of a system for the treatment of atrial fibrillation including a pacemaker and various leads going to the atria and ventricles for AF detection and pacing and ventricular pacing.
[0015] FIG. 2 is a cross sectional view of the heart showing the placement in the heart of the various leads from the embodiment of FIG. 1
[0016] FIG. 3 is a side view of the right atria showing an embodiment of an atrial lead having a distributed pattern of bipolar electrodes placed on the endocardial surface of the right atria for the detection and treatment of AF.
[0017] FIG. 4 is a side view of the left atria showing an embodiment of a parallel atrial lead configuration connected to a distributed pattern of bipolar electrodes placed on the epicardial surface of the left atria for the detection and treatment of AF.
[0018] FIG. 5 is a cross sectional view showing an embodiment of an atrial lead for sensing and pacing.
[0019] FIG. 6 a is a top down view showing an embodiment of a bipolar electrode assembly including a pair of bipolar electrodes positioned on a patch or other support layer.
[0020] FIG. 6 b is a cross sectional view showing positioning of an embodiment of the bipolar electrode assembly on the endocardial wall.
[0021] FIG. 7 is a block diagram illustrating some of the typical circuitry on a pacemaker or other implantable pacing or stimulating device.
[0022] FIGS. 8 a - 8 c are graphs showing an EKG for normal sinus rhythm ( FIG. 8 a ) and during an episode of atrial fibrillation, including the ventricles ( FIG. 8 b ) and atria ( FIG. 8 c ).
DETAILED DESCRIPTION OF THE INVENTION
[0023] Embodiments of the invention provide apparatus, systems and methods for the detection and treatment of atrial fibrillation and related conditions Many embodiments provide a system including a pacemaker coupled to endocardial or epicardial leads having a distributed pattern of bipolar electrode for the early detection and treatment of atrial fibrillation.
[0024] Referring now to FIGS. 1-2 , an embodiment of a system 5 for the detection and treatment of atrial fibrillation comprises a cardiac pace maker or related device 10 , and one or more leads 20 positionable in/on the atria A and/or ventricles V of the heart H. Leads 20 can be coupled to pacemaker 10 by means of a mufti-lead connector 12 . In various embodiments, leads 20 can include: a lead 21 positionable on the endocardial wall ENW of the right atria RA for sensing and pacing the right atria; a lead 22 positionable on the epicardial wall EPW of the left atria LA for sensing and pacing the left atria, a lead 23 positionable on the endocardial wall of the right ventricle RV for sensing and pacing the right ventricle and a lead 24 positionable on the endocardial wall of the left ventricle LV for sensing and pacing the left ventricle.
[0025] Referring now to FIGS. 3-6 , in various embodiments, leads 21 and/or 22 can comprise an apparatus 30 for the detection and treatment of atrial arrhythmia. Apparatus 30 can comprise a lead 40 having proximal and distal portions 41 and 42 and a plurality of electrode assemblies 50 coupled to the lead. As is described below, electrode assemblies 50 are distributed in a pattern 63 along lead 40 so as to define an area 60 for detecting and locating a foci of aberrant myoelectric activity causing atrial fibrillation. Apparatus 30 including lead(s) 40 , can be configured for placement in various locations in the heart including the right atria RA, as is shown in the embodiment of FIG. 3 , or the left atria LA, as is shown in the embodiment of FIG. 4 . FIG. 4 also shows an embodiment of device 30 having a plurality 40 p of leads 40 coupled in parallel to electrode assemblies 50 and pacemaker 10 . In these and related embodiments leads 40 can be coupled to a common connector 14 , which can be the same as connector 12 .
[0026] The proximal portion of lead 40 includes an end 41 e configured to be coupled to a pacemaker 10 or a related device. The distal portion 42 of the lead is configured to be positioned in an atrial chamber (right or left) AC of the heart H. Lead 40 comprises an outer sheath 43 surrounding a plurality of conductive wires 44 each having an insulative sheath 45 over all or a portion of their lengths. Conducive wires 44 can comprise copper or other conductive metal known in the art. Desirably, lead 40 also has sufficient flexibility and pushability as is known in the catheter arts to be advanced into the atrial chamber of the heart from a percutaneous introductory site such as the jugular vein in the neck or other like site.
[0027] In many embodiments, electrode assembly 50 comprises a pair 51 of bipolar electrodes 52 which are disposed in or otherwise positioned on a patch 53 or other support layer or structure 53 that can be attached to the heart wall. Electrode assembly 50 and electrodes 52 are configured to sense electrical activity within a region of myocardial tissue MT within the heart wall HW of the atria to detect an ectopic or other foci F of abnormal electric activity and send a pacing signal 56 to the heart wall to depolarize region MT containing the Foci F. Electrodes 52 are typically circular and can have diameters in the range of 1 to 10 mm with specific embodiment of 2, 5 and 7 mm, larger sizes are also contemplated. They can comprise various conductive metals known in the art including gold, platinum, silver, stainless steel and alloys thereof. They are desirably positioned on the tissue contacting surface 55 of assembly 50 , but also may be recessed within the interior of the assembly so as to be capacitively coupled to the heart wall.
[0028] In preferred embodiments, the electrodes 52 of electrode assembly 50 are configured as bipolar electrodes. Such embodiments allow the depth of electrical energy delivered to myocardial tissue for purposes of pacing and cardioversion to be precisely controlled. However in alternative embodiments, electrodes 52 can be configured as monopolar electrodes with current flowing to a return electrode (not shown) positioned at another location on lead 40 or another lead 20 .
[0029] Electrode assembly 50 can be attached to the heart wall HW through several different means. According to an embodiment shown in FIG. 6 b , the patch can include one or more attachment elements 57 that have tissue penetrating anchoring portions 57 a which penetrate and anchor into the heart wall HW. Suitable attachment elements 57 can include various helical coils or barbed needles as is shown in FIG. 6 b . Patch 53 may also be attached to the heart wall through use of biocompatible adhesives known in the art. In specific embodiments, the adhesive can comprise thermally activated adhesives that are activated by heat from flowing blood or electrical energy delivered from electrodes 52 .
[0030] In various embodiments, lead 40 can include a plurality of electrode pairs 52 /assemblies 50 which can be positioned in a distributed arrangement on the lead. In particular embodiments, the lead 40 can include between 2 to 10 pairs of electrodes with specific embodiments of 3, 4, 5, 6, 7 and 8 electrode pairs. Greater and lesser numbers of electrode pairs also contemplated depending upon the size and shape of atrial or ventricular chamber. The electrode pairs can be substantially equidistant from each with other spacing arrangements also contemplated. For example, particular spacing arrangements can be configured to account for the shape and size of a particular patient's atria which can be determined by prior imaging of the patient's heart. In specific embodiments, the spacing between electrode pairs 52 can be in the range from about 1 to about 5 cms with greater and lesser distances also contemplated.
[0031] Desirably, the spacing and number of electrodes pairs 52 on lead 40 or other lead are configured to allow the electrodes to sense the electrical activity (e.g., the amount and time course of depolarization) of a selected area 60 of myocardial tissue MT within the atria or ventricle. This in turn, allows for the generation of a conduction map 61 of tissue area 60 . Conduction map 60 can be used to detect for the presence of one or more ectopic or other foci F of aberrant electrical activity within area 60 .
[0032] In various embodiments, electrode pairs 52 can be arranged in a circular, oval or other distributed pattern 62 around a selected area 60 of the atrial or ventricular wall as is shown in the embodiments of FIGS. 3 and 4 . In particular embodiments, electrode pairs 52 /assemblies 50 are arranged in circular, oval or other pattern 62 around the SA node as is shown in the embodiment of FIG. 3 (desirably, the electrode pairs 52 are positioned to be substantially equidistant from the SA node). Such embodiments allow for the detection of particular foci F causing premature depolarization of the Atria by allowing comparison of the earliest depolarization within the entire area 60 (or adjacent to it) to that of the SA node. As is described herein, software algorithms resident 130 within pacemaker 10 can be used to detect the location LF of such foci F and then send a pacing signal to that location to take conductive control of the Foci and prevent it from causing AF.
[0033] In addition to electrodes 52 , lead 40 can also include other sensors 70 for detection of various electrical and/or mechanical properties. In particular embodiments, sensors 70 can include an accelerometer 70 , such as a 3 axis accelerometer for detection of atrial or other heart wall motion as is shown in the embodiment of FIG. 4 . Similar to electrodes 52 , sensors 70 be arranged in selectable distributed pattern 62 on the endocardial or epicardial surface of the heart, such as a circular, oval or other pattern.
[0034] Patch 53 will typically have an oval or other like shape, particularly for bipolar electrode embodiments, though other shapes are also contemplated. All or a portion of the patch can comprise various biocompatible polymers known in the art including PTFE, polyurethane, silicone and various other elastomers known in the. Desirably patch 53 has sufficient flexibility to conform to shape of heart wall as well as bend and flex with the motion of the heart so as to remain attached to the heart wall and not impede the motion of the heart wall. Patch 53 can also include one or more biocompatible non-thrombogenic coatings 58 such as silicone or other elastomeric coating. Coatings 58 can also have one more drugs 58 d embedded in the coating, so as to be elutable over an extended period of time up to years. Drugs 58 d can include various compounds such as Taxol or compound known in the stent arts for reducing platelet and cellular adhesion to the patch. Drugs 58 d can also include various antibiotics and antimicrobials such as vancomyacin, cefamandol, gentamicin and silver compounds for reducing the likelihood of bacterial adhesion and growth, or infection of patch 53 . In some embodiments, patch 53 can have a multilayer construction, in these and related embodiments, coating 58 can comprise a layer 58 which will typically be a tissue contacting layer 58 .
[0035] In various embodiments, all or a portion of patch 53 and/or electrodes 52 can comprise a radio-opaque or echogenic material for visualizing a location of assembly 50 and/or electrodes 52 in the heart under flouroscopy, ultrasound or other medical imaging modality. Suitable radio-opaque materials include platinum and titanium dioxide. In particular embodiments, patch 53 can include a marker section 59 made out of such materials for visualizing the location of the electrode pair 51 . Desirably, marker 59 is centrally located on the patch so as to be equidistant from each electrode 52 , to enable the physician to use the marker as a guide for placing the electrodes at a desired location on the heart wall. Alternatively, marker 59 can be positioned on an edge of patch 53 as is shown in FIG. 6 a.
[0036] In use, markers 59 allow for the precise placement of the electrode assemblies 50 along the endocardial wall of either the atria or the ventricles so as to define the selectable area 60 of the heart for measurement of electrical activity. For example, in particular embodiments the markers can be aligned with a superimposed image of an alignment template that marks the desired location for each electrode assembly. The markers also allow the physician to determine through various cardiovascular imaging methods that the electrode assemblies remain attached to heart wall over time. Additionally, once an ectopic or other foci F of aberrant electrical activity has been detected, they can be used as a point of reference for performing various RF ablative procedures to ablate the area of tissue responsible for the foci or otherwise create a conduction block around it.
[0037] Referring now to FIG. 7 , pacemaker 10 can include various circuitry and other components. Some of the typical circuitry 110 and electronic devices 120 in a pacemaker 10 or like device can include power control circuitry 111 , amplification and sensing circuitry 112 , pacing circuitry 113 , telemetry circuitry 114 , micro-controller/micro-processor devices 121 and memory devices 122 . One or more software algorithms 130 can be stored in memory device 122 and/or processor 121 for implementation by processor 121 . Such algorithms 130 can include cardiac mapping and foci detection algorithms, pacing algorithms (both atrial and ventricular), atrial fibrillation detection algorithms, ventricular fibrillation detection algorithms, cardioversion algorithms (high and low voltage (e.g., 8 to 10 volts) and combinations thereof.
[0038] In embodiments of methods for positioning apparatus 30 in the body, the physician can place the endocardial lead in the right atrium by advancement from a percutaneous introductory site in the jugular vein or a related site. As described above, the desired positioning of the electrode assemblies 50 in the atria can be achieved by imaging the heart during placement and observing the position of markers 59 . The epicardial leads can be placed using surgical techniques such as a mini-thoracotomy or a minimally invasive procedure using endoscopy. Additional leads can be positioned as needed in the right or left ventricles using minimally invasive or surgical techniques. One or more of these leads can be subsequently coupled to a pacemaker 10 positioned in the chest or other location.
[0039] In exemplary embodiments of methods for using the invention, system 5 and atrially positioned leads 40 can be used to detect and treat atrial fibrillation in the following fashion. The distributed electrode assemblies can be used to monitor the patient's EKG including the P wave as well as map conduction in the area within or adjacent that circumscribed by the electrode assemblies, preferably this area includes the SA node. Atrial fibrillation can be detected based on the elimination or abnormality of the P wave as is shown in FIGS. 8 b and 8 c . When AF occurs, using the conduction map, the location of the ectopic or other foci causing the atrial fibrillation can be identified by looking at the time course of depolarization and identifying locations that depolarize before the SA node. Cardioversion can then be performed as described below to return the heart to normal sinus rhythm.
[0040] After cardioversion is performed and the heart returned to normal sinus rhythm, the electrode assemblies nearest that foci can then be used to send a pacing signal to that site and surrounding tissue to prevent the site from causing another episode of atrial fibrillation. Also, the location of that site can be stored in memory of the pacemaker so that next time abnormal atrial depolarization is detected, a pacing signal can be sent immediately to that site to prevent the occurrence of AF. In some embodiments, a site of early activation can be paced continuously. Atrial pacing can be performed to produce a stimulated P wave, P s which can be triggered off the R wave, R, or the R to R interval, R i as is shown in FIGS. 8 a and 8 b with appropriate time adjustment Ta for firing during the time period Tp when the normal P wave would be expected to occur.
[0041] In addition to detection of foci and other early activation/abnormal conductions sites in the atria, atrial fibrillation can also be detected using an accelerometer 71 such as a 3 -axes accelerometer placed on the atrial wall (either epdicardial or endocardial) to sense atrial wall motion as is shown in the embodiment of FIG. 4 . Such motion is predictive of atrial fibrillation via the effects atrial fibrillation has on atrial wall motion which typically flutter as a result. The signal from the accelerometer can be used to supplement the electrical signals from the bipolar leads positioned on the left atria to increase the predictive power of various algorithms used by the pacemaker for the detection of AF. Additionally, sensory inputs from the accelerometer can also be used to assess the effectiveness of atrial pacing signal in preventing AF and/or returning the heart to normal sinus rhythm.
[0042] As described above, when an episode of atrial fibrillation has been detected embodiments of the invention can also be used for performing cardioversion to convert the atria from a fibrillative state back to normal sinus rhythm. In these and related embodiments, the pacemaker can simultaneously send a higher voltage pacing signal (in the range of 8 to 10 volts) to all or majority of the pairs of distributed electrodes to simultaneously depolarize (also described herein as conductively capture) a large enough area of the atrial myocardium to stop the aberrant currents causing the atrial fibrillation. These voltages, while higher than those used for pacing to prevent AF, are much lower than those typically used during conventional internal cardio version (in the hundreds of volts) or external cardioverions (in the thousands of volts). Such lower voltages can be used because the stimulation is delivered by a multipoint source (resulting in higher current densities) and to a much smaller area of the heart than during typical internal or external cardioversion. By using voltages lower than those typically used during internal or external cardioversion, the pain experienced by the patient can be greatly reduced. The other benefit of this approach is that by using bipolar electrodes at each site, the electrical energy delivered to the heart can be contained to a relatively small region so that the risk of stimulating the ventricles (an unwanted effect in this case) is very small. The voltage level for achieving cardioversion can be adjusted based on one or more of the following factors (the “conversion voltage adjustment factors”): i) the size of the area of tissue bounded by distributed electrode pairs (smaller areas require less voltage); ii) the location of the ectopic foci (the closer the foci to a particular electrode pair the less the required voltage; iii) the number of foci (larger number of foci may require larger voltages); iv) the number of electrode pairs defining the area (the more electrodes the lower the voltage); and v) the number of prior episodes of AF (a larger number of episodes may require higher voltage). One or more of these factors can be programmed into the algorithm resident within the pacemaker which controls the cardioverion process. Also the conversion algorithm can programmed to use the lowest possible voltage at first, and then progressively increase it until conversion is achieved. The voltage which achieves conversion can then be stored in memory and used again as a starting point in a subsequent conversion attempt with tuning or fine tuning using one or more of the five conversion voltage adjustment factors described above.
CONCLUSION
[0043] The foregoing description of various embodiments of the invention has been presented for purposes of illustration and description. It is not intended to limit the invention to the precise forms disclosed. Many modifications, variations and refinements will be apparent to practitioners skilled in the art. For example, embodiments of the apparatus for detection and treatment of atrial arrhythmias and fibrillation can also be adapted for detection and treatment of various ventricular arrhythmias.
[0044] Elements, characteristics, or acts from one embodiment can be readily recombined or substituted with one or more elements, characteristics or acts from other embodiments to form numerous additional embodiments within the scope of the invention. Moreover, elements that are shown or described as being combined with other elements, can, in various embodiments, exist as standalone elements. Hence, the scope of the present invention is not limited to the specifics of the described embodiments, but is instead limited solely by the appended claims. | Embodiments of the invention provide methods for the detection and treatment of atrial fibrillation (AF) and related conditions. One embodiment provides a method comprising measuring electrical activity of the heart using electrodes arranged on the heart surface to define an area for detecting aberrant electrical activity (AEA) and then using the measured electrical activity (MEA) to detect foci of AEA causing AF. A pacing signal may then be sent to the foci to prevent AF onset. Atrial wall motion characteristics (WMC) may be sensed using an accelerometer placed on the heart and used with MEA to detect AF. The WMC may be used to monitor effectiveness of the pacing signal in preventing AF and/or returning the heart to normal sinus rhythm (NSR). Also, upon AF detection, a cardioversion signal may be sent to the atria using the electrodes to depolorize an atrial area causing AF and return the heart to NSR. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 60/844,138 filed on 13 Sep. 2006, the complete subject matter of which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed generally to supporting structures for mounting devices, such as video projectors to a ceiling or other surface.
BACKGROUND
[0003] Video projectors and other ceiling mounted devices have been available for many years and are an integral part of both business and educational presentations. Early versions of these projectors were typically rested on a conference table or any convenient available surface and manually aimed at the intended viewing surface or screen. This placement had inherent drawbacks in that passers-by may block the projected image or inadvertently bump the table and knock the projector out of alignment, or even worse, liquid spillages on the conference table may damage the projector. Attempts to alleviate these problems have focused on mounting the projector on the ceiling or the wall.
[0004] One early mounting technique utilized a metal water pipe with a flange screwed onto each end. One flange was used to affix the mounting structure to the ceiling, while the other flange was attached to the projector. In the wake of solving some of the aforementioned problems, this mounting method unfortunately created a number of new problems. Foremost is the problem of assembly and installation. Because each installation may be different, the installers have to use pipe cutting and threading machines, which is time consuming, labor intensive and costly. There is also the question of safety with this method due to the cutting of threads into the piping and its subsequent weakening.
[0005] Probably the most widely used method of mounting a projector to the ceiling has been by the use of a single piece permanent mounting bracket. This device attaches to the projector on one side, and to the ceiling on the other. Although this requires minimal space, there exists the problem when the user wants to remove the projector for service or when it is in the way. This may require the use of a number of tools and may become very tedious when the working space is quite small.
[0006] Given the above, there is a need for a ceiling or wall mount device for a video projector which allows for both easy installation/mounting of the projector as well as an easy quick disconnect for ease of maintenance.
SUMMARY OF THE INVENTION
[0007] Generally, the present invention relates to a system and method for removably mounting a device to a surface including a release mechanism which is preferably magnetic.
[0008] In another embodiment there is disclosed an apparatus for removably mounting a device to a surface, having a first unit configured to be attached to a surface; a second unit configured to be attached to a device; one of said units including a contact plate, the other of said units including at least one magnet, said first and second units being configured to permit engagement of said magnet with said plate when said units are brought together; one of said units including a safety locking device having pivoting arm with an engagement claw; the other of said units having claw engaging portion shaped to engage said claw, and thereby locking the units together.
[0009] In another embodiment, the plate is floatably attached to one of said units.
[0010] In another embodiment, the plate is configured to articulate with three degrees of moment relative to said unit.
[0011] In another embodiment, the unit includes an interior base portion which further includes a rod extending from said base portion and being attached to said plate; said rod being free to float relative to said base portion, so that said plate floats with said rod.
[0012] In another embodiment, the base includes an aperture for receiving said rod, said aperture being larger than said rod so that said plate rod may float relative to said unit.
[0013] In another embodiment, the safety locking device further includes at least one disengagement prong pivotally moveable with said pivoting arm.
[0014] In another embodiment, the disengagement prongs extend away from said pivoting arm and when pivoted into engagement, with at least one magnet to urge the magnets apart when said pivot arm is operated to release the units from each other.
[0015] In another embodiment, there is an apparatus described for removably mounting a device to a ceiling surface, having: a first unit configured to be attached to the ceiling; a second unit configured to be attached to a device; one of said units including first adhesion element, the other of said units having a second adhesion element capable of releasably mating with said first element, said first and second units being configured to permit engagement when brought together; one of said units including an ejection element having pivoting arm with disengagement prongs extending away from said pivoting arm and when pivoted, urging the units to separate and disengage said adhesion elements.
[0016] In another embodiment, the adhesion elements are mechanically engaging devices.
[0017] In another embodiment, the adhesion elements employ chemical bonds.
[0018] In another embodiment, the adhesion elements include hook and loop fasteners.
[0019] In another embodiment, the pivoting arm further includes an engagement claw in one of said units and is configured to be received in the other of said units when said units are brought together.
[0020] In another embodiment, the pivot arm includes an aperture therethrough and further including a locking fastener sized to be received within said aperture and to engage the other of said units, so that when said fastener is inserted, the pivot arm is prevented from further pivoting.
[0021] In another embodiment, a method of securely docking a magnetic coupling to a receiving plate is described having the steps of: affixing a magnet element to one unit; affixing a plate element to another unit; configuring at one of the plates or magnet elements to be movable relative to the unit to which it is affixed, so that said movable element may move relative to said other element to accommodate angular misalignment between said elements when they approach each other.
[0022] In another embodiment, the method including the step of allowing angular movement of said plate relative to the unit to which it is affixed, providing a safely releasable securing device to a fixed mount, the device being mounted on a first unit with a second unit being fixedly mounted, one of the units having a magnet and the other unit having a ferro magnetic material,
[0023] In another embodiment, a method for attaching a video projector to a ceiling is described comprising the steps of: adhering ceiling attachment hardware to the ceiling; attaching mounting hardware to the video projector; and securing the ceiling attachment hardware to the video projector's mounting hardware via a mating magnetic force.
[0024] The above summary of the present invention is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures and the detailed description which follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
[0026] FIG. 1 is a perspective view of one embodiment of the mount with projector attached;
[0027] FIG. 1 a is perspective view like FIG. 1 taken from another angle;
[0028] FIG. 1 b is a side plan view of on attachment point;
[0029] FIG. 1 c is a side plan view of the environment of FIG. 1 b;
[0030] FIG. 2 is a perspective view of a portion of the mount;
[0031] FIG. 2 a is a perspective view of the portion of the mount typically attached to a ceiling;
[0032] FIG. 2 b is a side plan view, with portions broken away, of a mount;
[0033] FIG. 2 c is a close up plan view of a release portion shown in FIG. 2 b ; and
[0034] FIG. 2 d is a view like FIG. 2 b but with an extension arm and with the ceiling and device mount units separated.
[0035] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to over all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0036] In general, the present invention is directed to supporting structures for video projectors and more particularly to an apparatus for mounting such a device to a ceiling. The preferred embodiments of the invention provide a convenient method for both attaching and disengaging a video projector to and from its ceiling attached mount without the use of cumbersome tools such as screwdrivers, wrenches, and the like which can be awkward when used overhead. The invention also describes a convenient method for adjusting the projected video image to a desired screen location after the projector has been securely mounted to the ceiling, wherein the installer does not have to support the weight of the projector overhead while simultaneously attempting to mount and align the projector.
[0037] FIG. 1 shows one embodiment of a mounting device 100 mechanically attached to a video projector 110 on its bottom surface via screw 120 (not shown in FIG. 1 ), and which may in turn be secured to an overhead ceiling via screws 130 . To accommodate for irregularities in the mounting surface 150 of the video projector (e.g., non flat, slightly tilted, warped, etc.) threaded barrels 160 may independently be inserted/threaded through their respective sleeves 170 to level or otherwise stabilize the projector (see FIG. 1A for expanded view of the threaded barrels 160 in sleeve 170 ). The location at which each threaded barrel 160 contacts the top surface 150 of the projector may be altered by adjusting slotted leg 180 both radially and angularly until the desired contact location is reached and then affixed by tightening retaining screw 190 into gimball plate 191 . The mounting device 100 shown in FIG. 1 allows for close mounting of the video projector 110 to a ceiling, however, other embodiments to be shown later allow for greater spacing from the ceiling to the video projector.
[0038] FIG. 2 is an expanded view of the mounting device 100 depicted in FIG. 1 , highlighting the separation of the mounting device 100 into its two main sub-assemblies, the projector attachment unit 200 and the ceiling attachment unit 250 . One particular embodiment of the present invention allows for the ease of mating and dismounting the two main sub-assemblies as described below. The projector attachment unit 200 may have a pair of high energy magnets 202 mounted in housing unit 204 , likewise, the ceiling attachment unit 250 may have an appropriate metal insert 252 (shown in FIG. 2A ) mounted in housing unit 254 . It is understood that other adhesion element/means are possible besides magnets (permanent or electro), such a high strength hook and loop systems (Velcro®), releasable adhesives (chemical bonding), vacuum, mechanical engagements, such as snap fit structures which require a release force greater than the weight of the object supported, etc. All of these alternates will just be referred to as “magnets” or “adhesion elements”, for convenience.
[0039] The housing unit 204 is shown as elliptical, with the magnets 202 being mounted in spaced apart pairs, preferably with a magnet circuit completing plate joining the back side of the magnets. The magnet individually are “potted” with adhesive into the unit 204 . Alternatively, the magnets can be tapered toward their exposed ends with the apertures in the unit being likewise tapered (with narrow ends exposed) so that the unit prevents slippage of the magnets out of the unit. Other means, such as a thin cover plate over the exposed ends of the magnets which is attached (by adhesive, fasteners, etc) to the unit. The cover plate can be a non-magnetizable material in which case it does not need apertures, or otherwise, the apertures must be smaller than the magnet body diameter so that the magnets cannot be withdrawn from their open end.
[0040] When housing unit 204 is inserted into housing 254 , high energy magnets 202 attract and mate with metal insert/plate 252 , which is a material capable of being attracted by the magnet (referred to as magnetically responsive material) with a sufficient binding force to support the video projector unit 110 with its' attached mounting hardware. In one embodiment of the present invention, the metal insert 252 is secured to housing unit 254 by screw 253 which may be threaded through the central region of metal insert 252 . Screw 253 may have sufficient spacers to allow the inboard surface of metal insert 252 to stand-off from housing unit 254 and “float” on screw or rod 253 with respect to interior base wall of unit 250 (or 200 if reversed) upon which plate 252 abuts. Rod 252 passes through an aperture in the base which is sized to allow the rod to slide therein (i.e. aperture larger than the rod diameter) to allow floating. The rod is prevented from being withdrawn from the unit by an enlarged end (not shown) such as a fastener end.
[0041] With this construction, the rod is affixed to the plate in a floating relationship relative to the unit to which it is attached, providing the plate with at least 3 degrees of movement (in-out, rotational, angular deflection/tipping, or x-y, z axes, caused by the oversize aperture mentioned above).
[0042] By providing an adjustable gap, the plate is free to deflect in any angle to more easily mate with the magnets. So that if the magnets are not fully aligned with the plate at the point of contact, the plate will float to accommodate angular error and “snap” into engagement. In this configuration, the metal insert 252 may pivot about screw 253 to mate flush with the surface of the high energy magnets 202 , and thereby achieve the maximum available magnetic mating force. Thus the insert is free to move about a pivot point (the screw in this case) in any angular direction including in/out, to accommodate any inexact mating of the magnet 202 or other engagement means as mentioned above. Once the high energy magnets 202 attract and mate with metal insert 252 , mechanical locking device 256 may be engaged to ensure that any inadvertent additional weight applied to the projector attachment unit 200 does not result in disengaging the magnets 202 from the metal insert 252 . The mechanical locking device 256 may be part of the ceiling attachment unit 250 with an adjustable lever arm 258 securely anchored thereto. In one embodiment, the adjustable lever arm 258 may have an extended lip 260 which may be inserted into recessed slot 262 in the projector attachment unit 200 . When fully engaged, the adjustable lever arm 258 may be flush with the surface of the ceiling attachment unit 250 and the extended lip 260 fully inserted into recessed slot 262 , in this configuration if for some reason the high energy magnets 202 fail or mechanically disengage or eject from the metal insert 252 , the extended lip 260 is designed to bear the entire weight of video projector unit 110 with its' attached mounting hardware. In order to increase the binding force between the high energy magnets 202 and metal insert 252 , a magnetic booster element of may be inserted behind, and in close proximity, to the high energy magnets 202 . In one embodiment, the magnetic strength enhancer or booster element may be a steel rod or sheet or plate of ferro magnet material (materials which are attracted by magnets) located at the distal end of the magnets (underneath) 202 , either in contact therewith or spaced therefrom. This booster increases and concentrates the magnetic flux lines which eminate from the proximal ends of the magnets (i.e. the ends which engage plate 252 ) by connecting the magnets at proximate their distal ends
[0043] The magnets are maintained, preferably by glue in their housing 204 which is preferably a keyed shape, not round, in this case oval, to insure instant alignment with the receiver portion in unit 250 which is like shaped. In this configuration this housing 204 is tapered in a distal direction to enhance its ease of reception into housing 254 . Another solution to maintaining the magnets 202 in their housing is to provide a lip thereon at the proximal end (the end not visible) so that they cannot be remove by any amount of force. The lip could be circumferential portion which has a larger diameter than the aperture in which the rest of the magnet body resides in the housing. Another solution is to provide magnets which are at least slightly conical (tapered, from back to front—the front being the exposed end). With a like taper in the receiving aperture in the housing, the magnets cannot be withdrawn from the exposed side (i.e. in the direction of insertion), due to the taper.
[0044] For ease in disengaging the high energy magnets 202 from the metal insert 252 (when it may be desired to remove the video projector 150 from the ceiling but leave the ceiling attachment unit 250 in place) means are provided with using leverage to separate the magnets from the floating plate 252 . This lever means can take the form of a mechanical locking device 256 with disengaging prong(s) 266 incorporated therein. The prong or prongs 266 reside in a recess provided when not used for disengaging. (Non-magnet adhesion, as indicated previously, such leverage action is likewise useful to disengage the locking means). When the mechanical locking device 256 is caused to rotate away from being flush with the surface of the ceiling attachment unit 250 , the disengaging prongs 266 rotate inward and apply a force to partially, but not fully, disengage the high energy magnets 202 from the metal insert 252 .
[0045] FIGS. 2 a - d illustrate embodiments with close up views of the leverage disengagement/ejection feature 256 . As clearly visible in FIG. 2 c , it includes a pivot point aperture 257 which rotates on a pivot which is attached to the main body of the ceiling portion (though it could also be the projector portion), an extension lip or locking/latching claw 260 engages a mating recess 262 . FIG. 2 d shows the units separated, unlike FIG. 2 b which shows them joined. These figures differ primarily in their overall length, i.e. for installations which ceiling extension/off set is required. Disengagement is urged by disengaging prong(s) 266 which extend from pivot point 257 and are configured to engage some portion of the other section (i.e. other than the section to which the pivot is affixed) so ask to provide a separating force. In this embodiment, the prongs engage the floating plate 252 , but this is not a critical location. They could engage any part of the other unit or the magnets to urge the units apart. Notice that the prong 266 is actuated by contact with the magnet from unit 200 and consequently claw 260 automatically (and essentially simultaneously) engages notch 262 when units 200 and 250 are brought firmly together. The claw and prongs are rigidly connected together on said latch and configured to alternately disengage and latch said units together depending on the position of the latch, i.e. at one extreme, the prong ejecting the unit, and at the other, the claw captures the units together, and the latter is more or less automatic. This means that this safety feature can be made to be partially or fully engageable by the action of connecting the units thereby minimizing the chance that the safety latch will be forgotten. A further locking set screw can be provided to make the safety latch unremovable until the set screw is removed.
[0046] The pivot motion is initiated by the user by applying force against the finger extension 257 a which causes rotation on the pivot 257 and separation forces to be applied through the prongs 266 while simultaneously causing lip 260 to be withdrawn from the recess 262 . In the opposite direction, i.e. locking, the engagement of the magnet (or plate in a reverse configuration where the magnet and plate are swapped, not shown), with the prong 266 automatically causes lip 260 to engage notch 262 , though additional locking force manually applied is always prudent.
[0047] In one embodiment, the disengaging prongs 266 when engaged may reduce the binding force between the high energy magnets 202 and the metal insert 252 by as much as 30%, however, in this configuration the high energy magnets 202 will still have sufficient binding force to support the projector 150 with its' mounting hardware attached. However, to ensure that the adjustable lever arm 258 is not unintentionally (or mistakenly) rotated away from the surface of the projector attachment unit 200 , thereby partially disengaging the high energy magnets 202 and the metal insert 252 , means are provide as a secondary lock. In this embodiment a retaining screw (locking fastener) 300 (see FIGS. 1 and 2 ) may be inserted through the mechanical locking device 256 thereby anchoring the lever arm 258 to housing unit 204 . Other means of double-latching the arm may be provided as known in the art or may be later developed. For example, the arm may have protrusions on its side which engage recesses in the adjacent body to force a slight expansion of the body when forced into or out of locked position. A safety latch over the arm may also be provided.
[0048] With the video projector 150 securely mounted to the ceiling via the ceiling attachment unit 250 , the projected image may be aligned in the following manner. The bottom surface of housing unit 204 flares out to form a flange 268 which rests upon surface 270 of gimball plate 191 , which has a sufficient radius to form an adjustable ball and socket type configuration. When initially installed the projector housing unit 200 may be attached to the gimball plate 191 via screw 272 partially threaded into nut 274 , but not fully tightened. In this configuration, surface 270 (the “ball”) may be manually adjusted inside flange 268 (the “socket”) to adjust the projector 110 to the desired angle. Once the desired orientation of the projector 110 is achieved, set screws 276 may be tightened to apply sufficient vertical travel to screw 272 to mechanically secure the gimball plate 191 to flange 268 , thereby securing the projector 110 . In one embodiment of the present invention, surface 270 may be freely rotated within flange 268 by approximately 6° in any arbitrary angle relative to the vertical, however, other angles may be achieved by either modifying the ball and socket geometries shown in FIG. 2 b or employing an alternative pivot arm.
[0049] As noted above, the present invention is applicable to any device which must be removably detached from a fixed mount and is believed to be particularly useful for ceiling mounting. The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the present specification. The claims are intended to cover such modifications and devices. | A system and method of releasably mounting a device, usually to a ceiling, is disclosed. The system has a ceiling mounted unit ( 200 ) and a device mounted unit ( 250 ), releasably joined preferably by an magnetic coupling ( 202 ) which engages a floating plate ( 252 ) allowing for positive coupling even if the units are misaligned. A safety latch ( 256 ) with a locking/latching claw ( 260 ) and ejection/disengagement prong ( 266 ) provide positive locking and a method of separating the units despite strong adhesion forces. | 5 |
FIELD OF THE INVENTION
This invention relates to traffic control in a digital communication network and more particularly to a low-cost system for traffic shaping, scheduling, and dynamic rate control in a cell switched digital communication network.
BACKGROUND OF THE INVENTION
In a transmission of data over a cell switched digital communication network, such as an asynchronous transfer mode or ATM network, problems arise when multiple sources send data cells at widely varying rates through a switch node or link of the network at an aggregated rate which taxes the ability of that switch node or link to handle the data. Congestion occurs at the node of a network when data arrives at the node at a rate exceeding the rate at which the node can process and forward the data to other nodes. The excess data then accumulates in buffer storage at the node, which fills at a rate which is the difference between the arrival rate and the processing and forwarding rate. If the congestion persists for long periods of time, the buffer storage will be filled to maximum capacity and any additional data must be discarded.
In an effort to minimize such data loss, a rate-based flow control system has been disclosed to prevent or inhibit excess data from entering the network. In a rate-based system, the rate at which the data is permitted to enter the network is controlled to not exceed a certain transmission rate, and this transmission rate is adjusted via a feedback signal from a network reflecting the congestion of the network. One such rate controlled system is described in an ATM Forum document #95-0013R2 entitled "Draft Version 3.0 of ATM Forum Traffic Management Specification Version 4.0" authored by Shirish S. Sathaye and David Hughes, April 1995.
One key element in implementing the above described rate-based flow control system is a traffic shaping unit which delays the traffic generated at a source and injects it at a rate no larger than that specified by a flow control scheme. One way to implement such a traffic shaping function is to use a timing chain. A timing chain is composed of an array of slots, with each slot representing one cell time defined as the time needed to transmit one cell of data at the full link transmission speed. A current time pointer points to a slot representing the current time or the current slot to cause cells at that slot to be transmitted, with the time pointer moving forward one slot every cell time. To control cell transmission rate where the rate is under R cells every cell time, at a time when a cell is transmitted, a new cell is scheduled in a slot which is 1/R slots away from the current slot. That is to say the cell is scheduled to be transmitted at a time which is delayed from the current time by a time equal to 1/R cell times. When the current time pointer moves to a slot, all cells queued at the slot become eligible for transmission.
However, one major problem with the above described timing chain approach is its high cost in supporting low rate traffic shaping which needs to delay cells for a long period of time. When the transmission rate R is small, 1/R becomes large. Thus, a timing chain needs a large number of slots, i.e., 1/R slots, to shape a transmission rate of R, making the system very expensive. Low data rate traffic in general refers to the transmission of text, as opposed to high data rate traffic such as full frame video. It is important that any network be capable of supporting both text transfer as well as video transmission as efficiently as possible, and be capable of reducing transmission rates of sources when the network is congested.
SUMMARY OF INVENTION
In order to support low transmission rate without resorting to a large number of slots, a two-dimensional timing chain system is provided. In general, shaping systems are used to delay the transmission of incoming cells based on the bandwidth assigned to this stream of cells. If incoming cells are merely loaded into a delay line, then for low data rate traffic, the length of delay before the cells are coupled to the network is quite long, requiring many slots and extremely long delay line. In order to efficiently shape the incoming traffic, this long delay line is divided up into so-called timing subchains. Each of the subchain has a number of consecutive slots into which incoming cells are stored.
By providing each of the subchains with its own pointer for reading out the cells of the slots, and by driving the pointer for each successive subchain at a slower rate than the previous subchain, it is possible to minimize the number of slots required to accommodate low data rate traffic, while at the same time, accommodating the high data rate traffic.
What has effectively been done by this system is to readout low data rate cells less frequently than the high data rate cells, although with less resolution. By moving the pointers for each subchain at successively lower speeds or rates, the delay of the cells through the shaping system can be realized using fewer slots.
The slot into which a cell is deposited is determined by the amount that the system would ordinarily delay the cell prior to its being coupled to the network. Each cell represents data which is to be transmitted through the network at a given data rate. For instance, full frame video requires a data rate of 1.5 Mbps, whereas text traffic may need to be reduced to a data rate of 10 Kbps when a network is congested. The slot into which a cell is placed depends upon the data rate for the traffic it represents. This means that a cell is deposited into that timing subchain which has a slot such that the time the cell in the slot takes to go through the whole chain being no less than 1/R cell times. R refers to a transmission rate in a unit of cells per cell time. R is dependent upon the acceptable data transmission rate for this stream of traffic through the network. For different virtual circuits, R can be different depending on the bandwidth allocated to this circuit. There are two types of connections for cell switched digital communication networks. The first has a fixed bandwidth for the entire length of the time that the connection is established through the network. The second has a variable bandwidth depending on feedback from the network. In either case, each incoming cell has an associated rate. Thus, each cell can be deposited into the appropriate slot in one of the subchains.
In summary, a two-dimensional timing chain can be viewed as a delay line capable of delaying cells for a very long period of timing without using a lot of slots. In one embodiment, a two-dimensional timing chain is thus composed of multiple subchains of slots at each of which one or more cells may be queued. Each subchain has its own time pointer which moves forward at its own pace. As the time pointers advance, cells queued at slots of bottom subchains are moved to that of upper subchains and cells of the first subchain are moved to transmission queues and from where they are transmitted. A two-dimensional timing chain is able to support low rate traffic shaping at any specified control accuracy using much fewer slots than that of a conventional timing chain. Priority traffic scheduling and dynamic rate control can also be easily supported with a two-dimensional timing chain.
More particularly, in an ATM network, a traffic shaping system is provided with a number of tinting subchains each having slots at which cells are queued and each having a pointer to specify the readout of cells at a slot. The system eliminates the necessity for providing large numbers of slots for low data rate traffic while at the same time accommodating high data rate transmission by moving pointers for low data rate traffic at slower rates than pointers for higher data rates. In one embodiment, this is accomplished by increasing the time scale for slots far away from the current time by moving the time pointer increasingly slower for ever more distant slots. When a pointer is at a slot, cells queued at this slot are moved to a slot in the next prior subchain, with cells in the top subchain transmitted when selected by the associated pointer. More particularly, in one embodiment, a two-dimensional timing chain is composed of multiple subchains of slots, with each pointer for a subchain being driven slower than the pointer associated with the subchain immediately above it. In one embodiment, one or more cells are queued at slots in a subchain, with each subchain having its own time pointer which moves forward at its own pace. Once the transmission rate R is defined, cells are then placed in a slot of a subchain which is 1/R cell times away from the time associated with the pointer of the first subchain. As the pointers advance, cells queued at slots of bottom subchains are moved to slots of upper subchains, with cells of the top subchain moved to transmission queues and from whence they are transmitted. The subject two-dimensional timing chain can thus support very low rate traffic and facilitate traffic scheduling and dynamic rate control without requiring a large number of slots.
BRIEF DESCRIPTION OF DRAWINGS
These and other features of the Subject Invention will be better understood in conjunction with the Detailed Description taken in accordance with the Drawings of which:
FIG. 1 is a schematic diagram illustrating a source end system in which data cells are rate controlled by a traffic shaping unit and are then transmitted over a network to a destination end system.
FIG. 2 is a schematic diagram illustrating the usage of a conventional one-dimensional timing chain for traffic shaping.
FIG. 3 is a schematic diagram illustrating an example of a two-dimensional timing chain.
FIG. 4 is a schematic diagram illustrating the queueing of cells at a slot using a linked list data structure.
FIG. 5 is a schematic diagram illustrating the implementation of multiple priority cell transmission scheduling with the timing chain approach.
FIG. 6 is a schematic diagram illustrating another way of implementing multiple priority scheduling with the timing chain approach.
FIG. 7 is a schematic diagram illustrating how pointers to the next next priority can be added to expedite searching for the scheme illustrated in FIG. 6.
FIG. 8 is a schematic diagram illustrating a doubly linked list queueing structure to facilitate cell rescheduling and fast pate update.
FIG. 9 is a schematic diagram illustrating a doubly linked list structure used to reschedule a cell already in a timing chain.
DETAILED DESCRIPTION
Referring now to FIG. 1, a network 10 is utilized to connect a source end system 12 at a source node to a destination end system 14 at a destination node. A source end system sends cells 14 to a destination end system by establishing a virtual circuit through the network. To avoid network congestion and cell losses, the cell transmission rate of each virtual circuit must be controlled under R cells every cell time. Different virtual circuits may have different values of R and R may also be dynamically changed according to a rate-based flow control scheme. Implementation of such a rate control function requires a traffic shaping unit 18 to delay incoming traffic 16 such that the time interval between two consecutive cells of a virtual circuit injected into a network be controlled to be no smaller than 1/R cell times. The subject invention provides a low cost implementation of traffic shaping unit 18.
Referring now to FIG. 2, a timing chain 20 has previously been proposed to implement traffic shaping unit 18 of FIG. 1. A timing chain is composed of a number of slots 22 each representing one cell time. A current time pointer 24 points to a slot representing the current time and it moves forward one slot every cell time. When the time pointer reaches the end of a chain, it moves back to the first slot of the chain. When the current time pointer moves to a slot, any cells queued at the slot become eligible for transmission. To control the transmission rate of a virtual circuit assuming a rate of under R cells per cell time, at a time one cell of the virtual circuit is transmitted, a new cell is scheduled in a slot which is 1/R slots away from the slot that the current time pointer is pointing to, representing a time which is 1/R cell times delayed from the time. Notice that at most one cell per virtual circuit is scheduled in the chain. An arriving cell will not be scheduled until the previously scheduled cell of the same virtual circuit is transmitted. One major problem of using such a timing chain to implement a traffic shaping unit is that a large number of slots is required to support a low transmission rate such as that associated with text transmission, resulting in an expensive system.
Referring now to FIG. 3, the subject invention provides a two-dimensional timing chain system for traffic shaping unit 18 in FIG. 1 which is capable of supporting low rate traffic with fewer slots than that with the previously proposed one-dimensional timing chain system. In a preferred embodiment, an m×k two-dimensional timing chain is composed of k subchains 30, 32, 34, and 36 with each subchain having m slots and a time pointer. For i=1, . . . , k, each slot in the i-th subchain represents 2 i-1 cell times, thus the time pointer of the i-th subchain moves forward one slot every 2 i-1 cell times. When a time pointer reaches the end of a subchain, it moves back to the first slot of the subchain. Except for the first subchain 30, when the time pointer of the i-th subchain moves to a slot, any cells queued at the slot are transferred to the tail of the (i-1)-th subchain, which is defined as the slot that the time pointer has just left. For the first subchain 30, when the time pointer moves to a slot, cells queued at the slot are moved to a transmission queue 38 from where cells are transmitted. To control the transmission rate of a virtual circuit to under R cells per cell time, at a time when a cell of the virtual circuit is transmitted, a new cell is scheduled in a slot which is at least 1/R cell times away from the slot that the time pointer of the first subchain is pointing to. In other words, the cell should be placed in a slot such that it takes no less than 1/R cell times for the cell to be transferred into a transmission queue. At most one cell per virtual circuit can be scheduled in the chain and an arriving cell will not be scheduled until the previously scheduled cell is transmitted. If a cell arrives at a time when there is no cell of the virtual circuit in the timing chain, it is scheduled at a slot which is no less that 1/R cell times away from either the current time or the time when last cell of the virtual circuit was
An m×k two-dimensional timing chain as described above can delay a cell for a maximum of (2 k-1 )m cell times, thus supporting a lowest transmission rate of B link /((2 k-1 )m) where B link is the transmission bandwidth of the link connecting the source end system and the network. Except for the first subchain for which the rate control accuracy is the same as that of the one-dimensional timing chain, a rate control accuracy of δR/R=2/m is guaranteed, where R is the target rate to be controlled, and δR is the rate error introduced by the timing chain mechanism. Thus one may select an appropriate value of m to satisfy any rate control accuracy requirement. Notice that by synchronizing the advances of time pointers, a rate control accuracy of 1/m is achievable. Alternatively, one may coordinate the advances of time pointers in such a way that at most two pointers move forward at any given time, thus minimizing the maximum number of accesses to a timing chain in one cell time. For example, for a two-dimensional timing chain with four subchains, the advances of time pointers can be coordinated as follows: (1,2),(1,3),(1,2),(1,4),(1,2),(1,3),(1,2),(1,.sup.•), . . . , (repeating the pattern), where (i,j) means pointers of subchains i and j move forward together in one cell time.
The following example shows advantages of a two-dimensional timing chain over a one-dimensional timing chain. Suppose B link =155 Mbps. Using 1K slots, a 64×16 two-dimensional timing chain can support a lowest rate of 155/((2 16 -1)×64) Mbps=0.04 Kbps with a rate control accuracy of 2/64=3.1%. On the other hand, a one-dimensional timing chain with the same number of 1K slots can only support a lowest rate of 155/1024 Mbps=151 Kbps. This shows that with the same number of slots, a two-dimensional timing chain can support a rate which is several thousand times lower than that a one-dimensional timing can support.
Note that as cells arrive having different rates, they are queued in the subchains having slots that are the correct 1/R distance away, e.g. are associated with the correct delay. That subchain also has a pointer moving at the appropriate speed such that the number of slots can be minimized. This shows that low rate traffic can be accommodated with a minimum of slots due to the slower speed of the pointer associated with the subchain into which these low rate cells are deposited.
It should be noted that the two-dimensional timing chain system depicted in FIG. 3 is only an example showing how a low cost traffic shaping unit can be implemented with a timing chain in which pointers for different subchains move forward at different speeds to support low rate traffic shaping and at the same time maintain a high control accuracy. Variations of this mechanism can be easily constructed to achieve different rate control accuracies and lowest supportable transmission rates.
Referring now to FIG. 4, for a two dimensional timing chain depicted in FIG. 3, if the number of slots in each subchain is of powers of 2, say m=2 n , then the k time pointers of an m×k two-dimensional timing chain as depicted in FIG. 3 can be implemented with just a single (k+n)-bit wide counter 40. Specifically, for i=1, . . . , k, the bits between bit i 42 and bit i+n 44 of the counter can serve as the time pointer 46 for subchain i. In other words, the binary value represented by bit i to bit i+n identifies the slot in subchain i to which the time pointer is pointing.
Referring now to FIG. 5, queueing of cells at a slot can be implemented using a linked list data structure. Since each virtual circuit can at most have one cell queued in a timing chain, a queue of cells can actually be implemented as a queue of virtual circuits which can be implemented by adding next -- vc pointers 55-59 in a virtual circuit table 50 with each next -- vc pointer pointing to the next virtual circuit in a linked list. A tail pointer 52 and a header pointer 54 are stored in each slot of a timing chain 56 pointing to the header and tail of a linked list, respectively. The transmission queue 36 in FIG. 3 can also be implemented in this way by using a header pointer and a tail pointer. Addition of a virtual circuit to a queue and move a queue to the end of the transmission queue can be accomplished with the usual linked list pointer operation without requiring actual movement of virtual circuits or cells.
Referring now to FIG. 6, priority scheduling can be supported by using multiple queues 60 and 62 in parallel at each slot and multiple transmission queues 64 and 66. When a cell is scheduled at a slot, it is put at the end of its corresponding priority queue at the slot. When the time pointer advances, queues at slots are concatenated at the end of transmission queues of the same priority levels. Cells in a transmission queue of a higher priority are transmitted before those in a transmission queue of a lower priority. Priority scheduling is useful when some virtual circuits have transmission priority over others. For example, virtual circuits transferring video/audio data usually have priority over virtual circuits transferring text data to ensure timely delivery of real-time video/audio signals.
Referring now to FIG. 7, priority scheduling can also be supported by arranging priority queues 70 and 72 at slots and the transmission queues in serial 74, 76 in serial. One advantage of this data structure as compared to that depicted in FIG. 6 is its ability to accommodate many priority levels without requiring each slot to hold a large number of pointers to each of the priority queues. However, search operations are needed to add a cell of a certain priority to its corresponding position in the serial priority queues or merge two queues together while keeping the orders of cells according to their priorities.
Referring now to FIG. 8, pointers 80 and 82 can be added to the system in FIG. 6 to expedite searching. Specifically, to add a cell of low priority to a serial priority queue, one does not need to search through all cells of higher priorities to find the right position. Instead, pointers to the next priority can be used to directly find the tail of the queue of the next priority level.
Finally, referring to FIG. 9, a doubly linked list structure 90 can be used to reschedule a cell already in a timing chain and achieve fast rate update. In the example depicted in FIG. 9, a cell belonging to virtual circuit 94 can be removed from a tinting chain by simply removing links 98 and links 100, and adding a new links 102 in the virtual circuit table. The removed cell can be rescheduled into the tinting chain using a new rate value R. In this way, the transmission rate of a virtual circuit can be changed dynamically without having to wait after the previous scheduled cell of the virtual circuit is transmitted.
Having above indicated a preferred embodiment of the present invention, it will occur to those skilled in the art that modifications and alternatives can be practiced within the spirit of the invention. It is accordingly intended to define the scope of the invention only as indicated in the following claims. | In an ATM network, a traffic shaping system is provided with a number of timing subchains each having slots at which cells are queued and each having a pointer to specify the readout of cells at a slot. The system eliminates the necessity for providing large numbers of slots for low data rate traffic while at the same time accommodating high data rate transmission by moving pointers for low data rate traffic at slower rates than pointers for higher data rates. In one embodiment, this is accomplished by increasing the time scale for slots far away from the current time by moving the time pointer increasingly slower for ever more distant slots. When a pointer is at a slot, cells queued at this slot are moved to a slot in the next prior subchain, with cells in the top subchain transmitted when selected by the associated pointer. | 7 |
BACKGROUND OF THE INVENTION
[0001] This invention generally relates to a method for assuring enhanced signal integrity in various electronic components operating at higher frequencies. In particular, the present invention relates to a method for optimizing via structures in such components. More particularly, the present invention relates to a method for optimizing via structures for the enhanced high frequency performance of printed circuit boards and backplanes.
[0002] Today's electronic products, including computers, cellular telephones, and networking systems operate at ever increasing transmission data rates. At higher transmission data rates, resistance, dielectric absorption, and radiation losses, cross-talk, and structural resonances of passive interconnects can significantly degrade the quality of signals propagating through the interconnect. One of the primary circuit elements that attenuates and distorts analog, radio frequency and digital signals is the via. Via signal degradation is frequency/data rate dependent.
[0003] Numerous techniques have been used to mitigate the signal degradation problem including backdrilling of via stubs and removal of non-functional pads. These techniques, however, have seen limited, and to some extent, been subjectively applied in an attempt to improve the signal integrity of complex printed circuit boards and backplanes. It is, therefore, desirable to provide an objective, cost-effective method for the optimization of the shape and size of each via structure within such a printed circuit board or backplane. Additionally, it is desirable to provide such a method that is capable of being applied to other elements of an existing circuitry, such as collections of interconnect components (i.e., backplane assemblies that include vias, traces, and connectors) so as to enhance the circuit's overall signal integrity performance and thus its effectiveness for use at higher operating frequencies.
SUMMARY OF THE INVENTION
[0004] The present invention recognizes and addresses various of the foregoing limitations and drawbacks, and others, concerning prior art techniques aimed at improving high frequency performance for electronic circuitry Therefore, the present invention is directed to a method for optimizing via structures for the enhanced high frequency performance of printed circuit boards and backplanes.
[0005] It is, therefore, a principle object of the subject invention to provide a method of improving signal integrity performance of high frequency electrical circuits. More particularly, it is an object of the present invention to provide a method for optimizing at least one element of a circuit to improve its high frequency signal integrity performance. In such context, it is still a more particular object of the present invention to provide a method for optimizing a via structure's size and shape to enhance its high frequency signal integrity performance.
[0006] Still further, it is a principle object of this invention to provide a cost-effective optimization methodology for improving the signal integrity of an electrical circuit. In such context, it is an object of the present invention to provide a cost-effective methodology for improving the high frequency signal integrity performance of a via structure.
[0007] Additional objects and advantages of the invention are set forth in, or will be apparent to those of ordinary skill in the art from, the detailed description as follows. Also, it should be further appreciated that modifications and variations to the specifically illustrated and discussed features, method steps, and materials hereof may be practiced in various embodiments and uses of this invention without departing from the spirit and scope thereof, by virtue of present reference thereto. Such variations may include, but are not limited to, substitutions of the equivalent means, features, method steps, and materials for those shown or discussed, and the functional or positional reversal of various parts, features, method steps or the like.
[0008] Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of this invention, may include various combinations or configurations of presently disclosed features, elements, method steps or their equivalents (including combinations of features or configurations thereof not expressly shown in the figures or stated in the detailed description).
[0009] These and other features, aspects and advantages of the present invention will become better understood with reference to the following descriptions and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the descriptions, serve to explain the principles of the invention.
[0010] In one exemplary embodiment, there may be provided an interactive method of optimization for manipulating the physical characteristics of a single or multiple vias within a PCB or backplane to enhance their high frequency performance. In general, such method involves subdividing the via into one or more of the following three different kinds of sections: a transmission line bend section, a non-uniform transmission line thru section, and a loaded non-uniform transmission line stub section. Where possible the PCB stackup should be designed so the stub section lengths (if any are present) are minimized.
[0011] The transmission line bend sections may be converted into lumped element series impedances and shunt element admittances. The physical dimensions of the bend section components may be adjusted until several second-level characteristics of the section's electrically equivalent sub-circuits are optimized. In the case of a single via, such optimization of a transmission line bend section is generally equivalent to minimizing the magnitude of the lumped element series impedances and shunt element admittances.
[0012] Further, the non-uniform transmission line thru sections may be converted into a series of discretized RLGC sub-circuits comprised of one or more resistors, R, inductors, L, conductors, G, and capacitors, C. The physical dimensions of the thru section components associated with each sub-circuit may be manipulated until the values of R, L, G, and C are optimized. In the case of a single via, such optimization of a non-uniform transmission line thru section is generally equivalent to either 1) making the individual R, L, G, and C and associated discretized characteristic impedance values between adjacent sub-circuits as equal as possible, or 2) making the ratio of the sum of the series impedances over the sum of the shunt admittances as equal as possible.
[0013] Further still, the non-uniform stub transmission line sections may be converted into a series of discretized RLGC sub-circuits. The physical dimensions of the stub section components associated with each sub-circuit may be manipulated until the values of R, L, G, and C are optimized. In the case of a single via, such optimization of a non-uniform stub transmission line section is generally equivalent to making the magnitudes of series R and series L as large as possible and the magnitudes of shunt G and shunt C as small as possible.
[0014] Finally, the S-parameters of the via structure after optimization may be calculated to verify the optimization results. The present invention allows for constraints on the continued manipulation of the physical characteristics of the vias to avoid minute improvements in performance at exponentially greater and greater monetary costs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0016] [0016]FIG. 1 is a pair of cross-sectional views of a standard printed circuit board showing the individual internal layers and a corresponding view showing the internal connections between the layers including a plurality of vias;
[0017] [0017]FIG. 2 is a pair of cross-sectional views of a printed circuit board as in FIG. 1 with prior art modifications to the via structures for the enhancement of signal integrity performance;
[0018] [0018]FIG. 3 is a baseline cross-sectional view of a printed circuit board indicating the individual internal layers and a corresponding partial cross-sectional view showing microstrip and stripline transmission line cross sections for the upper three layers of such printed circuit board;
[0019] [0019]FIG. 4 is a partial cross-sectional view of a printed circuit board showing the views of the single-ended stripline of FIG. 3, as well as, the division of such stripline into identical length segments and its equivalent electrical circuit;
[0020] [0020]FIG. 5 is a pair of cross-sectional views of a printed circuit board showing the individual internal layers and a corresponding view showing the internal connections between the layers including a via thru section with an adjacent return via, and the equivalent circuit for the plurality of vias;
[0021] [0021]FIG. 6 is a pair of cross-sectional views as in FIG. 5 for a via thru section without an adjacent return via and it's equivalent circuit; and
[0022] [0022]FIG. 7 is a flowchart outlining the basic methodology of the present invention.
[0023] Repeat use of reference characters throughout the present specification and appended drawings is intended to represent the same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Reference will now be made in detail to presently preferred embodiments of the invention, examples of which are fully represented in the accompanying drawings. Such examples are provided by way of an explanation of the invention, not limitation thereof. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention, without departing from the spirit and scope thereof. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Still further, variations in selection of materials and/or characteristics may be practiced, to satisfy particular desired user criteria. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the present features and their equivalents.
[0025] As disclosed above, the present invention is particularly concerned with a method for optimizing via structures for the enhanced high frequency performance of printed circuit boards and backplanes 10 . Vias 12 degrade the signal integrity performance of printed circuit board interconnects because they attenuate and distort analog, radio frequency, and digital signals that propagate through them. The present invention may be used to optimize individual component structures that make up a via 12 , a collection of vias 12 , and even higher level interconnects such as printed circuit boards and backplane assemblies 10 containing vias 12 , interconnected traces, and connectors.
[0026] [0026]FIG. 1 shows a cross-section of a typical multi-layer printed circuit board 10 (PCB) with a plurality of vias 12 . A multi-layer PCB 10 is a printed board that consists of two or more planar conductive layers (L 1 , L 2 , L 3 , etc.) separated by one or more rigid or flexible planar insulating dielectric layers bonded together and electrically interconnected. An electrical connection between two or more patterns on different conductive layers is known as a via 12 . A buried via 14 is one that does not extend to the outer layers of a PCB 10 . A blind via 16 extends only to one outer layer. Blind and buried vias 14 and 16 are also known as interstitial vias. A plated through hole 18 (PTH) via extends through the entire PCB 10 (from the top outer layer to the bottom outer layer) and is capable of making electrical connection between conductive patterns on internal layers, external layers, or both.
[0027] A via 12 , regardless of its location, includes a number of components. At the least a via 12 includes a barrel 20 and one or more functional 22 or non-functional 24 pads. Where applicable, a via 12 may include a clearance region 26 (also called an anti-pad region) on those layers where the via 12 intersects that layer but must be electrically isolated from any conductive patterns located on such layer. A pad 22 or 24 is a localized conductive pattern that is electrically attached to the via 12 . If the pad 22 is also electrically connected to a conductive pattern (i.e., a signal trace, a ground or voltage plane, or a passive device, etc.) then it is a functional pad 22 .
[0028] [0028]FIG. 2 shows two methods currently in use to improve the signal integrity performance of a via 12 . It is common practice to remove non-functional pads 24 as a way to enhance the signal integrity performance of the via 12 . It is also common practice to remove the unused “stub” sections 28 of PTH vias 18 by backdrilling out the conductive portion of the via 12 that makes up the stub section 28 .
[0029] There are many problems with arbitrarily utilizing these commonly accepted methods without an optimization effort for each via 12 or the collection of vias 12 with a PCB or backplane 10 . There are situations where removing some of the non-functional pads actually degrades rather than improves signal integrity performance.
[0030] The method of the present invention involves subdividing the via 12 into one or more of the following three different kinds of sections: a transmission line bend section, a non-uniform transmission line thru section, and a loaded non-uniform transmission line stub section. Where possible the PCB stackup 10 should be designed so the stub section lengths 28 are minimized. The transmission line bend sections may be converted into lumped element series impedances and shunt element admittances, which are monotonically related to the scalable S-parameters of the circuitry including the non-optimized via 12 . Thus the iterative steps used in the process may be based on a straightforward sequential convergence algorithm.
[0031] The physical dimensions of the bend section components may be adjusted until several second-level characteristics of the section's electrically equivalent sub-circuit are optimized. Non-uniform transmission line thru sections and non-uniform stub transmission line sections may be converted into a series of discretized RLGC sub-circuits (see FIGS. 4-6). The physical dimensions of the thru section components associated with each sub-circuit may be manipulated until the values of R, L, G, and C are optimized.
[0032] To accomplish these conversions, signal traces and adjacent conductive plane regions may be formed into planar transmission lines as seen in FIG. 3. A planar transmission line is a wave-guiding structure whose fundamental mode of propagation along the transmission line is essentially a transverse electromagnetic wave. Planar transmission lines suitable for transmission of high frequency or narrow pulse electrical signals have defined conductor and dielectric material dimensions and shapes that are uniform along their length. Transmission lines can be described by an equivalent electrical circuit composed of distributed resistance, inductance, conductance, and capacitance elements (i.e., an RLGC sub-circuit). A microstrip transmission line 32 configuration consists of a conductor that is positioned over and parallel to a conductive plane with a dielectric therebetween. A stripline transmission line 34 configuration consists of a conductor that is positioned between and parallel to two conductive planes with a dielectric among them. A balanced transmission line 36 is a two-conductor transmission line that has distributed resistance, inductance, conductance, and capacitance elements equally distributed between its conductors. An unbalanced transmission line 38 is a transmission line that has distributed resistance, inductance, conductance, and capacitance elements not equally distributed between its conductors. Non-equal trace widths are one way to create an unbalanced transmission line 38 . It is common practice to denote the signal trace layer as the reference layer for microstrip 32 and stripline 34 transmission line structures. In FIG. 3, the single ended microstrip, the balanced differential microstrip, and the unbalanced differential microstrip are located on layer L 1 , even though the conductive plane on L 2 forms part of the transmission line structure. In a similar fashion, the single-ended stripline, balanced differential stripline, and unbalanced differential stripline are located on L 3 , even though the conductive planes on layers L 2 and L 4 also form part of the transmission line structure.
[0033] Because microstrips 32 and striplines 34 are uniform guided wave structures (e.g., their cross-sections do not change with distance along the line), they can be used to model the impact of signals propagating down the line through a series of identical lumped-element RLGC circuits 40 . As best seen in FIG. 4 and using the single-ended stripline 34 of FIG. 3 as an example, a transmission line is first divided into infinitesimally small increments, ΔZ. An electrically equivalent circuit 40 may be created based on the four physical phenomena all transverse electromagnetic wave mode transmission lines have in common. The series resistance, R, is used to quantify the conversion of signal power into heat inside the conductive regions of the transmission line. The shunt conductance, G, is used to quantify the conversion of signal power into heat inside the dielectric regions of the transmission line. Because transmission lines are guided wave structures, the bulk of the power contained in the propagating signal is in the electric and magnetic fields that exist in the dielectric regions surrounding the conductive portions of the transmission line. The capacitance, C, is used to quantify the impact the transmission line has on the electric field. A similar relationship exists between inductance, L, and the magnetic field. Altering the size and shapes of the conductors and dielectric materials used to create the transmission line will alter the values of R, L, G, and C.
[0034] When uniform transmission lines (such as microstrip 32 and stripline 34 interconnect traces) are connected to a via 12 , the via 12 and its localized surroundings may be divided into three different vertical regions: one or more bend regions, one or more stub regions, and one or more thru regions. The top and bottom surfaces that comprise these regions depend on the PCB stackup 10 and which layers incoming and outgoing planar transmission lines are routed on. A via bend section is that region of a via 12 connected to a planar transmission line. A bend signifies that the direction of the currents associated with the signal must change directions. In other words, the signal currents flowing horizontally along the interconnect traces must now flow vertically through the via 12 . As a general rule, the bend section consists of the vertical section of the via 12 located on the same layers used to create the signal trace transmission line structures. Because microstrip transmission lines 32 need two layers, a bend associated with a microstrip 32 encompasses at least two layers.
[0035] Similarly, a via stub section 28 is that portion of a via 12 which has one end that is not terminated. A via thru section or a via bend section cannot be part of a via stub section 28 . A via thru section is that portion of the via 12 which is required in order to complete an electrical circuit between an incoming and outgoing signal transmission line but is not part of a bend section. The electric and magnetic fields associated with the signal passing through the via 12 often extend into the regions between the conductive layers beyond the anti-pad boundary 26 .
[0036] When optimizing a via 12 one must include these regions 26 if the electric and magnetic fields contain a significant percentage of the energy contained in the signal. The penetration distance is dependent on a number of factors including the size and shape of the pad 22 and 24 and anti-pad 26 regions and thickness of both the conductive and dielectric layers in the region of interest. In PCB regions where the via density is high, which is often the case underneath connectors and high pin-count integrated circuits, the electric and magnetic fields generated by adjacent vias 12 can and do co-mingle. In those cases, the optimization of a given via 12 may also require the optimization of adjacent vias 12 .
[0037] [0037]FIG. 5 depicts an example of the conversion of a two via structure 52 into discrete segments for optimization. In this example, two microstrip transmission lines 32 are connected to a plated thru hole (PTH) via 18 . A buried via 14 is used to provide a direct current return path for the two microstrip lines 32 . The buried via 14 is positioned very close to the PTH via 18 so the electromagnetic fields generated by the currents in the two vias 14 and 18 are coupled. The vertical distance between layers L 1 and L 2 form a bend region. The vertical distance between layers L 11 and L 12 form a bend region. The remaining portion of the via 18 , layers L 2 through L 11 , form the thru section. There are no stub sections 28 in this configuration. One can define an equivalent circuit 40 for the thru section by dividing up the total height into a chain of series RL segments 54 and shunt GC segments 56 . The series R value can be computed from the resistance losses associated with the via segments defined in the region.
[0038] The series inductance can be computed from the magnetic field generated by the propagating signal between layers L 2 and L 3 . The shunt capacitance can be computed from the electric field generated by the propagating signal surrounding layer L 3 . The series impedance increases with the increasing separation between layers. The shunt admittance is dependent on how close the ground plane is to any non-functional pads. The shunt admittance of layer L 6 is greater than the shunt admittance of layer L 7 . The thickness of the conductive planes also impacts the shunt admittance. A thicker conductive layer has a lower admittance. Moving the conductive planes away from non-functional pads 24 , or removing a non-functional pad 24 increases the shunt admittance. Since optimization of the thru section generally requires the discretized characteristic impedance between the individual discretized RLGC circuits 40 to be as equal as possible, the pad 22 and 24 and anti-pad 26 diameters must be adjusted as needed to compensate for differences in dielectric material thickness, conductor thickness, etc. If adjustments of the pad/anti-pad diameters do not provide sufficient degrees of freedom, then the dielectric layer heights may require adjustment.
[0039] Note that a given transmission line structure is not limited to the four RLGC values noted herein. As long as expressions for series impedance and series admittance can be derived, the lumped element characteristic impedance of the transmission line structure can be calculated. As an example, consider the single via structure 62 shown of FIG. 6. In such a case, there is no adjacent DC return current via, and the equivalent circuit 40 includes a series capacitance, C pp , that provides a return path for an AC displacement current.
[0040] Also note that as the frequency increases, the discretized characteristic impedance approaches that obtained for the two-via case 52 described above. If the DC return via in the two-via case 52 is not in the immediate vicinity of the via 12 being analyzed, then the model defined by FIG. 6 must be used. The important point to make here is that once a given via structure 62 is defined, it is possible to convert it into an discretized non-uniform transmission line structure on which known calculations may be performed to optimize the physical characteristics of the via 12 or collection of vias 12 .
[0041] [0041]FIG. 7 provides a flowchart 70 of the present invention's methodology for optimizing the high frequency performance of via structures 12 . As the present invention is primarily concerned with improving signal integrity, the first step of the process 72 is to choose a parameter that may be calculated to evidence improvement in the printed circuit board's signal integrity by manipulating the physical characteristics of the vias 12 . One such parameter is the S-parameter. Due to their inherent difficulty to calculate in an iterative process where equivalent electrical representations of physical parameters are being evaluated, the S-parameters are best represented in terms of series impedances, shunt element admittances, and series discretized RLGC sub-circuits, where the values of R, L, G, C and the admittances and impedances may be quickly calculated. These may be chosen as the second level parameters 74 to determine optimization.
[0042] In order to calculate the second level parameters, the via must be subdivided into one of several types of transmission line segments 76 . These include transmission line bend sections, non-uniform transmission line thru sections, and loaded non-uniform transmission line stub sections, as necessary, to generate an electrical circuit equivalent to said at least one via structure. To ease the calculations and reduce reflective signal effects the stub section lengths of the vias should be minimized where possible 78 .
[0043] The transmission line segments may then be converted 80 into equivalent series impedances, shunt element admittances, and a series of discretized RLGC sub-circuits comprised of one or more resistors, R, inductors, L, conductors, G, and capacitors, C. The second level parameters for these equivalent circuits may be calculated as a baseline 82 . The physical characteristics of the vias 12 are then manipulated in a first direction 84 (i.e., increase or decrease the size of the hole or change its shape). The second level parameters are then recalculated 86 to determine if their values are moving in a direction desired by the user.
[0044] If the second level parameter values are moving towards an optimized value 88 , the physical characteristics of the vias may be further altered in the same manner 90 (i.e., if previously made smaller, make it smaller still) until such time that the calculated values of the second level parameters are either optimized 92 or until further optimization is cost prohibitive. If the second level parameters are not moving towards an optimized value 94 , the physical characteristics of the vias may be moved in the other direction 96 (i.e., if made smaller, then make it bigger) until such time the calculated values of the second level parameter are either optimized 100 or until further optimization becomes cost prohibitive. Optionally, the top level parameters may be calculated to ensure a high frequency performance improvement in the printed circuit board through the via's optimization.
[0045] Although a preferred embodiment of the invention has been described using specific terms and devices, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of the present invention, which is set forth in the following claims. In addition, it should be understood that aspects of various other embodiments may be interchanged both in whole or in part. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred version contained herein. | A method for enhancing the high frequency signal integrity performance of a printed circuit board (PCB) or backplane is provided. The method may involve the use of the S-parameters as the primary cost factors associated with an iterative process to optimize the physical dimensions and shape of a single or a collection of vias within the PCB or backplane. Such process involves the representation of the via components as equivalent lumped series admittances and impedances, as well as, RLGC sub-circuits upon which basic circuit analysis may be performed to optimize secondary characteristics, for example, the maximization of the sub-circuit's resistance and/or the minimization of the subcircuit's capacitance. The iterative process involves the alteration of physical dimensions and the shape of the via components such that the secondary characteristics are optimized. | 7 |
BACKGROUND OF THE INVENTION
In textile carding systems, the advantages of maintaining the uniformity of the sliver formed by the card, and reducing yarn count varaitions are well known. Conventional autoleveling to vary the rates of the speed of the doffer roll and the input feed roll in response to variations in the density of the sliver leaving the card is one familiar effort to improve sliver uniformity. Additionally, other efforts have been made to control the nature of the fiber batt that is fed to the card, to thereby improve the quality of end product of the card.
For example, systems are known in which the thickness of the batt formed by a fiber feeding device is sensed, and variations in the batt thickness are used to vary the speed of the discharge rolls through which the batt is fed from the fiber feeding device for delivery to the input of the card. It is also known, as disclosed in Erben U.S. Pat. No. 4,321,732, that the pressure of the collected fiber in a fiber feeding device may be used to vary the speed of inlet feed roll of such device, and, as disclosed in Krull U.S. Pat. No. 4,206,823, to sense the weight of the batt formed by a fiber feeder device and vary the speed of the discharge rolls of the fiber feeding device and the speed of the input rolls of the card. Also, in Beukent U.S. Pat. No. 3,896,523, a control system is disclosed by which the speed of the oscillation plate, or spanker plate, in the fiber feeding device is coordinated to vary proportionately to, and in dependence upon, the speed of the feeding means to the card.
In co-pending U.S. patent application Ser. No. 255,109, filed Apr. 17, 1981, now U.S. Pat. No. 4,387,486 a system is disclosed for improving sliver uniformity in which the spanker plate and inlet feed roll of a fiber feeder are normally operated at speeds which are proportional to the operating speed of the card, and the weight of the batt leaving the fiber feeder is sensed to generate a signal that is utilized to override the primary drive for the spanker plate and thereby vary the ratio between the operating speed of the spanker plate and the card. Additionally, the level of collected fiber in the fiber feeder is sensed to generate a signal that is utilized to override the primary drive of the inlet feed roll of the fiber feeder.
Finally, fiber feeding devices for forming batts have heretofore been provided with air pressure generating means, such as a blower, to improve the uniformity of the batt by compressing the fiber collected in the device and/or by equalizing the level of such collected fibers as disclosed for example in Husges U.S. Pat. No. 4,135,911, Hecker U.S. Pat. No. 3,482,883, and co-pending U.S. patent application Ser. No. 340,625, filed Jan. 19, 1982, now U.S. Pat. No. 4,476,611.
Thus, in general, the prior art discussed above falls into two categories, namely changing the card speed as the sliver density changes, or regulating the operations of the fiber feeding devices as the density of the batt delivered therefom varies. In the present invention, by contrast, the uniformity of the sliver is improved by sensing the density of the sliver and the batt, and directly controlling the compressing means in the fiber feeding devices to compensate for, and correct, the sensed variations in such densities.
SUMMARY OF THE INVENTION
In accordance with the present invention, a fiber feeding device is provided which preferably includes both a pneumatic means and a mechanical means for compressing the fiber which is collected in such device, and a control system is provided by which the density of the sliver formed by the card is sensed and high and low signals are generated when the sliver density is above or below, respectively, a predetermined density level. The high signal is used to vary the operation of the pneumatic and mechanical compressing means so as to decrease the compression of the fiber collected in the fiber feeding device, and the low signal is used in a corresponding manner to increase the compression of the collected fiber.
Additionally, the control system of the present invention preferably includes means for sensing the density of the batt formed by the fiber feeding device and generating high and low signal when such batt density is above or below, respectively, a predetermined level. These high and low batt density signals are utilized in conjunction with the high and low sliver density signals to vary the compression of the collected fiber in the fiber feeding device in a predetermined manner.
In the preferred embodiment of the present invention, the mechanical compressing means is a conventional oscillating spanker plate and the pneumatic compressing means is a blower which imposes air pressure on the collected fiber in the fiber feeder, and both the spanker plate and the blower are driven by the same motor which is controlled by the aforesaid control system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a fiber feeding device and a carding machine in which the present invention is employed; and
FIG. 2 is a diagrammatic illustration of the control circuit for the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A textile processing system is illustrated in FIG. 1 and includes a fiber feeding device 10 which, as will be described in greater detail presently, receives loose fiber from an inlet duct 12 and forms such fiber into a batt that is fed into a carding machine 14 which, in turn, forms the fiber into a sliver that is delivered through a trumpet 16 to a coiler 18.
The fiber feeding device 10 is generally similar to the fiber feeding device disclosed in greater detail in co-pending U.S. Patent Applications Ser. Nos. 336,016, filed Dec. 30, 1981 now U.S. Pat. No. 4,394,790, and 340,635, filed Jan. 19, 1982, now U.S. Pat. No. 4,476,611, and includes an inlet feed roll 20 operated by motor 22, and an opening roll 24 operated by a motor 26. A chute 28 is provided for collecting fiber delivered thereto by the opening roll 24, the chute 28 including a fixed wall portion 30 and an opposite movable wall portion 32 that is pivoted at 34 for oscillating movement toward and away from the fixed wall portion 30 to compress or densify the collected fiber therebetween. Oscillation of the pivoted wall portion 32 is obtained by a conventional drive which includes a linkage 36 connected to an eccentric drive 38 on a variable speed electric motor 40. The fiber feeding device 10 also includes a blower 42 that is driven through a belt drive 44 from the motor 40, the blower 42 being arranged to generate a flow of air that passes upwardly from the discharged end of the blower 42, around the upper portion of the opening roll 24, and downwardly therefrom the chute 28 where the air passes through a perforated plate 46 located above the oscillating wall portion 32, all as explained in greater detail in the aforesaid co-pending patent applications. This flow of pressurized air, in addition to equalizing the level of the fiber collected in the chute 28, tends to compress or densify such collected fiber by imposing air pressure at the upper surface thereof. Thus, it will be noted that compression of the collected fiber in the chute 28 is obtained from both the blower 42 and the oscillating wall portion 32, both of which are driven by the same motor 40, so that if the speed of the motor 40 is increased, the air pressure produced by the blower 42 and the rate of movement of the oscillating wall portion 32 are both increased to increase the compressive force imposed on the collected fiber in the chute 28. Similarly, decreasing the speed of the motor 40 will act to decrease the compressive force imposed on such collected fiber by the blower 42 and the oscillating wall 32.
A pair of discharge rolls 48 and 50 are disposed at the bottom or discharge end of the chute 28 for delivering therethrough a batt of fiber that is fed to the inlet end of the carding machine 14. One of these rolls, 48, is fixed, and the other, 50, is arranged in any conventional and well known manner for linear movement toward and away from the fixed roll 48 in response to variations in the thickness of the batt passing therethrough. Thus, the linear displacement of the movable roll 50 is a function of the thickness of the batt being discharged from the fiber feeding device 10, and, therefore, a function of the density of the batt. As shown diagrammatically in FIG. 1, a conventional linear displacement transducer 52 is associated with the movable roll 50 for generating electrical signals indicating whether the thickness of the butt is above or below a predetermined level for a purpose to be explained in greater detail presently. The displacement transducer 52 may be initially located with respect to the movable roll 50 so that no signal will be generated with the batt size is to desired thickness, and so that variations of the batt size above and below such desired thickness will cause the displacement transducer to generate different voltage signals, respectively, which are proportionate to the batt thickness variance from the desired thickness.
As noted above, the carding machine 14 includes a conventional trumpet 16 through which fiber that has been processed by the carding machine 14 is passed and formed into a sliver. A conventional differential air pressure transducer 54 is associated with the trumpet 16 which uses a controlled air flow and pressure differential sensing means to generate voltage signals indicating whether the size of the sliver is above or below a predetermined level, and the extent of such variance. The signals generated by the displacement transducer 52 and the pressure differential transducer 54 are indicative of the density of the batt and the sliver, respectively, and these signals are utilized in the present invention to vary the compression imposed on the collected fiber in the chute 28. FIG. 2 illustrates diagrammatically a typical electrical control circuit that is suitable for carrying out the control features of the present invention.
The control circuit includes the aforesaid displacement transducer 52 which generates a voltage signal that is indicative of the density of the batt passing between the rolls 46,48, and this voltage signal is fed to an amplifier 56 having a gain control 58 which can be set to vary the amplification of the voltage signal to any desired level, such amplified signal then being transmitted to the speed setter circuit 60.
The control circuit also includes the aforementioned differential pressure transducer 54 at the trumpet 16 which generates a voltage signal indicative of the density of the fiber passing through the trumpet 16, and this voltage signal is fed to an amplifier 62 having a gain control 64 which can be used to set the amplification of the signal to any desired level. A zero setter circuit 66 is also provided for the amplifier 62 to establish a selected voltage level representing the desired density of fiber passing through the trumpet 16, whereby if the voltage signal generated by the pressure transducer 54 is less than the selected voltage it will indicate the extent to which the fiber density is too light, and if such voltage signal is greater than the selected voltage it will indicate the extent to which the fiber density is too heavy.
The amplifier signal from amplifier 62 is then transmitted to a clock circuit 70 that is energized when the card 14 is started by start switch 72. The clock circuit 70 is designed to accept or "read" the voltage signal from the amplifier 62 at predetermined timed intervals (e.g. 10 seconds) and to transmit such signal to a sample and hold circuit 68 which, during such timed interval, transmits the sensed signal as a constant to the speed setter circuit 60, regardless of fluctuations in the voltage signal transmitted from the amplifier 62 during such timed interval. While it would be possible, if desired, to transmit the amplified signal directly from the amplifier 62 to the speed setter circuit 60, it is preferred to use the sample and hold circuit 68 and the clock circuit 70 to avoid constant, albeit usually small, variations in the signal that is transmitted to the speed setter circuit 60. The speed setter circuit 60 also receives an input signal from a preset speed circuit 74 which can be selectively set manually and which establishes a preset or uncorrected base speed for the motor 40.
The speed setter circuit 60 is designed so that if there are no correcting signals received from the circuits of either the differential pressuer transducer 54 or the displacement transducer 52, the signal from the preset speed circuit 74 is transmitted to the motor control circuit 76 which, in turn, operates the motor 40 at the aforesaid preset or base speed level. If, however, correcting signals are received from either the differential pressure transducer 54 or the displacement transducer 52, or from both, the speed setter circuit 60 will adjust the signal transmitted to the motor control circuit 76 to thereby vary the speed of the motor 40. The extent of this adjustment is determined by the design of the speed circuit 60, and if such circuit is receiving correcting signals from both transducers 52,54, it can be designed to vary the adjustment of the signal from the preset speed circuit 74 by an amount that is proportional to the difference between the correcting signals from the transducers 52,54. It will be noted, in this regard, that since both the amplifiers 56 and 62 include selectively settable gain control circuits 58 and 64, respectively, as described above, the level of the two voltage signals from the transducers 52,54, can be individually increased or decreased to thereby vary the proportionate corrective effectiveness of such signals when they are received by the speed setter circuit 60.
Thus, in some applications of the present invention, e.g. when processing synthetic fibers, it is generally more important to use the density of the fiber at the trumpet as the primary connecting signal, and in such applications the gain control 62 for the pressure transducer 54 would be increased so that it would have a proportionately greater correcting effect on the speed setter circuit 60. Similarly, when cotton fiber is being processed, it is usually preferably for the density of the batt leaving the chute 28 to have the primary correcting effect, and the gain control 64 would therefore usually be set at a relatively high level, In any event, it will be appreciated that the signals from both transducers 52,54 can be used simultaneously to vary the speed of the motor 40 to thereby vary the speed of operation of both the blower 42 and the oscillating wall 32, and the proportional corrective effectiveness of the two transducers 52,54 can be selectively varied.
The control circuit also includes a tolerance detector circuit 78 that receives the amplified signal from the amplifier 62, and that includes a high set input 80 and a low set input 82 which can be selectively adjusted to establish predetermined maximum and minimum voltage values for the tolerance detector circuit 78, the predetermined voltage range between such maximum and minimum values being the normal tolerance range for the varying voltage signals produced by the pressure transducer 54 and amplifier 62. If the voltage signal received by the tolerance detector circuit 78 is beyond this predetermined range, a signal indicating such abnormality is transmitted from the tolerance detector circuit 78 to the tolerance timer circuit 84 which has an input from a time set circuit 86. If the abnormal signal received by the tolerance timer circuit 84 continues for a determined time period, which may be selectively set by manually adjusting the time set circuit 86, a signal is transmitted to the speed setter circuit 60 which, upon receipt of such signal, will cause the motor control circuit 76 to operate the motor 40 at a predetermined maximum or minimum speed (depending upon whether the abnormal signal is above or below the predetermined range), regardless of how long the abnormal signal continues and regardless of how much variance there is between the abnormal signal and the normal range for such signals. Thus, for example, even if the density of the fiber at the trumpet 16 should reach a predetermined abnormally high level and remain there beyond a predetermined time interval, the operating speed of the shaker wall 32 and the blower 42 will not be permitted to exceed a predetermined maximum level after the abnormal signal is received. As a further safeguard, the tolerance timer circuit 84 also transmits a signal to a card shut down relay 88 to stop the operation of the card 14 when the aforesaid abnormal conditions exist. Finally, the tolerance detector circuit 78 generates signals which are transmitted to an indicator light circuit 90 which will usually include a plurality of indicator lamps (not shown) on the control panel 92 which, when lit, indicate varying conditions of the density of the fiber at the trumpet, such as indicating when the fiber density is at its predetermined desired level or above or below such level, and indicating when such density is abnormally high or low.
A "manual/auto" switch 94 is provided so that the speed setter circuit 60 can be selectively operated in an automatic mode in which the speed of the motor 40 is automatically controlled in response to signals from the transducers 52,54 as described above, or in a manual mode in which the speed of the motor 40 is operated at a preselected set speed that can be selected and set by the manual speed set circuit 96.
As is well known in the art, the initial start up of a card involves bringing the card up to perating speed slowly, and usually in progressive steps. The control circuit of the present invention includes a feature by which, at start up of the card 14, the motor 40 is automatically operated at a preset, generally low, speed for a predetermined time interval. Thus, the initial closing of the aforesaid start switch 72 energizes a start time circuit 98 having an input from a start speed set circuit 100 that can set the preset speed of the motor 40 at any desired level and having an input from a time delay circuit 102 that can be set to determine the time period at which the motor 40 will be operated at its preset speed. Upon closing the start switch 72, the start timer circuit 98 will transmit a signal to the speed setter circuit 60 which will operate the motor at the preset speed for a predetermined time interval during start up of the card 14. Additionally, the start timer circuit 98 may also transmit a signal to the aforementioned sample and hold circuit 68 to reset the latter by removing any prior conditioning established during a prior operating cycle of the card 14.
Finally, the control circuit of the present invention may include a further tolerance detector circuit 104 which receives voltage signals from the amplifier 56, and which is designed to sense when such signals are above or below predetermined levels that can be preset in the circuit or can be adjustably set by high set and low set circuits (not shown) similar to the above-described high and low set circuits 80,82. When the tolerance detector circuit 104 senses that the signal from amplifier 56 is above or below the predetermined levels, it will transmit a signal to the above-described clock circuit 70. The clock circuit 70 is designed such that if the signal received from the tolerance detector circuit 104 is opposite to the signal being received from the amplifier 62, e.g. the emplifier 62 signal indicates the sliver density is too heavy whereas the signal from the tolerance detector circuit 104 is too light, then the clock circuit 70 will not transmit any signal at all to the sample and hold circuit 68, whereby no correcting signal from the sliver pressure transducer 54 is transmitted to the speed setter circuit 60 and it will control the motor 40 only in response to correcting signals generated by the displacement transducer 54. By utilizing this feature of the control circuit, in the unusual circumstance when the two transducers 52,54 are indicating opposite predetermined density conditions of the sliver and the batt, the control circuit will respond only to correcting signals from the displacement transducer 52 because it is usually preferable to make density corrections based on variations of the density of the batt before it has reached the card 14 rather than relying upon the opposite sensed sliver density as it leaves the card.
The present invention has been described in detail above for purposes of illustration only and is not intended to be limited by this description or otherwise to exclude any variation or equivalent arrangement that would be apparent from, or reasonably suggested by the foregoing disclosure to the skill of the art. | Method and apparatus for processing textile materials and, in particular, controlling the density of fiber in a carding system. A fiber feeder is provided which includes a blower and an oscillating plate, both of which act to compress fiber collected in the chute of the fiber feeder. A first sensing device is utilized at the discharge of the fiber feeder to sense the density of the batt being fed therefrom to a card, and a second sensing device is utilized at the trumpet of the card to sense the density of the fiber which forms the sliver in such trumpet. Control means is provided to regulate the operating speed of the blower and the oscillating plate in response to the signals generated by the first and second sensing devices. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This non-provisional application claims priority to provisional application Ser. No. 60/844,436 filed on Sep. 14, 2006.
FIELD OF INVENTION
[0002] This particular invention relates to a catheter/IV cover that has special benefits for the ambulatory patient receiving intravenous therapy, and which cover is intended to protect the catheter and the loose and exposed tubing leading up to the catheter, with the cover having capability of being applied to the region of the arm, in the vicinity of the elbow, or above and below thereof, and the wrist area of the arm, and even for covering a catheter upon the hand.
BACKGROUND OF THE INVENTION
[0003] This invention does relate to a catheter/IV cover. Numerous types of straps or other devices have been devised for facilitating the application of a catheter cover, usually in the region of the arm, but such covers normally simply provide some form of coverage, but do not facilitate the retention of the catheter in place, particularly for an active patient, or one which may be moved to different regions of the hospital, or the rest home, or returning home, during treatment and convalescence.
[0004] For example, the patent to Rayhart, U.S. Pat. No. 3,160,158, shows a Support for Catheter and the Like. This device includes a snap pin that applies to the arm, and incorporates a strip that can be clasped on top of the closed strap, apparently for holding a catheter or other medical instrument in location.
[0005] The patent to Duncan, U.S. Pat. No. 4,481,942, shows an Infant Arm Restraint. This arm restraint is for application around the elbow of an infant to restrain movement of the infant's hands, to certain areas.
[0006] The patent to Turner, U.S. Pat. No. 4,531,942, shows an IV Securing Means. This device apparently is for securement to the hand, and includes a thumb opening, and incorporates a series of fibrous loop materials, when it is wrapped around the hand during usage. This is apparently for holding a needle in place.
[0007] The patent to Christie, U.S. Pat. No. 4,91,356, shows another Intravenous Needle Stabilizing Band. This device includes a band incorporating a strip, that applies to the arm, through the use of Velcro components, and includes a separate strip for securement of the tube part of the catheter to the band. This holds the tube part in position during usage.
[0008] The patent to Widman, U.S. Pat. No. 4,671,787, shows another Support Wrap System for Intravenous Tubing. This tubing is also applied to, in this instance, apparently near the elbow, or within its region, and wraps entirely around the arm, for locating of the IV tube, and its needle, in place.
[0009] The patent to Fritts, U.S. Pat. No. 5,188,608, shows another Protective Stabilizing Sleeve for IV Needle. The sleeve can be applied directly to the arm, in the location where the needle and its tube locate. As can be seen, the layered sleeve, which may be formed of cloth, polyester, or an elastic blend, are designed for overlying the IV device, to keep it from unauthorized removal or pulling free from the patient's arm.
[0010] The patent to Bird, et al., U.S. Pat. No. 5,352,209, shows another Band for Anchoring a Tubular Device to the Body. This is another type of a primary strap for securement of about a portion of the body, such as the leg, and has a supplemental strap portion for holding the catheter in place.
[0011] The patent to Shesol, et al., U.S. Pat. No. 5,897,519, shows another Intravenous Securing Device and Secondary Wound Dressing. This device apparently functions as a means for holding a catheter in place, or at least its tubing, but it also incorporates what appears to be a pad or gauze for use in treatment of the wound area.
[0012] The patent to Villapiano, U.S. Pat. No. 6,032,289, shows a Security Garment, incorporating fastening straps.
[0013] The design patent to Inglish, U.S. Pat. No. D453,831, shows an IV Cover. It is a form of cover that has loops at one end, and buttons at the other, for securement of the cover about the arm.
[0014] The patent to Wilke, U.S. Pat. No. 6,464,669, shows another Catheter Protector. This device includes a method of protecting a catheter that includes a step of inserting the catheter into the patient, and then covering the inserted site with this protector.
[0015] The patent to Rozier, et al., U.S. Pat. No. 6,526,981, is upon a Site Guard for Intravenous Sites and Other Sensitive Areas. It defines a site guard that incorporates a hollow member having a base, and a fabric connector that affixes to the edge of the hollow member.
[0016] The patent to Bird, et al., U.S. Pat. No. 6,645,185, shows another Band for Anchoring Tubular Device to the Body. This is another band, that apparently has elasticity applied to it, and which incorporates a slip resistant material, as it is applied about the leg.
[0017] There are also a number of published applications that have been issued by the Patent Office. For example, the published application US 2003/0055382, to Schaeffer, is upon an Intravenous Catheter Support. The essence of this invention sets forth a support incorporating a base member, with its tube holding loops or hooks and through which the various catheter tubing can be applied.
[0018] The publication to Rose, US 2004/0138623, shows another Device for Securing Intravenous Needles to Treatment Sites. This device is primarily used for holding pads in place, through the use of straps, that are identified and shown as crisscrossing over each other to hold the catheters in place.
[0019] The published application to Jenkins, US 2005/0133043, shows an Arm Immobilizer. This is a closeable sleeve of compressible material placed around the patient's arm above or below the elbow joint, and designed for holding various catheters in place at an intravenous site.
[0020] The published application to Walsh, et al., US 2005/0137496, shows a pad or base with its strap held by Velcro, though the use of a series of secondary straps, for holding the transducer, IV, or other assemblies in place.
[0021] There are a variety of other types of devices that are used for holding drug infusion and delivery systems in place, many of them have been reviewed in the foregoing patents and publications, and there is also a U.S. Pat. No. 6,257,240, upon a Combination Protective Medical Guard with Self-Contained Supports. As shown in this patent, it is for use for holding medical devices or for protecting a surgical site, and incorporates a top port for use for viewing the site through the top of the protective guard.
[0022] U.S. Pat. No. 5,167,240, shows another Infusion Site Guard. These are protective devices.
[0023] There are also certain publications that show various types of mid-arm protectors, such as the product from Brown Medical, and which provides a type of thermoplastic sleeve that acts as a covering for the dressing area. It provides a water-proof seal to the area.
[0024] There are also various types of gauze coverings, that are applied as wraps to the surgery area, to act as an IV cover. This can be seen in the Cystic-L Device.
SUMMARY OF THE INVENTION
[0025] The current invention provides what are believed to be enhancements and improvements over the types of covers as previously reviewed.
[0026] The current invention provides a patch like cover that is applied to ambulatory patients, which require the infusion of intravenous therapy, while convalescing, and which incorporates a resilient material, held by straps about the patient's arm, wrist, or hand, and which includes a window proximate which the various catheter(s) may locate, held in position during usage, and which also facilitates the bending of the arm during application, when the cover is applied in the region of the elbow.
[0027] In one embodiment of the invention, the cover is formed of a resilient material, preferably from a material identified as the Ultrasuede type, is of a rectangular configuration to provide for coverage at the vicinity where the catheter is applied, and to furnish means for holding of the catheter and its tubing in place, during usage. Ultrasuede is available from Toray UltraSuede, Inc., located in the State of New York. In this manner, it adds more permanence to the location of the catheter, and does not allow for its easy inadvertent disengagement during application.
[0028] In order to hold the cover in place, a series of lateral straps append to the cover, along one side, while the opposite side includes a series of loops, slits within tabs, or the like, and through which the straps may locate, and to be fastened either by Velcro, a buckle, or other means for securement. Velcro is available from Velcro Industries B.V., located in Amsterdam, Netherlands. The open portion of the cover may be to any dimensions, that allows for disclosure of the catheter therethrough, and also is provided for making the cover more susceptible to bending, at that location, in the region of the elbow, when the patient moves his/her arm in place. The cut out segment may be an oval cut, or to other configuration, and may be covered with a soft material, such as polyester tricot, which helps to retain the catheter in place, but at the same time, such material may be moderately transparent, so that the instrument can be also viewed, in place, to assure that it is maintaining its proper installation. In addition, there may be shaped guides affixed to the ends of the straps in order to facilitate their insertion through the various rings or loops, when the cover is being installed.
[0029] The best mode for connection of the straps to the Ultrasuede cover is to provide an extending tab from the Ultrasuede cover at the location where each strap is to be affixed, provide a slit through that tab, and then extend the end of the strap through the slit, fold back the tab under the cover overlaying the end of the strap, and then stitch the entire combination together to furnish a fully reinforced connection of a strap to the cover during its assembly.
[0030] The invention also contemplates the construction of similar types of covers, formed of the same type of resilient material, such as the Ultrasuede, and in the instance of the usage of the cover for application to the lower arm, or wrist, may have a cover segment that is of lesser square or rectangular dimensions than the cover as previously reviewed. Nevertheless, the cover will be fabricated of resilient material, so that it can adequately cover the instruments used in intravenous therapy, and assure that the catheter remains in place, when applied about the wrist area, during application and is comfortable to wear. Because of the fabrication of this wrist cover of the Ultrasuede material, the softness of such material is far more comfortable to the wearer, than any type of catheter/IV cover currently available. In this instance, since the cover is fabricated of a soft and resilient material that is of smaller dimensions, fewer straps may be required to secure the cover in place. Hence, in this embodiment, there may be a pair of straps that laterally extend from the one side of the cover, and can be applied through loops or slots at the opposite side of the cover, when the patch cover is applied in place. The straps and loops may be fabricated of similar materials to those as previously summarized, in order to provide for their effective usage in holding the various components in place.
[0031] A third embodiment for the cover, for use for overlying a catheter, is when it is applied into the region of the hand. In this instance, the cover will resemble the shape of the back of the hand, and have holes in its upper corners for application to the thumb and the little finger, with a strap provided at the bottom edge, for looping about the back of the hand, and securement, to provide a resilient protective cover over the catheter when it is applied in the region of the hand. Such a cover could be applied to the back of the hand, or also to the palm of the hand, during its usage, if this becomes necessary. It also is fabricated from a resilient soft material, but yet function as a structural cover for retention of the catheter in place, once installed, and applied, to assure that unauthorized removal or inadvertent disengagement does not take place.
[0032] It is, therefore, the principal object of this invention to provide a resilient patch cover for ambulatory patients receiving intravenous therapy to assure that the catheter and delivery tubing remains in place, upon the arm, wrist, or hand, and is not inadvertently disengaged.
[0033] Another object of this invention is to provide a catheter cover which is formed of a very soft and resilient material which is sufficiently sturdy to assure that the catheter and its operative components are held in place, but at the same time does not add to the discomfort of the patient.
[0034] Still another object of this invention is to provide a catheter/IV cover that has a cut out segment provided therein, and through which the catheter and tube may be observed, but also furnishes a location where the arm can be conveniently bent, as at the elbow, without any obstruction.
[0035] Still another object of this invention is to provide a catheter/IV cover that allows and maintains freedom of movement and comfort for the patient, during its usage and application.
[0036] Still another object of this invention is to provide a catheter/IV cover which has sufficient resiliency, and permeability, so as to allow air to circulate and to attain movement to lessen any generation of perspiration during usage.
[0037] Yet another object of this invention is to provide a catheter cover that allows the usage of normal clothing, to be worn without having to compensate for the presence of the application of the device.
[0038] Still another object of this invention is to provide a catheter/IV cover that can be worn while the patient is awake and active, or while he/she sleeps.
[0039] Still another object of this invention is to provide a catheter/IV cover that can be fabricated of various colorations, so as to add to the enjoyment and comfort of their usage and application.
[0040] It is still another object of this invention to provide a catheter/IV cover that is easy to maintain, and has enhanced washability attributes.
[0041] An important object of this invention is to provide a catheter/IV cover fabricated of select materials, and depending upon their assembly, can be used in the region of the elbow, the arm, the wrist, and upon the hand.
[0042] These and other objects may become more apparent to those skilled in the art upon review of the summary of the invention as provided herein, and upon undertaking a study of the description of its preferred embodiment, in view of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] In referring to the drawings,
[0044] FIG. 1 discloses a catheter/IV cover of this invention in place approximate the elbow region of the arm of the patient;
[0045] FIG. 2 shows a plan view of a catheter/IV cover for the upper arm;
[0046] FIG. 3 a - d discloses the catheter/IV cover in its various perspective views and in application on the upper arm;
[0047] FIG. 4 shows the catheter/IV cover, as modified, with a cut out segment to add flexibility to the cover during application, and to perhaps provide a viewing area to the region of the emplaced catheter on the upper arm;
[0048] FIG. 5 is an exploded view of the various components that make up the upper arm catheter/IV cover of FIG. 4 ;
[0049] FIG. 6 shows the catheter/IV cover, as modified, and applied to the wrist region of the patient;
[0050] FIG. 7 shows an exploded view of the catheter/IV cover of FIG. 6 ;
[0051] FIG. 8 a provides a perspective view of a catheter/IV cover, modified, for application to a region of the hand; and
[0052] FIG. 8 b provides a perspective view of the same catheter/IV cover in its flatten form.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0053] In referring to the drawings, and in particular FIG. 1 , the catheter/IV cover 10 of this invention is readily disclosed. It is generally of a rectangular configuration, which can be applied to the upper surface of the arm in the region of the elbow, a portion of the arm therebelow, and to extend slightly above the elbow, into the bicep area of said arm. As noted, its rectangular configuration is such that it furnishes full coverage for this region of the arm, and provide the necessary grip of the Velcro®, where located. This can be used for a PICC line, which is a peripheral by inserted catheter/IV.
[0054] There is provided a cut out segment 11 , which may be left open, for ease of viewing, or can have a mesh-like material applied therein, to add some transparency to the cover, and to apply pressure thereon, so that the catheter/IV C can be readily observed and that the catheter C can be readily maintained in place. This can also apply to a needle applicator. Preferably, though, the cut out segment will be of an oval configuration, as noted, and will be covered with a soft polyester tricot material, which is attached in place along the margins of the oval cut, so as to facilitate the bending of the arm when the catheter is in place, and the cover is overlying the same to secure the catheter components in place, at the same time, add to the comfort of the patient, but allow for the arm to be bent, at the elbow.
[0055] As can also be seen in FIGS. 2 through 5 , there are tabs 12 that extend from the one side of the device, and include slits, as at 13 , at the region where the tabs integrate with the cover 10 , and these tabs and slits cooperate with the straps 18 that extend correspondingly through the slits, and the tabs 12 are bent over, and all of these components are stitched or glued in place, so as to hold the straps reinforced to the cover, when assembled. In addition, the tabs 14 extending from the opposite edge of the cover, are designed for looping around the ring loops 17 , and it is these ring loops through which the straps 18 extend through and secure, by means of their Velcro® attachment, when the catheter/IV cover is held in place about the arm. The outer ends of the straps 18 may have guides, as at 19 , fasten therewith, as also by stitching or gluing, or the like, and which are somewhat narrowed in configuration so as to facilitate their application through the loops or rings 17 , when providing for securement of the cover about the arm.
[0056] It should be stated that the tabs 14 also extend through their associated loops 17 , and then are folded over for stitching or gluing or otherwise attachment in place to the underside of the formed cover. It also needs to be stated that the straps may be formed of an elastic material, such as Velstretch®, available from Velcro Industries, of the Netherlands. This ads further elasticity to the cover, and its straps, when it is applied about the patient's arm, during usage.
[0057] The oval opening 11 , and which may be to any other configuration, includes a covering material, in the manner as previously described, and this can be seen in FIG. 5 at 15 . It will be attached around its opening within the oval cut out 11 , when applied within the structured cover. In addition, when a cover is applied in the oval cutout 11 , it will be attached, stitched, or otherwise held in position about the edge of the opening, during its fabrication. There may even be a hemming material, as at 16 that may be applied around the periphery of the oval opening, in order to secure such cloth in place. This type of cloth material applied to the oval cut opening may comprise a window cover of flexible material, such as a polyester or netting, and which primarily adds flexibility to the cover, at the region of the elbow, so that the elbow can be easily bent, and not be obstructed by the catheter/IV cover at that location. The hemming material 16 may be fused, glued, or stitched in place, and may remain opened, to allow easy viewing of the catheter, when in place, or the polyester material 15 may be stitched, glued or fused in place, and it may provide softness and ease of bending of the cover, at that location, in the region of the elbow. And, as previously reviewed, it may be that the polyester material may be formed of a mesh, or other transparent like cloth material, in order to add to the viewing of the catheter in place, but at the same time, assure that the catheter is covered, and secure it against inadvertent access, when the cover is applied in place over an installed catheter.
[0058] FIGS. 2 and 3 also show the catheter/IV cover 10 , with their square ring loops 17 applied to one side, and the straps 18 extending from the opposite side. In addition, the extension tabs 19 provide a narrowing section that may easily be guided through the loops 17 , and these tabs may also be formed of Velcro®, to provide for rapid securement about the loops when fastened in place. The straps 18 themselves may be formed of a resilient or stretchable material, made of an elastic, such as Velstretch®, so that they will slightly give to provide for their snug fitting about the arm, and provide the necessary grip of the Velcro® when located. In addition, the lower strap, as noted at 18 a , may be slightly shortened, requiring additional stretch, so as to furnish a very secure and tight fit about the arm, to provide for the snug positioning of the entire cover in place, once installed.
[0059] As previously reviewed, the cloth material forming the cover 10 may be made of a slightly resilient material, and be of a softer grade, such as an Ultrasuede®, which can be purchased at most fabric stores in the United States. The purpose for this is to provide a little stretch in the resiliency of the cover, so that it can bias lightly against the catheter, and its components, to secure them in place, and to retard and resist against the unauthorized pulling of the tube, from its catheter, which may occur when the patient is a little more active, or if somebody nearby is inadvertent and pulls on the tube without knowing it. Hence, the cover will help keep the catheter and its tube in place, and prevent its untimely removal.
[0060] It needs to be commented at this time that the various components that make up the catheter/IV cover of this invention may be provided in various coloration, whether it be bright colors to add to the spirits of the patient, or any other color that may be appropriate under the circumstances. Or, various of the components may be of differing colors, coordinated, to add to the attractiveness of the catheter/IV cover, when used, or can be used to identify the type of treatment being given.
[0061] The catheter cover shown in FIG. 6 is of a slightly modified design, and is designed for being applied at the area of the wrist, as can be seen. The cover 10 a again is formed of the related cloth material, and may be either square or rectangular in configuration, as can be seen in FIG. 7 . Extending from the sides are at least one loop, such as the loops 17 as shown, and these may be either tabs, with a slit, as shown at 13 , and through which the straps 18 may apply, or these may be simply plastic or other material ring loops, as shown at 17 , and through which the straps 18 may locate, and be fastened upon themselves, as by means of Velcro®, buckles, or any other means of fastening. And, the straps include the extending tabs 19 , for reasons as previously explained, which may facilitate guidance of the strap through the loop 17 , when installed, and such tabs may be formed of Velcro®, to assure fastening of the stretchable like Velstretch® straps in place, once the device is assembled.
[0062] As can also be seen in FIG. 7 , the cover 10 a may include a pair of apertures, as at 10 b , and through which fingers may be inserted, when the cover is to be used for application to the hand, as will be subsequently described. This includes the use of a heplock line for treatment.
[0063] More specifically, the hand model of the catheter/IV cover is shown in FIG. 8 . It likewise includes a covering material 10 c , as noted. When in place, it can seen that it thoroughly covers the catheter C, and its tubing, when in place.
[0064] The cover is designed to provide for coverage over various parts of the hand, particularly the back of the hand, when the catheter is applied in this vicinity. The upper corners of the cover include a pair of apertures, or loops, as at 10 b , and through which the thumb and small or little finger locate, for positioning of the catheter/IV cover onto the hand. Then, the bottom edges of the cover include the shown loop 20 , and corresponding strap 21 , which may be fastened together in the manner as previously explained and reviewed with respect to the other forms of catheter/IV covers as embodied in this invention.
[0065] It is just as likely that the cover this invention may be applied to various other parts of the body, and act as a catheter/IV cover, as such a cover may also be applied not only to adults, but also to children. There is also the remote possibility that these types of covers could be used for holding a form of catheter in place, even in the animal veterinary field, where such a cover maybe essential for holding a catheter in place.
[0066] In summary, the catheter/IV covers of this invention are provided and constructed of the soft type material like Ultrasuede®, as described. The purposes for this have already been reviewed. They may be of bright or multiple colors, to add to their attractiveness. Preferably, the materials from which the cover is made will be washable, so they are capable of being reused by the patient, during treatment. Furthermore, the design of these covers indicate that they are of reasonably small size, can be folded into smaller sizes, for storage, or may even be applied into one's pocket, as when not in use. These are all advantages of this type of a cover as assembled. This particular catheter/IV cover is primarily for use with the ambulatory patient, when being moved from one location to another, and the purpose for the catheter may be temporarily disconnected. Hence, this cover provides a full cover for the catheter, and prevents a disruption to use of the catheter, or any inadvertent removal.
[0067] Variations or modifications to the subject matter of this invention may occur to those skilled in the art upon review of the invention as described herein. Such variations, if within the spirit of this development, are intended to be encompassed within the scope of invention provided herein. The depiction of the invention in the summary, and the detailed disclosure in the description of the preferred embodiment, and as shown in the drawings, are set forth for illustrative purposes only. | A catheter/IV cover including a covering portion, having at least one loop extending from one side of the cover, a strap of flexible material extending from the opposite side of the covering material, with the strap and loops capable of engagement, through any type of fastener, Velcro®, or buckle, when securing the catheter/IV cover in place about the arm, the wrist, or the hand. There may be provided an aperture through the covering portion, which allows for viewing of the underlying and emplaced catheter, and its tubing, or there may be a mesh material, or other material of softness and transparency, to allow for viewing of the catheter when in place, and which allows flexibility when covered by this cover, which also allows for freedom of bending of the hand, or the arm at the elbow, while the cover is affixed. | 0 |
This is a continuation of application Ser. No. 07/809,126 filed Dec. 18, 1991, now abandoned.
CROSS REFERENCE TO RELATED APPLICATIONS
Attention is directed to: 1) U.S. patent application Ser. No. 07/272,280 filed Nov. 17, 1988 by Swift et al, and a continuation-in-part thereof entitled "Pultruded Electronic Device", U.S. Ser. No. 07/806,061 filed Dec. 11, 1991; and 2) U.S. patent application Ser. No. 07/516,000 filed Apr. 16, 1990 by Orlowski et al, and a continuation-in-part thereof entitled "Fibrillated Pultruded Electronic Component". U.S. Ser. No. 07/806,062 filed Dec. 11, 1991; the disclosures of all of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to improvements in multilayer printed circuit or wiring boards, and, more particularly, to improvements in interconnections between multilayer printed circuits or wiring boards or the like, and to methods for making same.
2. References
"Button Connectors-Solderless, Low-Thermal Rise Interconnect For High-Speed Signal Transmission", MacCorquodale, Connection Technology, January, 1990, pp. 25-28, shows a button connecter for interconnection between multilayer printed circuit boards. The button connector is essentially a wad of crumpled wire, the cylindrical button being a mass of fine, springy, highly conductive wire that is fitted into a substrate through-hole by compression, thus limiting the necessity of solder. The dielectric substrate boards, loaded with the buttons, are placed between the circuit boards or components to be interconnected and clamped together.
U.S. Pat. No. 4,967,314 to Huggins, III shows the construction of a circuit board. A high density multi-level printed wiring board is disclosed having interlevel electrical connections made by via interconnect holes which are drilled or punched through only those layers of the wiring board that separate the two layers containing the conductors which are to be connected. The holes are filled with a low-resistance silver-filled conductive epoxy.
U.S. Pat. No. 4,584,456 to Oodaira et al. shows a method for producing a resistor from insulating material by local heating. The resistor is formed by locally heating a layer of insulating material between conductors to convert the heated material into a first resistor element. A second resistor element is formed to contact the first resistor element while measuring the resistance between the conductors, until a desired resistor composed of the first and second resistor element and having a predetermined resistance value is obtained.
U.S. Pat. No. 5,003,693 to Atkinson et al. shows a method for manufacturing electrical circuits within a carrier. The method provides an electrical circuit wherein a carrier, which is a film of insulating plastic material with a circuit pattern thereon, is supported in a mold and a molding material is applied by the application of heat and pressure to provide a substrate having a circuit embedded in or within a three-dimensional surface of the molded substrate.
U.S. Pat. No. 4,694,138 to Oodaira et al. shows a method of forming a conductive path within an insulated composition. The conductive path is formed by providing an insulating substrate having a surface region which is formed of an insulating composition. The insulating composition contains an organic polymeric material and at least one metal source. The surface region of the substrate is selectively heated along a predetermined pattern, thereby decomposing and evaporating the organic polymeric material at the heated portion and welding the metal in the heated portion so as to form a conductor path formed of metal.
U.S. Pat. No. 4,912,288 to Atkinson et al. shows a method of providing an electrical circuit molded within an insulated plastic surface. The method provides an electrical circuit on a surface of a three-dimensional shaped substrate of insulating plastic material, molded by the application of heat and pressure, so that the circuit is embedded in or within a surface of the molded substrate.
U.S. Pat. Nos. 4,841,099 and 4,970,553, to Epstein et al. and Orlowski et al., respectively, both assigned to the assignee of the present application show electrical components having conductive paths. A three-dimensional electrical component, having a first side and a second side formed from an electrically insulating polymer matrix capable of heat conversion to an electrically conducting polymer matrix, has at least one passageway from the first side to the second side having a tapered wall configuration with constantly changing cross-section of the passageway from the first side through the passageway to the second side and an electrically conducting path between the first side and the second side formed by the in situ heat conversion of the walls. The heat conversion of the electrically conductive paths are preferred to be completed by a laser.
SUMMARY OF THE INVENTION
In light of the above, it is, therefore, and object of the invention to provide an improved interconnect for electrically interconnecting different levels of printed circuit, or wiring boards, or the like.
It is another object of the invention to provide and interconnect of the type described that is of relatively low cost compared to currently used interconnect structures.
It is another object of the invention to provide a method for fabricating interconnects for use in multilayer printed circuit and wiring board structures.
It is another object of the invention to provide an improved multilayer printed or wiring board circuit.
It is another object of the invention to provide an interconnect for printed circuit or wiring boards which can be fabricated without the requirement of specialized fabrication equipment or special wire stuffing machinery or the like.
It is another object of the invention to provide an interlevel connector for interconnecting a printed circuit or wiring board, or the like to a substrate manufactured from an electrically insulating polymer matrix which is doped with an electrically insulating fibrous filler capable of heat conversion to an electrically conductive fibrous filler to form the conductors to be interconnected, formed as a wall or similar machine structure.
It is yet another object of the invention to provide an interlevel connector that enables either temporary or permanent interconnection of printed circuit or wiring boards, or the like.
These and other objects, features and advantages will become apparent to those skilled in the art from the following detailed description, when read in conjunction with the accompanying drawings and appended claims.
In accordance with a broad aspect of the invention, an interlevel connector is presented which includes a dielectric substrate having a plurality of through holes and a corresponding plurality of pultrusions. Each pultrusion includes a plurality of electrically conductive fibers and an electrically conductive or insulating host material carrying the plurality of fibers, each of the plurality of pultrusions being located in a respective through hole and having fibrillated portions extending from surfaces of the dielectric substrate.
The interlevel connector is used in the construction of a multilayer wiring assembly in which first and second wiring boards having respective conductive portions are interconnected. The interlevel connector is located adjacent and between the first and second wiring boards, whereby the fibrillated portions of the pultrusion extending from the surfaces of the dielectric substrate contact the conductive portions of the first and second wiring boards. The wiring boards, such as printed circuit boards, printed wiring boards, or devices having conductive connections, can be permanently or removably locatable adjacent the dielectric substrate, and, if desired, the wiring board can comprise a substrate manufactured from an electrically insulating polymer matrix which is doped with an electrically insulating fibrous filler capable of heat conversion to an electrically conductive fibrous filler to form the conductive portion to be interconnected and may serve as a wall or structural member of a machine.
In accordance with another broad aspect of the invention, a method for interconnecting wiring boards in a multilayer wiring assembly is presented. In accordance with the method, a dielectric substrate having top and bottom surfaces is provided, and through holes are formed in the dielectric substrate at desired wiring board interconnection locations. Segments of a pultrusion including a plurality of electrically conductive fibers and a host material carrying the plurality of fibers are located in each of the through holes, the segments being of length sufficient to provide extensions of the pultrusion above and below the top and bottom surfaces of the dielectric substrate. The extensions of the pultrusion are fibrillated, such as by exposing the extensions to a laser beam to remove the host material in the extensions and to affix the segments in place in the through holes, and the wiring boards are fixedly or removably positioned adjacent the top and bottom surfaces of the dielectric substrate.
BRIEF DESCRIPTION OF THE DRAWING
The invention is illustrated in the accompanying drawing in which:
FIG. 1 is a side view of a printed circuit board or dielectric substrate containing carbon fiber pultrusion interconnects, in accordance with a preferred embodiment of the invention.
FIG. 2 is a top elevation view of the printed circuit board or dielectric substrate of FIG. 1.
FIG. 3 is an enlarged cut away portion of the printed circuit board or dielectric substrate of FIG. 1, taken at 3--3, and showing the details of a continuous carbon fiber pultrusion configured and placed to form an electrical interconnect between multiple layers of printed circuit boards or printed wiring boards or the like.
And FIG. 4 is a cross-sectional elevation view of a multilayer printed circuit or wiring board structure fabricated using an interlevel connector, in accordance with a preferred embodiment of the invention.
In the drawings, the figures are not necessarily drawn to scale, and the sizes and the dimensions of the various parts have been exaggerated or distorted for clarity of illustration and ease of description. In addition, in the various figures of the drawing, like reference numerals are used to denote like or similar parts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, an electronic component is provided and a variety of electronic devices for conducting electrical current such as switches, sensors, etc. are provided which are of greatly improved reliability, are of low cost and easily manufacturable and are capable of reliably operating in low energy circuits. Typically these devices are low energy devices, using low voltages within the range of millivolts to hundreds of volts and currents within the range of microamps to hundreds of milliamps as opposed to power applications of tens to hundreds of amperes, for example. Although the present invention may be used in certain applications in the single amp region it is noted that best results are obtained in high resistance circuitry where power losses can be tolerated. It is also noted that these devices may be used in certain applications in the high voltage region in excess of 10,000 volts, for example, where excessive heat is not generated. These devices are generally electronic in nature within the generic field of electrical devices meaning that their principle applications are in signal level circuits although as previously stated they may be used in certain low power applications where their inherent power losses may be tolerated.
According to the present invention, an electronic component is made from a pultruded composite member having a fibrillated brush-like structure at one end which provides a densely distributed filament contact with another component. By the term densely distributed filament contact it is intended to define an extremely high level of contact redundancy insuring electrical contact with another contact surface in that the contacting component has in excess of 1000 individual conductive fibers per square millimeter.
The invention pertains to interconnects between printed circuit boards (PCB's), printed wiring boards (PWB's), multiple layer wiring boards (MWB's) and the like, such boards being referred to generally herein as printed circuit or wiring boards. In general, a printed circuit board is a flat board or substrate of insulating material, having a front side that may contain sockets or slots for integrated circuit chips, perhaps with connections for a variety of other electronic components, and having electrically conductive pathways to interconnect the components printed on one or both sides.
Boards with conductive pathways on both sides may use plated through holes or eyelets to provide electrical continuity between the sides, and are used in those applications in which the maximum number of interconnections or conductors in a given area are required for minimal cost. Furthermore, in complex circuit arrangements, printed circuit boards are often stacked in interconnected multiple layers, thus capitalizing on the reduced size of miniaturized and microelectronic parts, as the surface area that is required for mounting these subminiature parts and integrated circuit packages has decreased significantly while the number of interconnections has increased many fold.
In a typical multilayer printed circuit or wiring board structure, conductors are located on several insulated layers, interconnected in a sandwich structure with one or more interlevel connectors, such interlevel layers being formed upon a dielectric layer or substrate, sometimes referred to as "prepreg". Each of the layers on which conductors are formed are constructed of a number of two sided etched copper foiled (for example) boards, laminated or sandwiched together with the interlevel connector layer under controlled temperature pressure and time. One embodiment of such multilayer structure is shown in FIG. 4, and includes an intermediate dielectric substrate 10 having a pattern of pultrusion interconnection elements 12 that align with corresponding conductive portions of printed circuit boards mounted 31 and 32 on top of and below the dielectric interconnection substrate 10.
Thus, in accordance with the present invention, a interlevel connector structure is advanced in which specially configured pultruded distributed carbon fiber strands of the type including small diameter carbon or metalized carbon fibers perform the inter-board interconnect functions, for uses in such devices as printed circuit boards, molded wiring boards, flex-circuit interconnectors and the like, in which circuits on one surface of one substrate board must be reliably connected electrically to another substrate board, or to other external devices.
With reference now to FIGS. 1-3 of the drawing, a printed circuit or interlevel connector 10 is shown fabricated upon an insulating substrate 11 in which a plurality of continuous carbon fiber pultrusions 12, for example of 0.050 inch in diameter, are mounted and processed to form a conductive interconnect. The interlevel connector 10 may be positioned between a pair of printed circuit boards 31 and 32 mounted on the top and bottom surfaces of the dielectric substrate 10, as shown in FIG. 4. Thus, lengths of a continuous carbon fiber pultrusion are inserted in through holes 17 in the dielectric substrate 10, the lengths being cut so that top and bottom portions of the pultrusions 12 extend above the top surface and below the bottom surface of the dielectric substrate 10 a distance sufficient to enable interconnection to conductors 30 and 33 of respective adjacent printed circuit boards 31 and 32. After the pultrusions 12 have been located in the through holes 17, they are exposed to a laser beam to affix the pultrusions 12 within the through holes and to fibrillate the portions extending above the top surface and below the bottom surface to expose the fibers 13 by removal of the host material portion 14 of the pultrusions 12.
The pultrusions 12 are located in a through holes 17 in the dielectric substrate in a pattern that corresponds to the desired interconnection pattern to be established between the printed circuit boards 31 and 32. The methods of establishing such interconnection patterns and for forming the through holes in an intermediate or interlevel dielectric substrate are well known in the art and are not described in detail herein.
As mentioned, the pultrusion 12, in accordance with a preferred embodiment of the invention, can comprise continuous carbon fibers or strands 13 within a host polymer 14. Such pultrusions provide a convenient way to handle, process and use fine diameter, carbon fibers without the problems typically encountered with free conductive fibers, in contrast to previous interconnect techniques.
The process for making such pultrusions generally consists of pulling continuous lengths of fibers first through a resin bath or impregnator, then into a preforming fixture where the resulting section is at least partially shaped and excess resin and/or air are removed. The section is then pulled into heated dies where it is continuously cured. For a detailed discussion of pultrusion technology, reference is directed to "Handbook of Pultrusion Technology" by Raymond W. Meyer, first published in 1985 by Chapman and Hall, New York.
More specifically, conductive carbon fibers may be submersed in a polymer bath and drawn through a die opening of suitable shape at high temperature to produce a solid piece having dimensions and shapes of that of the die. The solid piece can then be cut, shaped, or machined. As a result, a structure can be achieved that has thousands of conductive fiber elements contained within the polymer matrix. The very large redundancy and availability of electrical contacts enables a substantial improvement in the reliability of these devices.
Since the plurality of small diameter conductive fibers are pulled through the polymer bath and heated die as a continuous length, the shaped member can be formed with the fibers being continuous from one end of the member to the other. Accordingly, the pultruded composite may be formed in a continuous length during the pultrusion process, then cut to suitable dimensions, with a very large number of potential electrical contacts provided at each end. The ends of the various contact members may then have its ends fibrillated.
Any suitable fiber having a high resistivity may be used in the practice of the invention. Typically, the conductive fibers are nonmetallic and have a DC volume resistivity of from about 1×10 -5 to about 1×10 10 ohm-cm and preferably from about 1×10 -4 to about 10 ohm-cm to minimize resistance losses and suppress RFI. The upper range of resistivities of up to 1×10 10 ohm-cm. could be used, for example, in those special applications involving extremely high fiber densities where the individual fibers act as individual resistors in parallel thereby lowering the overall resistance of the pultruded member enabling current conduction. The vast majority of applications however, will require fibers having resistivities within the above stated preferred range to enable current conduction. The term "nonmetallic" is used to distinguish from conventional metal fibers which exhibit metallic conductivity having resistivity of the order of 1×10 -6 ohm-cm and to define a class of fibers which are nonmetallic but can be treated in ways to approach or provide metal like properties. Higher resistivity materials may be used if the input impedance of the associated electronic circuit is sufficiently high. However, carbon fibers are particularly well suited as preferred filler because they are chemically and environmentally inert, possess high strength and stiffness, can be tailored
to virtually any desired resistivity, and exhibit a negative coefficient of thermal resistivity.
The individual conductive fibers 13 can be made of circular cross section shape shown, with a diameter in the order of from about 4 to about 50 micrometers, preferably from about 7 to 10 micrometers. This provides a very high degree of redundancy in a small cross sectional area. Thus, as contact materials, the fibers provide a multiple redundancy of contact points, for example, in the range between about 0.05×10 5 and 5×10 5 contacts/cm 2 , preferably about 0.05580 contacts/cm 2 . This is believed to enable ultrahigh contact reliability.
The fibers 13 are typically flexible and compatible with the polymer systems within which they are carried. Typical fibers may include carbon, carbon/graphite, metalized or metal coated carbon fibers and metal coated glass fibers. A particularly preferred class of fibers that may be used are those fibers that are obtained from controlled heat treatment processing to yield complete or partial carbonization of polyacrylonitrile (PAN) precursor fibers. It has been found for such fibers that by carefully controlling the temperature of carbonization within certain limits that precise electrical resistivities for the carbonized carbon fibers may be obtained. The carbon fibers from polyacrylonitrile (PAN) precursor fibers are commercially produced by the Stackpole Company, Celion Carbon Fibers, Inc., division of BASF and others in yarn bundles of 1,000 to 160,000 filaments. The yarn bundles are carbonized in a two-stage process. The first stage involves stabilizing the PAN fibers at temperatures of the order of 300° C. in an oxygen atmosphere to produce preox-stabilized PAN fibers. The second stage involves carbonization of the fibers at elevated temperatures in an inert atmosphere, such as an atmosphere containing nitrogen. The DC electrical resistivity of the resulting fibers is controlled by the selection of the temperature of carbonization. For example, carbon fibers having an electrical resistivity of from about 10 2 to about 10 6 ohms-cm are obtained if the carbonization temperature is controlled in the range of from about 500° C. to 750° C. while carbon fibers having D.C. resistivities of 10 -2 to about 10 -6 ohm-cm result from treatment temperatures of 1800° to 2000° C. For further reference to the processes that may be employed in making these carbonized fibers attention is directed to U.S. Pat. No. 4,761,709 to Ewing et al and the literature sources cited therein at column 8. Typically these carbon fibers have a modulus of from about 30 million to 60 million psi or 205-411 GPa which is higher than most steels thereby enabling a very strong pultruded composite member. The high temperature conversion of the polyacrylonitrile fibers results in a fiber which is about 99.99% elemental carbon which is inert and will resist oxidation.
One of the advantages of using conductive carbon fibers is that they have a negative coefficient of thermal conductivity so that as the individual fibers become hotter with the passage of, for example, a spurrious high current surge, they become more conductive. This provides an advantage over metal contacts since metals operate in just the opposite manner and therefore metal contacts tend to burn out or self destruct. The carbon fibers have the further advantage in that their surfaces are inherently rough and porous thereby providing better adhesion to the polymer matrix. In addition, the inertness of the carbon material yields a contact surface relatively immune to contaminants of the plated metal.
The carbon fibers 13 are enclosed in any suitable polymer matrix 14. The polymer matrix 14 should be of a resin binder material that will volatilize rapidly and cleanly upon direct exposure to the laser beam during laser processing below described. Polymers such as low molecular weight polyethylene, polypropylene, polystyrene, polyvinylchloride, and polyurethane may be particularly advantageously employed. Polyesters, epoxies, vinyl esters, polyetheretherketones, polyetherimides, polyethersulphones and nylon are in general, suitable materials with the polyesters and vinylesters being preferred due to their short cure time, relative chemical inertness and suitability for laser processing. If desired, in some applications, the host polymer can be appropriately doped to itself be conductive.
A laser (not shown) can be used to cut individual components for use as the interconnect elements 12, to affix the pultrusion segments within the through holes 17, and to fibrillate the end portions 15 and 16 on the top and bottom surfaces of the substrate 10, as shown. Optionally, one end of the pultrusion may be fibrillated and allowed to protrude above a surface of the substrate 10, while the other end may be soldered or otherwise connected or fastened to the circuity (not shown) which may be formed on the board. More particularly, a focused laser can be used to cut the pultrusion and simultaneously volatilize the binder resin in a controlled manner to produce in one step a distributed filament contact. The length of exposed carbon fiber can be controlled by the laser power and cut rate, and various tip shapes can be achieved by changing the laser incidence angle. Thus, a suitable pultrusion can be cut by laser techniques to form, for example, a top contact 15 (see FIG. 3) of desired length from the top surface of the substrate 10, with its ends fibrillated to provide a high redundancy fiber contact member to contact the conductive layers 30 of a printed circuit board 31 in contact therewith, and to form a bottom contact 16 of desired length from the bottom surface of the substrate 10, with its ends fibrillated to provide a high redundancy fiber contact member to contact the conductive layers 33 of a printed circuit board 32 in contact therewith.
Any suitable laser can be used which will be absorbed by the matrix of the host polymer 14, so that the host polymer 14 will be volatilized. Specific lasers which may be used include a carbon dioxide laser, the Nd YAG laser, or the argon ion laser. The carbon dioxide laser mentioned is particularly suited for this application, however, since it is the most reliable, best suited for polymer matrix absorption, and is most economical in manufacturing environments.
In use, the interlevel connector 10 in which the pultrusion segments 12 with fibrillated ends 13 have been mounted in the desired interconnection pattern is placed between the printed circuit or wiring boards 31 and 32 to be interconnected. The fibrillated pultrusion ends contact the respective conductors of the printed circuit boards 31 and 32, thereby establishing the desired electrical interconnection. If desired, the printed circuit boards 31 and 32 can be permanently affixed in the layered, sandwich configuration by temperature or pressure techniques, known in the art. Alternatively, the sandwich configuration can be temporarily fixed by appropriate fasteners, such as screws and bolts, or the like, for example, for ease of separation and replacement of one of the boards. The temporary connection capability enabled by the structure of this invention is of particular advantage, for example, in allowing field repairs or bench testing to be easily and rapidly performed by substitution of one printed circuit or wiring board for another. This is also of advantage in circuit development procedures in which one wiring board can be easily substituted for another without requiring expensive and time consuming multilayer printed circuit board fabrications.
Additionally, although the invention has been described hereinabove with reference to printed circuit or wiring boards, such wiring interconnections can easily be provided as a part of a machine structure. More particularly, for example, one of the wiring boards, such as the lower printed wiring board 32 shown in FIG. 4, can be a substrate manufactured from an electrically insulating polymer matrix which is doped with an electrically insulating fibrous filler capable of heat conversion to an electrically conductive fibrous filler to form the conductive portion to be interconnected. Such a substrate can be easily fabricated as a wall or other machine structure, and interconnected to a desired printed circuit or wiring board utilizing the interlevel connector 10 in a manner similar to that described above with respect to the interconnection of two printed circuit or wiring boards.
One technique by which the substrate having desired electrically conducting paths may be formed is to load or dope an electrically insulating polymer matrix that will provide the substrate to which connection will be made with a suitable polymeric fibrous material capable of heat conversion to conductive fibrous carbon within the polymer matrix. Examples of suitable fibrous filler are cellulose (rayon), petroleum pitch based carbon fibers which are heat convertible carbonaceous fibers, and thermally stabilized, polyacrylonitrile fibers. The fiber filed polymer matrix doped with such fibers may be formed into the hinge assemblies by conventional or injection molding or extruding techniques.
The selective heating required to convert the electrically insulating fibrous filler to an electrically conductive filler in the desired areas can be carried out in any suitable manner. Again, preferably, a laser, such as a carbon dioxide laser, may be used to direct the laser beam to the selected portions of the polymer matrix to be pyrolyzed by melting the polymer and heat converting the electrically insulating fibers to electrically conductive fibers to form the conductive path.
Thus, utilizing the above described conductor forming techniques, power, high voltage and/or logic signal paths can be provided in a wall or other machine structure, and control or signal processing circuitry can be provided on a separate printed circuit board. Utilizing an interlevel connector, of the type described hereinabove, the control or signal processing circuitry can be easily temporarily or permanently connected to the machine circuitry, thereby reducing machine fabrication time and complexity, while increasing its reliability.
Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the combination and arrangement of parts can be resorted to by those skilled in the art without departing from the spirit and scope of the invention, as hereinafter claimed. | An interlevel connector, a multilayer wiring board assembly, and method for making the same are presented. The interlevel connector includes a dielectric substrate having a plurality of through holes and a corresponding plurality of pultrusions. Each pultrusion includes a plurality of electrically conductive fibers and an electrically conductive or insulating host material carrying the plurality of fibers, each of the plurality of pultrusions being located in a respective through hole and having fibrillated portions extending from surfaces of the dielectric substrate. The interlevel connector is used in the construction of a multilayer wiring assembly in which first and second wiring boards having respective conductive portions are interconnected. The interlevel connector is located adjacent and between the first and second wiring boards, whereby the fibrillated portions of the pultrusion extending from the surfaces of the dielectric substrate contact the conductive portions of the first and second wiring boards. The wiring boards can be permanently or removably locatable adjacent the dielectric substrate. | 7 |
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates generally to medical imaging and, more particularly, to systems and methods for two-dimensional and three-dimensional image integration and synchronization.
BACKGROUND
[0002] Medical imaging devices typically record a series of two-dimensional images of a patient. This series of 2-dimensional images can be used to create a 3-dimensional image using tomography or other mathematical techniques.
BRIEF SUMMARY
[0003] Example systems and methods provide for 2D and 3D image integration and synchronization.
[0004] An example method includes displaying a two-dimensional image via a first image viewer on a screen, wherein the two-dimensional image is from a set of images. The example method includes displaying a three-dimensional image via a second image viewer on the screen, wherein the three-dimensional image is constructed from the set of images and wherein the first image viewer and the second image viewer are linked to share commands and messages. The example method includes receiving an instruction to modify either the two-dimensional image or the three-dimensional image. The example method includes modifying either the selected two-dimensional image or three-dimensional image based on the instruction via the first image viewer or the second image viewer corresponding to the selected image. The example method includes correspondingly modifying the two-dimensional image or the three-dimensional image that was not selected based on the instruction via the first image viewer or the second image viewer corresponding to the two-dimensional image or the three-dimensional image that was not selected.
[0005] An example tangible computer readable medium has a set of instructions that when read, cause the computer to at least display a two-dimensional image via a first image viewer on a screen, wherein the two-dimensional image is from a set of images. The example instructions cause the computer to display a three-dimensional image via a second image viewer on the screen, wherein the three-dimensional image is constructed from the set of images and wherein the first image viewer and the second image viewer are linked to share commands and messages. The example instructions cause the computer to receive an instruction to modify either the two-dimensional image or the three-dimensional image. The example instructions cause the computer to modify the selected two-dimensional image or three-dimensional image based on the instruction via the first image viewer or the second image viewer corresponding to the selected image. The example instructions cause the computer to correspondingly modify the two-dimensional image or the three-dimensional image that was not selected based on the instruction via the first image viewer or the second image viewer corresponding to the two-dimensional image or three-dimensional image that was not selected.
[0006] An example apparatus includes a first image viewer to display a two-dimensional image on a screen, wherein the two-dimensional image is from a set of images. The example apparatus includes a second image viewer to display a three-dimensional image on the screen, wherein the three-dimensional image is constructed from the set of images and wherein the first image viewer and the second image viewer are linked to share commands and messages. The example apparatus includes an input terminal to receive an instruction to modify either the two-dimensional image or the three-dimensional image, wherein upon receiving the instruction, either the first image viewer or the second image viewer corresponding to the selected image modifies either the selected two-dimensional image or the three-dimensional image based on the instruction and the first image viewer or the second image viewer corresponding to the two-dimensional image or the three-dimensional image that was not selected correspondingly modifies the two-dimensional image or the three-dimensional image that was not selected based on the instruction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a block diagram of an example medical imaging system constructed in accordance with the teachings of this disclosure.
[0008] FIG. 2 is an illustration of the example monitor of the medical imaging system of FIG. 1 .
[0009] FIGS. 3-5 are flowcharts representative of example machine readable instructions that may be executed to implement the example medical imaging system of FIG. 1 .
[0010] FIG. 6 is an example screenshot of an example output of the medical imaging system of FIG. 1 .
[0011] FIG. 7 is a block diagram of an example processing system capable of executing the example machine readable instructions of FIGS. 3-5 to implement the example medical imaging system of FIG. 1 .
DETAILED DESCRIPTION
[0012] Medical images of the human body are often used by doctors and other medical professionals to help diagnose and treat patients. Various medical imaging technologies can be used for this purpose, such as magnetic resonance imaging (MRI), positron emission tomography (PET), x-ray computed tomography (CT), or ultrasound. Typically, a medical imaging device using one of these imaging technologies or any other imaging technology scans a portion of a patient's body and creates a series of two-dimensional (2D) images or slices representing a series of cross-sections of the scanned portion of the patient's body. This series of 2D images can then be viewed by a doctor or others.
[0013] Alternatively, this series of 2D images can be used to construct a three-dimensional (3D) volume image of the scanned portion of the patient's body. This 3D image construction is typically done by computer software using a mathematical technique such as tomography. Because the 3D volume image is constructed from the series of 2D images, it is typically only possible to view either one of the 2D image or the constructed 3D image at any given time. A doctor would typically use one software program to view the 2D images and another completely different software program to view the 3D volume image. In some instances, these two different software programs might reside on different workstations, meaning that doctor would need to look at one workstation to view the 2D images and a different workstation to view the 3D volume image.
[0014] Furthermore, medical imaging software typically has a number of tools for enhancing, clarifying, rotating, changing the zoom level or otherwise modifying a displayed image. These various tools allow a displayed image to be fine-tuned to assist a doctor in making a diagnosis or any other purpose for which the image is being viewed. Because the 2D images and the 3D image can only be viewed with different software programs or even on different workstations, any image modification tools used on any of the 2D images will have no effect on the 3D image and vice versa.
[0015] Example systems, methods, apparatus, and/or articles of manufacture disclosed herein provide a mechanism for viewing one image from a series of 2D images alongside a 3D volume image constructed from the series of 2D images. In particular, examples disclosed herein provide a mechanism for viewing the 2D image and the 3D image on the same screen and in synchronicity with each other. Examples disclosed herein provide tools to modify the viewing conditions for the displayed 2D image that make a corresponding modification to the viewing conditions of the displayed 3D image. Examples disclosed herein provide tools to modify the viewing conditions for the displayed 3D image that make a corresponding modification to the viewing conditions of the displayed 2D image. Examples disclosed herein provide tools to load a different image from the series of 2D images that cause the view of the displayed 3D image to change to show the position in the 3D image corresponding to the loaded 2D image. Examples disclosed herein provide tools to change the cursor position in the displayed 3D image that cause a new 2D image to be loaded corresponding to the new cursor position in the 3D image. Specifically, two different software applications run simultaneously on a computer system. One software application displays a 2D image and the other software application displays a 3D image. The two software applications operate independently but communicate with each other by sending extensible markup language (XML) commands to each other. At any given time, a user controls one of the two software applications to modify the image displayed by that application. The application being controlled by the user then sends XML commands to the other software application with information about how the image displayed by the other software application should be modified.
[0016] FIG. 1 is a block diagram of an example medical imaging system 100 constructed in accordance with the teachings of this disclosure. The example imaging system 100 of FIG. 1 includes a medical imaging device 102 . This medical imaging device 102 can be any device capable of recording medical images such as an MRI, PET, CT or ultrasound scanner or any other such device. The example medical imaging device 102 scans a portion of a patient's body and stores the results of the scan on a server 104 . The example server 104 communicates with the medical imaging device 102 in order to receive medical imaging data from the medical imaging device 102 . The server 104 also has a database or other storage capability to store medical imaging data received from the medical imaging device 102 .
[0017] As the medical imaging device 102 scans a portion of the patient's body, a series of 2D images are created. Each of these 2D images represents a cross-section of the scanned portion of the patient's body. In some examples, the results of the scan are stored on the example server 104 in a Digital Imaging and Communications in Medicine (DICOM) format. The scan results are then transmitted from the medical imaging device 102 to the server 104 and stored on the server 104 .
[0018] The example imaging system includes a computer system 105 . The example computer system 105 communicates with the example server 104 to load 2D images stored on the server 104 from the server 104 to the computer system 105 . The computer system 105 is connected to the server 104 either directly or via a network. If a network connection is used, the network may be implemented using any type of public or private network such as, but not limited to, the Internet, a telephone network, a local area network (LAN), a cable network, and/or a wireless network. To enable communication via the network, the computer system 105 may include a communication interface that enables connection to an Ethernet, a digital subscriber line (DSL), a telephone line, a coaxial cable, or any wireless connection, etc.
[0019] The example computer system 105 communicates with an input terminal 112 to receive input from a user. The example computer system 105 communicates with a monitor 114 to display images and other output to a user. The example computer system also includes a 2D imager 106 , a 3D imager 108 and an XML transmitter 110 .
[0020] The example 2D imager 106 is a software application that runs on the example computer system 105 . In one example, the 2D imager 106 is written in C++, however any other programming language can be used to implement the 2D imager 106 . The 2D imager 106 controls an image viewer to display one or more 2D images. After the computer system 105 receives the 2D images from the server 104 , the 2D images are sent to the 2D imager 106 wherein the series of 2D images comprise one scan taken by the medical imaging device 102 . The 2D imager 106 stores the series of 2D images until another series of 2D images comprising another scan by the medical imaging device 102 is loaded from the server 104 to the computer system 105 .
[0021] The 2D imager 106 communicates, through device drivers on the computer system 105 , with the input terminal 112 and the monitor 114 . The 2D imager sends one or more 2D images to the monitor 114 to be displayed on the monitor 114 . The 2D imager receives input from a user through the input terminal 112 . The 2D imager 106 sends XML commands to a 3D imager 108 via the XML transmitter 110 . The 2D imager 106 also receives XML commands from the example 3D imager 108 via the example XML transmitter 110 . In one example, the XML transmitter 110 includes two TCP/IP ports, wherein one port is used to send XML commands from the 2D imager 106 to the 3D imager 108 and the other port is used to send XML commands from the 3D imager 108 to the 2D imager 106 . While the transmitter 110 is labeled as an XML transmitter for purposes of illustration, and resulting commands are identified as XML commands, it is understood that commands could be generated according to other formats. The example XML transmitter 110 therefore facilitates the transmission of XML commands between the example 2D imager 106 and the example 3D imager 108 . The communication protocol between the 2D imager 106 and the 3D imager 108 is established through known handshaking techniques.
[0022] The example 3D imager 108 is a software application that runs on the example computer system 105 . In one example, the 3D imager 108 is written in JAVA, however any other programming language can be used to implement the 3D imager 108 . The 3D imager 108 controls an image viewer to display one or more views of a 3D image from different viewing angles. After the computer system 105 receives the 2D images from the server 104 , the 2D images are sent to the 3D imager 108 , wherein the series of 2D images is the same series of 2D images sent to the 2D imager 106 . After the series of 2D images is received by the 3D imager 108 , the 3D imager 108 constructs a 3D volume image of the portion of the patient's body that was scanned from the series of 2D images. The 3D imager 108 constructs the 3D volume image using tomography or some other technique of three-dimensional image construction from a series of two-dimensional cross-sectional images. The 3D imager 108 stores the constructed 3D image until another series of 2D images comprising another scan by the medical imaging device 102 is loaded from the server 104 and a new 3D image is constructed.
[0023] The 3D imager 108 communicates, through device drivers on the computer system 105 , with the input terminal 112 and the monitor 114 . The 3D imager sends one or more views of a 3D image to the monitor 114 be displayed on the monitor 114 . The 3D imager receives input from a user through the input terminal 112 . The 3D imager 108 receives XML commands from the 2D imager 106 via the XML transmitter 110 . The 3D imager 108 also sends XML commands to the 2D imager 106 via the XML transmitter 110 .
[0024] The example monitor 114 communicates with the 2D imager 106 and the 3D imager 108 . The monitor 114 displays the output from the 2D imager 106 and the output from the 3D imager 108 . Although, the 2D imager 106 and the 3D imager 108 are two separate applications executing on the computer system 105 , their outputs on the monitor 114 are displayed in such a way that they appear to the user to be a single application.
[0025] The 2D imager 106 sends one or more 2D image to the monitor 114 , wherein the one or more 2D images are from the series of 2D images stored on the 2D imager 106 . The 3D imager 108 sends one or more views of the constructed 3D volume image to the monitor 114 . The monitor 114 displays the one or more received 2D images and the one or more received views of the 3D image. FIG. 2 illustrates an example display of the monitor 114 and its display. In the example of FIG. 2 only one 2D image and one 3D image are displayed. In other examples, multiple 2D images and multiple views of the 3D image could be displayed. In the example of FIG. 2 , one portion of the monitor 114 displays a 2D image 200 received from the 2D imager 106 . Another portion of the monitor 114 displays a 3D image 202 received from the 3D imager 108 . However, the sizes of the 2D image 200 and the 3D image 202 can vary, the positions of the 2D image 200 and the 3D image can vary and one of the images can partially overlap the other. As the 2D image 200 sent by the 2D imager 106 and the 3D image 202 sent by the 3D imager 108 are changed, as explained in further detail below, the 2D image 200 and the 3D image 202 displayed on the monitor 114 are updated accordingly.
[0026] The input terminal 112 of FIG. 1 is the mechanism by which a user interacts with the imaging system 100 . The input terminal 112 communicates with the 2D imager 106 and the 3D imager 108 . The input terminal 112 includes a mouse and a keyboard. The input terminal 112 can also include other methods of providing input to the imaging system 100 . The input terminal 112 is used to modify what is displayed on the monitor 114 .
[0027] One way that the display on the monitor 114 can be changed is that the user can use the input terminal 112 to resize and/or move the 2D image 200 and/or the 3D image 202 . In FIG. 2 , 2D image 200 and 3D image 202 are the same size and take up the same amount of space on the monitor 114 . However, both the 2D image 200 and the 3D image 202 can be resized and/or moved through the use of the input terminal 112 . The view on the monitor 114 can be modified such that the size of the 2D image 200 and/or the size of the 3D image 202 can be increased or decreased. Also, the 2D image 200 and/or the 3D image 202 can be minimized completely so that only one image is displayed on the monitor 114 . Also, the position of either of the 2D image 200 and the 3D image 300 can be moved.
[0028] FIG. 6 illustrates a screenshot 600 of an example display of the monitor 114 of the example imaging system 100 . Window 602 illustrates an example output of the 2D imager 106 and window 604 illustrates an example output of the 3D imager 108 . In the example of FIG. 6 , the 2D imager 106 has sent four 2D images to the monitor 114 and the 3D imager 108 has sent four views of the 3D image to the monitor 114 . Window 602 , the output of the 2D imager 106 has been made smaller than window 604 , the output of the 3D imager 108 . In the example of FIG. 6 , window 602 displays four different 2D images and window 604 displays four different angles of the constructed 3D image, although only two of those views are completely visible in FIG. 6 as the other two views are partially obscured by window 600 . Image 606 of FIG. 6 illustrates one of the four images output by the 2D imager 106 . Image 608 of FIG. 6 illustrates one of the four images output by the 3D imager 108 .
[0029] In addition to resizing the 2D image 200 and the 3D image 202 , the input terminal 112 can be used to modify what is displayed as the 2D image 200 and the 3D image 202 . Certain mouse and keyboard commands can cause the input terminal 112 to send commands to the 2D imager 106 or the 3D imager 108 . When commands are received from the input terminal 112 by the 2D imager 106 , the 2D imager 106 modifies the 2D image 200 accordingly and sends the modified 2D image 200 to the monitor 114 , which then updates the 2D image 200 displayed on the monitor 114 . When commands are received from the input terminal 112 by the 3D imager 108 , the 3D imager 108 modifies the 3D image 202 accordingly and sends the modified 3D image 202 to the monitor 114 , which then updates the 3D image 202 displayed on the monitor 114 . Any known image processing or image modification technique can be applied by either the 2D imager 106 or the 3D imager 108 such as modifying the zoom level of an image, modifying the contrast of an image, or modifying the window/level of an image. There are also many image modification tools typically used in radiology that can be applied by either the 2D imager 106 or the 3D imager 108 as well. Any such image modification can be programmed to be triggered by any type of input made by a user into the example input terminal 112 such as any series of keyboard or mouse commands.
[0030] Any such input made to the input terminal 112 to modify the display of the 2D image 200 causes the input terminal 112 to send a command to the 2D imager 106 to cause the 2D imager 106 to make the appropriate requested modification to the 2D image 200 that is sent to and displayed on the monitor 114 . In addition, when any such modifications are made to the 2D image 200 , the 2D imager 106 also sends XML commands to the 3D imager 108 via the example XML transmitter 110 . The XML commands sent from the 2D imager 106 to the 3D imager 108 via the XML transmitter 110 instruct the 3D imager 108 to make the same changes to the 3D image 202 that that 2D imager 106 made to the 2D image 200 . For example, if the input terminal 112 instructs the 2D imager 106 to change the window/level contrast of the 2D image 200 , the 2D imager 106 sends XML commands to the 3D imager 108 instructing the 3D imager 108 to make the same adjustments to the window/level contrast of the 3D image 202 . This ensures that the view of the 2D image 200 and the view of the 3D image 202 stay in synch with each other.
[0031] Similarly, any input by the user to the input terminal 112 to modify the display of the 3D image 202 causes the input terminal 112 to send a command to the 3D imager 108 to cause the 3D imager 108 to make the appropriate requested modification to the 3D image 202 that is sent to and displayed on the monitor 114 . In addition, when any such modifications are made to the 3D image 202 , the 3D imager 108 also sends XML commands to the 2D imager 106 via the example XML transmitter 110 . The XML commands sent from the 3D imager 108 to the 2D imager 106 via the XML transmitter 110 instruct the 2D imager 106 to make the same changes to the 2D image 200 that that 3D imager 108 made to the 3D image 202 . For example, if the input terminal 112 instructs the 3D imager 108 to change the zoom level of the 3D image 202 , the 3D imager 108 sends XML commands to the 2D imager 106 instructing the 2D imager 106 to make the same adjustments to the zoom level of the 2D image 200 .
[0032] The example input terminal 112 can also cause the 2D imager 106 to send a new 2D image 200 to the monitor 114 , wherein the new 2D image 200 is another one of the series of 2D images stored on the 2D imager 106 . Since the series of 2D images stored on the 2D imager 106 represent different cross sections of the portion of the patient's body scanned by the medical imaging device 102 , loading a new 2D image 200 allows a different cross section to be viewed on the monitor 114 . Accordingly, when a command to load a new 2D image 200 is made to the input terminal 112 , the input terminal 112 sends a command to the 2D imager 106 causing the 2D imager 106 to load a new 2D image 200 and send the new 2D image 200 to the monitor 114 where it is displayed.
[0033] When a new 2D image 200 is loaded by the 2D imager 106 , the 3D image 202 must be modified to maintain synchronicity with the displayed 2D image 200 . This is accomplished by moving a pointer on the 3D image 202 . The pointer can be any conspicuous dot or symbol that highlights a specific point on the 3D image 202 . The 3D volume image 202 is constructed from the series of two-dimensional cross sections recorded by the medical imaging device 102 . Accordingly, any given cross section of the 3D image 202 corresponds to one of the 2D images stored on the 2D imager 106 . Likewise, each one of the 2D images stored on the 2D imager 106 corresponds to a cross section of the 3D volume image 202 . Therefore, in order to synchronize the view of the 2D image 200 and the 3D image 202 , whenever a new 2D image 200 is loaded by the 2D imager 106 , the 2D imager 106 sends XML commands to the 3D imager 108 instructing the 3D imager 108 to move the pointer to a location on the 3D image 202 in which the cross section of the 3D image 202 at that location corresponds to the 2D image 200 that was loaded. When the XML commands are received by the 3D imager 108 , the 3D imager 108 changes the 3D image 202 such that the pointer is moved to the appropriate location and then sends the updated 3D image 202 to the monitor 114 for display.
[0034] The input terminal 112 can also be used to move the pointer to any location on the 3D image 202 . When this is done, the 2D image 200 must change in order to keep the 2D image 200 and the 3D image 202 in synchronization. Accordingly, when the user makes an input to the input terminal 112 to move the 3D pointer, the input terminal 112 instructs the 3D imager 108 to move the pointer to the appropriate location. The 3D imager 108 then changes the 3D image 202 such that the pointer is in the new location and sends the 3D image 202 to the monitor 114 to be displayed. The 3D imager 108 also sends XML commands to the 2D imager 106 instructing the 2D imager 106 to load a new 2D image 200 . The new 2D image 200 to be loaded is the cross section of the 3D image 202 that is closest to the point on the 3D image 202 where the pointer is. When the 2D imager 106 receives the XML commands, the 2D imager 106 loads the appropriate 2D image 200 and sends the 2D image 200 to the monitor 114 for display.
[0035] The input terminal 112 can also be used to add labels and/or annotations to the 2D image 200 . When the input terminal 112 sends a command to the 2D imager 106 to add a label or annotation to the 2D image 200 , the 2D imager 106 adds the requested label or annotation to the 2D image 200 and sends the updated 2D image 200 to the monitor 114 for display. The 2D imager 106 also sends XML commands to the 3D imager 108 instructing the 3D imager 108 to add the same label or annotation to the 3D image 202 . The XML commands sent by the 2D imager 106 instruct the 3D imager 108 to add the label or annotation to the 3D image 202 at a point on the 3D image 202 with the cross section represented by the 2D image 200 so that the two images are synchronized. The 3D imager 108 receives the XML commands, adds the label or annotation in the appropriate location to the 3D image 202 and sends the 3D image 202 to the monitor 114 for display.
[0036] The input terminal 112 can also be used to add labels and/or annotations to the 3D image 202 . When the input terminal 112 sends a command to the 3D imager 108 to add a label or annotation to the 3D image 202 , the 3D imager 108 adds the requested label or annotation to the 3D image 202 and sends the updated 3D image 202 to the monitor 114 for display. After adding a label or annotation to the 3D image 202 , the 3D imager 108 sends XML commands to the example 2D imager 106 . The XML commands sent by the 3D imager 108 to the 2D imager 106 instruct the 2D imager 106 to add the label or annotation in the correct location. However, because the 3D image 202 is a composite of all of the 2D images stored on the 2D imager 106 , not all of those 2D images should have every label or annotation made to the 3D image 202 . Accordingly, when a label or annotation is added to the 3D image 202 , the 3D imager 108 sends XML commands to the 2D imager 106 instructing the 2D imager 106 to add the label or annotation only to the 2D images stored in the 2D imager 106 that are cross sections of the 3D image 202 that intersect the label or annotation on the 3D image 202 . Upon receiving the XML commands, the 2D imager 106 internally records the label or annotation on each of the appropriate stored 2D images. As various 2D images 200 are displayed on the monitor 114 , every time a 2D image 200 that has had a label or annotation added is displayed, the label or annotation is displayed on both the 2D image 200 and the 3D image 202 .
[0037] While an example manner of implementing the medical imaging system 100 has been illustrated in FIG. 1 , one or more of the elements, processes and/or devices illustrated in FIG. 1 may be combined, divided, re-arranged, omitted, eliminated and/or implemented in any other way. Further, the example server 104 , the example 2D imager 106 , the example 3D imager 108 , the example XML transmitter 110 , and/or, more generally, the example medical imaging system 100 of FIG. 1 may be implemented by hardware, software, firmware and/or any combination of hardware, software and/or firmware. Thus, for example, any of the example server 104 , the example 2D imager 106 , the example 3D imager 108 , the example XML transmitter 110 , and/or, more generally, the example medical imaging system 100 of FIG. 1 could be implemented by one or more circuit(s), programmable processor(s), application specific integrated circuit(s) (ASIC(s)), programmable logic device(s) (PLD(s)), microprocessor(s), hardware processor(s), and/or field programmable logic device(s) (FPLD(s)), etc. When any of the system or apparatus claims of this patent are read to cover a purely software and/or firmware implementation, at least one of the example server 104 , the example 2D imager 106 , the example 3D imager 108 , the example XML transmitter 110 , and/or, more generally, the example medical imaging system 100 of FIG. 1 is hereby expressly defined to include a tangible computer readable storage medium such as a memory, DVD, CD, Blu-ray, etc. storing the software and/or firmware. Further still, the example medical imaging system 100 of FIG. 1 may include one or more elements, processes and/or devices in addition to, or instead of, those illustrated in FIG. 1 , and/or may include more than one of any or all of the illustrated elements, processes and devices.
[0038] FIGS. 3-5 are flowcharts representative of example machine readable instructions for implementing the example medical imaging system 100 of FIG. 1 . In the example flowcharts of FIGS. 3-5 , the machine readable instructions comprise program(s) for execution by a processor such as the processor 612 shown in the example computer 600 discussed below in connection with FIG. 6 . The program(s) may be embodied in software stored on a tangible computer readable storage medium such as a CD-ROM, a floppy disk, a hard drive, a digital versatile disk (DVD), a Blu-ray disk, or a memory associated with the processor 612 , but the entire program and/or parts thereof could alternatively be executed by a device other than the processor 612 and/or embodied in firmware or dedicated hardware. Further, although the example program(s) is described with reference to the flowcharts illustrated in FIGS. 3-5 , many other methods of implementing the example loop vectorizer 300 of FIG. 3 may alternatively be used. For example, the order of execution of the blocks may be changed, and/or some of the blocks described may be changed, eliminated, or combined.
[0039] As mentioned above, the example processes of FIGS. 3-5 may be implemented using coded instructions (e.g., computer readable instructions) stored on a tangible computer readable storage medium such as a hard disk drive, a flash memory, a read-only memory (ROM), a compact disk (CD), a digital versatile disk (DVD), a cache, a random-access memory (RAM) and/or any other storage media in which information is stored for any duration (e.g., for extended time periods, permanently, brief instances, for temporarily buffering, and/or for caching of the information). As used herein, the term tangible computer readable storage medium is expressly defined to include any type of computer readable storage device and/or disk and to exclude propagating signals. Additionally or alternatively, the example processes of FIG. 3 may be implemented using coded instructions (e.g., computer readable instructions) stored on a non-transitory computer readable medium such as a hard disk drive, a flash memory, a read-only memory, a compact disk, a digital versatile disk, a cache, a random-access memory and/or any other storage media in which information is stored for any duration (e.g., for extended time periods, permanently, brief instances, for temporarily buffering, and/or for caching of the information). As used herein, the term non-transitory computer readable storage medium is expressly defined to include any type of computer readable storage device and/or disk and to exclude propagating signals. As used herein, when the phrase “at least” is used as the transition term in a preamble of a claim, it is open-ended in the same manner as the term “comprising” is open ended. Thus, a claim using “at least” as the transition term in its preamble may include elements in addition to those expressly recited in the claim.
[0040] FIG. 3 is a flowchart of example machine readable instructions to initialize the example medical imaging system of FIG. 1 . Initialization begins when a user wishes to view medical images that have been recorded by the medical imaging device 102 and stored on the server 104 (block 300 ). The series of two-dimensional images stored on the server 104 are transferred to the computer system 105 and to the 2D imager 106 and the 3D imager 108 (block 302 ). The 2D imager 106 then sends one or more 2D images to the monitor 114 to be displayed on a portion of the monitor 114 (block 304 ). In the example of FIG. 6 , four 2D images are sent to the monitor 114 and the four 2D images are displayed in window 602 . One of the displayed 2D images is image 606 . The 3D imager 108 constructs a three-dimensional volume image from the series of 2D images received from the server 104 using tomography or some other three-dimensional image construction technique (block 306 ). One or more views of the constructed 3D image is then sent to the monitor 114 to be displayed on a portion of the monitor 114 (block 308 ). In the example of FIG. 6 , four views of the constructed 3D image, comprising four different viewing angles of the 3D image are sent to the monitor 114 and the four 3D images are displayed in window 604 . One of the displayed 3D images is image 608 . The imaging system 100 then assigns control to either the 2D imager 106 or the 3D imager 108 (block 310 ). This ends initialization of the imaging system 100 (block 312 ).
[0041] In certain examples, either the 2D imager 106 or the 3D imager 108 has control of the imaging system 100 at any given time. For example, the 2D imager 106 and the 3D imager 108 are separate applications executing simultaneously on the computer system 105 . When the 2D imager 106 is assigned control, the user interacts with the 2D imager 106 application. Furthermore, when the 2D imager 106 has control and more than one 2D image is displayed on the monitor 114 , as in window 602 of FIG. 6 , the user interacts specifically with one of the 2D images displayed, such as image 606 of FIG. 6 . When the 3D imager 108 is assigned control, the user interacts with the 3D imager 108 application. Furthermore, when the 3D imager has control and more than one 3D image is displayed on the monitor 114 , as in window 602 of FIG. 6 , the user interacts specifically with one of the 3D images displayed, such as image 608 of FIG. 6 . However, this assignment of control to either the 2D imager 106 or the 3D imager 108 is mostly transparent to the user of the imaging system 100 because the outputs of the 2D imager 106 and the 3D imager 108 are displayed together on the monitor 114 , as shown in the example of FIG. 6 , wherein window 602 and window 604 are displayed together. In other examples, the 2D imager 106 and the 3D imager 108 are elements of a single computer software program and/or unified user interface, and the user is unaware of the existence of both a 2D imager 106 component and a 3D imager 108 component.
[0042] Whichever one of the 2D imager 106 and the 3D imager 108 has control of the imaging system 100 is the application that can accept input from the example input terminal 112 at any given time. However, the user can easily change control from the 2D imager 106 to the 3D imager 108 and vice versa. In some examples, this control can be changed by simply using a mouse that is part of the input terminal 112 and moving the mouse cursor from one side of the monitor 114 to the other. For example, in FIG. 6 , the user could assign control to the 2D imager 106 by clicking anywhere in window 602 and the user could assign control to the 3D imager 108 by clicking anywhere win window 604 . In some examples, after initialization, initial control is assigned to the 2D imager 106 . In other examples, after initialization, initial control is assigned to the 3D imager 108 .
[0043] FIG. 4 is a flowchart of example machine readable instructions to implement the 2D imager 106 of FIG. 1 . The flowchart begins when control of the imaging system 100 is assigned to the 2D imager 106 (block 400 ). The 2D imager 106 then waits for a command to be received from the input terminal 112 (block 402 ). There are a variety of commands that can be received by the input terminal 112 as described above in connection with FIG. 1 . Some commands sent by the input terminal 112 cause the displayed 2D image, such as image 606 of FIG. 6 to be modified. Some commands sent by the input terminal 112 cause a new 2D image to be sent to the monitor 114 . Other commands sent by the input terminal 112 indicate that the user wishes to modify the 3D image, such as image 608 of FIG. 6 , and that therefore control of the imaging system 100 should pass to the 3D imager 108 . As such, when a command is received from the input terminal 112 , the 2D imager 106 first determines whether control should be passed to the 3D imager 108 (block 404 ). If the command from the input terminal 112 indicates that control should be passed to the 3D imager 108 , then control is passed to the 3D imager 108 and the example of FIG. 4 ends (block 406 ). If control is not to be passed to the 3D imager 108 , then the example of FIG. 4 moves to block 408 .
[0044] In block 408 , the 2D imager 106 interprets the command received from the input terminal 112 and takes the appropriate action. For example, the 2D image 606 of FIG. 6 displayed on the monitor 114 could be modified in some way or a new 2D image could be loaded from the images stored on the 2D imager 106 , depending on the specific command received from the input terminal 112 . After either the 2D image 606 of FIG. 6 is modified or a new 2D image is loaded, the 2D imager 106 sends XML commands to the 3D imager 108 through the XML transmitter 110 instructing the 3D imager 108 to make the same modification to the displayed 3D image, such as image 608 of FIG. 6 , to stay in synch with the displayed 2D image (block 410 ). The 3D imager 108 then receives the XML commands and makes the appropriate modifications to the 3D image 202 (block 412 ). The example of FIG. 4 then moves back to block 402 , and the 2D imager 106 awaits the next command from the input terminal 112 .
[0045] FIG. 5 is a flowchart of example machine readable instructions to implement the 3D imager 108 of FIG. 1 . The flowchart begins when control of the imaging system 100 is assigned to the 3D imager 108 (block 500 ). The 3D imager 108 then waits for a command to be received from the input terminal 112 (block 502 ). Some such commands from the input terminal 112 cause the 3D image 202 to be modified. Other such commands from the input terminal 112 cause control of the imaging system to be passed to the 2D imager 106 . When a command is received from the input terminal 112 , the 3D imager 108 first determines whether control should be passed to the 2D imager 106 (block 504 ). If the command from the input terminal 112 indicates that control should be passed to the 2D imager 106 , then control is passed to the 2D imager 106 , and the example of FIG. 5 ends (block 506 ). If control is not to be passed to the 2D imager 106 , then the example of FIG. 4 moves to block 508 .
[0046] In block 508 , the 3D imager 108 interprets the command received from the input terminal 112 and takes the appropriate action to modify the displayed 3D image, such as image 608 of FIG. 6 , and send the modified image to the monitor 114 . After the 3D imager 108 modifies the 3D image, the 3D imager 108 sends XML commands to the 2D imager 106 through the XML transmitter 110 instructing the 2D imager 106 to make the same modification to the 2D image 606 of FIG. 6 to stay in synch with the 3D image 608 (block 510 ). The 2D imager 106 then receives the XML commands and makes the appropriate modifications to the 2D image 606 of FIG. 6 (block 512 ). For example, modifications involve modifying the currently displayed 2D image 606 or loading a new 2D image from the 2D images stored in the 2D imager 106 . The example of FIG. 5 then moves back to block 502 and the 3D imager 108 awaits the next command from the input terminal 112 .
[0047] FIG. 7 is a block diagram of a processor platform 700 capable of executing the instructions of FIGS. 3-5 to implement the example medical imaging system 100 of FIG. 1 . The processor platform 700 can be, for example, a server, a personal computer, an Internet appliance, a DVD player, a CD player, a Blu-ray player, a gaming console, a personal video recorder, a mobile device (e.g., a smart phone, a tablet, etc.), a printer, or any other type of computing device.
[0048] The processor platform 700 of the instant example includes a processor 712 . As used herein, the term “processor” refers to a logic circuit capable of executing machine readable instructions. For example, the processor 712 can be implemented by one or more microprocessors or controllers from any desired family or manufacturer.
[0049] The processor 712 includes a local memory 713 (e.g., a cache) and is in communication with a main memory including a volatile memory 714 and a non-volatile memory 716 via a bus 718 . The volatile memory 714 may be implemented by Synchronous Dynamic Random Access Memory (SDRAM), Dynamic Random Access Memory (DRAM), RAMBUS Dynamic Random Access Memory (RDRAM) and/or any other type of random access memory device. The non-volatile memory 716 may be implemented by flash memory and/or any other desired type of memory device. Access to the main memory 714 , 716 is controlled by a memory controller.
[0050] The processor platform 700 also includes an interface circuit 720 . The interface circuit 720 may be implemented by any type of interface standard, such as an Ethernet interface, a universal serial bus (USB), and/or a PCI express interface.
[0051] One or more input devices 722 are connected to the interface circuit 720 . The input device(s) 722 permit a user to enter data and commands into the processor 712 . The input device(s) can be implemented by, for example, a keyboard, a mouse, a touchscreen, a track-pad, a trackball, isopoint and/or a voice recognition system.
[0052] One or more output devices 724 are also connected to the interface circuit 720 . The output devices 724 can be implemented, for example, by display devices (e.g., a liquid crystal display, a cathode ray tube display (CRT), a printer and/or speakers). The interface circuit 720 , thus, typically includes a graphics driver card.
[0053] The interface circuit 720 also includes a communication device such as a modem or network interface card to facilitate exchange of data with external computers via a network 726 (e.g., an Ethernet connection, a digital subscriber line (DSL), a telephone line, coaxial cable, a cellular telephone system, etc.).
[0054] The processor platform 700 also includes one or more mass storage devices 728 for storing software and data. Examples of such mass storage devices 728 include floppy disk drives, hard drive disks, compact disk drives and digital versatile disk (DVD) drives.
[0055] The coded instructions 732 of FIG. 7 may be stored in the mass storage device 728 , in the volatile memory 714 , in the non-volatile memory 716 , and/or on a removable storage medium such as a CD or DVD.
[0056] Although certain example apparatus, methods, and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all apparatus, methods, and articles of manufacture fairly falling within the scope of the claims of this patent. | System and methods for 2D and 3D image integration and synchronization are disclosed. An example method includes displaying a first two-dimensional image via a first image viewer on a first screen, wherein the first two-dimensional image is from a first set of images and displaying a three-dimensional image via a second image viewer on the first screen, wherein the three-dimensional image is constructed from the first set of images and wherein the first image viewer and the second image viewer are linked to share commands and messages. The example method also includes receiving a first instruction to modify a selected one of the first two-dimensional image or the three-dimensional image, modifying the selected one of the first two-dimensional image or the three-dimensional image based on the first instruction via the first image viewer or the second image viewer corresponding to the selected image and correspondingly modifying the other of the first two-dimensional image or the three-dimensional image based on the first instruction via the other of the first image viewer or the second image viewer corresponding to the unselected one of the first two-dimensional image or the three-dimensional image. | 6 |
FIELD OF THE INVENTION
The present invention relates generally to air deflectors for directing air from a ventilator into a room. More particularly, the invention relates to air deflectors for central air conditioning systems so that air is directed into a room in a manner that the system efficiently cools the room. Still more particularly, the invention relates a central air uptake attachment for a central air conditioning system, whereby chilled air introduced from a baseboard or floor ventilator is uplifted to an above-head elevation so that the chilled air may be introduced into a warm room to fall and diffuse into the room for efficient cooling thereof.
BACKGROUND OF THE INVENTION
Central air conditioning systems treat air in central air conditioning plants and convey the treated air through ducts to ventilators from which the air is diffused into rooms. Central heating systems do the same, except that the treatment of the air is in a heating plant. It is well known that some central treatment plants both heat and cool and can be regulated to provide air at a desired temperature. Thus, either system or a combined system may be used, depending on the temperature within a room, to bring comfort to human occupants.
Treated air is generally blown into a room under the influence of a blower system, usually housed in the central plant. Once introduced into the room, the treated air rapidly loses momentum generated by the blower system. Thus, the treated air is left to convective currents within the room.
Ventilators may be located at floors, baseboards, and ceilings. As cool air falls and warm air rises, the former locations, those near or at the floor, prove to be efficient for heating, while the latter location proves to be efficient for cooling.
The present invention focuses on the problem arising out of the architectural design of rooms with combination central heating and cooling systems, particularly with rooms designed for central heating systems which subsequently were converted into the combined systems. Many such rooms have ventilators and exhaust grate locations that were designed so that heated air is introduced into a room at lower elevations where it is beneficial to the occupants of the room as it rises to settle near the ceiling where either it is exhausted through an exhaust intake located near the ceiling before it is cooled, or it eventually falls after cooling into the proximity of an exhaust intake at a lower elevation. Such systems operate with a cooling cycle that has cool air being let in at the lower elevations where after a time it builds up while heated air is exhausted from a higher elevation or it is immediately exhausted from the room at the lower elevation without having served to cool the occupants of the room.
OBJECTS OF THE INVENTION
Because of the difficulties associated with air conditioning systems that outlet conditioned air into rooms at low elevations, it is one object of the present invention to provide a central air uptake attachment for directing conditioned air into a room at a high enough elevation for the air to efficiently cool the room for occupants of the room.
It is another object of the present invention to provide a central air uptake attachment for directing treated air into a room at elevations from which the air may be efficiently used to cool or heat the room to suit the occupants of the room.
It is yet another object of the present invention to provide a central air uptake attachment for introducing chilled air into a warm room from an above-head elevation so that the chilled air may fall and diffuse into the room for efficient cooling thereof.
Furthermore, it is an object of the present invention to provide a central air uptake attachment for a wall in a room having a baseboard ventilator or having a floor ventilator adjacent it whereby chilled air introduced from the baseboard or floor ventilator into the room bounded by the wall is uplifted to an above-head elevation so that the chilled air may be introduced into a warm room to fall and diffuse into the room for efficient cooling thereof.
Still further, it is an object of the present invention to provide a central air uptake attachment for a wall in a room having a baseboard or floor ventilator whereby warm air introduced into the room when the room is chilled is introduced at a low elevation so that room air may rise up to warm the room and chilled air introduced from the baseboard or floor ventilator is uplifted to an above-head elevation at which the chilled air may be introduced into the room to fall and diffuse into the room for efficient cooling thereof.
A related object of the invention is to provide a kit for attaching a central air uptake attachment.
Another related object of the invention is to provide a self-contained kit for quickly and conveniently attaching a central air uptake attachment, without requiring tools in addition to the kit.
Yet another related object of the present invention is to provide a kit which may be packaged for sale in a department or hardware store to be conveniently transported in an automobile trunk to the site at which it is to be attached.
SUMMARY OF THE INVENTION
These and other objects are accomplished in the present invention by a central air uptake attachment for a room wall that has a heat and air conditioning outlet. The attachment is to be used in a preferred orientation such that it is structurally distributed between an upper and a lower elevation, and the attachment is to be attached to the room wall over the heat and air conditioning outlet.
A housing for the attachment has a lower air outlet, and an upper air outlet and has an uplift channel between the two outlets. Only one of the two outlets is operative at any one time. One, preferably the lower outlet, is to be used for introducing heating air into the room, and the other, preferably the upper outlet, is to be used for introducing cooled air--air conditioning--into the room.
Preferably, the housing has at least three housing walls. One of the housing walls is a center wall which will be spaced outwardly from the room wall when the attachment is attached to the room wall. The others of the housing walls, then, function as return walls which are generally perpendicular to the center wall, so that the three housing walls, with the complement of the room wall, form a box channel for channeling the conditioned air to the upper outlet when so desired. Accordingly, when the air conditioner wall uptake is used in the preferred orientation and at a preferred location, the center wall is substantially parallel to the room wall, and the return walls are contiguous to, while being substantially perpendicular to, the room wall. Specifically, it is the uplift channel that is a box channel formed of portions of each of the housing walls and the room wall. The four walls thus cooperate to form an open-ended enclosing structure capable of channeling air from the lower to the higher elevation.
The attachment also includes a diverter which also functions as a door. In particular, the diverter operates as a diverter to divert air to the lower air outlet when the lower outlet is being used. At the same time, the diverter closes off the uplift channel so that heated air introduced into the housing from the room wall outlet will not rise to escape through the higher outlet.
Functioning as a door, the diverter closes off the lower outlet so that conditioned air, that is, cooled air, cannot escape through the lower outlet into the room. At the same time, the diverter no longer blocks the uplift channel so that the chilled air can find its way up the uplift channel, constrained by the walls of the housing, to the upper outlet and therethrough escape into the room.
The diverter is pivotally attached to the housing and a lever extends opposite the diverter so that the lever may be used as a means of selecting the orientation of the diverter. Its orientation determines its function as a door or a diverter, particularly with respect to the lower outlet. Because of structural constraints providing for the diverter to function as a door or diverter, the constraints also providing that the housing project minimally into the room from the wall to which it is attached, the lower outlet is preferably located at a higher elevation than the room wall outlet. An optional shield deflector may be used to direct the air downwardly again to the lower elevations within the room if so desired.
The housing is preferably made of lightweight construction material such as plastic, treated paper or cardboard, or mixed materials. Whatever the material, it is to be appreciated by those skilled in the art that the housing may be treated as the wall treatment so that it appears to be the construction of the room. The construction of the housing is also to allow for the attachment to be boxed conveniently for consumers to purchase the attachment in a package which can be taken in the trunk of an automobile and carried to the site of its intended use. Enhancements are provided in the kit package so that the attachment may be attached to a wall without other tools being needed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the central air attachment according to the present invention.
FIG. 2 is a sectional view taken in the direction of arrows 2--2 of FIG. 1.
FIG. 3 is an enlarged partial sectional view taken in the direction of arrows 3--3 of FIG. 1.
FIG. 4 is a front elevational view of a second embodiment of the central air attachment according to the invention.
FIG. 5 is a perspective view of the central air attachment of either of the embodiments shown in FIGS. 1 and 2, showing means for attaching the attachment and also showing how the attachment is folded for packaging.
FIG. 6 is a view of the enhancements packaged with the central air attachment for use in attaching the attachment.
FIG. 7 is a sectional view showing the folded attachment of FIG. 5 in a packaging box.
FIG. 8 is an enlarged partial view of the central air uptake attachment shown in FIG. 1.
FIG. 9 is a partial section of another embodiment of the central air uptake attachment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a central air uptake attachment for a room wall is shown generally at 10. As the shape and dimensions of the central air uptake attachment 10 are generally characteristic of the shape and dimensions of its housing, the housing is also represented in general by numeral 10. The attachment and housing 10 is to be used in a preferred orientation such that it is structurally distributed between an upper and a lower elevation.
A room 12 is bounded by a conventional wall construction, shown generally at 14 in FIGS. 2 and 3. The wall construction 14 includes a wall 16, typically constructed of plasterboard or plastic and lathe, through which a conditioned air wall outlet 18 or registry is situated. Room air outlet 18 lets air conditioned by being heated in a furnace or cooled by a compressor into the room 12 respectively for cooling room 12 or for heating room 12.
In a manner later to be explained, housing 10 is to be attached to room wall 16 (see FIG. 2), while positioned over existing heat and air conditioning wall outlet 18 of wall 16. Housing 10 has a lower air outlet 20 and an upper air outlet 22, only one of which is operative at any one time. One of the outlets 20 and 22, preferably the lower outlet 20, is to be used for introducing heated air into room 12. The other of the outlets 20 and 22, preferably the upper outlet 22, is to be used for introducing cooled air--that is, air conditioning--into room 12.
Between lower air outlet 20 and upper air outlet 22, housing 10 comprises an uplift channel 24. Preferably, housing 10 has at least three housing walls 26, 28 and 30. Two walls 26 and 28, which are parallel to one another, function as return walls for a center wall 30. As shown in FIG. 2, center wall 30 is to be spaced outwardly from room wall 16 when attached thereto. Return walls 26 and 28 are generally perpendicular to center wall 30. Return walls 26 and 28 have respective flanges 26a and 28b connected along the lengths of returns walls 26 and 28. Flanges 26a and 28b mount flushly against wall 16 in a manner later to be explained.
The three housing walls 26, 28 and 30, with the complement of room wall 16, form a box channel that is an air conditioner wall uptake 32 for channeling the conditioned air to the upper outlet 22 when so desired. Accordingly, when the air conditioner wall uptake attachment incorporated in housing 10 is used in the preferred orientation and at a preferred location, center wall 30 is substantially parallel to room wall 16, and the return walls 26 and 28 are contiguous to, while being substantially perpendicular to, the room wall 16. More specifically, the uplift channel 32, which is a box channel, is formed of portions of each of the housing walls 26, 28 and 30 situated between lower and upper outlets 20 and 22 and room wall 16. The four walls 16, 20, 22 and 30 thus cooperate to form an open-ended enclosing structure capable of channeling air from the lower to the higher elevation.
Referring more particularly to FIG. 3, the attachment incorporated in housing 10 also includes a diverter 34. Diverter 34 also functions as a door. First, diverter 34 functions or operates to divert air to the lower air outlet 20 when the lower outlet 20 is being used. Second, at the same time, the diverter 34 closes off the uplift channel 24 so that heated air introduced into the housing from the room wall outlet will not rise to escape through the higher outlet 22.
Functioning as a door as shown in phantom in FIG. 3, diverter 34 closes off the lower outlet 20 so that conditioned air, that is, cooled air, cannot escape through the lower outlet 20 into room 12. At the same time, diverter 34 no longer blocks the uplift channel 24 so that the chilled air can find its way up the uplift channel 24, constrained by walls 26, 28 and 30 of housing 10, to upper outlet 22 and therethrough escape into room 12.
Still referring to FIG. 3 but also with reference to FIG. 8, diverter 34 is pivotally attached to housing 10 by means known to those skilled in the art, as for example, by clips such as clips 36 shown on the outside of housing 10 supporting a deflector 38 whose function will be explained. A lever 40 extends generally opposite diverter 34 so that lever 40 may be used as a means of selecting the orientation of diverter 34. The orientation of diverter 34 determines the function of diverter 34 as a door or a diverter, particularly with respect to lower outlet 20.
Architectural constraints limit the projection of housing 10 into room 12. For example, a projection from wall 16 of about four inches, that is, the distance between parallel walls 16 and 30, would not be an overbearing obtrusion upon room 12 from both aesthetic and space-saving perspectives. But such constraints while providing for diverter 34 to function as a door or diverter, call for a preferable location lower outlet 20 at a higher elevation than room wall outlet 20, as is shown in FIGS. 2 and 3. This structural aberration allows diverter 34 to be pivoted open across the housing so as to touch wall 16 without having the leading edge of wall 16 intercepted by wall outlet 18.
An optional shield deflector 38, shown with particularity in FIG. 8, may be used to direct the air downwardly again to the lower elevations within the room if so desired. Deflector 38 is provided with rod projections to fit into clips 36 located to either side of outlet 20 so that deflector 38 may be removed to expose lever 40.
FIG. 9 shows another embodiment of the invention which is suitable for a floor vent 118 in a floor 116a. Except for a projection 142 of wall 130 outwardly into room 112, and side walls of housing 110 that meet all edges of wall 130, the central air uptake attachment is in all respects the same as in the embodiments shown in the other figures.
Housings 10 and 110 are preferably made of lightweight construction material such as plastic, treated paper or cardboard, or mixed materials. Whatever the material, it is to be appreciated by those skilled in the art that housing 10 or 100 may be treated as the wall treatment to which housing 10 or 110 is attached, so that the central air uptake attachment appears to be a part of the construction of room 12 or 112. As can be seen in FIG. 5, housing 10 may be provided, on the backs of flanges 26a and 28a, with pressure-sensitive adhesive strips 44 for attachment to wall 16 of FIG. 1. Other means of attachment, such as by use of epoxy or other types of bonding material 46 and masking or covering tapes 48 shown in FIG. 6, may also be used. Bonding material 46 would be used on flanges 26a and 28a in lieu of or in conjunction with adhesive strips 44. Tape 48 may be used over the flanges 26a and 28a in a "tape and float" operation to visually blend the central air uptake attachment into the wall treatment in a manner well-known in the home improvement arts.
The construction of housing 10 allows for the central air uptake attachment to be boxed conveniently for consumers to purchase the central air uptake attachment. As seen in FIGS. 1, 5, and 7, a fold line 50 in housing 10 allows housing 10 to fit into a convenient-sized kit package 52 which can be placed in the trunk of an automobile and carried to the site of its intended use. Enhancements 46 and 48 are provided in a tool packet 54 included in the kit package 52, so that the central air uptake attachment may be attached to a wall without other tools being needed. | A central air uptake attachment has a housing with upper and lower outlets. The housing is juxtaposable to a room wall air outlet communicating with the ducts of a central air conditioning system. With the room wall, the housing defines an internal chamber for channeling air from the room wall air outlet to the upper or lower outlet. The central air uptake attachment is constructed to be conveniently packaged and transported and readily attached to the room wall. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for locking a steering gear and includes a locking bar which may be protruded from the body of the device by external manipulation to engage the bar with the steering gear shaft to lock the shaft and prevent it from being turned.
2. Discussion of the Related Art
A conventional device for locking the steering gear of a motor vehicle includes a body, a cylinder in the body, and a locking bar which may be protruded from the body to the steering gear shaft by manipulation of the cylinder so that the bar is engaged with the shaft to lock it and prevent the steering gear shaft and associated steering wheel from being turned. If torque is applied to the steering wheel thus locked, a strong force acts on the body which guides the locking bar. For that reason, the body is made of a metal to withstand the strong force.
Recently, the parts of such a motor vehicle have been required to be reduced in weight to make the vehicle lighter. However, since the body of the conventional steering gear device is made of metal, it is difficult to reduce the weight of the body. It is possible to make the body out of a light alloy such as a magnesium alloy; however, such alloys are expensive and increase the cost of the device.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above circumstances and has as an object to reduce the weight of a device for locking a steering gear without increasing the cost of the device.
Additional objects and advantages of the invention will be set forth in part in the description which follows and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the objects and in accordance with the purpose of the invention, as embodied and broadly described herein, the device for locking a steering gear of this invention comprises a body having a first cylindrical portion and a second cylindrical portion extending nearly perpendicular from the first cylindrical portion, a reinforcing member fitted within the second cylindrical portion, the reinforcing member having an inner surface, an outer surface and a bottom portion connected to a tube containing the steering gear, a locking bar disposed within the reinforcing member and movable between a locked position for locking the steering gear and an unlocked position for allowing the steering gear to rotate, and means for moving the locking bar between the locked position and unlocked position.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification illustrate an embodiment of the invention and, together with the description, serve to explain the objects, advantages and principles of the invention. In the drawings,
FIG. 1 is a sectional view of a part of a locking device which is an embodiment of the present invention;
FIG. 2 is a cutaway side view of the device;
FIG. 3 is a front view of the reinforcing member of the device;
FIG. 4 is a plan view of the reinforcing member;
FIG. 5 is a side view of the reinforcing member; and
FIG. 6 is a sectional view of the part of the locking device in a state different from that shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention is hereafter described in detail with reference to the drawings attached hereto.
FIGS. 1 through 6 show an exemplary embodiment of a device for locking the steering gear of a motor vehicle in accordance with the present invention. The device comprises a body 1, a cylinder 4, a cam shaft 6, a cam 7, a switch support 8, a switch 9, mounting juts 11, a sliding space 12, a locking stopper 13, a compressed helical spring 15, a locking lever 16, a reinforcing member 18, a locking bar 20, a curved securing metal member 30, and a tube 31.
The device includes a locking bar 20 which may be protruded from the body 1 of the device by external manipulation so that the bar is engaged with the steering shaft of the steering gear. The device is characterized in that the body 1 is molded of a resin; and a reinforcing member 18 is secured to the body therein so as to guide the bar. When the locking bar 20 is protruded from the body 1, the bar is engaged with the steering shaft to lock it to prevent the shaft from being turned.
Since the body is entirely molded of the resin, the weight of the body is reduced. Since the locking bar is guided by the reinforcing member secured to the body therein, the body is not damaged even if a strong force acts on the bar. For these reasons, the weight of the device can be reduced without increasing the cost thereof.
The body 1 is made of a nylon resin mixed with fiberglass and molded through the use of dies. As shown in FIG. 2, the body 1 includes a first cylindrical portion 2, and a second cylindrical portion 3 slenderly extending nearly perpendicular to the former. The cylinder 4 is fitted in the first cylindrical portion 2 so that the cylinder can be put in each of a locking position, an accessory switch-on position, an engine switch-on position, and an engine start position. An ignition key 5 of the motor vehicle can only be inserted into the cylinder 4 or pulled out of it when the cylinder 4 is in the locking position.
The cam shaft 6 extends from the cylinder 4 along the first cylindrical position 2 of the body 1. The cam 7 is integrally formed on the cam shaft 6 so that the cam is rotated when the ignition key 5 is inserted into the cylinder 4 and rotated. The tip of the cam shaft 6 projects into the switch support 8 formed on the first cylindrical portion 2 at the end thereof. The switch 9 is fitted in the switch support 8. The tip of the cam shaft 6 is fitted in the rotary shaft of the switch 9 so that a turn-on signal corresponding to the position of the cylinder 4 is sent out through the switch and turns on a relay.
The second cylindrical portion 3 of the body 1 has a support hole 10 of rectangularly shape in cross section. The mounting juts 11 are integrally formed on the second cylindrical portion 3 at both the sides of the support hole 10. The body 1 has a sliding space 12 provided at the end of the second cylindrical portion 3 and communicating with the support hole 10.
Means for moving the locking bar between a locked and unlocked position include a locking stopper 13, compressed helical spring 15, cam 7, and cam shaft 6. The locking stopper 13, which is shaped as a rectangular frame, is provided in the sliding space 12. The cam shaft 6 extends through the locking stopper 13. The inner surface of the locking stopper 13 has an oblique portion 14 on which the cam 7 formed on the cam shaft 6 is located. The compressed helical spring 15 is provided between the locking stopper 13 and the inner surface of the body 1 at the end of the sliding space 12 so as to urge the stopper in a direction A shown in FIG. 1.
The locking lever 16 extends from the cylinder 4 in parallel with the cam shaft 6, and is urged onto the side surface of the locking stopper 13 by a compressed helical spring (not shown) However, the lever 16 is not urged by the spring when the ignition key 5 is not in the cylinder 4. The side surface of the locking stopper 13 has an engagement recess 17 in which the locking lever 16 is engaged when the stopper is moved in a direction reverse to the above-mentioned direction A.
The reinforcing member 18 is inserted in the support hole 10 of the second cylindrical portion 3. The locking bar 20 extends through the hole 19 of the reinforcing member 18 in such a manner that the bar is engaged with the peripheral portion of the locking stopper 13 at one end of the bar, and projects from the reinforcing member at the other end of the bar. The reinforcing member 18 has a stocky portion 21 and a slender portion 22, as shown in FIGS. 3, 4 and 5. The end of the stocky portion 21, which is located opposite the slender portion 22, is arc-shaped to correspond to the form of the inner surface of the second cylindrical portion 3 of the body 1. A projection 23 is formed on the arc-shaped end of the stocky portion 21. The slender portion 22 has slender raised grooves 24, 25, 26 and 27 shaped in such a manner that the height of each slender groove gradually decreases from the end of the slender portion adjacent the stocky portion toward the other end of the slender portion. The slender grooves 25 and 27 have notches 28 and 29 at the ends of the grooves opposite the stocky portion 21. Slender projections, not shown in the drawings, are formed on the second cylindrical portion 3 and located in the support hole 10 thereof so that when the reinforcing member 18 is inserted into the support hole as shown in FIG. 1, the reinforcing member is press-fitted in the support hole while the slender grooves 25 and 27 of the reinforcing member grind the slender projections at the ends of the grooves opposite the stocky portion 21. Since particles made as a result of the grinding are sealed in the notches 28 and 29 of the slender grooves 25 and 27, the particles do not deteriorate the guiding function of the reinforcing member 18 of the locking bar 20.
The compressed helical spring 15, the locking stopper 13, the locking bar 20 and the reinforcing member 18 are inserted, in that order, into the body 1 from the outer end of the support hole 10 of the second cylindrical portion 3 of the body during the assembly of the device. The assembly is thus simplified.
The securing metal member 30 is attached to the mounting juts 11 on the second cylindrical portion 3 of the body 1 so that the tube 31 supporting a steering shaft extending through the tube but not shown in the drawings is secured to the body by the mounting juts and the metal member. The projection 23 of the reinforcing member 18 is fitted in the hole of the tube 31 so that the reinforcing member and the tube are coupled with each other. A locking holder (not shown), is welded on the steering shaft of the steering gear. When the tip of the locking bar 20 is inserted into the hole of the locking holder, the steering shaft is locked by the device so that the steering wheel of the steering gear cannot be turned.
The operation of the device is described in detail below. When the ignition key 5 is inserted into the cylinder 4 and the cylinder is then turned with the key from the locking position in order to operate the motor vehicle, and the cam shaft 6 extending from the cylinder is rotated. When the cylinder 4 is put in one of the other positions, rotation of the cam 7 formed on the cam shaft 6 moves the locking stopper 13 in the direction reverse to the direction A, so that the locking bar 20 is moved into the reinforcing member 18. As a result, the steering wheel may be turned, and the locking lever 16 is located in the engagement recess 17 of the locking stopper 13 as shown in FIG. 6,-so that the stopper is held where it is. When the cylinder 4 is thereafter turned back to the locking position with the key 5, in order to get out of the motor vehicle, the cam 7 is rotated back to its original position as shown in FIG. 1, so that the cam ceases to hold the locking stopper 13. At that time, the locking stopper 13 is still held by the locking lever 16 so that the stopper is unmovable. When the key 5 is then pulled out of the cylinder 4, the locking lever 16 is pivoted so that it ceases to hold the locking stopper 13. As a result, the locking stopper 13 is moved in the direction A so that the locking bar 20 is engaged with the locking holder on the steering shaft to lock it to prevent the steering wheel from being turned.
Since the body 1 is made of the nylon resin, the device weighs less than a conventional device whose body is made of a metal or an alloy. Since the locking bar 20 is guided by the reinforcing member 18 provided in the body 1, the member receives a strong force when the force acts to the bar. For that reason, the force from the locking bar does not directly act on the body 1. Therefore, the body 1 made of the nylon resin is protected from damage. Since the reinforcing member 18 is supported at both ends by the second cylindrical portion 3 of the body 1, the member does not play even if the strong force acts on the member through the locking bar. Since the projection 23 of the reinforcing member 18 is fitted in the tube 31 on the steering shaft, a force acting on the reinforcing member is dispersed to the tube. Since the part of the body 1, to which the locking stopper 13 is opposed, is closed and integrated with the other part of the body, the former part is effectively prevented from being easily destroyed when trying to unlock the steering shaft. In a conventional device in which a locking stopper is inserted into the body of the device through the joining of first and second cylindrical portions of the body, the joint is then covered with a closing member which can be easily destroyed to unlock the steering shaft.
The foregoing description of preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiment was chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents. | A device for locking a steering gear having a body with a first cylindrical portion, a second cylindrical portion extending nearly perpendicular from the first cylindrical portion, and a reinforcing member disposed within the second cylindrical portion. The reinforcing member has an inner surface and an outer surface and a bottom portion connected to a tube containing the steering gear. The device also includes a locking bar disposed within the reinforcing member and movable between a locked position for locking the steering gear and an unlocked position to allow the steering gear to rotate, and means for moving the locking bar between the locked position and unlocked position. | 8 |
RELATED APPLICATION
This application claims priority to U.S. Provisional Patent Application No. 61/351,159, entitled “SYSTEM AND METHOD FOR ENABLING USER COOPERATION IN AN ASYNCHRONOUS VIRTUAL ENVIRONMENT,” and filed Jun. 3, 2010, which is hereby incorporated by reference into the present application in its entirety.
FIELD OF THE INVENTION
The invention relates to enabling synchronous cooperation between users in an asynchronous virtual environment, such as an asynchronous videogame or virtual space.
BACKGROUND OF THE INVENTION
A variety of asynchronous virtual environments are known. Such environments are typically hosted, served, or otherwise supported by a server accessible to users over a network (e.g., the Internet). However, asynchronous virtual environments generally do not provide for direct in-environment interactions between users that are provided in synchronous multi-user environments. Instead, individual users are provided with access to separate instances of the asynchronous virtual environment that does not represent interactions of other users with the asynchronous virtual environment.
Due to the asynchronous nature of known asynchronous virtual environments, typically users may not able to cooperate with each other in a synchronous, time-sensitive manner. Instead, any cooperation, competition, or other in-environment interactions between the users may be accommodated on an asynchronous manner (e.g., turn-based, leader board competition, and/or other asynchronous interactions).
SUMMARY
One aspect of the invention relates to a system and method for providing an asynchronous virtual environment to users in which synchronous, time-sensitive cooperation between the users is enabled in spite of the asynchronous nature of the virtual environment. Synchronous, time-sensitive cooperation between users may have an impact on gaining and/or retaining users in a virtual environment, such as a videogame or virtual space. For example, such cooperation between users may strengthen a sense of group, community, and/or camaraderie between cooperating users.
In order to facilitate synchronous, time-sensitive cooperation between users in the asynchronous virtual environment, a group activity may be presented to a user group. The group activity may be defined by a set of activity criteria. The activity criteria may define a common task or set of related tasks. The activity may define a time period or other timing interval within which the task(s) are to be attempted by the users in the user group. The users in the user group may separately and individually attempt to perform the task(s) within their own instance of the asynchronous virtual environment in a concurrent and/or time sensitive manner. Success of the user group as a whole for the group activity may depend on the cumulative successes and/or failures of the individual users with their separate performances. The users in the user group may receive a consequence of their success or failure, as a group, in performing the group activity.
In some implementations, the system may include one or more virtual environment servers configured to execute one or more computer program modules. The one or more computer program modules may include one or more of an environment module, an activity definition module, activity initiation module, a group performance monitoring module, an activity evaluation module, an activity consequence module, and/or other modules.
The environment module may be configured to provide the asynchronous virtual environment to users via client computing platforms used by the users. As used herein, a “virtual environment” may include a virtual space, one or more interactive electronic media, and/or other virtual environments. As used herein, the term “asynchronous virtual environment” may refer to a virtual environment that is provided to a given user individually such that the given user may interact with a separate instance of the virtual environment (e.g., rather than interacting with a common instance shared with a plurality of users) in real-time or near-real-time. However, the interactions of other users in other instances of the virtual environment may not be reflected in views of the virtual environment presented to the given player, at least not in real-time or near-real-time. As such, individual users may be somewhat isolated within the virtual environment from the other users. Although the virtual environment may be the same, real-time interaction between the users within the virtual environment may not be possible.
In some implementations, the asynchronous virtual environment may include an asynchronous virtual space in which the users separately and individually participate in a videogame. In order to participate in the videogame a user controls one or more objects (e.g., an avatar) within the virtual space to achieve game objectives. In the virtual space, the performance of the same or corresponding activities in the virtual space by others are not represented to the user. Instead, each user may appear to be “alone” in the virtual space, interacting with the topography, buildings, non-player characters, and/or other objects that are not controlled or influenced by other players.
The activity definition module may be configured to obtain activity criteria that define a group activity for a user group. The group activity may include a task (defined by the activity criteria) to be performed separately by users in the user group separately within their own instances of the asynchronous virtual environment. By way of non-limiting example, the task may include defeating a boss character, travelling to a checkpoint, learning a skill, opening a door or gate, pushing an obstacle, and/or other tasks. The activity criteria may include one or more of group parameters, task parameters, timing parameters, group participation parameters, consequence parameters, and/or other parameters.
The group parameters of a group activity may define the user group to be included in the group activity. As such, the group parameters may include identities, usernames, avatar names, and/or other identifiers of the user group to be included in the group activity. The group parameters may include group parameters that are predefined and/or predetermined. For example, a set of users may have previously formed a user group, and the group parameters may have been previously defined for this user group. A given user may belong to more than one such user group. As such, if the given user is going to initiate a group activity, the activity definition module may be configured to receive a user selection from the given user of the user group for the group activity.
The activity definition module may be configured such that a given user initiating an activity may select individual users to be included in a user group for the group activity. In such implementations, the activity definition module may obtain the group parameters by receiving the user selections.
The group parameters may be obtained by the activity definition module by defining a user group of users that are currently participating in the asynchronous virtual environment, and/or are at the same or a similar location within the asynchronous virtual environment. The activity definition module may obtain the group parameters by determining the group parameters for the defined user group.
The task parameters of the group activity may define the task to be performed separately by the individual users in the user group. The task parameters may be obtained by the activity definition module from a predetermined set of tasks with previously defined task parameters. The task parameters may be obtained by the activity definition module by receiving user selection of one or more task parameters from a user initiating the group activity. For example, a user interface configured to receive user selection of one or more task parameters may be presented to users via client computing platforms.
The timing parameters may dictate the timing with which the individual users in a user group attempting a group activity must separately perform the task. The timing parameters may specify a time window (e.g., an amount of time from initiation of the group activity) within which the task must be finished for performance to count toward accomplishment of the group activity. The timing parameter may specify a time window within which the task must be started for performance to count toward accomplishment of the group activity. The timing parameters may vary from group activity to group activity. The timing parameters may be specified in advance for a group activity.
The group participation parameters may dictate a threshold amount of users that must accomplish the task for successful performance of the group activity. Accomplishment of the task may require that the task be performed in accordance with the timing parameters for the group activity. The threshold amount of users dictated by the group participation parameters may include a fixed number of users, or an amount that varies based on one or more of how many users are in the user group, how many users in the user group are currently participating in the asynchronous virtual environment, how many users in the user group are in a position within the asynchronous virtual environment to attempt the task, and/or other considerations. Group participation parameters may be uniform across the asynchronous virtual environment. Group participation parameters may be specific to a group activity (e.g., predefined on a per-activity basis).
The consequence parameters may dictate the consequences of a successful attempt of a group activity. The consequence parameters may define a reward that may be provided to at least one of the users in the user group (e.g., the user that initiated the group activity, all of the users, and/or a subset of the users in the user group) as a consequence of successfully completing the group activity. The reward may include one or more of points, manna, virtual currency, access to content, acquired or enhanced skill or abilities, virtual goods, and/or other rewards. The consequence parameters may define a penalty that may be provided to at least one of the users in the user group as a consequence of unsuccessfully attempting the group activity. The penalty may include a decrease, reduction, or restriction of one or more of points, manna, virtual currency, access to content, acquired or enhanced skill or abilities, virtual goods, and/or other penalties. The consequence parameters for a group activity may be predetermined.
The activity initiation module may be configured to initiate a group activity. Once a group activity is initiated, the user group may be committed to the group activity. Initiation of a group activity may be triggered automatically. For example, progress through a game within the asynchronous virtual environment may bring the users to a certain point, hereafter referred to as a trigger point, at which a group activity may be used to advance (e.g., access additional content). Progression of a given user within the asynchronous virtual environment to the trigger point may cause the activity initiation module to initiate a group activity corresponding to the trigger point. Arrival at a trigger point may include being positioned at a virtual location within the asynchronous virtual environment, interacting with the asynchronous virtual environment in a predetermined manner, and/or other actions within the asynchronous virtual environment. A group activity may be triggered automatically at predetermined intervals (e.g., every day, at specific times of day, weekly, monthly, and/or other intervals).
The activity initiation module may be configured to initiate a group activity responsive to reception of a user selection indicating that the group activity should be initiated. The user selection may be received through a user interface provided to the user via a client computing platform. The user interface may be presented to a user responsive to the user reaching a trigger point in the asynchronous virtual environment. The user interface may be presented to a user responsive to a request from the user for a group activity.
At the initiation of a group activity by the activity initiation module, the activity initiation module may transmit an initiation message to users in the user group. The initiation message may indicate to the users in the user group that the group activity is beginning. The initiation message may convey some of the activity criteria to the users in the user group. The activity criteria conveyed in the initiation message may include one or more of group parameters (or other information identifying the user group), task parameters (or other information identifying the task), timing parameters, group participation parameters, consequence parameters, and/or other activity criteria. Transmission of the initiation message to the users may enable the individual users in the user group to accept or reject the group activity. The activity initiation module may be configured to receive the acceptances and/or rejections of the group activity by the users.
The group performance monitoring module may be configured to monitor the separate performances of (or attempts to perform) the task by the individual users in the user group. This may included receiving information related to performance of the task by the users from the environment module. Such information may include information generated by the client computing platforms and provided to the group performance monitoring module via the environment module, and/or information generated by the environment module during the group activity.
The activity evaluation module may be configured to evaluate performance of the group activity by the user group. Such evaluation may be based on the separate performances of the task by the individual users within the asynchronous virtual environment and the activity criteria. For example, the activity evaluation module may compare the separate performances of the task by the individual users to determine which (and/or how many) users performed the task according to timing parameters associated with the group activity. The activity evaluation module may then compare the number of users that performed the task according to the timing parameters to a threshold amount of users dictated by the group participation parameters. If the number of users that successfully performed the task according to the timing parameters reaches the threshold amount, the activity evaluation module may determine that performance of the group activity has been successful. If the number of users that successfully performed the task does not reach the threshold amount, then the activity evaluation module may determine that the attempt of the group activity has been unsuccessful. A successful performance of the group activity may require the user that initiated the group activity to successfully complete the task, if this is required in the activity criteria.
The activity consequence module may be configured to provide a consequence to the users in the user group based on the evaluation of performance by the activity evaluation module. The consequence may be provided in accordance with the consequence parameters included in the activity criteria. Responsive to the activity evaluation module determining that the group activity has been performed successfully, the activity consequence module may provide a reward to at least one user in the user group. The rewards provided to the users may include one or more of points, manna, virtual currency, access to content, acquired or enhanced skill or abilities, virtual goods, and/or other rewards. Responsive to the activity evaluation module determining that an attempt of the group activity has been unsuccessful, the activity consequence module may assess a penalty to at least one user in the user group. The penalties assessed to the users may include a decrease, reduction, or restriction of one or more of points, manna, virtual currency, access to content, acquired or enhanced skill or abilities, virtual goods, and/or other penalties.
These and other objects, features, and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a system configured to provide an asynchronous virtual environment to users, in accordance with one or more embodiments of the invention.
FIG. 2 illustrates a user interface configured to receive user selection or entry of a user group, according to one or more embodiments of the invention.
FIG. 3 illustrates a user interface configured to receive user selection or entry of users for a user group, in accordance with one or more embodiments of the invention.
FIG. 4 illustrates a user interface configured to receive user acceptance of a user activity, according to one or more embodiments of the invention.
FIG. 5 illustrates a method of providing an asynchronous virtual environment to users, according to one or more embodiments of the invention.
DETAILED DESCRIPTION
FIG. 1 illustrates a system 10 configured to provide an asynchronous virtual environment to a plurality of users. The system 10 may be configured to enable and/or encourage cooperative and even coordinated activity between users, despite the asynchronous nature of the virtual environment. This may enable system 10 to support coordinated group-based activities within an environment that is asynchronous between the users. Since asynchronous virtual environments tend to be less costly to provide to users (e.g., in processing capabilities, serving capabilities, bandwidth requirements, and/or other costs), system 10 may reduce the cost associated with a virtual environment in which users participate in cooperative activities.
In some implementations, system 10 may include one or more virtual environment servers 12 , and/or other components. The system 10 may operate in communication and/or coordination with one or more external resources 14 . Users may interface with system 10 and/or external resources 14 via client computing platforms 16 . The components of system 10 , virtual environment servers 12 , external resources 14 , and/or client computing platforms 16 may be operatively linked via one or more electronic communication links. For example, such electronic communication links may be established, at least in part, via a network such as the Internet and/or other networks. It will be appreciated that this is not intended to be limiting, and that the scope of this disclosure includes implementations in which virtual environment servers 12 , external resources 14 , and/or client computing platforms 16 may be operatively linked via some other communication media.
A given client computing platform 16 may include one or more processors configured to execute computer program modules. The computer program modules may be configured to enable one or more users associated with the given client computing platform 16 to interface with system 10 and/or external resources 14 , and/or provide other functionality attributed herein to client computing platforms 16 . By way of non-limiting example, the given client computing platform 16 may include one or more of a desktop computer, a laptop computer, a handheld computer, a NetBook, a Smartphone, a gaming console, and/or other computing platforms.
The external resources 14 may include sources of information, hosts and/or providers of virtual environments outside of system 10 , external entities participating with system 10 , and/or other resources. In some implementations, some or all of the functionality attributed herein to external resources 14 may be provided by resources included in system 10 .
The virtual environment servers 12 may be configured to provide the asynchronous environment to the users via client computing platforms 16 . This may include serving the asynchronous environment to the users. The virtual environment servers 12 may include electronic storage 18 , one or more processors 20 , and/or other components. The virtual environment servers 12 may include communication lines, or ports to enable the exchange of information with a network and/or other computing platforms.
Electronic storage 18 may comprise electronic storage media that electronically stores information. The electronic storage media of electronic storage 18 may include one or both of system storage that is provided integrally (i.e., substantially non-removable) with virtual environment servers 12 and/or removable storage that is removably connectable to virtual environment servers 12 via, for example, a port (e.g., a USB port, a firewire port, etc.) or a drive (e.g., a disk drive, etc.). Electronic storage 18 may include one or more of optically readable storage media (e.g., optical disks, etc.), magnetically readable storage media (e.g., magnetic tape, magnetic hard drive, floppy drive, etc.), electrical charge-based storage media (e.g., EEPROM, RAM, etc.), solid-state storage media (e.g., flash drive, etc.), and/or other electronically readable storage media. Electronic storage 18 may store software algorithms, information determined by processor 20 , information received from virtual environment servers 12 , information received from client computing platforms 16 , and/or other information that enables virtual environment servers 12 to function properly.
Processor(s) 20 is configured to provide information processing capabilities in system servers 14 . As such, processor 20 may include one or more of a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information. Although processor 20 is shown in FIG. 1 as a single entity, this is for illustrative purposes only. In some implementations, processor 20 may include a plurality of processing units. These processing units may be physically located within the same device, or processor 20 may represent processing functionality of a plurality of devices operating in coordination.
As is shown in FIG. 1 , processor 20 may be configured to execute one or more computer program modules. The one or more computer program modules may include one or more of an environment module 22 , an activity definition module 24 , activity initiation module 26 , a group performance monitoring module 28 , an activity evaluation module 30 , an activity consequence module 32 , and/or other modules. Processor 20 may be configured to execute modules 22 , 24 , 26 , 28 , 30 , and/or 32 by software; hardware; firmware; some combination of software, hardware, and/or firmware; and/or other mechanisms for configuring processing capabilities on processor 20 .
It should be appreciated that although modules 22 , 24 , 26 , 28 , 30 , and 32 are illustrated in FIG. 1 as being co-located within a single processing unit, in implementations in which processor 20 includes multiple processing units, one or more of modules 22 , 24 , 26 , 28 , 30 , and/or 32 may be located remotely from the other modules. The description of the functionality provided by the different modules 22 , 24 , 26 , 28 , 30 , and/or 32 described below is for illustrative purposes, and is not intended to be limiting, as any of modules 22 , 24 , 26 , 28 , 30 , and/or 32 may provide more or less functionality than is described. For example, one or more of modules 22 , 24 , 26 , 28 , 30 , and/or 32 may be eliminated, and some or all of its functionality may be provided by other ones of modules 22 , 24 , 26 , 28 , 30 , and/or 32 . As another example, processor 20 may be configured to execute one or more additional modules that may perform some or all of the functionality attributed below to one of modules 22 , 24 , 26 , 28 , 30 , and/or 32 .
The environment module 22 may be configured to provide the asynchronous virtual environment to users via client computing platforms 16 . As used herein, a “virtual environment” may include a virtual space, one or more interactive electronic media, and/or other virtual environments.
A virtual space may comprise a simulated space (e.g., a physical space) that is accessible by a client (e.g., client computing platforms 16 ) that presents a view of the virtual space to a user. The simulated space may have a topography, express ongoing real-time interaction by the user, and/or include one or more objects positioned within the topography that are capable of locomotion within the topography. In some instances, the topography may be a 2-dimensional topography. In other instances, the topography may be a 3-dimensional topography. The topography may include dimensions of the virtual space, and/or surface features of a surface or objects that are “native” to the virtual space. In some instances, the topography may describe a surface (e.g., a ground surface) that runs through at least a substantial portion of the virtual space. In some instances, the topography may describe a volume with one or more bodies positioned therein (e.g., a simulation of gravity-deprived space with one or more celestial bodies positioned therein). A virtual space may include a virtual world, but this is not necessarily the case. For example, a virtual space may include a game space that does not include one or more of the aspects generally associated with a virtual world (e.g., gravity, a landscape, etc.).
Within a virtual space provided by virtual environment servers 12 , avatars associated with the users may be controlled by the users to interact with the virtual space. As used herein, the term “avatar” may refer to an object (or group of objects) present in the virtual space that represents an individual user. The avatar may be controlled by the user with which it is associated. The avatars may move through and interact with the virtual space (e.g., non-player characters in the virtual space, other objects in the virtual space). The avatar associated with a given user may be created and/or customized by the given user. The avatar may be associated with an “inventory” of virtual goods and/or currency that the user can use (e.g., by manipulation of the avatar and/or the items) within the virtual space.
Interactive electronic media may include one or more of a social network, a virtual space, a micro-blogging service, a blog service (or host), a browser-based game, a mobile game, a file (e.g., image file, video file, and/or other files) sharing service, a messaging service, a message board, a forum, and/or other electronically distributed media that are scalable and enable interaction between users and the virtual environment.
As used herein, the term “asynchronous virtual environment” may refer to a virtual environment that is provided to the users individually such that each user is able to interact with the virtual environment (and view their own interactions) in real-time or near-real-time. However, the interactions of other users with the virtual environment may not be reflected in views of the virtual environment, at least not in real-time or near-real-time. As such, each user may be somewhat isolated within the virtual environment from the other users. Although the virtual environment may be the same, real-time interaction between the users within the virtual environment may not be possible.
It will be appreciated that the description of an “asynchronous virtual environment” above does not preclude some minimal level of awareness between the users of the activities of other users. For example, a user may be presented with the current “status” of other users in the virtual environment (e.g., present, absent, fighting, leveling, and/or other status information). The system 10 may facilitate communication between users. However, such communication may be ancillary to and/or separate from the virtual environment. For instance, system 10 may support chat and/or messaging features. This communication does not directly convey to the users the interactions of the other users with the virtual environment. As another example, a user may receive updates or notifications about the general progress or activities of other users within the virtual environment. But the interactions of the other users that resulted in the updates or notifications are not provided to the user within the virtual environment in a real-time, ongoing manner.
In some implementations, the asynchronous virtual environment may include an asynchronous virtual space in which the users separately and individually participate in a videogame. In order to participate in the videogame a user controls one or more objects (e.g., an avatar) within the virtual space to achieve game objectives. In the virtual space, the performance of the same or corresponding activities in the virtual space by others are not represented to the user. Instead, each user may appear to be “alone” in the virtual space, interacting with the topography, buildings, non-player characters, and/or other objects that are not controlled or influenced by other players.
The provision of the asynchronous virtual environment to the users by environment module 22 may be accomplished in cooperation with a client application that is executed on client computing platforms 16 . The client application may be a “fat” client, a “thin” client, and/or other types of client applications.
The client executed on client computing platforms 16 may provide a relatively large amount of the processing cost associated with presenting the asynchronous virtual environment to the user. For example, the client may create an instance of the asynchronous virtual environment locally on the client computing platforms 16 . The client executing on one of client computing platforms 16 may display views of the virtual environment that are obtained form the local instance of the asynchronous virtual environment. The client may provide information to environment module 22 related to the interactions of the user with the instance of the asynchronous virtual environment executed on the client computing platform 16 . The client may receive instructions or commands from environment module 22 regarding interactions of the virtual environment directed toward the user.
The client executed on client computing platforms 16 may provide a relatively small amount of the processing associated with presenting the asynchronous virtual environment to the user. For example, the environment module 22 may create instances of the asynchronous virtual environment on virtual environment servers 12 for the individual users. View information describing views of the instances may then be transmitted by environment module 22 from virtual environment servers 12 to client computing platforms 16 , where the corresponding views may be assembled from the view information and presented to the users by the client.
The activity definition module 24 may be configured to obtain activity criteria that define a group activity for a user group. The group activity may include a task (defined by the activity criteria) to be performed separately by users in the user group separately within their own instances of the asynchronous virtual environment. By way of non-limiting example, the task may include defeating a boss character, travelling to a checkpoint, learning a skill, opening a door or gate, pushing an obstacle, and/or other tasks. The activity criteria may include one or more of group parameters, task parameters, timing parameters, group participation parameters, consequence parameters, and/or other parameters.
The group parameters of a group activity may define the user group to be included in the group activity. As such, the group parameters may include identities, usernames, avatar names, and/or other identifiers of the user group to be included in the group activity. The group parameters may include group parameters that are predefined and/or predetermined. For example, a set of users may have previously formed a user group, and the group parameters may have been previously defined for this user group. A given user may belong to more than one such user group. As such, if the given user is going to initiate a group activity, the activity definition module 24 may be configured to receive a user selection from the given user of the user group for the group activity.
By way of illustration, FIG. 2 shows an exemplary user interface 34 configured to receive user selection of a user group for a group activity. The user interface 34 may be presented to a user through a client computing platform being used by the user to access the asynchronous virtual environment. The user interface 34 may include selectable predefined user groups 36 to which the user presented with user interface 34 belongs. The user interface 34 may include an indicator 38 for the user groups 36 indicating an amount of users in the individual user groups 36 that are currently participating in the asynchronous virtual environment. The indicator 38 may include, for a example, a number of active users, a percentage of active users, or other indicators of status or current participation in the asynchronous virtual environment. Responsive to reception of selection of a user group through user interface 34 , the group parameters for the selected user group may be obtained.
Referring back to FIG. 1 , activity definition module 24 may be configured such that a given user initiating an activity may select individual users to be included in a user group for the group activity. In such implementations, activity definition module 24 may obtain the group parameters by receiving the user selections. By way of illustration, FIG. 3 depicts an exemplary user interface 40 configured to receive user selections of individual users for inclusion in a user group. The user interface 40 may be presented to the user by a client computing platform being used by the user to access the asynchronous virtual environment. The user interface 40 may include fields 42 that receive selection and/or entry of individual users for inclusion in the user group. A status identifier 44 may be provided for the individual users that indicates whether the individual users are currently participating in the asynchronous virtual environment.
Turning again to FIG. 1 , the group parameters may be obtained by activity definition module 24 by defining a user group of users that are currently participating in the asynchronous virtual environment, and/or are at the same or a similar location within the asynchronous virtual environment. The activity definition module 24 may obtain the group parameters by determining the group parameters for the defined user group.
The task parameters of the group activity may define the task to be performed separately by the individual users in the user group. The task parameters may be obtained by activity definition module 24 from a predetermined set of tasks with previously defined task parameters. The task parameters may be obtained by activity definition module 24 by receiving user selection of one or more task parameters from a user initiating the group activity. For example, a user interface configured to receive user selection of one or more task parameters may be presented to users via client computing platforms 16 .
The timing parameters may dictate the timing with which the individual users in a user group attempting a group activity must separately perform the task. The timing parameters may specify a time window (e.g., an amount of time from initiation of the group activity) within which the task must be finished for performance to count toward accomplishment of the group activity. The timing parameter may specify a time window within which the task must be started for performance to count toward accomplishment of the group activity. The timing parameters may vary from group activity to group activity. The timing parameters may be specified in advance for a group activity.
The group participation parameters may dictate a threshold amount of users that must accomplish the task. Accomplishment of the task may require that the task be performed in accordance with the timing parameters for the group activity. The threshold amount of users dictated by the group participation parameters may include a fixed number of users, or an amount that varies based on one or more of how many users are in the user group, how many users in the user group are currently participating in the asynchronous virtual environment, how many users in the user group are in a position within the asynchronous virtual environment to attempt the task, and/or other considerations. Group participation parameters may be uniform across the asynchronous virtual environment. Group participation parameters may be specific to a group activity (e.g., predefined on a per-activity basis).
The consequence parameters may dictate the consequences of a successful attempt of a group activity. The consequence parameters may define a reward that may be provided to at least one of the users in the user group (e.g., the user that initiated the group activity, all of the users, and/or a subset of the users in the user group) as a consequence of successfully completing the group activity. The reward may include one or more of points, manna, virtual currency, access to content, acquired or enhanced skill or abilities, virtual goods, and/or other rewards. The consequence parameters may define a penalty that may be provided to at least one of the users in the user group as a consequence of unsuccessfully attempting the group activity. The consequence parameters for a group activity may be predetermined.
The activity initiation module 26 is configured to initiate a group activity. Once a group activity is initiated, the user group may be committed to the group activity. Initiation of a group activity may be triggered automatically. For example, progress through a game within the asynchronous virtual environment may bring the users to a certain point, hereafter referred to as a trigger point, at which a group activity may be used to advance (e.g., access additional content). Progression of a given user within the asynchronous virtual environment to the trigger point may cause activity initiation module 26 to initiate a group activity corresponding to the trigger point. Arrival at a trigger point may include being positioned at a virtual location within the asynchronous virtual environment, interacting with the asynchronous virtual environment in a predetermined manner, and/or other actions within the asynchronous virtual environment. A group activity may be triggered automatically at predetermined intervals (e.g., every day, at specific times of day, weekly, monthly, and/or other intervals).
The activity initiation module 26 may be configured to initiate a group activity responsive to reception of a user selection indicating that the group activity should be initiated. The user selection may be received through a user interface provided to the user via client computing platform 16 . The user interface may be presented to a user responsive to the user reaching a trigger point in the asynchronous virtual environment. The user interface may be presented to a user responsive to a request from the user for a group activity.
At the initiation of a group activity by activity initiation module 26 , activity initiation module 26 may transmit an initiation message to users in the user group. The initiation message may indicate to the users in the user group that the group activity is beginning. The initiation message may convey some of the activity criteria to the users in the user group. The activity criteria conveyed in the initiation message may include one or more of group parameters (or other information identifying the user group), task parameters (or other information identifying the task), timing parameters, group participation parameters, consequence parameters, and/or other activity criteria. Transmission of the initiation message to the users may enable the individual users in the user group to accept or reject the group activity. The activity initiation module 26 may be configured to receive the acceptances and/or rejections of the group activity by the users.
FIG. 4 illustrates a user interface 46 configured to receive acceptance of a group activity by a user. The user interface 46 may be presented to a user via a client computing platform on which the user may access an asynchronous virtual environment. As can be seen in FIG. 4 , user interface 46 may include a view 48 of the asynchronous virtual environment, an activity interface 50 , and/or other components. The activity interface 50 may include an acceptance field 52 configured to receive selection or entry of acceptance of a group activity corresponding to the activity interface 50 . The activity interface 50 may present information about the group activity to the user. For example, such information may include a title of the group activity and/or activity criteria defining the group activity. The activity interface 50 may be presented to a user initiating the group activity (e.g., by user selection and/or through progress to a trigger point). The activity interface 50 may be presented to a user as an initiation message requesting the user's participation in a group activity initiated by another user.
Referring back to FIG. 1 , group performance monitoring module 28 may be configured to monitor the separate performances of (or attempts to perform) the task by the individual users in the user group. This may included receiving information related to performance of the task by the users from environment module 22 . Such information may include information generated by client computing platforms 16 and provided to group performance monitoring module 28 via environment module 22 , and/or information generated by environment module 22 during the group activity.
The activity evaluation module 30 may be configured to evaluate performance of the group activity by the user group. Such evaluation may be based on the separate performances of the task by the individual users within the asynchronous virtual environment and the activity criteria. For example, activity evaluation module 30 may compare the separate performances of the task by the individual users to determine which (and/or how many) users performed the task according to timing parameters associated with the group activity. The activity evaluation module 30 may then compare the number of users that performed the task according to the timing parameters to a threshold amount of users dictated by the group participation parameters. If the number of users that successfully performed the task according to the timing parameters reaches the threshold amount, activity evaluation module 30 may determine that performance of the group activity has been successful. If the number of users that successfully performed the task does not reach the threshold amount, then activity evaluation module 30 may determine that the attempt of the group activity has been unsuccessful. A successful performance of the group activity may require the user that initiated the group activity to successfully complete the task, if this is required in the activity criteria.
The activity consequence module 32 may be configured to provide a consequence to the users in the user group based on the evaluation of performance by activity evaluation module 30 . The consequence may be provided in accordance with the consequence parameters included in the activity criteria. Responsive to activity evaluation module 30 determining that the group activity has been performed successfully, activity consequence module 32 may provide a reward to at least one user in the user group. The rewards provided to the users may include one or more of points, manna, virtual currency, access to content, acquired or enhanced skill or abilities, virtual goods, and/or other rewards. Responsive to activity evaluation module 30 determining that an attempt of the group activity has been unsuccessful, activity consequence module 32 may assess a penalty to at least one user in the user group. The penalties assessed to the users may include a decrease, reduction, or restriction of one or more of points, manna, virtual currency, access to content, acquired or enhanced skill or abilities, virtual goods, and/or other rewards.
The activity consequence module 32 may be configured to provide the same consequence to all of the users in the user group that receive a consequence. The activity consequence module 32 may be configured to provide different consequences to the users in the user group. For example, responsive to activity evaluation module 30 determining that the group activity has been successfully performed, activity consequence module 32 may be configured to provide a primary reward to the user that initiated the group activity and a secondary reward to other ones of the users in the user group. Responsive to an unsuccessful attempt of the group activity, activity consequence module 32 may be configured to assess a primary penalty to the user that initiated the group activity and a secondary penalty to other ones of the users in the user group.
In some implementations, a group activity may include at least some activity criteria that are predetermined within the virtual environment. Users may participate in this group activity more than once. The activity consequence module 32 may be configured to provide, responsive to activity evaluation module 30 determining that this group activity has been successfully performed, a first reward to users in the user group that have not previously successfully performed the group activity and a second reward to users in the user group that have previously performed the group activity.
During a group activity, not all of the users in the user group may attempt the task. For some of the users may not be present in the asynchronous virtual environment, may not be in a position within the asynchronous virtual environment to attempt the task, may not have an interest in the group activity, and/or may not attempt the task for other reasons. The activity consequence module 32 may be configured to provide, responsive to activity evaluation module 30 determining that the group activity has been successfully performed, a first reward to users in the user group that have attempted the task. A second reward may be provided to users in the user group that have not attempted the task. The first reward or the second reward may be no reward. The activity consequence module 32 may be configured such that responsive to an unsuccessful attempt of the first activity, a first penalty may be assessed to users that attempted the task, while a second penalty may be assessed to users that did not attempt the task. The first penalty or the second penalty may be no penalty.
During a group activity, not all of the users in the user group may successfully perform the task. The activity consequence module 32 may be configured to provide, responsive to activity evaluation module 30 determining that the group activity has been successfully performed, a first reward to users in the user group that have successfully performed the task and a second reward to users in the user group that have not successfully performed the task. The first reward or the second reward may be no reward. The activity consequence module 32 may be configured such that responsive to an unsuccessful attempt of the first activity, a first penalty may be assessed to users that successfully performed the task, while a second penalty may be assessed to users that did not successfully perform the task. The first penalty or the second penalty may be no penalty.
In some implementations, activity consequence module 32 may be configured such that the rewards and/or penalties provided to the users based on group activity performance may scale with the number of users that successfully performed the task. The more users in the user group that successfully perform the task, the greater the rewards provided to the users for a successful performance of the group activity may be. The more users in the user group that successfully perform the task in a failed attempt of a group activity, the smaller the penalties assessed to the users in the user group may be.
FIG. 5 illustrates a method 54 of providing an asynchronous virtual environment to users, in which cooperation between the users is enabled and/or encouraged. The operations of method 54 presented below are intended to be illustrative. In some embodiments, method 54 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 54 are illustrated in FIG. 5 and described below is not intended to be limiting.
In some embodiments, method 54 may be implemented in one or more processing devices (e.g., a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information). The one or more processing devices may include one or more devices executing some or all of the operations of method 54 in response to instructions stored electronically on an electronic storage medium. The one or more processing devices may include one or more devices configured through hardware, firmware, and/or software to be specifically designed for execution of one or more of the operations of method 54 .
At an operation 56 , views of the asynchronous virtual environment may be provided to the users. The views of the asynchronous virtual environment may include views of separate instances of the asynchronous virtual environment for the individual users. In some implementations, operation 56 may be performed by an environment module similar to or the same as environment module 22 (shown in FIG. 1 and described above).
At an operation 58 , a determination may be made to initiate a group activity within the asynchronous virtual environment. The determination may be made based on user selection and/or based on a user arriving at a trigger point in the asynchronous virtual environment. Arrival at a trigger point may include being positioned at a virtual location within the asynchronous virtual environment, interacting with the asynchronous virtual environment in a predetermined manner, and/or other actions within the asynchronous virtual environment. The determination may be made based on a predetermined time interval (e.g., every day, at specific times of day, weekly, monthly, and/or other intervals). In some implementations, operation 58 may be performed by an activity initiation module similar to or the same as activity initiation module 26 (shown in FIG. 1 and described above).
At an operation 60 , activity criteria defining the group activity may be obtained. The activity criteria may include one or more of group parameters, task parameters, timing parameters, group participation parameters, consequence parameters, and/or other criteria. Obtaining the activity criteria may include one or more of receiving user selection and/or entry of activity criteria, accessing previously stored activity criteria, determining activity criteria, and/or other forms of obtaining criteria. In some implementations, operation 60 may be performed by an activity definition module similar to or the same as activity definition module 24 (shown in FIG. 1 and described above).
At an operation 62 , acceptance of the group activity may be received from one or more of the users in the user group. The users may include the user that initiated the group activity and/or other users in the user group. In some implementations, operation 62 may be performed by an activity initiation module similar to or the same as activity initiation module 26 (shown in FIG. 1 and described above).
At an operation 64 , separate performances of a task within the asynchronous virtual environment by the users in the user group may be monitored. The task may be a task associated with the group activity. The task may be defined by the activity criteria. The users in the user group may perform the task separate from other users within their own view(s) of the asynchronous virtual environment. In some implementations, operation 64 may be performed by a group performance monitoring module similar to or the same as group performance monitoring module 28 (shown in FIG. 1 and described above).
At an operation 66 , performance of the group activity by the user group may be evaluated. Evaluation of the performance of the group activity may be based on the separate performances (and/or attempts to perform) the task by the individual users in the user group and the activity criteria. In some implementations, operation 66 may be performed by an activity evaluation module similar to or the same as activity evaluation module 30 (shown in FIG. 1 and described above).
At an operation 68 , consequences of the group activity may be provided to at least one of the users in the user group. Responsive to the user group successfully performing the group activity, at least one user in the user group may be provided with a reward. Responsive to the user group unsuccessfully performing the group activity, at least one user in the user group may be assessed a penalty. In some implementations, operation 68 may be performed by an activity consequence module similar to or the same as activity consequence module 32 (shown in FIG. 1 and described above).
Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment. | An asynchronous virtual environment may be provided to users in which synchronous, time-sensitive cooperation between the users is enabled in spite of the asynchronous nature of the virtual environment. Synchronous, time-sensitive cooperation between users may have an impact on gaining and/or retaining users in a virtual environment, such as a videogame or virtual space. For example, such cooperation between users may strengthen a sense of group, community, and/or camaraderie between cooperating users. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. application Ser. No. 11/614,811, filed Dec. 21, 2006, which is a nonprovisional of U.S. application Ser. Nos. 60/752,980, filed Dec. 21, 2005 and 60/755,897, filed Dec. 30, 2005, the entire disclosure of which are herein expressly incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to the field of self-validating documents in supply chain management, documentation services, method and data processing system for creating the same.
[0003] Millions of documents are passed in global commerce between supplier and recipient containing control statements within certification documents, such as for the safe use and handling of a product or its compliance with applicable restrictions. Studies have shown a high rate of error in such documents.
[0004] Global trade in products between a supplier and a customer depends upon the control statements made in certification documents, such as Material Safety Data Sheets and Safety Data Sheets (MSDS or SDS), letters of certification or compliance certifications, because such control statements define the parameters of use of the product. For example, an MSDS for a hazardous substance or formulation, has become the common means by which the supplier communicates to the customer the controls necessary for safe handling of the product as well as its compliance with applicable restrictions whether in the U.S. at the federal or state level, or the requirements of another country or international convention.
[0005] With regard to other types of products, a letter of certification or compliance certification document, from the supplier of food and consumer products contains control statements that communicate requirements applicable to the use of the product. For instance, a certification document might accompany the supplier's shipment of a food packaging material to stipulate that the product could be used only with certain types of foodstuffs under the requirements of the Food and Drug Administration or similar governmental agencies of other countries. Such certifications may relate to regulations, standards, religious codes (e.g., keeping Kosher), scientific studies and the like. Millions of such documents are generated and transmitted every year in many different languages and countries for many different types of products and uses.
[0006] In many cases such documents are a compilation of standard control statements defining various parameters of use of the product. It is common for such documents to be prepared and generated using a document authoring system or enterprise resource planning (ERP) system such as SAP from a phrase library that may have different language variants.
[0007] However, although the recipient of a generated certification document has the control statements for the product, he is not able to obtain or validate the source document supporting a control statement in an automatic way. Nor can the recipient automatically determine whether a change relevant to a control statement in the received certification document might have occurred from the time of the document's creation.
[0008] Moreover, the recipient may wish to use the product in a different market or area of the world, and is unable to relate the control statements relevant in one jurisdiction to parameters of use in other jurisdictions or areas. Independently of the supplier's certifications the recipient may also simply wish to review the control statements in a certification document to determine whether information is missing or for which he requires additional information by reviewing the source document of such a statement. Finally, the recipient may wish to relate the general information conveyed about the product in the received document to information about a specific shipment of that product received from the supplier where the shipment has, for example, a particular RFID code. This last aspect is especially important where a product recall or alert has occurred for specific shipments of a product.
[0009] It is desirable, therefore, to provide a data processing system to support the automatic validation of control statements made about products flowing through the supply chain. Normally, validation of a control statement is done as a manual task by the recipient. Providing a data processing system for such information will improve the safety of products in the supply chain, will improve the transparency of global product requirements, will reduce cost of product approval, and will reduce mistakes.
[0010] It is also desirable for the customer to validate the control statements of the supplier whenever possible through an automatic data processing system. Although the customer must legally rely on the statements of the supplier, a prudent customer may wish to independently validate such a certification by looking up the reference to determine that it is current or to assure himself or herself that important omissions have not been made.
[0011] The communication of control statements is not simply a one-to-one relationship between a supplier and a customer, but rather between a many-to-one relationship of multiple upstream suppliers in a supply chain with the customer. The customer may receive a certification document with control statements that depend upon the specific claims of an upstream manufacturer of raw materials used by the immediate supplier of the customer; however, the upstream manufacturer may be unwilling to disclose important source information to the immediate supplier without a non-disclosure agreement, because of claims of confidentiality or trade secrecy.
[0012] For example, a manufacturer of a plastic sells to a small converter that produces formed cups to a yogurt food processor. The small converter may provide certifications, but these depend on the materials used in the conversion process. Often it is not the certification statement itself that is confidential; rather it is the source document supporting the statement that is confidential (e.g., test results or toxicological study). Thus, the yogurt food processor has a critical need to be assured of claims or compliance certifications that include both the immediate supplier and the upstream raw material suppliers. The need of the customer is to validate control statements of the immediate supplier as well as—to the extent permitted by the upstream supplier and under terms agreed to by the customer—the control statements passed through the supply chain from upstream manufacturers that concern raw materials or other conditions important to the immediate customer's use of the received product.
[0013] Many such certification documents transmitted by suppliers to customers—important though they are—contain omissions or errors. Indeed, according to a recent study of the completeness of safety data sheets: “The deficiencies for the different headings [that is, of the 16 sections of a standard format MSDS] vary between twenty percent and forty percent”. ECLIPS: “European Classification and Labeling Inspections of Preparations, including for Safety Data Sheets”, Final Report 2004 published by the European Enforcement Network, page 11. In consequence, the control statements made in the safety data sheets reviewed in the study have deficiencies that may include missing control statements, out-of-date control statements, or other errors. Further, according to the report, the error rates of regulatory statements in section fifteen of the MSDS, where required regulatory certification statements are made, averaged 35%. Ibid. Similar findings have resulted from Canadian studies. Welsh M. S.; Lamesse M.; Karpinski E. The Verification of Hazardous Ingredients Disclosures in Selected Material Safety Data Sheets.” Applied Occupational and Environmental Hygiene, Volume 15, Number 5, 1 May 2000, pp. 409-420(12). OSHA has performed studies of MSDS quality:
Based on the chemical ingredients identified, the accuracy in the other four areas of concern was evaluated based on information obtained from readily available reference sources. The evaluation indicated that 37% of the MSDSs examined accurately identified health effects data, 76% provided complete and correct first aid procedures, 47% accurately identified proper personal protective equipment, and 47% correctly noted all relevant occupational exposure limits. Only 11% of the MSDSs were accurate in all four information areas, but more (51%) were judged accurate, or considered to include both accurate and partially accurate information, than were judged inaccurate (10%). (Found at the world wide web address osha.gov/dsg/hazcom/finalmsdsreport.html).
[0015] Given the importance of such certification documents and the control statements that they contain to the safety of the recipient, means to improve accuracy, as addressed in the present invention should be established. A number of studies agree: Error rates in supplier certification statements are high.
[0016] In the area of food safety, FDA has established processes for review of hazards: Hazard Analysis and Critical Control Point (HACCP). Nevertheless frequent reports appear where a food processor has purchased a material that contains a contaminant not reviewed adequately.
[0017] The probability of error between supplier and customer increases with the volume of certification documents and the number of suppliers. In chemical-using industries, the number of raw materials for a single manufacturer can be thousands or tens of thousands and the number of suppliers in the hundreds or thousands. The same holds true in the food-processing and food-related industries. As a result there is an essential need to improve methods of validation of supplier's statements and to monitor important changes that may have occurred that relate to the supplier's statements.
[0018] It is true that the supplier may have proprietary evidence to support a certification and may not have revealed the full composition of a formulation under restrictions on the disclosure of confidential business information, in which case an independent evaluation is limited. Nevertheless, the customer can perform many checks based on the information presented by the supplier, and may as a standard practice adopt a review and validation of a supplier's certification statement.
[0019] Further, apart from any regulatory requirements, a number of industries have established their own internal standards that must be met in any procurement of raw materials by the company. For example, Volvo has established: VOLVO Corporate Standard STD 1009, 11 (Established February 1998) CHEMICAL SUBSTANCES WHOSE USE WITHIN THE VOLVO GROUP SHALL BE LIMITED (VOLVO'S GREY LIST).
[0020] Such ad hoc customer procurement standards that are in addition to any mandatory governmental requirement and accepted only in the face of market pressure have become widely accepted in part because of the difficulties and high error rates in certification documents being passed in the supply chain between supplier and customer. In addition, these standards are subject to change without notice. Such ad hoc standards increase the cost of compliance and its complexity, and reflect the need for an improved method of producing, distributing, and validating certification documents in the supply chain.
[0021] A customer has several validation needs:
Accuracy and Currency. Has the supplier correctly cited a supporting reference related to the safe handling of a product and is it current? Access to Source Documents. Can the customer obtain the cited reference? Access to Cited References. How can the customer obtain a cited sub-reference within the cited document? Completeness. Are there other related restrictions or references that have been omitted or overlooked? Global Scope. Are there similar restrictions in other countries or languages? Customer's Use vs. Supplier's Scope. Are there other restrictions that apply to the customer's use in another market, but which the supplier has not directly addressed in the certification that are nonetheless critical to the customer (e.g., the customer purchases a product in the U.S., and receives a U.S. certification document but intends to use it as a component or trans-ship it to another country)? Change Management Regarding Supplier Statements. After a period of time subsequent to the first receipt of the certification how can the customer be informed if an important amendment or modification has occurred related to a certification for the product that the customer has purchased? Again, although many regulations require the automated updating of MSDS or other certifications in the event of a “significant” regulatory change, many recipients seek to independently review supplier information. Change Management with Regard to Customer's Uses. After a period of time subsequent to the first receipt of the certification how can the customer be informed of other related changes of interest but not provided by the supplier that may affect the customer's use of the product, for example, in a country to which transshipment occurs? Upstream Supplier Certifications. Access to upstream supplier certifications relating to the immediate supplier's product or changes in these certifications under authorized terms and conditions acceptable to the upstream supplier.
[0031] Today, suppliers and customers seek to establish checks within their business processes and to establish review systems within their organizations, but it is prone to error and oversight especially in light of the complexity of global markets. The reason is straightforward: These review systems are separated from the certification document itself. The present invention provides a data processing system to support automatic validation and addresses this need.
[0032] There are many ways in which suppliers generate such certification documents either manually or by automated means within a system. For example, enterprise resource planning systems (ERP's) such as that of SAP (e.g., SAP EH&S) assist suppliers in automatically generating MSDS.
[0033] The components of such systems often include:
A composition database containing products and detailed composition and raw materials Properties tables or databases containing associated values, classifications, and restrictions applicable to substances and properties. Such property tables may also include the automated calculations from business rules; Phrase libraries—sometimes with translations of phrases—that contain control statements to be included in generated documents; Transaction control tables that include data that prevents or alerts the potential shipment, purchase, import, export, or sale of a product that may be forbidden; Document databases that include the generated documents or other documents that may be associated with a product, substance, or process; and, Business rule tables with conclusions (Left Hand Side—LHS) actions that depend on criteria (Right Hand Side—RHS parameters). For example, if benzene is a component in a formulation greater than 0.1 percent used in the United States, then insert the phrase code associated with the conclusion “carcinogenic” into the properties table for this substance identifier.
[0040] There are a number of current limitations in such systems:
ERP and document authoring systems as SAP EH&S, do not today include a dynamic component, such as a hyperlink, in phrase libraries of control statements used in the creation of certification documents, one that permits the recipient to validate a control statement within a received document in an automatic manner; ERP and document authoring systems do not provide for validation of control statements through automatic means in generated certification documents for products from within the generated documents; Although it is common for a manufacturer to hyperlink from a product listing on a web-site page to a related MSDS or technical document associated with the product, for example, it does not exist that the control statements in the certification document hyperlink to the authoritative source document for that statement or data element. Data processing systems do not exist to pass certification documents containing dynamic control statements with hyperlinks in business-to-business exchange of such between computer systems in computer readable form so that the control statements with hyperlinks can be extracted and placed in a database for further use. As a result, such data processing systems do not today allow the generation of certification documents that permit automated third-p arty validation and change management support services in association with control statements made. Such data processing systems do not use the loading and storage of certification documents with control statements using hyperlinks. It is not possible to obtain direct access to upstream manufacturer control statements or certification documents as described through a central service and no general practice or data processing system exists to provide this information.
[0048] One of the most difficult tasks of regulatory managers within supplier and customer organizations is keeping up with new or modified regulations or standards. Such compliance tracking tasks focus on the raw materials purchased, the substances manufactured, the processes themselves, or the products sold or distributed. The regulatory manager may use enterprise systems, subscribe to publications, participate in trade organizations, or search the web for information about change.
[0049] Equally difficult is the task of determining or obtaining upstream raw material certifications for products obtained from the immediate supplier.
[0050] It is desirable, therefore, to provide the capability for such a regulatory manager to validate a dynamic control statement within a certification document by a hyperlink to the source document supporting the control statement. In addition, it is desirable to provide the capability for the recipient of a certification document to determine by clicking a hyperlink whether amendments, new requirements, or modifications that pertain to a control statement have occurred for a given period of time, for example, since the time that the certification document was generated.
[0051] It is desirable, therefore, to provide a system by which a recipient's computer system can receive a certification document with its control statement from an upstream supply chain actors in such a manner that the recipient can store and re-use these control statements in authoring a further certification document for a product where the parameters of use are dependent on the control statements of the upstream supplier. Further, the downstream recipient does not have a system by which he can validate the control statements of the upstream provider, if authorized.
[0052] There are many services where you can enroll to receive updates of journals, regulations with customized scope defined by the user. Such services include:
Westclip on Westlaw ECLIPSE on Lexis/Nexis U.S. Federal Register
[0056] However, the regulatory manager, researcher, or document recipient is interested in changes that relate to the context of the certification document and a particular control statement within it, which at present means that the process of analyzing the control statements within a certification document is separate from and totally independent of the process of tracking changes. The complexity and discontinuity of these two important processes—receiving the certification document and determining changes that relate to such a document's control statements—increase the probability of accidental non-compliance.
[0057] In addition to the data processing system for self-validation of certification documents, it is desirable for the researcher to obtain relevant documents from a searching or indexing system that will return a compilation of documents that includes not only direct references to the search term for a material but also a synonym, identifier, translation, or reference to a class or group containing the search term as a member. It is also desirable if the document reference from such a search will return the document opened at the relevant page with the applicable direct reference, synonym, identifier, translation, or reference to a class or group containing the search term as a member. Finally, it is desirable if the researcher can obtain a subset of documents, for example, only those that have changed where the returned reference is to a document containing not only a direct reference, but also a synonym, identifier, translation, or reference to a class or group containing the search term as a member.
[0058] Publishers maintain large libraries of abstracts of knowledge in various areas related to science and business, among other fields. One example is the ILLUMINA® system published by CSA and another is SCOPUS® by Reed-Elsevier. Although such systems may contain links to the full-text documents associated with an abstract, they do not include either the search capabilities or validation system as described in this invention.
[0059] Referring now to FIG. 12 , an example prior art search from Google® illustrates the need. In this instance, the researcher has searched for a material, specifically, a chemical, which is “crotonic acid”. Google® returns two thousand five hundred and twenty (2,520) document references. Entering a synonym, “(E)-2-Butenoic acid” returns only twenty-two (22) document references. A Dutch synonym, “Crotonzuur” returns no hits and the message: “Try different keywords”. This search illustrates both a searching display and a searching index that does not return document references that include a compilation of not only direct references, but also synonyms or translations of a material term. This is a common approach of existing search displays and indexing methods, for example, Google®, SCOPUS®, ILLUMINA®, and others.
[0060] In searching for documents relevant to a material, the research is often interested in documents that include a reference to a class of which the search term is a member. For example, if the user enters the term, “crotonic acid”, he or she may be interested in a document that refers to “Ungesättigte aliphatische Mono- and Dicarbonsäuren” because the meaning of this chemical class with many members includes the specific substance, crotonic acid. Similarly, if the user searches for “sodium chromate”, the user would be interested in documents that include a reference to “hexavalent chromium compounds”. Such indirect references to broad classes including the direct search term are not returned by the example searches above of Google®.
[0061] The search term and interest in a reference to a broad group may not necessarily be a chemical, but also a foodstuff, biologic, or formulation. A comprehensive search for the term, “orange”, according to the present invention, should return a link to a document including a reference to “citrus fruits, except lemon and limes”. Current search systems may return synonyms, (e.g., TOXNET) and may include related identifiers and translations of substance names, but do not include a systematic cross-referencing system for such; nor do they include parent classes within the context of the regulation or referenced document.
[0062] An identifier for a material is a particular type of synonym. Many such identification systems are used by regulatory or scientific organizations, where an alphanumeric code represents a material. For example, the European Union uses EINECS numbers to refer to existing chemicals. FDA has its own system, as do the governments of Japan and Korea. Other systems, include color index numbers, etc. It is desirable to provide a system and method that spans any identifier returning documents that include a reference, whether that reference is a synonym, translation, parent group or class, or identifier in addition to any direct reference.
[0063] Web-based search engines do not include such features whether in the simultaneous display of document links containing references to synonyms, translations, identifiers, and parent groups in addition to direct references or whether in methods used to index documents to extract references to such terms.
[0064] Current systems, including those noted above, do not:
Search with the scope and methods described above or in this invention; nor Return a document opened at the relevant page with the term highlighted.
SUMMARY OF THE INVENTION
[0067] One embodiment of the present invention includes a system for validating at least a portion of a certification document for at least one material. The system includes a certification document including at least one dynamic control statement relating to and defining parameters of use for the at least one material, wherein the certification document is accessible by at least one recipient, and, wherein the dynamic control statement is validated by retrieving validation information relating to the dynamic control statement from a dynamic source of validation information.
[0068] Another embodiment of the present invention includes a method for indexing documents in a data processing system, the documents including a reference to at least one material, comprising: inputting a document into the data processing system; extracting at least one alphanumeric string from the document; determining relevant alphanumeric strings from the extracted alphanumeric strings by processing the extracted alphanumeric strings utilizing at least one algorithm by comparing, in sequence and in combination, the extracted alphanumeric strings with material terms in at least a dictionary database of common material terms; matching the relevant alphanumeric strings with materials alphanumeric strings stored in the data processing system; and storing the matched alphanumeric strings in respective matched records in the data processing system.
[0069] Another embodiment of the present invention provides methods for generating, distributing, validating, and searching documents about products that include standardized phrases that are claims made about the compliance of the product with guidelines, standards, and laws or that are properties of the product supported by a bibliographic reference to a literature reference.
[0070] Yet another embodiment of the invention provides for a database of standard phrases (hyperlinked standard phrase database) each with its own with unique identification code, a text phrase that defines a specific claim or statement, optional translated variants of the text phrase in a one-to-one relationship to the unique identification code, and a hyperlink to a server that can retrieve a document or translation supporting the specific claim made by the standard phrase. In this manner, the Hyperlinked Standard Phrase Database can be distributed and used by many parties in the supply chain so that any document generated that includes the phrase will have a standard meaning and any recipient of the document can validate the statement through clicking on the hyperlink.
[0071] Another embodiment of the invention provides for the Hyperlinked Standard Phrase Library Database including a hyperlink that will return an index, compilation or reference to all changes in the source documents relating to the statement.
[0072] A further aspect of the method above is that it allows the author of the document to use a standard enterprise resource planning system (ERP), such as SAP, Oracle, or other document authoring system to include standard phrases from the phrase database as well as his or her own phrases in a flexible manner so that the document can contain a combination of phrases that are standard, other phrases from upstream suppliers of raw materials, and phrases inserted by the document's author. The standard phrases can be selected based on need by the document's author in a completely free and flexible manner. What is new is that the standard phrase will have a hyperlink to a document or function retrieving the relevant text. In addition, the standardization of the hyperlinks permits the recipient of a document in any form that accepts hyperlinks to retrieve source documents associated with a claim from a centralized service that can route and retrieve hyperlinked source documents from any server wherever located.
[0073] A further aspect of the method above is that it allows for a system of user authorization associated with standard phrases contained in generated product documents. In this manner, an upstream supplier can pass to his direct customer a statement with a hyperlink to a secure server open only to authorized users. Let us suppose that the statement is public but the source documents supporting the claim are confidential. Thus, the customer can include the statement in an authored document and distribute the document to his downstream customers, but the control to open access to the confidential supporting document is controlled by the provider of the standard phrase.
[0074] Another embodiment of the present invention also relates to a method for indexing documents including a description of at least one material in a data processing system. The method includes inputting a document into the data processing system; extracting at least one alphanumeric string from the document; determining relevant alphanumeric strings from the extracted alphanumeric strings by processing the extracted alphanumeric string utilizing at least one algorithm by comparing, in sequence and in combination, the extracted alphanumeric strings with material terms in at least a dictionary database of common material terms; matching the relevant alphanumeric strings with materials alphanumeric strings stored in the data processing system; and storing the matched alphanumeric strings in respective matched records in the data processing system.
[0075] Another embodiment of the present invention provides methods for searching document management systems and an improved means of efficiently locating, searching, and categorizing documents stored on Internet web-sites to enable identification and cross-referencing of references to dangerous chemicals within documents in any language.
[0076] One aspect of the present invention provides for post-processing of identified documents to permit a document to be opened at a relevant page with the term of interest highlighted, and in the integration of found documents into a validation system supporting certification documents transmitted between supplier and recipient.
[0077] Another aspect of the present invention provides a validation that can be established from within the document itself in an analogous manner to the checks that occur in giving a credit card to a merchant in order to effect a purchase. A third-party service supports the security of the transaction between merchant and customer that reduces fraud and improves the efficient functioning of markets—based on the credit card itself.
[0078] Another aspect of the present invention provides a review system and related validation technologies based on the certification document itself.
[0079] One aspect of the present invention provides for a system of self-validating documents with independent validation support services. Another aspect of the present invention provides a self-validating certification documents passed between supplier and recipient based on standard phrases to be included in such documents together with validation hyperlinks that invoke a series of services, including: a) the retrieval of a cited document opened at a referenced page with a highlighted section associated with a material, material class, topic, use, or legal citation; b) the retrieval of summary reports of all requirements related to the standard certification phrase; c) the retrieval of all amendments, additions, and deletions of requirements related to the certification phrase; d) the retrieval of related property data records that may be automatically loaded into a document management or enterprise resource planning system; and e) the retrieval of transaction control alerts. One embodiment of the present invention provides for the generation indexing, extraction, and formation of documents containing validation links
[0080] Another aspect of the present invention provides a system of self-validating documents through which a downstream recipient of a certification document can assure himself of upstream certifications related to the submission of the immediate supplier in a confidential manner acceptable to an upstream supplier. Another aspect of the present invention provides self-validating certification documents passed to the validation service by the upstream supplier, including a standard phrase, a validation hyperlink to the source document, and an authorization procedure. If the downstream user accepts or meets the conditions of the authorization procedure, a series of services are made available that relate to the upstream certification in the context of the immediate supplier's product or use, including: a) the retrieval of a cited upstream supplier document opened at a referenced page with a highlighted section associated with a material, material class, topic, use, or legal citation; b) the retrieval of summary reports of all requirements related to the standard certification phrase, including the supplier's confidential certification statements; c) the retrieval of all amendments, additions, and deletions of requirements related to the certification phrase, including the upstream supplier's confidential certifications; d) the retrieval of related property data records that may be automatically loaded into a document management or enterprise resource planning system, including upstream supplier data; and e) the retrieval of transaction control alerts, including transaction control alerts that relate to the upstream supplier's certifications.
[0081] Another aspect of the present invention provides for the generation indexing, extraction, and formation of documents containing validation links.
[0082] Yet another aspect of the present invention provides that the user to search for a standard synonym and return a highlighted reference to a literal reference on the page of a document, which provides the capability to link proper synonyms to literal names found within the text of a document that may not be “acceptable”, as well as the ability to link in synonyms based on confidential upstream supplier references.
[0083] Another aspect of the present invention provides linking not only to sets of chemical substances but to any “material” that may not be chemicals in the proper sense at all that may be biological agents, products, or concepts (‘sweeteners’), including but not limited to confidential upstream supplier materials.
[0084] Another aspect of the present invention provides a system of self-validating documents including direct submissions between a supplier and a recipient as well as multiple party submissions through a chain of supplier-user relationships.
[0085] An aspect of the invention provides for supporting the validation system in its method to search and index documents in order to extract references to materials, material classes, and legal citations.
[0086] An aspect of the invention provides for supporting the validation system through access to upstream supplier certifications or certification documents through an authorization system.
[0087] Additional objects and advantages of the present invention will be apparent in the following detailed description read in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0088] FIG. 1 is a block diagram of a system for validating certification documents according to one embodiment of the present invention.
[0089] FIG. 1A is a block diagram of a system for validating certification documents according to one embodiment of the present invention.
[0090] FIG. 2 is a block diagram of an alternative embodiment of the system of the present invention.
[0091] FIG. 3 is a chart illustrating an example of a hyperlinked standard phrase library of the system of one embodiment of the present invention.
[0092] FIG. 4 is a diagram of a certification document including a dynamic control statement according to one embodiment of the present invention.
[0093] FIG. 5A is a block diagram of a data processing system according to one embodiment of the present invention.
[0094] FIGS. 5B and 5C are flowcharts of a method for indexing documents in a data processing system according to one embodiment of the present invention.
[0095] FIG. 6 is a diagram of a database produced by the method for indexing documents of one embodiment of the present invention.
[0096] FIG. 7 is a diagram of a result of a search for a chemical term according to one embodiment of the present invention.
[0097] FIG. 8 is a diagram showing an alphanumeric string in a document to be indexed utilizing the method of one embodiment of the present invention.
[0098] FIG. 9 is a chart illustrating a materials database of one embodiment of the present invention; and
[0099] FIG. 10A is a block diagram of an alternative embodiment of a data processing system described herein.
[0100] FIGS. 10B and 10C are flowcharts of an alternative embodiment of a method for indexing documents in a data processing system described herein.
[0101] FIG. 11 is a diagram showing a materials database of one embodiment of the present invention.
[0102] FIG. 12 is a diagram showing results of a search for a materials term according to the prior art.
DETAILED DESCRIPTION OF THE INVENTION
[0103] “certification document”—As used in this invention, a certification document comprises: A purchase order, advanced shipment notice, shipping document, material safety data sheet, compliance certification statement, customer procurement standard, compliance statement, technical dossier, label, guideline, legislation, regulation, and standard as well as any document, submission, or compilation required for REACH (Registration, Evaluation, Authorization and Restriction of Chemicals under any related requirements).
[0104] “control statement”—As used in this invention, a control statement is a phrase intended to be included in a document to communicate the parameters of use of a material.
[0105] “authoring system”—As used in this invention, an authoring system is a software application employed for one of the preparation, generation, and distribution of a certification document.
[0106] “dynamic control statement”—As used in this invention, a dynamic control statement is a control statement that includes a function that can be executed by the recipient to retrieve one of a document, document reference, document link, compilation, summary, data, and function to perform the same. An example of a function that is included in a dynamic control statement is a hyperlink. An illustration of such a dynamic control statement might be “This product complies with EU Directive 2002/72/EC” found on the worldwide web at decernis.com/reference/document/2002 — 72_en.pdf.
[0107] “parameter of use”—As used in this invention, a parameter of use is a restriction, limitation, approval, guideline, standard, practice, recommendation, characteristic, behavior, measure, and data for a material.
[0108] “recipient”—As used in this invention, a recipient is a human being and a computer system.
[0109] “validation information”—As used in this invention, validation information is a dynamic control statement, source document, compilation, summary, alert, recall, and reference supporting said dynamic control statement.
[0110] “data processing system”—As used in this invention, a data processing system is a one or more programmable electronic devices that can store, retrieve, and process data.
[0111] “logical function”—As used in this invention, a logical function is a business rule, programmable computer routine that performs a calculation with variables and returns a result. For example, a business rule expressed descriptively is “if the concentration of a component of a mixture is above 0.1% and that component is a listed carcinogen, then insert the control statement database key which is associated with the phrase ‘Carcinogenic’.” An example of a logical function expressed descriptively is “if the web server receives a request from a dynamic control statement for a variable associated with the retrieval of a document from the server's document database, then a check should be performed of the user's authorization in the authorization database”.
[0112] “material”—As used in this invention, a material means a chemical, formulation, biological product, any virus, therapeutic serum, toxin, antitoxin, or analogous product, and finished article. Examples of materials include but are not limited to formaldehyde, perfume, compounds, Irganox, processed foods, and serums. Examples of a finished article includes a toy.
[0113] “document”—As used in this invention, a document means a computer file whether as a whole or deconstructed into component parts for electronic transmission and communication.
[0114] “alphanumeric string”—As used in this invention, an alphanumeric string means a sequence of computer codes representing letters, numbers, and control characters, such as a line ending and punctuation mark.
[0115] “algorithm”—As used in this invention, an algorithm is a computer procedure that begins in an initial state and terminates in a definite end state, applied here to process alphanumeric strings to prepare for, compare, determine the relevance of, and terminate indexing and searching related to a material term. For example, an algorithm to prepare an individual alphanumeric string for matching with a material term, is to strip all punctuation codes, raise all letters to capital, and to store the result in temporary memory. Another example of an algorithm is to compare any given alphanumeric string after processing with a database of material terms similarly processed and sorted in order of longest terms first.
[0116] “sequence”—As used in this invention, a sequence is one or more alphanumeric strings extracted from a document in a defined order. For example, the order of extraction includes but is not limited to the presentation of columns within a document and processing in order within a column. Another example is that the order of extraction of alphanumeric strings should follow the natural order of the language, i.e., from left-to-right in English.
[0117] “dictionary database”—As used in this invention, a dictionary database is a collection or records stored systematically in an electronic medium so that it may be queried.
[0118] “common words”—As used in this invention, common words means a dictionary of terms that are ignored as noise in indexing.
[0119] “matching”—As used in this invention, matching is a procedure that terminates in accepting or rejecting an alphanumeric string extracted from a document to determine whether it is identical to a term describing a material stored in a database.
[0120] An embodiment of the invention is a data processing system that improves the capability of a recipient of a certification document to validate dynamic control statements made in the document to define the parameters of use of a product by including within the document hyperlinks that retrieve the source document or reference supporting the given dynamic control statement from a web server (see FIG. 1 ). This embodiment has the effect of communicating data about the parameters of use of a product to improve product safety and compliance.
[0121] Referring now to FIGS. 1 and 1A , a data processing system using hyperlinked dynamic control statements in a certification document is illustrated according to one embodiment of the present invention. A certification document 152 is generated by an author from a client computer 100 via a document authoring application 101 that resides on a document authoring server 151 for a product sent to a recipient 153 . Dynamic control statements for a product retrieve, e.g., by hyperlink, an authoritative source document 102 and are included in an electronic certification document 104 for electronic transmission to the recipient 153 via a network. However, a recipient may also receive the electronic document via computer readable medium, such as XML or other electronic document exchange or by posting or sending a link to a secure web server, discussed in more detail below, to the recipient 153 . The recipient 153 validates a dynamic control statement, for example, by clicking on a hyperlink in the electronic certification document 104 that returns from a validation server 154 at least one of the following sources of validation information: (a) a source document 107 supporting the dynamic control statement; (b) a list of change(s) 109 relevant to the dynamic control statement; (c) a compilation 108 of references related to the dynamic control statement, and (d) alerts 110 . The validation server 154 is preferably a dynamic source of validation information, as the information is preferably updated at least at predetermined intervals.
[0122] The request 113 is passed to the web-server 106 , which may be in a number of different forms, including but not limited to HTTP, SOAP, remote object function calls, web services protocols, and the like. The web-server 106 passes the request to the application server 111 that returns a response to the request 114 .
[0123] A hyperlinked standard phrase library 102 includes for each dynamic control statement at least one of the following and preferably including a hyperlink, hyperlink fragment, or other variable that serves to invoke a function: a unique identification code, a phrase identification code, a language code, a text string, and a hyperlink or hyperlink fragment stored in a database. In a preferred embodiment each dynamic control statement may have translated variants associated with dynamic components, e.g., hyperlinks, that will return from a server the source document supporting the statement. In another preferred embodiment the hyperlink may be fully formed or a unique fragment associated with the unique phrase code which when appended to a base URL address where the server application has been loaded will return from a server the source document supporting the statement.
[0124] A dynamic control statement with a hyperlink in the present invention can be included in a certification document, advantageously to providing the recipient 153 the capability to validate it.
[0125] The hyperlinked standard phrase library 102 is preferably integrated into a document authoring application 101 , for example an enterprise resource planning system, such as SAP R/3, SAP EH&S, product life cycle management system, or material safety data sheet generation system. The author of the document 100 to be prepared for a material stored in the Product Composition Database 103 selects unique dynamic control statements with the hyperlinks that represent parameters of use to be included in the certification document for a given product. For example, a food contact certification document for a particular grade of polyethylene is being manufactured and an author selects the phrase “Kunstoffverordnung Nr. 476/2003” (with its associated dynamic component, e.g., hyperlink) to indicate the compliance of the manufactured product with an applicable food contact regulation in Austria. The author electronically places into a certification document the phrase with its hyperlink to the authoritative document so that the recipient can validate the dynamic control statement independently.
[0126] The generated certification document 152 may be in any form that accepts a hyperlink or logical function to retrieve validation information for a dynamic control statement 104 , including HTML, RTF, Microsoft Word, Excel, Adobe PDF, or in a structured data format such as XML but not limited thereto.
[0127] The document received by the recipient 153 includes dynamic control statements with a hyperlink or logical function to retrieve the source document accessible from a validation server 154 . The recipient of the certification document who wishes to examine the authority for a particular dynamic control statement may request 113 the source document from the hyperlink through the validation server. The web server 106 receives the request that is processed by the validation application 111 to retrieve the requested data from the database 112 . The recipient is directed to the source document 114 through the web server 106 .
[0128] FIG. 3 illustrates one example of an embodiment of the present invention for a Hyperlinked Standard Phrase Library of dynamic control statements with hyperlinks, providing a more detailed illustration of 102 in FIG. 1 . In this example of a preferred embodiment, a unique identification code 300 groups dynamic control statements that have been translated into different languages so that the document authoring application 101 can produce a certification document 152 in FIG. 1 in any of the languages available in the Hyperlinked Standard Phrase Library. The Phrase Code 301 identifies the specific dynamic control statement in the database. The Language Code 302 defines the language of the text phrase, i.e., the dynamic control statement, 303 . In addition, the hyperlink or hyperlink fragment 304 references the source document or documents supporting the specific dynamic control statement in any available language. The address of the hyperlink can refer to any one of the following to produce the results 107 , 108 , 109 , or 110 for a dynamic control statement: A specific document, compilation, or summary in the document database 112 of FIG. 1 , an index pointing to a document, compilation, or summary, or an argument of a function that will retrieve or generate a requested document, compilation, or summary.
[0129] Referring now to FIG. 2 a data processing system using hyperlinked dynamic control statements in a certification document 252 is illustrated according to one embodiment of the present invention in which the certification document 252 is transmitted in computer readable form. In this embodiment of the present invention the certification document 252 is produced in a computer readable form, including XML or other electronic document exchange formats, in such a manner that a dynamic control statement 204 can be received by the recipient's enterprise system 253 via the receiving computer 215 . The dynamic control statement can then be extracted and stored in the recipient's database 216 .
[0130] Again referring to FIG. 2 , in this embodiment of the present invention the recipient can produce electronic reports from the database 216 in the enterprise system 205 that include dynamic control statements received in certification documents for a product. The recipient using the enterprise system 253 can validate such dynamic control statements by clicking on a hyperlink in any such generated recipient electronic report will produce a request 213 that will return ( 214 ) from the validation server 254 at least one of the following sources of validation information: (a) a source document 207 supporting the dynamic control statement; (b) changes 209 relevant to the dynamic control statement; (c) a compilation 208 of references related to the dynamic control statement, and (d) alerts 210 . The validation server 154 is preferably a dynamic source of validation information, as the validation information is preferably updated at least at predetermined intervals.
[0131] In a further embodiment of the present invention, the recipient can implement a document authoring system as in FIG. 1 and load the received dynamic control statements with hyperlinks or logical functions into the recipient's equivalent Hyperlinked Standard Phrase Library as in 102 of FIG. 1 , thus permitting the reuse of dynamic control statements in a plurality of document authoring systems for any dynamic control statement passed through the supply chain. In an embodiment, the recipient's Hyperlinked Standard Phrase Library includes at least one of the following with hyperlinks: standard dynamic control statements, the recipient's own dynamic control statements, and received dynamic control statements. The recipient who has implemented a data processing system of the present invention can generate certification documents including dynamic control statements passed to the recipient.
[0132] One embodiment of the present invention provides a certification document with such hyperlinked dynamic control statements can be passed to a recipient in a computer readable medium so that the recipient can then include a received hyperlinked dynamic control statement in authoring a further certification document. In consequence, the embodiment provides a data processing system to improve the means of passing information in a supply chain to control the safe use and compliance of products in a standard manner and in a manner that permits the validation of a dynamic control statement included in a certification document being transmitted in a supply chain.
[0133] The present invention provides an improved capability to prepare and distribute hyperlinked standard phrase libraries that are industry, subject-specific, or within a supply chain with hyperlinks and optionally translation variants so that a manufacturer may prepare a certification document in a flexible way with any selection of applicable hyperlinked dynamic control statements according to the conclusions of the expert author of the certification document and thus to permit the recipient to evaluate the stated parameters of use of the product by reviewing the source document supporting each dynamic control statement made.
[0134] Further, one embodiment of the present invention improves upon current practice by providing a method by which the author of a certification document may add locally authored dynamic control statements to the hyperlinked standard phrase library or to insert in a certification document hyperlinked dynamic control statements received from upstream suppliers of raw materials, which improves the capability for upstream suppliers to communicate parameters of safe and compliant use of materials through certification documents that includes a data processing system that can be implemented by both direct recipients of a certification document as well as downstream recipients of a dynamic control statement associated with the raw materials of a value-added produce to validate the source documents or references associated with any given dynamic control statement.
[0135] Through the availability of translated variants, documents generated with a hyperlinked dynamic control statement may be in any language. Such translated variants may be required where the use of the document is in a country with more than one national language, for example, Belgium, Canada, or Switzerland.
[0136] A further embodiment of the invention improves upon the capability of the recipient of a certification document 152 to determine changes in associated source documents relevant to an included dynamic control statement 104 for a given period of time. Referring to FIG. 1 and FIG. 3 , the recipient of a certification document 152 can request 113 changes 109 relevant to a dynamic control statement 104 in a certification document 152 for a given period of time. In an embodiment the argument of the hyperlink of a dynamic control statement can include a date in order to request ( 113 ) changes ( 109 in FIGS. 1 and 3 ) relevant to the source documents supporting a given dynamic control statement 104 . For example, the argument of a hyperlink may include the date of the certification document's 152 generation in order that the recipient can be informed of amendments to a regulation cited by the dynamic control statement.
[0137] The invention provides a data processing system that improves upon one of the most difficult tasks for a recipient of a document in the supply chain, which is to determine whether important amendments or modifications have come into force, or further studies or standards, relevant to a specific claim made in a dynamic control statement. At present, this task is disadvantageously performed manually by the recipient. For example, if the text of the dynamic control statement is, “This product complies with EU directive 2002/72/EC for plastic materials in contact with foodstuffs” then the hyperlink request 113 to the validation server 106 , 109 can return 114 references to all successive amendments to this directive since the time of the certification document's 152 generation. The invention thus provides an improved capability to provide a data processing system for standardized change management alerts for dynamic control statement 104 claims made in certification documents 152 to support the safe use of a product.
[0138] A further embodiment of the present invention is a data processing system to provide for product recalls and product alerts for specific shipments. In an embodiment of the present invention, an RFID identification number is associated with the certification document 152 or 252 or to one or more dynamic control statements 104 or 204 with hyperlinks or logical functions in order to return from the validation server 254 a product recall, alert, or other information applicable to a specific shipment.
[0139] The present invention improves the capability for a data processing system to provide alerts regarding product recalls 110 , 210 or other information as described above from a validation server 106 , 206 not only in relation to the product in general but to a specific shipment of that product identified by RFID identification code, such information regarding a product recall or alert being automatically provided in response to a request 113 , 213 either from a human being 153 or from a computer system 253 , which provides for the advanced shipment notice or other commercial business-to-business interaction in electronic document exchange format or in XML format to include a reference to a document generated with the Hyperlinked Standard Phrase Library and to an RFID identification of a specific shipment.
[0140] The described embodiments of the present invention improve the capability of the recipient to review MSDS and similar compliance certification documents, which otherwise must be carried out manually. The data processing system of the present invention further supports review of compliance and review of supplier certifications for foodstuffs, medical devices, pharmaceuticals, etc. The present invention is an improvement in that it is based on the document itself and not on an adjunct manual review process. An aspect of the present invention is to provide supply chain actors with a validation service bureau where such actors may generate may connect generate regular documents, regulatory compliance document preparation with the source document validation management that the invention provides.
[0141] A certification document or safety document is self validating upon review by the recipient. Currently a recipient must contact the supplier directly to validate documents.
[0142] Another embodiment of the present invention applicable to certification documents is that the document opened by the hyperlink or logical function of the invention may open a document, may open a document at a cited page, or may open a document at a cited page with a relevant section of the page or document highlighted. In such a form, the hyperlink or logical function contains an argument that includes the page(s) number of the cited document and the sections of those pages to highlight with the coordinates describing areas of the page to highlight. One example is to specify coordinates of the highlighted page by defining one or more rectangular areas of the page to highlight identified by the x,y positions of the axes of the rectangle that can be positioned on the space of a page. Other highlighted shapes or coordinate systems may be provided for within this invention. What is improved is the capability for the user of a certification document to click on the hyperlink or invoke a logical function so that the source document which will be returned from the validation server opened at the relevant page associated with the statement in the document with the highlighted relevant section of the page(s) of the source document.
[0143] A further embodiment of present invention provides access to a data processing system which is controlled by the level of service agreed to in a service agreement. In this aspect of the invention the hyperlink contains an additional argument which is an authorization code to control users authorized to view or download the source document referenced by the statement in the received document, which improves the general capability for upstream supply chain actors to provide documents containing statements referencing confidential information to intermediate and downstream actors in the supply chain. The downstream user can pass along the statement with the hyperlink or logical function to customers who may rely on this statement and be granted access based upon the privileges granted by the owner of the information hyperlinked with the statement, which improves the potential for a service bureau to manage authorization privileges for statements included in a Hyperlinked Standard Phrase Library. In this aspect of the invention it is not necessary for the service bureau to maintain the confidential documents themselves, only references to them with the reviewed authorization privileges.
[0144] To provide an example of the type of certification document depicted at 152 , 252 FIG. 4 shows a certification document for a Polyethylene product containing dynamic control statements that the product meets required approvals for its use in several countries. Each dynamic control statement contains a hyperlink of the type defined in the invention that permits the customer to receive a document that can perform one or more of the following:
hyperlink to the text of the applicable cited regulation, optionally opened to the relevant page with a highlight of a section of the page. hyperlink to a validation server that will return all regulatory changes for the dynamic control statement since the date of the document's generation for the context of the letter for which the behavior of the returned format or information can be customized; this includes the capability for authorized users to obtain from a validation server the changes to the certifications of an upstream supplier; hyperlink to a validation server to return a summary report or compilation of other relevant requirements or restrictions of interest to the customer; This includes the capability for authorized users to obtain from a validation server a summary report including the certifications of an upstream supplier; hyperlink to a validation server to return a transaction control alert, such as “forbidden in transport by air”; hyperlink to a validation server to return data in a structured format.
[0150] In the example, 400 illustrates a dynamic control statement for the United States ( 401 ) while 402 illustrates a dynamic control statement for Sweden. Dynamic control statement 400 hyperlinks to document 403 with a preferred embodiment in which the section is highlighted 405
[0151] 400 illustrates a claim and instruction by the supplier for the safe use of the product, i.e., a dynamic control statement, that the product complies with 21 CFR 177.1520 (a)(3) (2003). In the simplest case, the user may be interested in an immediate review of the relevant source regulation opened at the page with the relevant page with the section highlighted that relates to FDA regulation of “Olefin polymers” (as illustrated), a family of plastics that subsumes the specific product, Polyethylene. To produce this result, the supplier receives a Hyperlinked Standard Phrase Library ( FIG. 1 , 102 ) that contains identifiers, a phrase code, phrase texts in optionally different languages, and a validation hyperlink, as illustrated in FIG. 3 . In this example embodiment the dynamic control statement is:
[0152] “FDA, CFR, Title 21 (2003), 177.1520 (a)(3)(i)(c)(1), (b) and (c) 3. la. Olefin Polymers.”
[0000] The validation hyperlink for that phrase code is:
[0153] //decernis.com/reference/navpdf2.jsp?timestarnp-6 — 5 2003&profile=1155&doc=2 158789.pdf&pg=3&11x=156&11y=173&rux=196&ruy=183&:lib=document in which the validation hyperlink or logical function may contain one or more components, such as:
[0154] URL [http://decernis.com/reference]
[0155] Target function [navpdf.jsp]
[0156] Timestamp [6 — 5 — 2003]
[0157] Source
[0158] Identifier
[0159] Profile [1155]
[0160] Topic
[0161] Material
[0162] Document [2158789.pdf, page 3, and the document itself is to be retrieved]
[0163] XY positions [lower left x position (11x) at 156 , lower left y position (11y) at 173 , right upper x (rux) position at 196 , right upper y position (ruy) at 183 ]
In consequence, the validation hyperlink or logical function can alternatively contain, for example, systematic information that can be associated with certification phrases in the document.
[0165] In this manner, a database of hyperlinked dynamic control statements as a component of the data processing system of the present invention can be distributed to many different suppliers permitting consistency and validation by recipients in the communication of the parameters of use of a product, while allowing for significant customization to meet the needs of a supplier. The validation database can include dynamic control statements of an upstream supplier that include a hyperlink to the source document contained in a database available only to authorized users. In this manner, the author of a document can assemble certification statements in a standardized as well as customizable manner that include both the immediate user's claims as well as upstream supplier claims although the upstream supplier claims would only be accessible to an authorized user. As a result certifications can be passed from multiple parties upstream in the supply chain, simplifying greatly the assessment task of an downstream user
[0166] The supplier can use his or her document authoring environment to embed the appropriate phrase codes within a defined report template for a given product. The invention is providing a component that can be used in ERP or document authoring systems.
[0167] Once the document authoring step has been completed the supplier distributes the certification document in at least two ways:
The recipient may be an end-user ( 153 ), e.g., procurement expert for a customer reviewing compliance for global raw material acquisitions; The recipient may be another ERP system ( 253 ) automatically connected in a business-to-business network in which the transaction data and documents are passed from the supplier's ERP directly into the recipient's ERP system.
[0170] The end-user can open the document in a number of different formats (Adobe PDF, Microsoft Word, HTML, etc.), and click on the validation hyperlink within the document itself ( 401 ). The user may invoke (or depending on the customization of the validation hyperlink) a number of different services from the validation hyperlink:
The source document may be returned opened at the relevant page, optionally with a relevant section highlighted ( 107 , 207 ); The validation service may provide a report of all amendments or modifications to the cited document since the date of the document's generation relative to the timestamp of the validation phrase code ( 109 , 209 ); The validation service may return a summary report of other regulations within the topical context of the document as defined in a profile ( 108 , 208 ); The validation service may return alerts, news of proposals relevant to the certification, or other transaction control information ( 110 , 210 ).
[0175] In addition, if the document above contained a statement, such as “Raw materials used in processing comply with FDA requirements, according to supplier certification”, the source document would be opened as above, but only to an authorized user.
[0176] The supplier of the Polyethylene certification has cited a 2003 dated CFR in the above example. An obvious question for the recipient is whether FDA has promulgated any changes to the citation from the time that the document was created. Two related issues arise: a) Was the supplier correct and current in citing the FDA approval; and b) have any changes occurred since? One aspect of the present invention provides validating documents for a quicker and more effective answer to these questions.
[0177] Further, the customer may wish to trans-ship the received polyethylene [as the example in this case] to another country not included in the list of certifications. At this point, although the supplier may not have, in some cases, disclosed all information necessary for a conclusive answer by the customer, the customer may wish to make an independent evaluation based upon the information provided for a number of reasons. The customer's intended market or use may be perceived as confidential information that the customer may be unwilling to disclose to the supplier.
[0178] As a result a rich set of validation services is provided on the basis of the system of validation of the invention, and these services are available to both supplier and recipient, as well as downstream in the supply chain.
[0179] Document Searching, Indexing, and Extraction of References to Materials and Material Classes: An aspect of the invention provides for supporting the validation system is its method to search and index documents in order to extract references to materials and material classes. The invention provides methods for:
Indexing, searching, and extracting direct references, identifiers, synonyms and multi-lingual references to “materials” from a document (e.g., 608 , 703 , 704 ); and Indexing, searching, and extracting multi-lingual references to “material classes” from a document (e.g., 609 , 701 , 702 ).
[0182] A material in the database has a common identification even if it may be referenced by many other identifiers as used in regulations or documents. Although prior art has defined any number of different types of databases of substances, the present invention is unique in several respects:
The database has a superset and unique concept of material that cuts across and relates individual occurrences to it; The database structure links together proper names, synonyms, translations, identifiers, and literal names (i.e., alphanumeric sequences used in documents that refer to a material but may be erroneous or have ancillary alphanumeric characters associated with them), allowing a reference in a document, which may be entirely erroneous or in a different language, to be related back to both a proper synonym as well as to a larger concept of material; and, The database structure links all of these references together to the associated documents.
[0186] A material class is a superset containing one or more materials. An example of a class defined in many environmental, safety, and health regulations is “Chrome VI” compounds, which defines a particular membership of chromium compounds and includes sodium chromate. In order for the user of a material to meet applicable requirements, he or she must be aware not only of direct references to the substance but also indirect references, which apply through parent-child relationships. For example, sodium chromate is a “child” of the “parent” class, “Chrome VI compounds”. In many cases, because the legal definition of the regulation's scope—or more precisely, the document's definitional context—the use in question may not be a scientific relationship but an arbitrarily defined one. As noted above, an automaker may define a set of materials that it has chosen not to purchase, as a matter of policy. Or, a document may refer to a particular list of salts, but not all salts of an acid.
[0187] Although prior art includes many uses of parent-child relationships in databases and to parent-child relationships of substances to groups, the present invention is unique in that:
Materials and material class references are related to their occurrence within documents; Materials and material classes are defined within the scope of a document or regulation; Materials can themselves be supersets of substances; Materials and material classes are structurally linked to multi-lingual occurrences and to literal name occurrences.
[0192] One embodiment of the present invention is a method and data processing system to cross-index references to chemicals and materials in documents not only by a direct reference to a material but also by one or more of the following: synonym, identifier, translation, or material class of which the chemical is a member.
[0193] An illustration from prior Art of the need for the embodiment of the present invention to provide a method and data processing system to cross-index references to chemicals and materials in documents is illustrated in FIG. 12 , which provides results from three searches from Google Scholar 1202 , found on the worldwide web at scholar.google.com/. The first example 1203 is a search for the chemical, “crotonic acid” that returns two thousand five hundred and twenty document references (2,520) 1204 . The second example is a search for a synonym of the chemical, “(E)-2-Butenoic acid” 1205 that returns twenty document references (22) 1206 that are not consistent with the references found in the first search. The third example is a search for a translation of the chemical, “Crotonzuur” 1207 that returns no search results from the Google Scholar index or search engine 1208 . Similar results would occur for a chemical class of which crotonic acid is a member, such as “Ungesättigte aliphatische Mono- and Dicarbonsäuren C3-C8” or “Ácidos”. The approach to indexing chemical terms by prior Art embodied by other suppliers provides similar inconsistencies: for example, the search above would provide similar inconsistent results but for a different document index library if the same three searches were performed on the publicly accessible demonstration of Illumina, found on the worldwide web at csa.com/.
[0194] One embodiment of present invention provides all matching available document references to the entered search term, synonyms of the search term, identifiers of the search term, translations of the search term or classes of which the chemical or material is a member can be returned from a search for a chemical or material term (see FIG. 7 ).
[0195] Referring now to FIGS. 5A , 5 B, and 5 C, an embodiment of the present invention is illustrated, providing the steps to index chemical entries in a document that includes a reference to at least one material, so that the data processing system can permit a search for a given chemical in order to return from a web server not only a direct reference but also a compilation of references to documents containing the chemical term including: (a) documents containing a synonymous reference to the chemical term, (b) documents containing a translated reference to the chemical term; (c) documents containing a reference to an identifier associated with the chemical term; (d) documents containing a reference to a parent class of which the chemical term is a member.
[0196] Referring now to FIG. 5C , in a method 501 at a step 502 , the document is input, preferably in electronic format, such as HTML, Adobe PDF, Microsoft Excel, Microsoft Word, or in computer readable form such as XML or other document exchange format and preferably input into a document database 530 . The software of the present invention extracts all of the words or alphanumeric strings in the document in a step 503 and tests that it is a word and not simply a sequence of control codes or other information. In one embodiment of the present invention, a found word is compared to a dictionary of common words in order to suppress words that are not chemical terms, which has the effect of decreasing the size of the database and the speed of the indexing. Once the words are found in the document, a record in the index database is stored. In a preferred embodiment of the present invention the word is stored, including the address of the document whether a filename or hyperlink, the page on which the word is found, and the position of the word on the page. One method for defining the position of the term on the page is to define a rectangular area that encompasses the area of the word on the page, and to store the coordinates of the rectangle in the index record.
[0197] In a step 504 the relevance of the extracted words or alphanumeric strings in the document as stored in the index is determined by comparing, in sequence and in combination, the extracted words or alphanumeric strings to a dictionary database of material terms. The material terms dictionary database contains at least one of the following: a unique material identification code, a preferred name of the instance of the material, and a name used for matching against a document term (Matchname). An extracted word or alphanumeric string is compared to an index of Matchnames from the database of material terms, such as by retrieving the extracted word or alphanumeric string from a document index, discussed in more detail below. If a match occurs in a step 505 , an index record is prepared for at least one of the following: (a) found chemical, (b) document, (c) document address, (d) material code, after which the record is stored in the materials index in a step 506 . As a result of this embodiment of the indexing system, a particular chemical name is indexed against any entry in a plurality of documents in the document database.
[0198] Referring to FIG. 5B the sub-step 504 is shown in greater detail. After the alphanumeric strings have been extracted in the step 503 , the first alphanumeric string is extracted in a step 535 . In a step 536 , the alphanumeric string is prepared for matching, such as by converting lower case characters to upper case, stripping punctuation, converting Greek letters to alphanumeric equivalents or the like. In a step 537 , the alphanumeric string is compared with a dictionary database of material terms. In a step 538 , if a match occurs, the method proceeds to the step 539 and the matched term is added to a stored set of matching material terms, after which the combined matching terms are combined in a step 541 and the method proceeds to the step 544 to test if there are more strings in the document. If there are no more strings, the sub-step 504 ends and the method 501 proceeds to the step 505 . If there are more strings, the method returns to the step 535 to begin a new determination of relevance.
[0199] If no match occurs in the step 538 , the method tests, in a step 540 if the stored material terms exist. If the stored material term does exist, the method proceeds to a step 542 where a stored matching material term is retrieved, which is accepted as a material reference and the method writes an index record in a step 543 after which the method proceeds to the step 544 to test if there are more strings in the document. If there are no more strings, the sub-step 504 ends and the method 501 proceeds to the step 505 . If there are more strings, the method returns to the step 535 to begin a new determination of relevance. If no stored material terms exist in the step 540 , the method proceeds to the step 544 to test if there are more strings in the document. If there are no more strings, the sub-step 504 ends and the method 501 proceeds to the step 505 . If there are more strings, the method returns to the step 535 to begin a new determination of relevance.
[0200] Referring now to FIG. 5A , the materials database or dictionary database of common material terms is illustrated at 515 as including one or more of the following: (a) A unique material identification code or key 516 ; (b) a proper chemical name 517 ; (c) synonyms 518 ; (d) identifiers, e.g., an EU Reference Number, an EINECS number, etc. 519 ; (e) translations of chemical names 520 ; (f) members of parent classes, e.g., sodium chromate is a member of the class hexavalent chromium compounds; and other material attributes.
[0201] The document database is illustrated at 530 as including one or more of the following: (a) A unique material identification code or key 531 , which is related to 516 ; (b) a document address or filename using the Matchname of the material; (c) a page number for the occurrence of the Matchname 533 ; and (d) the location on the page of the term 534 .
[0202] A master materials database is shown at 523 and defines the relationship with a master “material” that encompasses one or more entries in the materials database 515 . A master material record has one or more of the following elements: (a) a unique master materials code or key 524 ; (b) a proper master name 525 ; (c) master identifiers associated with the master material 526 ; (d) attributes associated with the master material 527 ; (e) an identification that this is a parent class.
[0203] After the method 501 is complete, a cross-index is generated by retrieving a matched alphanumeric string from the step 505 , matching the retrieved alphanumeric string with a matching master materials database key 524 and cross-indexing the matching records in the document database 530 , the materials database 515 , and the master materials database 523 . In this embodiment of the present invention, the resulting cross-index permits a particular occurrence of a chemical term to be related not only to all indexed documents in the document database 530 containing the term, but to any synonym, translation, identifier or membership in a broad chemical class in the materials database 515 or the master materials database 523 .
[0204] Referring now to FIG. 6 , the results of the indexing of chemical terms in documents is illustrated in an example of an embodiment of the present invention. An example master material key ( 516 in FIG. 5A ) is illustrated at 601 . If there is an associated reference to a master material key ( 524 in FIG. 5A ) that is a parent class the key entry is represented in 602 . For example 608 , in this instance the preferred name for the material entry is (E)-2-butanoic acid 603 , indicating here as the “head_name” with a material identifier code 304 ( 601 ). One instance of a material linked to this index entry is the name, “crotonic acid” 604 . This entry is found in the file, 21cfr176.180.pdf ( 607 ). An attribute of this entry is a citation, “21 CFR 176.180 Paper/paperboard (dry food)”.
[0205] In another instance 609 , the material is a member of a chemical class “Ungesättigte aliphatische Mono- and Dicarbonsäuren C3-C8”, and this class is referenced in a document with the citation “BfR Empf 35 [XXXV.] Mischpolymerisate: Ethylen, Propylen, Butylen, Vinylestern, ungesättigten aliphat.” with the filename, de — 350deutsch.pdf. (E)-2-butanoic acid is a member of the referenced class of chemicals.
[0206] FIG. 8 is an illustration of an example of a fragment from a document, 21 CFR §178.2010, with a sequence of words at 810 , beginning “3.1 Mineral oil (CAS Reg. No. 8012-95-1): Not to exceed 40 percent by weight of the stabilizer formulation”. In applying the method 501 of the present invention for indexing chemical terms to this portion of the document, the chemical term of interest in this fragment is “Mineral oil”, which is embedded in a sequence of other alphanumeric characters and other non-alphanumeric punctuation, bit streams, and control codes. The first term of this sequence is extracted as indicated in steps 503 and 506 . This alphanumeric sequence, “3.1”, does not match any term in the materials database and is discarded.
[0207] One difficulty with existing indexing methods that is addressed by the present invention is that a chemical term may span many separated words 901 as illustrated in FIG. 9 . Extracting only the first word length term in sequence, i.e., “Mineral” would not correctly represent the term in this example extract. One advantageous aspect of this embodiment of the present invention is that the comparative indexing method in the step of determining relevance 506 heuristically evaluates a series of possibilities as it processes the document by considering a plurality of terms in sequence. In one embodiment of this method, the terms in the material database 515 are taken in order of the longest alphanumeric sequence first.
[0208] In an illustration of this approach, the indexing utility extracts the word, “Mineral” in the step 503 and stores this term temporarily until the indexing method 501 can conclude that the best match has been found for the series, rejecting or accepting terms as the processing continues. For instance, “Mineral” might possibly be followed by “reinforced nylon resins”, “Mineral oils and hydrocarbons”, “Mineral oil based greases”, or the like as shown at 901 although it does not in the document example 801 . At this step the indexing method 501 has found a chemical term with a plurality of matches, and then seeks to narrow the possible matches by taking the second term, “oil” 801 following the term, “Mineral”. “Mineral oil” in combination eliminates all other available terms in this example, and the method determines that “Mineral oil” with the internal identification material identification key ( 516 from FIG. 5A ) of “1476” ( 902 in FIG. 9 ) matches this series of words in the document in the step 509 . This match is then stored in the step 510 .
[0209] The indexing method 501 then moves in sequence or sequentially to consider the following term, “(CAS” and the subsequent term “No”. 803 that are discarded without matches. In a preferred embodiment of this method, a database of common (i.e. nonmaterial) words may be additionally used to make the comparison more efficient by eliminating any common word, such as “the”, “No.”, “not”, “to”, “exceed”. A common word in such a list would be ignored by the indexing method 501 . In consequence, if the database of common words is used in the heuristic comparison step 508 , the words of the phrase “Not to exceed” would be discarded as “common words” or “noise” without comparison to the material database.
[0210] In a further aspect of this embodiment of the present invention, the CAS Registry Number, “8012-95-1” 803 , is an example of an identifier for the substance, “mineral oil” that can be itself extracted from the document by the indexing method 501 of the present invention and used in association with other material identification keys that are themselves linked to other document references.
[0211] In an embodiment of the indexing method 501 , the words are pre-processed to strip punctuation and capitalize terms so that the comparison step can consider a number of equivalent chemical terms more easily. Taking an example, such as “(+) 1,6-Di-(4-amidinophenoxy)-n-hexan”, whether the chemical appears with the use of parentheses or bracket characters does not matter, because the indexing method would treat the punctuation as noise. Similarly the embodiment would ignore case sensitivity, such as initial capitalization in a document reference.
[0212] Additionally, certain alphanumeric sequences taken together are considered as equivalent in the preferred embodiment of the indexing method. For example “Alphamuurolen”, “α-Muurolene”, and “α-Muuolene” are equivalent, permitting the “Alpha”, “a-”, and “α-” alphanumeric character sequences to be indexed as companion terms. Such terms can be in any position within the word, such as “2-Metossi-4-(2-propenil)fenil-β-D-glucopiranoside” which should be treated synonymously to “2-Metossi-4-(2-propenil)fenil-beta-D-glucopiranoside”. These variants are assigned to the matching material key 516 or 531 .
[0213] In the previous example, the indexing method 501 found the term, “Mineral oil” in the text of the document and its associated reference to the material identification key “1476” 902 . Once this identification has occurred, the material identification key 516 or 531 and thus the document reference may be related to all other references associated with the master material key 524 . The master material key 524 may include direct references, synonyms, translations, or chemical or material classes. As an example of a material class, the material, “mineral oil” with its material identification key can be considered a member of the class, “cottonseed and other edible oils”. Thus the master material identification key 524 would include a reference to this class.
[0214] The indexing method 501 of this embodiment of the present invention can be used to support a search for “mineral oil” that will return a reference to any available document that uses the term “cottonseed and other edible oils”. In this example, the benefit of this cross-indexing is that the user would be able to rapidly determine that “mineral oil” is permitted as a surface lubricant by FDA in the production of resinous and polymeric coatings used in food contact uses under 21 CFR §175.300.
[0215] The method 501 for indexing and searching chemical terms has significant, beneficial application that assist in improving the safe and globally compliant use of product, for instance. The method 501 of the present invention permits a cross-referencing of documents by: (a) preferred chemical name, (b) identifier; (c) translation; (d) synonym; and (e) membership in a parent class.
[0216] Referring now to FIG. 7 , a data processing system is illustrated as a preferred embodiment of the present invention that returns in response to a search based on the index described above for a particular material name, “crotonic acid”, found references to documents that include a reference to a synonym 703 , one or more references to parent classes 701 , 702 , or a translated name 703 . In this illustration of a preferred embodiment, the hyperlink to the document opens at the page of the document on which the particular reference is found.
[0217] Another aspect of this embodiment of the present invention is that the indexing method can be applied to a subset, such as those documents that have changed over a particular period of time.
[0218] Referring now to FIG. 10 , an embodiment of the present invention is illustrated in which the body of documents selected for search are “new” or “changed”. The subset of documents subject to indexing and search may be assembled by either manual or automatic means. For example, manual research may have identified amendments to a certain topical area of regulations over a period of time, or a subsequent studies that have been published, or other subsequent publications during the given period. Automatic means may select a document subset as well.
[0219] In consequence, the present embodiment supports a search for a chemical that is affected by a change, whether the document that has changed refers directly to the chemical term, uses an identifier, a translation, or refers to a chemical class encompassing the term.
[0220] Referring now to FIG. 11 , a search for the term “acetone” 1101 returns a reference to a Mercosaur Agreement defining a positive list of substances permitted for use in plastics manufactured in South American countries subject to the Mercosaur Agreement. This document is a member of a subset of documents added or changed during a given period of time. The benefit of the present embodiment are that a researcher can more effectively keep abreast of changes that affect his or her use of materials that are referenced in newly published regulations or documents through the present data processing system. At present, the researcher must perform this task manually or through partially automated searches.
[0221] Referring now to FIGS. 10A , 10 B, and 10 C, an embodiment of the present invention is illustrated providing the steps to index chemical entries in a new, subset, or changed document that includes a reference to at least one material, so that the data processing system can permit a search for a given chemical in order to return from a web server not only a direct reference but also a compilation of references to documents containing the chemical term including: (a) documents containing a synonymous reference to the chemical term; (b) documents containing a translated reference to the chemical term; (c) documents containing a reference to an identifier associated with the chemical term; (d) documents containing a reference to a parent class of which the chemical term is a member.
[0222] Referring now to FIG. 10C , in a method 1001 at a step 1002 , the document is input,
[0000] preferably in electronic format, such as HTML, Adobe PDF, Microsoft Excel, Microsoft Word, or in computer readable form such as XML or other document exchange format and preferably input into a document database 1030 . The software of the present invention extracts all of the words or alphanumeric strings in the document in a step 1003 and tests that it is a word and not simply a sequence of control codes or other information. In one embodiment of the present invention, a found word is compared to a dictionary of common words in order to suppress words that are not chemical terms, which has the effect of decreasing the size of the database and the speed of the indexing. Once the words are found in the document, a record in the index database is stored. In a preferred embodiment of the present invention the word is stored, including the address of the document whether a filename or hyperlink, the page on which the word is found, and the position of the word on the page. One method for defining the position of the term on the page is to define a rectangular area that encompasses the area of the word on the page, and to store the coordinates of the rectangle in the index record.
[0223] In a step 1004 the relevance of the extracted words or alphanumeric strings in the document as stored in the index is determined by comparing, in sequence and in combination, the extracted words or alphanumeric strings to a dictionary database of material terms. The material terms dictionary database contains at least one of the following: a unique material identification code, a preferred name of the instance of the material, and a name used for matching against a document term (Matchname). An extracted word or alphanumeric string is compared to an index of Matchnames from the database of material terms, such as by retrieving the extracted word or alphanumeric string from a document index, discussed in more detail below. If a match occurs in a step 1005 , an index record is prepared for at least one of the following: (a) found chemical, (b) document, (c) document address, (d) material code (in this case for the subset of documents), after which the record is stored in the materials index in a step 1006 . As a result of this embodiment of the indexing system, a particular chemical name is indexed against any entry in a plurality of documents in the document database.
[0224] Referring to FIG. 10B the sub-step 1004 is shown in greater detail. After the alphanumeric strings have been extracted in the step 1003 , the first alphanumeric string from the document subset is extracted in a step 1035 . In a step 1036 , the alphanumeric string is prepared for matching, such as by converting lower case characters to upper, stripping punctuation, converting Greek letters to alphanumeric equivalents or the like. In a step 1037 , the alphanumeric string is compared with a dictionary database of material terms. In a step 1038 , if a match occurs, the method proceeds to the step 1039 and the matched term is added to a stored set of matching material terms, after which the combined matching terms are combined in a step 1041 and the method proceeds to the step 1044 to test if there are more strings in the document. If there are no more strings, the sub-step 1004 ends and the method 1001 proceeds to the step 1005 . If there are more strings, the method returns to the step 1035 to begin a new determination of relevance.
[0225] If no match occurs in the step 1038 , the method tests, in a step 1040 , if the stored material terms exist. If the stored material term does exist, the method proceeds to a step 1042 where a stored matching material term is retrieved, which is accepted as a material reference and the method writes an index record in a step 1043 after which the method proceeds to the step 1044 to test if there are more strings in the document. If there are no more strings, the sub-step 1004 ends and the method 1001 proceeds to the step 1005 . If there are more strings, the method returns to the step 1035 to begin a new determination of relevance. If no stored material terms exist in the step 1040 , the method proceeds to the step 1044 to test if there are more strings in the document. If there are no more strings, the sub-step 1004 ends and the method 1001 proceeds to the step 1005 . If there are more strings, the method returns to the step 1035 to begin a new determination of relevance.
[0226] Referring now to FIG. 10A , the materials database or dictionary database of common material terms according to one embodiment of the present invention is illustrated at 1015 as including one or more of the following: (a) A unique material identification code or key 1016 ; (b) a proper chemical name 1017 ; (c) synonyms 1018 ; (d) identifiers, e.g., an EU Reference Number, an EINECS number, etc. 1019 ; (e) translations of chemical names 1020 ; (f) members of parent classes, e.g., sodium chromate is a member of the class hexavalent chromium compounds; and other material attributes.
[0227] The change document database is illustrated at 1030 as including one or more of the following: (a) A unique material identification code or key 1031 , which is related to 1016 ; (b) a document address or filename using the Matchname of the material; (c) a page number for the occurrence of the Matchname 1033 ; and (d) the location on the page of the term 1034 .
[0228] A master materials database is shown at 1023 and defines the relationship with a master “material” that encompasses one or more entries in the materials database 1015 . A master material record has one or more of the following elements: (a) a unique master materials code or key 1024 ; (b) a proper master name 1025 ; (c) master identifiers associated with the master material 1026 ; (d) attributes associated with the master material 1027 ; (e) an identification that this is a parent class.
[0229] After the method 1001 is complete, a cross-index is generated by retrieving a matched alphanumeric string from the step 1005 , matching the retrieved alphanumeric string with a matching master materials database key 1024 and cross-indexing the matching records in the document database 1030 , the materials database 1015 , and the master materials database 1023 . In this illustration of the present invention, the resulting cross-index permits a particular occurrence of a chemical term to be related not only to all indexed documents in the document database 1030 containing the term, but to any synonym, translation, identifier or membership in a broad chemical class in the materials database 1015 or the master materials database 1023 .
[0230] Embodiments of the present invention may also be practiced by a computer readable medium storing executable software code thereon for executing the indexing method and the system for validating certification documents in accordance with the present invention, as will be appreciated by those skilled in the art Embodiments of the present invention may also be practiced by a device, such as a personal computer or the like, having a processor, wherein the processor is responsive to software instructions; and software instructions adapted to enable the processor to execute the indexing method and the system for validating certification documents in accordance with the present invention, as will be appreciated by those skilled in the art.
[0231] Embodiments of the present invention produce an advantageous technical effect by providing a data processing system that more effectively communicates parameters of use of products in a supply chain by utilizing dynamic control statements in certification documents that may be validated by a recipient of the certification document, thereby improving the safe and compliant use of the products in the supply chain by the recipient. The present invention thereby provides a further technical effect which lends technical character to the embodied computer programs in the control of an industrial process and in processing data that represents parameters of use of physical entities through the dynamic control statements. In consequence, the present invention provides a solution to a difficult supply chain management problem by the automatic validation of certification documents.
[0232] Embodiments of the present invention have been described in terms of preferred embodiments and nonlimiting examples, however, it will be appreciated that various modifications and improvements may be made to the described embodiments and examples without departing from the scope of the invention. | The present invention relates generally to the field of self-validating documents in supply chain management, documentation services and method for creating the same. | 6 |
This application is a continuation of application Ser. No. 08/592,525, filed Jan. 26, 1996 now abandoned.
FIELD OF THE INVENTION
This invention relates to gene therapy for digestive cancers and the like. More particularly, it relates to a method for transducing a gene for treatment to target cells, such as cancer cells, by endoscopically administering a vector having the gene or cells capable of producing such a vector directly to the affected site, such as a digestive cancer lesion.
BACKGROUND OF THE INVENTION
The rapid progress of genetic engineering has enabled development of various molecular biological techniques. With the development, remarkable advancements have been shown in analyses of genetic information and functions, and a number of attempts to apply the results to actual therapy have been made. Above all, gene therapy is mentioned as one of the fields which received the greatest development. Various genes relating hereditary diseases have been discovered and decoded, while methods for introducing these genes into cells through physical and chemical techniques have been developed. Thus, gene therapy has now stepped up from the stage of fundamental experiments to actual clinical application.
As it has been clarified that the abnormal gene participates in congenital diseases, such as familial hypercholesterolemia and adenosine deaminase (ADA) deficiency, and cancers and AIDS which are considered as acquired hereditary diseases, gene therapy by transducing the gene to the somatic cells of a patient has been attracting attention as a new method of therapy. After the first clinical test of gene therapy in the United States in 1989, clinical tests were commenced also in Italy, The Netherlands, France, England, and China. In the U.S., in particular, 81 protocols for gene therapy were approved by Recombinant DNA Advisory Committee (RAC) of National Institute of Health (NIH), and about 500 cases underwent gene therapy by June, 1995.
By the kind of the cells to which genes are transduced (target cells), gene therapy is divided into germ cell gene therapy and somatic cell gene therapy. It is also divided into augmentation gene therapy (a new (normal) gene is added with an abnormal gene as it is) and replacement gene therapy (an abnormal gene is replaced with a new (normal) gene). For the time being, only augmentation gene therapy to somatic cells are allowed due to bioethical and technical limitations.
A great technical subject in the above-mentioned clinical application of gene therapy is how to introduce foreign genes into target cells efficiently and safely. Early in 1980, application of physical techniques such as microinjection was attempted but not turned to practical use because the efficiency and stability of gene transduction were low and also because the technique of large scale cell culture was limited in those days. Thereafter, recombinant viruses (virus vectors) serving as a vector for efficient transduction of an foreign gene into target cells were developed, which enabled clinical application of gene therapy for the first time.
One of the most general methods of gene therapy is ex vivo gene therapy by autograft, in which target cells are taken from a patient and, after transducing thereto a gene for therapy, the cells are returned to the patient (see Science, Vol. 249, p. 1285 (1990)). Application of ex vivo gene therapy is limited to those cases in which the cells subject to the therapy can be taken outside the body. In addition, since special equipment is required for mass culture of the cells taken from the patient, the facilities available for the therapy are limited.
On the other hand, for the cases where the target cells are fixed at an organ or tissues, so-called in vivo gene therapy has been studied, in which a gene for treatment is administered directly to the site from which the disease is originated. For example, a method for transducing a gene into an organ, such as the heart or the liver, comprising inserting a balloon catheter through a blood vessel and, after stopping the blood flow, directly infusing the gene to the inner wall of the blood vessel has been proposed (see unexamined published Japanese patent application 6-509328 based on a PCT application PCT/US92/05242 (International Publication No. WO93/00051)).
Clinical researches of in vivo gene therapy for cerebroma (see Human Gene Therapy, Vol. 4, p. 39 (1993)) or malignant melanoma (Blood, Vol. 80, p. 2817 (1992)) have also been carried on. Such in vivo gene therapy is expected as a new method taking the place of conventional surgical treatment or chemotherapy.
Gene therapy for cancers is generally divided into indirect killing of cancer cells and direct killing of cancer cells.
The former is a method for treating a cancer by making use of immunity essentially possessed by a living body. More specifically, this method is to make a tumor disappear by enhancing the anti-tumor immunity of the patient by transducing of a gene which codes cytokines, such as interleukin (IL) 2 (see Cell, Vol. 60, p. 397 (1990)), IL 4 (see Cell, Vol. 57, p. 503 (1989)), interferon (INF) γ (see Proc. Natl. Acd. Sci. U.S.A., Vol. 86, p. 9456 (1989)), a granulocyte-macrophage colony-stimulating factor (GM-CSF) (see Proc. Natl. Acd. Sci. U.S.A., Vol. 90, p. 3539 (1993)), and a tumor necrosis factor (TNF) (see J. Immunolo., Vol. 146, p. 3227 (1991)), and an intercellular adhesive factor (see Science, Vol. 259, p. 368 (1993)). With respect to the mechanism of the tumor disappearance, induction of cytotoxic T lymphocytes (CTL) and tumor infiltrating lymphocytes (TIL) has been reported (see Science, Vol. 256, p. 808 (1992)).
The latter therapy is a method of introducing a gene directly acting on cancer cells. Specifically, this method is characterized in that a gene coding an enzyme capable of converting a cytotoxin precursor to an activated form is transduced into cancer cells, and the cytotoxin precursor is administered locally or systemically thereby to specifically kill the transduced cancer cells. The method is called virus-directed enzyme/prodrug therapy (VDEPT). For example, introduction of a self-killing gene, such as a thymidine kinase (tk) gene of herpes simplex virus (HSV), combined with ganciclovir (GCV) is mentioned (see Science, Vol. 256, p. 1550 (1992)). The cells to which the tk gene has been transduced metabolize GCV to produce cytotoxic GCV-triphosphate (GCV-TP) and thereby suffer injury and death. At this time, a lethal effect occurs also in the cancer cells into which the gene has not been integrated (a so-called bystander effect) and the tumor reduces (see Human Gene Therapy, Vol. 4, 725 (1993)). Further, in cases where carcinogenesis is induced by variation of anti-oncogene, such as p53 and Rb, transduction of the anti-oncogene has been suggested in an attempt to normalize the cells (see Science, Vol. 249, p. 912 (1990)).
About a half of cases of gastric cancer, one of digestive organ cancers, are now found in the initial stage owing to the recent highly advanced medical techniques, and more than a half of the cases can be cured completely. However, advanced cases of gastric cancer are still incurable even with every possible treatment, and establishment of new therapy has been keenly demanded.
The conventional treatment for gastric cancer is generally divided into (1) surgical treatment and (2) chemotherapy as described below.
(1) Standard surgical therapy generally applied to gastric cancer is the extended radical surgery comprising complete extirpation of not only the stomach inclusive of the lesion but the surrounding lymph nodes. However, the recent rapid advancement of medical treatment on gastric cancer has allowed application of reduced surgery comprising removal of the affected site to cases with gastric cancer at the early stage with little possibility of spread to lymph nodes. The reduced surgery includes endoscopic mucosal resection, laparoscopic local resection of the stomach, and the like, and the scale of the operation is decided according to the depth of the affected part.
Endoscopic mucosal resection (see Takemoto, T. et al., Digest Endosco., Vol. 1, No. 1, p. 4 (1989)) is a surgical treatment involving no laparotomy. Strip biopsy is widely performed as one embodiment of endoscopic mucosal resection, in which the lesion is lifted by submucous infusion of physiological saline and resected by means of a direct vision 2-channel scope. Strip biopsy is advantageous in that the time for an operation and anesthesia can be reduced and the amount of transfused blood is smaller than that needed in a standard surgical operation so that hepatic disorders can be minimized and the pain or burden on a patient can be alleviated. Although complete extirpation of the surrounding lymph nodes is difficult because the resectable area is limited, an increased capacity of the remaining stomach is secured, making it possible to improve the patient's postoperative quality of life (QOL). However, the cases to which strip biopsy is applicable are limited to those with protuberant tumors having a diameter of smaller than 2 cm and depressed tumors having a diameter of smaller than 1 cm.
For the management of larger lesions which should be removed by divided endoscopic mucosal resection and raise a possibility of increasing an incomplete resection ratio, laparoscopic local stomach resection (see Ohgami, M. et al., Dig. Surg., Vol. 11, pp. 64-67 (1994)) is effective. However, the gas in the stomach may escape through the possible perforation made for the resection. It may follow that the visual field is lost due to deflation of the stomach, which sometimes forces switch-over to laparotomy.
The above-mentioned reduced surgery gives rise to problems of occurrence of multiple cancer and carcinogenesis of the residual stomach and also involves a possibility of metastases. Therefore, care should be taken in resection not to bring the tumor tissue into contact with other tissues. Further, the target of the reduced surgery is a primary cancer that can be surgically resected with ease and accordingly is not expected to have effects on metastatic lesions in lymph nodes.
(2) For the gastric cancer that cannot be completely resected or with observed metastasis to lymph nodes, endoscopic chemotherapy is adopted for the purpose of extirpation of the affected lymph nodes. This method is medication for complete extirpation chiefly aiming at metastatic lesions in lymph nodes that are difficult to extirpate by surgical means. Drugs comprising a lymph-directed carrier, such as an emulsion, liposomes, or fine activated carbon powder, having included therein or adsorbed thereon an anticancer agent are used for the chemotherapy. The anticancer agents include 5-FU, adriamycin, mitomycin C, and so on. However, there is a possibility of occurrence of side effects, such as epilation, reduction of leucocytes, and internal organ disturbances. While it has been proposed to previously transduce a multidrug-resistant gene (MDR-1) into hematopoietic stem cells to endow the patient with resistant against chemotherapy, chemotherapy serves as nothing but preoperative auxiliary treatment for the time being.
Anyway, the above-mentioned therapeutic methods differ in applicability, and there has not been established therapy aiming at a tumor site and surrounding lymph nodes at the same time.
SUMMARY OF THE INVENTION
In the light of the above situation, the inventors have conducted extensive studies for the purpose of providing a method for simultaneously treating a tumor site and a metastatic lesion in a lymph node without relying on a conventional surgical treatment including resection of the tumor site and extirpation of the lymph node. As a result, it has been surprisingly found that when a recombinant virus vector, etc. carrying a gene for treatment is endoscopically delivered directly to a primary lesion, such as a tumor site, by means of a needle, etc., the gene is transduced not only into the primary lesion but specifically to metastatic lesions in lymph nodes and expressed in these sites and thereby expected to produce effects in extirpation of the lymph nodes as well. The present invention has been completed based on this finding.
Accordingly, an object of the present invention is to provide a method for transducing a gene for treatment into the tumor tissue cells of a patient with a digestive cancer or the like by a direct in vivo technique (direct transduction of a gene into an affected site). At the same time, an object of the present invention is to provide a method for transducing a gene for treatment into a metastatic lesion in a lymph node through transfer of a vector for gene therapy to the lymph node, which is a newly found effect. More particularly, the object of the present invention is to provide a method enabling endoscopic treatment of those cases which conventionally require laparotomy for complete extirpation of the subject organ (e.g., stomach) by transducing a gene for treatment also into a metastatic lesion in a lymph node, which has been difficult to treat by conventional endoscopic mucosal resection or laparoscopic local resection of the stomach.
The present invention provides, in its first embodiment, a method for transducing a gene for treatment into an affected site by means of a vector for gene therapy while monitoring the tumor site on a monitor screen.
The present invention also provides, in its second embodiment, a method for not only transducing a gene for treatment into cancer cells by using a virus vector as a gene carrier but also achieving the properties of the virus vector to transfer to lymph nodes by the above-mentioned endoscopic topical administration.
From the above viewpoint, the present invention further provides, in its third embodiment, a method for transducing a gene for treatment into lymph nodes surrounding a tumor site by making use of the virus vector's properties of transferring to the lymph nodes, which comprises topically injecting the virus vector into the submucous layer surrounding a tumor by the above-described method.
The present invention furthermore provides, in its fourth embodiment, a specific therapeutic method which makes use of a thymidine kinase gene of human herpes simplex virus origin which has been transduced into a primary cancer lesion and a metastatic lesion by means of a virus vector.
According to the first embodiment, a carrier for a gene for treatment, such as a virus vector, can be topically injected to an affected site while observing through a monitor. As a result, a gene included in the carrier, e.g., a virus vector, can be transduced specifically into cancer cells.
According to the second embodiment, a gene for treatment is transduced into tumor cells by means of a carrier, such as a virus vector, which carries the gene and has been topically injected under endoscopic observation. In addition, the carrier is given properties of transferring to lymph nodes and is directed to and accumulated in the lymph nodes.
According to the third and forth embodiments, a gene for treatment can be transduced into lymph nodes by means of a carrier for the gene for treatment, such as a virus vector. Therefore, the metastatic lesions in the lymph nodes can be cured without extirpating the lymph nodes, thereby to prevent recurrence of the cancer.
BRIEF DESCRIPTION OF THE DRAWINGS
The file of this patent contains at least one drawing executed in color. Copies of this patent with color drawing(s) will be provided by the Patent and Trademark Office upon request and payment of the necessary fee.
FIG. 1 is a schematic illustration showing the structure of an expression cosmid pAdexCAGTK having a tk-coding gene inserted.
FIG. 2 is a schematic illustration showing the structure of an expression cosmid pAdexCALacZL having a lacZ-coding gene inserted.
FIG. 3 is an electron micrograph of the X-gal-stained gastric mucous layer preparation to which a gene for treatment has been transduced.
FIG. 4 is an electron micrograph of the X-gal-stained lymph node preparation to which a gene for treatment has been transduced.
FIG. 5 is an electron micrograph of the gastric mucous layer preparation which shows reduction of tissues as a result of GCV administration.
FIG. 6 is an electron micrograph of the lymph node preparation which shows reduction of tissues as a result of ganciclovir administration.
FIG. 7 shows the results of Southern hybridization of the whole DNA prepared from the transduced gastric mucosa and lymph node, with a tk gene as a probe.
DETAILED DESCRIPTION OF THE INVENTION
The subjects of the therapy according to the present invention are, for example, vertebrates, preferably warm-blooded animals, still preferably mammals, and particularly preferably humans.
The therapy of the present invention is applicable to all the diseases that can be treated with an endoscope. Examples of such diseases include digestive organ cancers, such as gastric cancer and colon and rectum cancer, pulmonary cancer, urinary bladder cancer, and mammary cancer, especially gastric cancer.
The gene for treatment which can be used in the gene therapy of the present invention is not limited to self-killing genes such as a tk gene and includes any kind of genes which can be used for treatment of disease, in particular, those suppress growth or metastasis of cancer cells. Examples of usable genes for treatment include tumor suppressor genes, such as p53 (see Baker, S. J. et al., Science, Vol. 249, p. 912 (1990)), Rb (see Bookstein R. et al., Science, Vol. 247, p. 712 (1987)), and WT-1 (see Weissman, B. E. et al., Science, Vol. 236, p. 175 (1987); and metastasis suppressor genes, such as TIMP (see Tsuchiya, Y. et al., Cancer Res., Vol. 53, p. 1397 (1993)).
These genes for treatment are usually used after integrating it into a carrier that can express the gene (e.g., a vector) by general genetic recombination techniques. Such a vector includes those of virus origin, such as an adenovirus vector (hereinafter described in Examples), a retrovirus vector (see Miller, A. D., Current Topics in Microbiology and Immunology, Vol. 158, p. 1 (1992), etc.), a herpes virus vector (see Palella T. D., Mol. Cell Biol., Vol. 8, p. 457 (1988), etc.), HIV, and an adeno-associated virus vector (see Muzyczka, N., Current Topics in Microbiology and Immunology, Vol. 158, p. 97 (1992), etc. Any other virus vectors and non-virus vectors, such as liposomes and polyamino acids, which can carry a gene for treatment can be used. In addition, cells capable of producing a virus vector can be used to provide a virus vector for gene therapy. In such a case, cells capable of producing a virus vector may preferably be suspended as complete as possible in order to avoid clogginess of the syringe for injection.
The vector having integrated therein a gene for treatment is given through, for example, a needle, and is therefore preferably administered as dissolved in a solvent. The solvent to be used is not limited as long as the vector, when suspended therein, does not undergo reduction in titre. Physiological saline, an isotonic phosphate buffer or an isotonic glucose solution is preferred as solvent. In order to improve storage stability of the vector, a stabilizer, e.g., gelatin, may be added to the vector solution. In order to prevent leakage of the vector injected to the affected site, a thickener may be added to the vector solution.
The titre of the vector for gene therapy is preferably 1×10 7 cfu/ml, more preferably 1×10 8 cfu/ml, since effective effect of treatment is expected by the increased gene transduction efficiency. The amount of the solution or suspension containing the vector for gene therapy to be administered is preferably from 0.01 ml to 30 ml, and more preferably 0.1 ml to 10 ml.
The endoscope which can be used in the present invention is not particularly limited as long as a needle for injecting a virus vector or virus vector-producing cells can be fitted thereto.
Nucleotide analogues which can be administered after injection of a virus vector into a lesion is preferably ganciclovir (hereinafter abbreviated as GCV). The nucleotide analogue, e.g., GCV, is usually administered intravenously, preferably by an intravenous drip over 1 hour of about 6 mg/kg per day.
The present invention will now be illustrated in greater detail by way of Examples with reference to the accompanying drawings, but it should be understood that the present invention is not construed as being limited thereto.
EXAMPLE 1
Preparation of Recombinant Adenovirus Vector Having tk Gene of Human Herpes Simplex Virus Origin
A recombinant adenovirus vector to be used for tk gene expression (FIG. 1) and a recombinant adenovirus vector having a lacZ gene (FIG. 2) were prepared by a COS-TPC method in a known manner (see Kanegae, Y. et al., Jikken Kagaku, Vol. 12, No. 3 (1994) and Kanegae, Y. et al., Jpn. J. Med. Sci. Biol., Vol. 47, p. 157 (1994)). All the manipulations concerning the construction of plasmids were in accordance with general gene recombination techniques.
EXAMPLE 2
Preparation of Gastric Cancer Model in Beagle
A 4-month-old male beagle was allowed drink water containing 5 mg/500 ml of N-ethyl-N'-nitro-N-nitrosoguanidine (ENNG) every day for a 8-month period and then fed under usual conditions for 6 months to develop a tumor.
EXAMPLE 3
Confirmation of Tumor with Endoscope
An endoscope EVIS 200 System manufactured by Olympus Optical Co., Ltd. was used.
The beagle was deprived of food from the previous day of endoscopic observation. Anesthesia was induced by intramuscular injection of 10 mg of Ketalar (produced by Sankyo Co., Ltd.) and maintained by inhalation of 2% Halothane (produced by Hoechst A. G.) by means of an automatic respiratory apparatus at an oxygen-nitrous oxide ratio of 1:3. An endotracheal tube with a cuff was inserted into the respiratory tract by using a mouth gag (Termo Corp.) to secure air passage, followed by mechanical aeration. The endoscope was inserted along the upper part of the larynx to confirm the tumor on the monitor screen. Further, the tumor tissue was collected by means of a clamp (produced by Olympus Optical Co., Ltd.), and the tissue was subjected to pathological examination to confirm carcinogenesis of the cells.
EXAMPLE 4
Administration of Virus Vector under Endoscopic Observation
A needle for esophageal varix puncture (produced by Sumitomo Bakelite Co., Ltd.) was inserted into the stomach through the endoscope and the recombinant adenovirus vector (5×10 8 cells/500 μl) was directly infused to the tumor site while observing on the monitor screen. After the infusion, the needle was not removed for about 1 minute so that the vector solution might not leak from the mucous membrane and might thoroughly penetrate the tumor site. The vector may be injected by a means other than the above-described needle, for example, a branched catheter with a needle for injection being fitted to each of the tips of the branches.
EXAMPLE 5
Confirmation of Gene-transduced Site by Marker
A recombinant adenovirus vector having a lacZ gene prepared in Example 1 was locally injected to the submucous layer at the gastric tumor site of the beagle, and the dog was fed in a usual manner for 3 days and subjected to an autopsy. The stomach was excised, cut into pieces, and stained with a staining solution containing X-gal as a substrate. Microscopic observation of a cut piece at an appropriate magnification revealed a plurality of blue-stained areas, confirming to the transduction of the gene into the tumor submucous layer (FIG. 3). In contrast, there was observed no blue-stained area in the control area distant from the injected area. In the autopsy, the surrounding lymph nodes and other tissues were also excised and stained similarly. As a result, the lymph nodes were also found stained, confirming to the transduction of the gene into the lymph nodes (FIG. 4).
EXAMPLE 6
Therapy of Tumor Tissue by GCV Administration
The recombinant adenovirus vector with a tk gene prepared in Example 1 was locally injected to the gastric cancer submucous layer according to the above-described method. From the next day, 50 mg/kg of GCV was intravenously injected twice a day (morning and evening) in a total daily dose of 100 mg/kg, and the dog was fed for 4 days, followed by an autopsy to conduct histological study. The cells into which the tk gene was transduced suffered cell injury and finally death due to specific metabolism of GCV. As a result, the histological study revealed cavity formation in the tissues surrounding the tumor site (FIG. 5) and in the lymph nodes (FIG. 6). The whole DNA at the tumor site was prepared and subjected to Southern hybridization with a tk gene as a probe. As a result, it was confirmed that the aimed gene had been transduced specifically into the tumor and the surrounding lymph nodes (FIG. 7).
As described in detail, the therapy according to the present invention enables in vivo transduction of a gene for treatment directly into the target site, which makes specific treatment of only the affected site possible. Further, the gene for treatment can also be introduced to the surrounding lymph nodes. Accordingly, the present invention offers gene therapy showing remarkable effects on both the primary cancer lesions and metastatic lesions in the lymph nodes.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A therapy for a disease, e.g., gastric cancer, comprising endoscopic local administration of a vector having a gene for treatment or cells producing the vector to a lesion to transduce the gene into target cells. The direct in vivo transduction of a gene for treatment into the affected site is expected to produce therapeutic effects specific on the lesion. Since the gene is introduced also into lymph nodes which may have developed a metastatic lesion, both the primary lesion and the metastatic lesion in the surrounding lymph nodes can be treated simultaneously. | 0 |
FIELD OF THE INVENTION
The present invention relates to a system for providing efficient depressurising of high pressure pipeline fluids. The system may provide for net power generation without the fluid undergoing liquefaction, solidification or unacceptable temperature reduction as a result of a Joule-Thompson process. The system is particularly relevant for depressurising high pressure natural gas pipelines in an energy efficient manner whilst making possible net power generation.
BACKGROUND TO THE INVENTION
Natural gas is transmitted via high pressure pipelines and distributed to end users at considerably lower pressures. Generally, compressor stations are used to raise the pressure and to maintain it during long distance transmission. It is noteworthy that differing line pressures are used for transmission lines in differing geographical settings, and the pressures must be reduced accordingly in compliance with network design requirements in a varying number of steps, which depend upon the size and nature of the end user or subdistribution node on the system.
The process of pressure reduction is normally accomplished by means of a small orifice or throttling valve and results in a substantial lowering of the gas' temperature. Naturally, the extent of temperature drop is directly proportional to the extent of pressure reduction that occurs.
Temperature drop caused by Joule-Thompson processes is undesirable and must be avoided, or at least limited for a number of reasons. Excessive chilling can cause undesirable stresses in the pipes and ancillary equipment; it can degrade certain pipe coatings and pipe materials; it can also cause freezing of the earth surrounding the pipeline with the associated risk of frost heave. Furthermore, the gas itself may contain condensable components whose liquefaction or solidification in reduced temperatures may pose problems for the downstream network.
The most direct method for avoiding such problems is to heat the gas stream immediately before its pressure is reduced. The amount of heat delivered is controlled so that the post-expansion gas temperature remains high enough to circumvent low temperature problems upon pressure release.
Burning a portion of the gas represents a logical source of heat available to the natural gas pressure reduction station. Unless there is another reliable and uninterrupted source of heat available to the pressure reduction station, a bank of high efficiency gas fired boilers is usually deployed to provide the necessary heat. This remedy is effective and generally straightforward to implement, but it comes at the cost of consuming some of the deliverable energy in the gas. Proposals have been made to use fuel cells or combined heat and power (CHP) units rather than boilers to supply heat along with power, but the energy loss in terms of gas consumption still remains.
Prior art methods for reducing or eliminating the waste of energy in the process of pressure reduction in natural gas are described below.
U.S. Pat. No. 4,677,827 describes adding an inhibitor to the gas upstream of the pressure reduction. The purpose of the inhibitor is to prevent condensation in the chilled gas. After the inhibitor is added the pressure reduction is allowed to take place without preheating.
Reheating after pressure reduction can be accomplished by establishing thermal contact with the ambient since the expanded gas will generally have a temperature below ambient. This can be done in a number of ways. For example: by providing free refrigeration to an available load (provided that such a load can be found); by providing a direct or indirect heat exchange connection between the gas and the ambient or by supplementing passive heat exchange with heat supplied by a heat pump. These methods allow much if not all of the reheating to be supplied from the ambient, with a consequent saving in heat produced by gas burning.
Difficulties with this approach include the necessity to provide an additional consumable, i.e. the inhibitor, to each site and to meter its injection into the gas stream. In addition it may be necessary to recover the inhibitor before the gas is supplied to the end user. Recovery of the inhibitor entails additional equipment and adds materially to the complexity of the station and to its operation.
Pozivil ( Acta Montanistica Slovaca , Rocnik 9 (2004), cislo 3, 258-260) reports transformation of the kinetic energy released in the gas expansion process into mechanical energy in an expansion turbine and, in most cases, subsequently into electrical power. This electrical power can then be used in a variety of ways: supplied back to the electricity grid; used to provide some or all of the electrical requirements of the site and possibly used to power a heat pump to supply heat to the expanded gas.
There are a number of issues to be addressed in considering the use of any of these power-generating methods. First is the fact that the gas temperature drop which accompanies a power-producing expansion is several times larger than that which accompanies a throttling expansion to the same final pressure. If this cooling is to be counteracted by burning gas upstream of the expander, the reheating process will consume more energy than can be generated even by the most efficient expander-generator unit. There must also be a full-time electrical load available to the station to utilise the electrical energy produced. In practical terms this usually means a grid connection through which the electricity is fed back into the network. In any case there is a net loss of usable energy even if the electricity generated is fully used. Justification for the expenditure for this arrangement must be sought from factors other than energy savings.
A variation of this approach is to use a CHP unit in addition to the expander-generator unit. The size of the CHP is determined by the amount of reheat required so that the thermal output of the CHP can be used to counteract the expansion-induced gas cooling. The electrical output of the expander-generator is added to that of the CHP unit and both are supplied to the grid. Both of the electrical outputs produce an economic return to the operator, but the primary energy and CO 2 advantages of the approach are less straightforward to establish. The reason for deploying the CHP unit is mainly to take advantage of its thermal output, so this part of the combustion energy must be seen as sacrificial in the overall scheme. The role of the CHP could be replaced by a fuel cell, and the overall approach would be the same.
If the heat is to be added post-expansion, then it will be necessary to add condensation inhibitors to the gas stream. Indeed, because of the very large temperature drop it may be necessary to increase the dosage of inhibitor for it to remain effective. It will also be necessary to evaluate the implications for equipment of chilling by temperature drops down to −80° C. which can occur even in a single expansion stage. This method is capable of achieving significant primary energy savings, but its implementation presents in more extreme form all of the difficulties noted above in connection with the inhibitor addition method.
U.S. Pat. No. 5,628,191 communicates a system comprising a heat pump to heat the gas pre-expansion. Utilising the pre-expansion heat pump approach, one is faced with the problem of heating the gas up to temperatures as high as 80-90° C. from an inlet temperature typically of 5-10° C. so as to avoid the cooling problems discussed above (supra). Achieving the very high final temperatures is a Herculean challenge for any conventional heat pump to achieve. In addition, the necessity of achieving such a large temperature lift in a single pass will have a very deleterious effect on the heat pump efficiency. If the heat pump efficiency does not achieve a minimum threshold efficiency level, the process may still require supplementary (combustion) heating.
U.S. Patent Application Publication No. 2003/0172661 provides for use of multiple small-ratio expansion stages to restrict the temperature drops to a range which a heat pump could handle. Such an approach would entail much greater equipment cost and complexity, without any additional benefit. The above considerations taken together make it unlikely that conventional heat pumps can play any significant role in this particular application.
Notwithstanding the state of the art it would still be desirable to provide for a system that is capable of pre-heating a pressurised fluid to a sufficient extent such that upon fluid depressurisation the problems associated with cooling are avoided. It would be desirable that the system be energy efficient. Furthermore, a system capable of net power generation would also be desirable.
SUMMARY OF THE INVENTION
The present invention provides for a system to minimise the effects of expansion cooling of any fluid undergoing depressurisation in a continuous or near continuous process. The system may be utilised to recover energy released by the expansion of the fluid.
In particular, the present invention provides for a system utilised to mitigate expansion cooling in natural gas pipeline depressurisation processes. Advantageously, the system may provide for energy recovery during the process of expansion cooling the natural gas.
In one aspect the present invention provides for a system for depressurisation of a pressurised fluid in a pipeline comprising:
at least one depressuriser for expanding the pressurised fluid in the pipeline to a lower pressure; and a transcritical heat pump for circulating a supercritical (refrigerant) fluid, wherein the supercritical fluid undergoes cooling so as to release heat for transmission to the pressurised fluid in the pipeline prior to at least one expansion of said pressurised fluid.
As will be appreciated by a person skilled in the art, upon cooling of the supercritical refrigerant fluid the temperature and pressure of the refrigerant fluid may fall below the critical temperature and critical pressure of the refrigerant fluid. As such the transcritical heat pump may also have a low pressure, low temperature side for circulating a refrigerant fluid at a temperature and pressure below its critical temperature and critical pressure. The transcritical heat pump may have:
a high temperature, high pressure side for circulating a refrigerant fluid at a temperature and pressure above its critical temperature and critical pressure; and a low temperature, low pressure side for circulating a refrigerant fluid at a temperature and pressure below its critical temperature and critical pressure.
The transcritical heat pump may also be understood to comprise a heat rejection phase for transferring heat from the refrigerant fluid at a temperature and pressure above its critical temperature and critical pressure.
The system of the present invention may further comprise at least one heat exchanger for transmission of heat to the pressurised fluid in the pipeline.
The heat released by the supercritical fluid undergoing cooling may be transmitted directly to the pressurised fluid in the pipeline prior to at least one expansion of said pressurised fluid. For example, a refrigerant fluid may undergo heating and compression in the heat pump such that it becomes supercritical and may be directly conducted to the at least one heat exchanger for heating the pressurised fluid in the pipeline. The supercritical fluid may undergo cooling in the heat exchanger to heat the pressurised fluid in the pipeline.
Conversely, heat released by the supercritical fluid undergoing cooling may be transmitted indirectly to the pressurised fluid in the pipeline prior to at least one expansion of said pressurised fluid. For example, this may comprise a secondary heat transfer circuit, which is in turn coupled to the at least one heat exchanger for heating the pressurised fluid in the pipeline. The heated supercritical fluid may undergo cooling in a heat exchanger so as to transmit heat to the secondary heat transfer circuit, thereby heating a fluid (for example water) in the secondary heat transfer circuit. The heated fluid in the secondary heat transfer circuit may be conducted to the at least one heat exchanger for heating the pressurised fluid in the pipeline.
The system of the present invention may provide for indirect heating of the pressurised fluid in the pipeline by the supercritical fluid. Advantageously, the configuration for indirect heating of the pressurised fluid in the pipeline by the supercritical fluid can be built into standard heat pump packages. Installation of the transcritical heat pump comprising the associated heat exchangers would require only plumbing trade skills rather than transcritical refrigeration skills.
The system of the present invention does not preclude a depressurisation step prior to heating of the pressurised fluid by the heat exchanger. Provided the incoming gas temperature is high enough to allow a small degree of depressurisation, and or the extent of depressurisation is sufficiently small, problems associated with cooling, such as liquefaction or solidification, should be avoided.
The heated supercritical fluid may undergo cooling in the heat exchanger so as to heat the pressurised fluid in the pipeline prior to expanding said pressurised fluid.
As used herein the term “transcritical heat pump” relates to a heat pump in which a refrigerant fluid undergoes a transcritical cycle, i.e. the refrigerant fluid changes between supercritical and subcritical states. In the system of the present invention the supercritical fluid may undergo cooling as part of a transcritical cycle to release heat to the pressurised fluid in the pipeline.
Desirably, the system of the present invention operates without the requirement for extra consumables, for example condensation inhibitors, at the pressure reduction site. This eliminates the extra costs associated with metering the inhibitor into the pressurised fluid pipeline and recovering the inhibitor before the fluid is supplied to the end user.
The system of the present invention provides for high efficiency heating as a consequence of the ability of a transcritical heat pump to deliver heat over the long continuously descending temperature ramp of a cooling supercritical fluid (as opposed to the nearly isothermal heat delivery characteristic of condensation in the normal reverse Rankine cycle).
In the system of the present invention, the heat rejection process (in the heat exchanger of the transcritical heat pump) takes place at a pressure above the critical pressure of the supercritical fluid. Thus, enabling the supercritical fluid to reach considerably higher temperatures. In addition, the heat rejection process in a transcritical heat pump occurs over a wide temperature band rather than at a single condensing temperature. This enables highly efficient heating of a pressurised fluid in a pipeline, such that the temperature of the pressurised fluid can be raised sufficiently so as to mitigate the temperature drop associated with expansion cooling of the pressurised fluid.
The system of the present invention may be capable of supplying electrical energy to the site (i.e. back to the system). Energy released in the fluid expansion (depressurisation) step may be harnessed. The harnessed energy may be supplied back to the system of the present invention as a source of energy. For example, the transcritical heat pump of the system of the present invention may be powered by an energy generator. The energy generator may be driven by the energy released in the fluid expansion step.
The energy released by gas depressurisation may be directly coupled to a transcritical heat pump compressor. This arrangement may allow reductions in cost as it eliminates the requirement for an electric generator and associated equipment.
Alternatively, the system of the present invention may be adapted to supply energy external to the system, for example to supply electrical energy to a grid connection. The system of the present invention may be adapted to supply electrical energy back to the system of the present invention in addition to supplying electrical energy to a grid connection.
The transcritical heat pump of the present invention may be thermally coupled to an ambient heat source (through a heat exchanger). Heat from the ambient may be transferred to the refrigerant fluid directly or indirectly (similar to above).
Direct heating by the ambient may comprise direct heat transfer between the refrigerant fluid and the heat exchanger coupled to the ambient heat source. Indirect coupling to the ambient may be achieved through a secondary heat transfer circuit, which may be coupled to the ambient heat source heat exchanger, and which takes in heat from the ambient to in turn heat the refrigerant fluid. The ambient heat source may be selected from the group comprising air, ground, ground water, surface water or combinations thereof. This may allow for the intake of low temperature thermal energy by the heat pump. The ambient may provide heat to the refrigerant fluid when it is in a subcritical state.
The heat exchanger in communication with the pressurised fluid in the pipeline may be disposed in a contraflow arrangement to the pressurised fluid in a pipeline. This provides for more efficient heat rejection.
The refrigerant for the transcritical cycle may be a fluid with a critical temperature high enough to allow evaporation by boiling up to about 20-25° C. and low enough that standard refrigeration heat rejection temperatures 40-80° C. are above its critical temperature. The fluid should have a large heat of vaporisation. Desirably, the fluid will be miscible with oil so as to provide sufficient lubrication. As the skilled person will appreciate, any suitable fluid may be utilised. For example, the transcritical refrigerant may be selected from CO 2 , C 2 H 6 , N 2 O, B 2 H 6 , C 2 H 4 . The present invention also embraces combinations thereof. The fluid undergoing transcritical cooling may be CO 2 . Advantageously, CO 2 is a non-flammable and non-toxic fluid. Further advantageously, CO 2 has an Ozone Depletion Potential (ODP) of zero and a Global Warming Potential (GWP) of one, making it one of the most attractive transcritical fluid options.
The depressuriser of the system of the present invention may comprise a throttling valve.
Desirably, the system of the present invention is configured to generate all of the energy required to heat the pressurised fluid, without burning any of said pressurised fluid in the heating process. For example, when the pressurised fluid is natural gas, without burning any of the natural gas. Such a system would be energy efficient.
The system may further comprise an energy generator for converting the energy released by the expanding fluid into electrical energy. Desirably, the pressurised fluid in the pipeline is heated by the heat exchanger prior to converting the energy released by the expanding fluid into electrical energy. Advantageously, by heating the pressurised fluid to a sufficiently high temperature the system of the present invention would eliminate consumption of the pressurised fluid, for example through burning, to counteract unwanted cooling arising from depressurisation.
The energy released by the expanding fluid may be transmitted to an energy generator. The energy generator may comprise a mechanical component driven by the expanding fluid to generate energy. For example, the pressurised fluid may be expanded through a turbine. In one desirable arrangement, the energy released by the expanding pressurised fluid may be harnessed by a turbo expander. Desirably, the pressurised fluid in the pipeline is heated (in a heat exchanger) prior to expanding the pressurised fluid through the energy generator.
The system of the present invention comprising an energy generator exploiting the fluid expansion process may provide for net power generation. The power-producing expander (for example, the turbo expander) can produce considerably more energy than that required to run the transcritical heat pump. Hence, the system of the present invention may be configured to produce a surplus of energy, a surplus of heat (for supply to the pressurised fluid in the pipeline) or a combination thereof.
The expansion of the pressurised fluid may be split between one or more depressurisers, for example a turbo expander and one or more Joule-Thompson throttling valves. Expander-generator units are more expensive than Joule-Thomson throttling valves and it may be more economic to split the expansion between an expander-generator unit and a number of Joule-Thomson throttling valves.
The system of the present invention may provide for a number of depressurisers in a series type arrangement. This may facilitate stepwise expansion of the pressurised fluid. Each depressuriser may expand the pressurised fluid through an energy generator so as to generate energy from each expansion. Alternatively, one of a plurality of depressurisers may expand the pressurised fluid through an energy generator. The remaining depressurisers may be throttling valves.
The system of the present invention may further comprise at least one of:
at least one depressuriser for expanding the pressurised fluid prior to heating of the pressurised fluid by the heat exchanger;
at least one depressuriser for expanding the pressurised fluid subsequent to a prior expansion of the heated pressurised fluid; and
combinations thereof.
Incorporating, in the system of the present invention, a depressuriser for expanding the pressurised fluid prior to heating of the pressurised fluid by the heat exchanger may be beneficial to the overall process. A slight precooling of the pressurised fluid may allow for a lower gas inlet temperature to the heat exchanger on the gas line. This may have a positive effect on the coefficient of performance of the heat pump and may increase the efficiency of the heat pump.
A pre-expansion of the pressurised fluid may increase the total pressure drop that can be achieved in a single stage. Thus, it may increase the overall pressure reduction capability of the system of the present invention beyond the limit imposed by the maximum inlet/outlet pressure ratio of the expander-generator acting alone. Provided the incoming gas temperature is high enough to allow a small degree of depressurisation, problems associated with cooling, such as liquefaction or solidification, should be avoided.
Incorporating, in the system of the present invention, a depressuriser for expanding the pressurised fluid subsequent to a prior expansion of the heated pressurised fluid mitigates the ability of the heat pump to produce more heat than is required to counteract the cooling which results from the energy-producing gas expansion step. Thus, additional cooling may be provided by further depressurisation.
The system of the present invention may provide for a plurality of pressure reduction lines, optionally disposed in parallel to one another. Each pressure reduction line may comprise at least one heat exchanger. Alternatively, one heat exchanger may heat the pressurised fluid for subsequent distribution into each pressure reduction line. Each pressure reduction line may comprise a depressuriser. Each pressure reduction line may comprise at least one depressuriser.
Each pressure reduction line may comprise at least one depressuriser configured to expand the pressurised fluid through an energy generator (expander-generator). In a desirable arrangement, one pressure reduction line comprises an energy generator which may provide the energy needed to heat the fluid in each of the pressure reduction lines. For example, a single energy generator may provide energy to power a single heat pump or a plurality of heat pumps. The heat exchangers associated with the heat pumps may be disposed in the same pressure reduction line or in separate pressure reduction lines. Alternatively, a single energy generator may provide energy to power a single heat pump, the heat exchanger element of which heats the pressurised fluid prior to distribution of the pressurised fluid into each pressure reduction line.
Each pressure reduction line may be configured to expand the pressurised fluid to a different pressure. This may be particularly advantageous where the pressurised fluid, for example natural gas, is to be distributed to different end users via the different pressure reduction lines. Suitably, the system of the present invention may provide for 2 to 5 pressure reduction lines disposed in parallel to one another.
It will be appreciated that the pressurised fluid in the pipeline of the system of the present invention may be gaseous. The pressurised fluid may be natural gas.
In a further aspect, the present invention provides for use of a supercritical fluid in a heat pump for the transmission of heat to a pressurised fluid in a pipeline prior to depressurisation of the pressurised fluid. The supercritical fluid may undergo cooling in a heat rejection phase in a heat exchanger. The supercritical fluid may undergo cooling as part of a transcritical cycle to release heat to the pressurised fluid in the pipeline. The heat provided by cooling of the supercritical fluid may be transmitted to the pressurised fluid in the pipeline directly or indirectly. Direct heating may comprise direct heat transfer between the supercritical fluid and the pressurised fluid in the pipeline. Indirect heat transfer may be achieved through a secondary heat transfer circuit comprising a fluid (for example water), which is coupled to a heat exchanger for heating the pressurised fluid in the pipeline, and which is heated by the supercritical fluid undergoing cooling to in turn heat the pressurised fluid in the pipeline. The pressurised fluid in the pipeline may be natural gas.
In yet a further aspect, the present invention provides for a method for heating a pressurised fluid in a pipeline comprising:
providing a transcritical heat pump, and
cooling a supercritical fluid to release heat for transmission to the pressurised fluid in the pipeline.
The supercritical fluid may undergo cooling as part of a transcritical cycle to release heat to the pressurised fluid in the pipeline. The heat provided by cooling the supercritical fluid may be transmitted to the pressurised fluid in the pipeline directly or indirectly. Direct heat transfer may comprise direct transmission of heat from the supercritical fluid undergoing cooling and a heat exchanger in communication with the pressurised fluid in the pipeline. A transcritical heat pump may directly conduct the heated supercritical fluid to the heat exchanger.
Indirect heat transfer may be achieved through a secondary heat transfer circuit comprising a fluid (for example water), which is coupled to a heat exchanger for heating the pressurised fluid in the pipeline, and which is heated by the supercritical fluid undergoing transcritical cooling to in turn heat the pressurised fluid in the pipeline. The pressurised fluid in a pipeline may be natural gas.
The straightforward nature of the system of the present invention means that its operation should entail little if any change from existing arrangements for service and maintenance. The expected long service life and minimal service/adjustment requirements of the system give it excellent prospects for cost-effectiveness.
Where suitable, it will be appreciated that all optional and/or additional features of one embodiment of the invention may be combined with optional and/or additional features of another/other embodiment(s) of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the invention and from the drawings in which:
FIG. 1 illustrates a system according to the present invention comprising an energy generator;
FIG. 2 illustrates a system according to the present invention comprising a throttling value for depressurisation of a pressurised fluid prior to heating;
FIG. 3 illustrates a system according to the present invention wherein the pressurised fluid undergoes further expansion subsequent to a first energy generating expansion;
FIG. 4 illustrates a system according to the present invention wherein the pressurised fluid undergoes depressurisation at a number of locations;
FIG. 5 illustrates a system according to the present invention having two pressure reduction lines in parallel;
FIG. 6 illustrates a system according to the present invention having a mechanical coupling directly coupled to the transcritical heat pump; and
FIG. 7 illustrates a system according to the present invention comprising secondary heat exchange circuits.
DETAILED DESCRIPTION OF THE INVENTION
It should be readily apparent to one of ordinary skill in the art that the examples disclosed herein below represent generalised examples only, and that other arrangements and methods capable of reproducing the invention are possible and are embraced by the present invention.
The system of the present invention provides for a fluid expansion energy conversion device (typically a radial inflow expansion turbine coupled to an electrical generator) and an ambient source transcritical heat pump. The ambient heat may be sourced from at least one of water, air, or the ground. The configuration of the components for pressure reduction in a high pressure natural gas line assembly is shown in FIG. 1 .
Incoming high pressure gas in pipe 101 is taken through a heat exchanger 102 in which it is heated, preferably in a counterflow arrangement, by refrigerant fluid undergoing transcritical cooling. The temperature of the gas emerging from the heat exchanger via pipe section 103 is maintained at a level high enough to prevent any low temperature problems after the expansion step.
The gas proceeds to enter the energy-producing gas expansion device 104 , preferably a high efficiency radial inflow expansion turbine, in which the gas temperature drops back to a level close to that of the incoming high pressure gas. The pressure of the outgoing gas in pipe section 105 is lower than that of the entering gas 101 by the design pressure reduction ratio for the particular station. The gas then passes to further processing steps (which may comprise one or more further expansion steps) or to the distribution system for distribution to an end user. The gas expansion energy produced in the expander 104 is transmitted, from the expander 104 , by a mechanical coupling 106 to a generator 107 where it is transformed into electricity.
All or a portion of the generated electricity is used to power a transcritical heat pump unit 108 . The energy generator 107 may be directly connected (not shown) to the heat pump 108 . The present disclosure incorporates a transcritical heat pump 108 in order to overcome several difficulties which render most heat pumps inefficient at or incapable of meeting the temperature demands of the application. In the transcritical cycle, the heat rejection process takes place at a pressure above the critical pressure of the refrigerant, thus enabling it to reach considerably higher temperatures. In addition, the heat rejection process in a transcritical heat pump occurs over a wide temperature band rather than at a single condensing temperature, making it particularly well suited to the current application.
The coefficient of performance (COP) of the transcritical process is determined by the average heat release temperature. This, in combination with the long continuously descending temperature ramp of a cooling supercritical fluid allows the transcritical heat pump to achieve very favourable COP values while supplying the high final gas temperatures required.
The heat pump 108 , whose heat rejection component is the above-described heat exchanger 102 , also comprises a compressor, an evaporator, an internal heat exchanger and other components required for the operation of the transcritical heat pump cycle. The compressor, heat exchangers, flow control devices and internal refrigerant circuit components may be any of the types used in the refrigeration/heat pump industry for transcritical systems. Hot high-pressure refrigerant fluid is carried to the heat exchanger 102 from the heat pump 108 by means of the heated refrigerant supply pipe 109 . Cooled high-pressure refrigerant is returned to the heat pump 108 from the high temperature heat exchanger 102 by pipe 110 . Optionally, the heat delivery loop comprising heat exchanger 102 and pipes 109 and 110 could circulate water or other suitable liquid instead of the refrigerant itself. The evaporator of the heat pump 108 is thermally coupled to the local ambient. It may be coupled to the air, the ground, a ground or surface water source, a waste heat stream or any combination of these elements. The ambient coupling heat exchange circuit 111 may either be direct (for example, circulating the system refrigerant throughout the heat-gathering circuit) or indirect (for example, using a freeze-protected liquid to collect ambient heat). The ambient coupling heat exchanger 112 may take a variety of forms depending on the specific type of heat exchange best suited to each site.
Energy to operate the system equipment, such as the compressor and other electrical peripherals in the heat pump is provided by the generator 107 (which is in turn coupled to the expander unit 104 ). The thermal energy is sourced from the ambient and raised in temperature by a transcritical heat pump to provide heat to the incoming gas prior to its expansion. The heat pump (including its ambient energy source) is sized to provide the necessary gas heating and not necessarily to fully exploit the available gas expansion energy.
The amount of heat which must be delivered to the gas stream by the heat exchanger 102 to counteract expansion cooling will be significantly greater than the amount of electrical energy generated by the generator 107 . The efficiency of the expander 104 , the generator 107 and the power conversion electronics will limit the power which can be supplied to the heat pump from gas expansion energy recovery. Even with well-adjusted contemporary equipment, the energy recovered as electricity is unlikely to exceed 75-80% of the available gas expansion energy.
Invariably, the above energy losses are not recoverable as usable heat for the gas warming task. Hence these energy losses must be supplied from the thermal output of the heat pump. In addition to making up these losses, it is necessary to supply heat to counteract the Joule-Thomson cooling which takes place even in the absence of any gas energy recovery. The performance of the heat pump therefore must exceed a minimum heating COP of approximately 2 in order to provide full temperature recovery of the incoming high temperature gas without the consumption of any gas (or other purchased fuel). The transcritical heat pump is uniquely able to meet this performance requirement while supplying the high temperatures and the high temperature lift needed for preheating.
In FIG. 2 the system includes an optional gas expansion step, using a throttling valve 213 , located upstream of the heat exchanger 102 and the main expander 104 . Provided the incoming gas temperature is high enough to allow a small degree of depressurisation, the liquefaction and solidification problems associated with cooling should be avoided. A mechanical coupling 106 connects the expander 104 to an energy generator 107 . The energy generated by the generator 107 may be utilised to power the transcritical heat pump 108 . The transcritical heat pump 108 is thermally coupled to the ambient through circuit 111 and heat exchanger 112 . Pipe sections 109 and 110 connect the heat exchanger 102 to the transcritical heat pump 108 . The pressure of the outgoing gas in pipe section 105 is lower than that of the entering gas 101 . The gas then passes to further processing steps (which may comprise one or more further expansion steps) or to the distribution system for distribution to an end user.
The provision of an additional gas expansion step, via throttling valve 213 , upstream of the heat exchanger 102 may be beneficial to the overall process in two different ways. Firstly, a slight precooling of the gas allows for a lower gas inlet temperature to the heat exchanger on the gas line 101 . This has a positive effect on the coefficient of performance of the heat pump and increases the efficiency of the heat pump. Secondly, a pre-expansion of the gas increases the total pressure drop which can be achieved in a single stage and thereby increases the overall pressure reduction capability of the aggregate beyond the limit imposed by the maximum inlet/outlet pressure ratio of the expander acting alone.
FIG. 3 illustrates a variation in which there is a pressure reduction step, through throttling valve 314 , downstream of the energy-producing expansion process. A mechanical coupling 106 connects the expander 104 to an energy generator 107 . The energy generated by the generator 107 may be utilised to power the transcritical heat pump 108 . The transcritical heat pump 108 is thermally coupled to the ambient through circuit 111 and heat exchanger 112 . Pipe sections 109 and 110 connect the heat exchanger 102 to the transcritical heat pump 108 . The pressure of the outgoing gas in pipe section 105 is lower than that of the entering gas 101 .
The variation illustrated in FIG. 3 mitigates the ability of the transcritical heat pump 108 to produce more heat than is required to counteract the cooling which results from the energy-producing gas expansion step through expander 104 . The downstream pressure reduction step is achieved through the use of conventional throttling equipment 314 and will be accompanied by Joule-Thomson cooling. The size of the second pressure reduction step whose associated chilling can be counteracted by the excess heat supplied by the heat pump will be limited by the heat pump efficiency achievable at each individual site. The gas may then pass to further processing steps (which may comprise one or more further expansion steps) or to the distribution system for distribution to an end user.
In favourable circumstances the second pressure reduction ratio, via throttling valve 314 , can be as large as the first (energy-recuperative) pressure reduction ratio. This may provide for a two-stage pressure reduction in which the entire reheating requirement can be supplied by a single expander-generator heat pump assembly.
A system having throttling expansion steps included both upstream, via throttling valve 413 , and downstream, via throttling valve 414 , of the power-producing expander 104 is provided in FIG. 4 . A mechanical coupling 106 connects the expander 104 to an energy generator 107 . The energy generated by the generator 107 may be utilised to power the transcritical heat pump 108 . The transcritical heat pump 108 is thermally coupled to the ambient through circuit 111 and heat exchanger 112 . Pipe sections 109 and 110 connect the heat exchanger 102 to the transcritical heat pump 108 . The pressure of the outgoing gas in pipe section 105 is lower than that of the entering gas 101 . The gas then passes to further processing steps (which may comprise one or more further expansion steps) or to the distribution system for distribution to an end user.
This arrangement depicted in FIG. 4 allows the system to be optimised for maximum heat pump COP while producing a larger pressure reduction than can be achieved in a single power-producing stage.
In FIG. 5 there are two pressure reduction lines 515 and 516 in parallel. Each pressure reduction line 515 and 516 has a heat exchanger 517 and 518 . Heated supercritical fluid is conducted to the heat exchangers 517 and 518 in pipe sections 109 and 109 a by transcritical heat pump 108 . Cooled fluid returns to the pump in pipes 110 and 110 a . The transcritical heat pump 108 is thermally coupled to the ambient through circuit 111 and heat exchanger 112 . As will be appreciated, the system may comprise a number of pressure reduction lines in parallel. Each pressure reduction line may comprise an energy producing expander. Each pressure reduction line may comprise a throttling valve. Each of the plurality of pressure reduction lines may comprise either an energy producing expander or a throttling valve (depending on the needs of the system).
Pressure reduction line 516 comprises an energy-producing expander 104 , and the energy released is harnessed by a mechanical coupling 106 to an energy generator 107 . The pressure of the outgoing gas in pipe 521 is lower than that of the gas in pipe 516 . The gas then passes to further processing steps (which may comprise one or more further expansion steps) or to the distribution system for distribution to an end user.
Pressure reduction line 515 comprises a throttling valve 519 . The energy released during depressurisation is not harnessed by an energy generator. The pressure of the outgoing gas in pipe section 520 is lower than that of the gas in pipe 515 . The gas then passes to further processing steps (which may comprise one or more further expansion steps) or to the distribution system for distribution to an end user. The energy required to heat the gas in the pressure reduction lines 515 and 516 can be provided by the transcritical heat pump 108 , which in turn may be powered by the energy-producing expander 104 .
Each pressure reduction line 515 and 516 may be configured to expand the pressurised gas to a different pressure. This may be particularly advantageous where the natural gas is to be distributed to different networks or end users via the different pressure reduction lines 515 and 516 .
In each of FIGS. 1 to 5 discussed above it will be appreciated that electrical energy in excess of that required to operate the transcritical heat pump 108 may be supplied by the generator 107 . In such a circumstance, the primary requirement is that the expander 104 -generator 107 unit is selected to make full use of the recoverable expansion energy while the heat pump 108 is designed to deliver no more than the minimum reheat needed and to use the minimum of input in the process. Provided that there is a useful load (for example, a grid connect, lighting, controls, instrumentation and communications equipment, battery banks, pumps, and other peripherals to the site services) which can always accept the generated electrical energy, this option offers a means of recovering the maximum amount of energy available in the pressure reduction process. To implement this option there need only be one or more additional outputs from the generator. For example, one or more extra connections to the generator electrical terminals and a capability within the system controller to manage the electrical power delivery from the generator may be provided.
In FIG. 6 the mechanical power generated by gas depressurisation is coupled directly to a compressor 622 . The compressor 622 is connected to the transcritical heat pump 108 through circuit 623 . A mechanical coupling 106 connected to the expander 104 powers the compressor 622 . The transcritical heat pump 108 is thermally coupled to the ambient through circuit 111 and heat exchanger 112 . Pipes 109 and 110 connect the heat exchanger 102 to the transcritical heat pump 108 . The pressure of the outgoing gas in pipe 105 is lower than that of the entering gas 101 . The gas then passes to further processing steps (which may comprise one or more further expansion steps) or to the distribution system for distribution to an end user.
The configuration illustrated in FIG. 6 comprising a compressor 622 directly coupled to expander 104 (via mechanical coupling 106 ) precludes generation of surplus electricity, but it achieves a higher energy efficiency and eliminates the need for an electric generator, a power conversion package and a electric compressor driver. This arrangement allows reductions in cost and is more readily adapted to close coupled systems which can be pre-manufactured, particularly for smaller applications where the generation and export of surplus electricity is unlikely to be economically feasible.
In FIG. 7 the heat generated by the cooling supercritical fluid is transferred to the pressurised fluid in the pipeline 101 by means of a secondary heat exchange fluid circuit 701 in communication with heat exchanger 102 . The secondary heat exchange fluid circuit 701 is powered by a pump 702 , making the secondary heat exchange fluid circuit 701 separate from the transcritical heat pump 108 . Heat transfer between the heated supercritical fluid and secondary heat exchange fluid circuit 701 occurs in heat exchanger 703 . Typically, the secondary heat exchange fluid in the circuit 701 would be water. The water may contain a small fraction of antifreeze added to protect the system in the event of a shutdown.
A further secondary heat exchange circuit 706 is provided in FIG. 7 . Circuit 706 runs between heat exchanger 704 and the ambient source heat exchanger 112 . The secondary heat exchange fluid circuit 706 is powered by a pump 705 , making the secondary heat exchange fluid circuit 706 separate from the transcritical heat pump 108 . Heat from the ambient is transferred to secondary heat exchange circuit 706 in ambient heat exchanger 112 . The heat is subsequently transferred to the cooled refrigerant fluid in heat exchanger 704 . The fluid utilised in secondary heat exchange circuit 706 would require substantial freeze protection since it could operate near or below zero degrees Celsius.
A mechanical coupling 106 connects the expander 104 to an energy generator 107 . The energy generated by the generator 107 may be utilised to power the transcritical heat pump 108 and or pumps 702 and 705 . The pressure of the outgoing gas in pipe section 105 is lower than that of the entering gas 101 .
Advantageously, the configuration illustrated in FIG. 7 can be built into packages similar to those used with existing non-transcritical heat pumps. Installation of transcritical heat pump 108 packaged together with associated heat exchangers 703 and 704 would require only plumbing trade skills rather than transcritical refrigeration skills.
It will be appreciated that each of the embodiments disclosed in the above Figures (supra) may be used one or more times, for example two or more systems in series or series/parallel arrays to achieve the gas heating and power production tasks needed at any single site.
The words “comprises/comprising” and the words “having/including” when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.
It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. | The present invention relates to a system for depressurisation of high pressure pipeline fluids. The system may provide for net power generation without the pressurised fluid undergoing liquefaction or solidification or unacceptable temperature reduction as a result of a Joule-Thompson process. The system is particularly relevant for depressurising high pressure natural gas pipelines in an energy efficient manner whilst making possible net power generation. The system for depressurisation of a pressurised fluid in a pipeline comprises at least one depressuriser for expanding the fluid in the pipeline to a lower pressure; and a transcritical heat pump for circulating a supercritical fluid, wherein the supercritical fluid undergoes cooling so as to release heat for transmission to the pressurised fluid in the pipeline prior to at least one expansion of said pressurised fluid. | 5 |
FIELD OF THE INVENTION
The invention relates to a safety apparatus for elevator apparatuses, as well as a method for retrofitting an elevator apparatus and a retrofitting apparatus therefor.
BACKGROUND OF THE INVENTION
The prior art has disclosed conventional safety apparatuses for elevators which use electrical or electromechanical contacts and switches in order to determine the locking or closing state of an elevator door. The intention here is for an elevator cab to only be allowed to travel when all the doors are locked.
The object of the invention is to propose a safety apparatus and an elevator apparatus in which the susceptibility to the need for maintenance can be improved.
The object is achieved, starting from a safety apparatus and an elevator apparatus of the type mentioned at the outset.
SUMMARY OF THE INVENTION
By virtue of the measures mentioned hereinafter, advantageous developments and embodiments of the invention are possible.
Correspondingly, a safety apparatus for elevator apparatuses which can move a cab by means of a drive comprising: a first safety circuit, which has a closed conduction state and an open conduction state, with an interrupting apparatus for interrupting the drive depending on the conduction state of the first safety circuit, and an additional safety device, which comprises at least two sensors, which can be switched between at least two switching states depending on the closing state of the elevator door, is characterized by the fact that a switching unit is provided which can be switched between at least two switching states by connection to the safety device. In addition, the switching unit is designed to effect the closed and/or open conduction state of the first safety circuit. The interrupting apparatus serves the purpose of interrupting the drive, with the interruption being dependent on the nature of the switching states of the switching unit and furthermore other switches in the first safety circuit, i.e. on whether all of the doors are actually locked. This measure makes it possible to correspondingly improve the susceptibility to the need for maintenance and to increase the safety of the elevator.
If a plurality of doors is provided, travel can only be begun or continued when all of the doors are locked. Correspondingly, it is expedient if the corresponding sensors which are each assigned to a door are connected in series.
The first safety circuit has, for example, normally closed switches and a relay/contactor as the interrupting apparatus. The normally closed switches can be in the form of electromechanical switches in conventional safety circuits. If an open conduction state is effected, i.e. the first safety circuit is interrupted, the relay or the contactor also opens and interrupts a motor of the elevator, for example.
The safety device can to a certain extent be considered to be an equivalent circuit for individual normally closed switches or for all of the normally closed switches which monitor the closing state or locking state of the door. In principle, the safety device may also be a second safety circuit.
Correspondingly, in one embodiment of the invention, the safety device can be in the form of a second safety circuit which comprises at least two sensors which can be switched between at least two switching states depending on the closing state of the elevator door. However, the interrupting apparatus can be designed to interrupt and/or continue the drive, inter alia depending on the switching state of a switching unit (not of the sensor directly). The switching unit can in turn be switched between at least two switching states by connection to the safety circuit. The interrupting apparatus and the switching of the interrupting apparatus are therefore dependent on the safety circuit, but are not coupled directly to said safety circuit, but indirectly via an interposed switching unit. This apparatus makes it possible to a certain extent for the safety circuit or the arrangement of sensors to be “decoupled” as a separate apparatus. This can be advantageous in particular when an apparatus with comparatively high voltages is required for the interrupting apparatus. Such an apparatus is associated with corresponding disadvantages in terms of fitting and maintenance since there is the possibility that contact could be made with live parts carrying a relatively high voltage; these disadvantages can be circumvented with the safety apparatus according to the invention. The safety circuit itself can in principle be, operated on relatively low voltages, however.
In addition, the sensors can in turn be connected in series. In particular, when such decoupling has taken place, it is possibly advantageous to identify a fault state of a sensor. In a conventional series circuit, however, it is in principle not possible to perceive which sensor might have been interrupted by a defect. In the case of a large number of sensors, this requires a corresponding amount of time and therefore also corresponding costs during maintenance. This can be counteracted by virtue of the fact that an indicator apparatus for indicating the switching state of the individual sensors with assignment of the individual switching states to the corresponding sensors is provided. In principle, a corresponding indicator apparatus is capable of indicating which of the sensors has which switching state at that time or which sensor does not have a specific switching state at that time, for example which sensor is open.
In particular, in a development of the invention, the safety device can also be in the form of a bus system, the sensors each having an electronics unit. In addition, the sensor is connected to the bus via its corresponding electronics unit. Such a bus makes it possible in particular to transmit and/or interchange data. For example, data of individual sensors can thus be read on command. In principle, a bidirectionally operating bus is conceivable in which data can be transmitted and received. In principle, however, a unidirectional bus is also conceivable. As data it is possible to transmit the switching states, but it is also possible for identification data of the sensors to be transmitted which give information on which sensor is the sensor in question. These identification data can also be addressings of the individual sensors, for example. This makes it possible, in a particularly elegant manner, to read which sensor is indicating a specific state at that time. In addition, bus systems can also operate particularly quickly, if appropriate.
In a preferred development of the invention, at least one of the sensors has the following construction: a sensor for safety apparatuses for elevator apparatuses which can move a cab by means of a drive, the sensor being in the form of an optical sensor which comprises a transmitter for transmitting an optical signal and a receiver for receiving the optical signal. A particularly advantageous feature of the sensor is that it can operate in contactless fashion, i.e. without any wear as well. In addition, the sensor therefore does not have any live contact areas, or only has a few live contact areas, and is furthermore safe during fitting. The sensor according to the invention can therefore replace a conventional switch, a so-called interlock switch, from the prior art. In addition, the sensor provides the possibility of there being no need for the circuit to be interrupted, in contrast to an electromechanical switch.
By virtue of the sensor, it is also possible to avoid a defect which can occur, for example in the case of electromechanical sensors and contacts, as a result of contact erosion owing to flashover during opening or closing of the electrical contacts and can ultimately result in a loss of function.
Owing to the fact that the circuit does not need to be interrupted with this sensor, in contrast to a switch, improved diagnosis in the case of defects is advantageously possible.
In addition, a contact bridge and a contact receptacle for receiving the contact bridge are provided which are arranged in such a way that the closing state of the elevator door can be determined by connection of the contact receptacle and the contact bridge. The detection state of the sensor is therefore dependent on the proximity of the contact bridge to the contact receptacle.
An elevator itself generally has firstly a cab which can be moved between individual stories or floors. The individual floors each have shaft openings, in the region of which the cab can be moved into a stop position when said cab is intended to travel to the corresponding floor. In this stop position, access to the cab is then enabled. This access can be enabled by virtue of the elevator doors being opened and then closed again and locked prior to continued travel of the elevator. Elevator doors may be shaft doors or cab doors. The shaft doors are fitted or mounted movably on the shaft itself in the region of the shaft opening. The cab doors are in turn fitted or mounted movably on the cab. In general, in each case one cab door is assigned to a shaft door, with the two being arranged so as to overlap one another (so as to overlap one another at least partially) in the stop position. Generally, said doors are also moved at least substantially synchronously.
In order that a journey in the cab can be begun or that the cab can continue to travel, it is necessary for all of the doors to be closed and locked. This can be checked by means of corresponding safety apparatuses which can possibly stop the drive by means of an interrupter apparatus. In principle, the interrupting apparatus or interruption circuit can activate the monitoring unit, i.e. controller or regulator, of the motor or the drive, with the result that said monitoring unit stops the drive; it is also conceivable for the interrupting apparatus to directly interrupt the power supply to the drive/motor.
The corresponding sensor is therefore designed to check whether the corresponding door of an elevator or a shaft is open or closed and locked. In the present case, it is particularly advantageous for the sensor to have a similar design to a plug-type connection, with the result that a contact bridge can engage in a contact shaft. In addition, this measure provides the possibility of an apparatus which is mechanically very stable. In principle, the sensor can be designed in such a way that the contact bridge is accommodated in the shaft of the contact receptacle with play or in interlocking fashion.
In addition, the contact bridge is designed in such a way that it comprises at least one transmission element for transmitting an optical signal. This advantageously makes it possible in particular to achieve a so-called failsafe circuit. Only when the contact bridge has reached a particular position by corresponding connection to the contact receptacle when the door is closed, is it possible for corresponding enabling for travel to be issued. In the case of simply a light barrier, this would in principle not be the case: the transmission element can be designed in such a way that the transmission of the optical signal takes place in a particular way which can only be manipulated with considerable difficulty and can also not readily be realized by accident. In the case of a simple light barrier, for example, which would be interrupted when the door is closed, this would mean that the drive would also be enabled when, for example, a corresponding object, a fly or the like interrupts the light barrier.
A further option is to arrange the transmitter or the receiver on the contact receptacle. The transmission of light by means of the transmission element can then only take place via the contact bridge. This design enables a particularly compact construction.
One possibility consists in designing the transmission element as a reflective surface, with this reflective surface then reflecting the optical signal or the light and only in this way guiding it onto the corresponding receiver. The reflective surface can be arranged in a notch in the contact bridge, for example. However, it is also conceivable for the transmission element to be an optical medium. It is conceivable, for example, for the light refraction to be utilized in the transition from the air into this optical medium and the light beam is therefore directed in a certain direction, with the result that only then is it guided either onto the receiver or not onto the receiver.
In addition, a fiberoptic conductor can be provided as optical medium. The optical signal is transmitted when the light from said signal is coupled into the fiberoptic conductor, propagates through the fiberoptic conductor and passes into the receiver via the fiberoptic conductor.
It is particularly advantageous to design the transmitter as a light-emitting diode and/or the receiver as a photodiode. Particularly cheap standard electronic components can be used; this results in the possibility of particular cost savings.
Moreover, it is also conceivable for the contact receptacle to comprise transmission elements for transmitting the optical signal, for example reflective surfaces or optical media such as fiberoptic conductors, for example. It is conceivable for a subsection of the propagation path of the optical signal from the transmitter to the receiver to be over a reflective surface or through a fiberoptic conductor in the contact receptacle. It is also conceivable for the fiberoptic conductor in the contact receptacle or in the contact bridge to be shifted, by virtue of the contact bridge being received, in such a way that transmission of the light is enabled.
Furthermore, the sensor can comprise an electronics unit for the evaluation of the receiver, said electronics unit being designed to interpret the evaluation of the receiver in one of the switching states and/or into an electrical signal. This means that the electronics unit is designed to generate an electrical signal or produce an electrical contact. However, since the mechanical closing state is detected purely optically, this means that it is not absolutely necessary for a mechanical contact or a mechanical opening state to be produced in order to produce an electrical signal. It is conceivable, for example, for the optical signal to enable the receiver, for example a photodiode, and therefore for it to be possible for a conduction state to be reached (in contrast to an interruption). As a result, an interpretation of the switching state of the sensor is performed electronically to a certain extent. However, the electronics unit can also additionally be designed to enable a connection to further electronics. For example, it can also be designed to enable a connection to a bus. This design makes it possible in particular to improve the relatively low susceptibility to the need for maintenance even further since mechanical contacts and sensors are substantially avoided. It is also particularly advantageous that it is merely necessary for the contact bridge to enter the contact receptacle as the mechanical contact closure.
In order that no parasitic light passes accidentally from the transmitter into the receiver, an isolating web for optically isolating the transmitter and the receiver can also be provided. This once again reduces in principle the possibility of errors occurring as a result of an incorrect interpretation of the signals. In addition, a diffuser can moreover also be provided, said diffuser distributing parasitic light diffusely. It is also conceivable for the receiver to be set during the detection to a certain threshold value as regards the intensity of the incident light, with the result that, in the case of a certain amount of parasitic light which possibly enters the receiver, a corresponding sequential signal which should only be resolved when light enters the receiver via the transmission element is nevertheless not triggered.
A connection can be produced so as to be particularly robust, for example, in which the contact receptacle comprises a shaft and the contact bridge comprises a tongue-shaped lug, which engages in the shaft during connection of contact bridge and contact receptacle. It is particularly advantageous here also that corresponding coding can be performed, i.e. the contact bridge, in a similar way to a key, needs to be provided with a particular design in order for it to be able to enter the contact receptacle. In particular, this can increase the safety of this apparatus, in particular when the contact receptacle shaft is designed in such a way that it is not possible for a hand to gain access.
It is likewise possible in the case of a corresponding sensor to provide at least two transmission elements which are arranged in series in the movement direction of the contact bridge, which means that, when the door is locked, the contact bridge dips correspondingly into the contact receptacle and is initially visible for the optical signal and the optical light beam of one of the transmission elements (namely the first transmission element in the movement direction). As the movement progresses, the next transmission element then becomes visible, while the previous transmission element is pushed out of the optical path. It is thus possible for a plurality of optical signals to occur with a temporal offset. In addition, it is conceivable to design the electronics unit or to pass on the corresponding signals to a further evaluation unit so that the occurrence of the corresponding signals is determined as a function of time, for example. It is thus possible for conclusions to be drawn in respect of the speed of the locking process. This also makes it possible to draw a conclusion in respect, of the functional and maintenance state of the locking device of the doors. In principle, the locking process and not the door lock is moreover monitored. Depending on the way in which the corresponding transmission elements are arranged and how many of the transmission elements are arranged, the precision of such a determination can possibly be increased.
In principle, the first safety circuit can also furthermore have electromechanical normally closed switches. Said switches are possibly intended to be retained in an existing elevator system, for example, and not to be correspondingly replaced by optical sensors during retrofitting, for example. Optical sensors can be provided in particular for checking the correct locking of elevator doors. If the elevator is intended to be stopped during its movement even when the locking has not been correctly performed, however, but there is another fault, electromechanical normally closed switches can also continue to be used for checking such faults, if appropriate.
The sensors and/or normally closed switches can be connected in series in order for the drive to be stopped in the event of an interruption. Therefore, the circuit corresponds to an AND circuit, i.e. the motor only runs when all of the sensors or normally closed switches complete the circuit and do not interrupt the line.
Likewise, a corresponding indicator apparatus can be provided which makes it possible, for example, to identify which of the sensors has a specific switching state at that time and is possibly defective.
Furthermore, the sensor can comprise an electronics unit for the evaluation of the receiver, said electronics unit being designed to interpret the evaluation of the receiver in one of the switching states and/or into an electrical signal. This means that the electronics unit is designed to generate an electrical signal or produce an electrical contact. However, since the mechanical closing state is detected purely optically, this means that it is not absolutely necessary for a mechanical contact or a mechanical opening state to be produced in order to produce an electrical signal. It is conceivable, for example, for the optical signal to enable the receiver, for example a photodiode, and therefore for it to be possible for a conduction state to be reached (in contrast to an interruption). As a result, an interpretation of the switching state of the sensor is performed electronically to a certain extent. However, the electronics unit can also additionally be designed to enable a connection to further electronics. For example, it can also be designed to enable a connection to a bus. This design makes it possible in particular to improve the relatively low susceptibility to the need for maintenance even further since mechanical contacts and sensors are substantially avoided. It is also particularly advantageous that it is merely necessary for the contact bridge to enter the contact receptacle as the mechanical contact closure.
In one development of the invention, the electronics unit is for communication with a switching unit, in particular for transmission of switching states and/or identification signals. The switching unit is a component part which can be used to open or close a line by virtue of a switching operation, in a similar way to in the case of a relay or contactor. However, the switching operation is triggered when a corresponding signal or a corresponding item of information is passed on to the switching unit from the sensors. In particular, it is advantageous that the line between the switching unit and the sensor no longer needs to be interrupted, as is often the case in the case of a contactor/relay, for example.
The electronics unit can in particular be arranged in or on the contact receptacle in which the transmitter and receiver are also arranged. The contact receptacle can be arranged, for example statically, in the elevator apparatus, while the contact bridge is arranged on a moving part and merely represents the “key” in order to enable signal transmission in the contact receptacle.
A sensor can comprise precisely two terminals which are used firstly for power supply and secondly for communication with the electronics unit. The same line which is also used for power supply is therefore used for the communication. This measure enables a particularly compact and inexpensive design. In addition, this means that no additional lines or terminals need to be laid during retrofitting, when a conventional sensor is replaced by a sensor according to the invention, for example.
In addition, in the case of a sensor the communication can take place via modulation of its internal resistance of the sensor. In the circuit with the switching unit, the voltage and/or the current intensity can thus be modulated depending on the circuitry. This modulation then carries the information which is intended to be transmitted during the communication. For example, a circuit which comprises sensors connected in series and a switching unit (likewise connected in series) is conceivable. If the resistance of a sensor in the case of sensors connected in series is changed, the current intensity changes. If, for example, a constant current source is used for the circuit, a change in the resistance has the effect that the voltage needs to be increased in order to compensate for the resulting reduction in the current intensity which is initially caused by the lower resistance. The modulation can therefore act as an information carrier. The changes in the current intensity or voltage can be measured and can be interpreted as information.
In turn, in one development of the invention, the switching unit is designed to perform the communication with the sensors by modulation of the current intensity or the voltage. This measure can be performed by virtue of changes in resistances or corresponding changes in or matching of voltage or current intensity.
In the case of a series circuit, it is particularly advantageous if the sensor has a low transfer resistance. The resistance of a sensor can be, for example, in the range of from 1 ohm to 100 ohms, in particular in the range of from ohms to 20 ohms, preferably less than 10 ohms. Precisely in the case of a series circuit, it is advantageous to design the transfer resistance to be as low as possible, in particular lower than 10 ohms, in order that the voltage drop across the sensor is not excessively high.
Correspondingly, in addition an elevator apparatus according to the invention with a cab and at least one elevator door for opening and/or closing the cab and with a safety apparatus is characterized by the fact that a safety apparatus according to the invention are provided. As a result, the above-explained advantages can be used directly, inter alia.
It is conceivable in particular for the contact bridge to be fitted to an elevator door and for the contact receptacle to be fitted to the cab itself. In principle, however, a reverse design is also conceivable, namely the contact receptacle on the elevator door and the contact bridge on the cab. Similarly, the contact bridge and the contact receptacle can also be arranged on the shaft door and on the shaft or the shaft frame.
The contact receptacle itself can furthermore have a housing with fitting elements and the above-described insertion slot for the contact bridge. The electronics unit can be equipped with a light-emitting diode (LED) as fiberoptic conductor printed circuit board (PCB) and is equipped with a corresponding photodiode as receiver. The isolating web can correspondingly be arranged between the transmitter and the receiver. In addition, it is also conceivable for corresponding contacts, for example for making contact with the photodiode, to enable a connection to a corresponding electronics unit. The electronics unit can also be provided as a separate component part or so as to be integrated in another part of the elevator. In principle, the optical contact between the transmitter and the receiver can be converted into an electrical signal to a certain extent. In turn, the contact bridge can have a mounting plate, namely a corresponding tongue with optical fibers, wherein in this case the corresponding optical fibers can conduct light from the LED to the photodiode when the tongue is inserted. If appropriate, the corresponding parts can in particular also be prefitted.
A particular advantage of the subject matter according to the invention is that virtually no live contact areas are provided, i.e. fitting is very safe. The evaluation of the speed of the increase in illumination at the photodiode or the sequence of light pulses of two light transmission elements makes it possible to draw a conclusion in respect of the speed of the locking of the door with reference to the maintenance state. In addition, items of information relating to the maintenance state or the aging of the apparatus can thus be determined. In addition, an evaluation of the final illumination intensity can be performed in connection with the development of the illumination over time. This can make it possible in particular to draw a conclusion with regard to the insertion depth and also the locking safety. A plurality of transmission elements also enable dynamic detection. In addition, it is conceivable to increase the robustness by virtue of providing design measures which envisage the LED or the photodiode being covered. Precisely the design of a contact receptacle in the form of a shaft makes this particularly advantageously possible.
As has already been mentioned, a separate evaluation unit can be provided which can communicate with the corresponding bus via an interface, for example. A particular advantage of the apparatus according to the invention is that no interruption of an electrical contact is envisaged, but merely transmission of a signal optically is enabled or prevented.
A further advantage of the invention consists in that the apparatus according to the invention can be retrofitted particularly easily. In an existing elevator system, until now it has been particularly disadvantageous that virtually all of the sensors in the individual stories need to be investigated separately in the event of a defect in one sensor. In addition, it may not be possible to identify whether the defect is in a single sensor or a plurality of sensors, with the result that all of the sensors may need to be checked. The states of the sensors, i.e. defective or not or open or not, can be indicated centrally via an evaluation unit also in a convenient manner using a computer, control panel or the like.
In a corresponding retrofitting method according to the invention, the safety device can be used as a replacement part. The connection to the normally closed switches, for example conventional electromechanical switches, can be capped. Instead, the switching unit of the safety device is connected. In the case of elevators, the retrofitting complexity can therefore be considerably reduced. It is generally sufficient to draw in a relatively long connecting line over the stories. Both lines to the old normally closed switches can in addition usually be capped in uncomplicated fashion at a location in the vicinity of the control center.
In connection with the retrofitting, a retrofitting apparatus is installed in a corresponding elevator apparatus which is to be retrofitted, the elevator apparatus having a safety circuit which, in the context of the invention, corresponds to the first safety circuit and has normally closed switches. The retrofitting apparatus according to the invention comprises sensors which can be switched between at least two switching states depending on the closing state of the elevator door. Furthermore, the retrofitting apparatus comprises a switching unit which can be used instead of the normally closed switches which are intended to be replaced. The switching unit can be switched by means of the sensors. The sensors and the switching unit can interchange information, for example via modulation of the voltage/current intensity or the internal resistance of the sensors.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention are illustrated in the drawings and will be explained in more detail below with further details and advantages being given.
Specifically, in the drawings:
FIG. 1 shows a sensor comprising a contact bridge with reflective strips and a contact receptacle in accordance with the invention,
FIG. 2 shows a contact receptacle in accordance with the invention,
FIG. 3 shows a contact bridge with reflective strips in accordance with the invention,
FIG. 4 shows a sensor comprising a contact bridge with a fiberoptic conductor and a contact receptacle in accordance with the invention,
FIG. 5 shows a contact receptacle in accordance with the invention, as in FIG. 2 ,
FIG. 6 shows a contact bridge with a fiberoptic conductor in accordance with the invention,
FIG. 7 shows the connection (temporal sequence) of the contact bridge and contact receptacle in accordance with the invention,
FIG. 8 shows a sensor with reflective strips in accordance with the invention,
FIG. 9 shows a safety apparatus with sensors in accordance with the invention,
FIG. 10 shows a safety apparatus with a safety circuit in accordance with the invention,
FIG. 11 shows a safety apparatus with a bus in accordance with the invention,
FIG. 12 shows a safety apparatus with a bus and an integrated contactor in the switching unit in accordance with the invention,
FIG. 13 shows a circuit diagram for an elevator in accordance with the invention,
FIG. 14 shows a sensor with fiberoptic conductors in accordance with the invention,
FIG. 15 shows a perspective view of the sensor shown in FIG. 14 , and
FIG. 16 shows a schematic illustration illustrating the way in which communication with individual sensors takes place in a safety apparatus in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a sensor 1 with a contact receptacle 2 (shaft) and a contact bridge 3 , the contact bridge having reflective strips 9 , which reflect light emitted from a transmitter of the contact receptacle 2 in the direction of a receiver of the contact receptacle 2 .
In turn, FIG. 2 shows the corresponding contact receptacle 2 with a transmitter 4 and a receiver 5 , with an isolating web 6 being arranged between said transmitter and said receiver, to be precise in a front view, a side view and a plan view. Fitting apparatuses or fitting aids are indicated by the reference symbol 7 . The contact receptacle 2 has additional electrical terminals, via which the sensor 1 can be connected to the rest of the sensor apparatus or to the safety circuit.
FIG. 3 shows a contact bridge in different views, to be precise in a front view, a side view and a plan view. Said contact bridge also comprises corresponding fitting aids 8 . Slots are incorporated into the contact bridge 3 as transmission elements 9 , said slots each having reflective surfaces. In total there are three reflection units 9 a , 9 b , 9 c , with the result that dynamic contact detection is enabled to a certain extent since first the reflection unit 9 a , then the reflection unit 9 b and finally 9 c enter the contact receptacle 2 or the optical path when the contact bridge 3 is inserted and therefore dynamic measurement of the signal with temporal dependence is possible.
FIG. 4 shows a sensor 1 ′ with a contact receptacle 2 (shaft) and a contact bridge 3 ′, the contact bridge having a fiberoptic conductor; the light emitted by a transmitter of the contact receptacle 2 passes into the fiberoptic conductor inlet 4 ′, propagates through the fiberoptic conductor and emerges from the fiberoptic conductor outlet 5 ′ again, with the result that it passes to the receiver of the contact receptacle 2 .
In turn, FIG. 5 shows the corresponding contact receptacle 2 , as has already been described in relation to FIG. 2 , said contact receptacle also being suitable for a sensor 1 ′ with a fiberoptic conductor.
FIG. 6 shows a contact bridge 3 ′ in different views, to be precise in a front view, a side view and a plan view. Said contact bridge also comprises corresponding fitting aids 8 . A fiberoptic conductor is incorporated into the contact bridge 3 ′ as transmission element L and the light signal transmitted by the contact receptacle can propagate through said fiberoptic conductor. The figure also shows the light inlet 4 ′ and the light outlet 5 ′.
FIG. 7 shows the contact bridge 3 (with reflective strips) entering the contact receptacle 2 in this way, with the contact bridge not yet being connected to the contact receptacle 2 in situation A. In situation B, the reflection unit 9 a has just entered in the region of the optical path and transmits the light path from the transmitter to the receiver. In situation C, the contact bridge 3 is positioned at this time such that the optical signal is interrupted since the contact bridge 3 , in terms of its height, is precisely between the reflection units 9 b and 9 c and the optical path is therefore interrupted. Only in situation D is the contact bridge, which has been completely inserted into the contact receptacle 2 , in such a position that the optical path is not interrupted and light can pass from the receiver 4 into the detector/photodiode via the reflection element 9 c . The reflection units 9 , and also other transmission units such as optical media, can have different forms and provide characteristic reflections or light transmissions, with the result that these can each be identified, if appropriate, by means of the receiver or the electronics unit as well.
FIG. 8 shows a similar illustration in which the contact bridge 3 enters the contact receptacle 2 .
In turn, FIG. 9 shows a safety apparatus with a plurality of optical sensors 10 , which are all connected in series. Furthermore, a series of further electromechanical normally closed switches 11 is provided which can otherwise be used in connection with an elevator. In addition, a voltage source 13 is provided. All of these switches or sensors 11 and 10 are connected in series and are connected to a switching unit 12 . This circuit comprising a series circuit comprising the switches 11 , the sensors 10 and the switching unit 12 forms a safety circuit. If one of the switches 11 is interrupted, the entire circuit is interrupted, and the switching unit 12 disconnects the motor M, which represents the drive for the elevator cab. The switches 11 can be normally closed switches of the known type. If one of the sensors 10 detects that the elevator has not been locked properly, for example, said sensor transmits a corresponding signal via the circuit, and this signal is received by the communication unit of the switching unit 12 , with the result that said unit can disconnect the motor M. Correspondingly, the switching unit 12 partially takes over the function of your relay; in addition, switching operations of the switching unit are also dependent on signals from the sensors, however. The switching unit 12 therefore does not only respond to line interruptions.
FIG. 10 shows a safety apparatus with a safety device, namely a (second) safety circuit 14 , with corresponding optical sensors 10 . This safety circuit is connected to the first safety circuit 16 via a switching unit 12 ′, said first safety circuit in turn having further sensors 11 . The switching unit 12 ′ is similar to the switching unit 12 and has the same mode of operation; in this case, in contrast to the switching unit 12 shown in FIG. 9 , however, the voltage source is also integrated in the switching unit 12 ′. A contactor/relay 15 , which can in turn disconnect a drive M, is located in the first safety circuit 16 . The contactor 15 is merely designed to disconnect the motor M in the event of a line interruption in the circuit 16 . If one of the sensors 10 is interrupted optically, the switching unit 12 ′ is also interrupted, and therefore the line in the first safety circuit 16 . The contactor 15 disconnects the motor M. Instead of the conventional normally closed switches, the sensors according to the invention are combined in a dedicated safety circuit 14 and are connected to the original, first safety circuit 16 via the switching unit 12 ′. The safety circuit 16 can in this case partly use the wiring of the original safety apparatus.
In addition, FIG. 10 illustrates how retrofitting of a conventional apparatus can be performed by virtue of the original first safety circuit 16 being capped at the points U and the second safety circuit 14 with the switching unit 12 ′ being used correspondingly. It is then only necessary for a relatively long cable K to be drawn in.
FIG. 11 shows a corresponding apparatus in which, instead of a second safety circuit, a bus 20 is arranged as the safety device. The corresponding sensors 21 have an electronics unit which enable a connection to the corresponding bus 20 . The bus is likewise connected to a switching unit 25 , with the result that when one of the optical sensors 21 is interrupted, said sensor in turn transmits a signal to the switching unit 25 which in turn interrupts the first safety circuit 26 . Owing to the interrupted line of the safety circuit 26 , the motor M is disconnected by the contactor 15 . The switching unit 25 can form the master in the bus, for example, while the sensors 21 have a slave configuration.
FIG. 12 shows a similar apparatus to that shown in FIG. 8 , but in this case the contactor 15 is additionally integrated in the switching unit 27 , with the contactor disconnecting the motor, if appropriate.
FIG. 13 shows an exemplary circuit diagram 30 for an elevator in accordance with the invention.
FIG. 14 shows a sensor 41 in a plan view and in a side view with a contact receptacle 42 and a contact bridge 43 , in which a fiberoptic conductor 44 is arranged. In this case, the contact bridge 43 is overall in the form of a fiberoptic conductor 44 , i.e. consists of the corresponding optical medium. The contact receptacle 42 comprises a transmitter 45 and a receiver 46 for transmitting/receiving optical signals. The optical signal transmitted by the transmitter 45 can propagate through the fiberoptic conductor 44 , as soon as the contact receptacle 42 has received the contact bridge 43 , and therefore passes into the receiver 46 . The contact bridge 43 (or the fiberoptic conductor 44 ) is in the form of a U and, when it is plugged into the contact receptacle 42 , engages only with both limbs in the two shafts of the contact receptacle 42 . The fiberoptic conductor 44 correspondingly likewise has a U-shaped design. FIG. 15 in turn shows the sensor 41 in a perspective view.
FIG. 16 shows a schematic illustration of the communication in the safety circuit 14 between the controller 57 of the switching unit and the individual sensors 10 or microcontrollers μC thereof. The communication from the controller 57 to the individual sensors takes place via current modulation, while, conversely, that from the sensor 10 to the controller 57 takes place via voltage modulation.
It is generally necessary for notable current or voltage changes or modulations to take place since, owing to the long cable lengths occurring in an elevator system, the change would otherwise be unnoticeable. For example, current changes in the region of a factor of 3 are conceivable.
The units 50 , 51 each correspond to a sensor. Variable resistors are denoted by the reference symbols 52 , 53 . Each sensor is assigned a variable resistor. The resistance can be changed in different ways: it is conceivable for resistors to be added into this circuit in parallel with other resistors, as a result of which the total resistance is correspondingly reduced. However, it is also conceivable for the resistance to be influenced by means of the circuitry used, for example by individual transistors being switched off. The change in resistance can be influenced optically, for example by means of phototransistors, photodiodes, optocouplers or the like.
The circuit comprises constant current sources 54 , 55 , which are each designed to match their voltage in the event of a change in the resistance in the circuit in such a way that a constant current flows. A change in the resistance (communication: controller 57 to sensor 10 ) regulates the constant current source 54 to a constant current intensity, with the result that the voltage measured via the voltmeter 56 changes.
If a further constant current source 55 is added into the circuit, the current intensity can also be modulated, i.e. the voltage does not remain constant (communication: sensor to controller). The change in the voltage applied to the circuit can be determined by the voltmeter 58 .
The states of the individual sensors or other data relating to the sensors can therefore be output via an output 60 . The relay 59 is controlled corresponding to the sensors via the microcontroller 57 .
FIG. 16 illustrates a switching unit 12 ″, as is also illustrated in FIG. 9 as switching unit 12 or in FIG. 10 as switching unit 12 ′. The switching unit 12 ′ also comprises a voltage source. The switching unit 12 from FIG. 9 in particular also comprises the function of a relay, which can disconnect the motor M in the event of a line interruption as well. The switching unit 12 is connected to a (second) safety circuit 14 in FIG. 16 .
LIST OF REFERENCE SYMBOLS
1 Sensor
1 ′ Sensor
2 Contact receptacle
3 Contact bridge
3 ′ Contact bridge
4 Transmitter
4 ′ Fiberoptic conductor inlet
5 Receiver
5 ′ Fiberoptic conductor outlet
6 Isolating web
7 Fitting unit
8 Fitting unit
9 Reflective surface
9 a Reflective surface
9 b Reflective surface
9 c Reflective surface
10 Optical sensor
11 Electromechanical normally closed switch
12 Switching unit
12 ′ Switching unit (with voltage source)
12 ″ Switching unit
13 Voltage source
14 Second safety circuit
15 Contactor/relay
16 First safety circuit
20 Bus
21 Optical sensor with electronics unit
25 Switching unit
26 Safety circuit
27 Switching unit with integrated contactor
30 Circuit diagram
41 Sensor
42 Contact receptacle
43 Contact bridge
44 Fiberoptic conductor
45 Transmitter
46 Receiver
50 Communication unit
51 Communication unit
52 Variable resistor
53 Variable resistor
54 Constant current source
55 Constant current source
56 Voltmeter
57 Microcontroller of switching unit
58 Voltmeter
59 Relay
60 Output
A View at first time
B View at second time
C View at third time
D View at fourth time
K Cable/electrical line
L Fiberoptic conductor
M Drive motor
μC Microcontroller of a sensor
U Interruption | A safety apparatus for elevator apparatuses which can move a cab by way of a drive, including: a first safety circuit, which has a closed conduction state and an open conduction state, with an interrupting apparatus for interrupting the drive depending on the conduction state of the first safety circuit, a safety device, which includes at least two sensors, which can be switched between at least two switching states depending on the closing state of the elevator door. In order to be able to improve the susceptibility to maintenance, a switching unit is provided which can be switched between at least two switching states by connection to the safety device and is designed to effect the closed and/or open conduction state of the first safety circuit. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates to a method for the synthesis of 2,4-dichloro-5-trifluoromethyl-pyrimidine useful as intermediate in the manufacture of pharmaceutically active ingredients.
BACKGROUND OF THE INVENTION
[0002] 2,4-dichloro-5-trifluoromethyl-pyrimidine (5-TFP) is an important intermediate for the manufacture of pharmaceutically active ingredients, for example for the treatment of cancer as described in WO 2010/055117.
[0003] The known chemical syntheses of this intermediate offer only limited accessability of 5-TFP and all face severe drawbacks that do not allow for a sustainable and environmentally friendly supply with this important intermediate. Therefore there was a need to develop a novel approach to this compound. This disclosure describes a novel, environmentally benign and sustainable process for the manufacture of 5-TFP.
[0004] The known routes to 5-TFP are described in the following:
[0005] 5-TFP can be prepared by a two-step process using gaseous CF 3 I as a trifluoromethylation reagent (scheme 1) via trifluoromethyl uracil (5-TFU) as described in WO 2007/055170.
[0000]
[0006] The disadvantage of this process is the difficult handling of the toxic and expensive gaseous reagent. Additionally, this process has to be run in environmentally inappropriate solvents like dimethylsulfoxide.
[0007] A further route of synthesis is disclosed in CN 101955466. Therein, the combination of H 2 SO 4 and FeSO 4 of step 1 in variant 1 as depicted in scheme 1 above is replaced by HBF 4 /Fe 2 (SO 4 ) 3 (scheme 2), however, all main disadvantages of that route remain.
[0000]
[0008] An alternative process to 5-trifluoromethyl-uracil (5-TFU) as a precursor of 5-TFP is revealed in U.S. Pat. No. 5,352,787 describing a four-step access starting from 5-methyl-uracil (scheme 3). This process suffers from the necessity to use large amounts of two highly toxic and corrosive gases (Cl 2 and HF), which make this process inappropriate for normal pharmaceutical manufacturers and environmentally and from a safety point of view unfavorable.
[0000]
[0009] Recently LANGLOIS reagent (sodium trifluoromethanesulfinate, CF 3 SO 2 Na) was successfully used as reagent in the trifluoromethylation reaction of uracil (PNAS 2011, 14411-14415) under biphasic conditions.
[0000]
[0010] However, mixtures of chlorinated organic solvent with water or sulfoxides with water are used. These conditions are unsuitable for larger scale application because of the uncontrollable exothermic nature of the reaction, the vigorous stirring needed and the large amounts of chlorinated organic wastes. In addition, the inventors identified a new unknown impurity when a scaled-up prior art trifluoromethylation process was applied to uracil causing additional need for purification. As additional drawbacks inconsistent yields with incomplete conversion of starting material, long reaction times, accumulation of peroxides (also due to high number of equivalents needed) and the need to use lab grade (=expensive) CF 3 SO 2 Na instead of commercial grade (=cheap; usually only 50-70 pure) CF 3 SO 2 Na were identified which make the prior art process not feasible for an economically competitive way to produce larger amounts of the title compound.
[0011] Thus, it was necessary to investigate a potential new method to address these drawbacks.
DETAILED DESCRIPTION OF THE INVENTION
[0012] After careful investigation of the above prior art methods, the CF 3 transfer reaction using LANGLOIS reagent as shown in scheme 4 was further elaborated:
[0013] First of all, when applying the standard procedure disclosed in PNAS to uracil (DCM/water 2:1, 0° C. with lab grade CF 3 SO 2 Na) complete conversion of starting material was reached after 22 h and 5-TFU was obtained in a yield of 55% (crude product; comparative example 1). A previously unknown impurity with high polarity was found by HPLC during the reaction which might cause problems in any downstream steps.
[0014] When this reaction is run in DCM or DMSO on larger scale, a large volume of organic waste is generated. Additionally, the use of organic peroxides in an organic medium poses very high safety constrains since accumulation of these peroxides may lead to explosive mixtures. Thus, a transfer of the trifluoromethylation step to aqueous medium and use of lower amounts of peroxides is desirable and allows for a large reduction of organic waste and safer running conditions, since in water the use of organic peroxides is much safer than in organic media and the exotherm reaction can be controlled more easily.
[0015] However, when the standard procedure was adapted to use water only (water, 0° C. with lab grade CF 3 SO 2 Na) the obtained results worsened significantly. After 24 h the conversion rate only reached 36% (comparative example 2) making this method completely useless. This shows that as far as water-soluble uracil is concerned a simple shift to water (in contrast to the disclosure of PNAS) is not possible on a large scale.
[0016] It was very surprising to find out that the results obtained in water could be significantly improved when the reaction mixture is kept at a temperature of about 40-100° C. after the addition of an aqueous solution of the organic peroxide. Reaction time to full conversion can be reduced, total amount of organic peroxide can be reduced, reasonable yields are obtained and build-up of peroxides can be prevented.
[0017] Thus, the present invention relates to a method for preparing 5-trifluoromethyl-uracil (5-TFU) comprising
[0000] a) trifluoromethylation of uracil with sodium trifluoromethanesulfinate (CF 3 SO 2 Na) and organic peroxide in water to form 5-trifluoromethyluracil (5-TFU), wherein the reaction temperature after the addition of an aqueous solution of organic peroxide is kept in a range of about 40-100° C.
[0018] In addition, the present invention relates to a method for preparing 2,4-dichloro-5-trifluoromethyl-pyrimidine (5-TFP) comprising
[0000] a) trifluoromethylation of uracil with sodium trifluoromethanesulfinate (CF 3 SO 2 Na) and organic peroxide in water to form 5-trifluoromethyluracil (5-TFU), wherein the reaction temperature after the addition of an aqueous solution of organic peroxide is kept in a range of about 40-100° C., and
b) reacting 5-trifluoromethyluracil (5-TFU) with phosphoryl chloride (POCl 3 ) to form 2,4-dichloro-5-trifluoromethyl-pyrimidine (5-TFP).
[0000]
[0019] Uracil required as the starting material is commercially available.
[0020] The first step according to the method is the trifluoromethylation of uracil with sodium trifluoromethanesulfinate (CF 3 SO 2 Na) and organic peroxide, e.g. tert-butyl hydroperoxide (TBHP), in water and optionally a transition metal catalyst, e.g. FeSO 4 .
[0021] Sodium trifluoromethanesulfinate (CF 3 SO 2 Na) which is also called LANGLOIS reagent, is a safely and easily handable solid and commercially available (usually 50-70% pure).
[0022] Commercially available 70% aqueous solution of tert-butyl hydroperoxide (TBHP) is a suitable oxidant for the trifluoromethylation.
[0023] All the reagents used in the trifluoromethylation step are soluble in water being a good solvent for this step.
[0024] The strongly exothermic nature of this method can be well controlled by adjusting the dosing rate of organic peroxide, e.g. tert-butyl hydroperoxide (TBHP), and/or addition of a transition metal catalyst.
[0025] THF, 2-MeTHF, ethyl acetate and isopropyl acetate can be used as extraction solvents in the workup of the reaction step a). THF and 2-MeTHF have advantages in terms of solubility, ethyl acetate and isopropyl acetate however yield slightly higher quality of the produced intermediate (5-TFU).
[0026] Alternatively, 5-TFU can be obtained from the reaction mixture by concentration of the aqueous phase and filtration of the precipitate.
[0027] If necessary, the intermediate 5-TFU can be further purified by recrystallization from water or isopropyl acetate.
[0028] In one embodiment of the methods the sodium trifluoromethanesulfinate (CF 3 SO 2 Na) used in step a) has a commercial grade of equal to or below 80% sodium trifluoromethanesulfinate (CF 3 SO 2 Na).
[0029] In one embodiment of the methods the sodium trifluoromethanesulfinate (CF 3 SO 2 Na) used in step a) has a commercial grade of about 50-70% sodium trifluoromethanesulfinate (CF 3 SO 2 Na).
[0030] In a further embodiment of the methods the commercial grade sodium trifluoromethanesulfinate (CF 3 SO 2 Na) is pre-treated before use in step a).
[0031] In a further embodiment of the methods the commercial grade sodium trifluoromethanesulfinate (CF 3 SO 2 Na) is pre-treated before use in step a) by slurrying in ethyl acetate, filtration and concentration.
[0032] In a further embodiment of the methods the commercial grade sodium trifluoromethanesulfinate (CF 3 SO 2 Na) is pre-treated before use in step a) by slurrying the commercial grade sodium trifluoromethanesulfinate (CF 3 SO 2 Na) in ethyl acetate, heating of the resulting suspension to about 40-50° C., stirring at this temperature, filtering of the suspension, adding water to the filtrate and removing substantially all ethyl acetate.
[0033] One method of pre-treatment of sodium trifluoromethanesulfinate (CF 3 SO 2 Na) when used as reagent is known from US 2011/0034530. However, the purification method used therein is much more laborious and the type of reaction the reagent is used for is different (sulfinylation).
[0034] The pre-treatment of commercial grade sodium trifluoromethanesulfinate (CF 3 SO 2 Na, 50-70% pure) does not only allow the use of this cheap ingredient but also has significant advantages in terms of possible yields. When commercial grade sodium trifluoromethanesulfinate (CF 3 SO 2 Na) is used without pre-treatment the yields which could be obtained turned out to be inconsistent and tended to result in lower yields (comparative example 3).
[0035] In a further embodiment of the methods the organic peroxide used in step a) is tert-butyl hydroperoxide (TBHP), preferably as an aqueous solution.
[0036] In a further embodiment of the methods the organic peroxide used in step a) is tert-butyl hydroperoxide (TBHP), wherein the aqueous solution of tert-butyl hydroperoxide (TBHP) has a content of about 70% tert-butyl hydroperoxide (TBHP).
[0037] In a further embodiment of the methods the organic peroxide used in step a) is continuously dosed to the reaction mixture.
[0038] In a further embodiment of the methods the organic peroxide used in step a) is used in an amount of about 4 eq. in relation to uracil.
[0039] In a further embodiment of the methods the addition rate of the organic peroxide used in step a) is controlled to keep the reaction temperature in a range of about 45-75° C., preferably 45-55° C., during addition.
[0040] The control of the addition rate helps to slow the dosage of the organic peroxide and the rate of peroxide decay can be carefully controlled in order to run the method without risking accumulation of peroxides.
[0041] In a further embodiment of the methods the reaction temperature in step a) is kept in a range of about 40-100° C. after the addition of an aqueous solution of organic peroxide until the ratio of uracil:5-trifluoromethyl-uracil is equal to or below 3:97.
[0042] In a further embodiment of the methods the reaction temperature in step a) is kept in a range of about 40-80° C. after the addition of an aqueous solution of organic peroxide.
[0043] In a further embodiment of the methods the reaction temperature in step a) is kept in a range of about 45-70° C. after the addition of an aqueous solution of organic peroxide.
[0044] In a further embodiment of the methods the reaction temperature in step a) is kept in a range of about 60-70° C. after the addition of an aqueous solution of organic peroxide.
[0045] In a further embodiment of the methods the reaction temperature in step a) is kept in a range of about 45-60° C. after the addition of an aqueous solution of organic peroxide.
[0046] In a further embodiment of the methods the reaction in step a) is carried out in the presence of a transition metal catalyst.
[0047] In a further embodiment of the methods the reaction in step a) is carried out in the presence of FeSO 4 as catalyst.
[0048] The optional addition of a transition metal catalyst, e.g. FeSO 4 , further reduces the risk of peroxide accumulation. Without this catalyst, the reaction also works, however, peroxide accumulation may render severe issues of process safety. Therefore the revealed method includes, but does not necessitate, the use of for example a FeSO 4 additive for large scale production.
[0049] In a further embodiment of the methods the reaction in step a) is carried out in the presence of silica gel.
[0050] The addition of silica gel as HF absorber has the advantage of preventing HF corrosion of the glass lining (HF is formed in the reaction) and of further improving process safety.
[0051] In a further embodiment of the methods a solvent selected from among THF, 2-MeTHF, ethyl acetate and isopropyl acetate is used to extract 5-TFU obtained in reaction step a).
[0052] In a further embodiment of the methods 5-TFU obtained in reaction step a) is isolated without extraction by concentration of the aqueous phase and filtration.
[0053] In a further embodiment of the method the intermediate 5-TFU obtained in step a) is chlorinated with or without isolation of 5-TFU.
[0054] In a further embodiment of the method the intermediate 5-TFU obtained in step a) is chlorinated with or without isolation of 5-TFU to 5-TFP in step b) using a mixture of phosphoric acid (H 3 PO 4 ), phosphoryl chloride (POC1 3 ) and diisopropylethyl amine (DIPEA).
EXAMPLES
Example 1
Preparation of 5-trifluoromethyluracil (5-TFU)
Pretreatment of Commercial Grade Sodium Trifluoromethanesulfinate (CF 3 SO 2 Na)
[0055] A 1 L jacket reactor (reactor A) is charged with CF 3 SO 2 Na (125.0 g, ˜65% purity, ˜0.52 mol, 2.89 eq.) followed by ethyl acetate (625.0 g). The resulting suspension is heated to 40-50° C. and kept stirring at this temperature for 1 h. The suspension is filtered with the aid of Celite® (5.0 g) at 30-50° C. and the cake is washed with ethyl acetate (50 g). The combined filtrate is transferred to a 500 mL jacket reactor (reactor B) and concentrated to about 80-100 mL (jacket temperature 70° C./100-500 mbar). Water (100 mL) is added into the mixture. The resulting biphasic mixture is concentrated to about 90 mL (jacket temperature 70° C./100-500 mbar) to remove residual ethyl acetate.
[0000] Trifluoromethylation Uracil (20.0 g, 0.18 mol, 1.0 eq.), silica gel (4.0 g), ferrous sulfate (FeSO 4 ) heptahydrate (2.0 g, 0.007 mol, 0.04 eq.) and water (100.0 mL) are charged into reactor B. The resulting suspension is heated to 45-50° C., tert-butyl hydroperoxide (91.8 g, 0.71 mol, 70% aqueous solution, 3.9 eq.) is added slowly into the mixture through an addition funnel while keeping the internal temperature between 45-55° C. during addition by controlling the addition rate and jacket reactor in about 30 min. A strong exotherm together with release of gas is observed during the addition of the tert-butyl hydroperoxide. A large amount of SO 3 and trace amount of HF are detected. Silica gel is used to minimize the corrosion of the glass reactor. After the addition, the internal temperature is kept to 60-70° C. for 1.0-1.5 h. The reaction is monitored by HPLC until ratio of uracil:5-TFU <3:97 (HPLC area). Aqueous sodium sulfite solution (15 g (15 weight %), 0.0178 mol, 0.1 eq.) is added and stirred for another 30 min between 60-70° C. to quench residual tert-butyl hydroperoxide. The peroxide level is checked with test strip (Merckoquant 110011 test strips until it is lower than 10 ppm). The mixture is then cooled to 25-35° C., diluted with THF (40 mL), the resulting mixture is filtered (to remove silica gel) and the filter cake is washed with THF (20 mL). The combined filtrate is concentrated to about 170-190 mL (jacket temperature 70° C./100-500 mbar). The resulting suspension is cooled to 10-15° C. in 2 h and held at this temperature for 1 h. The suspension is filtered, the filter cake is washed with cold water (20 mL) and dried at 45-50° C. to obtain white crystal (24 g; crude yield 75%, HPLC assay yield is 73%, area purity>97% (220 nm). (Note: The resulting product containing some inorganic impurities was used directly in the following chlorination step. Around 4 g of product is lost in the aqueous mother liquor, which can be recovered by extraction with THF if necessary.) (Note: From a quality point of view the reaction without FeSO 4 and silica gel gives similar results)
5-trifluoromethyluracil (5-TFU)
[0056] White solid.
[0057] 1 H NMR (CD 3 COCD 3 ): δ 8.1 (s, 1H), 10.5 (brs, 2H).
[0058] 19 F NMR (CD 3 COCD 3 ): δ −63.8
[0059] ESI MS (m/z) 179 [M−1] −
Example 2
Preparation of 2,4-dichloro-5-trifluoromethylpyrimidine (5-TFP)
[0060] To a jacket reactor (500 mL) is added 5-trifluoromethyluracil (5-TFU, 40 g, ˜70% assay, ˜0.16 mol, 1.0 eq.), H 3 PO 4 (2.4 g; 0.02 mol, 0.13 eq.) and POCl 3 (128 g; 0.83 mol, 5.2 eq.) (a white suspension is formed). DIPEA (35 g, 0.27 mol, 1.69 eq.) is added to the suspension dropwise in about 10 min and then the reaction mixture is heated to 110-120° C. (clear solution). The reaction is monitored with HPLC until ratio 5-TFU:5-TFP<5:95 (reaction normally finished in 7-8 h; if reaction is not complete, additional POCl 3 (5 g, 0.032 mol, 0.2 eq) and DIPEA (1.3 g, 0.01 mol, 0.06 eq) are charged and stirred for another 1-2 h). The reaction is then cooled to rt and n-butyl acetate (80 mL) is added to the reaction mixture. About 60 mL of distillate (POCl 3 and some n-butyl acetate) is collected at 63-65° C./450-500 mbar. The resulting dark solution is slowly added to a mixture of conc. HCl (165 g, 27 weight %, 1.23 mol, 7.7 eq.) and methyl tertiary butyl ether (MTBE, 120 mL) while the temperature is maintained below 20° C. The organic phase is separated and the aqueous phase is extracted with MTBE (2×120 mL). The organic phase is gathered, washed with water until the pH value reaches ca. 5-6. MTBE is removed under reduced pressure (˜42° C./200 mbar), the final product is purified through distillation (87-89° C./55 mbar) to afford 5-TFP as colorless oil (25.3 g, yield 72.9%; purity 98%).
2,4-dichloro-5-trifluoromethylpyrimidine (5-TFP)
[0061] Colorless to light yellow oil
[0062] 1 H NMR (CD 3 COCD 3 ): δ 8.8 (s, 1 H),
[0063] 19 F NMR (CD 3 COCD 3 ): δ −63.7
[0064] ESI MS (m/z) 216 [M−1] −
Comparative Example 1
Preparation of 5-trifluoromethyluracil (5-TFU) According to PNAS 2011, 14411-14415 Under Biphasic Conditions
[0065] To a mixture of uracil (0.5 g, 4.5 mmol) and sodium trifluoromethanesulfinate (2.1 g, 13.5 mmol, 3.0 eq.) in DCM (18 mL) and water (7 mL) is added dropwise tert-butyl hydroperoxide (70% solution in water, 2.9 g, 22.5 mmol, 5 eq.) with vigorous stirring while controlling the inner temperature around 0-2° C. The reaction is allowed to warm to rt (20-22° C.) and monitored by HPLC until completion (completed in 22 h). The reaction mixture is distilled under vacuum at rt to remove DCM, the resulting mixture is extracted with ethyl acetate (4×20 mL). The combined organic layers are dried with sodium sulfate and concentrated to obtain 5-TFU as white solid (assay yield 55%). Note: A new impurity with high polarity was found under 254 nm by HPLC during the reaction.
Comparative Example 2
Preparation of 5-trifluoromethyluracil (5-TFU) According to PNAS 2011, 14411-14415 Under Monophasic (Aqueous) Conditions
[0066] To a mixture of uracil (0.5 g, 4.5 mmol) and sodium trifluoromethanesulfinate (2.1 g, 13.5 mmol, 3.0 eq.) in water (25 mL) is slowly added tert-butyl hydroperoxide (70 solution in water, 2.9 g, 22.5 mmol, 5 eq.) with vigorous stirring while controlling the inner temperature around 0-2° C. The reaction is allowed to warm to rt (20-22° C.) and monitored by HPLC. The conversion is only 36% after 24 h.
Comparative Example 3
Preparation of 5-trifluoromethyluracil (5-TFU) According to Process of the Invention Without Pre-Treatment of Sodium Trifluoromethanesulfinate (CF 3 SO 2 Na)
[0067] A jacket reactor (2 L) is charged with uracil (50 g, 0.446 mol, 1 eq.), sodium trifluoromethanesulfinate (311.0 g, 65%, 1.293 mol, 2.9 eq.), ferrous sulfate (FeSO 4 ) heptahydrate (5.0 g) and water (500 mL). The resulting suspension is heated to 40° C. Tert-butyl hydroperoxide (287 g; 70% aqueous solution, 2.232 mol, 5 eq.) is added slowly into the mixture while keeping the internal temperature between 55-75° C. After addition of peroxide, the resulting mixture is stirred between 50-60° C. for 0.5 to 1.0 h. The reaction is monitored by HPLC until the ratio of uracil:5-TFU<3:97 (HPLC area). The peroxide residue is quenched with aqueous sodium sulfite solution until peroxide concentration is below 10 ppm. The resulting mixture is extracted with 2-MeTHF (4×250 mL) and the combined organic phase is washed with NaCl aqueous solution (25%; 150 mL). The organic phase is then concentrated to get the crude product as white solid. HPLC assay yield is 48%.
[0068] Note: Direct use of the commercial grade CF 3 SO 2 Na gives variable yield. In this batch, the assay yield is around 20% lower than the normal result when using the reagent after pre-treatment (see pre-treatment procedure in example 1; i.e. the reaction under the conditions of comparative example 3 with pre-treatment according to example 1 has an HPLC assay yield of 67%). Significant amounts of impurities with high polarity are found in the HPLC monitoring of the reaction (220 nm).
[0000]
HPLC method
Equipment
Agilent 1200 series Gradient HPLC apparatus
Eluent A
water
Eluent B
methanol
Column
Luna 3u phenyl-hexyl 150 × 4.60 mm
Column
40° C.
Temperature
Flow
0.7 mL/min
Gradient
time (min)
water (%)
methanol (%)
0.00
95
5
7.00
30
70
12.00
20
80
18.00
20
80
Diluent
methanol: H 2 O = 1:1
Sample
ca. 25 mg of sample was dissolved in 25 mL methanol/water
Preparation
(1:1)
Injection
1 μL
Volume
UV Detection
wavelength: 254 nm, 220 nm, bandwidth: 8 nm
reference: off
peakwidth (response time): >0.1 min (6 s) or comparable
System
For purity testing of final product the attributes of the
Suitability
principal peak should not violate following ranges:
Symmetry factor between 0.8 and 1.5.
Height between 0.8 and 1.2 AU (resp. 0.8 to 1.2 V).
Retention time as stated below ±5%.
[0000]
GC method for the final product
Equipment
Agilent 7891A Gas chromatograph with
flame ionization detector (FID)
Carrier Gas
Helium (constant flow = 1.5 mL/min)
Detector Gases
Gas
Flow
hydrogen
35
mL/min
synth. air:
350
mL/min
makeup (Helium):
26.5
mL/min
Injection Mode
Split 1:20
Injection Volume
1 μL
Diluent
ACN
Sample Preparation
Sample was diluted in ACN
Column
Type: HP-5.5% phenyl methyl siloxan; L =
30 m; ID = 0.32 mm; Film = 0.25 μm
Supplier: agilent; Part No.: 19091J-413
Temperature (Injector)
260° C.
Temperature (Detector)
280° C.
Temperature (Oven)
Initial temp.: 50° C.
Hold time: 5 min
Rate: 15° C./min
Final Temp.: 250° C.
Run time = 17 min
System Suitability
For purity testing of final product the
attributes of the principal peak should not
violate following ranges:
Symmetry factor between 0.8 and 1.5.
Height between 0.8 and 1.2 AU (resp. 0.8
to 1.2 V).
Retention time as stated below ±5%. | This invention relates to a novel method for the synthesis of 2,4-dichloro-5-trifluoromethyl-pyrimidine useful as intermediate in the manufacture of pharmaceutically active ingredients. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This continuation patent application claims priority to the nonprovisional patent application having Ser. No. 10/283,878, which was filed on Oct. 30, 2002, which claims priority to the PCT International patent application having Ser. No. PCT/US01/14365, which was filed on May 4, 2001, which claims priority to the provisional patent application having Ser. No. 60/202,851, which was filed on May 8, 2000.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to a nursing bottle, that incorporates enhanced features and parameters that provide for its full venting during both usage and storage.
[0003] Nursing bottles of a multitude of designs are available in the prior art. In many instances, as is well known in the art, frequently a vacuum will be generated within the bottle during dispensing of its contents, as when nursing the infant, and which is believed can cause various physiological impairments to the child when subjected to this type of condition over prolonged feedings. It is theorized that the vacuum generated within the bottle, due to the infant's sucking, can cause pressure imbalance at the location of various features of the body, such as in the ear canal, or perhaps elsewhere, and which may possibly lead to the generation of infection, illness, or other predicaments. Thus, the presenting of a nursing bottle that incorporates air venting means, so as to prevent the creation of a vacuum inside the bottle, has been considered a desirable development in the field of infant serving products. Such can be seen in the applicants' prior U.S. Pat. No. 5,779,071 and No. 5,570,769, wherein the reservoir tube that provides for venting, externally of the bottle cap, at an upper proximity, extends into the lower portion of the container, to function as a vent while the contents of the bottle are being consumed, when partially or fully inverted.
[0004] Other attempts have been made to provide a nursing bottle with an air vent, to enable the ambient air to enter the container during usage, and to dilute or prevent the generation of any vacuum. For example, the U.S. Pat. No. 598,231, to Roderick, discloses one such nursing bottle with a U-shaped air tube. Other patents show related types of technology, and provide means for venting air from the interior of its shown container, as can be seen in the U.S. Pat. No. 927,013 to Van Cleave. In addition, the U.S. Pat. No. 1,441,623, to Davenport, in addition to the prior U.S. Pat. No. 2,061,477, to Perry, show other means for venting of air from within a nursing bottle.
[0005] The current invention, on the other hand, provides means for venting of any air pressure within the bottle, and to prevent the generation of any vacuum or pressure therein, regardless whether the nursing bottle is being used, stored in an upright position, or partially or fully inverted as during consumption of its contents.
[0006] Other United States patents that relate to the subject matter of this invention include the U.S. Pat. No. 189,691; to Briere, U.S. Pat. No. 345,518, to Lelievre; U.S. Pat. No. 679,144, to Hardesty; U.S. Pat. No. 834,014, to Lyke; U.S. Pat. No. 1,600,804 to Donaldson; U.S. Pat. No. 2,156,313, to Schwab; U.S. Pat. No. 2,239,275, to Schwab; U.S. Pat. No. 2,610,755, to Gits; U.S. Pat. No. 2,742,168, to Panetti; U.S. Pat. No. 2,744,696, to Blackstone; U.S. Pat. No. 3,059,707, to Wilkinson, et al; U.S. Pat. No. 5,570,796, to Brown, et al. In addition British patent No. 273,185; and, British patent No. 454,053, show related development.
SUMMARY OF THE INVENTION
[0007] This invention contemplates the establishment of a structured relationship between the container or vessel that holds the formula for a nursing bottle, having sufficient size so that as the formula is prepared and deposited within the container, its surface will be arranged below the vent port or the vent leading towards the exterior of the container, for venting purposes, and in addition, even when the vessel is inverted, by the infant or parent, during feeding, the liquid formula still will be maintained at a surface level below the vent port, but in this case, when in the inverted condition. Thus, the concept of this invention is to provide a container with sufficient bulk and volume, so that the formula or milk as supplied therein, whether it be in the four ounce, six ounce, eight ounce, plus category, will always leave the identified vent port exposed to attain the attributes of venting, for the nursing bottle, at all times.
[0008] Thus, no appreciably positive or negative pressure can build up in the container, since the vent port will be opened, for exhausting purposes, when the nursing bottle is maintained in an upright direction, as while it is being warmed or heated, in preparation for a feeding, and even while the bottle may be inverted, as during a feeding, so as to allow for the venting of any reduced pressure, internally generated within the container, that may occur as a result of the sucking action of the infant, during feeding.
[0009] This feature of providing sufficient internal volumetric size to the container is achieved through usage of containers that are of excessive dimensions, such as being large and spherical in shape, or cylindrical in shape and flattened upon each surface, or which has a size equivalent to that of a Mason jar. In one instance, the container may be shaped in a spherical form. In another embodiment, the container will be of a cylindrical shape, but be flattened or pancacked on the sides, as can be understood. In a further embodiment, the container may be of the jar shape, or even contain some concavity upon its sides, to facilitate its lifting. In addition, where the spherical or cylindrical type of container is used, it may have a flattened bottom, to add stability to the nursing bottle, when rested upon a surface.
[0010] In the preferred embodiment, the venting port cooperates with a vent tube, and lateral vent slots, that are built into the insert that is secured to the top of the container by means of its associated threaded collar, that holds both the vent tube within the vessel, and the conventional nipple, in place. The vent port associated with the vent tube may open directly, downwardly into the vessel, or it may have said lateral ports, to either side, so as to prevent the entrance of any formula, into the vent tube, as the container is being inverted during usage, but still allow the necessary venting.
[0011] In a further embodiment, the container, collar, and nipple may be of the conventional type, but having the volumetric sizes from the shaped containers as previously explained, but the vent tube and port may extend through the surface of the container, rather than cooperate with the collar, in the manner as previously described in U.S. Pat. No. 5,779,071.
[0012] Nevertheless, the orientation of the vent port, at its entrance point, leading to the vent tube, will normally be arranged somewhere centrally of the configured container, regardless what shape or structures the containers may possess, so as to allow the formulation to either be below the vent port, or above it, as the nursing bottle is either at rest, or being inverted as during usage, in the manner as previously explained.
[0013] Thus, it is the principal object of this invention to provide a volumetric sized container for use as a nursing bottle, and which incorporates a vent tube with vent port that is arranged approximately centrally thereof, so that the vent port avoids coverage from any of the formula or milk contained therein, either during usage when feeding the infant, or during nonusage when the bottle has been set on its base, as during storage, while heating, or when at rest.
[0014] A further object of this invention is to provide for structure means within a nursing bottle that provides for continuous venting of any pressure or vacuum generated within its container, regardless of usage or nonusage of the subject bottle.
[0015] Still another object of this invention is to provide for the structure of a wide rimmed collar for use with a standard wide mouth container as structured into a nursing bottle, and useful for feeding formula to an infant.
[0016] These and other objects may become more apparent to those skilled in the art upon review of the summary of the invention as provided herein, and upon undertaking a study the of the description of its preferred embodiment, in view of the illustrated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In referring to the drawings, FIG. 1 is a top view of a spherical shaped nursing bottle;
[0018] FIG. 2 is a side view thereof;
[0019] FIG. 2A is a side view of the bottle during usage;
[0020] FIG. 3 shows a modification to a spherical shaped nursing bottle wherein the vent tube extends structurally upwardly from its bottom;
[0021] FIG. 4 is a side view of the nursing bottle of FIG. 3 ;
[0022] FIG. 5 is a back view of the nursing bottle of FIG. 3 ;
[0023] FIG. 6 is a top view thereof;
[0024] FIG. 7 is a side view of a modified form of nursing bottle having a wide rim configuration for mounting of its collar and nipple, and supporting the vent structure therein;
[0025] FIG. 8 is a side view of the container for the nursing bottle as shown in FIG. 7 ;
[0026] FIG. 9 is an exploded view of the operative components of the structured nursing bottle as shown in FIG. 7 ;
[0027] FIG. 10 is a front view of a wide structured nursing bottle of a rectangular configuration having its collar and nipple applied to a wide rim at its upper end;
[0028] FIG. 11 is a top view thereof;
[0029] FIG. 12 is a bottom view thereof;
[0030] FIG. 13 is a side view thereof, and showing its internal venting structure;
[0031] FIG. 14 is a top view of the vent insert applied within the collar when affixed to the wide rim of the container of the nursing bottle as shown in FIG. 13 ;
[0032] FIG. 15 is a sectional view of the vent insert, taken along the line 15 - 15 of FIG. 14 ;
[0033] FIG. 16 is a front view of a nursing bottle having a volumetric structured vessel with the collar, vent insert and nipple applied to its wide rim top, for disposing its vent tube, and vent port approximately centrally of its shown container;
[0034] FIG. 17 is a front view of another spherical form of container for a nursing bottle having the vent tube operatively structured and disposed with its bottom segment;
[0035] FIG. 18 is a front view of a further rectangularly shaped volumetric sized container for a nursing bottle having the collar, vent insert, and vent tube all operatively associated therewith;
[0036] FIG. 19 is a top view of a further modified wide rim nursing bottle of this invention;
[0037] FIG. 20 is a front view thereof;
[0038] FIG. 21 is a further modified wide rim nursing bottle of this invention having its vent tube extending inwardly towards centrally from the upper container surface;
[0039] FIG. 22 is a further modified wide rim nursing bottle having its oblique vent tube extending inwardly from the approximate upper surface of its container;
[0040] FIG. 23 is a further modified wide rim nursing bottle having the vent tube extending inwardly from the surface of its container;
[0041] FIG. 24 is similar to the bottle of FIG. 22 , with the vent tube structured further downwardly along the side of the shown bottle;
[0042] FIG. 25 is a front view of a further shaped vented nursing bottle of this invention; and
[0043] FIG. 26 is a top view of an oval shaped wide rim nursing bottle of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0044] In referring to the drawings, and in particular FIGS. 1 and 2 , the fully vented, wide rim nursing bottle of this invention is disclosed. It includes a spherical shaped container 1 that has ample volumetric capacity therein, so as to achieve the sought after results for this invention. That is, when a formula, such as at 2 , is applied into the container, with the formula being applied at an amount that normally furnishes a feeding for the infant, it will only fill the container up to a level that is yet below the bottom of the vent tube 3 , and more specifically its vent port 4 , as can be noted.
[0045] Thus, when the nursing bottle is being heated, and should any pressure build up within its container, it will be immediately vented to the atmosphere, because of the openness of the vent port 4 , to absorb any generated pressure, no matter how slight, and allow it to be vented to the atmosphere, externally of the shown nursing bottle. The nipple 5 , the threaded collar 6 , and the vent insert 7 , that are threadedly applied to the upper edge of the container 1 , are all fabricated in the manner as previously described in the U.S. Pat. No. 5,779,071, with the exception that these components are fabricated of a wider dimension, so as to fit upon a wide rim style of opening for the shown container 1 , thereby providing the type of ample volumetric capacity for the nursing bottle, even though the standard size of nipple may be employed, to achieve the relationship between its structure, such as the vent port, and the level of any standard amount of formulation applied therein, during usage, to achieve the benefits of this invention. In addition, when the nursing bottle of this invention is applied, for feeding an infant, and is inverted, the formulation may rise to the opposite side of the inverted container 1 , but yet will have a surface level that will still be below the vent port 4 , so that any sucking action generated by the infant, during feeding, and the formation of any vacuum, or partial thereof, within the container, during feeding, will be continuously vented by its vent port 4 , through the vent tube 3 , and out of the vent insert 7 , as previously reviewed.
[0046] It should be noted that the container 1 of this invention will obviously include a minor flattened surface, as at 8 , at its bottom, in order to facilitate the free standing of this nursing bottle, as when not in use, when stored, or when being warmed or heated in preparation for consumption of its formulated content.
[0047] FIG. 2A shows the container 1 and its nursing bottle when inverted, as during a feeding, to disclose how the fluid level 2 will yet remain below the opened vent port 4 , so as to not obstruct the venting of any partial vacuum generated therein, during the feeding process.
[0048] FIGS. 3 and 4 disclose a modification to the shape of the container 9 for the shown nursing bottle, with the further modification that the vent tube 10 will be integrally structured with the bottom 11 of the shown container, disposing its vent port generally centrally of the container, as can be noted at 12 . Thus, regardless at what position the container 9 of this nursing bottle may undertake, the surface level 13 of the formula will not obstruct the entrance of any generated vacuum or pressure into the vent port 12 , for venting purposes, in this case, out of the bottom opening 14 of the shown vessel. This is so regardless whether the container 9 , as during storage, or feeding, may be positioned vertically, as shown in FIG. 3 , or inverted, as can be understood. In this particular instance, the threaded collar 15 and nipple 16 are conventional, and threadedly engage to the wide rim 17 of the container 9 , in order to enhance the volumetric capacity of the nursing bottle, during usage, and to attain the results desired and required for this particular development. In addition, as can be seen in FIG. 4 , the structure of wide rim container 9 is generally spherical, as can be noted in FIG. 3 , but flattened on its front and back surfaces, as disclosed in FIG. 4 , and yet attains the volumetric capacity for the formula, as desired and required for this development.
[0049] FIGS. 5 and 6 provide both a back view, and top view, of the modified nursing bottle as previously described in FIGS. 3 and 4 .
[0050] FIGS. 7 through 9 show a further modified nursing bottle of this invention, wherein its container 18 has a Mason jar style of configuration, thereby affording the wide rimmed 19 style of opening, at its upper end, for accommodating the vent tube 20 , receptacle portion 25 , the vent insert 21 , the nipple 22 , and the threaded collar 23 , that all threadedly engage onto the threads 24 of the shown container. These components 20 through 23 and 25 are very similar in structure to that as previously described in U.S. Pat. No. 5,779,071, with the exception that the components are fabricated to a wider dimension, in order to be accommodated upon the wide rimmed opening 19 of the shown container 18 . The vent tube communicates with its upper inner receptacle portion 25 , forming the reservoir-like configuration as noted, and which positions thereon and locates therein the internal vent tube 26 of the vent insert 21 , to function in the manner as previously explained in said earlier patent. But in this particular instance, it should be noted that the vent port 27 of the vent structure, as all mounted to the wide rim of the volumetric container 18 , when inserted, is disposed approximately at the center of the internal space of the shown container 18 , in order to achieve the benefits and results as explained for this invention. Hence, the surface level 28 of the formula applied therein will always be below the entrance to the vent port 27 , so as to avoid its blockage, regardless whether the container 18 is maintained in its rest position, as shown in FIG. 7 , or when the container is tilted to any angulation, or should it be inverted, placed on its side or any position, as during the feeding process. This allows the reduced pressure generated within the container, during feeding with the nursing bottle, to always be vented, to the atmosphere, as can be understood. In addition, it is to be noted, particularly upon review of U.S. Pat. No. 5,779,071, that wherever these vent tube and vent insert configurations are inserted upon the wide rim and held in position by means of the collar 23 , that the vent tube 26 internally communicates with the lateral vent passages 29 and opens to atmosphere internally of the collar 23 , to provided venting thereof, at all times, to achieve the purposes and advantages of this invention.
[0051] It can also be noted in FIG. 8 that the sides of the container 18 may be integrally concaved, as at 30 , in order to facilitate the gripping and holding of the larger sized bottle, during its usage.
[0052] FIGS. 10 through 13 disclose a larger volumetric sized nursing bottle, having a container 31 that is generally of a rectangular configuration. It has a wide rimmed opening, as at 32 for accommodating the shown collar 33 , its supported nipple 34 , the vent tube 35 , and the vent insert 36 when installed. The vent insert is shown more carefully in FIGS. 14 and 15 , and it can be seen that the bottom of the vent port 37 is closed, and venting is achieved through the lateral port 38 that extends to the front and back of the vent tube, to attain venting from internally of the shown container. In addition, the lateral port 38 is arranged approximately at the volumetric midpoint of the bottle. In addition, the purpose of the lateral vents 38 is to prevent the entrance of any of the formula 39 therein, as when the nursing bottle is inverted, as during a feeding. Nevertheless, as can be seen in FIG. 13 , the level of the formula will always be at a location spaced from the bottom of the vent tube 35 , to attain the purposes of this invention. Furthermore, as can be seen in FIG. 15 , and as noted from our prior patents, the vent insert 36 has the lateral vents 38 that communicate with the vent 35 , for allowing the discharge of any vacuum, pressure, or the like, generated within the nursing bottle during usage, to the atmosphere, externally of the bottle, in order to achieve the benefits and results of this development.
[0053] FIG. 16 shows a nursing bottle that incorporates a semi-spherical container 40 , and having mounted onto its integral wide rim 41 the collar 42 , nipple 43 , and the vent insert 44 as noted. In addition, the vent tube 45 extends downwardly into the container 40 , with the bottom 46 of the vent tube being arranged approximately, once again, at the approximate midpoint of the volumetric capacity of the nursing bottle, to achieve the benefits of this invention.
[0054] FIG. 17 discloses a spherical form of nursing bottle wherein its container 61 has mounted to its wide rim 62 by threaded engagement the collar 63 and the nipple 64 , as noted.
[0055] The vent tube, in this instance, as at 65 , extends integrally upwardly from the bottom of the container 61 , and internally is vented to the atmosphere, out the bottom of the bottle, and has at its upper end the lateral vent ports 66 as noted. Again, these vent ports are arranged at the approximate midpoint of the volumetric capacity for the shown container, to achieve the benefits of this invention.
[0056] FIGS. 18 and 19 disclose a modification to the nursing bottle of this invention, wherein its container 51 is generally rectangular of configuration in one dimension, but has an oval shape 52 along its vertical disposition. Its collar 53 supports the nipple 54 , and the vent insert 55 to the wide rim 56 of the integral container 51 , for the nursing bottle. The vent tube 57 of the insert extends downwardly, and includes an extended vent tube 58 , whereby its vent port 59 at its bottom end is disposed approximately, once again, at the volumetric midpoint of the shown container 51 for the nursing bottle. Thus, any formula 60 contained therein, and processed for feeding, will always be below the disposition of the vent port 59 , regardless whether the nursing bottle is rested upright, as shown in FIG. 18 , or inverted, as during the feeding process.
[0057] FIG. 20 shows a similar style of nursing bottle, to that of FIG. 16 , but in this instance, its container 47 has integrally formed of its flattened bottom 48 an upwardly extending vent tube 49 , whose upper end 50 , forming the vent port, is arranged once again at the approximate volumetric midpoint of its shown container.
[0058] FIGS. 21 through 25 show variations upon the arrangement of the vent tube of this invention. As noted, in FIG. 21 the shown nursing bottle has its container 67 mounting upon its wide rim 68 , its threaded collar 69 , and the shown nipple 70 . For venting purposes, in this particular embodiment, the vent tube 71 is integrally formed of the container 67 , and extends radially inwardly, along an oblique angle, into the approximate midpoint of the shown container, having its vent port 72 disposed approximately at this location, as noted.
[0059] Thus, any formula 73 provided therein, and particularly of the standard amount normally fed to an infant, will always be below the entrance to the vent port 72 , and not cause any blockage thereof. This is so regardless whether the nursing bottle is being stored, or inverted as during usage, as can be understood.
[0060] FIG. 22 shows the semispherical style of container 74 for the shown nursing bottle. The bottle has a wide rim 75 , and to which the threaded collar 76 and the nipple 77 are attached.
[0061] In this instance, similar to that of the bottle as described in FIG. 21 , the vent tube 78 is integrally formed of the container, and is arranged obliquely within it, to dispose its vent port, as at 79 , and more specifically its lateral vents 80 , internally at the approximate volumetric midpoint of the shown container, to achieve the benefits of this invention.
[0062] FIG. 23 is similar to the structured nursing bottle as described in FIG. 21 , but in this instance, as can be noted, the container 81 has its vent tube 82 arranged further down the side of the shown container, opening to atmosphere as at 83 , and having its vent port 84 provided at the approximate midpoint of the shown container 81 .
[0063] FIG. 24 shows a structure for a nursing bottle similar to that as previously explained in FIG. 22 , but in this particular instance, the container 85 has its vent tube 86 integrally formed further down the side of the shown container, as can be noted at 87 . This may be integrally formed, or structurally applied thereto, as by adherence of the flanges 88 to the opening 89 provided through the wall of the container 85 . The inner end of the vent tube 86 , has its vent port 90 , arranged, once again, at the approximate volumetric midpoint of the shown container, in order to achieve the results and benefits of this invention.
[0064] FIGS. 25 and 26 disclose a further modification to the nursing bottle of this invention, wherein its rectangularly configured container 91 has an oval appearance along the vertical, as can be noted in FIG. 26 , as at 92 .
[0065] It provides sufficient volumetric capacity so that the surface of the formula added thereto, as at 93 , will always be below the vent tube 94 , and its vent port 95 , regardless of the position undertaken by the nursing bottle, when used. In accordance with the structure of the venting characteristics of this development, and as can be seen in FIG. 26 , the vent tube 94 has lateral vents 96 that extend laterally to the sides of the vent insert 97 , and which provides venting of any pressure or vacuum developed within the container 91 to the atmosphere, by passing through the configured threads 101 , as can be understood from our prior patents.
[0066] As known from our prior development, the vent insert 97 includes a series of supporting vanes 98 that provide intermediate spacing, as at 99 , and through which the formula may flow, when the nursing bottle is inverted, as during a feeding. But, the lateral vents 96 communicate with the vent tube 94 , to allow passage of any pressure, or lack thereof, therethrough, and through said vents, to be discharged to atmosphere, by passing through the imperfect seal formed of the threaded connection between the collar 100 , and the threads 101 of the wide rimmed structure of the container 91 , of the shown nursing bottle. Nevertheless, the criticality regarding the location of the vent port 95 , at the approximate volumetric midpoint of the shown container 91 , is essential so as to prevent any blockage to it, when formula is applied therein, so that venting can effectively occur, regardless whether the nursing bottle is being used, stored, heated, or inverted, as during a feeding process.
[0067] Variations or modifications to the subject matter of this invention may occur to those skilled in the art upon reviewing the development as described herein. Such variations, if within the scope of this development, are intended to be encompassed within the principles of this invention, as explained herein. The description of the preferred embodiment in addition to the depiction within the drawings is set forth for illustrative purposes only. | A nursing bottle ( 1 ) formed of a large volume container, incorporating a vent tube ( 3 ) that extends inwardly of the container, having a vent port ( 4 ) arranged approximately at the volumetric midpoint ( 12 ) of the container, so as to allow for venting of pressure, whether of excessive or vacuum, to the atmosphere, at all times. The volumetric capacity of the nursing bottle container may be formed of a spherical shape ( 1 ), hemispherical shape ( 40 ), cylindrical shape ( 18 ), or to other configurations that provide for the internal volumetric capacity so that any formula placed therein will be prevented from blocking the vent port ( 4 ), the vent tube ( 3 ), regardless of the angular disposition undertaken by the nursing bottle during usage. The vent tube ( 10 ), with its disposed vent port ( 12 ), may either extend upwardly within the container, or extend downwardly ( 3 ) from its connection with the vent insert ( 7 ), operatively associated with a collar ( 6 ), that holds both the vent structures and the nipple ( 5 ) to the wide rimmed opening ( 19 ) for these type containers. In addition, as an alternative, the vent tube may be integrally formed, or connected by a flange, through the surface of the nursing bottle container, either at its bottom ( 14 ), or along a side ( 74 ), and either extend upwardly, or obliquely radially inwardly ( 82 ), so as to dispose its vent port ( 84 ) at that desired location approximately at the volumetric midpoint of the nursing bottle. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from and the benefit of Korean Patent Application No. 10-2014-0112346, filed on Aug. 27, 2014, which is hereby incorporated by reference for all purposes as if fully set forth herein.
BACKGROUND
Field
Exemplary embodiments relate to a display substrate, and a method of fabricating the same. More particularly, exemplary embodiments relate to reducing the number of masks from five (5) to four (4) when fabricating the display substrate used in a liquid crystal display device in a horizontal field (Plane to Line Switching (PLS)) mode.
Discussion of the Background
In general, a liquid crystal display device includes a display substrate comprising a switching element and a pixel electrode, an opposing substrate opposite to the display substrate, and a liquid crystal layer interposed between the display substrate and the opposing substrate. The liquid crystal display device displays an image by applying different levels of voltages to the liquid crystal layer and controlling the light transmittance.
The liquid crystal display device may be divided into a vertical field mode and a horizontal field mode according to the direction of the electric field.
Currently, liquid crystal display devices operated using a vertical field mode have problems with wide angle viewing, which led to active development of liquid crystal display devices operated using horizontal field mode. Particularly, research for reducing manufacturing costs of a liquid crystal display device operated in a Plane to Line Switching (PLS) mode, which is an example of the horizontal field mode, is being conducted.
The display substrate includes a plurality of thin film patterns formed by patterning a thin film formed on an insulating substrate through a photolithography process. Each of the thin film patterns may be formed by forming a photo-resistant pattern on the thin film, and etching the thin film by using the photo-resistant pattern as an etch mask. The photolithography process may be performed by dry etching or wet etching according to the properties of the thin film. When the thin film includes metal, it may generally be patterned by using a composition of etchants, and when the thin film is an insulating layer, including a silicon oxide and the like, it may generally be patterned by using etching gas.
In order to form one thin film pattern, a mask including a design of the thin film pattern is used. In order to minimize the use of a high-priced mask or to simplify a process, two or more thin films may be patterned by using one mask. However, even when one mask is used, when properties of the thin films are different from each other, the etching process must be performed using different methods. So it is not easy to substantially decrease the number of process steps.
Accordingly, the present disclosure shows a method of decreasing a five mask (M) processes to a four mask (M) processes, which will be described in detail herein.
The above information disclosed in this Background section is only for enhancement of understanding of the background of the inventive concept, and, therefore, it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY OF THE INVENTION
The present disclosure has been made in an effort to solve the above-described problems associated with the prior art, and provides a display substrate, of which production cost may be lowered by reducing a five mask (M) processes utilized in fabricating the display substrate used in a liquid crystal display device in a Plane to Line Switching (PLS) mode to a four mask processes.
The present disclosure has also been made in an effort to solve the above-described problems associated with the prior art, and provides a method of fabricating a display substrate, which may improve productivity by decreasing the number of masks from five (5) to four (4) for fabricating the display substrate used in a liquid crystal display device in a Plane to Line Switching (PLS) mode.
Additional aspects will be set forth in the detailed description which follows, and, in part, will be apparent from the disclosure, or may be learned by practice of the inventive concept.
An exemplary embodiment of the present disclosure provides a display substrate that includes a lower common electrode formed on a substrate, an insulating layer formed on the lower common electrode, a gate pattern including a gate electrode formed on the insulating layer and a common electrode contact part spaced apart from the gate electrode, a gate insulating layer formed on a substrate including the gate pattern, a semiconductor layer disposed on the gate insulating layer, source and drain electrodes formed on the semiconductor layer, a passivation layer formed on the source and drain electrodes, a pixel unit formed on the passivation layer, and a common electrode contact connection part spaced apart from the pixel unit and configured to make the common electrode contact part be in side contact with the lower common electrode.
The lower common electrode may be entirely deposited and not patterned.
The lower common electrode and the pixel unit may use Transparent Conductive Oxide (TCO)-based metal.
The insulating layer and the gate insulating layer may use a Si-based insulating layer.
The gate electrode and the source/drain electrodes use material selected from a group consisting of copper, aluminum, molybdenum, tungsten, titanium, and chrome, in single or alloy form.
Another exemplary embodiment of the present disclosure includes a method of fabricating a display substrate. It includes steps of entirely depositing a lower common electrode on a substrate, depositing an insulating layer on the lower common electrode, depositing and first patterning gate metal on the insulating layer to form a gate electrode and a common electrode contact part, forming a gate insulating layer on a substrate including a gate pattern, depositing and second patterning a semiconductor material on the gate insulating layer to form a semiconductor layer, depositing and third patterning source/drain metal on the semiconductor layer to form source and drain electrodes, depositing and fourth patterning a passivation layer on the source and drain electrodes to open a pixel area, and forming a first contact hole and a second contact hole at the common electrode contact part, depositing pixel metal at the first contact hole and the second contact hole, and forming an upper pixel unit and a common electrode contact connection part.
The common electrode contact part may be in contact with the side of lower common electrode with pixel metal when the passivation layer is patterned.
The gate pattern may be patterned by wet etching, while the area from gate electrode to the lower common electrode is patterned by dry etching.
According to the exemplary embodiments of the present disclosure, the display substrate and the method of fabricating the same use less number of photo masks than the conventional process, and may thereby improve the productivity.
Further, according to the exemplary embodiments of the present disclosure, the common electrode is entirely deposited, thereby decreasing defects caused by static electricity.
The foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the inventive concept, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the inventive concept, and, together with the description, serve to explain principles of the inventive concept.
In the drawing figures, dimensions may be exaggerated for clarity of illustration. It will be understood that when an element is referred to as being “between” two elements, it can be the only element between the two elements, or one or more intervening elements may also be present. Like reference numerals refer to like elements throughout.
FIG. 1 is an exploded perspective view illustrating a display device including a display substrate according to a first exemplary embodiment of the present invention.
FIG. 2 is a cross-sectional view of the display substrate according to the first exemplary embodiment of the present invention.
FIGS. 3A to 3F are schematic diagrams illustrating a method of fabricating the display substrate according to the first exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of various exemplary embodiments. It is apparent, however, that various exemplary embodiments may be practiced without these specific details or with one or more equivalent arrangements. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring various exemplary embodiments.
In the accompanying figures, the size and relative sizes of layers, films, panels, regions, etc., may be exaggerated for clarity and descriptive purposes. Also, like reference numerals denote like elements.
When an element or layer is referred to as being “on,” “connected to,” or “coupled to” another element or layer, it may be directly on, connected to, or coupled to the other element or layer or intervening elements or layers may be present. When, however, an element or layer is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. For the purposes of this disclosure, “at least one of X, Y, and Z” and “at least one selected from the group consisting of X, Y, and Z” may be construed as X only, Y only, Z only, or any combination of two or more of X, Y, and Z, such as, for instance, XYZ, XYY, YZ, and ZZ. Like numbers refer to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
Although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are used to distinguish one element, component, region, layer, and/or section from another element, component, region, layer, and/or section. Thus, a first element, component, region, layer, and/or section discussed below could be termed a second element, component, region, layer, and/or section without departing from the teachings of the present disclosure.
Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for descriptive purposes, and, thereby, to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the drawings. Spatially relative terms are intended to encompass different orientations of an apparatus in use, operation, and/or manufacture in addition to the orientation depicted in the drawings. For example, if the apparatus in the drawings is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. Furthermore, the apparatus may be otherwise oriented (e.g., rotated 90 degrees or at other orientations), and, as such, the spatially relative descriptors used herein interpreted accordingly.
The terminology used herein is for the purpose of describing particular embodiments and is not intended to be limiting. As used herein, the singular forms, “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Moreover, the terms “comprises,” comprising,” “includes,” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components, and/or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Various exemplary embodiments are described herein with reference to sectional illustrations that are schematic illustrations of idealized exemplary embodiments and/or intermediate structures. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, exemplary embodiments disclosed herein should not be construed as limited to the particular illustrated shapes of regions, but are to include deviations in shapes that result from, for instance, manufacturing. For example, an implanted region illustrated as a rectangle will, typically, have rounded or curved features and/or a gradient of implant concentration at its edges rather than a binary change from implanted to non-implanted region. Likewise, a buried region formed by implantation may result in some implantation in the region between the buried region and the surface through which the implantation takes place. Thus, the regions illustrated in the drawings are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to be limiting.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure is a part. Terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense, unless expressly so defined herein.
FIG. 1 is an exploded perspective view illustrating a display device including a display substrate according to a first exemplary embodiment of the present invention.
Referring to FIG. 1 , the display device includes a display substrate 100 including a plurality of pixels PXL, an opposing substrate 200 opposite to the display substrate 100 , and a liquid crystal layer LC disposed between the display substrate 100 and the opposing substrate 200 .
Each pixel of the display substrate 100 includes at least one thin film transistor, a pixel electrode, and a common electrode for driving liquid crystal molecules. The opposing substrate 200 may include color filters for expressing colors of an image.
The liquid crystal layer LC includes a plurality of liquid crystal molecules having dielectric anisotropy. When an electric field is applied between the pixel electrode and the common electrode of the display substrate 100 , the liquid crystal molecules of the liquid crystal layer LC rotates in a specific direction between the display substrate 100 and the opposing substrate 200 , thus allowing the transmittance of light incident to the liquid crystal layer LC to be adjusted.
FIG. 2 is a cross-sectional view of the display substrate according to the first exemplary embodiment of the present invention. FIGS. 3A to 3F are schematic diagrams illustrating a process of fabricating the display substrate according to the first exemplary embodiment of the present invention.
Referring to FIG. 2 , the display substrate 100 includes an insulating substrate 110 including a plurality of pixel areas, a common electrode 120 , a gate electrode 140 , a source electrode 171 and a drain electrode made from the same layer as a data line 170 , and a plurality of pixel electrodes 190 . Here, each of the pixels has the same structure, so that, for convenience of the description, FIG. 2 illustrates one pixel PXL among the pixels, and one common electrode line CL, one gate line GL, and two data lines DL adjacent to the pixel PXL.
Referring to FIGS. 2 and 3A , the substrate 110 may be formed of a transparent insulating material. A plurality of pixel areas may be disposed on the substrate 110 in a matrix form.
A lower common electrode 120 is disposed on the substrate 110 . The lower common electrode 120 is deposited on the entire substrate 110 , and is not patterned. The common electrode 120 is entirely deposited on the substrate 110 , thereby exhibiting a similar effect as that of metal deposition on a rear surface. This effectively decreases the static electricity, because the electrical potential difference between the gate line and the data line is decreased.
A Transparent Conductive Oxide (TCO)-based material, for example, IZO and ITO, may be used in the lower common electrode 120 , and the lower common electrode 120 may be formed in a predetermined thickness by a generally known method in this field, for example, sputtering or Chemical Vapor Deposition (CVD).
As illustrated in FIG. 3B , an insulating layer 130 is disposed on the lower common electrode 120 . Here, a Si-based material, for example, SiNx, SiOx, or SiONx, may be used as insulating layer. The insulating layer may be formed in a predetermined thickness by a general method in this field, for example, sputtering or CVD.
The insulating layer 130 insulates the lower common electrode 120 from the gate electrode 140 .
A gate layer is formed on the insulating layer 130 and patterned to include the gate line GL and the gate electrode 140 . Further, a common electrode contact part (com-CNT) 141 is patterned on the same layer together with the gate electrode 140 while being spaced apart from the latter.
The gate line GL and the gate electrode 140 is formed of the same material as the common electrode contact part 141 disposed on the same layer.
The insulating layer 130 formed on the lower common electrode 120 is patterned when patterning the gate electrode 140 . Also, the common electrode contact part 141 disposed on the same layer as that of the gate electrode 140 may be formed simultaneously.
In this case, the gate pattern and the common electrode contact part 141 disposed on the same layer may be formed by patterning the gate electrode 140 by using photoresist as a first mask (not illustrated). The gate pattern may be patterned by a generally known method in this field, for example, dry etching or wet etching. More preferably, the gate pattern may be patterned by wet etching, and the insulating layer 130 may be patterned by dry etching.
The insulating layer 130 between the gate electrode 140 and the common electrode 120 may exist only in an area in which the gate pattern is formed, and in this case, the insulating layers may have a structure protruding to the outside of the gate pattern.
Material, such as copper, aluminum, molybdenum, tungsten, or chrome, may be used for the gate line GL, the gate electrode 140 , and the common electrode contact part 141 , and Mo, Ti, or an Mo/Ti alloy may be used at an upper/lower side of the metal, and may be formed as a single layer, a multilayer, or an alloy layer, for example, a molybdenum-aluminum-molybdenum (Mo—Al—Mo) triple layer or a molybdenum-aluminum alloy layer.
As illustrated in FIG. 3C , the gate insulating layer 150 is formed on the substrate on which the gate electrode 140 and the common electrode contact part 141 are formed, and the gate insulating layer 150 covers the gate electrode 140 , the gate line GL, and the common electrode contact part 141 . They are insulated from another conductive thin film, which is formed later, by the gate insulating layer 150 .
Then, a semiconductor layer 160 is formed by depositing a semiconductor thin film on the gate insulating layer 150 and patterning the semiconductor thin film. In this case, the semiconductor layer 160 is formed by patterning the semiconductor thin film by using photoresist as a second mask (not illustrated). Similarly, the semiconductor thin film may be patterned by a generally-known method in this field, for example, dry etching or wet etching.
Si-based material, for example, SiNx, SiOx, or SiONx, may be used as the gate insulating layer 150 , and the gate insulating layer 150 may be formed in a predetermined thickness by a generally-known method in this field, for example, sputtering or CVD.
A general semiconductor layer in this field may be used as the semiconductor layer 160 , and for example, amorphous silicon (n+ a-Si) doped with n+ at a high concentration and the like may be used, so that the semiconductor layer 160 may be formed in a predetermined thickness, but the semiconductor layer 160 is not limited thereto.
As illustrated in FIG. 3D , a source and drain electrode 170 is disposed on the semiconductor layer 160 .
That is, source/drain metal is deposited and patterned on source and drain electrode regions on the semiconductor layer 160 to form the data line DL and the source and drain electrode 170 .
Here, material such as copper, aluminum, molybdenum, tungsten, or chrome, may be used as the data line DL and the source/drain electrode, and Mo, Ti, or an Mo/Ti alloy may be used at an upper/lower side of the metal, and may be formed in a single layer, a multilayer, or an alloy layer, for example, a molybdenum-aluminum-molybdenum (Mo—Al—Mo) triple layer or a molybdenum-aluminum alloy layer.
The source electrode 171 is branched from the data line DL. In plane, the source electrode 171 overlaps a part of the semiconductor layer 160 . The drain electrode 172 is spaced apart from the source electrode 171 , and overlaps another part of the semiconductor layer 160 .
In this case, the source electrode 171 and the drain electrode 172 are formed by patterning the source/drain metal by using photoresist as a third mask (not illustrated). A Half-Tone (HT) mask may be used for this patterning step.
As illustrated in FIG. 3E , the display substrate 100 includes a passivation layer 180 on the source and drain electrode 170 . The passivation layer 180 may be formed of an organic or inorganic insulating material. The passivation layer 180 is patterned to form a first contact hole 181 , and a second contact hole 182 at the common electrode contact part 141 .
In this case, the first contact hole 181 and the second contact hole 182 are formed by patterning the passivation layer 180 by using photoresist as a fourth mask (not illustrated).
As illustrated in FIG. 3F , a pixel unit 190 is formed of a TCO-based material in the pixel area. The TCO-based material is deposited on the second contact hole, to form a common electrode-contact connection part 195 , in which the common electrode contact part 141 is in side-contact with the common electrode-contact connection part 195 . In other words, the common electrode-contact connection part 195 directly contacts a side surface of the common electrode contact part 141 .
The method of fabricating the display substrate according to the exemplary embodiment of the present disclosure may improve production yield by decreasing the number of existing processes.
Example embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. In some instances, as would be apparent to one of ordinary skill in the art as of the filing of the present application, features, characteristics, and/or elements described in connection with a particular embodiment may be used singly or in combination with features, characteristics, and/or elements described in connection with other embodiments unless otherwise specifically indicated. Accordingly, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention as set forth in the following claims. | Disclosed are a display substrate, of which productivity is improved by decreasing five mask (M) processes utilized for fabricating the display substrate used in a liquid crystal display device in a horizontal field (Plane to Line Switching (PLS)) mode to four mask processes, and a method of fabricating the same. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a relay system in a network.
(Concept of Domain)
A routing domain has hitherto been thought as follows. The routing domain is configured with one or more networks. The routing domain is defined as a range in which a network layer packet managed by one or more routing protocols cooperating with each other is reachable. For example, the Internet is configured by a plurality of networks where a variety of routing protocols function. Therefore, the Internet may be conceived as one routing domain (which will hereinafter simply be referred to as a domain).
A multiplicity of enterprises have been configuring by now intra-organization networks (Intranets) using the Internet technology as company's own information infrastructures. The Intranet needs a Fire Wall provided between the Internet and the Intranet itself in order to keep a confidentiality of the enterprise and to block an interference from outside. The Fire Wall monitors and restricts the communications with the Internet. It is a general practice in the Intranet that pieces of internal routing information in the Intranet are not distributed to the Internet for the reason of security. Further, the Intranet generally uses private addresses because of a deficiency of IPv4 addresses.
The private address is within a category of the Internet address that an office user can use as the user intends. It is, however, inhibited to distribute these pieces of routing information to the Internet. The Intranet using the private addresses is therefore incapable of communicating directly with the Internet. Accordingly, the intranet may be defined as a domain independent of the Internet.
It is required that a NAT ((IP)NetworkAddressTranslation) device be used for the Intranet to communicate with the Internet. The NAT device translates a private address attached to the packet into a global address at a boundary between the two domains in order to let the packet having the private address go through the Internet in which routing is conducted based on the global address.
Further, a router comes to have a NAT function (which will hereinafter be referred to as a NAT router) in order to correspond to a more complicated architecture of the Intranet and more diversified router functions. This type of router is capable of managing two domains.
Under such circumstances, a communication from the domain using the private address (which will hereinafter be called a private address domain) to a domain using the global address (which will hereinafter be called a global address domain), is performed as follows.
Namely, a default route is set so that each of the routers within the private address domain forwards all the packets of which destination addresses are other than within the Intranet to the NAT router. The packets addressed to the global address domain can be thereby sent to a relay system provided at the domain boundary (which will hereinafter be termed a domain boundary relay system).
This domain boundary relay system does not distribute the routing information of the private address domain to the global address domain, and distributes the routing information obtained from the global address domain to the private address domain. With this contrivance, each host (node) in the private address domain is capable of sending the packet addressed to the global address domain to the relay system.
The domain boundary relay system obtains a next hop router within the global address domain from the routing information received from the global address domain (an external router is in fact specified as a default route in the relay system as the case may be). Thus, the domain boundary relay system is capable of routing the packet to an interface directed to the global address domain. At this time, as a matter of fact, the domain boundary relay system translates a packet address before being routed.
The address is translated by a few methods. For instance, at first, the relay system provided at the boundary between the domains pools some global addresses. This domain boundary relay system replaces a source address categorized as a private address of the packet arrived with one of the global addresses pooled (which will hereinafter be called an Alias address).
Next, this domain boundary relay system forwards the packet as if being a source host within the global address domain. At this time, the domain boundary relay system records a mapping of the source address replaced to that Alias address. Then, the domain boundary relay system, when receiving a response traffic with respect to the packet transmitted using alias address, transmits the packet backward to the original source host within the private address domain.
When a response packet to a preceding packet forwarded to the global address domain from the private address domain is returned, the destination address may be conceived as the Alias address. Namely, in the global address domain, the source address of the preceding packet is the Alias address of the relay system. Therefore, the domain boundary relay system refers to the previous address translation table from private address into the global address and vice versa, and is capable of thus translating the packet destination address into a source address of the private address domain. Thus, the domain boundary relay system output the reply packet to the interface connected to the private address domain.
The communications between the two domains can be performed owing to the address translation function described above. In this case, the communication in a forward direction requires a routing table in the destination domain. On the other hand, if the address translation table is set to record the private address and the global address together the interface receiving the forward-streamed packet, the relay system may transfer a backward-streamed packet to its receiving interface. On this occasion, the relay system searches the routing information of the source domain, then determines a next hop router in the private address domain, and transfers the packet to the above interface.
The domain boundary relay system in the prior art has a routing control program that terminates a plurality of routing protocols and only one routing table. Note that the routing table categorized herein is a table to be searched in order to determine an output interface and a next hop router when routing the packet.
The conventional relay system executes management control as to whether or not pieces of routing information obtained by the plurality of routing protocols are mixed with each other. If mixed with each other, however, the prior art relay system writes all pieces of routing information obtained from the plurality of routing protocols to the same routing table. Namely, the relay system provided at the boundary between the private address domain and the global address domain, manages the routing information obtained from the domains within the one single table.
(Example of IP Navigator by Lucent Technologies Corp.)
FIG. 19 shows an outline of processing of IP Navigator by Lucent Technologies Corp. The IP Navigator is a communication program for supporting a plurality of routing tables. The IP Navigator runs on a relay system (which will hereinafter be called a router) that equips MPLS (Multi Protocol Label Switching) protocol as a technology for ISP (Internet Service Provider) network.
This IP Navigator segments an ISP (Internet Service Provider) network into partitions by making an LSP (Label Switch Path) for connecting the routers corresponding to each of the plurality of routing tables in an LSR (Label Switch Router). Then, the IP Navigator aims at providing the office user with each partition as a private network. According to this method, the routing tables are provided to the plurality of domains. This method is, however, incapable of performing the communications between an arbitrary couple of domains through the address translation function.
(Implementation of IPv6 Router)
An IP protocol (Ipversion4 that will hereinafter be abbreviated to IPv4) has been used up to now as a typical network layer protocol. Further, anew version (Ipversion6 abbreviated to IPv6) of the IP protocol comes to an advent to obviate the deficiency of the IP addresses. IPv4 and IPv6 coexist at the present. Generally, the IPv4 domain and the IPv6 domain communicate with each other by use of an address translator. There is a router (such as NR60 manufactured by Hitachi Ltd.) corresponding to these two domains, by which the IPv4 domain having an IPv4 routing table and the IPv6 domain having an IPv6 routing table are communicable with each other by translating the addresses.
This type of router has the plurality of routing tables for the two IPv4 and IPv6 domains, and is capable of performing the communications between the two domains by the address translation. A user is, however, unable to further define a domain in an IP address space and connect the two or more domains as the user intends through the address translation.
(Unidirectional NAT)
FIG. 20 shows an outline of a unidirectional NAT. The unidirectional NAT actualizes the communications under such a condition that the routing information of a domain 1 is unable to be distributed to a domain 2 as with the private address and the global address. The domain 1 can get informed of a route to the domain 2 and is therefore capable of routing the packet addressed to the domain 2 .
The NAT device translates a source address of the packet passing therethrough into an Alias address assigned to own interface directed to the domain 2 . The NAT device forwards the packet with its address translated to the domain 2 , and stores the mapping between the Alias address and the source address before being translated.
With this operation, a receiving host within the domain 2 forwards a response packet toward the Alias address. Namely, the domain 2 is uninformed of the route to the domain 1 but is capable of replying the packet to the translated Alias address of the NAT device.
Further, the NAT device re-forwards the packet received with this Alias address toward the original source address stored on the side of the domain 1 using the mapping between the Alias address and the source address.
In this case, the routing tables of the NAT device are those not separated according to the domain 1 and the domain 2 . If the packet addressed to the domain 1 from the domain 2 is received by a forwarding interface, this packet might be forwarded referring to the routing table. Therefore, a packet filter against an unauthorized packet is needed.
(Bidirectional NAT)
FIG. 21 shows an outline of a bidirectional NAT. The bidirectional NAT actualizes the communications under such a condition that neither the domain 1 nor the domain 2 can exchange the routing information with each other. When a host in the domain 1 starts the communication with a host in the domain 2 , the host in the domain 1 executes a name resolution by use of DNS (Domain Name System) in advance of the communications.
A resolution request in the domain 1 is sent via a DNS server within the domain 1 and translated by a translation server on the NAT device into a resolution request within the domain 2 . When a resolution response is returned from the DNS server in the domain 2 , the NAT device sets, in the respective interfaces, the pooled Alias addresses suited to the domain 1 and the domain 2 . Then, the NAT device notifies the inquirer host in the domain 1 of the Alias address on the side of this domain 1 . The NAT device records a mapping of the resolution address received from the domain 2 to each Alias address.
The source host transmits the packet to the Alias address of the NAT device on the side of the domain 1 . The NAT device translates a destination address of the header into an address obtained from the DNS of the domain 2 owing to the resolution response and translates a source address into an Alias address on the side of domain 2 by use of the mapping given above. In this case, there is no problem if the address systems are absolutely different as in the case of IPv4 and IPv6. In an architecture wherein both of the domains are configured as being a part of the IPv4 address space, however, if the NAT device receives a malicious packet with an interface address other than the Alias address, and if the packet filter is not set correctly, the NAT device might forward this packet.
(Application Gateway)
The domains can be also isolated by using an application gateway. FIG. 22 shows an outline of the application gateway.
An application program 40 on the application gateway once terminates the communication from the domain 1 , and receives the data. Further, this application program 40 retransmits the data onto the connection on the side of the domain 2 . This method involves preparing on the gateway the application program 40 corresponding to an application used by an end host. Moreover, a problem inherent in this method is that the processing is heavy.
(Address Translator Corresponding to Plural Domains)
A router supporting a plurality of domains has been proposed. The conventional router of the type is provided with a single routing table. Further, the router uses the packet filter that blocks packets ruled out of an address translation policy between the domains. This type of router can be utilized in a simple setting. The prior art router becomes, however, intricate in processing if there are a multiplicity of management domains. Further, it is required that a judgement about the inter-domain communications be made with respect to all the packets.
(Problems)
According to an address translation algorithm such as the NAT etc, the router performs a forward-streamed packet transfer by searching the routing table after executing the address translation process. The router sets the packet filter with respect to the packet's source/destination addresses, thereby judging whether the packet should be routed or not. On the other hand, the router behaves as if being a source host for the global address domain with respect to backward-streamed packets. Then, the router as an end host terminates the packet addressed to the global address pooled in the router.
Similarly, the router judges whether or not a packet addressed to the private address domain and arrived from the global address domain should be routed between the domains through the packet filter. Therefore, if a malicious packet addressed to the private address domain arrives at the router, and if the packet filter is not correctly set, the router refers to only one routing table and might forward this malicious packet to the private address domain. This implies a possibility in which a multiplicity of unknown packets are to be unexpectedly received from the Internet, and might turn out to be a security hole.
Moreover, it is assumed in the router capable of connecting the plurality of domains that each domain takes the same private address space. In this case, if the router writes the routing information obtained from the respective domains to one single routing table, contradictions occur in the routing table.
To obviate the problem described above, the packet filter can restrict the packet from the global address domain not to be forwarded. If the number of domains that can be managed increases, however, the setting becomes complicated.
For example, the packet filter is capable of restricting the packet routing, wherein an input interface, and output interface, a source address, a destination address, a L 4 (Layer 4 ) port number etc are available as keys. If the multiplicity of domains are connected by a router having the multiplicity of interfaces, it is troublesome to set a filtering condition for every couple of domains. Further, the router having such an architecture contains a possibility in which a mistake in setting might be induced. Moreover, this kind of complicated filtering process becomes a burden for the router, with the result that a high-speed routing process is hard to take place.
SUMMARY OF THE INVENTION
It is a primary object of the present invention, which was devised to obviate the problems inherent in the prior art, to provide a technology capable of executing, even when there are both streams of inter-domain and intra-domain communications, communications with security ensured without setting a complicated packet filter between the domains, and routing a packet at a high speed within the domain in a relay system for relaying communication data between a plurality of domains by an address translation.
To accomplish the above object, according to one aspect of the present invention, a communication data relay system for relaying between two or more domains each configured by one or more networks, a relay source domain having routing information to a relay destination domain, comprises two or more interface modules for accessing the network, a domain definition module for defining the domain configured by one or more networks, an inter-domain communication definition module for defining a communicability between the domains, a routing information storage module for storing pieces of routing information each indicating a relay destination of communication data in a way that separates the routing information for every domain, and a relay control unit for controlling relay of the communication data. In this communication data relay system, the relay control unit controls the relay of the communication data with reference to the routing information storage module corresponding to the domain concerned with respect to the relay within the same domain, and judges a connectability for the relay in accordance with definitions in the inter-domain communication definition module with respect to a relay between the domains different from each other.
The communication data relay system may further comprise a destination address search module for the relay destination domain. If the relay source domain does not have routing information to the relay destination domain, the destination address search module may search a destination address to the relay destination domain in response to a request from a source communication device within the relay source domain, and notify the source communication device of a relay address within the relay source domain that corresponds to the destination address. The relay control unit may relay the communication data addressed to the relay address to the destination address in the relay destination domain.
This destination address search module is structured to search an address from an network name of a communication device like DNS system. This destination address search module may also be structured to request other communication device to search a destination address.
The communication data relay system may further comprise a routing control information storage module for the domain to which a communication data processing device for processing the communication data is connected. The relay control unit, when controlling the relay of the communication data, may cause the communication data processing device to process the communication data, and relays the thus processed communication data. The communication data processing device is herein a device for, e.g., checking a content of the communication data.
As described above, according to the present invention, the communication data relay system for relaying between the two or more domains each configured by connecting one or more networks, includes the domain definition module for defining the domain configured by one or more networks, the inter-domain communication definition module for defining a communicability between the domains, and the routing information storage module for storing the routing information indicating the relay destination of communication data in a way that separates the routing information for every domain. The relay control unit controls the relay of the communication data with reference to the routing information storage module corresponding to the domain concerned with respect to the relay within the same domain, and judges the connectability for the relay in accordance with definitions in the inter-domain communication definition module with respect to the relay between the domains different from each other. Accordingly, it is feasible to route the packet at a high speed within the domain and to execute, even when there are both streams of inter-domain and intra-domain communications, the communications with security ensured without setting a complicated packet filter between the domains.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a network architecture in a first embodiment of the present invention;
FIG. 2 is a diagram showing a hardware architecture of a router in the first embodiment of the present invention;
FIG. 3 is a view showing an architecture of functions of the router in the first embodiment of the present invention;
FIG. 4 is a flowchart ( 1 ) showing processes of a control program;
FIG. 5 is a flowchart ( 2 ) showing processes of the control program;
FIG. 6 is a chart showing a data structure of a domain definition table;
FIG. 7 is a chart showing a data structure of an inter domain connection definition table;
FIG. 8 is a chart ( 1 ) showing a data structure of a destination domain routing table;
FIG. 9 is a chart ( 2 ) showing a data structure of the destination domain routing table;
FIG. 10 is a chart ( 3 ) showing a data structure of the destination domain routing table;
FIG. 11 is a chart showing a data structure of an address translation table;
FIG. 12 is a chart showing an example of a data structure of an actual routing table;
FIG. 13 is a view showing a network architecture in a second embodiment of the present invention;
FIG. 14 is a view showing an architecture of functions of the router in the second embodiment of the present invention;
FIG. 15 is a flowchart showing processes of an address translation pre-registering module;
FIG. 16 is a chart showing a registered result by the address translation pre-registering module in an address translation table;
FIG. 17 is a flowchart showing a forwarding process with an address of a receiving interface;
FIG. 18 is a diagram showing an architecture of functions of the router in a third embodiment of the present invention;
FIG. 19 is a view showing an outline of a prior art LSP (label Switch Path);
FIG. 20 is a view showing an outline of a unidirectional NAT in the prior art;
FIG. 21 is a view showing an outline of a bidirectional NAT in the prior art; and
FIG. 22 is a view showing an outline of an application gateway in the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will hereinafter be described with reference to the accompanying drawings.
First Embodiment
A first embodiment of the present invention will hereinafter be discussed referring to FIGS. 1 through 12 .
FIG. 1 is a view showing a network architecture in the first embodiment. FIG. 2 is a diagram showing a hardware architecture of a router 3 shown in FIG. 1 . FIG. 3 is a diagram showing functions of the router 3 . FIG. 4 and FIG. 5 are flowcharts showing processes of a control program executed by a CPU 14 shown in FIG. 2 . FIGS. 6 through 12 are diagrams each showing a data structure of data dealt with by the CPU 14 .
<Network Architecture>
FIG. 1 is the view showing the network architecture in the first embodiment. As shown in FIG. 1 , in the first embodiment, the router 3 connects Intranets A, B, C to the Internet. As illustrated in FIG. 1 , the router 3 connects the networks via logical interfaces de 0 , de 1 , de 2 and de 3 (which correspond to interface modules).
A private address of the Intranet A is 10.25.165.0/24. The Intranet A solely configures a domain 1 . The Intranet A is connected to the interface de 1 of the router 3 . This Intranet A becomes connectable to the Internet by executing an address translation in the router 3 .
A private address of the Intranet B is 192.168.0.0/16. A communication device 192.168.5.1 is connected to the Intranet B. The Intranet B is connected to the interface de2 of the router 3 . This Intranet B also becomes connectable to the Internet via the router 3 .
A private address of the Intranet C is 192.172.0.0/16. The Intranet C is connected to the interface de 3 of the router 3 . This Intranet C is also connectable to the Internet via the router 3 . Further, the Intranets B and C configure a domain 2 .
The Internet is accessed with a global address. Further, networks 4 and 5 are connected to the Internet. Moreover, the Internet is connected to the interface de 0 of the router 3 .
A global address of the network 4 is 100.10.5.0/24. Further, a communication device 100.10.5.2 is connected to the network 4 .
A global address of the network 5 is 150.10.23.0/24. Further, a communication device 150.10.23.5 is connected to the network 5 . The internet and the networks 4 , 5 configure a domain 0 .
The respective domains shown in FIG. 1 execute independent routing controls with no reachability to each other on the network layer. Moreover, in the first embodiment, connections to the domains 0 and 1 from the domain 2 are permitted by executing the address translation. While on the other hand, a connection (communication) from the domain 1 to the domain 2 is not permitted. A connection to the domain 0 from the domain 1 is permitted by translating addresses.
<Hardware Architecture of Router 3 >
FIG. 2 is a diagram showing a hardware architecture of the router 3 in the first embodiment.
This router 3 includes a memory 13 for storing a control program and data, a CPU 14 for executing the control program stored in the memory 13 , and a plurality of physical interfaces 15 a , 15 b , 15 c controlled by the CPU 14 to perform communications with other communication devices.
The memory 13 is stored with the control program executed by the CPU 14 and the data processed by the CPU 14 .
The CPU 14 executes the control program stored in the memory 13 , thereby providing a function as the router 3 .
The physical interfaces 15 a , 15 b , 15 c send or receive the communication data to or from a network 10 in response to a command given from the CPU 14 .
<Architecture of Functions>
FIG. 3 is a diagram showing an architecture of functions of the router 3 . The CPU 14 executes a relay control program 31 and a routing control program 30 , thereby providing a function of the router 3 . Further, a function of the relay control program may be actualized not based on the CPU but by hardware.
The relay control program 31 includes a packet receiving module 28 , a route search module 25 , a, inter-domain communication judging module 26 , an address translation module 27 , and a packet forwarding module 29 . The CPU 14 executing this relay control program corresponds to a relay control unit.
On the other hand, the CPU 14 executes the routing control program 30 separately from the relay control program 31 . The CPU 14 thereby exchanges routing information with respect to other communication devices and other routers.
[Destination Domain Routing Table 20 ]
An Destination domain routing table 20 is a table registered with a forwarding interface corresponding to a destination network.
FIGS. 8 , 9 and 10 show examples of the destination domain routing table 20 in which destinations are the domains 0 , 1 and 2 . In the first embodiment, the destination domain routing table 20 contains addresses of the destination networks, addresses of next hop gateways and pieces of information for identifying the forwarding interfaces corresponding to the destination networks.
Further, as shown in FIGS. 8 , 9 and 10 , the destination domain routing table 20 in the first embodiment takes an independent table structure for every destination domain.
The CPU 14 , when routing a packet, refers to the destination domain routing table 20 and determines an output interface.
[Receiving Interface Domain Routing Table 21 ]
A receiving interface domain routing table 21 is stored with routing information of the domain corresponding to the interface that receives the packet (which will hereinafter be called a receiving interface). This receiving interface domain routing table 21 and the destination domain routing table 20 described above, correspond to a routing information storage module.
[Domain Definition Table 22 ]
A domain definition table 22 is a table (corresponding to a domain definition module) containing definitions of the domains corresponding to the respective interfaces. FIG. 6 shows an example of definitions in the domain definition table 22 in the first embodiment.
As shown in FIG. 6 , the domain definition table 22 in the first embodiment is stored with information (interface numbers) for identifying the interfaces, and information (domain numbers) for identifying the domains. For instance, a domain corresponding to an interface number de0 is the domain 0 .
Note that a logical interface as a substitute for the physical interface may be registered.
[Inter-Domain Communication Definition Table 23 ]
An inter-domain communication definition table 23 is a table (corresponding to an inter-domain communication definition module) in which a connectability of each domain defined in the domain definition table 22 with other domain is defined. FIG. 7 shows an example of the definitions in the inter-domain communication definition table 23 in the first embodiment.
As shown in FIG. 7 , the inter-domain communication definition table 23 has records each consisting of a source domain→destination domain field, an inter-domain communicability field and a translation rule (address translation mode) field. According to setting in the first embodiment, for example, the communications from the domain 0 to the domains 1 and 2 are not permitted. Further, the communications from the domain 2 to the domains 0 and 1 are permitted, and NAT is applied as a translation rule.
[Address Translation Table 24 ]
An address translation table 24 is a table showing a mapping of a set of records before the translation to a set of records after the translation. FIG. 11 shows an example of the address translation table 24 in the first embodiment.
As shown in FIG. 11 , the address translation table 24 has a set of records each consisting of a source address field, a destination address field and a receiving interface field before the translation, and a set of records after the translation. The data in these fields are set when a packet transmitted to its destination from a source passes at first through the router 3 . Thereafter, the address translation table 24 is referred to in the communications of the second and subsequent packets.
[Route Search Module 25 ]
A route search module 25 searches the routing table, with a packet destination address used as a key.
[Inter-Domain Communication Judging Module 26 ]
An inter-domain communication judging module 26 judges which domain the communication device of a destination belongs to, using packet header information and a name service (a program for showing an address corresponding to a host name of the communication device).
[Address Translation Module 27 ]
An address translation module 27 receives pieces of information (source addresses and destination addresses) before and after the translation from the inter-domain communication judging module 26 . Based on these pieces of information, the address translation module 27 translates a content of a packet header.
[Packet Receiving Module 28 ]
A packet receiving module 28 monitors the physical interfaces 15 a etc. Then, the packet receiving module 28 receives a packet from the network connected to the physical interface 15 a etc.
[Packet Forwarding Module 29 ]
A packet forwarding module 29 controls the physical interfaces 15 a etc, and forwards the packet to the network connected to the physical interface 15 a etc.
[Routing control program 30 ]
A routing control program 30 executes a routing protocol. Namely, the routing control program 30 receives routing information 102 exchanged within the domain, and updates a routing table of the router itself in accordance with the routing information 102 received. Further, the routing control program 30 sets, in the routing information 102 , network reachability to other network within the same domain from the router itself, a connection cost etc, and distributes the routing information 102 to other routers. The routing control program 30 in the first embodiment is prepared individually for every domain. Each of the routing control program 30 exchanges the routing information with a corresponding domain. The routing information per domain, which has been obtained as a result of the exchange, is stored per destination domain in the destination domain routing table 20 .
Note that RIP (Routing Information Protocol; see RFC1058 (Request For Comments), a standard document about Internet) and OSPF (Open Shortest Path First; see RFC1131) are known as the routing protocols.
<Outline of Functions>
An outline of the functions of the router 3 will hereinafter be explained referring to FIG. 3 .
(1) The router 3 receives the packet 100 destined to destination host by the packet receiving module 28 .
(2) To start with, the route search module 25 searches the routing table (the receiving interface domain routing table 21 ) for the domain which the receiving interface belongs to. If the search hits a route in the receiving interface domain routing table 21 , the route search module 25 processes the packet as intra-domain routing. Namely, the route search module 25 indicates the packet forwarding module 29 to forward the packet to an output interface.
The search does not hit any route in the receiving interface domain routing table 21 , procedures indicated by the following items (3) through (8) are executed.
(3) The inter-domain communication judging module 26 searches the address translation table by forward lookups or reverse lookups, wherein the header information of the received packet and the receiving interface are used as keys. If the search hits by either the forward lookups or the reverse lookups, the inter-domain communication judging module 26 transfers the packet to the address translation module.
If the search does not hit, the inter-domain communication judging module 26 checks based on the packet header information, the destination domain routing table 20 and the domain definition table 22 which domain a destination address of the received packet belongs to. Next, the inter-domain communication judging module 26 checks which domain registered in the domain definition table 22 the receiving interface belongs to. Subsequently, the inter-domain communication judging module 26 refers to the inter-domain communication definition table 23 , and judges a communicability between the domain to which the receiving interface belongs and the destination domain. Note that the inter-domain communication definition table 23 also shows an address translation rule.
(4) The inter-domain communication judging module 26 , if communicable between the domain to which the receiving interface belongs and the destination domain, notifies the route search module 25 that the destination domain routing table 20 should be referred to.
(5) The route search module 25 is called from the inter-domain communication judging module 26 and searches the destination domain routing table 20 . This search is done, wherein the destination address in the packet header information is used as a key.
(6) The address translation module 27 translates the packet header information according to the translation rule defined with respect to the packet in the inter-domain communication definition table 23 .
(7) The packet forwarding module 29 forwards the packet to the searched output interface.
(8) The routing control program 30 is started for every domain and modifies the destination domain routing table 20 for the respective domains and the receiving interface domain routing table 21 .
<Normal Procedure>
The followings are conditions of the inter network connections in the first embodiment.
[Connecting Condition 1 ] The intranet A (10.25.165.0) is, when the router 3 executes the address translation, communicable with the Internet.
[Connecting Condition 2 ] The intranet B (192.168.0.0) is connected via the router 3 to the Intranet C (192.172.0.0) conceived as a branch office.
[Connecting Condition 3 ] Both of the Intranets B and C are connectable via the router 3 to the Internet.
FIGS. 4 and 5 show processes of the relay control program 31 for establishing the connections described above. This relay control program 31 is executed by the CPU 14 .
To begin with, the processes for the communication in the forward direction (in which a source communication device forwards the packet to a destination communication device), will be explained.
(1) Packet Receipt by Router 3
Now, supposing that the router 3 receives the packet via the interface de 2 from the network 192.168.100.0 belonging to the domain 2 , the discussion on the processes will be made based on this assumption. A destination address of this packet is 100.10.5.2, and a source address is 192.168.5.1.
(2) Judgement of Addressed-to-Relay-Device Packet
The CPU 14 of the router 3 at first judges whether or not this packet is a packet addressed to the router 3 itself (which is hereinafter expressed as “addressed-to-relay-device (or more simply “router-addressed”). This term “router addressed” may also be expressed as “node-addressed”) (step S 1 that will hereinafter be abbreviated to S 1 ). The router-addressed packet is processed as a communication packet to the router 3 itself (S 3 ).
In the first embodiment, the router-addressed packet may be defined as an administrative packet for the router 3 . An issuance of this administrative packet is triggered for a network administrator by issuing a remote log-in to the router 3 . An explanation of the administration itself of the router 3 is herein omitted.
Now, the packet is not categorized as the administrative packet, and therefore a judgement in S 2 is negative (No). Accordingly, the CPU 14 advances the processing to a intra-domain communication judgement (S 4 ).
(3) Intra-Domain Communication Judgement
Next, the CPU 14 judges whether or not this packet is addressed to a destination within the same domain (S 4 ). This judgement involves searching the receiving interface domain routing table 21 . If the search hits (Yes judgement in S 5 ) this implies that the source domain corresponding to the receiving interface is identical with the destination domain. Namely, the packet may be routed to within the same domain (S 6 ).
Whereas it the search does not hit (No judgement in S 5 ) the processing is transferred to the inter-domain communication judging module 26 (S 7 ). In this example, the CPU 14 proceeds with the control to a process in S 7 because of not being the communication within the same domain.
(4) Processes by Inter-Domain Communication Judging Module 26 , Address Translation Module 27 and Packet Forwarding Module 29
The inter-domain communication judging module 26 searches the address translation table 24 in FIG. 11 , wherein the source address and the destination address of the received packet are use as keys. If the search hits in the address translation table 24 (Yes judgment in S 8 ), the packet is sent together with a searched result to the address translation module 27 (S 9 ). This indicates that the packet is the one of which the address should be translated in the communication in the forward direction. The address translation module 27 rewrites the packet header based on the searched result given to the address translation module 27 itself. Further, the CPU 14 obtains a forwarding interface from the address translation table 24 ( FIG. 11 ).
Next, the CPU 14 transfers the control to the packet forwarding module 29 , and the packet forwarding module 29 forwards the packet to the network via the above forwarding interface (S 11 ).
If the above search does not hit (No judgement in S 8 ), the CPU 14 transfers the control to a process shown in FIG. 5 . To be specific, the CPU 14 searches the address translation table, wherein the destination address of the packet is used as a key for source address after being translated in the address translation table 24 , and the source address of the packet is used as a key for destination address after being translated in the address translation table 24 (S 12 ).
Herein, if the search hits (Yes judgement in S 13 ), the CPU 14 judges that the packet concerned is a packet in a response communication (in the reversed direction) with respect to the communication in the forward direction. Then, the CPU 14 transfers the packet together with a searched result to the address translation module 27 . Further, indicates an address reverse translation (S 14 ). As a result, the CPU 14 rewrites the packet destination into a source address before being translated in the address translation table. Further, the CPU 14 obtains a reply destination interface (the receiving interface in FIG. 11 ) from the address translation table 24 .
Next, the CPU 14 transfers the control to the packet forwarding module 29 , and the packet forwarding module 29 forwards the packet via the forwarding interface to the network (S 16 ).
If the search hits neither of them (No judgement in S 13 ), the CPU 14 judges whether the communications over the domain are performed or not (processes in S 17 and S 18 ). These are processes needed when the inter-domain communications start afresh.
More specifically, the CPU 14 searches the whole of the destination domain routing table 20 with the destination address being used as a key, and thus obtains the forwarding interface.
Now, the destination address is 100.10.5.2, and hence the CPU 14 obtains the forwarding interface de 0 . Next, the CPU 14 , with this forwarding interface using as a key, searches the domain definition table 22 , thereby obtaining the destination domain. Now, the interface is the forwarding interface de 0 , and therefore the CPU 14 obtains the domain 0 as the destination domain. Further, the CPU 14 searches the domain definition table 22 with the receiving interface using as a key. The CPU 14 , based on the interface number of the interface via which the packet is received and the domain definition table 22 ( FIG. 6 ), obtains the domain 2 as the source domain (S 17 ).
Subsequently, the CPU 14 searches the inter-domain communication definition table 23 shown in FIG. 7 , wherein the source domain and the destination domain serve as keys (S 18 ).
Now, this search hits (Yes in S 19 ), it can be understood that a connection between these two domains is permitted. It can be also understood that a NAT-based address translation is specified.
Only the source address is translated according to NAT actualized in the first embodiment. This address translation involves the use of IP addresses pooled for every destination domain.
At this time, the CPU 14 registers a mapping of the address before being translated to the address after being translated in the address translation table 24 in FIG. 11 (S 20 ).
Further, the CPU 14 registers the receiving interface and the forwarding interface in the address translation table 24 (S 21 ).
Next, the CPU 14 transfers the control to the packet forwarding module 29 , and the packet forwarding module 29 forwards the packet to the network via the forwarding interface (S 22 ).
If it is judged in S 18 that the connection between the two domains is prohibited (No judgement in S 19 ), the CPU 14 discards the packet (S 23 ).
<Effects>
According to what has been described so far, the destination domain routing table 24 can be referred to with respect to only the packet permitted by the inter-domain communication judging module 26 both in the forward direction and in the reverse direction, and it is therefore feasible to avoid a malicious packet from being mistakenly routed.
Moreover, the router 3 in the first embodiment separates the routing tables for every destination domain, and preferentially refers to the receiving interface domain routing table 21 at a stage of receiving the packet. Therefore, the search for the routing table with respect to the packet (to the destination within the same domain) addressed to the domain corresponding to the receiving interface, is limited to the routing table (the receiving interface domain routing table 21 ) corresponding to this domain. As a result, the routing of the packet addressed to within the same domain can be performed efficiently.
On the other hand, the inter-domain communication judging module 26 executes a process for eliminating the malicious packet intruding the Intranet from the Internet, and this process may be done against the packets other than those addressed to within the same domain.
Modified Example
In the first embodiment, the destination domain routing table 20 and the receiving interface routing table 21 are structured as those different from each other. The embodiment of the present invention is not, however, limited to this structure. For instance, the receiving interface routing table 21 may be structured as a part of the destination domain routing table 20 . As in the first embodiment, however, the destination domain routing table 20 is to take the table structure logically independent for every destination domain.
In this case, when the packet receiving module receives the packet, the domain definition table is searched, in which the interface receiving the packet serves as a key. Then, the receiving domain is thus determined, and a suitable domain routing table is selected.
In the first embodiment, the routing control program 30 is prepared individually for every destination domain. The embodiment of the present invention is not, however, limited to this architecture. For example, there may be provided one single routing control program 30 (which may be defined as one process on the CPU 14 that executes a routing protocol). In this case, this program may sequentially repeat the process of exchanging the routing information for every destination domain.
In the first embodiment, the router 3 sets the mapping of the interfaces de 0 , de 1 , de 2 to the domains. The embodiment of the present invention is not, however, limited to this mapping. For instance, there may be set a mapping of the physical interfaces 15 a , 15 b or 15 c directly to the respective domains without using the logical interfaces de 0 etc. In this case, the physical interfaces 15 a etc correspond to an interface module.
In the embodiment discussed above, the destination domain routing tables 20 are structured in separation for every destination domain as shown in FIGS. 8 through 10 . The embodiment of the present invention is not, however, limited to the above structure. For example, as shown in FIG. 12 , even when the destination domain routing table 20 is structured as one single table, the requirement may be such that the records constituting the table are separated for every destination domain.
The router 3 in the first embodiment, based on the destination address of the first packet communicated between the domains, searches the whole of all the destination domain routing tables, thereby obtaining the output interface. Then, the destination domain is determined from this output interface, and the inter-domain connectability between the source domain and the destination domain is judged (the processes in S 17 and S 18 in FIG. 5 ). The embodiment of the present invention is not, however confined to such processing steps. Namely, taking into consideration a case where there is an overlap of address between the destination domain routing tables, the process in S 18 may be executed in advance. To start with, the inter-domain communication definition table 23 is searched, thereby determining the receiving domain with the communications permitted. Then, it is also feasible to obtain the output interface by searching only the routing table of the domain with such communications permitted (which corresponds a mode in which the process in S 18 in FIG. 5 is executed in advance, and the process in S 17 is executed afterwards).
Second Embodiment
A second embodiment of the present invention will hereinafter be described with reference to FIGS. 13 through 17 . FIG. 13 is a view showing a network architecture in the second embodiment. FIG. 14 is a diagram showing an architecture of functions of the router 3 in the second embodiment. FIG. 15 is a flowchart showing processes by an address translation pre-registering module 25 executed by the CPU 14 of the router 3 . FIG. 16 is a diagram showing a result of processing by the address translation pre-registering module 25 . FIG. 17 is a flowchart showing processes of the relay control program 31 executed by the CPU 14 of the router 3 .
The first embodiment discussed above has exemplified the router 3 provided with the destination domain routing table 20 and the receiving interface domain routing table 21 . In this case, the route to the domain 0 is already known by the domain 2 in the first embodiment discussed above.
The second embodiment will deal with a routing process in a case where the two domains connected to the router 3 are uninformed of their routes to each other. It is, however, assumed that the source domain has a means for knowing an address within the other domain from a host name of the other domain. Other configurations and operations are the same as those in the first embodiment and marked with the same numerals, and their repetitive explanations are omitted. Further, as the necessity may arise, the drawings in FIGS. 1 through 12 are referred to.
<Architecture>
FIG. 13 is a view showing a network architecture in the second embodiment. The second embodiment will deal with the router 3 for connecting the domain 0 to the domain 2 that are uninformed of their routes to each other.
As shown in FIG. 13 , the domain 0 contains a network 4 with a name of sub 1 . 0 . Further, a host having a host name of n 0 .sub 1 . 0 is connected to the network 4 . An address of this host n 0 .sub 1 . 0 is 100.10.5.2.
Further, a host specified by its address 192.168.5.1 is connected to the domain 2 . The domain 0 and the domain 2 are uninformed of their routes to each other. In the second embodiment, however, it is assumed that the host 192.168.5.1 of the domain 2 knows the host name n 0 .sub 1 . 0 of the destination host.
In such a case, according to the second embodiment, the source host 192.168.5.1 is capable of inquiring the router 3 about an address corresponding to a name of the destination.
FIG. 14 shows an architecture of the functions of the router 3 in the second embodiment. The architecture in FIG. 14 is a different from the architecture in the first embodiment illustrated in FIG. 3 in terms of such a point that the address translation pre-registering module 25 (corresponding to an destination address search module) is added.
The address translation pre-registering module 25 has a function of registering the address translation table 24 in advance with pieces of information before and after being translated.
<Processes in Address Translation Pre-registering Module 25 >
Given hereinafter is an explanation of processes executed when the source host 192.168.5.1 inquires the router 3 about a destination address corresponding to a host name of the destination.
FIG. 15 shows the processes of the address translation pre-registering module 25 , which are executed by the CPU 14 of the router 3 . To begin with, the CPU 14 inquires an unillustrated server which implement a name service (RFC921) about an address within the domain 0 that corresponds to the host name n 0 .sub 1 . 0 of that destination (S 41 ). As a result, the CPU 14 obtains an address 100.10.5.2 of the destination host.
Next, the CPU 14 searches the destination domain routing tables 20 which is separated according to the destination domains, on the basis of the domain number 0 of the destination host, thereby obtaining the output interface de 0 (S 42 ).
Subsequently, the CPU 14 obtains the domain 2 to which the receiving interface de 2 belongs as in the first embodiment (S 43 ).
Next, the CPU 14 judges based on the inter-domain communication definition table 23 about a connectability between the two domains (the connectability from the domain 2 to the domain 0 ) (S 44 ). If the communication between the two domains is not permitted (No judgement in S 44 ), the router 3 notifies the source host 192.168.5.1 of a fail of name resolution (S 45 ).
Whereas if the communication from the domain 2 to the domain 0 is permitted (Yes judgement in S 44 ), the CPU 14 obtains an Alias address 192.168.5.2 in the domain 2 that is pooled beforehand (S 46 ) (This Alias address is hereinafter called a receiving interface address). Further, the CPU 14 obtains an Alias address 120.10.4.2 (This Alias address is hereinafter called a forwarding interface address) in the domain 0 that is pooled beforehand.
Then, the CPU 14 registers, in the address translation table 24 , the source address 192.168.5.1, the receiving interface address 192.168.5.2, the receiving interface de 2 , the forwarding interface address 120.10.4.2, the destination address 100.10.5.2 and the forwarding interface de 0 (S 47 ). FIG. 16 shows a result of this registration.
Next, the router 3 notifies in advance the source host 192.168.5.1 of this receiving interface address 192.168.5.2 as a result of name resolution (S 48 ). With this notification, the source host 192.168.5.1 gets informed that the packet can be forwarded to a desired destination host n 0 .sub 1 . 0 if the packet is sent to the receiving interface address 192.168.5.2.
The processes described above are executed between the source host 192.168.5.1 and the router 3 in advance of the performing the communications. After this sort of setting has been done, the router 3 having received the packet addressed to the receiving interface address 192.168.5.2 translates its address into an address 100.10.5.2 in accordance with the address translation table 24 , and forwards the packet from the output interface de 0 . As a result, the packet is routed to the domain 0 from the domain 2 .
<Connecting Procedure Based on Receiving Interface Address>
FIG. 17 is a flowchart showing forwarding procedures based on the receiving interface address. The CPU 14 of the router 3 executes these forwarding procedures as the relay control program 31 .
(1) Receipt of Packet
Now, a process executed when the router 3 receives the packet from a network 192.168.0.0 belonging to the domain 2 via the interface de 2 , will be explained. A destination address of this packet is 192.168.5.2 (the receiving interface address) and a source address is 192.168.5.1.
(2) Judgement of Router-Addressed Packet
At first, the CPU 14 of the router 3 judges whether this packet is a router-addressed packet or not (S 1 ).
In the second embodiment, the router-addressed packet may be defined an environment setting packet addressed to the router 3 itself, or a packet addressed to the receiving interface address notified.
Now, the packet is the packet addressed to the receiving interface address, and hence a judgement in S 2 is affirmative (Yes). Accordingly, the CPU 14 proceeds with the control to the processes from S 31 onward.
(3) Processing of Router-Addressed Packet
Next, the CPU 14 searches the address translation table 24 , wherein the source address 192.168.5.1 and the destination address 192.168.5.2 are used as keys (S 31 ).
This couple of addresses given above are already registered in the address translation table 24 (see FIG. 16 ), and therefore this search hits (Yes judgement in S 32 ). Then, the CPU 14 proceeds with the control to processes from S 33 onward.
To be specific, the CPU 14 executes the address translation module 27 (S 33 ). As a result, it obtaines the forwarding interface de0 and the destination address 100.10.5.2 within the domain 0 that corresponds to the receiving interface address 192.168.5.2.
Next, the CPU 14 executes the packet forwarding module 29 , thereby forwarding the packet to the destination address 100.105.2 from the forwarding interface de 0 .
(4) Packet Reply Procedures
Processes of a reply packet from the destination host 100.105.2 are the same as the processes from S 12 to S 16 in the flowchart in FIG. 5 explained in the first embodiment, and hence their repetitive explanations are omitted.
The router 3 is provided with the address translation pre-registering module 25 , whereby the packet can be routed to between the two domains that do not exchange the routing information with each other.
Further, in the router 3 in the second embodiment, the destination domain routing tables 20 are structured in separation for every destination domain. Accordingly, even if a private address is overlapped in the plurality of domains, the address translation pre-registering module 25 is capable of obtaining a proper output interface from the destination domain routing table 20 .
<Modified Example>
The second embodiment has dealt with the router 3 for connecting the two domains that do not exchange the routing information with each other. The embodiment of the present invention is not limited to the characteristics of the inter-domain connection described above. Namely, the present invention can be similarly embodied even in such a case that only one of the two domains to which the packet is routed have the routing information to the other domain.
Third Embodiment
The discussion on the first embodiment has focused on the router 3 provided with the destination domain routing table 20 and the receiving interface domain routing table 21 .
A third embodiment will exemplify the router 3 for causing a server (corresponding to a communication data processing device) on other domain to execute one of the functions provided by the address translation module 27 in the architecture in the first embodiment. For example, one of those functions is content check.
The third embodiment of the present invention will be explained referring to FIG. 18 . FIG. 18 is a diagram showing an architecture of the functions of the router 3 in the third embodiment. FIG. 18 is different from FIG. 3 in terms of such a point that a server domain routing table 33 of the router 3 and a content check server 32 are added. Other configurations and operations are the same as those in the first and second embodiments, and the same components are marked with the same numerals, of which the repetitive explanations are omitted. Further, as the necessity may arise, the drawings in FIGS. 1 through 17 are referred to.
As shown in FIG. 18 , the CPU 14 of the router 3 in the third embodiment includes the server domain routing table 33 stored with the routing information to the server. The CPU 14 searches this server domain routing table 33 . The CPU 14 , based on a result of this search, translates an address of the packet to be forwarded into an address to the content check server 32 . Next, the CPU 14 receives the packet with the content check finished. Subsequently, the CPU 14 executes a reverse translation of the address of that packet into an address to the original destination domain.
Thus, the content check server 32 is made to execute the content check, thereby reducing a load on the router 3 and enabling a high-speed routing process. | A technology in a relay system for relaying communication data between a plurality of domains by an address translation, is capable of executing, even when there are both streams of inter-domain and intra-domain communications, the communications with security ensured without setting a complicated packet filter between the domains, and routing a packet at a high speed within the domain. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] Aspects of the invention can relate to gray scale correction processing of image data. More specifically, the invention can relate to gray scale correction processing, such as color correction or gamma (γ) correction based on lookup tables (LUTs).
[0003] 2. Description of Related Art
[0004] Related art gamma correction processing is processing for adjusting display characteristics of image data in accordance with characteristics of a display device, such as a CRT or an LCD in an image display apparatus for displaying image data. Generally, gamma correction processing can be carried out using, for example, an LUT storing gamma characteristics data (gray scale correction characteristics data) created on the basis of the display characteristics of a display device. Gamma characteristics define relationship between input gray scale values and output gray scale values. The image display apparatus obtains output gray scale values corresponding to input gray scale values of input image data by referring to the gamma characteristics, and displays an image corresponding to the image data on a display device according to the output gray scale values.
[0005] Also, when the image display apparatus performs color correction on input image data to achieve desired color characteristics for display, an LUT storing color conversion characteristics prepared in advance is used. An example of such related art color correction and gamma correction is disclosed in Japanese Unexamined Patent Application Publication No. 9-271036.
[0006] With the recent improvement in picture quality in cellular phones and other electronic apparatuses, the capacity of a storage device, such as a RAM needed to implement an LUT for gray scale correction characteristics data increases as the number of gray scale levels of image data increases. In view of this, a method has been proposed in which gray scale correction characteristics data for a number of gray scale levels smaller than the number of gray scale levels of input image data is stored in an LUT and gray scale correction characteristics data for the insufficiency is interpolated by linear approximation or the like. (Refer to, for example, PCT Japanese Translation Patent Publication No. 2002-534007).
[0007] In order to interpolate gray scale correction characteristics data by linear approximation or the like, output gray scale values of two endpoints of a portion to be interpolated are needed, so that reading operation must be executed twice with an LUT storing a single set of gray scale correction characteristics data. Thus, power consumption increases due to the increased number of times of reading operation, and a clock rate higher than a normal clock rate is required.
SUMMARY OF THE INVENTION
[0008] An aspect of the invention can provide an image processing circuit for gray scale correction, an image display apparatus, and an image processing method that allow reduction in the storage capacity needed for storing correction characteristics data without increasing clock rate in relation to interpolation processing of correction characteristics.
[0009] According to an aspect of the invention, an exemplary image processing circuit can include an input unit that receives input of image data represented in n gray scale levels, first and second lookup-table storage units that store gray scale correction characteristics data for m gray scale levels, m being less than n, an interpolation circuit that linearly interpolates the gray scale correction characteristics data using outputs from the first and second lookup-table storage units, the outputs being associated with mutually adjacent input gray scale values, and a gray scale correcting circuit that corrects gray scales of the image data using gray scale correction characteristics data obtained by the linear interpolation.
[0010] The image processing circuit according can be applied, for example, to color correction or gamma correction of color image data. Gray scale correction characteristics data for a number of gray scale levels that is than the number of gray scale levels of input image data is stored in first and second lookup table storing units. Considering a gray scale value of a pixel that is being considered for gray scale correction processing as an input gray scale value, the first and second lookup-table storing units are referred to, obtaining an output gray scale value corresponding to the input gray scale value and an output gray scale value corresponding to an adjacent input gray scale value. An adjacent gray scale value refers to a gray scale value that is higher by one or lower by one than another input gray scale value. Then, output gray scale values between these two adjacent output gray scale values are calculated by linear interpolation, obtaining output values for all input gray scale values. Then, gray scale correction is performed for each pixel of input image data, outputting corrected image data.
[0011] Since a lookup table that stores gray scale correction characteristics data for a smaller number of gray scale levels than the gray scale levels of input image data is used, compared with a case where gray scale correction characteristics data for all the gray scale levels is stored, the capacity of a storage device, such as a RAM, needed to implement the lookup table is reduced. Although mutually adjacent two output gray scale values are needed for linear interpolation of gray scale correction characteristics data, since linear interpolation is carried out using output gray scale values read from two lookup tables, it is not required to read twice from a single lookup table by a high-speed (e.g., twice as fast) clock. Thus, clock rate is not increased, and increase in power consumption is avoided.
[0012] According to a mode of the image processing circuit, the first and second lookup-table storage units store the same gray scale correction characteristics data. Accordingly, it is possible to obtain mutually adjacent two output gray scale values from the respective lookup-table storage units and to interpolate output values therebetween by linear interpolation.
[0013] In a preferred embodiment of the mode, the interpolation circuit uses a first output gray scale value output from the first lookup-table storage unit and a second output gray scale value output from the second lookup-table storage unit, the second output gray scale value being less than the first output gray scale value, to interpolate gray scale correction characteristics data between the first output gray scale value and the second output gray scale value.
[0014] According to another exemplary mode of the image processing circuit, the first lookup-table storage unit stores gray scale correction characteristics data for the m gray scale levels, and the second lookup-table storage unit stores difference values between adjacent gray scale values in the gray scale correction characteristics data for the m levels. Accordingly, using an output gray scale value corresponding to an input gray scale value and a difference value between the input gray scale value and an adjacent input gray scale value, output gray scale values between output gray scale values can be obtained by linear interpolation.
[0015] In a preferred embodiment of the mode, the interpolation circuit can use a first output gray scale value output from the first lookup-table storage unit and a difference value output from the second lookup-table storage unit to interpolate gray scale correction characteristics data between the first output gray scale value and a second output gray scale value that is adjacent to the first output gray scale value.
[0016] According to another exemplary mode of the image processing circuit, the first lookup-table storage unit can store gray scale correction characteristics data associated with odd-numbered input gray scale values among the gray scale correction characteristics data for the m levels, and the second lookup-table storage unit stores gray scale correction characteristics data associated with even-numbered input gray scale values among the gray scale correction characteristics data for the m levels. Accordingly, it can be possible to obtain two mutually adjacent output gray scale values simultaneously from the respective lookup-table storage units and to obtain output gray scale values therebetween by linear interpolation. Furthermore, since mutually adjacent two input gray scale values are a pair of an odd-numbered input gray scale value and an even-numbered input gray scale value, by providing lookup-table storage units respectively for odd-numbered input gray scale values and even-numbered input gray scale values, the storage capacities of the respective lookup-table storage units can be reduced to one half.
[0017] In a preferred embodiment of the mode, the interpolation circuit can include a device for determining, based on the image data, magnitude relationship of a first output gray scale value output from the first lookup-table storage unit and a second output gray scale value output from the second lookup-table storage unit; and a device for interpolating gray scale correction characteristics data between the first output gray scale value and the second output gray scale value based on the magnitude relationship. Since the magnitude relationship of two output gray scale values is determined based on whether an input gray scale value is an even number or an odd number, linear interpolation can be readily performed.
[0018] According to another mode of the image processing circuit, when an input gray scale value associated with a larger one of the first and second output gray scale values is 0, the interpolation circuit carries out interpolation while setting a smaller one of the first and second output gray scale values to 0 . According to another mode of the image processing circuit, when an input gray scale value associated with a smaller one of the first and second output gray scale value is a maximum gray scale value, the interpolation circuit carries out interpolation while setting a larger one of the first and second output gray scale values to a maximum gray scale value. In either mode, all the lacking output gray scale values can be provided by linear interpolation.
[0019] According to another exemplary mode of the image processing circuit, a color reduction processing circuit can be further provided, which performs dither processing on the image data obtained by the gray scale correction to reduce colors, outputting image data represented in the m gray scale levels. Accordingly, the amount of image data can be reduced without causing degradation in picture quality, in accordance with the display capability of a display device used to display the image data.
[0020] It is possible to implement an image display apparatus including the image processing circuit described above and an image display unit for displaying the image data obtained by the gray scale correction. For example, an image display apparatus such as a portable phone, a PDA, or a digital camera can be implemented using an LCD as an image display unit.
[0021] According to another exemplary aspect of the invention, an image processing method can be carried out in an image processing circuit including first and second lookup-table storage units that store gray scale correction characteristics data for m gray scale levels in relation to input image data represented in n gray scale levels, m being less than n. The image processing method can include a step of receiving input of the input image data, a step of linearly interpolating the gray scale correction characteristics data using outputs from the first and second lookup-table storage units, the outputs being associated with mutually adjacent input gray scale values, and a step of correcting gray scales of the image data using the gray scale correction characteristics data obtained by the linear interpolation.
[0022] The image processing circuit according can be applied, for example, to color correction or gamma correction of color image data. Gray scale correction characteristics data for a number of gray scale levels that is than the number of gray scale levels of input image data is stored in first and second lookup table storing units. Considering a gray scale value of a pixel that is being considered for gray scale correction processing as an input gray scale value, the first and second lookup-table storing units are referred to, obtaining an output gray scale value corresponding to the input gray scale value and an output gray scale value corresponding to an adjacent input gray scale value. Then, output gray scale values between these two adjacent output gray scale values can be calculated by linear interpolation, obtaining output values for all input gray scale values. Then, gray scale correction is performed for each pixel of input image data, outputting corrected image data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention will be described with reference to the accompanying drawings, wherein like numerals reference like elements, and wherein:
[0024] FIG. 1 is an exemplary block diagram of an image display apparatus including an image processing circuit according to the invention;
[0025] FIG. 2 is an exemplary block diagram showing the internal construction of an image processing circuit 101 shown in FIG. 1 ;
[0026] FIG. 3 is an exemplary block diagram showing the construction of a color conversion calculator;
[0027] FIG. 4 is an exemplary block diagram of a gray scale corrector according to a first exemplary embodiment;
[0028] FIG. 5 is an exemplary diagram for explaining a method of linear interpolation calculation;
[0029] FIG. 6 is an exemplary diagram showing an example of dither matrix and an example of processing in a color reduction processor;
[0030] FIG. 7 is an exemplary block diagram showing the construction of the color reduction processor;
[0031] FIG. 8 is an exemplary block diagram showing a gray scale corrector according to a second exemplary embodiment;
[0032] FIG. 9 is an exemplary block diagram showing a gray scale corrector according to a third exemplary embodiment; and
[0033] FIG. 10 is an exemplary diagram for explaining a method of linear interpolation calculation according to a modification.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] Now, preferred embodiments of the invention will be described with reference to the drawings.
[0035] FIG. 1 is a schematic block diagram showing an exemplary construction of an image display apparatus including an image processing circuit according to the present invention. As shown in FIG. 1 , an image display apparatus 100 can include an image processing circuit 101 and an image display unit 102 . The image display apparatus 100 is, for example, a cellular phone, a portable terminal, a PDA, or a digital camera.
[0036] The image processing circuit 101 performs processing for correcting gray scale characteristics, including color correction and gamma correction, on externally supplied image data D 1 , supplying corrected image data D 10 to the image display unit 102 . The image processing circuit 101 also receives input of a clock signal CLK that is synchronized with the image data D 1 . The image display unit 102 can include a display device, such as a CRT or an LCD (liquid crystal display), and it displays the corrected image data D 10 .
[0037] FIG. 2 is an exemplary block diagram showing the internal construction of the image processing circuit 101 shown in FIG. 1 . As shown in FIG. 2 , the image processing circuit 101 includes a color conversion calculator 10 , a gray scale corrector 20 , and a color reduction processor 30 . The color conversion calculator 10 performs color conversion processing on the externally supplied image data D 10 to achieve desired color characteristics, supplying image data D 2 obtained by the color conversion to the gray scale corrector 20 . The input image data D 10 is digital data having eight bits for each color of RGB. The color conversion calculator 10 performs color conversion processing by a 3×3 matrix calculation. The image data D 2 obtained by the color conversion also has eight bits for each color of RGB. The color conversion calculator 10 also receives input of a register control signal Sc in addition to the image data D 1 .
[0038] The gray scale corrector 20 is implemented using an image processing circuit according to the present invention. The gray scale corrector 20 performs gamma correction on the image data D 2 obtained by the color conversion, correcting the gray scale characteristics of the image data D 2 , and supplies corrected image data D 3 to the color reduction processor 30 . The corrected image data D 3 also has eight bits for each color of RGB. The gray scale corrector 20 receives input of the register control signal Sc.
[0039] The color reduction processor 30 performs color reduction processing on the image data D 3 obtained by the gamma correction. As described above, the image data D 3 obtained by the gamma correction has eight bits for each color of RGB. The color reduction processor 30 bit-slices, for example, the high-order six bits of the image data D 3 to obtain data having six bits for each color of RGB, and performs dither processing based on the low-order two bits, supplying image data D 10 having six bits for each color of RGB (equivalent to eight bits for each color due to the dither processing) to the image display unit 102 .
[0040] Depending on the display capability of the image display unit 102 , the color reduction processor 30 may supply image data having eight bits for each color to the image display unit 102 without performing color reduction processing. For example, when the image display unit 102 is capable of displaying an image at a resolution of eight bits for each color, the color reduction processor 30 supplies the image data D 10 having eight bits for each color to the image display unit 102 without performing color reduction processing. On the other hand, when the image display unit 102 is capable of displaying an image only at a resolution of six bits for each color, the color reduction processor 30 performs color reduction processing to create image data having six bits for each color, and supplies the image data to the image display unit 102 . The color reduction processor 30 receives input of the register control signal Sc, and a horizontal synchronization signal Hsync and a vertical synchronization signal Vsync that are synchronized with the image data D 1 , in addition to the image data D 3 obtained by the gamma correction.
[0041] Next, the color conversion calculator 10 will be described in detail. FIG. 3 ( a ) shows an exemplary construction of the color conversion calculator 10 . The color conversion calculator 10 can include three multipliers 11 to 13 , an adder 14 , and a register value controller 15 , and it executes a 3×3 matrix calculation shown in FIG. 3 ( b ). The multipliers 11 to 13 use multiplication coefficients a 1 to a 3 , b 1 to b 3 , and c 1 to c 3 , respectively, determined by the register value controller 15 based on the register control signal Sc and set to the respective multipliers 11 to 13 .
[0042] More specifically, the multiplier 11 multiplies R (red) data Rin of the image data D 1 with the coefficients a 1 to a 3 , outputting the results to the adder 14 . The multiplier 12 multiplies G (green) data Gin of the image data D 1 with the coefficients b 1 to b 3 , outputting the results to the adder 14 . The multiplier 13 multiplies B (blue) data Bin of the image data D 1 with the coefficients c 1 to c 3 , outputting the results to the adder 14 . The adder 14 adds together the outputs of the multipliers 11 to 13 to generate Rout, Gout, and Bout, outputting these components as image data D 2 .
[0043] The color characteristics of the output image data D 2 (i.e., Rout, Gout, and Bout) vary depending on the coefficients a 1 to a 3 , b 1 to b 3 , and c 1 to c 3 set by the register value controller 15 . When the coefficients a 1 , b 2 , and c 3 are set to “1” and the other coefficients are set to “0”, the input image data D 1 and the output image data D 2 have the same color characteristics. For example, when color characteristics with some emphasis on red are desired for the output image data D 2 , the coefficients a 1 to a 3 for multiplying Rin therewith should be chosen to be somewhat larger.
First Exemplary Embodiment of Gray Scale Corrector
[0044] Next, a first exemplary embodiment of gray scale corrector will be described. FIG. 4 schematically shows the construction of a gray scale corrector 20 according to the first embodiment. As shown in FIG. 4 ( a ), the gray scale corrector 20 includes LUTs 21 and 22 , a linear interpolation calculation circuit 23 , and a register value controller 24 . Each of the LUTs 21 and 22 stores gamma characteristics for 64 gray scale levels (corresponding to six bits) of input gray scale values and 256 gray scale levels of output gray scale values. Since the image data D 2 output from the color conversion calculator 10 has eight bits (equivalent to 256 gray scale levels) for each color of RGB, the gray scale correction characteristics data stored in the LUTs 21 and 22 have a smaller number of gray scale levels when compared with input image data. Thus, the capacity of RAMs or the like for implementing the LUTs 21 and 22 may be smaller. Although FIG. 4 ( a ) shows only parts associated with R data among data of the three colors of RGB, similar arrangements are provided for G data and B data.
[0045] FIG. 5 ( b ) shows an example of gray scale correction characteristics data (gamma characteristics data) stored in the LUTs 21 and 22 . Gray scale correction characteristics 60 can be represented by a graph showing relationship between input gray scale values and output gray scale values. Each of the LUTs stores addresses data corresponding to output gray scale values at addresses corresponding to input gray scale values. Thus, considering a gray scale value of a pixel of input image data as an input gray scale value, data stored at an address of the LUT corresponding to the input gray scale value is output as an output gray scale value. In this embodiment, the input gray scale values are represented in 64 gray scale levels, and the output gray scale values are represented in 256 gray scale levels.
[0046] The LUTs 21 and 22 shown in FIG. 4 ( a ) store the same gray scale correction characteristics data. The reason why two LUTs are provided is that output gray scale values of two endpoints of characteristics to be interpolated are needed in a linear interpolation calculation by the linear interpolation calculation circuit 23 .
[0047] Referring to FIG. 4 ( a ), the LUT 21 receives input of the high-order six bits Rout(7 . . . 2) of R data of a pixel in the image data D 2 . In the following description, inside the parentheses of a notation Rout( ) are subject bits. For example, a notation Rout(7 . . . 0) is used in the case of all the eight bits, and a notation Rout(1 . . . 0) is used in the case of low-order two bits. The LUT 21 , considering the R data as an input gray scale value, outputs a corresponding output gray scale value Xn to the linear interpolation calculation circuit 23 .
[0048] The LUT 22 receives input of a gray scale value Rout−1(7 . . . 0) that is lower by one than Rout(7 . . . 0) input to the LUT 21 as an input gray scale value, and outputs a corresponding output gray scale value Xn-1 to the linear interpolation calculation circuit 23 . Furthermore, the value of the low-order two bits Rout(1 . . . 0) of the same pixel is supplied to the linear interpolation calculation circuit 23 .
[0049] FIG. 4 ( b ) schematically shows a linear interpolation calculation by the linear interpolation calculation circuit 23 . As described above, while input image data has eight bits for each color of RGB, the input gray scale values of gray scale correction characteristics data stored in the LUTs 21 and 22 have only six bits (equivalent to 64 gray scale levels). Thus, output gray scale values corresponding to input gray scale values associated with the lacking two bits must be interpolated by the linear interpolation calculation circuit 23 . As shown in FIG. 4 ( b ), the linear interpolation calculation circuit 23 performs a calculation for linearly interpolating three output gray scale values between an output gray scale value Xn corresponding to an input gray scale value Rout(7 . . . 2) of a pixel and an output gray scale value Xn-1 corresponding to an input gray scale value Rout−1(7 . . . 0) lower by one than the input gray scale value Rout(7 . . . 2), based on the value of the low-order two bits Rout(1 . . . 0) of the pixel. Thus, the linear interpolation calculation circuit 23 is allowed to create gray scale correction characteristics data for 256 gray scale levels (equivalent to eight bits) using the. LUTs 21 and 22 for 64 gray scale levels (equivalent to six bits).
[0050] More specifically, the calculation by the linear interpolation calculation circuit 23 can be expressed by the following equation.
R (lut_out)= Xn− 1+( Xn−Xn− 1)×( R out (1 . . . 0)[Dec]/4)+OFF_set (equation 1)
where Xn−1=0 when Rout−1(7 . . . 2)=−1. ([Dec] indicates decimal notation.)
[0051] Now, the where clause for equation 1 will be described. When gray scale correction characteristics data for input gray scale values of 64 gray scale levels are linearly interpolated to create gray scale correction characteristics data for input gray scale values of 256 gray scale levels, if three gray scale values are interpolated in each interval of adjacent two gray scale values among the gray scale values 0 to 63, as shown in FIG. 4 ( b ), the overall number of gray scale levels can be calculated as follows:
64 (number of gray scale levels in LUTs)+63 (number of intervals between 0 to 63)×3 (gray scale values)=253. Thus, an insufficiency of three gray scale levels arises relative to 256 gray scale levels. Thus, three gray scale levels are provided below an input gray scale value (an address input to LUTs) of 0 to achieve 256 gray scale levels as a whole.
[0053] Referring to FIG. 5 ( a ), for example, when gray scale values output from the LUTs 21 and 22 are Xn=X 1 and Xn-1=X 0 , three output gray scale values designated by a reference numeral 90 are interpolated between the output gray scale values X 0 and X 1 . When the output value Xn=X 0 , instead of simply considering the output gray scale value Xn-1 to be absent, the output gray scale value Xn-1 is always set to 0 when an input gray scale value Rout−1(7 . . . 2) is −1, thereby interpolating three gray scale values as indicated by a reference numeral 91 in FIG. 5 ( a ). This corresponds to interpolating a portion 61 denoted by a broken line in FIG. 5 ( b ). Thus, gray scale correction characteristics data for input gray scale values of all the 256 gray scale levels can be created.
[0054] In the construction shown in FIG. 4 ( a ), the register value controller 24 supplies an offset OFF_set to the linear interpolation calculation circuit 23 based on the register control signal Sc, so that the example gray scale correction characteristics 60 shown in FIG. 5 ( b ) are shifted as a whole in a direction of increase in gray scale value as indicated by an arrow 70 .
[0055] As described above, the gray scale corrector 20 stores in LUTs gray scale correction characteristics data for input gray scale values having six bits (equivalent to 64 gray scale levels) for each color with regard to input image data having eight bits for each color of RGB (equivalent to 256 gray scale levels). With regard to the insufficiency, the gray scale corrector 20 generates output gray scale values by linear interpolation based on the low-order two bits of input gray scale values to perform correction of gray scale characteristics (gamma correction). Thus, it is not required to store gray scale correction characteristics data for input gray scale values of 256 gray scale levels corresponding to all the gray scale levels of input image data. This serves to reduce the needed capacity of storage devices for implementing LUTs, such as RAMs. In this embodiment, as compared with a case where gray scale correction characteristics data for input gray scale values of 256 gray scale levels is stored in a RAM, since it suffices to provide two LUTs that store gray scale correction characteristics data for input gray scale values of 64 gray scale levels, the total RAM capacity can be reduced to one half.
[0056] In this embodiment, two LUTs are provided, and output gray scale values Xn and Xn-1 of two endpoints used for linear interpolation are read from the respective LUTs. As described above, a read clock rate must be increased when output gray scale values of two endpoints are read from a single LUT. However, that is not needed in this exemplary embodiment, so that increase in power consumption is avoided.
[0057] Color Reduction Circuit
[0058] Now, the color reduction processor will be described. As shown in FIG. 2 , the color reduction processor 30 performs bit slicing and dithering on the image data D 3 output from the gray scale corrector 20 , having eight bits for each color of RGB, i.e., R(lut_out), G(lut_out), and B(lut_out), to output image data D 10 having six bits for each color of RGB. FIG. 7 shows an example construction of the color reduction processor 30 . Although FIG. 7 shows only parts associated with R data, similar arrangements are provided for G-data and B data.
[0059] Referring to FIG. 7 , the color reduction processor 30 can include 2-bit counters 31 and 32 , a dither matrix circuit 33 , an adder 34 , a switcher 35 , and a register value controller 36 . FIG. 6 ( a ) shows an example of 4×4 dither matrix used in the dither matrix circuit 33 .
[0060] The counter 31 counts the clock signal CLK synchronized with the image data D 3 to output a 2-bit X address Xad to the dither matrix circuit 33 . The counter 31 is reset by the horizontal synchronization signal Hsync. The counter 32 counts the horizontal synchronization signal Hsync to output a 2-bit Y address Yad to the dither matrix circuit 33 . The counter 32 is reset by the vertical synchronization signal Vsync.
[0061] The dither matrix circuit 33 , based on the input X address Xads and Y address Yads, supplies a value defined in the dither matrix to the adder 34 as R(D_out). As shown in FIG. 6 ( b ), the adder 34 adds together the R data R(lut_out) output from the gray scale corrector 20 and the high-order two bits of the value R(D_out) output from the dither matrix circuit 33 , outputting the high-order six bits of the result to an input terminal b of the switcher 35 as R(ADD_out). Thus, the image data D 3 having eight bits for each color of RGB, supplied from the gray scale corrector 20 , is reduced to image data having six bits for each color. Since dither processing is performed, the image data having six bits for each color has color characteristics equivalent to eight bits for each color.
[0062] The output of the switcher 35 is switched according to a register value output from the register value controller 36 based on the register control signal Sc. When an input terminal a of the switcher 35 is selected, image data having eight bits for each color of RGB, not having undergone color reduction processing, is output as image data D 10 . On the other hand, when the input terminal b of the switcher 35 is selected, image data having six bits for each color of RGB, obtained by color reduction processing, is output as image data D 10 .
Second Exemplary Embodiment of Gray Scale Corrector
[0063] Next, a second embodiment of gray scale corrector will be described. FIG. 8 ( a ) shows the construction of a gray scale corrector 20 a according to the second exemplary embodiment. In the second embodiment, the contents of gray scale correction characteristics data stored in two LUTs differ from each other. In the gray scale corrector 20 according to the first embodiment, the same gray scale correction characteristics data are stored in the two LUTs 21 and 22 . In contrast, in the second embodiment, one LUT 26 stores gray scale correction characteristics data for input gray scale values of 64 gray scale levels, and another LUT 25 stores values of differences between adjacent gray scale values among the gray scale correction characteristics data stored in the LUT 26 . Otherwise, the second embodiment is substantially the same as the first embodiment.
[0064] An input gray scale value Rout(7 . . . 2) of a pixel in input image data is input to the LUT 25 , and a difference value AX associated therewith is supplied to the linear interpolation calculation circuit 23 . Furthermore, an input gray scale value Rout−1(7 . . . 2) of the same pixel, lower by one than the input gray scale value Rout( 7 . . . 2 ), is input to the LUT 26 , and a corresponding output gray scale value Xn-1 is supplied to the linear interpolation calculation circuit 23 .
[0065] FIG. 8 ( b ) schematically shows a linear interpolation calculation by the linear interpolation calculation circuit 23 . As shown in FIG. 8 ( b ), the difference value ΔX output from the LUT 25 represents a difference between an output gray scale value corresponding to an input gray scale value of the pixel and an output gray scale value corresponding to an input gray scale value that is lower by one. Thus, the linear interpolation calculation circuit 23 uses the output gray scale value Xn-1 and the difference value ΔX to interpolate between these adjacent output gray scale values. More specifically, the linear interpolation calculation circuit 23 performs the calculation expressed by the following equation.
R (lut_)= Xn− 1 +ΔX ×( R out(1 . . . 0)[Dec]/4)+OFF_set (equation 2)
where Xn−1=0 when Rout−1(7 . . . 2)=−1. ([Dec] indicates decimal notation.) The meaning of the where clause for equation 2 is the same as that for equation 1.
[0066] It suffices for the LUT 25 to store difference values ΔX between adjacent output gray scale values. As will be understood from FIG. 8 ( b ), the difference values ΔX can be represented by a smaller number of gray scale levels compared with the original gray scale correction data, so that it suffices for the LUT 25 to store a smaller number of gray scale values (i.e., a smaller number of bits) than the LUT 26 . For example, when the LUT 25 for storing difference values is implemented by an LUT having an output of 16 gray scale levels (i.e., four bits), the capacity of a RAM for implementing the LUT 25 may be one half of the capacity of a RAM for implementing the LUT 26 . In that case, compared with the case where a single LUT having output gray scale values of eight bits (equivalent to 256 gray scale levels) is used, the total RAM capacity needed for LUTs is reduced to ⅜.
[0067] In the case of the first exemplary embodiment, when gray scale correction characteristics data is stored in the LUTs 21 and 22 , gray scale correction characteristics data prepared in advance is simply stored in the LUTs. On the other hand, in the case of the second exemplary embodiment, in addition to storing gray scale correction characteristics data prepared in advance in the LUT 26 , difference values must be calculated based on the gray scale correction characteristics data and stored in the LUT 25 .
Third Exemplary Embodiment of Gray Scale Corrector
[0068] Next, a third exemplary embodiment of gray scale corrector will be described. In the first exemplary embodiment, the same gray scale correction characteristics data for input gray scale values of 64 gray scale levels is stored in the two LUTs 21 and 22 . Two output gray scale values used in a linear interpolation calculation are an input gray scale value of a pixel of image data and an input gray scale value that is adjacent thereto (i.e., upper or lower by one). Thus, when one of these two adjacent input gray scale values is an odd number, the other is an even number. Conversely, when one of these two adjacent input gray scale values is an even number, the other is an odd number. In other words, it is impossible that two adjacent input gray scale values are simultaneously even numbers or simultaneously odd numbers. Accordingly, in the third embodiment, gray scale correction characteristics data for 64 gray scale levels are divided into gray scale correction characteristics data associated with odd-numbered input gray scale values and gray scale correction characteristics data associated with even-numbered input gray scale values, storing the respective gray scale correction characteristics data separately in two LUTs. Thus, the capacity of RAMs for implementing LUTs can be further reduced.
[0069] FIG. 9 shows the construction of the gray scale corrector according to the third exemplary embodiment. The LUT 27 stores gray scale correction characteristics data for 32 gray scale levels associated with odd-numbered input gray scale values, and the LUT 28 stores gray scale correction characteristics data for 32 gray scale levels associated with even-numbered gray scale values. Furthermore, a data switcher 29 is provided at a subsequent stage of the LUTs 27 and 28 .
[0070] Of the input image data, Rout(7 . . . 3) corresponding to an even-numbered input gray scale value is input to the LUT 28 , and a corresponding output gray scale value Xq is output to the data switcher 29 . Also, Rout(7 . . . 2) corresponding to an odd-numbered input gray scale value is input to the LUT 27 , and a corresponding output gray scale value Xp is output to the data switcher 29 . Furthermore, Rout(2) representing the third lowest bit of the input image data is input to the data switcher 29 . Rout(2) indicates whether the high-order six bits of the pixel being considered for correction of gray scale characteristics is an even number or an odd number, and it is used as a control signal for switching by the data switcher 29 . The data switcher 29 switches relationship of input/output based on Rout(2), supplying the larger one of Xp and Xq as an output gray scale value Yn and the smaller one of Xp and Xq as an output gray scale value Yn-1 to the linear interpolation calculation circuit 23 .
[0071] FIG. 9 ( b ) schematically shows a linear interpolation calculation by the linear interpolation calculation circuit 23 . The linear interpolation calculation circuit 23 interpolates between the output gray scale values Yn and Yn-1 supplied from the data switcher 29 based on the output gray scale values Yn and Yn-1 and Rout(1 . . . 0) representing the low-order two bits of the input gray scale value. More specifically, the linear interpolation calculation can be expressed by the following equation.
R (lut_out)= Yn− 1+( Yn−Yn− 1)×( R out(1 . . . 0)[Dec]/4)+OFF_set (equation 3)
where Yn−1=0 when Rout−1(7 . . . 2)=−1. ([Dec] indicates decimal notation.). The meaning of the where clause for equation 3 is the same as that in the first and second embodiments.
[0072] As described above, in the third exemplary embodiment, gray scale correction characteristics data for 64 gray scale levels are stored separately in the LUT 27 associated with odd-numbered input gray scale values and the LUT 28 associated with even-numbered input gray scale values. Thus, the capacity of RAMs needed to implement LUTs can be further reduced. Actually, the total RAM capacity is reduced to ¼ compared with the case where a single LUT having input gray scale values for 256 gray scale levels is used, and the total RAM capacity is reduced to one half when compared with the first embodiment.
[0073] Modifications.
[0074] In the first to third exemplary embodiments of the gray scale corrector, as described with reference to FIG. 5 , in the linear interpolation processing, three gray scale values are added below an input gray scale value of zero to provide 256 gray scale levels as a whole. Alternatively, as shown in FIG. 10 , three gray scale values may be added above an input gray scale value of 63 to provide 256 gray scale levels as a whole. In that case, when the smaller one of two input gray scale values in the first embodiment is 63, i.e., when Xn−1=63, the output gray scale value corresponding to the input gray scale value Xn is set to ”255”. This is also true in the second and third exemplary embodiments.
[0075] It is to be noted, however, that “0” must be stored in a register or the like when three gray scale values are added to the smaller side of gray scale values, while “255” must be stored when three gray scale values are added to the larger side of gray scale values. Thus, a smaller area of the register is occupied when three gray scale values are added to the smaller side of gray scale values. Furthermore, of the smaller and larger sides of gray scale values, when gray scale values are added to the side corresponding to black color of a displayed image, the displayed image is less affected.
[0076] In the first exemplary embodiment described above, two input gray scale values used in linear interpolation processing are a gray scale value Rout(7 . . . 2) of a pixel and a gray scale value Rout−1(7 . . . 2) that is lower by one. Alternatively, linear interpolation may be carried out using a gray scale value Rout(7 . . . 2) of a pixel and a gray scale value Rout+1(7 . . . 2) that is higher by one.
[0077] In the second exemplary embodiment, a difference value between a gray scale value Rout(7 . . . 2) of a pixel and a gray scale value Rout−1(7 . . . 2) that is lower by one is stored in an LUT. Alternatively, a difference value between a gray scale value Rout(7 . . . 2) of a pixel and a gray scale value Rout+1(7 . . . 2) that is higher by one may be stored in an LUT.
[0078] While this invention has been described in conjunction with the specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, preferred embodiments of the invention as set forth herein are intended to be illustrative, not limiting. There are changes that may be made without departing from the spirit and scope of the invention. | Aspects of the invention can provide an image processing circuit for gray scale correction, an image display apparatus, and an image processing method that allow reduction in the storage capacity needed for storing correction characteristics data without increasing clock rate in relation to interpolation processing of correction characteristics. A exemplary image processing circuit according to the invention can be applied, for example, to color correction or gamma correction of color image data. Gray scale correction characteristics data for a number of gray scale levels that is less than the number of gray scale levels of input image data can be stored in first and second lookup table storing units. Considering a gray scale value of a pixel that is being considered for gray scale correction processing as an input gray scale value, the first and second lookup-table storing units are referred to, obtaining an output gray scale value corresponding to the input gray scale value and an output gray scale value corresponding to an adjacent input gray scale value. An adjacent gray scale value refers to a gray scale value that is higher by one or lower by one than another input gray scale value. Then, output gray scale values between these two adjacent output gray scale values can be calculated by linear interpolation, obtaining output values for all input gray scale values. Subsequently, gray scale correction can be performed for each pixel of input image data, outputting corrected image data. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a system for constructing a structure in which supporting members carry transverse supported members, the method of construction and the special clip used in the construction. Examples of such structures are house and patio decks, boardwalks, benches, stair treads, bench seating, trellis systems and the like.
Decks are usually built onto the side of a house, rather than as freestanding structures, although they may be either. If built onto the side of a house, a ledger board or header is fastened to the side of the house, usually with lag screws, expansion bolts, or carriage bolts, but any fastener can be used. The vertical placement of the ledger board or header determines the height of the deck. According to standard practice, the deck area is then marked off using strings and batterboards. The top few inches of soil where the deck is to be constructed is removed and a sheet of black polyethylene can be placed over the ground so that vegetation does not grow up through the deck when it is completed. Holes for the supporting posts are then located and dug. The holes are generally at least two feet deep, but are recommended to always be deeper than the frost line. The posts can be set in the ground, in gravel or concrete, or on concrete piers. The posts are plumbed and aligned with each other so that the deck will be plumb with straight edges. Beams are then used to connect the posts, and joists—the supporting members—are attached on top of the beams. Joist hangers can be used or the joists can be screwed or nailed to the headers. The joists are typically placed on 16-inch or 24-inch centers. Decking—the supported members—is placed with the growth rings facing down so that they will not be visible in the completed deck. A ⅛″ space is usually left between the decking boards to allow for expansion. A 10 d nail can be used as a convenient spacer. Decking is traditionally fastened down to the joists with spiral shank nails, ring shank nails, or coated screws. When pressure-treated wood is used, the manufacturer's suggestions for nail spacing and the size of nails should be followed. Decking can be laid down in a number of patterns, such as a herringbone, but the traditional method is to lay the decking parallel to the house. In any case, the decking must be laid transversely, whether at an angle or not, across the joists, so that at least two supporting members support each supported member. Rails and often stairs are then added to complete the deck.
The standard method of nailing directly through the deck boards has a number of attendant problems, including nails backing out of the wood with seasonal swelling and shrinkage, rusting of the nails and concomitant staining of the deck boards, wood bruises of the deck boards by hammer marks, and loosening of the boards due to nail pullout.
Some of these problems are addressed by a variety of existing deck tie and clips, but none of these excel the present invention in simplicity of design, ease of installation, or economy.
SUMMARY OF THE INVENTION
The gist of the present invention is the use of a clip in a system and method for constructing a structure in which the clip is attached to an adjoining supported member and driven directly into the supporting member. In this manner, the supported members are connected to the supporting members without any clip interposed therebetween.
An object of the present invention is to construct a structure such as a deck using the present method according to which no fasteners are driven through the top surface of the supported deck boards, thereby giving the appearance that no nails are used in the construction of the structure.
Another object is to provide a structure in which no fasteners are driven through the top surface of the supported deck boards, thereby eliminating staining due to rusting fastener heads.
A further object is to provide a method of installation which is easy, fast and provides a relatively planar surface with ordinary diligence.
Still another object is to provide a system which will remain relatively secure through seasonal changes that normally cause shrinkage and swelling of the wood.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of an embodiment of the method of the present invention.
FIG. 1B is a perspective view of an embodiment of the method of the present invention.
FIG. 1C is a top plan view of an embodiment of the connector of the present invention.
FIG. 1D is a front elevation view of an embodiment of the connector of the present invention.
FIG. 1E is a side elevation view of an embodiment of the connector of the present invention.
FIG. 1F is a bottom plan view of an embodiment of the connector of the present invention.
FIG. 1G is a side elevation view of a connection formed according to the method of the present invention.
FIG. 2A is a perspective view of an embodiment of the method of the present invention.
FIG. 2B is a perspective view of an embodiment of the method of the present invention.
FIG. 2C is a top plan view of an embodiment of the connector of the present invention.
FIG. 2D is a front elevation view of an embodiment of the connector of the present invention.
FIG. 2E is a side elevation view of an embodiment of the connector of the present invention.
FIG. 2F is a bottom plan view of an embodiment of the connector of the present invention.
FIG. 3A is a perspective view of an embodiment of the method of the present invention.
FIG. 3B is a perspective view of an embodiment of the method of the present invention.
FIG. 3C is a perspective view of an embodiment of the method of the present invention.
FIG. 3D is a top plan view of an embodiment of the connector of the present invention.
FIG. 3E is a front elevation view of an embodiment of the connector of the present invention.
FIG. 3F is a side elevation view of an embodiment of the connector of the present invention.
FIG. 3G is a bottom plan view of an embodiment of the connector of the present invention.
FIG. 3H is a side elevation view of an embodiment of the method of the present invention.
FIG. 3I is a side elevation view of an embodiment of the method of the present invention.
FIG. 4A is a perspective view of an embodiment of the method of the present invention.
FIG. 4B is a perspective view of an embodiment of the method of the present invention.
FIG. 4C is a top plan view of an embodiment of the connector of the present invention.
FIG. 4D is a side elevation view of an embodiment of the connector of the present invention.
FIG. 4E is a front elevation view of an embodiment of the connector of the present invention.
FIG. 4F is a side elevation view of an embodiment of the connector of the present invention.
FIG. 4G is a bottom plan view of an embodiment of the connector of the present invention.
FIG. 5A is a perspective view of an embodiment of the method of the present invention.
FIG. 5B is a perspective view of an embodiment of the method of the present invention.
FIG. 5C is a perspective view of an embodiment of the method of the present invention.
FIG. 5D is a top plan view of an embodiment of the connector of the present invention.
FIG. 5E is side elevation view of an embodiment of the connector of the present invention.
FIG. 5F is a front elevation view of an embodiment of the connector of the present invention.
FIG. 5G is a side elevation view of an embodiment of the connector of the present invention.
FIG. 5H is a bottom plan view of an embodiment of the connector of the present invention.
FIG. 6A is a perspective view of an embodiment of the method of the present invention.
FIG. 6B is a perspective view of an embodiment of the method of the present invention.
FIG. 6C is a top plan view of an embodiment of the connector of the present invention.
FIG. 6D is a side elevation view of an embodiment of the connector of the present invention.
FIG. 6E is a front elevation view of an embodiment of the connector of the present invention.
FIG. 6F is a bottom plan view of an embodiment of the connector of the present invention.
FIG. 7A is a perspective view of an embodiment of the method of the present invention.
FIG. 7B is a perspective view of an embodiment of the method of the present invention.
FIG. 7C is a top plan view of an embodiment of the connector of the present invention.
FIG. 7D is a side elevation view of an embodiment of the connector of the present invention.
FIG. 7E is a front elevation view of an embodiment of the connector of the present invention.
FIG. 7F is a bottom plan view of an embodiment of the connector of the present invention.
FIG. 7G is a front elevation view of a connection formed according to the method of the present invention.
FIG. 7H is a perspective view of an embodiment of the method of the present invention.
FIG. 7I is a perspective view of an embodiment of the method of the present invention.
FIG. 8A is a perspective view of an embodiment of the method of the present invention.
FIG. 8B is a perspective view of an embodiment of the method of the present invention.
FIG. 8C is a perspective view of an embodiment of the method of the present invention.
FIG. 8D is a perspective view of an embodiment of the method of the present invention.
FIG. 8E is a top plan view of an embodiment of the connector of the present invention.
FIG. 8F is a side elevation view of an embodiment of the connector of the present invention.
FIG. 8G is a front elevation view of an embodiment of the connector of the present invention.
FIG. 7H is a bottom plan view of an embodiment of the connector of the present invention.
FIG. 9A is a perspective view of an embodiment of the method of the present invention.
FIG. 9B is a perspective view of an embodiment of the method of the present invention.
FIG. 9C is a perspective view of an embodiment of the method of the present invention.
FIG. 9D is a top plan view of an embodiment of the connector of the present invention.
FIG. 9E is a front elevation view of an embodiment of the connector of the present invention.
FIG. 9F is a side elevation view of an embodiment of the connector of the present invention.
FIG. 9G is a front elevation view of an embodiment of the method of the present invention.
FIG. 9H is a front elevation view of an embodiment of the method of the present invention.
FIG. 9I is a front elevation view of an embodiment of the method of the present invention.
FIG. 10A is a perspective view of an embodiment of the method of the present invention.
FIG. 10B is a perspective view of an embodiment of the method of the present invention.
FIG. 10C is a perspective view of an embodiment of the method of the present invention.
FIG. 10D is a top plan view of an embodiment of the connector of the present invention.
FIG. 10E is a front elevation view of an embodiment of the connector of the present invention.
FIG. 10F is a side elevation view of an embodiment of the connector of the present invention.
FIG. 10G is a front elevation view of an embodiment of the method of the present invention.
FIG. 10H is a front elevation view of an embodiment of the method of the present invention.
FIG. 10I is a front elevation view of an embodiment of the method of the present invention.
FIG. 11A is a perspective view of an embodiment of the method of the present invention.
FIG. 11B is a perspective view of an embodiment of the method of the present invention.
FIG. 11C is a perspective view of an embodiment of the method of the present invention.
FIG. 11D is a perspective view of an embodiment of the method of the present invention.
FIG. 11E is a top plan view of an embodiment of the connector of the present invention.
FIG. 11F is a side elevation view of an embodiment of the connector of the present invention.
FIG. 11G is a front elevation view of an embodiment of the connector of the present invention.
FIG. 11H is a bottom plan view of an embodiment of the connector of the present invention.
FIG. 11I is a side elevation view of an embodiment of the method of the present invention.
FIG. 11J is a side elevation view of an embodiment of the method of the present invention.
FIG. 11K is a side elevation view of an embodiment of the method of the present invention.
FIG. 11L is a side elevation view of an embodiment of the method of the present invention.
FIG. 11M is a side elevation view of an embodiment of the method of the present invention.
FIG. 11N is a side elevation view of an embodiment of the method of the present invention.
FIG. 12A is a perspective view of an embodiment of the driver tool of the present invention.
FIG. 12B is a perspective view of an embodiment of the driver tool of the present invention.
FIG. 12C is a top plan view of an embodiment of the driver tool of the present invention.
FIG. 12D is a side elevation view of an embodiment of the driver tool of the present invention.
FIG. 12E is a cross-sectional view of an embodiment of the driver tool of the present invention.
FIG. 13 is a top plan of the present invention.
FIG. 14A is a top plan view of an embodiment of the connector of the present invention.
FIG. 14B is a front elevation view of an embodiment of the connector of the present invention.
FIG. 15 is a front elevation view of an embodiment of the driver tool and connector of the present invention.
DETAILED DESCRIPTION
As best shown in FIGS. 1A and 1B , the present invention is a method for installing a first supported member 1 , having a first substantially planar side 2 , a second side 3 , a top side 4 and a bottom side 5 , of a plurality of generally parallel closely spaced adjoining supported members 6 , as best shown in FIG. 13 , to a first supporting member 7 of a plurality of supporting members 8 positioned transversely to the plurality of supported members 6 .
As best shown in FIGS. 1A and 1B , in the most preferred form of the present invention, the plurality of supported members 6 is wood decking planks and the plurality of supporting members 8 are wood deck joists. As such, the plurality of supported members 6 is horizontally oriented, but the method encompasses any plurality of supported members 6 and any plurality of supporting members 8 in any orientation, although the plurality of supporting members 8 is generally transverse to the plurality of supported members 6 . These members can be formed from any material into which the first fasteners 15 and connectors 9 of the present invention can be driven.
As best shown in FIGS. 1A and 1B , initially, the method of the present invention comprises positioning the first supported member 1 across the supporting members 8 , so that the bottom side 5 of the first supported member 1 substantially interfaces with the at least two of the plurality of supporting members 8 . A minimum of two supporting members 8 is needed to carry the first supported member 1 . Then the method of the present invention comprises positioning a first connector 9 , best shown in FIGS. 1C–1F , 2 C– 2 F, 3 D– 3 G, 4 C– 4 G, 5 D– 5 H, 6 C– 6 F, 7 C– 7 F, 8 E– 8 H, 9 D– 9 F, 10 D– 10 F, 11 E– 11 H and 14 A– 14 B, having a narrow longitudinal member 10 with a first face 11 and a second face 12 , a top 13 and a bottom 14 , proximate the first supporting member 7 so that the first face 11 substantially interfaces with the first side 2 of the first supported member 1 . The narrow longitudinal member 10 occupies substantially a single plane, as it is designed to fit between narrowly-spaced supported members 6 . Then the method of the present invention comprises attaching the first connector 9 to the first side 2 of the first supported member 1 with a first fastener 15 . The first fastener 15 is preferably a nail, but any kind of fastener can be used, nail, screw, bolt, brad, staple, or the like. Then the method of the present invention comprises driving, parallel to the plane of the first side 2 of the first supported member 1 , the first connector 9 into the first supporting member 7 .
As shown in FIGS. 3A–3I , 5 A– 5 H and 8 A– 8 H, in a first preferred embodiment of the present invention, the first connector 9 preferably has a first fastener opening 16 in the longitudinal member 10 and the first fastener 15 is driven through the first fastener opening 16 . The first fastener opening 16 of the first connector 9 is preferably a longitudinal slot. The slot can be centered in longitudinal member 10 or it can be offset. The longitudinal member 10 has a top edge 17 at the top 13 , a bottom edge 18 at the bottom 14 , a first side edge 19 and second side edge 20 , and the bottom edge 18 tapers. The bottom edge 18 can taper in equally on either side. It can taper to a point or merely narrow the cross-section of the of the bottom edge 18 . This reduces the leading edge cross-section of the first connector 9 and increases the pressure applied to the first supporting member 7 when the first connector 9 is driven, thereby easing driving. Preferably, the first side edge 19 and the second side edge 20 have serrations 52 along at least a portion of their length. This improves the withdrawal resistance of the first connector 9 . As shown in FIGS. 11A–11C , 11 G and 14 B Preferably the longitudinal member 10 has longitudinal corrugations 54 . This stiffens the longitudinal member 10 against driving forces. The need to corrugate the longitudinal member 10 is a function of the driving forces and the hardness of the wood into which it is driven. If the wood is relatively soft, the longitudinal member 10 can be formed out of relatively thick sheet metal, 12 gauge steel for example. If the wood is relatively hard, the longitudinal member 10 must be formed from relatively thin sheet metal, 20 or 22 gauge steel in the most preferred form, in order to prevent the first connector 9 from acting as a wedge that splits the first supporting member 7 into which it is driven. When the longitudinal member 10 is formed from very light gauge metal, it may be necessary to longitudinally corrugate the metal in order to stiffen it against driving forces. It may be preferable under certain conditions to form the connector of the present invention from stainless steel, which is both harder and more corrosion resistant than untreated or galvanized steel.
As shown in FIGS. 8A–8H , in a preferred form of the invention, the top edge 17 is integrally joined at a first juncture 21 to a tab 22 that continues in the same plane as the longitudinal member 10 .
As shown in FIGS. 3I , 5 C and 6 B, the first connector 9 of the present invention can be driven until the top 13 is flush with the top side 4 of the first supported member 1 . In this case, the first connector 9 can be driven with a hammer 42 or, in fact, any instrument that applies sufficient driving force to the first connector 9 . However, as shown in FIGS. 1B , 1 G, 2 B, 4 B, 7 B, 7 G and 7 I it is preferable to drive the first connector 9 until the top 13 is slightly below the top side 4 of the first supported member 1 . This hides the top 13 of the first connector 9 from view when subsequent supported members of the plurality of supported members 6 are attached. In the preferred method, a driving tool 43 is interposed between the hammer 42 and the first connector 9 . If the first connector 9 is being driven between two closely spaced supported members 6 of the plurality of supported members 6 , the driving tool 43 must be sufficiently narrow that it fits between the supported members. It is in any case preferable to use a driving tool 43 because the hammer 42 will leave marks on the top side 4 of the first supported member 1 if nothing is interposed between it and the first connector 9 . As shown in FIGS. 8A–8D , the tab 22 of the form described above acts as an integral driving tool 43 . When the first connector 9 has been driven into the supporting member 7 , one breaks away the tab 22 along the first juncture 21 . First juncture 21 eases the breakaway of the tab 22 .
As detailed above, the first connector 9 is preferably made of sheet metal. Preferably, the first fastener 15 is a nail.
In another embodiment, the first fastener opening 16 can be a hole. Alternatively, there need not be a first fastener opening 16 , and the first fastener 15 is then driven directly through the longitudinal member 10 such that first juncture 21 is below the top side 4 of the first supported member 1 . The first connector 9 is then driven into the first supporting member 7 and the tab 22 is then broken away.
As shown in FIGS. 9E and 10E , in another preferred embodiment of present invention, the first fastener opening 16 in the first connector 9 is a round hole. As shown in FIGS. 9A–9C , 9 G– 9 I, 10 A– 10 C and 10 G– 10 I, in this embodiment, the first connector 9 rotates around the first fastener 15 in order to drive the connector 9 into the first supporting member 7 . Preferably, the longitudinal member 10 has concentric corrugations 54 centered on the fastener opening 16 .
As shown in FIGS. 10A–10I , in one form of this preferred embodiment, the longitudinal member 10 is substantially triangular in profile. Preferably, the first connector 9 is made of sheet metal. Preferably, the first fastener 15 is a nail. As best shown in FIGS. 9A–9I , in another form of this preferred embodiment, the longitudinal member 10 has two wings 23 that extend away from the first fastener opening 16 . Preferably, the first connector 9 is made of sheet metal. Preferably, the first fastener 15 is a nail. The form with the triangular profile is stronger than the form with the two wings 23 . The primary advantage of these forms, in particular the form with two wings 23 , is that they can be accessed from below the structure and rotated back out of the first supporting member 7 if the first supporting member 7 rots. Removing the first supported member 1 when it is attached with the other preferred embodiments of the present invention is more difficult and more destructive.
As shown in FIGS. 1A–1G , 2 A– 2 F, 4 A– 4 G and 7 A– 7 F, in another preferred embodiment of the present invention, the first fastener 15 has a shank 24 and a head 25 . The longitudinal member 10 has a first leg 26 and a second leg 27 laterally spaced to accommodate the shank 24 of the first fastener 15 therebetween, and a first connecting portion 28 between the first leg 26 and the second leg 27 . And the first leg 26 is driven into the first supporting member 7 until the connecting portion 28 reaches the shank 24 . As shown in FIGS. 4A–4G , the second leg 27 can be shorter than the first leg 26 . As shown in FIGS. 1A–1G and FIGS. 2A–2F , the second leg 27 is preferably equal in length to the first leg 26 and the second leg 27 is driven into the supporting member 7 alongside the first leg 26 . As shown in FIGS. 1A–1G , the first leg 26 and the second leg 27 preferably have serrations 52 along at least a portion of their length. This increases the resistance of the first connector 9 to pullout. Preferably, the first 9 connector is made of sheet metal. As shown in FIG. 14B , preferably, the first leg 26 and the second leg 27 each have a longitudinal reinforcing embossment 53 . Preferably, the first fastener 15 is a nail.
As shown in FIGS. 6A and 6B , in another preferred embodiment, the method of the present invention includes driving a second fastener 29 having a shank 30 and a head 31 into the first side 2 of the first supported member 1 such that the head 31 is a selected distance away from the first side 2 . The longitudinal member 10 preferably has a third leg 32 laterally spaced from the first leg 26 to closely accommodate the shank 30 of the second fastener 29 therebetween, a second connecting portion 33 between the first leg 26 and the third leg 32 , and the second leg 27 and the third leg 32 are laterally spaced to each side of the first leg 26 . This gives the first connector 9 a trident-shaped profile. Preferably, the first leg 26 has serrations 52 along at least a portion of its length.
Although in most embodiments the first connector of the present invention is preferably formed from sheet steel, any similarly hard material may be suitable. As shown in FIGS. 7A–7I , in an alternate preferred embodiment, the first connector 9 is bent out of a single piece of wire. In this embodiment, the first fastener 15 is preferably a nail.
As shown in FIGS. 11A–11N , in another preferred embodiment, the longitudinal member 10 has a first leg 26 and a second leg 27 laterally spaced, a first connecting portion 28 between the first leg 26 and the second leg 27 , a third leg 32 laterally spaced from the first leg 26 , and a second connecting portion 33 between the first leg 26 and the third leg 32 . The method additionally comprises positioning a second supported member 34 of the plurality of supported members 6 , having a first substantially planar side 35 , a second side 36 , a top side 37 and a bottom side 38 , above the plurality of supporting members 8 on the opposite side of the first connector 9 from the first supported member 1 . For ease of installation, the second supported member 34 can be rested on another member before being lowered onto the supporting members 8 . One then drives a second fastener 29 between the first leg 26 and the third leg 32 into the second side 36 of the second supported member 34 . One then lowers the second supported member 34 to the plurality of supporting members 8 . As in all embodiments, the first connector 9 is attached to the first side 2 of the first supported member 1 with a first fastener 15 , and the first connector 9 is driven into the first supporting member 7 . This embodiment allows a single first connector 9 to attach a first supported member 1 and a second supported member 34 to the first supporting member 7 .
As shown in FIG. 11G , in this embodiment, the first leg 26 and the third leg 32 preferably has serrations 52 along at least a portion of their length. Preferably, the first connector 9 is made of sheet metal. Preferably, the second leg 27 and the third leg 32 each have a longitudinal reinforcing embossment 53 . Preferably, the first fastener 15 is a nail and the second fastener 29 in a nail.
As shown in FIGS. 7G–7I , in another preferred embodiment, the first fastener 15 has a first leg 39 and a second leg 40 joined by a connecting portion 41 . In this embodiment, the first fastener 15 and the first connector 9 are essentially the same and can be identical. This greatly simplifies installation, as no distinction needs to be made between these parts. Preferably, the first connector 9 is bent out of a single piece of wire and the first fastener 15 is bent out of a single piece of wire. The longitudinal member 10 has a first leg 26 and a second leg 27 laterally spaced to accommodate the first leg 39 of the first fastener 15 therebetween, and a first connecting portion 28 between the first leg 26 and the second leg 27 . And the first leg 26 is driven into the first supporting member 7 until the connecting portion 28 reaches the first leg 39 of the first fastener 15 .
In a preferred embodiment, the first connector 9 is driven by a hammer 42 . As shown in FIGS. 1A , 2 A, 3 C, 4 A, 5 C, 6 A, 7 A, 71 , 91 , 10 I, 11 D and 11 N, preferably, a driving tool 43 having an upper portion 44 and a lower portion 45 is interposed between the first connector 9 and the hammer 42 so that the driving force is transferred from the hammer 42 through the driving tool 43 into the first connector 43 . The lower portion 44 of the driving tool 43 is dimensioned to fit between the first supported member 1 and a second supported member 34 when the first supported member 1 and the second supported member 34 are closely spaced adjacent and parallel each other. In its most basic form, the driving tool 43 comprises a flat metal rectangle. As shown in FIG. 15 , preferably, the lower portion 45 of the driving tool 43 is dimensioned to closely interface with the top 13 of the first connector 9 , thereby limiting slip between the two. This close interface can be made by forming the lower portion 45 of the driving tool 43 to conform to the contour of the top 13 of the longitudinal member 10 , and it can have a groove or slot formed in the lower portion 45 .
As shown in FIGS. 12A–12E , in another preferred embodiment, the driving tool 43 has a body 46 , a longitudinal cavity 47 in the body 46 formed to accept the first connector 9 and a sliding force transferring member 48 , a lower projection 49 in the lower portion 45 , a first arm 50 extending laterally from the lower portion 45 , and a second arm 51 extending laterally from the lower portion 45 opposite the first arm 50 . Preferably, the first connector 9 is placed inside the longitudinal cavity 47 , the driving tool 43 is positioned so that the first arm 50 interfaces with the first supported member 1 , the second arm 51 interfaces with the second supported member 34 , and the lower projection 49 is substantially between the first supported member 1 and the second supported member 34 , the first connector 9 is positioned directly over the first fastener 15 . The force transferring member 48 is struck with a hammer 42 until the first connector 9 is driven into the first supporting member 7 and the top 13 of the first connector 9 is below the top side 4 of the first supported member 1 and the top side 37 of the second supported member 34 . Preferably, the body 46 is cast in aluminum, and the force transferring member 48 is steel.
In deck construction, the first supported member 1 , a deck plank, typically is screwed or toenailed against the ledger board or header, simply because it can be easier than using the connector 9 of the present invention, which may be difficult to install against a ledger board or header. Once the first supported member 1 has been laid down, a first fastener 15 can be driven into the first side 2 of the first supported member 1 , or joist, that faces away from the ledger board or header, leaving a gap between the head 25 of the first fastener 15 and the first side 2 of the first supported member 1 large enough to accommodate the thickness of the first connector 9 . In the forms that allow it, the first connector 9 can then be slid down over the exposed first fastener 9 shank 24 below the head 25 and driven into the first supporting member 7 below it. The first connector 9 can be driven with a hammer 42 until it is flush with the top side 4 of the first supported member 4 , but a narrow driving tool 43 , in its simplest form a length of sheet steel, may be needed to drive the first connector 9 down below the top side 4 of the first supported member 7 when two supported members 6 are closely spaced. As shown in FIG. 13 , preferably the connectors 9 are staggered on every other of the supporting members 8 .
In the most basic form, a second supported member 34 is preferably installed as follows. The second supported member 34 , having a first substantially planar side 35 , a second side 36 , a top side 37 , and a bottom side 38 , is positioned across the supporting members 8 , so that the bottom side 38 of the second supported member 34 substantially interfaces with at least two of the plurality of supporting members 8 , and so that the first side 35 is parallel and in close proximity to the second side 3 of the first supported member 1 . Because it is in close proximity, the gap between the first supported member 1 and the second supported member 34 is relatively narrow, permitting and, moreover, encouraging the use of the method of the present invention and the narrow connector 9 of the present invention, which are particularly well-adapted for such installations. A second connector 9 , having a narrow longitudinal member 10 with a first face 11 and a second face 12 , a top 13 and a bottom 14 , is positioned proximate the first supporting member 7 so that the first face 11 substantially interfaces with the first side 35 of the second supported member 34 . The second connector 9 is attached to the first side 35 of the second supported member 34 with a first fastener 15 and the first connector 9 is driven, parallel to the plane of the first side 35 of the second supported member 34 , into the first supporting member 7 .
If the supporting members 8 are wide enough, connectors 9 can be placed side-by-side, attaching facing supported member 6 . The standard joist is 6×2 or 8×2, so there usually isn't enough room for side-by-side installations. The gap between the boards is set according to preference. Green wood is usually closely spaced because it will shrink and widen the gap. Some prefer a wider gap in order to allow debris to be swept through the gaps.
In the preferred form, the second side 3 of the first supported member 1 is preferably connected as follows. After connecting the first side 2 , one positions a second connector 9 , having a narrow longitudinal member 10 with a first face 11 and a second face 12 , a top 13 and a bottom 14 , proximate one of the plurality of supporting members 8 so that the first face 11 substantially interfaces with the second side 3 of the first supported member 1 . One then attaches the connector 9 to the second side 3 of the first supported member 1 with a first fastener 15 . Finally, one drives, parallel to the plane of the second side 3 of the first supported member 1 , the connector 9 into the proximate one of the plurality of supporting members 8 .
Since the supported member 1 is already attached to the supporting member 7 when this connector 9 on the second side 3 is driven in, the embodiment used here must be able to slide past the second side 3 of the supported member 1 while it is being driven into the supporting member 7 .
A second supported member 34 can then be installed. The second supported member 34 , having a first substantially planar side 35 , a second side 36 , a top side 37 , and a bottom side 38 , is positioned across the supporting members 8 , so that the bottom side 38 of the second supported member 34 substantially interfaces with at least two of the plurality of supporting members 8 , and so that the first side 35 is parallel and in close proximity to the second side 2 of the first supported member 1 . Because it is in close proximity, the gap between the first supported member 1 and the second supported member 34 is relatively narrow, permitting and, moreover, encouraging the use of the method of the present invention and the narrow connector 1 of the present invention, which are particularly well-adapted for such installations. A second connector 9 , having a narrow longitudinal member 10 with a first face 11 and a second face 12 , a top 13 and a bottom 14 , is positioned proximate one of the plurality of supporting members 8 so that the first face 11 substantially interfaces with the first side 35 of the second supported member 34 . The second connector 9 is attached to the first side 35 of the second supported member 34 with a first fastener 15 and the first connector 9 is driven, parallel to the plane of the first side 35 of the second supported member 34 , into the proximate one of the plurality of supporting members 8 .
In order to connect both sides of the second supported member 34 , after connecting the first side 35 , one positions another connector 9 , having a narrow longitudinal member 10 with a first face 11 and a second face 12 , a top 13 and a bottom 14 , proximate one of the plurality of supporting members 8 so that the first face 11 substantially interfaces with the second side 36 of the second supported member 34 . One then attaches the connector 9 to the second side 36 of the second supported member 34 with a first fastener 15 . Finally, one drives, parallel to the plane of the second side 36 of the second supported member 34 , the connector 9 into the proximate one of the plurality of supporting members 8 . | A method of forming a connection, and a connector, that attaches supported members, such as deck boards, to supporting members, such as deck joists. In some forms, each connector attaches a single supported member. In others, the connector attaches two supported members. Many forms of the connector are possible, but all are narrow enough to fit between two supported members laid side-by-side, all are attached to the supported members by fasteners, and all are driven directly into the supporting members. The resulting structure is characterized by the apparent absence of nails or other fasteners. | 4 |
TECHNICAL FIELD
[0001] The present invention relates to a methodology to cleave the β-O-4 ether bond in a monomeric or polymeric compound.
BACKGROUND
[0002] Reductive cleavage of the β-O-4 bond in lignin is a rare transformation. One example using a simplified lignin model compound was performed by the Bergman group (Nichols, J. M.; Bishop, L. M.; Bergman, R. G.; Ellman, J. A. “Catalytic C—O Bond Cleavage of 2-Aryloxy-1-arylethanols and its Application to the Depolymerization of Lignin Related Polymers” J. Am. Chem. Soc. 2010, 132, 12554-12555). In this publication, a Ru-based catalyst performed the cleavage to generate the acetophenone and the phenol. A disadvantage is that inert atmosphere was required for efficient catalysis.
[0003] Very recently, a Ni catalyzed reduction of different model compounds and also pyrolysis oil was reported using isopropanol as hydrogen donor (X. Wang, R. Rinaldi, “Exploiting H-transfer reactions with RANEY Ni for upgrade of phenolic and aromatic biorefinery feeds under unusual, low-severity conditions”, Energy Environ. Sci., 2012, 5, 8244). The main transformation described in said publication is the reduction of the aromaticity in aromatic compounds to generate the saturated hydrocarbons. The authors also show with a few examples that phenolic and benzylic ethers are cleaved to generate saturated alcohols or hydrocarbons. However, the authors do not include the β-O-4 bond in a simplified or parent model. This bond is much more difficult to cleave than to cleave the highly activated phenolic and benzylic bonds, which are considered standard procedures. Another disadvantage with the previous report using Ni was that an excess of the metal was used. Thereby, the metal was not used in catalytic amount, and may only be considered to mediate and not catalyze the reaction.
[0004] It is well known that Ni is active in the hydrogenolysis of aryl ethers using hydrogen gas (A. G. Sergeev, J. F. Hartwig, “Selective, Nickel-catalyzed Hydrogenolysis of Aryl Ethers” Science, 2011, 332, 439-443). Also, that Ni and hydrogen gas or hydrogen donor is active in the reduction of the aromaticity in phenols and other aromatic compounds (C. Zhao, Y. Kou, A. A. Lemonidou, X. Li, J. A. Lercher, “Hydrodeoxygenation of bio-derived phenols to hydrocarbons using RANEY Ni and Nafion/SiO 2 catalysts,” Chem. Commun., 2010, 46, 412-414).
SUMMARY OF THE INVENTION
[0005] As described above, Ni with hydrogen or a hydrogen donor is known to reduce the aromaticity and also to cleave benzyl and phenyl ether bonds. However, the combination of Ni and a mild hydrogen donor is not known to cleave the β-O-4 bond in simplified or parent lignin model, lignin, lignosulfonate, or lignin from other pulping or separation method.
[0006] The object of the present invention is to provide a way to perform a cleavage of the β-O-4 bond in for example lignin using an alcohol as the hydrogen donor by means of catalysis. This has to the knowledge of the present inventors never before been presented.
[0007] The invention can be used in the depolymerization of lignin to generate hydrocarbon monomers that can be used as fine chemical feed-stock, fuel additives or as a component or starting material in fuel production.
[0008] One aspect of the present invention relates to a method of cleaving a β-O-4 bond to the corresponding C—H bond in a compound using a hydrogen donor and a transition metal based catalyst as defined in claim 1 .
[0009] Another aspect of the present invention relates to a method in which the metal catalyst is not used in stoichiometric or over stoichiometric amount.
[0010] Preferred embodiments of the above mentioned aspect are described below; all the embodiments below should be understood to refer to both aspects described above.
[0011] In one embodiment the hydrogen donor is glycerol, glycol, glucose, isopropanol, methanol or ethanol.
[0012] In another embodiment one solvent is polar or non-polar and wherein said solvent may be protic or aprotic.
[0013] In another embodiment one solvent is selected between isopropanol, methanol, ethanol, water, ethylacetate, or a combination of two or more of the listed solvents.
[0014] In another embodiment the hydrogen donor is formic acid or hydrogen gas.
[0015] In another embodiment the hydrogen donor is not hydrogen gas.
[0016] In another embodiment the reaction is conducted at a temperature of at least 40° C., preferably 70-120° C.
[0017] In another embodiment the catalyst is nickel on carbon, Ni/Si, Ni/Fe, Nickel nanopowder or Raney nickel, or a palladium catalyst.
[0018] In another embodiment the compound is a β-O-4 bond in a lignin model compound.
[0019] In another embodiment the compound is a polymer.
[0020] In another embodiment the compound is a biopolymer.
[0021] In another embodiment the compound is lignin.
[0022] In another embodiment the compound is lignosulfonate.
[0023] In another embodiment the reaction is conducted in an atmosphere of carbon dioxide.
[0024] In another embodiment the catalyst is used in 0.1-500 mol %.
DESCRIPTION OF FIGURES
[0025] FIG. 1 . GPC-results, Comparison of Lignin type A, solvolysis of Lignin type A and nonsoluble polymer after solvolysis.
[0026] FIG. 2 , GPC-results. Comparison of Lignin type A, solvolysis of Lignin type A, and Lignin type A reacted with Nickel Nanoparticles.
[0027] FIG. 3 , GPC-results showing the results from the reaction mixtures, Lignin type A reacted with NaBH 4 , KOH and K 2 CO 3 .
[0028] FIG. 4 , GPC-results showing the results from the reaction mixtures Lignin type A reacted with 6 mg Nickel, 16 mg Nickel and 43 mg Nickel.
[0029] FIG. 5 , shows the results from the reaction mixtures
[0030] FIG. 6 , shows the results from the reaction mixtures
[0031] FIG. 7 , shows the results from the reaction mixtures of Lignin type B with Nickel nanoparticle and Raney Nickel.
[0032] FIG. 8 , HSQC of Lignin type B
[0033] FIG. 9 , HSQC of product from Example 38
[0034] FIG. 10 , HSQC Overlay: Lignin type B in red/pink, reacted lignin type B in blue/green.
[0035] FIG. 11 , shows the results from the reaction mixtures (Lignin type B and Lignin type B reacted in MeOH, in t-BuOH and in MeOH/t-BuOH
[0036] FIG. 12 , shows the results from the reaction mixtures Lignin type B reacted with MeOH/i-PrOH 16:1
[0037] FIG. 13 , shows the results from the reaction mixtures (Lignin type B reaction in glycerol and reaction in MeOH.
[0038] FIG. 14 , GPC showing the results from the reaction mixture
[0039] FIG. 15 , GPC showing the results from the reaction mixtures.
[0040] FIG. 16 , showing the results from the reaction mixture and the reaction mixture after water treatment.
[0041] FIG. 17 , show the results from the reaction mixture, water treated reaction and as a comparison reaction in MeOH
[0042] FIG. 18 , shows the results from the reaction mixtures.
[0043] FIG. 19 shows the results from the reaction mixtures.
[0044] FIG. 20 shows the results from the reaction mixtures.
[0045] FIG. 21 shows the results from the reaction mixtures.
[0046] FIG. 22 shows the results from the reaction mixtures.
[0047] FIG. 23 shows the results from the reaction mixtures.
[0048] FIG. 24 compares different lignin sources, Lignin type A, B and C.
[0049] FIG. 25 shows the results from the reaction mixture and the reaction mixture after water treatment.
[0050] FIG. 26 shows HSQC experiment from Prod 2.
DETAILED DESCRIPTION
[0051] In the present invention the term “hydrogen donor” should be interpreted as a substance or compound that gives or transfers hydrogen atoms to another substance or compound.
[0052] The invention relates to a method to cleave a substrate, wherein said substrate involves the β-O-4 bond,
[0000]
[0000] which is abundant in lignin. Without being bound by theory but it is believed that the cleavage is a reductive cleavage.
[0053] A general method comprises adding a catalyst to a reaction flask or container, adding a solvent followed by addition of a hydrogen donor and the substrate to be treated or cleaved. The reaction is then stopped or quenched and the obtained product is isolated and preferably dried. The method comprises of providing a set of components, a substrate to be cleaved, a hydrogen donor, a transition metal based catalyst and at least one solvent. The hydrogen donor is preferably an alcohol or a combination of alcohols. The components are then mixed to form a mixture. The mixing may be done using any suitable technique for example shaking or stirring. The order of addition of each component is not crucial. The mixture is heated to a temperature of not more than 200° C. and left to react, i.e. to cleave the β-O-4 bond in the substrate, for a suitable period of time.
[0054] The solvent may be a mixture of solvents or a second solvent may be added during the reaction wherein the second solvent may be reducing the aromatic parts of the substrate as well as cleaving β-O-4 bonds. In one embodiment the mixture contains iso-propanol. In another embodiment the second solvent is iso-propanol.
[0055] The method may further comprise one or more additional steps where the method is repeated. For example the method may comprise a first step as described above thereafter the obtained product (the cleaved substrate) may be isolated and dissolved in a second solvent together with a second catalyst. The second solvent may be the same as the solvent in the first step but may be a different solvent as well. For example the second solvent may be iso-propanol or a mixture comprising iso-propanol. The second catalyst may be the same as the catalyst in the first step. A base may added in the second step as well and the reaction mixture may be neutralized using any suitable acid. Before isolation the catalyst from the first step may be removed, for example by the use of a magnet. The isolation may be performed using any suitable technique and the isolated product may be washed with a suitable solvent for example water. The additional, or the second, step may be performed at a temperature of not higher than 200° C. The additional/second step is believed to reduce the aromatic feature (CH-groups in the rings are reduced to CH 2 -groups) of the substrate and making the substrate more oil like, besides cleaving β-O-4 bonds. This solves the problem of dissolving the substrate in oils or solvents suitable for the fuel preparation steps for example. All embodiments described herein apply to both the first and the second step.
[0056] The phenyl group may be substituted in ortho, meta or para position. The reaction is performed using a transition metal catalyst (for example catalysts based on Ni, Pd, Pt) to generate the hydrocarbon in good (45-65% yield) to excellent yields (65-100% yield) with only water as side product. A suitable catalytic amount of catalyst can be 0.1 to 500 mol %, such as 0.5 mol % or more, or 1 mol % or more, or 2 mol % or more, or 4 mol % or more, or 5 mol % or more, or 8 mol % or more, or 400 mol % or less, or 250 mol % or less, or 200 mol % or less, or 150 mol % or less, or 100 mol % or less, or 50 mol % or less, or 20 mol % or less, or 15 mol % or less or 12 mol % or less or 10 mol % or less. The amount in equivalents may be at least 0.5 equivalents, or at least 1 equivalent, or at least 1.5 equivalent, or at least 2 equivalents, or at least 3 equivalents, or at least 4 equivalents.
[0057] The hydrogen donor may be any suitable compound that may act as a hydrogen donor, for example alcohol and/or formic acid. A non-limiting list of suitable alcohols is methanol (MeOH), ethanol (EtOH), propanol, iso-propanol (i-PrOH), glycerol, glycol, butanol, t-butanol (i-BuOH) or combinations thereof. In one embodiment the solvent is the hydrogen donor.
[0058] The reaction may be performed in any suitable solvent, or solvents, and the solvent may for example be selected from water, alkanes, alcohols, esters or ethers such as hexane, heptane, methanol (MeOH), ethanol (EtOH), propanol, iso-propanol (i-PrOH), glycerol, glycol, butanol, t-butanol (i-BuOH), ethyl acetate, or tert-butyl methyl ether (TBME), acetone or mixtures thereof. Non-limiting examples of mixtures are methanol-iso-propanol, methanol-t-butanol, ethanol-iso-propanol and hexane-iso-propanol. The solvents may be used as received or they may be degassed prior to use. In one embodiment at least one of the solvents are water when formic acid is used as a hydrogen donor. When the method is performed using two or more steps, the solvent of the first step may be an alcohol preferably methanol or ethanol, and the solvent of the second step an alcohol preferably iso-propanol.
[0059] In one embodiment the method is performed in the presence of an added base. A non-limiting list of suitable bases is KOH, NaOH, NaBH 4 , ammonium formate (NH 4 COOH) or K 2 CO 3 . The amount of base may be not more than 500 weight %, or not more than 400 weight %, or not more than 300 weight %, or not more than 200 weight %, or not more than 100 weight %. In one embodiment the amount of base is 10 weight % or more, or 50 weight % or more. Hydrogen peroxide (H 2 O 2 ) may also be added, preferably dissolved in water, to form radicals in order to break down lignin. In order to neutralize the reaction mixture an acid may be added, for example HCl.
[0060] The reactions can be performed under mild reaction conditions (25° C.-200° C.) by conventional heating or by heating in a microwave oven, but can also be performed at higher reaction temperatures. In one embodiment the temperature is 180° C. or less, or 150° C. or less, or 120° C. or less. In another embodiment the temperature is 45° C. or more, or 70° C. or more, or 80° C. or more.
[0061] When using a carbon dioxide atmosphere, the atmosphere may comprise other compounds such as oxygen and nitrogen. The atmosphere could be air comprising carbon dioxide or an inert atmosphere (such as argon or nitrogen gas) comprising carbon dioxide.
[0062] The following compounds are non-limiting examples of substrates that could be treated or cleaved by the method according to the invention: phenylmethanesulfonic acid, 3-(4-(2-(4-hydroxy-3-methoxyphenyl)-2-oxoethoxy)phenyl)acrylaldehyde, ethyl 3-(4-(2-(4-hydroxy-3-methoxyphenyl)-2-oxoethoxy)phenyl)acrylate, 2-phenoxy-1-phenylethanone and 1,4-bis(benzo[d][1,3]dioxol-5-yl)hexahydrofuro[3,4-c]furan, 1-(3,4-dimethoxyphenyl)-2-(2-methoxyphenoxyl)propane-1,3-diol, lignin, black liquor from Kraft pulping, green liquor, red or brown liquor, lignosulfonate, extracted or separated lignin or lignin from ethanol production.
[0063] When the substrate is a solution or mixture containing lignin, for example black or green liquor, the substrate may be pretreated in any suitable way. For example the substrate may be acidified and precipitated, solvolysed or filtrated using any suitable technique such as ultra- or microfiltration and/or cross-flow filtration for example.
[0064] In one embodiment the substrate is a sample comprising lignin or lignin derivatives having an average molecular weight of 5000 g/mol or less, or 3000 g/mol or less, or 1500 g/mol or less.
[0065] The method may cleave more than 50% of the present β-O-4 bonds, or preferably more than 75%, or preferably more than 90% or preferably more than 95%, or more than 98%, or even more preferably near 100% analyzed using 2D NMR (HSQC) (Bruker Avance II equipped with a QCI-P cryoprobe, 600 Mhz, solvent DMSO-d6/pyridine-d5 4:1.) at 298K. This cleavage percentage may in one embodiment be obtained within 50 hours, or preferably within 36 hours, or even more preferably within 18 hours, or even more preferably within 12 hours, preferably within 6 hours, or preferably within 2 hours, or even more preferably within 1 hour.
EXAMPLES
[0066] In some of the examples below the following lignin types have been used
[0000] Lignin type A—acid precipitated lignin from black liquor
Lignin type B—filtrated black liquor
Lignin type C—extracted from pine using dioxane, and
Lignin type D—from sulfite liquor
Lignin type E—from ethanol production
Example 1
Reaction of Trans-Ferulic Acid
[0067] Trans-Ferulic acid (39 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 35 mg of a reaction mixture which is, according to analysis by HNMR, 4-hydroxy-3-methoxy benzenepropanoic acid. The double bond was saturated.
Example 2
Reaction of Vanillin
[0068] Vanillin (31 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 25 mg of a reaction mixture which is, according to analysis by HNMR, 2-methoxy-4-methylphenol. The aldehyde was reduced to methyl.
Example 3
Reaction of 4-Methyl Catechol
[0069] 4-Methyl catechol (25 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 20 mg of a reaction mixture which is, according to analysis by HNMR, a complex mixture of mainly, 2-hydroxy-4-methyl-Cyclohexanone; 2-hydroxy-5-methyl-Cyclohexanone; 4-methyl-1,2-Cyclohexanediol. The aromatic ring was saturated.
Example 4
Reaction of 4-hydroxybenzaldehyde
[0070] 4-hydroxybenzaldehyde (25 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 20 mg of a reaction mixture which is, according to analysis by HNMR, is 4-methylphenol. The aldehyde was reduced to methyl.
Example 5
Reaction of Syringaldehyde
[0071] Syringaldehyde (25 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 20 mg of a reaction mixture which is, according to analysis by HNMR, is 2,6-dimethoxy-4-methylphenol. The aldehyde was reduced to methyl.
Example 6
Reaction of Catechol
[0072] Catechol (22 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 20 mg of a reaction mixture which is, according to analysis by HNMR, a complex mixture of mainly, cyclohexane-1,2-diol. The aromatic ring was saturated.
Example 7
Reaction of 3-Methoxy catechol
[0073] 3-Methoxy catechol (29 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 26 mg of a reaction mixture which is, according to analysis by HNMR, a complex mixture of mainly, 3-methoxy cyclohexane-1,2-diol. The aromatic ring was saturated.
Example 8
Reaction of Para-Coumaric Acid
[0074] Para-Coumaric acid (32 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 30 mg of a reaction mixture which is, according to analysis by HNMR, 3-(4-hydroxyphenyl)propanoic acid. The double bond was saturated.
Example 9
Reaction of 4-Hydroxyacetophenone
[0075] 4-Hydroxyacetophenone (27 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 25 mg of a reaction mixture which is, according to analysis by HNMR, 4-ethylcyclohexan-1-ol. The ketone and the aromatic ring were reduced.
Example 10
Reaction of 2,6-Dimethoxyphenol
[0076] 2,6-Dimethoxyphenol (30 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 28 mg of a reaction mixture which is, according to analysis by HNMR, starting material+cyclohexanol. The aromatic ring was saturated.
Example 11
Reaction of Guaiacol
[0077] Guaiacol (24 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 20 mg of a reaction mixture which is, according to analysis by HNMR, starting material+phenol+cyclohexanol. The aromatic ring was partly saturated.
Example 12
Reaction of Phenol
[0078] Phenol (18 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 10 mg of a reaction mixture which is, according to analysis by HNMR, cyclohexanol. The aromatic ring was saturated.
Example 13
Reaction of 3,5-Dimethoxy-4-hydroxyacetophenone
[0079] 3,5-Dimethoxy-4-hydroxyacetophenone (39 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 35 mg of a reaction mixture which is, according to analysis by HNMR, 4-ethylphenol+4-ethylcyclohexan-1-ol. The ketone was reduced and the aromatic ring was partly reduced.
Example 14
Reaction of Acetovanillone
[0080] Acetovanillone (33 mg, 2×10 −4 mol) and wet Raney Ni 4200 (12 mg, 2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 30 mg of a reaction mixture which is, according to analysis by HNMR, only non-aromatic compounds 4-ethylcyclohexan-1-ol. The ketone/aromatic ring was reduced.
Example 15
Reaction of 2-phenoxy-1-phenylethan-1-ol
[0081] 2-phenoxy-1-phenylethan-1-ol (30 mg, 1.4×10 −4 mol) and wet Raney Ni 4200 (25 mg, 4.2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 25 mg of a reaction mixture which is, according to analysis by HNMR, 1-cyclohexylethan-1-ol. The β-O-4 bond was broken and the aromatic ring was saturated.
Example 16
Reaction of 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol
[0082] 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol (30 mg, 1.4×10 −4 mol) and wet Raney Ni 4200 (25 mg, 4.2×10 −4 mol, 100 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 25 mg of a reaction mixture which is, according to analysis by HNMR, is 1-(4-methoxyphenyl)ethan-1-ol and 2-methoxyphenol. The β-O-4 bond was 100% broken.
Example 17
Reaction of 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol
[0083] To a vial was added wet Raney Ni 4200 (8 mg, 7×10 −5 mol, 50 mol %) then 3 mL hexane followed by 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol (38 mg, 1.4×10 −4 mol) and of NaBH 4 (3 mg, 7×10 −5 mol, 50 mol %). The vial was capped and heated to 80° C. for 24 hours. The reaction was cooled, opened and 10 mg of NH 4 COOH was added. 50 mL of Et 2 O was used to transfer the crude to an erlenmeyer containing MgSO 4 . After drying the solution was filtered and concentrated. HNMR gave 63% conversion to 1-(4-methoxyphenyl)ethan-1-one and 1-(4-methoxyphenyl)ethan-1-ol in a ratio 3:7. 63% of the β-O-4 bond was broken.
Example 18
Reaction of 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol
[0084] To a vial was added wet Raney Ni 4200 (8 mg, 7×10 −5 mol, 50 mol %), then 3 mL degassed hexane followed by 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol (38 mg, 1.4×10 −4 mol). The vial was capped and heated to 80° C. for 24 hours. The reaction was cooled, opened and 10 mg of NH 4 COOH was added. 50 mL of Et 2 O was used to transfer the crude to an erlenmeyer containing MgSO 4 . After drying the solution was filtered and concentrated. HNMR gave 88% conversion to 1-(4-methoxyphenyl)ethan-1-one and only traces of 1-(4-methoxyphenyl)ethan-1-ol was detected. 88% of the β-O-4 bond was broken.
Example 19
Reaction of 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol
[0085] Wet Raney Ni 4200 was dried under vacuum and carefully weight (20 mg (dry weight), 3.5×10 −4 mol, 250 mol %). 4 mL degassed heptane was added, followed by 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol (38 mg, 1.4×10 −4 mol). The reaction was heated at 120° C. for 24 hours. Workup: The reaction was cooled, opened and 10 mg of NH 4 COOH was added. 50 mL of Et 2 O was used to transfer the crude to an erlenmeyer containing MgSO 4 . After drying the solution was filtered and concentrated. HNMR gave 100% conversion to 1-(4-methoxyphenyl)ethan-1-one, 100% of the β-O-4 bond was broken.
Example 20
Reaction of 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol
[0086] Wet Raney Ni 4200 was dried under vacuum and carefully weight (39 mg (dry weight), 6.8×10 −4 mol, 150 mol %). 6 mL degassed heptane was added, followed by 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)ethan-1-ol (120 mg, 4.4×10 −4 mol). The reaction was heated at 120° C. for 24 hours. The reaction was cooled, opened and 10 mg of NH 4 COOH was added. 50 mL of Et 2 O was used to transfer the crude to an erlenmeyer containing MgSO 4 . After drying the solution was filtered and concentrated. HNMR gave 38% conversion to 1-(4-methoxyphenyl)ethan-1-one, 38% of the β-O-4 bond was broken.
Example 21
Reaction of Reference Compounds
[0087] 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)propane-1,3-diol (24 mg, 8×10 −5 mol) and wet Raney Ni 4200 (23 mg, 3.9×10 −4 mol, 500 mol %) and KOH (13 mg, 2.4×10 −4 mol, 300%) is weighed into a reaction flask under argon. Degassed MeOH (2 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 10 mg of a reaction mixture which is, according to analysis by HNMR, contains a complex mixture of starting material and decomposition products.
Example 22
Reaction of Reference Compounds
[0088] 2-(2-methoxyphenoxy)-1-(4-methoxyphenyl)propane-1,3-diol (24 mg, 8×10 −5 mol) and wet Raney Ni 4200 (23 mg, 3.9×10 −4 mol, 500 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (2 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 10 mg of a reaction mixture which, according to analysis by HNMR, contains a complex mixture of nonaromatic decomposition products and no starting material.
Example 23
Reaction of Reference Compounds
[0089] 2-(2-hydroxyphenyl)phenol (20 mg, 1.1×10 −4 mol) and wet Raney Ni 4200 (32 mg, 5.4×10 −4 mol, 500 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (2 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 10 mg of a reaction mixture which is, according to analysis by HNMR, contains 2-(2-hydroxycyclohexyl) cyclohexan-1-ol. The aromatic rings were saturated.
Example 24
Reaction of Reference Compounds
[0090] 5-[4-(2H-1,3-benzodioxol-5-yl)-hexahydrofuro[3,4-c]furan-1-yl]-2H-1,3-benzodioxole (38 mg, 1.1×10 −4 mol) and wet Raney Ni 4200 (32 mg, 5.4×10 −4 mol, 500 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (2 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 20 mg of a reaction mixture which, according to analysis by HNMR, contains 4-[4-(3,4-dihydroxycyclohexyl)-hexahydrofuro[3,4-c]furan-1-yl]cyclohexane-1,2-diol. The aromatic rings were saturated.
Example 25
Reaction of Reference Compounds
[0091] Phenoxybenzene (18 mg, 1.1×10 −4 mol) and wet Raney Ni 4200 (32 mg, 5.4×10 −4 mol, 500 mol %) is weighed into a reaction flask under argon. Degassed i-PrOH (2 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 4 hours and the reaction mixture is cooled. Nickel was removed with a magnet. Concentration gave 10 mg of a reaction mixture which is, according to analysis by HNMR, contains cyclohexanol. The aromatic rings were saturated and the ether bond was cleaved.
Example 26
Solvolysis of Lignin Type A
[0092] To 40 mg of Lignin type A under Argon, was added 4 mL degassed EtOH and the reaction was stirred at 120° C. for 50 hours. Solids were visible. The reaction was cooled and the solvent (without solids) was transferred to a clean round bottom flask. The solvent was evaporated to yield 20 mg of product which was dissolved in 1.3 mL of THF, filtered through a syringe-filter into a HPLC-vial. The remaining solid (7 mg) was dissolved in THF, filtered through a syringe-filter into a HPLC-vial. Both are injected into an HPLC-system (GPC).
[0093] See FIG. 1 , Comparison of Lignin type A, solvolysis of Lignin type A and nonsoluble polymer after solvolysis.
Example 27
Reaction of Lignin Type A with Nickel Nanoparticles and Base
[0094] Nickel nanoparticles (4 mg, 7×10 −4 mol, 30 mol %) and Lignin type A (40 mg, 2.2×10-4 mol, 300 mol %), is weighed into a reaction flask under argon. Degassed ethanol (4 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 50 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the reaction mixture is injected into an HPLC-system (GPC).
[0095] See FIG. 2 , Comparison of Lignin type A, solvolysis of Lignin type A, and Lignin type A reacted with Nickel Nanoparticles.
Example 28
Reaction of Lignin Type A with Nickel Nanoparticles and Base
[0096] Nickel nanoparticles (4 mg, 7×10 −4 mol, 30 mol %), NaBH 4 (25 mg, 6.7×10 −4 mol, 300 mol %) and Lignin type A (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed ethanol (4 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 50 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the reaction mixture is injected into an HPLC-system (GPC).
Example 29
Reaction of Lignin Type A with Nickel Nanoparticles and Base
[0097] Nickel nanoparticles (4 mg, 7×10 −4 mol, 30 mol %), KOH (37 mg, 6.7×10 −4 mol, 300 mol %) and Lignin type A (40 mg, 2.2×10-4 mol, dry), is weighed into a reaction flask under argon. Degassed ethanol (4 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 50 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the reaction mixture is injected into an HPLC-system (GPC).
Example 30
Reaction of Lignin Type A with Nickel Nanoparticles and Base
[0098] Nickel nanoparticles (4 mg, 7×10 −4 mol, 30 mol %), K 2 CO 3 (46 mg, 3.3×10 −4 mol, 150 mol %) and Lignin type A (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed ethanol (4 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 50 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the reaction mixture is injected into an HPLC-system (GPC).
[0099] See FIG. 3 , show the results from the reaction mixtures, Lignin type A reacted with NaBH 4 , KOH and K 2 CO 3 .
Example 31
Reaction of Lignin Type A with Nickel Nanoparticles and Hydrogen Peroxide
[0100] Nickel nanoparticles (6 mg, 6×10 −5 mol, 15 mol %) and Lignin type A (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed ethanol (3 mL) is added followed by H 2 O 2 (0.2 mL, 30% in water, 1.78×10 −3 mol, 800%). The flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
Example 32
Reaction of Lignin Type A with Nickel Nanoparticles and Hydrogen Peroxide
[0101] Nickel nanoparticles (16 mg, 2.7×10 −4 mol, 40 mol %) and Lignin type A (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed ethanol (3 mL) is added followed by of H 2 O 2 (0.2 mL, 30% in water, 1.78×10 −3 mol, 800%). The flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
Example 33
Reaction of Lignin Type A with Nickel Nanoparticles and Hydrogen Peroxide
[0102] Nickel nanoparticles (43 mg, 7.3×10 −4 mol, 110 mol %) and Lignin type A (120 mg, 6.7×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed ethanol (3 mL) is added followed by H 2 O 2 (0.3 mL, 30% in water, 2.67×10 −3 mol, 400%). The flask is capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0103] See FIG. 4 , show the results from the reaction mixtures Lignin type A reacted with 6 mg Nickel, 16 mg Nickel and 43 mg Nickel.
Example 34
Reaction of Lignin Type A
[0104] Nickel nanoparticles (3 mg, 6×10 −4 mol, 25 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type A (40 mg, 2.2×10-4 mol, dry), is weighed into a reaction flask under argon. Degassed ethanol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0105] See FIG. 5 , show the results from the reaction mixture.
Example 35
Reaction of Lignin Type B
[0106] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed methanol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0107] See FIG. 6 , show the results from the reaction mixtures
Example 36
Reaction of Lignin Type B
[0108] Nickel nanoparticles (15 mg, 2.4×10 −3 mol, 110 mol %) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed ethanol (3 mL) is added followed by H 2 O 2 (0.2 mL, 30% in water, 1.78×10 −3 mol, 800%). The flask is capped with a rubber septa and the mixture is heated to 80° C. The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
Example 37
Reaction of Lignin Type B
[0109] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 , mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed ethanol (3 mL) is added followed by H 2 O 2 (0.2 mL, 30% in water, 1.78×10 −3 mol, 800%). The flask is capped with a rubber septa and the mixture is heated to 80° C. The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0110] See FIG. 7 , show the results from the reaction mixtures Reaction of Lignin type B with Nickel nanoparticle and Raney Nickel.
Example 38
Reaction of Lignin Type B
[0111] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed methanol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC) and analyzed by 2dNMR (HSQC). The size was reduced and no β-O-4 bonds could be detected.
Example 39
Reaction of Lignin Type B, t-BuOH Effect
[0112] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed methanol/t-BuOH 1:1 (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
Example 40
Reaction of Lignin Type B, t-BuOH Effect
[0113] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed t-BuOH (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0114] See FIGS. 8 to 10 (HSQC) and FIG. 11 show the results from the reaction mixtures (Lignin type B reacted in MeOH, in t-BuOH and in MeOH/t-BuOH 1:1.
Example 41
Reaction of Lignin Type B, i-PrOH
[0115] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed MeOH (3 mL) followed by i-PrOH (0.2 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0116] See FIG. 12 , show the results from the reaction mixtures Lignin type B reacted with MeOH/i-PrOH 16:1.
Example 42
Reaction of Lignin Type B, in MeOH
[0117] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed MeOH (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 50 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
Example 43
Reaction of Lignin Type B, in Glycerol
[0118] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed Glycerol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (150° C.). The reaction is run for 50 hours and the reaction mixture is cooled. MeOH is added and Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0119] See FIG. 13 , show the results from the reaction mixtures (Lignin type B reaction in Glycerol and reaction in MeOH.
Example 44
Reaction of Artificial Polymer
[0120]
[0121] (10 mg, 7×10 −5 mol) and wet Raney Ni 4200 (22 mg, 3.6×10 −4 mol, 500 mol %) and KOH (12 mg, 2.2×10 −4 mol, 300%) is weighed into a reaction flask under argon. Degassed MeOH (1 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0122] See FIG. 14 , show the results from the reaction mixture.
Example 45
Reaction of Artificial Polymer
[0123]
[0124] (12 mg, 7×10 −5 mol) and wet Raney Ni 4200 (22 mg, 3.6×10 −4 mol, 500 mol %) and KOH (12 mg, 2.2×10 −4 mol, 300%) is weighed into a reaction flask under argon. Degassed MeOH (1 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 24 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0125] See FIG. 15 , show the results from the reaction mixtures.
Example 46
Reaction of Lignin Type B
As in Example 38 with Water Wash
[0126] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed methanol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized 3 drops of using concentrated HCl. The solvent is evaporated. 15 mL of water is added, the suspension is sonicated and the solid is filtered off. The solid reaction mixture is again dissolved in MeOH and injected into an HPLC-system (GPC). Analysis gave that water treatment did not change the size of the reacted polymer and that salts can easily be removed.
[0127] See FIG. 16 , show the results from the reaction mixture and the reaction mixture after water treatment.
Example 47
Reaction of Lignin Type B
180° C. in Glycerol
[0128] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed Glycerol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (180° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized 3 drops of using concentrated HCl and injected into an HPLC-system (GPC). 15 mL of water is added, the suspension is sonicated and the solid is filtered off. The solid reaction mixture is again dissolved in MeOH and injected into an HPLC-system (GPC).
[0129] See FIG. 17 , show the results from the reaction mixture, water treated reaction and as a comparison reaction in MeOH.
Example 48
Reaction of Lignin Type C
[0130] Wet Raney Ni 4200 (˜30 mg, 5×10 −4 mol, 500 mol %), KOH (18 mg, 3×10 −4 mol, 300%) and Lignin type C (20 mg, dry), is weighed into a reaction flask under argon. Degassed methanol (1.5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
Example 49
Reaction of Lignin Type C
[0131] Wet Raney Ni 4200 (˜30 mg, 5×10 −4 mol, 500 mol %) and Lignin type C (20 mg, dry), is weighed into a reaction flask under argon. Degassed i-PrOH (1.5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0132] See FIG. 18 , show the results from the reaction mixtures.
Example 50
Reaction of Lignin Type B
In Dioxane/i-PrOH 3:1
[0133] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed Dioxane (3 mL) and i-PrOH (1 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. MeOH is added and Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
Example 51
Reaction of Lignin Type B
In Ethylene Glycol
[0134] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed ethylene glycol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. MeOH is added and Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0135] See FIG. 19 , show the results from the reaction mixtures.
Example 52
Reaction of Lignin Type B
[0136]
[0000]
Ni/KOH/MeOH
Ni/MeOH
MeOH
KOH/MeOH
Ni/Et 3 N/MeOH
Rank 1
Rank 2
Rank 5
Rank 3
Rank 4
[0137] Omitting reagents as in table above. Procedure as follows: Lignin type B (40 mg, 2.2×10 −4 mol, dry), wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 7×10 −4 mol, 300%) or alternatively Et 3 N (94 μL, 7×10 −4 mol, 300%) is weighed into a reaction flask under argon. Degassed MeOH (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. MeOH is added and Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0138] See FIG. 20 , show the results from the reaction mixtures.
Example 53
Reaction of Lignin Type A
[0139]
[0000]
Ni/KOH/MeOH
Ni/MeOH
MeOH
KOH/MeOH
Ni/Et 3 N/MeOH
Rank 1
Rank 2
Rank 2
Rank 2
Rank 2
[0140] Omitting reagents as in table above. Procedure as follows: Lignin type A (40 mg, 2.2×10 −4 mol, dry), wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 7×10 −4 mol, 300%) or alternatively Et 3 N (94 μL, 7×10 −4 mol, 300%) is weighed into a reaction flask under argon. Degassed MeOH (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. MeOH is added and Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0141] See FIG. 21 , show the results from the reaction mixtures.
Example 54
Reaction of Lignin Type B
[0142] Lignin type B (40 mg, 2.2×10 −4 mol, dry), wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), base (7×10 −4 mol, 300%) [Bases used: NaOH (27 mg), K 2 CO 3 (92 mg), NaBH 4 (25 mg), NH 4 COOH (42 mg)] is weighed into a reaction flask under argon. Degassed MeOH (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. MeOH is added and Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
[0143] See FIG. 22 , show the results from the reaction mixtures.
Example 55
Reaction of Lignin Type D
[0144] Lignin type D (80 mg, 4.4×10 −4 mol, dry), wet Raney Ni 4200 (˜140 mg, 2×10 −3 mol, 500 mol %), KOH (74 mg, 1.4×10 −3 mol, 300%) is weighed into a reaction flask under argon. Degassed MeOH (6 mL) and water (2 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with magnet, and the reaction was neutralized with 2 drops of concentrated HCl. The mixture was concentrated, washed with 10 mL of water and dried. 30 mg of a solid was collected. The solid was dissolved in THF/MeOH 1:1 and the mixture was injected into an HPLC-system (GPC). The starting material is not soluble in THF but soluble in water and cannot be analyzed in the GCP. After the reaction a THF soluble solid was collected in 38% yield.
[0145] See FIG. 23 , show the results from the reaction mixtures.
[0146] See FIG. 24 , compares different lignin sources. Lignin type A, Lignin type B. Lignin type C.
Example 57
2-phenoxy-1-phenylethanol
[0147] Nickel on carbon (50 mg, 20×10 −4 mol, 10 mol %) is weighed into a reaction flask. Isopropanol (4 mL) and 2-phenoxy-1-phenylethanol (1.6×10 −4 mol, 34 mg), is added and the flask capped with a rubber septa and the mixture is heated (80° C.). The reaction is run for 4 hours and the reaction mixture is filtered. The solvents are evaporated and the product is purified by column chromatography. The product acetophenone and phenol was analyzed by 1 H NMR and produced in 80% yield.
Example 58
Reaction of Lignin Type B in Glycerol at 180° C. for 60 min
[0148] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed methanol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (180° C.). The reaction is run for 60 minutes and the reaction mixture is cooled. The reaction is diluted with MeOH/THF, the mixture was neutralized and nickel was removed with a magnet. The reaction mixture is injected into an HPLC-system (GPC). The results showed that the reaction was fully completed.
Example 59
Reaction of Lignin Type B at 45° C.
[0149] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed methanol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (45° C.). The reaction is run for 50 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC). The results showed that the reaction had gone half way.
Example 60
Reaction of Lignin Type C with Pd/C
[0150] Pd/C (5 wt %) (0.027 g, 5 mol %), NH 4 HCO 2 (0.064 g, 1.0 mmol) and lignin type C (0.050 g, 0.252 mmol) were added to a 5 mL vial. The vial was sealed and 2.4 mL of ethyl acetate and 0.6 mL of water were added via syringe. Another needle was inserted through a septum to release pressure during the solvent addition. The needle was removed and the vial was placed in a preheated oil bath (120° C.) with a stirring speed of 1000 rpm for 24 h. The vial was cooled to room temperature and then formic acid (20 μL, 0.5 mmol) was added via syringe and the reaction was run for 12 h. The vial was cooled to room temperature and reaction mixture was filtrated through a filter paper, using acetone (10 mL) following by ethanol (10 mL) as eluent. Solvent was removed in vaccuo and the crude oil was co-evaporated two times with 15 mL of ethanol (99.5%). The oil obtained was analyzed by 2D NMR (HSQC). The reaction mixture is injected into an HPLC-system (GPC).
Example 61
Reaction of Lignin Type B at 120° C. for 60 min
[0151] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type B (40 mg, 2.2×10 −4 mol, dry), is weighed into a reaction flask under argon. Degassed methanol (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (45° C.). The reaction is run for 50 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
Example 62
Reaction of Lignin Type E
[0152] Lignin type E (40 mg, 2.2×10 −4 mol, dry), wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 0.7×10 −3 mol, 300%) is weighed into a reaction flask under argon. Degassed MeOH (3 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with magnet, and the reaction was neutralized with 2 drops of concentrated HCl. The product was mostly not dissolved in THF/MeOH 1:1 but the soluble mixture was injected into an HPLC-system (GPC). The starting material is not soluble in THF but soluble in water and cannot be analyzed in the GCP. After the reaction a THF soluble solid was collected in 5% yield.
Example 63
Reaction of Lignin Type C with Pd/C
[0153] Pd/C (5 wt %) (0.054 g, 0.02 mmol, 10 mol %), KOH (0.037 g, 0.67 mmol, 300 mol %) and lignin type B (0.040 g, 0.22 mmol) were added to a 5 mL vial. The vial was sealed and 3 mL of MeOH were added. The vial was placed in a preheated oil bath (120° C.) and the reaction was run for 12 h. The vial was cooled to room temperature and reaction mixture was filtrated through a filter paper, using THF/MeOH. The reaction mixture is injected into an HPLC-system (GPC).
Example 64
Reaction of Lignin Type C in Acetone
[0154] Wet Raney Ni 4200 (˜30 mg, 5×10 −4 mol, 500 mol %) and Lignin type C (20 mg, dry), is weighed into a reaction flask under argon. Degassed acetone (5 mL) is added and the flask is capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture is cooled. Nickel was removed with a magnet, and the mixture is neutralized. The reaction mixture is injected into an HPLC-system (GPC).
Example 64
Reaction of Lignin Type C, Water Wash and a Second Reduction Step
[0155] Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %), KOH (37 mg, 6.7×10 −4 mol, 300%) and Lignin type C (40 mg, 2.2×10 −4 mol, dry), was weighed into a reaction flask under argon. Degassed methanol (3 mL) is added and the flask was capped with a rubber septa and the mixture is heated (120° C.). The reaction was run for 18 hours and the reaction mixture was cooled. Nickel was removed with a magnet, and the mixture was neutralized using 3 drops of concentrated HCl. The solvent was evaporated. 15 mL of water was added, the suspension was sonicated and the solid was filtered off. The solid reaction mixture was again dissolved in MeOH and injected into a HPLC-system (GPC).
[0156] See FIG. 25 , show the results from the reaction mixture after water treatment.
[0157] The product (Prod 1) obtained above was dissolved in 3 mL degassed isopropanol and again Wet Raney Ni 4200 (˜70 mg, 1×10 −3 mol, 500 mol %) was added. The flask was capped with a rubber septa and the mixture is heated (120° C.). The reaction is run for 18 hours and the reaction mixture was cooled. Nickel was removed with a magnet. The solvent was evaporated, giving a second product mixture (Prod 2). The reaction mixture was again dissolved in THF and injected into an HPLC-system (GPC). Analysis gave a very weak signal. NMR (HSQC) analysis showed that most of the aromatic protons had disappeared and new CH2 signals had appeared, FIG. 26 . Benzene rings present in lignin type C is reduced to cyclohexanes. | The present invention relates to a method of cleaving a β-O-4 bond to the corresponding C—H bond in a substrate, by use of a hydrogen donor and a metal catalyst in a solvent. Thereby it is possible to depolymerize a polymer having a repeating β-O-4 bond. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to co-pending U.S. patent application Ser. No. 11/285,945, filed Nov. 23, 2005 by Nerheim, which is a continuation of U.S. patent application Ser. No. 10/447,447, filed May 29, 2003 by Nerheim, incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to electronic disabling devices, and more particularly, to electronic disabling devices with time monitoring.
BACKGROUND OF THE INVENTION
[0003] The original stun gun was invented in the 1960's by Jack Cover. Such prior art stun guns incapacitated a target by delivering a sequence of high voltage pulses into the skin of a subject such that the current flow through the subject essentially “short-circuited” the target's neuromuscular system causing a stun effect in lower power systems and involuntary muscle contractions in more powerful systems. Stun guns, or electronic disabling devices, have been made in two primary configurations. A first stun gun design requires the user to establish direct contact between the first and second stun gun output electrodes and the target. A second stun gun design operates on a remote target by launching a pair of darts which typically incorporate barbed pointed ends. The darts either indirectly engage the clothing worn by a target or directly engage the target by causing the barbs to penetrate the target's skin. In most cases, a high impedance air gap exists between one or both of the first and second stun gun electrodes and the skin of the target because one or both of the electrodes contact the target's clothing rather than establishing a direct, low impedance contact point with the target's skin.
[0004] One of the most advanced existing stun guns incorporates the circuit concept illustrated in the FIG. 1 schematic diagram. Closing safety switch S 1 connects the battery power supply to a microprocessor circuit and places the stun gun in the “armed” and ready to fire configuration. Subsequent closure of the trigger switch S 2 causes the microprocessor to activate the power supply which generates a pulsed voltage output on the order of 2000 volts which is coupled to charge an energy storage capacitor up to the 2000 volt power supply output voltage. Spark gap “GAP 1 ” periodically breaks down, causing a high current pulse through transformer T 1 which transforms the 2000 volt input into a 50,000 volt output pulse.
[0005] TASER International of Scottsdale, Ariz., the assignee of the present invention, has for several years manufactured sophisticated stun guns of the type illustrated in the FIG. 1 block diagram designated as the TASER® Model M18 and Model M26 stun guns. High power stun guns such as these TASER International products typically incorporate an energy storage capacitor having a capacitance rating of from 0.2 microfarads at 2000 volts on a light duty weapon up to 0.88 microfarads at 2000 volts as used on the TASER M18 and M26 stun guns.
[0006] After the trigger switch S 2 is closed, the high voltage power supply begins charging the energy storage capacitor up to the 2000 volt power supply peak output voltage. When the power supply output voltage reaches the 2000 voltage spark gap breakdown voltage. A spark is generated across the spark gap designated as “GAP 1 .” Ionization of the spark gap reduces the spark gap impedance from a near infinite impedance to a near zero impedance and allows the energy storage capacitor to almost fully discharge through step up transformer T 1 . As the output voltage of the energy storage capacitor rapidly decreases from the original 2000 volt level to a much lower level, the current flow through the spark gap decreases toward zero causing the spark gap to deionize and to resume its open circuit configuration with a near infinite impedance. This “reopening” of the spark gap defines the end of the first 50,000 volt output pulse which is applied to output electrodes designated in FIG. 1 as “E 1 ” and “E 2 .” A typical stun gun of the type illustrated in the FIG. 1 circuit diagram produces from 5 to 20 pulses per second.
[0007] Because a stun gun designer must assume that a target may be wearing an item of clothing such as a leather or cloth jacket which functions to establish a ¼ inch to 1 inch air gap between stun gun electrodes E 1 and E 2 and the target's skin, stun guns have been required to generate 50,000 volt output pulses because this extreme voltage level is capable of establishing an arc across the high impedance air gap which may be presented between the stun gun output electrodes E 1 and E 2 and the target's skin. As soon as this electrical arc has been established, the near infinite impedance across the air gap is promptly reduced to a very low impedance which allows current to flow between the spaced apart stun gun output electrodes E 1 and E 2 and through the target's skin and intervening tissue regions. By generating a significant current flow within the target across the spaced apart stun gun output electrodes, the stun gun essentially short circuits the target's electromuscular control system and induces severe muscular contractions. With high power stun guns, such as the TASER M18 and M26 stun guns, the magnitude of the current flow across the spaced apart stun gun output electrodes causes numerous groups of skeletal muscles to rigidly contract. By causing high force level skeletal muscle contractions, the stun gun causes the target to lose its ability to maintain an erect, balanced posture. As a result, the target falls to the ground and is incapacitated.
[0008] The “M26” designation of the TASER stun gun reflects the fact that, when operated, the TASER M26 stun gun delivers 26 watts of output power as measured at the output capacitor. Due to the high voltage power supply inefficiencies, the battery input power is around 35 watts at a pulse rate of 15 pulses per second. Due to the requirement to generate a high voltage, high power output signal, the TASER M26 stun gun requires a relatively large and relatively heavy 8 AA cell battery pack. In addition, the M26 power generating solid state components, its energy storage capacitor, step up transformer and related parts must function either in a high current relatively high voltage mode (2000 volts) or be able to withstand repeated exposure to 50,000 volt output pulses.
[0009] At somewhere around 50,000 volts, the M26 stun gun air gap between output electrodes E 1 and E 2 breaks down, the air is ionized, a blue electric arc forms between the electrodes and current begins flowing between electrodes E 1 and E 2 . As soon as stun gun output terminals E 1 and E 2 are presented with a relatively low impedance load instead of the high impedance air gap, the stun gun output voltage will drop to a significantly lower voltage level. For example, with a human target and with about a 10-inch probe to probe separation, the output voltage of a TASER Model M26 might drop from an initial high level of 50,000 volts to a voltage on the order of about 5,000 volts. This rapid voltage drop phenomenon with even the most advanced conventional stun guns results because such stun guns are tuned to operate in only a single mode to consistently create an electrical arc across a very high, near infinite impedance air gap. Once the stun gun output electrodes actually form a direct low impedance circuit across the spark gap, the effective stun gun load impedance decreases to the target impedance-typically on the order of 1000 ohms or less. A typical human subject frequently presents a load impedance on the order of about 200 ohms.
[0010] Conventional stun guns have by necessity been designed to have the capability of causing voltage breakdown across a very high impedance air gap. As a result, such stun guns have been designed to produce a 50,000 to 60,000 volt output. Once the air gap has been ionized and the air gap impedance has been reduced to a very low level, the stun gun, which has by necessity been designed to have the capability of ionizing an air gap, must now continue operating in the same mode while delivering current flow or charge across the skin of a now very low impedance target. The resulting high power, high voltage stun gun circuit operates relatively inefficiently yielding low electro-muscular efficiency and with high battery power requirements.
DESCRIPTION OF THE DRAWING
[0011] The invention is pointed out with particularity in the appended claims. However, other objects and advantages together with the operation of the invention may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein:
[0012] FIG. 1 illustrates a high performance prior art stun gun circuit.
[0013] FIG. 2 represents a block diagram illustration of one embodiment of the present invention.
[0014] FIG. 3A represents a block diagram illustration of a first segment of the system block diagram illustrated in FIG. 2 which functions during a first time interval.
[0015] FIG. 3B represents a graph illustrating a generalized output voltage waveform of the circuit element shown in FIG. 3A .
[0016] FIG. 4A illustrates a second element of the FIG. 2 system block diagram which operates during a second time interval.
[0017] FIG. 4B represents a graph illustrating a generalized output voltage waveform for the FIG. 4A circuit element during the second time interval.
[0018] FIG. 5A illustrates a high impedance air gap which may exist between one of the electronic disabling device output electrodes and spaced apart locations on a target illustrated by the designations “E 3 ,” “E 4 ,” and an intervening load Z LOAD .
[0019] FIG. 5B illustrates the circuit elements shown in FIG. 5A after an electric spark has been created across electrodes E 1 and E 2 which produces an ionized, low impedance path across the air gap.
[0020] FIG. 5C represents a graph illustrating the high impedance to low impedance configuration charge across the air gap caused by transition from the FIG. 5A circuit configuration into the FIG. 5B (ionized) circuit configuration.
[0021] FIG. 6 illustrates a graphic representation of a plot of voltage versus time for the FIG. 2 circuit diagram.
[0022] FIG. 7 illustrates a pair of sequential output pulses corresponding to two of the output pulses of the type illustrated in FIG. 6 .
[0023] FIG. 8 illustrates a sequence of two output pulses.
[0024] FIG. 9 represents a block diagram illustration of a more complex version of the FIG. 2 circuit where the FIG. 9 circuit includes a third capacitor.
[0025] FIG. 10 represents a more detailed schematic diagram of the FIG. 9 circuit.
[0026] FIG. 11 represents a simplified block diagram of the FIG. 10 circuit showing the active components during time interval T 0 to T 1 .
[0027] FIGS. 12A and B represent timing diagrams illustrating the voltages across capacitor C 1 , C 2 and C 3 during time interval T 0 to T 1 .
[0028] FIG. 13 illustrates the operating configuration of the FIG. 11 circuit during the T1 to T2 time interval.
[0029] FIGS. 14A and B illustrate the voltages across capacitors C 1 , C 2 and C 3 during the T1 to T2 time interval.
[0030] FIG. 15 represents a schematic diagram of the active components of the FIG. 10 circuit during time interval T 2 to T 3 .
[0031] FIG. 16 illustrates the voltages across capacitors C 1 , C 2 and C 3 during time interval T 2 to T 3 .
[0032] FIG. 17 illustrates the voltage levels across Gap 2 and E 1 to E 2 during time interval T 2 to T 3 .
[0033] FIG. 18 represents a chart indicating the effective impedance of GAP 1 and GAP 2 during the various time intervals relevant to the operation of the present invention.
[0034] FIG. 19 represents an alternative embodiment of the invention which includes only a pair of output capacitors C 1 and C 2 .
[0035] FIG. 20 represents another embodiment of the invention including an alternative output transformer designer having a single primary winding and a pair of secondary windings.
[0036] FIG. 21 illustrates a preferred embodiment of the microprocessor section of the present invention.
[0037] FIG. 22 represents an electrical schematic diagram of the system battery module.
[0038] FIG. 23 and FIG. 24 taken together illustrate one preferred embodiment of a high voltage power supply according to the present invention.
[0039] FIG. 25 represents an alternative embodiment of the portion of the power supply illustrated in FIG. 24 .
[0040] FIG. 26 represents a timing diagram illustrating the variable output cycle feature of one embodiment of the present invention.
[0041] FIG. 27 represents a battery consumption table.
[0042] FIG. 28 represents a view from the side of one embodiment of a stun gun incorporating the present invention.
[0043] FIG. 29 represents a view from below of the stun gun illustrated in FIG. 28 .
[0044] FIG. 30 represents a partially cutaway side view of the stun gun illustrated in FIG. 28 , particularly illustrating the shape and configuration of the removable battery module.
[0045] FIG. 31 illustrates a view from above of the battery module illustrated in FIG. 30 .
[0046] FIG. 32 illustrates a partially cutaway view from below of the stun gun shown in FIG. 28 where the battery module has been removed.
[0047] FIG. 33 represents a view from the left side of the stun gun depicted in FIG. 28 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0048] In order to better illustrate the advantages of the invention and its contributions to the art, a preferred embodiment of the invention will now be described in detail.
[0049] Referring now to FIG. 2 , an electronic disabling device for immobilizing a target according to the present invention includes a power supply, first and second energy storage capacitors, and switches S 1 and S 2 which operate as single pole, single throw switches and serve to selectively connect the two energy storage capacitors to down stream circuit elements. The first energy storage capacitor is selectively connected by switch S 1 to a voltage multiplier which is coupled to first and second stun gun output electrodes designated E 1 and E 2 . The first leads of the first and second energy storage capacitors are connected in parallel with the power supply output. The second leads of each capacitor are connected to ground to thereby establish an electrical connection with the grounded output electrode E 2 .
[0050] The stun gun trigger controls a switch controller which controls the timing and closure of switches S 1 and S 2 .
[0051] Referring now to FIGS. 3-8 and FIG. 12 , the power supply is activated at time T 0 . The energy storage capacitor charging takes place during time interval T 0 -T 1 as illustrated in FIGS. 12A and 12B .
[0052] At time T 1 , switch controller closes switch S 1 which couples the output of the first energy storage capacitor to the voltage multiplier. The FIG. 3B and FIG. 6 voltage versus time graphs illustrate that the voltage multiplier output rapidly builds from a zero voltage level to a level indicated in the FIG. 3B and FIG. 6 graphics as “V HIGH ”.
[0053] In the hypothetical situation illustrated in FIG. 5A , a high impedance air gap exists between stun gun output electrode E 1 and target contact point E 3 . The FIG. 5A diagram illustrates the hypothetical situation where a direct contact (i.e., impedance E 2 -E 4 equals zero) has been established between stun gun electrical output terminal E 2 and the second spaced apart contact point E 4 on a human target. The E 1 to E 2 on the target spacing is assumed to equal on the order of 10 inches. The resistor symbol and the symbol Z LOAD represents the internal target resistance which is typically less than 1000 ohms and approximates 200 ohms for a typical human target.
[0054] Application of the V HIGH voltage multiplied output across the E 1 to E 3 high impedance air gap forms an electrical arc having ionized air within the air gap. The FIG. 5C timing diagram illustrates that after a predetermined time during the T1 to T2 high voltage waveform output interval, the air gap impedance drops from a near infinite level to a near zero level. This second air gap configuration is illustrated in the FIG. 5B drawing.
[0055] Once this low impedance ionized path has been established by the short duration application of the V HIGH output signal which resulted from the discharge of the first energy storage capacitor through the voltage multiplier, the switch controller opens switch S 1 and closes switch S 2 to directly connect the second energy storage capacitor across the electronic disabling device output electrodes E 1 and E 2 . The circuit configuration for this second time interval is illustrated in the FIG. 4A block diagram. As illustrated in the FIG. 4B voltage waveform output diagram, the relatively low voltage V LOW derived from the second output capacitor is now directly connected across the stun gun output terminals E 1 and E 2 . Because the ionization of the air gap during time interval T 1 to T 2 dropped the air gap impedance to a low level, application of the relatively low second capacitor voltage “V LOW ” across the E1 to E3 air gap during time interval T 2 to T 3 will allow the second energy storage capacitor to continue and maintain the previously initiated discharge across the arced-over air gap for a significant additional time interval. This continuing, lower voltage discharge of the second capacitor during the interval T 2 to T 3 transfers a substantial amount of target-incapacitating electrical charge through the target.
[0056] As illustrated in FIGS. 4B , 5 C, 6 and 8 , the continuing discharge of the second capacitor through the target will exhaust the charge stored in the capacitor and will ultimately cause the output voltage from the second capacitor to drop to a voltage level at which the ionization within the air gap will revert to the non-ionized, high impedance state causing cessation of current flow through the target.
[0057] In the FIG. 2 block diagram, the switch controller can be programmed to close switch S 1 for a predetermined period of time and then to close switch S 2 for a predetermined period of time to control the T1 to T2 first capacitor discharge interval and the T2 to T3 second capacitor discharge interval.
[0058] During the T3 to T4 interval, the power supply will be disabled to maintain a factory present pulse repetition rate. As illustrated in the FIG. 8 timing diagram, this factory present pulse repetition rate defines the overall T0 to T4 time interval. A timing control circuit potentially implemented by a microprocessor maintains switches S 1 and S 2 in the open condition during the T3 to T4 time interval and disables the power supply until the desired T0 to T4 time interval has been completed. At time T 0 , the power supply will be reactivated to recharge the first and second capacitors to the power supply output voltage.
[0059] Referring now to the FIG. 9 schematic diagram, the FIG. 2 circuit has been modified to include a third capacitor and a load diode (or resistor) connected as shown. The operation of this enhanced circuit diagram will be explained below in connection with FIG. 10 and the related more detailed schematic diagrams.
[0060] Referring now to the FIG. 10 electrical schematic diagram, the high voltage power supply generates an output current I 1 which charges capacitors C 1 and C 3 in parallel. While the second terminal of capacitor C 2 is connected to ground, the second terminal of capacitor C 3 is connected to ground through a relatively low resistance load resistor R 1 or as illustrated in FIG. 9 by a diode. The first voltage output of the high voltage power supply is also connected to a 2000 volt spark gap designated as “GAP 1 ” and to the primary winding of an output transformer having a 1:25 primary to secondary winding step up ratio.
[0061] The second equal voltage output of the high voltage power supply is connected to one terminal of capacitor C 2 while the second capacitor terminal is connected to ground. The second power supply output terminal is also connected to a 3000 volt spark gap designated GAP 2 . The second side of spark gap GAP 2 is connected in series with the secondary winding of transformer T 1 and to stun gun output terminal E 1 .
[0062] In the FIG. 10 circuit, closure of safety switch S 1 enables operation of the high voltage power supply and places the stun gun into a standby/ready to operate configuration. Closure of the trigger switch designated S 2 causes the microprocessor to send a control signal to the high voltage power supply which activates the high voltage power supply and causes it to initiate current flow I 1 into capacitors C 1 and C 3 and current flow 12 into capacitor C 2 . This capacitor charging time interval will now be explained in connection with the simplified FIG. 11 block diagram and in connection with the FIG. 12A and FIG. 12B voltage versus time graphs.
[0063] During the T0 to T1 capacitor charging interval illustrated in FIGS. 11 and 12 , capacitors C 1 , C 2 and C 3 begin charging from a zero voltage up to the 2000 volt output generated by the high voltage power supply. Spark gaps GAP 1 and GAP 2 remain in the open, near infinite impedance configuration because only at the end of the T0 to T1 capacitor charging interval will the C1/C2 capacitor output voltage approach the 2000 volt breakdown rating of GAP 1 .
[0064] Referring now to FIGS. 13 and 14 , as the voltage on capacitors C 1 and C 2 reaches the 2000 volt breakdown voltage of spark gap GAP 1 , a spark will be formed across the spark gap and the spark gap impedance will drop to a near zero level. This transition is indicated in the FIG. 14 timing diagrams as well as in the more simplified FIG. 3B and FIG. 6 timing diagrams. Beginning at time T 1 , capacitor C 1 will begin discharging through the primary winding of transformer T 1 which will rapidly ramp up the E1 to E2 secondary winding output voltage to negative 50,000 volts as shown in FIG. 14B . FIG. 14A illustrates that the voltage across capacitor C 1 relatively slowly decreases from the original 2000 volt level while the FIG. 14B timing diagram illustrates that the multiplied voltage on the secondary winding of transformer T 1 will rapidly build up during the time interval T 1 to T 2 to a voltage approaching minus 50,000 volts.
[0065] At the end of the T2 time interval, the FIG. 10 circuit transitions into the second configuration where the 3000 volt GAP 2 spark gap has been ionized into a near zero impedance allowing capacitors C 2 and C 3 to discharge across stun gun output terminals E 1 and E 2 through the relatively low impedance load target. Because as illustrated in the FIG. 16 timing diagram, the voltage across C 1 will have discharged to a near zero level as time approaches T 2 , the FIG. 15 simplification of the FIG. 10 circuit diagram which illustrates the circuit configuration during the T2 to T3 time interval shows that capacitor C 1 has effectively and functionally been taken out of the circuit. As illustrated by the FIG. 16 timing diagram, during the T 2 to T3 time interval, the voltage across capacitors C 2 and C 3 decreases to zero as these capacitors discharge through the now low impedance (target only) load seen across output terminals E 1 and E 2 .
[0066] FIG. 17 represents another timing diagram illustrating the voltage across GAP 2 and the voltage across stun gun output terminals E 1 and E 2 during the T2 to T3 time interval.
[0067] In one preferred embodiment of the FIG. 10 circuit, capacitor C 1 , the discharge of which provides the relatively high energy level required to ionize the high impedance air gap between E 1 and E 3 , can be implemented with a capacitor rating of 0.14 microfarad and 2000 volts. As previously discussed, capacitor C 1 operates only during time interval T 1 to T 2 which, in this preferred embodiment, approximates on the order of 1.5 microseconds in duration. Capacitors C 2 and C 3 in one preferred embodiment may be selected as 0.02 microfarad capacitors for a 2000 volt power supply voltage and operate during the T 2 to T3 time interval to generate the relatively low voltage output as illustrated in FIG. 4B to maintain the current flow through the now low impedance dart-to-target air gap during the T 2 to T3 time interval as illustrated in FIG. 5C . In this particular preferred embodiment, the duration of the T 2 to T3 time interval approximates 50 microseconds.
[0068] The duration of the T 1 to T2 time interval can be varied from 1.5 to 0.5 microseconds. The duration of the T2 to T3 time interval can be varied from 20 to 200 microseconds. Due to many variables, the duration of the T0 to T1 time interval charge. For example, a fresh battery may shorten the T0 to T1 time interval in comparison to circuit operation with a partially discharged battery. Similarly, operation of the stun gun in cold weather which degrades battery capacity might also increase the T0 to T1 time interval.
[0069] Since it is highly desirable to operate stun guns with a fixed pulse repetition rate as illustrated in the FIG. 8 timing diagram, the circuit of the present invention provides a microprocessor-implemented digital pulse control interval designated as the T3 to T4 interval in FIG. 8 . As illustrated in the FIG. 10 block diagram, the microprocessor receives a feedback signal from the high voltage power supply via a feedback signal conditioning element which provides a circuit operating status signal to the microprocessor. The microprocessor is thus able to detect when time T 3 has been reached as illustrated in the FIG. 6 timing diagram and in the FIG. 8 timing diagram. Since the commencement time T 0 of the operating cycle is known, the microprocessor will maintain the high voltage power supply in a shut down or disabled operating mode from T 3 until the factory preset pulse repetition rate defined by the T0 to T4 time interval has been achieved. While the duration of the T 3 to T4 time interval will vary, the microprocessor will maintain the T0 to T4 time interval constant.
[0070] The FIG. 18 table entitled “Gap On/Off Timing” represents a simplified summary of the configuration of GAP 1 and GAP 2 during the four relevant operating time intervals. The configuration “off” represents the high impedance, non-ionized spark gap state while the configuration “on” represents the ionized state where the spark gap breakdown voltage has been reached.
[0071] FIG. 19 represents a simplified block diagram of a circuit analogous to the FIG. 10 circuit except that the circuit has been simplified to include only capacitors C 1 and C 2 . The FIG. 19 circuit is capable of operating in a highly efficient or “tuned” dual mode configuration according to the teachings of the present invention.
[0072] FIG. 20 illustrates an alternative configuration for coupling capacitors C 1 and C 2 to the stun gun output electrodes E 1 and E 2 via an output transformer having a single primary winding and a center-tapped or two separate secondary windings. The step up ratio relative to each primary winding and each secondary winding represents a ratio of 1:12.5. This modified output transformer still accomplishes the objective of achieving a 1:25 step-up ratio for generating an approximate 50,000 volt signal with a 2000 volt power supply rating. One advantage of this double secondary transformer configuration is that the maximum voltage applied to each secondary winding is reduced by 50%. Such reduced secondary winding operating potentials may be desired in certain conditions to achieve a higher output voltage with a given amount of transformer insulation or for placing less high voltage stress on the elements of the output transformer.
[0073] Substantial and impressive benefits may be achieved by using the electronic disabling device of the present invention which provides for dual mode operation to generate a time-sequenced, shaped voltage output waveform in comparison to the most advanced prior art stun gun represented by the TASER M26 stun gun as illustrated and described in connection with the FIG. 1 block diagram.
[0074] The TASER M26 stun gun utilizes a single energy storage capacitor having a 0.88 microfarad capacitance rating. When charged to 2000 volts, that 0.88 microfarad energy storage capacitor stores and subsequently discharges 1.76 joules of energy during each output pulse. For a standard pulse repetition rate of 15 pulses per second with an output of 1.76 joules per discharge pulse, the TASER M26 stun gun requires around 35 watts of input power which, as explained above, must be provided by a large, relatively heavy battery power supply utilizing 8 series-connected AA alkaline battery cells.
[0075] For one embodiment of the electronic disabling device of the present invention which generates a time-sequenced, shaped voltage output waveform and with a C1 capacitor having a rating of 0.07 microfarads and a single capacitor C 2 with a capacitance of 0.01 microfarads (for a combined rating of 0.08 microfarads), each pulse repetition consumes only 0.16 joules of energy. With a pulse repetition rate of 15 pulses per second, the two capacitors consume battery power of only 2.4 watts at the capacitors (roughly 3.5 to 4 watts at the battery), a 90% reduction, compared to the 26 watts consumed by the state of the art TASER M26 stun gun. As a result, this particular configuration of the electronic disabling device of the present invention which generates a time-sequenced, shaped voltage output waveform can readily operate with only a single AA battery due to its 2.4 watt power consumption.
[0076] Because the electronic disabling device of the present invention generates a time-sequenced, shaped voltage output waveform as illustrated in the FIG. 3B and FIG. 4B timing diagrams, the output waveform of this invention is tuned to most efficiently accommodate the two different load configurations presented: a high voltage output operating mode during the high impedance T 1 to T 2 first operating interval and, a relatively low voltage output operating mode during the low impedance second T 2 to T 3 operating interval.
[0077] As illustrated in the FIG. 5C timing diagram and in the FIGS. 2 , 3 A and 4 A simplified schematic diagrams, the circuit of the present invention is selectively configured into a first operating configuration during the T2 to T1 time interval where a first capacitor operates in conjunction with a voltage multiplier to generate a very high voltage output signal sufficient to breakdown the high impedance target-related air gap as illustrated in FIG. 5A . Once that air gap has been transformed into a low impedance configuration as illustrated in the FIG. 5C timing diagram, the circuit is selectively reconfigures into the FIG. 3A second configuration where a second or a second and a third capacitor discharge a substantial amount of current through the now low impedance target load (typically 1000 ohms or less) to thereby transfer a substantial amount of electrical charge through the target to cause massive disruption of the target's neurological control system to maximize target incapacitation.
[0078] Accordingly, the electronic disabling device of the present invention which generates a time-sequenced, shaped voltage output waveform is automatically tuned to operate in a first circuit configuration during a first time interval to generate an optimized waveform for attacking and eliminating the otherwise blocking high impedance air gap and is then returned to subsequently operate in a second circuit configuration to operate during a second time interval at a second much lower optimized voltage level to efficiently maximize the incapacitation effect on the target's skeletal muscles. As a result, the target incapacitation capacity of the present invention is maximized while the stun gun power consumption is minimized.
[0079] As an additional benefit, the circuit elements operate at lower power levels and lower stress levels resulting in either more reliable circuit operation and can be packaged in a much more physically compact design. In a laboratory prototype embodiment of a stun gun incorporating the present invention, the prototype size in comparison to the size of present state of the art TASER M26 stun gun has been reduced by approximately 50% and the weight has been reduced by approximately 60%.
[0080] An enhanced stun gun one embodiment of which is currently designated as the TASER® X26 system includes a novel battery capacity readout system designed to create a device that is more reliable and dependable in the field. With previous battery operated stun guns, users have experienced major difficulty in determining exactly how much battery capacity remains in the batteries.
[0081] In most electronic devices the remaining battery capacity can be predicted either by measuring the battery voltage during operation or integrating the battery discharge current over time. Because the X26 system draws current at very different rates depending on the mode in which it operates, prior art battery management methods yield unreliable results. Because the X26 system is expected to function over a wide operating temperature range, non-temperature compensated prior art battery capacity prediction methods produce even less reliable results.
[0082] The battery consumption of the X26 system varies with its operating mode as described in Table 1.
[0000]
TABLE 1
Operating
Mode
Battery Consumption
1
The X26 system includes a real time clock
which draws around 3.5 microamps.
2
If the system safety switch is armed, the
now-activated microprocessor and its clock
system draw around 4 milliamps.
3
If enabled, and if the safety switch is armed,
the X26 system laser target designator will
draw around 11 milliamps.
4
If enabled, and if the safety switch is armed,
the forward facing low intensity twin white
LED flashlight will draw around 63
milliamps.
5
If the safety switch is armed and the trigger
is pulled, the X26 system will draw about 3
to 4 amps.
[0083] As evident from the above examples, the minimum to maximum current drain will vary in a ratio of 1,000,000:1.
[0084] To further complicate matters, the capacity of the CR123 lithium batteries packaged in the system battery model varies greatly over the operating temperature range of the X26 system. At −20° C., the X26 dual in-series CR123 battery module can deliver around 100 of the 5-second discharge cycles. At +30° C., the X26 system battery module can deliver around 350 of the 5-second discharge cycles.
[0085] From the warmest to the coldest operating temperature range and from the lowest to the highest battery drain functions, a battery life ratio of around 5,000,000:1 results. Since the wide range in battery drain makes prior art battery prediction methods unreliable, a new battery capacity assessment system was required for the X26 system. The new battery capacity assessment system predicts the remaining battery capacity based on actual laboratory measurements of critical battery parameters under different load and at different temperature conditions. These measured battery capacity parameters are stored electronically as a table ( FIG. 27 ) in an electronic non-volatile memory device included with each battery module. ( FIG. 22 ) As illustrated in FIGS. 21 and 22 and in FIGS. 31 and 32 , appropriate data interface contacts enable the X26 microprocessor to communicate with the table electronically stored in the battery module to predict remaining battery capacity. The X26 system battery module with internal electronic non-volatile memory may be referred to as the Digital Power Magazine (DPM) or simply as the system battery module.
[0086] The data required to construct the data tables for the battery module were collected by operating the various X26 system features at selected temperatures spanning the X26 system operating temperature range while recording the battery performance and longevity at each temperature interval.
[0087] The resulting battery capacity measurements were collected and organized into a tabular spreadsheet of the type illustrated in FIG. 27 . The battery drain parameters for each system feature were calculated and translated into standardized drain values in microamp-hours based on the sensible operating condition of that feature. For example, the battery drain required to keep the clock alive is represented by a number in microamp-hours that totals the current required to keep the clock alive for 24 hours. The battery drain to power up the microprocessor, the forward directed flashlight, and the laser target designator for 1 second are represented by separate table entries with values in microamp-hours. The battery drain required to operate the gun in the firing mode is represented by numbers in microamp-hours of battery drain required to fire a single power output pulse.
[0088] To enable the X26 system to be operated at all various temperatures, while keeping track of battery drain and remaining battery capacity, the total available battery capacity at each incremental temperature was measured. The battery capacity in microamp-hours at 25° C. (ambient) was programmed into the table to represent a normalized 100% battery capacity value. The battery table drain numbers at other temperatures were adjusted to coordinate with the 25° C. total (100%) battery capacity number. For example, since the total battery capacity at −20° C. was measured to approximate 35% of the battery capacity at 25° C., the microamp-hours numbers at −20° C. were multiplied by 1/0.35
[0089] A separate location in the FIG. 27 table is used by the X26 system microprocessor to keep track of used battery capacity. This number is updated every 1 second if the safety selector remains in the “armed” position, and every 24 hours if the safety selector remains in the “safe” position. Remaining battery capacity percentage is calculated by dividing this number by the total battery capacity. The X26 system will display this percentage of battery capacity remaining on the 2-digit Central Information Display (CID) 14 shown in FIG. 33 for 2 seconds each time the weapon is armed. See, for example, the 98% battery capacity read-out depicted in the FIG. 33 X26 system rear view.
[0090] FIG. 22 illustrates the electronic circuit located inside the X26 battery module 12 . As illustrated in the FIG. 22 schematic diagram and in the FIG. 30 view of X26 system 10 , the removable battery module 12 consists of two series-connected, 3-volt CR123 lithium batteries and a nonvolatile memory device. The nonvolatile memory device may take the form of a 24AA128 flash memory which contains 128K bits of data storage. As shown in FIGS. 21 and 22 , the electrical and data interface between the X26 system microprocessor and battery module 12 is established by a 6-pin jack JP1 and provides a 2-line I 2 C serial bus for data transmission purposes.
[0091] While the battery capacity monitoring apparatus and methodology has been described in connection with monitoring the remaining capacity of a battery energized power supply for a stun gun, this inventive feature could readily be applied to any battery powered electronic device which includes a microprocessor, such as cell phones, video camcorders, laptop computers, digital cameras, and PDA's. Each of these categories of electronic devices frequently shift among various different operating modes where each operating mode consumes a different level of battery power. For example, for a cell phone, the system selectively operates in the different power consumption modes described in Table 2.
[0000]
TABLE 2
Operating
Mode
Battery Consumption
1
power off/microprocessor clock on
2
power on standby/receive mode
3
receiving an incoming telephone call and
amplifying the received audio input signal
4
transmit mode generating an RF power
output of about 600 milliwatts
5
ring signal activated in response to an
incoming call
6
backlight “on”
[0092] To implement the present invention in a cell phone embodiment, a battery module analogous to that illustrated in the FIG. 22 electrical schematic diagram would be provided. That module would include a memory storage device such as the element designated by reference number U 1 in the FIG. 22 schematic diagram to receive and store a battery consumption table as illustrated in FIG. 27 . The cell phone microprocessor can then be programmed to read out and display either at power up or in response to a user-selectable request the battery capacity remaining within the battery module or the percentage of used capacity.
[0093] Similar analysis and benefits apply to the application of the battery capacity monitor of the present invention to other applications such as a laptop computer which selectively switches between the different battery power consumption modes described in Table 3.
[0000]
TABLE 3
Operating
Mode
Battery Consumption
1
CPU “on,” but operating in a standby power
conservation mode
2
CPU operating in a normal mode with the
hard drive in the “on” configuration
3
CPU operating in a normal mode with the
hard drive in the “off” configuration
4
CPU “on” and LCD screen also in the “on”
fully illuminated mode
5
CPU operating normally with the LCD
screen switched into the “off” power
conservation configuration
6
modem on/modem off modes
7
optical drives such as DVD or CD ROM
drives operating in the playback mode
8
optical drives such as DVD or CD ROM
drives operating in the record or write mode
9
laptop audio system generating an audible
output as opposed to operating without an
audio output signal
[0094] In each of the cases addressed above, the battery capacity table would be calibrated for each different power consumption mode based on the power consumption of each individual operating element. Battery capacity would also be quantified for a specified number of different ambient temperature operating ranges.
[0095] Tracking the time remaining on the manufacturer's warranty as well as updating and extending the expiration date represents a capability which can also be implemented by the present invention.
[0096] An X26 system embodiment of the present invention is shipped from the factory with an internal battery module 12 (DPM) having sufficient battery capacity to energize the internal clock for much longer than 10 years. The internal clock is set at the factory to the GMT time zone. The internal X26 system electronic warranty tracker begins to count down the factory preset warranty period or duration beginning with the first trigger pull occurring 24 hours or more after the X26 system has been packaged for shipment by the factory.
[0097] Whenever the battery module 12 is removed from the X26 system and replaced 1 or more seconds later, the X26 system will implement an initialization procedure. During that procedure, the 2-digit LED Central Information Display (CID) designated by reference number 14 in FIG. 33 , will sequentially read out a series of 2-digit numbers which represent the data described in Table 4.
[0000]
TABLE 4
Series
Position
Data
1, 2, 3
The first 3 sets of 2-digit numbers represent
the warranty expiration date. The format is
YY/MM/DD.
4, 5, 6
The current time is displayed: YY/MM/DD.
7
The internal temperature in degrees
Centigrade is displayed: XX (negative
numbers are represented by blinking the
number).
8
The software revision is displayed: XX.
[0098] The system warranty can be extended by different techniques including by Internet and by extended warranty battery module. For extending by Internet, the X26 system includes a USB data interface module accessory which is physically compatible with the shape of the X26 system receptacle for battery module 12 . The USB data module can be inserted within the X26 system battery module receptacle and includes a set of electrical contacts compatible with jack JP1 located inside the X26 system battery module housing as illustrated in FIG. 32 . The USB interface module may be electrically connected to a computer USB port which supplies power via jack JP1 to the X26 system. While the USB interface is normally used to download firing data from the X26 system, it can also be used to extend the warranty period or to download new software into the X26 microprocessor system. To update the warranty, the user removes the X26 battery module 12 , inserts the USB module, connects a USB cable to an Internet enabled computer, goes to the www.taser.com website, follows the download X26 system warranty extension instructions, and pays for the desired extended warranty period by credit card.
[0099] For extending by Extended Warranty Battery Module, the system warranty can also be extended by purchasing from the factory a specially programmed battery module 12 having the software and data required to reprogram the warranty expiration data stored in the X26 microprocessor. The warranty extension battery module is inserted into the X26 system battery receptacle. If the X26 system warranty period has not yet expired, the data transferred to the X26 microprocessor will extend the current warranty expiration date by the period pre-programmed into the extended warranty battery module. Once the extended warranty expiration date has been stored within the X26 system, the microprocessor will initiate a battery insertion initialization sequence and will then display the new warranty expiration date. Various different warranty extension modules can be provided to either extend the warranty of only a single X26 system or to provide warranty extensions for multiple system as might be required to extend the warranty for X26 systems used by an entire police department. If the warranty extension module contains only one warranty extension, the X26 microprocessor will reset the warranty update data in the module to zero. The module can function either before or after the warranty extension operation as a standard battery module. An X26 system may be programmed to accept one warranty extension, for example a 1-year extension, each time that the warranty extension module is inserted into the weapon.
[0100] The warranty configuration/warranty extension feature of the present invention could also readily be adapted for use with any microprocessor-based electronic device or system having a removable battery. For example, as applied to a cell phone having a removable battery module, a circuit similar to that illustrated in the FIG. 22 electrical schematic diagram could be provided in the cell phone battery module to interface with the cellular phone microprocessor system. As was the case with the X26 system of the present invention, the cell phone would be originally programmed at the factory to reflect a device warranty of predetermined duration at the initial time that the cell phone was powered up by the ultimate user/customer. By purchasing a specially configured cell phone replacement battery including data suitable for reprogramming the warranty expiration date within the cell phone microprocessor, a customer could readily replace the cell phone battery while simultaneously updating the system warranty.
[0101] Alternatively, a purchaser of an electronic device incorporating the warranty extension feature of the present invention could return to a retail outlet, such as Best Buy or Circuit City, purchase a warranty extension and have the on-board system warranty extended by a representative at that retail vendor. This warranty extension could be implemented by temporarily inserting a master battery module incorporating a specified number of warranty extensions purchased by the retail vendor from the OEM manufacturer. Alternatively, the retail vendor could attach a USB interface module to the customer's cell phone and either provide a warranty extension directly from the vendor's computer system or by means of data supplied by the OEM manufacturer's website.
[0102] For electronic devices utilizing rechargeable battery power supplies such as is the case with cell phones and video camcorders, battery depletion occurs less frequently than with the system described above which typically utilizes non-rechargeable battery modules. For such rechargeable battery applications, the end user/customer could purchase a replacement rechargeable battery module including warranty update data and could simultaneously trade in the customer's original rechargeable battery.
[0103] For an even broader application of the warranty extension feature of the present invention, that feature could be provided to extend the warranty of other devices such as desktop computer systems, computer monitors or even an automobile. For such applications, either the OEM manufacturer or a retail vendor could supply to the customer's desktop computer, monitor or automobile with appropriate warranty extension data in exchange for an appropriate fee. Such data could be provided to the warranted product via direct interface with the customer's product by means of an infrared data communication port, by a hard-wired USB data link, by an IEEE 1394 data interface port, by a wireless protocol such as Bluetooth or by any other means of exchanging warranty extension data between a product and a source of warranty extension data.
[0104] Another benefit of providing an “intelligent” battery module is that the X26 system can be supplied with firmware updates by the battery module. When a battery module with new firmware is inserted into the X26 system, the X26 system microcontroller will read several identification bytes of data from the battery module. After reading the software configuration and hardware compatibility table bytes of the new program stored in the nonvolatile memory within the battery module to evaluate hardware/software compatibility and software version number, a system software update will take place when appropriate. The system firmware update process is implemented by having the microprocessor (see FIG. 21 ) in the X26 system read the bytes in the battery module memory program section and programming the appropriate software into the X26 system nonvolatile program memory.
[0105] The X26 system can also receive program updates through a USB interface module by connecting the USB module to a computer to download the new program to a nonvolatile memory provided within the USB module. The USB module is next inserted into the X26 system battery receptacle. The X26 system will recognize the USB module as providing a USB reprogramming function and will implement the same sequence as described above in connection with X26 system reprogramming via battery module.
[0106] The High Voltage Assembly (HVA) schematically illustrated in FIGS. 23 and 24 converts a 3 to 6 Volt battery level to powerful 50 KV pulses having the capability of instantly incapacitating a subject. To provide maximum safety, to avoid false triggering, and to minimize the risk that the X26 system could activate or stay activated if the microprocessor malfunctions or locks up, the ENABLE signal from the microprocessor ( FIG. 22 ) to the HVA ( FIGS. 23 , 24 ) has been specially encoded.
[0107] To enable the HVA, the microprocessor must output a 500 Hz square wave with an amplitude of 2.5 to 6 volts and around a 50% duty cycle. The D6 series diode within the HVA power supply “rectifies” the ENABLE signal and uses it to charge up capacitor C 6 . The voltage across capacitor C 6 is used to run pulse width modulation (PWM) controller U 1 in the HVA.
[0108] If the ENABLE signal goes low for more than around 1 millisecond, several functions operate to turn the PWM controller off. First, the voltage across capacitor C 6 will drop to a level where the PWM can no longer run causing the HVA to turn off. Second, the input to the U 1 “RUN” pin must be above a threshold level. The voltage level at that point represents a time average of the ENABLE waveform (due to R 1 and C 7 ). If the ENABLE signal goes low, capacitor C 7 will discharge and disable the controller after just over 1 millisecond.
[0109] As the ENABLE signal goes high, resistor R 3 charges capacitor C 8 . If the charge level on C 8 goes above 1.23 Volts, the PWM will shut down—stopping delivery of 50 KV output pulses. Every time the ENABLE signal goes low, capacitor C 8 is discharged, making sure the PWM can stay “on” as the ENABLE signal goes back high and starts charging C 8 again. Any time the ENABLE signal remains high for more than 1 millisecond, the PWM controller will be shut down.
[0110] The encoded ENABLE signal requirements dictate that the ENABLE signal must be pulsed at a frequency of around 500 Hz (1 millisecond high, 1 millisecond low) to activate the HVA. If the ENABLE signal sticks at a high or low level, the PWM controller will shut down, stopping the delivery of the 50 KV output pulses.
[0111] The configuration of the X26 system high voltage output circuit represents a key distinction between the X26 system and conventional prior art stun guns. Referring now to FIGS. 23 and 24 , the structure and function of the X26 system high voltage “shaped pulse” assembly will be explained. The switch mode power supply will charge up capacitors C 1 , C 2 , and C 3 through diodes D 1 , D 2 , and D 3 . Note that diodes D 1 and D 2 can be connected to the same or to different windings of T 1 to modify the output waveform. The ratios of the T 1 primary and secondary windings and the spark gap voltages on GAP 1 , GAP 2 , and GAP 3 are configured so that GAP 1 will always breakover and fire first. When GAP 1 fires, 2 KV is applied across the primary windings of spark coil transformer T 2 from pin 6 to pin 5 . The secondary voltage on spark coil transformer T 2 from pins 1 to 2 and from pins 3 to 4 will approximate 25 KV, depending on the air gap spacing between the two output electrodes E 1 and E 2 . The smaller the air gap, the smaller the output voltage before the air gap across output terminals E 1 to E 2 breaks down, effectively clamping the output voltage level.
[0112] The voltage induced in the secondary current path by the discharge of C 1 through GAP 1 and T 2 sets up a voltage across C 2 , GAP 2 , E 1 to E 2 , GAP 3 , C 3 and C 1 . When the cumulative voltage across the air gaps (GAP 2 , E 1 to E 2 , and GAP 3 ) is high enough to cause them to break down, current will start flowing in the circuit, from C 2 through GAP 2 , through the output electrodes E 1 to E 2 , through GAP 3 , and through C 3 in series with C 1 back to ground. As long as C 1 is driving the output current through GAP 1 and T 2 , the output current as described will remain negative in polarity. As a result, the charge level stored in both C 2 and C 3 will increase. Once C 1 has become somewhat discharged, T 1 will not be able to maintain the output voltage across the output windings (from pin 1 to pin 2 , and from pin 3 to pin 4 ). At that time, the output current will reverse and begin flowing in a positive direction and will begin depleting the charge on C 2 and C 3 . The discharge of C 1 is known as the “arc” phase. The discharge of C 2 and C 3 is known as the muscle “stimulation” phase.
[0113] Since the high voltage output coil T 2 as illustrated in FIG. 24 consists of two separate secondary windings that create a negative polarity spark voltage on E 1 followed by a positive polarity spark voltage on E 2 , the peak voltage measured from either electrode E 1 or E 2 to primary weapon ground will not exceed 25 KV, yet the peak voltage measured across power supply output terminals E 1 and E 2 will reach 50 KV. If the output coil T 2 had utilized only a single secondary winding as is the case with all prior art stun guns and in other embodiments of the present invention, the maximum voltage from one output electrode (E 1 or E 2 ) referenced to primary weapon ground would reach 50 KV. Since a 25 KV output can establish an arc across a gap less than half the size of a gap that can establish an arc with a 50 KV output, reducing the peak output terminal to ground voltage by 50% from 50 KV to 25 KV reduces by more than a 2:1 ratio the risk that the user of this version of the X26 system will be shocked by the high voltage output pulses. This represents a significant safety enhancement for a handheld stun gun weapon.
[0114] Referring now to the FIGS. 23 and 24 schematic diagrams, a feedback signal from the primary side of the HVA (T1 pin 8 ) provides a mechanism for the FIG. 21 microprocessor to indirectly determine the voltage on capacitor C 1 , and hence where the X26 system power supply is operating within its pulse firing sequence. This feedback signal is used by the microprocessor to control the output pulse repetition rate.
[0115] The system pulse rate can be controlled to create either a constant or a time-varying pulse rate by having the microcontroller stop toggling the ENABLE signal for short time periods, thereby holding back the pulse rate to reach a preset, lower value. The preset values can changed based on the length of the pulse train. For example, in a police model, the system could be preprogrammed such that a single trigger pull will produce a 5-second long power supply activation period. For the first 2 seconds of that 5-second actuation period the microprocessor could be programmed to control (pull back) the pulse rate to 19 pulses per second (pps), while for the last 3 seconds of the 5-second activation period the pulse rate could be programmed to be reduced to 15 pps. If the operator continues to hold the trigger down, after the 5-second cycle has been completed, the X26 system could be programmed to continue discharging at 15 pps for as long as the trigger is held down. The X26 system could alternatively be programmed to produce various different pulse repetition rate configurations as described, for example, in Table 5.
[0000]
TABLE 5
Operating
Duration
Pulse Repetition Rate
(Seconds)
(Pulses Per Second)
0-2
17
2-5
12
5-6
0.1
6-12
11
12-13
0.1
13-18
10
18-19
0.1
19-23
9
[0116] Such alternative pulse repetition rate configurations could be applied to a civilian version of the X26 system where longer activation periods are desirable. In addition, lowering the pulse rate will reduce battery power consumption, extend battery life, and potentially enhance the medical safety factor.
[0117] To explain the operation of the X26 system illustrated in FIGS. 21-24 in more detail, the operating cycle of the HVA can be divided into the following four time periods as illustrated in FIG. 26 .
[0118] For the first time period, T 0 to T 1 , capacitors C 1 , C 2 and C 3 are charged by one, two or three power supplies to the breakdown voltage of spark gap GAP 1 .
[0119] For the second time period, T 1 to T 2 , GAP 1 has switched ON, allowing C 1 to pass a current through the primary winding of the high voltage spark transformer T 2 which causes the secondary voltage (across E 1 to E 2 ) to increase rapidly. At a certain point, the high output voltage caused by the discharge of C 1 through the primary transformer winding will cause voltage breakdown across GAP 2 , across E 1 to E 2 , and across GAP 3 . This voltage breakdown completes the secondary circuit current path, allowing output current to flow. During the T1 to T2 time interval, capacitor C 1 is still passing current through the primary winding of the spark transformer T 2 . As C 1 is discharging, it drives a charging current into both C 2 and C 3 .
[0120] For the third time period, T 2 to T 3 , capacitor C 1 is now mostly discharged. The load current is being supplied by C 2 and C 3 . The magnitude of the output current during the T2 to T3 time interval will be much lower than the much higher output current produced by the discharge of C 1 through spark transformer T 2 during the initial T 1 to T 2 current output time interval. The duration of this significantly reduced magnitude output current during time interval T 2 to T 3 may readily be tuned by appropriate component parameter adjustments to achieve the desired muscle response from the target subject.
[0121] Finally, during the time period T 0 through T 3 , the microprocessor measured the time required to generate a single shaped waveform output pulse. The desired pulse repetition rate was pre-programmed into the microprocessor. During the fourth time period, the T3 to T4 time interval, the microprocessor will temporarily shut down the power supply for a period required to achieve the preset pulse repetition rate. Because the microprocessor is inserting a variable length T 3 to T 4 shut-off period, the system pulse repetition rate will remain constant independent of battery voltage and circuit component variations (tolerance). The microprocessor-controlled pulse rate methodology allows the pulse rate to be software controlled to meet different customer requirements.
[0122] The FIG. 26 timing diagram shows an initial fixed timing cycle TA followed by a subsequent, longer duration timing cycle TB. The shorter timing cycle followed by the longer timing cycle reflects a reduction in the pulse rate. Hence, it is understood that the X26 system can vary the pulse rate digitally during a fixed duration operating cycle. As an example, a 19 pps pulse rate can be achieved during the first 2 seconds of operation and then reduced to 15 pps for 3 seconds, to 0.1 pps for 1 second, and then increased to 14 pps for 5 seconds, etc.
[0123] The embodiment illustrated in FIGS. 23 and 24 utilizes 3 spark gaps. Only GAP 1 requires a precise break-over voltage rating, in this case 2000 volts. GAP 2 and GAP 3 only require a break-over voltage rating significantly higher than the voltage stress induced on them during the time interval before GAP 1 breaks down. GAP 2 and GAP 3 have been provided solely to ensure that if a significant target skin resistance is encountered during the initial current discharge into the target that the muscle activation capacitors C 2 and C 3 will not discharge before GAP 1 breaks down. To perform this optional, enhanced function, only one of these secondary spark gaps (either GAP 2 or GAP 3 ) need be provided.
[0124] FIG. 25 illustrates a high voltage section with significantly improved efficiency. Instead of rectifying the T1 high voltage transformer outputs through diodes directly to very high voltages, as is the case with the FIG. 24 circuit, transformer T 1 has been reconfigured to provide three series-connected secondary windings (windings 6 - 7 , 8 - 9 and 9 - 10 ) where the design output voltage of each winding has been limited to about 1000 volts.
[0125] In the FIG. 24 circuit, capacitor C 1 is charged directly up to 2000 volts by transformer winding 3 - 4 and diode D 1 . In the FIG. 25 circuit, C 1 is charged by combining the voltages across C 5 and C 6 . Each T1 transformer winding coupled to charge C 5 and C 6 is designed to charge each capacitor to 1000 volts, rather than to 2000 volts as in the FIG. 24 circuit.
[0126] Since the losses due to parasitic circuit capacitances are a function of the transformer AC output voltage squared, the losses due to parasitic circuit capacitances with the FIG. 25 1000 volt output voltage compared to the FIG. 24 2000 volt transformer output voltage are reduced by a factor of 4. Furthermore, in the FIG. 25 embodiment, the current required to charge C 2 is derived in part from capacitor C 6 , the positive side of which is charged to 2 KV. Hence, to charge C 2 to 3 KV, the voltage across transformer winding pins 6 to 7 is reduced to only 1 KV in comparison to the 3 KV level produced across transformer T 1 winding 1 - 2 in the FIG. 24 circuit.
[0127] Another benefit of the novel FIG. 24 and FIG. 25 circuit designs relates to the interaction of C 1 to C 3 . Just before GAP 1 breaks down, the charge on C 1 is 2 KV while the charge on C 3 is 3 KV. After C 1 has discharged and the output current is being supported by C 2 and C 3 , the voltage across C 3 remains at 3 KV. However, since the positive side of C 3 is now at ground level, the negative terminal of C 3 will be at −3 KV. Hence a differential voltage of 6 KV has been created between the positive terminal of C 2 and the negative terminal of C 3 . During the time interval when C 2 and C 3 discharge after C 1 has been discharged, the T 2 output windings merely act as conductors.
[0128] The X26 system trigger position is read by the microprocessor which may be programmed to extend the duration of the operating cycle in response to additional trigger pulls. Each time the trigger is pulled, the microprocessor senses that event and activates a fixed time period operating cycle. After the gun has been activated, the Central Information Display (CID) 14 on the back of the X26 handle indicates how much longer the X26 system will remain activated. The X26 system activation period may be preset to yield a fixed operating time, for example 5 seconds. Alternatively, the activation period may be programmed to be extended in increments in response to additional, sequential trigger pulls. Each time the trigger is pulled, the CID readout 14 will update the countdown timer to the new, longer timeout. The incrementing trigger feature will allow a civilian who uses the X26 system on an aggressive attacker to initiate multiple trigger pulls to activate the gun for a prolonged period, enabling the user to lay the gun down on the ground and get away.
[0129] To protect police officers against allegations of stun gun misuse, the X26 system may provide an internal non-volatile memory set aside for logging the time, duration of discharge, internal temperature and battery level each time the weapon is fired.
[0130] The stun gun clock time always remains set to GMT. When downloading system data to a computer using the USB interface module, a translation from GMT to local time may be provided. On the displayed data log, both GMT and local time may be shown. Whenever the system clock is reset or reprogrammed, a separate entry may be made in the system log to record such changes.
[0131] It will be apparent to those skilled in the art that the disclosed electronic disabling device for generating a time-sequenced, shaped voltage output waveform may be modified in numerous ways and may assume many embodiments other than the preferred forms specifically set out and described above. Accordingly, it is intended by the appended claims to cover all such modifications of the invention which fall within the true spirit and scope of the invention. | An apparatus for impeding locomotion by a human or animal target conducts a current through the target. The apparatus includes a trigger, a circuit, and a display. The trigger provides a signal. The circuit, responsive to the signal, provides the current for an interval as a series of pulses, and that tracks a remaining time of the interval. The display provides a presentation in accordance with the remaining time. The presentation may include a decreasing digital count. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of co-pending U. S. patent application Ser. No. 09/997,661, entitled “Neck Cleaning Method For A CRT” filed on Nov. 29, 2001.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the manufacture of cathode ray tubes and, in particular, to a method of cleaning the neck of a cathode ray tube.
BACKGROUND
[0003] The color cathode ray tube (CRT) typically includes an electron gun, a shadow mask, and a screen. The tube has a funnel shape, i.e., a wide opening that leads to a narrow neck. The electron gun is mounted in the neck of the tube and the screen is mounted proximate to the wide opening of the funnel of the tube. The shadow mask is interposed between the electron gun and the screen. A faceplate is sealed to the wide opening of the funnel. The screen is located on an inner surface of the faceplate of the CRT. The screen has an array of three different color-emitting phosphors (e.g., green, blue and red) formed thereon. The shadow mask functions to direct electron beams generated in the electron gun toward the appropriate color emitting phosphors on the screen of the CRT.
[0004] As part of the manufacturing process for a color CRT, the inside surface of the tube is coated with a conductive coating used to carry high voltage from a location on the side of the tube to the shadow mask. One method of applying the conductive coating is to use a flow coating process. The flow coating process comprises pouring the conductive coating material into the wide opening of the funnel and allowing the material to flow out along the funnel and through the neck of the tube. The material completely coats the funnel and neck. However, to create an operational CRT, the coating cannot extend along the entire neck of the tube. As such, it is necessary to clean the coating from a portion of the neck to a controlled dimension along the neck. The transition from the uncoated to coated portions of the neck must be uniform and the neck should be free of all contaminants.
[0005] Presently, the process for cleaning the neck consists of inserting a multi-blade squeegee into the neck to a predefined distance along the neck. The squeegee is rotated to wipe the coating material from the inner surface of the neck. The problem with this system is that the squeegee wears during use and will ultimately leave streaks of coating material within the neck.
[0006] Therefore, there is a need in the art for a more effective method and apparatus for cleaning the neck of a color CRT.
SUMMARY OF THE INVENTION
[0007] A method of cleaning the neck of a funnel of a CRT during the manufacture thereof. The method comprises: inserting a drain tube within the neck, wherein the outer dimensions of the drain tube are less than the corresponding inner dimensions of the neck and a gap exists between the drain tube and the neck; directing a fluid through the gap; and draining the fluid that was directed through the gap, through the drain tube, whereby the fluid removes material and dirt from the neck.
[0008] The method utilized a cleaning apparatus, wherein the apparatus comprises: a cleaning unit having a housing that surrounds the neck; the drain tube that extends through the bottom of the housing into the neck to a predefined position within the neck which is below the top end of the housing; and a labyrinth flow controller positioned within the housing adjacent to the drain tube forming a laminar flow section whereby a flow of fluid is directed through the housing and along the interior of the neck and into the end of the drain tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will now be described in greater detail, with relation to the accompanying drawing, in which:
[0010] [0010]FIG. 1 is a schematic view of the apparatus for cleaning the neck of a picture tube in accordance with the present invention;
[0011] [0011]FIG. 2 depicts a cross-sectional view of the cleaning unit of the present invention; and
[0012] [0012]FIG. 3 depicts a top plan view of the labyrinth flow controller of FIG. 2.
DETAILED DESCRIPTION
[0013] [0013]FIG. 1 depicts a schematic view of the apparatus for cleaning the neck of a tube of a CRT in accordance with the present invention. The apparatus 100 comprises a warm air source 102 , a mechanism 128 for supporting the funnel 106 , a cleaning fluid source 104 , and a cleaning unit 112 . Prior to being mounted in support mechanism 128 , the funnel 106 is heated to between 50 and 55° C. before being coated with a layer 108 of graphite, iron oxide or other conductive material, along the entire inner surface of the funnel 106 and the neck 114 of the funnel 106 . The coating process is conventional and well known in the art.
[0014] Once coated, the funnel 106 is mounted in the support mechanism 128 before the coating has time to fully cure. The support mechanism 128 generally supports the funnel 106 above the cleaning unit 112 . Since the layer of coating material is not completely cured, the coating material can be removed using a non-caustic cleaning agent such as de-ionized water. The support mechanism 128 is positioned at location 122 above the cleaning unit 112 by a predefined distance 120 . When mounted, the neck 114 is inserted into the cleaning unit 112 . The distance 120 represents the length of the neck 114 that shall remain coated with the conductive coating material. The reference line 124 , which is a predefined position, approximates the location up to where the coating material will be removed. Once the funnel 106 is mounted, a warm air source 102 blows heated air toward the inner surface of the funnel 106 . A conduit 118 directs the warm air toward the neck 114 . Cleaning fluid source 104 provides cleaning fluid through the conduit 110 to the cleaning unit 112 . The flow of cleaning fluid through the cleaning unit 112 causes any dirt and the conductive coating within the neck to be removed (cleaned) completely from the neck and up to the reference line 124 .
[0015] [0015]FIG. 2 depicts a cross-sectional view of the cleaning unit 112 while FIG. 3 depicts a top plan view of the cleaning unit 112 . To best understand the invention, the reader should simultaneously refer to both FIGS. 2 and 3 while reading the following disclosure.
[0016] The cleaning unit 112 comprises a housing 200 , a drain tube 230 and a labyrinth flow controller 201 . The housing 200 comprises a sidewall 203 and a bottom 205 that together define a volume in which the labyrinth flow controller 201 is positioned. The sidewall 203 is substantially cylindrical in the depicted embodiment. However, other embodiments may have non-cylindrical surfaces such as hexagonal or octagonal. The drain tube 230 extends through a bore 210 in the bottom 205 of the housing 200 . The drain tube 230 extends a distance into the volume that is defined by the housing 200 . The end 202 of the drain tube 230 is positioned a distance from the top of the housing 200 such that, as cleaning fluid is added to the volume, fluid will flow into the drain tube 230 before overflowing the top edge 240 of the housing 200 . The end 212 of the drain tube 230 has an inner surface 214 that is contoured to facilitate laminar flow of cleaning fluid over the end 212 into the inner portion 226 of the drain tube 230 .
[0017] The labyrinth flow controller 201 comprises a first baffle 204 and a second baffle 206 . The first baffle 204 is mounted within the housing 200 on standoffs 300 to cause the first baffle 204 to be spaced apart from the second baffle 206 of the housing 200 as shown in FIG. 3. The first baffle 204 extends near the top edge 240 of the housing 200 and stops a distance from the bottom 205 of the housing 200 . The second baffle 206 extends from the bottom 205 of the housing 200 and stops near the end 212 of the drain tube 230 . As such, the baffles 204 and 206 define a first, second and third channels 218 , 220 and 222 , respectively. The channels cause fluid that enters from the conduit 110 to flow downward through the first channel 218 , then up through the second channel 220 , and then through the third channel 222 . When the neck 114 of the tube 106 is inserted into the cleaning unit 112 over the drain tube 230 , a fourth channel 224 is produced that extends from the flare 126 of the neck 114 along the inside of the tube neck 114 to the input end 212 of the drain tube 230 . To enhance the laminar flow of fluid through the labyrinth flow controller 201 , the bottom 205 of the housing 200 is contoured to be sloped, or rounded at location 216 and the fourth channel 224 is caused to be shaped to match the flare 126 of the neck 114 at a second location 208 . Location standoff tabs (not shown in FIG. 2) on the outside surface of the drain tube 230 aids to position the drain tube 230 within the neck to create a desired uniform forth channel 224 between the outside surface of the drain tube 230 and the inside surface of the neck. The position of the drain tube 230 within the neck 114 establishes a distance along the neck 114 where the conductive material is removed. By fixing the distance between the yoke reference line 122 and the input end 212 of the drain tube 230 , the distance 120 along the neck 114 is established.
[0018] Heated dry air is provided through conduit 118 into the neck volume 228 . The heated air dries or cures the conductive coating layer 108 in the neck 114 that is not removed while the uncured conductive coating is removed by the cleaning fluid. (Essentially, a siphon effect is created by the fluid as it drains through the drain tube 230 , thereby helping to draw the heated air downward toward the neck 114 and conductive coating layer 108 .) Typically, deionized water suffices to remove dirt and uncured conductive coatings.
[0019] To insure that the transition from no conductive coating to conductive coating is uniform, the fluid flow through the cleaning unit 112 must have very little turbulence and the flow along the inner surface of the neck 114 of the funnel 106 should substantially be laminar. To facilitate such laminar flow, the forth channel 224 through which the fluid flows along the inside surface of the neck 114 is approximately 0.14 cm. Furthermore, within the forth channel 224 to clean the neck 114 , each sequential channel 218 , 220 , 222 , 224 is provided to create a smooth, uniform, nonturbulent laminar flow.
[0020] The housing 200 and the baffles 204 , 206 of the labyrinth flow controller 201 may be fabricated of plastic, stainless steel, or some other material that is compatible with both the cleaning solution and the conductive material removed from the tube's neck 114 . If the cleaning unit 112 is fabricated of plastic, then the various components of the unit are epoxied to one another to form the depicted cleaning unit 112 . For stainless steel components, the components are welded in a conventional manner to form the cleaning unit 112 . In one embodiment of the invention, the cleaning unit has a diameter of the housing 200 of between 15-20 cm and the unit holds a volume of cleaning fluid of approximately 3 liters.
[0021] In this illustrative unit, the first channel 218 is approximately 3.8 cm wide, the second channel 220 is approximately 1 cm wide, the third channel 222 is approximately 0.45 cm wide, the fourth channel 224 is approximately 0.14 cm and the drain tube 230 has an inner diameter of 1.3 cm.
[0022] While the foregoing is directed to the preferred embodiment of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope of thereof, and the scope thereof is determined by the claims that follow. One skilled in the art can appreciate other embodiments wherein the dimensions of the channels and number of channels could be varied to accommodate differing fluid solutions and differing neck dimensions. | A method of cleaning the neck of a funnel of a CRT during the manufacture thereof. The method comprises: inserting a drain tube within the neck, wherein a gap exists between the drain tube and the neck; directing a fluid through the gap; and draining the fluid that was directed through the gap through the drain tube, whereby the fluid removes material from the neck that was applied during a prior coating process and any dirt. The drain tube is part of a cleaning apparatus that further comprises a housing and a labyrinth flow controller positioned within the housing adjacent to the drain tube forming a laminar flow section whereby fluid is directed through the housing and into the tube. | 7 |
RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 560,357, filed Jul. 31, 1990 now U.S. Pat. No. 5,118,322 of Hall et al entitled "Ozone Decolorization of Garments".
FIELD OF THE INVENTION
The present invention relates to the fading or decolorization of dyes or coloring agents on fabrics. More particularly, the invention is concerned with the decolorization and/or fading of garments containing cellulosic materials which contain an oxidizable dye or coloring agent through the use of oxidizing gases without any substantial deterioration of the garment. The invention is particularly useful in preparing fashion garments such as faded denim blue jeans, and the like, without the use of harsh chemical bleaches or the abrasive effects of stones, pumice, sand or the like.
BACKGROUND OF THE INVENTION
Denim blue jeans which have been faded, "stone-washed", ice washed, or sand blasted to produce a particular appearance are very popular. However, to produce the desired effect it has been necessary to utilize processes which cause substantial deterioration or degradation of the fabric. Bleaching solutions containing chlorine or actual pelleting of the garment with sand or stones to produce a fashion effect causes damage to the fabric which affects its wear life.
The woven goods that are made into denim are typically manufactured from warp yarns (yarns that are in the machine direction on the loom) that have been dyed with Indigo (CI vat blue 1). The crosswise or filling yarns are typically undyed. The yarns are woven in such a way so as to place a high proportion of the colored (blue dyed) yarns on the face of the fabric. This is typically done by weaving the yarns using one of the twill weaves. The result is a fabric which is characteristically known as Blue Jeans when fabricated into garments. It has been discovered that bleaching of the Indigo color by one of a number of techniques can lead to desirable styling effects. Several of the bleaching or decolorizing treatments involves potassium (or sodium) permanganate. This compound is the agent of choice when obtaining staying effects by the acid wash or stone wash technique.
Occasionally, garments which have been treated by these methods undergo yellowing during storage of the garments during warehousing and prior to shipment to the retailer or while in the retailers possession if he stores them for any length of time.
The precise causes for the yellowing phenomena is not known. Several possible causes have been identified to include finishing agents (added to the garment to provide a softer hand etc.), atmospheric pollutants or to degradation products associated with the permanganate reactions which are not properly removed during the treatments among other causes. However, not all garments will be yellowed in a particular lot or shipment. The yellowing phenomena may not manifest itself until after the garments have been stored or shipped to the customer. Most likely the yellowed garments do emanate from a particular laundry cycle or machine; however, after the treated garments are removed from the machine the garments from the affected treatment cycle may then become mixed with those from other machines such that their processing lot identity becomes lost. Usually the contaminated (yellow) garments are returned to the seller or are sold at a considerably reduced price.
Another source of yellowing is the usual type of yellowing that is encountered world wide, that is, in all areas of the world and on all types of fibers. Usually the causative agent works on the fibers themselves or on some material that was either accidentally or deliberately added to the fabric. Some of the factors which are found to cause such yellowing in fabrics or garments are optical brighteners and finishing agents, atmospheric pollutants, sulfides and lignins in paper and cardboard, antioxidants used in packaging materials among others. Perhaps the most common and major cause for yellowing is due to the reaction of antioxidants with oxides of nitrogen to produce yellow compounds. Of these, butylated hydroxytoluene (BHT), is the most common contaminate causing such yellowing. It has been found that as little as 2 ppm of this compound on the fabric or garment can result in significant yellowing. This compound has widespread use in the industry because of its effectiveness, and the fact that it is fairly inexpensive and easy to obtain.
Ozone has been used in the bleaching of cellulosic materials. U.S. Pat. No. 4,283,251 to 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 4,300,367 to Thorsen, which are herewith incorporated by reference, describe a method and an apparatus for treatment of undyed fabrics with a 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, p. 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. The term "fabric" as used herein is meant to include woven and non-woven cloth, knitted fabrics, garments, and the like.
It should be understood that the term "ozone and steam" 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
In accordance with the invention there is provided a process for selectively decolorizing a fabric containing cellulosic material having an oxidizable coloring agent such as a dye, pigment, organic or inorganic residues, and the like. The fabric may comprise cotton, linen, or other bast fibers or rayon alone or in combination with other materials including natural and synthetic fibers, for example, wool, nylon, polyester, and the like.
The oxidizing agent can be gaseous or a liquid or a solid oxidant in a vapor state. Gaseous oxidizing agents include ozone, NO x and SO x . These gases can be used alone, in admixture or diluted with a inert or low reactive gases such as air. The oxidizing gases can be used in combination with steam or in an aqueous system.
The non-gaseous oxidants should be used in a vapor phase, preferably with wetted fabrics. More preferably, the non-gaseous oxidants are used in combination with steam. Hydrogen peroxide solution diluted with steam is a preferred non-gaseous oxidant.
The oxidant, for example, ozone primarily reacts with the colorant on the fabric when the fabric is wet. Therefore, the garment is wetted or treated in a wet state. The water content of the wetted fabric when treated in the vapor phase is preferably about 20 to 40% by weight or higher depending upon the degree of treatment, the type of oxidant and the effect desired. The process may either be batchwise or continuous and is performed in a chamber in which the oxidant is generally present in an amount of about 10 to 100 mg. per liter. The oxidant and the steam are injected into the chamber so as to provide a temperature in the chamber of about 40 to 100° C., preferably 50 to 65° C. In the absence of steam, heating elements in the chamber can be used to maintain the temperature. Any excess oxidant emitted may be recycled back into the chamber or used to treat any effluent of the process.
In accordance with a preferred embodiment of the invention, one or more fabrics having an oxidizable coloring agent which have been treated with an oxidation blocking agent or dyes of different reactivity or sensitivity to an oxidant are placed in an enclosed chamber. The oxidant is emitted into the chamber so as to react with the colorant of the fabric. The concentration of the oxidant in the chamber in a vapor phase is maintained between 10 to 100 mg per liter by monitoring with an ozone photometer. When the fabric reach a predetermined color, that is, the colorant has undergone a desired degree of decoloration with the oxidant whereby a desired color is obtained, the reaction is terminated prior to any substantial reaction of the oxidant with the cellulosic material of the fabric.
According to another embodiment of the invention, a cellulosic fabric with an oxidizable colorant is contacted with ozone or other oxidants with or without steam in an extractor.
Still another embodiment of the invention provides the recycling of the oxidizing gas alone or within a liquid to other steps of the fabric treatment process to either treat the fabric or the effluent to make it environmentally safe.
It is a general object of the invention to fade or decolorize fabrics containing an oxidizable colorant.
It is a further object of the invention to decolorize dyed garments with ozone without degrading the fabric.
It is yet still further object of the invention to selectively and/or evenly decolorize or fade dyed garments to produce fashion garments.
It is another object of the invention to provide garments with different degrees of color by use of dyes of varying ozone sensitivity and/or to provide different levels of colorization throughout the garment.
It is also an object of the invention to either avoid yellowing or to eliminate yellowing in fabrics and garments.
It is yet another object of the invention to recycle the oxidizing agents used in the process to either further treat the fabric or to treat effluent from the process and make it environmentally acceptable.
Other objects and a fuller understanding of the invention will be had by referring to the following description and claims of a preferred embodiment, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of one form of a fabric treatment apparatus of the invention, and,
FIG. 2 is a schematic view of a process of the invention for treating garments.
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 structure of the invention selected for illustration in the drawings and are not intended to define or limit the scope of the invention.
FIG. 1 schematically represents a typical fabric treatment process with several treatment areas which includes the various embodiments of the present invention so as to result in a dyed cellulosic fabric in which undesirable colorants are oxidized and/or the dye is decolorized or faded. The treatment also reduces the yellowing which occurs upon long term storage of the fabric.
As shown, a dyed cellulosic fabric 10 is preferably passed in countercurrent flow through a scouring bath 14 by means of rolls 12 in a continuous process. However, the process may be carried out step-wise or batchwise depending upon the fabric.
The scouring bath 14, which generally comprises a 2 to 10% solution of sodium hydroxide and about 0.1 to 0.5% detergent, is at ambient to elevated temperature (about 100° C.). If desired, an oxidizing gas such as ozone may optionally be added to the bath according to the process.
Following the scouring bath, the fabric is conveyed to a steamer 18 after passage through contact or squeegee rolls 16, 16' and a conveyor roll 17. The treatment in the steamer 18 is usually for a period of about one half hour.
After the steam treatment the fabric is conveyed from the steamer 18 over a conveyor roll 17 to a vacuum or aspirator means 20 for removal of a substantial portion of any residual sodium hydroxide solution. Also, the fabric may be washed with brine or water to remove alkaline residue from the fabric in bath 31.
The fabric 10 can be further steamed in J-box 22 and passed into a wash bath so as to wet the fabric prior to treatment with ozone.
The wet fabric is then passed into an ozone treatment apparatus 26. The length of time that the fabric 10 remains in contact with ozone within the apparatus 26 is dependent upon the purpose of the ozone treatment. A shorter stay of the fabric 10 within the apparatus 26 usually occurs if the ozone treatment is to prevent or remove yellowing. When the fabric 10 is to be faded or decolorized, ozone may be injected into the apparatus 26 together with steam. Excess ozone or ozone and steam may be recycled back into apparatus 26 or sent through line 27 to other treatment areas including the treatment of waste. The recycling is beneficial since excess ozone need not be further treated before passing into the environment and ozone treatment of waste effluent satisfies environmental guidelines.
It is understood that in combination with ozone or in lieu of ozone there may be used other oxidizing gases such as chlorine, nitrous oxides and/or sulfur oxides. For example chlorine when added to water produces hypochlorous acid (HOCl). Even under alkaline conditions a portion of the sodium hypochlorite (NaOCl) exists as the hypochlorous acid. For example in the study by Ridge and Little (J. Text. Inst., 1942, 33T, p. 59) the equilibria at different pH values are governed by the reactions:
HOCl→H.sup.+ +OCl.sup.- and HOCl+H.sup.+ +Cl.sup.- →Cl.sub.2 +H.sub.2 O
The fraction of the hypochlorite existing as free hypochlorous acid increases as the pH falls below 10. At pH of 5, all of the chlorine is in the hypochlorous acid form. Under neutral conditions about 73% exists in this form. Thus, chlorine added to neutral or slightly acidic steam will contain high amounts of oxidant as hypochlorous acid. Areas of the fabric which may need to be protected from the oxidizing effects of the hypochlorous acid can be coated with a preferential reaction product (blocking agent) such as starch. That is, the starch will be preferentially attacked by the hypochlorous acid and the underlying substrate (cotton, rayon etc.) will be protected and not undergo any significant bleaching or decolorization. Also, if the fabric is wet, chlorine gas will primarily react with the water to form HOCl according to the reaction.
H.sub.2 O+Cl.sub.2 →HOCl
and will bleach the fabric only in the wet areas. If dyed wool is to be processed by this method it may be satisfactory to use sulfur dioxide in the steam to achieve the same bleaching effect that chlorine will have on the non-wool garment.
Another oxidant that will be somewhat soluble in the steam is peracetic acid. It is used primarily as a bleaching agent for nylon.
Following treatment with the oxidizing gases the fabric can be further steamed in J-box 28 and passed into the final wash 30 prior to passage for further treatment.
FIG. 2 illustrates the process of the invention in connection with the treatment of garments such as denim jeans. The jeans which have been previously dyed and sized are placed in an abrading and desizing apparatus 40. The desizing and abrasion steps are conventional in the field. Chemicals or enzymes can be used to desize. The abrasion aids in the desizing and in addition provides a fashion look. Addition of ozone in this stage of the process not only aids in desizing but also initiates the start of decolorizing the garment. In some cases only partial desizing may be required since the sizing can act as a blocking agent for the oxidant.
After the abrasion and desizing, the garments are washed in a washer 42 one or more times to remove the sizing and other chemicals. The garments while still wet from the wash can be optionally treated with an ozone blocking agent in apparatus 44. Typically, clay is sprayed onto the garments while still wet so that the clay adheres. Alternatively, the garments could be dried and hydrocarbon oils, greases or waxes are sprayed onto the garments. Masking tape can also be used to provide special effects. Some starch may be left in the garments so as to act as a preferential reaction medium for the ozone.
Preferably, the garments while still wet are placed in an extractor in which an oxidizing gas such as ozone is injected. Preferably, the extractor 46 is provided with a heating means 47 such as steam coils or thermocouples. When steam is injected together with ozone a further heating means is generally not required. The temperature within the chamber is generally about 40° C. to 100° C., preferably, about 50 to 65° C. The ozone in the chamber of the extractor 46 may be monitored with an ozone photometer, such as a Dasibi Model 1003 HC ozone photometer. There are alternative methods for determining the termination or end period for the ozone treatment. One method involves the prior use of test fabrics to determine the operating parameters. Another method which can be used is visual inspection.
It is understood that dry garments may be placed in the ozone chamber and that they are wetted by the steam.
Excess ozone and ozone containing extract can be recycled back into the extractor 46 or through lines 48 and/or 49 to initiate decolorization at an earlier stage. It has been found to be helpful to include ozone in the desizing step when the desizing is performed with a chemical.
The ozone and ozone containing fluid from the extractor can also be used to treat the effluent from the desizing and wash apparatuses 40 and 42 prior to release in the environment.
After the ozone treatment the garment can be washed or post treated to remove the oxidation blocking agents in apparatus 50 and then dried in apparatus 51.
The type of dye used on the garment 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 or blends of cellulose with synthetic fibers that can be used include, 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, Jan. 1980, pp 26/11.
The garments may be treated with one or more dyes. Utilizing dyes of differing degrees of ozone reactivities provides the garment with zones of different appearances or effects. For example, faded, stone washed, ice-washed, sand blasted or mottled effects may be obtained. The same effect can be achieved by utilizing ozone blocking agents. The ozone blocking agents may comprise organic materials such as pearl starch, modified or derivitized starches, hydrocarbon oils, greases or waxes or inorganic materials such as clay. Masking tape, or other coverings may be used. A further alternative method to achieve a special effect is to partially or selectively wet the garment since the ozone-dye reaction effectively takes place where the garment is wet. The ozone generally does not react with the fabric where it is not wet.
The blocking agent can also be any chemical agent which itself is reactive with ozone but prevents or blocks a dye or portion of a dye on the fabric and prevents it from becoming decolorized.
It is understood that the reaction period and amount of ozone utilized is dependent upon different factors. That is, the time and amount of ozone depends upon the effect desired, the type of dye utilized, the temperature, degree of wetness, etc. Longer treatment at lower concentrations of ozone can result in the same effect as a short treatment with a large excess of ozone on the same dyes. Therefore, the sensing of the conditions in the reaction chamber is essential to optimize the present process.
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 on 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.
A garment to be faded, such as denim blue jeans, is generally first laundered to remove any sizing or fashion process coatings or materials which may interfere with the process of the invention. For example starch can act as an ozone blocking agent. The washing operation could include desizing using enzymes, as is common in the industry followed by laundering to cleanse the garment. The garment is then hydroextracted or padded dry so as to remove excess water. The water content of the garment should be about 20-40% by weight. If the garment is not wet, then it can be wetted by water spraying or placing it within a water bath.
The garment is treated with a blocking agent which is determined on the effect desired. For example, if a sand blasted or stone washed effect is desired, the wet garment can be sprayed with clay or some other inorganic powder to act as an ozone blocker. However, if a mottled look is desired, the garment may be treated with a suitable hydrocarbon oil, grease or wax which shields parts of the garment from the effects of ozone in a selected manner. The garment can be printed, the color can be applied by painting or using a mordant.
In lieu of the ozone blocking, special effects can also be achieved by selectively treating the garment with dyes having different degrees of ozone reactivity. The different dyes can be added earlier in the process so that the use of ozone blocking agents becomes optional. The non-reactive or lesser ozone reactive dyes may be applied by spraying, brushing, dipping, or the like in the same manner as placing the oxidation blocking agents. The non-reactive dyes include the pigment colors.
The following example is illustrative of the invention, but is not to be construed as to limiting the scope thereof in any manner. The percentages herein disclosed relate to percent by weight.
EXAMPLE 1
A. A lot of 30 cotton denim blue jeans vat dyed with a blue indigo dye (CI Vat Blue 1) were washed in a standard laundry detergent at 120° F. in a conventional washer which includes a spin extractor. The garments after extraction had a moisture content of about 35% by weight. One half (15) garments were removed and the remaining were treated for 25 minutes in an ozone atmosphere while still in the laundering machine.
All of the garments were dried and stored for six (6) months.
The garments which were not treated with ozone showed significant yellowing. The garments which were post treated with ozone did not show any signs of yellowing.
B. All of the garments which showed yellowing were washed as in Step A and placed in the extractor. After extraction the garments had a moisture content of about 35%. The garments were treated with ozone for twenty five (25) minutes the same as in Step A. The yellow color disappeared.
EXAMPLE 2
The following experiments were performed to determine the degree of degradation of the fabric based on the warp yarn which contains the dye.
Experimental Procedures
Grab Break tests were determined using ASTM Test method D-1682 Five breaks for the warp yarn were made for each sample and averaged. Abrasion tests were determined according to ASTM method D-3885 (stoll flex). Five samples were run and averaged. The fabrics were standard Levi style 501 garments.
Results
The overall results are given in Table 1. A standard ice wash procedure was used as the control.
A. Comparison of Ozone treated fabrics to chlorine treated fabrics.
The results for chlorine (Sodium Hypochloride) treatments are shown both in Table 1. The treatment was done at normal (C1) medium (C2) and high (C3) chlorine contents in order to obtain increasing levels of color removal ranging from a medium blue to white. These treatments were matched to various ozone treatment times needed to achieve the same level of color removal. For example, C1 matched the ozone treatment for 1 hour while C2 matched the ozone treatment for 1.5 hours. No ozone treatment matched the C3 (totally white) jeans which is included for completeness. From the results it is observed that the ozone treated fabrics do not loose as much warp strength as the chlorine bleached fabrics. It is the warp yarns which contain the indigo dye.
B. Ozone Treatments
Fabrics were treated with ozone for 0.5 to 2.0 hours. The test results are given in Table 1 and shown graphically in the attached bar graphs. The fabric color become lighter with increasing time of ozone treatment. The color (dye) level in the garments was monitored by a Bausch and Lomb Color Scan Spectrophotometer.
C. Ozone treatment of an ice washed garment.
An ice washed garment (control) was treated for 15 minutes in an ozone atmosphere (sample 031/4 hr.). Some loss in strength resulted, however, considerable abrasion resistance was restored (See Table 1 or bar graphs). The other surprising result was that the blue shade of the unbleached portion of the ice washed fabric could be further reduced in color to give a shading affect that cannot be achieved by the original ice washing technique. Further, ice washing produces a yellow color (staining) in the white (bleached) regions of the garment which reduces the garment attractiveness. This yellow color (dye) is due to breakdown fragments (compounds) of the indigo dye which remain in the fabric to discolor the white background. The ozone treatment was effective in decolorizing these yellow compounds and gave a superior "white" background to the garments. That is, the ozone treatment corrects a major defect of ice wash treatments.
TABLE 1______________________________________Comparison of strength (Grab Break and Abrasion) forvarious Fabric Treatments Test ResultsTreatment Grab Break (lbs) Abrasion(Cycles) W W______________________________________Ice Washed (Control) 174 5473Ozone (03)0.25 Hrs 139 90140.50 Hrs 224 95271.0 Hrs 245 204281.5 Hrs 195 89062.0 Hrs 174 5588Chlorine(Cl) Medium Blue 225 14080(C2) Light Blue 179 5823(C3) White 143 3266______________________________________
Although the invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. | A process for selectively decolorizing a fabric containing cellulosic material oxidizable colorants which comprises the steps of wetting the fabric and then contacting the wetted fabric with an oxidizing gas or vapor. The contact with the oxidizing gas or vapor is terminated before any substantial degradation of the fabric occurs. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the Korean Application No. P2003-0026744 filed on Apr. 28, 2003, which is hereby incorporated by reference as is fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dryers, and more particularly, to a sensor assembly for determining dryness of a load of wet clothes being dried in an automatic dryer.
2. Background of the Related Art
The automatic dryer dries a wet state drying object (for an example, clothes and the like) having washing thereof completed, automatically. In general, the dryers, having a system for supplying hot air heated by a heater to a drum for drying, are sorted as exhaust type dryers and condensing type dryers.
The exhaust type dryer dries the drying object by discharging air having carried out the drying to have a low temperature and to become humid to an exterior, drawing fresh airs heating the air, and supplying the heated air to the drum.
The condensing type dryer dries the drying object by condensing the air having carried out the drying to have a low temperature and to become humid, for removing moisture therefrom, heating, and supplying to the drum again.
In general, both the exhaust, and condensing type dryers employ an operating method in which a heater and a blower are operated for a preset time period for drying the drying object in the drum. However, the dryers having employed the method have the following problems.
The drying of different kinds of drying objects having different materials, weights, volumes, moisture contents, and the like by the same operating method for the preset time period causes to fail to provide an optimal drying performance, always. That is, there can be an occasion when drying of some of the drying objects is not finished even if operation of the dryer is finished, when re-operation of the dryer is required.
The failure in constant provision of the optimal drying performance leads the dryer set to operate for a longer time period, to require a much drying time period and a long time operation of the heater, and blower motor more than required, to result in waste of energy.
Taking the foregoing problems into account, introduction of a feed back system is required, in which the dryer is operated after dryness or humidity of laundry is sensed and provided to a controller during drying, an optimal operation condition is calculated based on information obtained by sensing, and setting of a heating quantity of the heater, a blowing rate of the blower, a rotation speed of the drum, an operation time period, and the like are changed.
In order to introduce the foregoing feed back system, a sensor is required for sensing dryness or humidity of the laundry. However, since the drum keeps rotating during operation, it is required to fit the sensor such that a stable exchange of electrical signals between the sensor and the controller is possible. Consequently, for the introduction of the feed back system, a solution for a sensor fitting structure is also required, as well.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a sensor assembly for an automatic dryer that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
An object of the present invention designed owing to the foregoing requirements lies on providing a sensor assembly for an automatic dryer that can provide a structure in which a sensor is fitted to an inside of the dryer for sensing dryness or humidity of laundry and transmitting to a controller during drying of the laundry so that a feed back system can be introduced to the dryer.
Another object of the present invention is to provide a sensor assembly which can be assembled easily, and replaceable at a low cost.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, a sensor assembly for an automatic dryer having a rotatable drum containing a load of wet clothes to be dried includes a bulkhead having an air outlet opening that exhausts humidified air from the drum, an electrical non-conductive sensor body secured directly to the bulkhead and positioned so as to cover a portion of the air outlet opening, and at least one sensing element disposed on a first surface of the sensor body. The sensing element is exposed to inside of the drum so as to make contact with the wet clothes for measuring moisture content and temperature of the clothes.
The sensor body described above includes an extension member extended from a second surface (opposite to the first surface exposed to the inside of the drum) of the sensor body. Also, a first mounting bracket having an aperture provided thereon is extended from the bulkhead and the extension member is inserted into the aperture for slip fit engagement with the first mounting bracket. The extension member of the sensor body may include a detent which engages with the first mounting bracket to prevent the extension member from being disengaging from the first mounting bracket.
In addition, a first end of the sensor body may include a first screw hole adapted to receive a first screw for securing the first end directly to the bulkhead, and a second end of the sensor body may include a second screw hole adapted to receive a second screw for securing the second end to a mounting bracket extended from the bulkhead. Alternatively, the first end of the sensor body may include a slot adapted to receive a thin portion of the bulkhead for securing the first end to the thin portion of the bulkhead.
The sensor assembly described above further includes a perforated air outlet grill secured to the bulkhead where the air outlet grill covers the remaining portion of the air outlet opening. The air outlet grill may include a caved channel formed on a lower circumferential edge of the air outlet grill for receiving the sensor body where the first surface of the sensor body is slopped away from a surface of the air outlet grill to thereby project into the inside of the drum for improved contact with the wet clothes. In addition, the sensor body includes a groove formed on an upper edge of the first surface and the air outlet grill includes a ridge that engages with the groove for pressing down the upper edge of the first surface so as to prevent disengagement of the sensor body from the caved channel of the air outlet grill.
In further aspect of the present invention, an automatic dryer comprises a cabinet, a drum rotatably provided in the cabinet for containing a load of wet clothes to be dried, a rear bulkhead comprising an air inlet opening that exhausts dry air into the drum, and a front bulkhead comprising an air outlet opening that exhausts humidified air from the drum. The automatic dryer further comprises an electrically non-conductive sensor body secured directly to the front bulkhead and positioned so as to cover a portion of the air outlet opening, at least one sensing element disposed on a first surface of the sensor which is exposed to inside of the drum so as to make contact with the wet clothes, and a perforated air outlet grill being rigidly secured to the from the front bulkhead for covering the remaining portion of the air outlet opening.
The sensor body included in the automatic dryer may include an extension member extended from a second surface (opposite to the first surface) of the sensory body. A first mounting bracket having an aperture formed thereon is extended from the front bulkhead so that the extension member can be inserted into the aperture for slip engagement with the first mounting bracket. The extension member of the sensor body may include a detent which engages with the first mounting bracket to prevent the extension member from being disengaged from the first mounting bracket.
In addition, a first end of the sensor body may include a first screw hole adapted to receive a first screw for securing the first end directly to the bulkhead, and a second end of the sensor body may include a second screw hole adapted to receive a second screw for securing the second end to a mounting bracket extended from the bulkhead. Alternatively, the first end of the sensor body may include a slot adapted to receive a thin portion of the bulkhead for securing the first end to the thin portion of the bulkhead.
The sensor body may further include a groove formed on an upper edge of the first surface and the air outlet grill may include a ridge that engages with the groove for pressing down the upper edge of the first surface so as to prevent disengagement of the sensory body from the caved channel of the air outlet grill. The first surface of the sensor body is slopped away from the surface of the air outlet grill to thereby project into the inside of the drum for improved contact with the wet clothes.
It is to be understood that both the foregoing description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings;
FIG. 1 illustrates a perspective view with a partial cut away view for showing an inside of a dryer in accordance with a preferred embodiment of the present invention;
FIG. 2 illustrates a perspective disassembled view showing assembly of some of components of the dryer in accordance with a preferred embodiment of the present invention;
FIGS. 3 and 4 illustrate perspective views each seen from an inside of a drum showing the sensor and the air outlet grill in FIG. 2 respectively mounted to a front bulkhead;
FIG. 5 illustrates a perspective disassembled partial view seen from an outside of a drum showing mounting of a sensor in accordance with a first preferred embodiment of the present invention;
FIG. 6 illustrates a perspective view showing the sensor mounted;
FIGS. 7A , 7 B, and 7 C illustrate cross-sections showing different embodiments of the first fastening means;
FIG. 8 illustrates a perspective view showing a sensor in accordance with a second preferred embodiment of the present invention;
FIGS. 9 and 10 illustrate perspective views each seen from an inside of a drum showing the sensor in FIG. 8 mounted on a front bulkhead;
FIG. 11 illustrates a perspective view showing a sensor in accordance with a third preferred embodiment of the present invention;
FIG. 12 illustrates a perspective view seen from an inside of a drum showing the sensor in FIG. 11 mounted on a front bulkhead;
FIG. 13 illustrates a perspective view seen from an inside of a drum showing a sensor another embodiment of the second fastening means applied thereto mounted on a front bulkhead, together with an air outlet grill, in accordance with a first, second, or third preferred embodiment of the present invention;
FIG. 14 illustrates a section showing a sensor mounted in accordance with a fourth preferred embodiment of the present invention; and
FIG. 15 illustrates a perspective view showing the sensor in FIG. 14 being mounted.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
FIG. 1 illustrates a perspective view with a partial cut away view for showing an inside of a dryer in accordance with a preferred embodiment of the present invention, and FIG. 2 illustrates a perspective disassembled view showing assembly of some of components of the dryer in accordance with a preferred embodiment of the present invention.
Referring to FIGS. 1 and 2 , a drum 20 is rotatably provided to a cabinet 10 of a dryer shown in FIG. 1 . For this, a belt 40 connects a motor 30 and the drum 20 provided to an inside of the cabinet 10 . According to this system, since the belt 40 transmits a power from the motor 30 to the drum 20 , the drum 20 can rotate inside of the cabinet 10 .
The drum 20 has tumbling ribs 25 provided to an inside circumferential surface thereof for lifting and dropping the drying objects held inside of the drum 20 when the drum rotates.
Opposite ends of the drum 20 are opened, to which a front bulkhead 100 and a rear bulkhead 50 are provided adjacently. The front bulkhead 100 and the rear bulkhead 50 are fixed to the cabinet 10 or a supporting member provided to an inside of the cabinet 10 , and not rotatable with the drum 20 .
The rear bulkhead 50 has an air inlet opening 55 for introduction of hot air heated by the heater (not shown) into the drum 20 . As shown in FIG. 2 , the front bulkhead 100 has two openings; one for exhausting air from an inside of the drum 20 , and the other for serving as an introduction opening for introduction/taking drying objects into/out of the drum 20 through the opening when a door (not shown) of the dryer is opened. The two openings are divided by a dividing member 150 . For convenience of description, the opening serving as the introduction opening is called as a first opening 110 , and the opening serving as an air exhaust opening is called as an air outlet opening 120 .
Provided to the air outlet opening is an air outlet grill 300 for prevention of the drying objects held inside of the drum 20 from escaping therethrough, and a sensor 200 for measuring information on an inside of the drum 20 , for an example, humidity or temperature of the drying object. The air outlet grill 300 and the sensor 200 , provided to the air outlet opening 120 , are mounted on and fixed to the front bulkhead 100 , respectively.
FIGS. 3 and 4 illustrate perspective views each seen from an inside of a drum 20 showing the sensor 200 and the air outlet grill 300 in FIG. 2 respectively mounted to an air outlet opening 120 in a front bulkhead 100 , as an example. As shown, the sensor 200 is mounted to an inside circumference of the front bulkhead 100 to occupy an area of the air outlet opening 120 , and the air outlet grill 300 is mounted on the front bulkhead 100 after the sensor 200 is mounted on the front bulkhead 100 so that the air outlet grill 300 covers an entire remained area of the air outlet opening 120 excluding a portion of area occupied by the sensor 200 . Meanwhile, the sensor 200 and the air outlet grill 300 respectively mounted to the front bulkhead 100 are not attached or fixed to each other.
The sensor 200 thus mounted includes electrically non-conductive sensor body 210 , a sensing element, and fastening means. The sensing element, provided for sensing a temperature and humidity of the drying object, includes, for an example, an electrode 215 for coming into direct contact with, for an example, air or the drying object inside of the drum 20 and measuring moisture content of the drying object. The sensing element is provided to a surface of the sensor body 210 facing the inside of the drum 20 for easy and direct contact with air or the drying object inside of the drum 20 . In the meantime, the fastening means, provided for mounting the sensor 200 on the front bulkhead 100 , provides a variety of embodiments of the sensor mounting structure as the fastening means has a variety of systems. In the meantime, FIGS. 3 and 4 are exemplary, and do not limit the structure of the fastening means of the present invention.
The air outlet grill 300 has a grill structure in which a plurality of members are crossed for free pass of air. As shown in FIG. 3 , the air outlet grill 300 has a caved channel 310 formed in a form of a channel in a part of an outer circumferential surface for preventing interference with the sensor 200 when the air outlet grill 300 is provided to the air outlet opening 120 .
The air outlet grill 300 also includes air outlet grill fastening means for easy mounting of the air outlet grill 300 to the front bulkhead 100 . In FIGS. 3 and 4 , one example of the air outlet grill fastening means, a plurality of first pass through holes 320 are shown. In a case the first pass through holes 320 are provided to the air outlet grill 300 , second pass through holes 160 in correspondence to the first pass through holes 320 are provided to the front bulkhead 100 . The first and second pass through holes 320 and 160 are screw holes. When the correspondent first and second pass through holes 320 and 160 are provided to the air outlet grill 300 and the front bulkhead 100 respectively, the air outlet grill 300 can be fastened to the front bulkhead 100 with screws or the like firmly, after the air outlet grill 300 is mounted on the front bulkhead 100 to cover the air outlet opening 120 , as shown in FIG. 4 , once the air outlet grill 300 is fastened, the sensor 200 and the air outlet grill 300 can be respectively fastened to the front bulkhead 100 independently, because the caved channel 310 in the air outlet grill 300 secure a space for the sensor 200 .
However, the air outlet grill fastening means is not limited to the first pass through holes 320 shown in FIGS. 3 and 4 . A plurality of hooks on the air outlet grill 300 and hook holes in the front bulkhead 100 for receiving the hooks may work as the fastening means. Therefore, the air outlet grill fastening means is not limited to the first pass through holes 320 , but any structure that can fasten the air outlet grill 300 to the front bulkhead 100 is adequate for the air outlet grill fastening means.
A variety of embodiments of a structure in which the sensor 200 is mounted to the front bulkhead 100 depending on a variety of the fastening means provided to the sensor 200 will be described in more detail, with reference to drawings.
FIG. 5 illustrates a perspective disassembled partial view seen from an outside of the drum 20 showing mounting of the sensor 200 inclusive of first fastening means on the front bulkhead 100 in accordance with a first preferred embodiment of the present invention.
Referring to FIG. 5 , the first fastening means includes an ‘L’ extension member provided to one surface of the sensor body 210 , for an example, a surface opposite to a surface the electrode is mounted thereon. The extension member 220 provided as the first fastening means is fastened to the front bulkhead 100 by means of elastic force and friction force.
FIG. 5 shows an example of an aperture 135 provided to a first mounting bracket 130 extended from the front bulkhead 100 vertical to an inside circumferential surface of the front bulkhead 100 , i.e., a surface the sensor 200 is mounted thereon. In more detail, an example is shown, in which the extension member 220 includes a vertical part 221 projected from the sensor body 210 , and a horizontal part 225 bent in one direction at an end of the vertical part 221 . For reference, the unexplained reference symbol 216 denote terminals of the electrode 215 shown in FIGS. 3 and 4 .
The sensor 200 having the foregoing extension member 220 is fastened by inserting the extension member 220 in the aperture 135 and pushing in a direction of the horizontal part 225 . That is, the extension member 220 is inserted into the aperture 135 for slip fit engagement with the first mounting bracket 130 . On doing so, the first mounting bracket 130 is inserted between the horizontal part 225 of the extension member 220 and the sensor body 210 tightly as shown in FIGS. 6 ˜ 7 B.
Referring to FIG. 6 , according to this operation, the sensor 200 is securely fastened to the front bulkhead 100 by an elastic force of the extension member 220 , and friction forces at surfaces the extension member 220 and the first mounting bracket 130 are in contact, and the first mounting bracket 130 and the sensor body 210 are in contact. For the secure fastening of the sensor 200 , it is preferable that a thickness of the first mounting bracket 130 is equal to, or slightly greater than a distance between the horizontal part 225 of the extension member 220 and the sensor body 210 .
The present invention also provides a structure for preventing the sensor 200 once fastened to the front bulkhead 100 from being disengaged from the front bulkhead 100 easily due to vibration and the like. Referring to FIG. 7B , first and second detents 226 and 131 are provided to the extension member 220 and the first mounting bracket 130 for prevention of disengagement. The first detent 226 provided to the extension member 220 is projected from the horizontal part 225 of the extension member 220 toward the sensor body 210 . The second detent 131 is projected from the first mounting bracket 130 toward the horizontal part 225 so as to be positioned between the vertical part 221 of the extension member 220 and the first detent 226 . Once the first and second detents 226 and 131 are provided, movement of the sensor 200 is prevented by the first and second detents 226 and 131 even if an external force, such as vibration or the like, is occurred after the sensor 200 is mounted. In the meantime, as another embodiment, a structure may be possible in which at least one projection and recess for receiving the projection are provided to the extension member 220 and the first mounting bracket 130 .
In the meantime, the first fastening means of the sensor 200 is not limited to above embodiment. That is, as shown in FIG. 7C , the first fastening means may include two extension members 220 , and a wedge form at an end of each of the extension members 220 for easy insertion of the extension member 220 into the aperture 135 . As shown in FIG. 7C , the fastening means permits firm fastening of the sensor 200 as the extension members 220 are elastically deformed toward a center of the aperture 135 when the extension member is inserted into the aperture 135 for slip fit engagement with the first mounting bracket 130 , and restored again when the wedge forms pass the aperture 135 .
Though the first fastening means can be fastened to the aperture 135 in the first mounting bracket 130 extended from the front bulkhead 100 , the first fastening means may be fastened to the front bulkhead 100 , directly. If an aperture is formed in an inside circumferential surface of the front bulkhead 100 , and the first fastening means is provided to a surface of the sensor 200 which is brought into contact with the inside circumferential surface of the front bulkhead 100 , according to a principle as above, the sensor 200 can be mounted on the front bulkhead 100 . Therefore, positions of the first fastening means illustrated in FIGS. 5 and 6 are exemplary, and do not limit the position of the first fastening means in the present invention.
In the meantime, referring to FIGS. 5 and 6 , the sensor 200 is provided with second fastening means, further. The second fastening means is provided for maintaining a fastened state more firmly after the sensor 200 is fastened by using the first fastening means. FIGS. 5 and 6 illustrate examples of a first screw hole 230 provided to one end of the sensor 200 as the second fastening means. In a case the first screw hole 230 is provided to the sensor 200 thus, a second screw hole 141 is provided to the front bulkhead 100 in correspondence to the first screw hole 230 . In this instance, as shown in FIGS. 5 and 6 , the second screw hole 141 is provided to a second mounting bracket 140 extended from the front bulkhead 100 vertical to an inside circumferential surface of the front bulkhead 100 , a surface the sensor 200 is mounted thereon.
The first and second screw holes 230 and 141 are formed at positions the first and second screw holes 230 and 141 meet when the sensor 200 is mounted on the front bulkhead 100 . Then, since the first and second screw hole 141 form a continuous screw hole, a screw can be fastened to the one screw hole the first and second screw holes 141 form after the sensor 200 is fastened by using the first fastening means. Thus, the sensor 200 can be mounted to the front bulkhead 100 , more firmly.
After the sensor 200 is mounted on the bulkhead 100 by using the first and the second fastening means, the air outlet grill 300 is mounted on the front bulkhead 100 . Referring to FIG. 3 , when it is intended to mount the air outlet grill 300 , the first pass through holes 320 in the air outlet grill 300 and the second pass through holes 160 in the front bulkhead 100 are aligned, and fastens with fastening members, such as screws. One of the second pass through holes 160 can be provided to the second mounting bracket 140 as shown in FIGS. 5 and 6 .
In the meantime, FIGS. 8 ˜ 10 illustrate a second embodiment of the present invention, which will be described in detail, with reference to the drawings.
The sensor 200 in the embodiment illustrated in FIGS. 8 ˜ 10 includes fastening means having second fastening means and third fastening means. As shown in FIGS. 8 ˜ 10 , the second fastening means has a first screw hole 230 in one side part of the sensor 200 , which is identical to an example described in association with FIGS. 5 and 6 , and description of which will be omitted. The third fastening means will be described, hereafter.
The third fastening means 200 includes a third screw hole 240 provided to the other end of the sensor 200 , i.e., an end opposite to an end the first screw hole 230 is provided thereto. While the first screw hole 230 vertically passes through a surface the electrodes 215 are provided thereto and is in communication with the second screw hole 141 in the second mounting bracket 140 extended in a vertical direction from the inside circumferential surface of the front bulkhead 100 , i.e., the surface the sensor 200 is mounted thereon, the third screw hole 240 is in communication with a fourth screw hole 170 which vertically passes through the surface the sensor 200 is mounted thereon and is provided to the inside circumferential surface of the front bulkhead 100 as shown in FIG. 9 .
Once the sensor 200 has the second screw hole 141 and the third screw hole 240 , opposite ends of the sensor 200 can be respectively fastened to the second mounting bracket 140 extended for the front bulkhead 100 and the inside circumferential surface of the front bulkhead 100 with screws or the like, firmly.
In this embodiment too, the air outlet grill 300 is mounted to the front bulkhead 100 so as to cover the air outlet opening 120 after the sensor 200 is mounted, of which detailed description will be omitted as the description is the same with before.
FIGS. 11 and 12 illustrate a third preferred embodiment of the present invention, which will be described in detail with reference to the drawings.
In the embodiment illustrated in FIGS. 11 and 12 , the sensor 200 includes fastening means having second fastening means and third fastening means. The second fastening means, having the first screw hole 230 provided to one side part of the sensor 200 , is identical to the embodiments described with reference to FIGS. 5 ˜ 10 , and of which description will be omitted. The third fastening means will be described.
In the third embodiment of the present invention, the third fastening means includes a slot 230 provided in an up and down direction in the other end of the sensor 200 , i.e., an end opposite to an end the first screw hole 230 is formed therein. FIG. 11 or 12 illustrates an embodiment in which the slot 255 is provided to a third plate 250 extended from the other end of the sensor 200 in parallel to the inside circumferential surface of the front bulkhead 100 , i.e., a surface the sensor is mounted thereon. Once the third embodiment has the foregoing system, no separate fastening member is required for fastening the other end of the sensor 200 , which will be described.
After the sensor 200 is brought into contact with the front bulkhead 100 , a thin part of the front bulkhead 100 , for an example, an end of a side the slot 255 is provided thereto, is pushed up toward a corner part where the inside circumferential surface of the front bulkhead 100 and the dividing member 150 are joined. Then, as shown in FIG. 12 , since a part of the front bulkhead 100 is inserted in the slot 255 , the sensor 200 can not move in a direction excluding a length or up and down direction of the slot 255 . It is preferable that a width of the slot 255 is equal to or slightly smaller than a thickness of the corner part where the inside circumferential surface of the front bulkhead 100 and the dividing member 150 are joined. In a state a part of the front bulkhead 100 is inserted in the slot 255 , when a screw or the like is fastened to the first screw hole 230 and the second screw hole 141 , the sensor 200 is mounted, firmly.
In the third embodiment too, the air outlet grill 300 is mounted to the front bulkhead 100 after the sensor 200 is mounted, description of which will be omitted since the description is the same with the previous description. Anyhow, after the air outlet grill 300 is mounted, a more stable mounting state of the sensor 200 can be maintained, undoubtedly.
In the meantime, FIGS. 3 ˜ 12 illustrate examples in which the second fastening means includes the first screw hole 230 which passes through one end of the sensor 200 directly, the second screw hole 141 in correspondence to the first screw hole 230 is provided to the second mounting bracket 140 extended from the inside circumferential surface of the front bulkhead 100 , and, along with this, the second mounting bracket 140 is provided with the second screw hole 141 for mounting the sensor 200 , and the second pass through hole 160 for mounting the air outlet grill 300 . However, in the first, second, or third embodiment, the second fastening means is not limited to the examples illustrated in FIGS. 3 ˜ 12 . Other example of the second fastening means in the first, second, or third embodiment of the present invention will be described, with reference to FIG. 13 .
Though, in the example described with reference to FIGS. 3 to 12 , the second mounting bracket 140 is provided with two holes, i.e., the second screw hole 141 and the second pass through hole 160 , in the example in FIG. 13 , the second mounting bracket 140 is provided with one hole, i.e., a second pass through hole 160 , only.
In the embodiment illustrated in FIG. 13 , the first screw hole 230 provided for fastening one end of the sensor 200 , the first pass through hole for fastening the air outlet grill 300 , and the second pass through hole 160 provided to the second mounting bracket 140 are designed to receive one fastening member, for an example, a screw, at the same time. To do this, the first screw hole 230 is provided such that the first screw hole 230 pass through a thin fourth plate 270 extended from the one end of the sensor 200 .
Once the first screw hole 230 is provided thus, after sensor 200 is disposed such that the first screw hole 230 and the second screw hole form one hole, and the first pass through hole in the air outlet grill 300 and the first screw hole 230 are aligned, the holes are fastened with one screw, to mount the sensor 200 and the air outlet grill 300 to the front bulkhead 100 , firmly. Of course, it is preferable that, before above fastening, the sensor 200 is fastened in advance by using the first or third fastening means provided to the sensor 200 .
Thus, the second fastening means may differ from the embodiments illustrated in FIGS. 3 ˜ 12 . Therefore, the examples shown in FIGS. 3 ˜ 12 are exemplary, but not limit the second fastening means.
In the meantime, FIGS. 14 and 15 illustrate a fourth preferred embodiment of the sensor mounting structure of the present invention, which will be described in more detail.
Referring to FIGS. 14 and 15 , the fastening means provided to the fourth embodiment includes a groove 217 in an upper surface of the sensor 200 . The groove 217 is provided as the fastening means in the fourth embodiment in a recess form along upper and side edges of the sensor 200 as shown in FIG. 15 , for engagement with a part of the air outlet grill 300 as shown in FIG. 14 . For engagement with the groove 217 in the sensor 200 , the caved channel is provided with a long ridge 330 .
Once the groove 217 and the ridge 330 are provided to the sensor 200 and the air outlet grill 300 respectively, without using a separate fastening member, such as a screw, the sensor 200 can be mounted to the inside circumferential surface of the front bulkhead 100 . That is, as shown in FIG. 14 , if the air outlet grill 300 is fastened after positioning the sensor 200 at the inside circumferential surface of the front bulkhead 100 , the ridge 330 of the air outlet grill 300 is engaged with the groove 217 in the sensor 200 such that the sensor 200 is locked by the caved channel 310 of the air outlet grill 300 , to limit movement of the sensor 200 and maintain a fastened state by a friction force. In the meantime, as shown in FIG. 14 , if a top surface of the groove 217 and a bottom surface of the ridge 330 , which engage with each other, are sloped, a width direction movement of the sensor 200 can be prevented more effectively.
In the meantime, though not shown, in the fourth embodiment, more than one of the first, second, third fastening means described with reference to FIGS. 3 ˜ 13 may be provided for firmer fastening of the sensor 200 .
In the meantime, as shown in FIG. 14 , the surface the electrodes 215 are provided thereto may have a sloped surface. Such embodiment is not limited to the fourth embodiment, but applicable to the first, second, and third embodiments. As shown in FIG. 14 , the sloped surface has a lower part projected inward more than an upper part. Such a sloped surface of the sensor 200 permits more positive contact with the drying object, thereby improving a performance for sensing dryness of the drying object.
The present invention that can be realized in a variety of embodiments thus has a structure in which the sensor 200 is fabricated separate from the air outlet grill 300 , and the sensor 200 and the air outlet grill 300 are mounted to the front bulkhead 100 respectively.
Since the sensor 200 and the air outlet grill 300 of the present invention have very simple structures, molding thereof is very easy. Also, since mounting structures of the sensor 200 and the air outlet grill 300 to the front bulkhead 100 are very simple, assembly is simple.
The separate fabrication and mounting of the sensor 200 and the air outlet grill 300 on the front bulkhead 100 permits replacement of the sensor 200 only when the sensor 200 is out of order without replacement of other components, which is very economic.
Moreover, since the foregoing sensor mounting structure requires no special design change or re-design of peripheral components even in a case mounting of a different kind of sensor is required depending on models of the dryer in production of the dryer, only to require fabrication of the sensor in the same form, the present invention is very economical.
When the dryer of the present invention having the sensor 200 mounted thereon is put into operation to dry the drying object, the sensor 200 senses information, such as humidity in the drum 20 , and transmits to the controller of the dryer. The controller, having received the information from the sensor 200 , determines an extent of progress of the present drying from the information, and selects an operation method suitable to the extent of the progress, and controls various components.
When feed back is made thus, the controller re-determines a heating rate of the heater, a blowing rate and speed of the blower, rotation speed of the drum, a drying time period, and the like depending on the extent of dryness of the drying object in the drum 20 , and controls the dryer.
That is, if the extent of drying progress of the drying object is later than expectation after drying the drying object for a certain time period, the heating rate of the heater, the blowing rate of the blower, rotation speed of the drum, and the like are increased for fast drying.
Opposite to this, if the extent of drying progress of the drying object is faster than expectation after drying the drying object for a certain time period, the heating rate of the heater, the blowing rate of the blower, rotation and speed of the drum are decreased for slow down of the drying.
Upon completion of the drying, the sensor 200 senses it, and the controller stops operation, to prevent unnecessary excessive operation in advance.
Thus, the dryer of the present invention having the optimal feed back system always permits to progress an optimal drying, and reduce a drying time period and energy consumption by using the foregoing principle.
In the meantime, the device of the present invention having the sensor 200 which can sense information on an inside of the drum 20 provided thereto is applicable, not only to the dryer, but also to a drum type washing machine having a drying function.
The present invention has the following advantages.
First, the availability of easy realization of the feed back system at the dryer and drum type washing machine, permitting the controller to control components proper to an extent of drying progress of the drying object, can always provide an optimal dry service.
Second, the prevention of unnecessary excessive operation permits to shorten a drying time period, and reduce energy consumption.
Third, the very simple shapes of the sensor body and the air outlet grill permits easy formation of molds thereof, and the very simple assembly structure thereof with the front bulkhead provides a good assembly work.
Fourth, a component replacing cost can be saved, since what is required is replacement of the sensor only when the sensor is out of order.
Fifth, in designing a dryer or a drum type washing machine having another kind of sensor to be applied thereto, because what is required is fabrication of the sensor having the same shape, design change of the appliance is very simple and a new appliance can manufactured at a low cost.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention.
For an example, the fastening means for the sensor is not limited to the embodiments described with reference to FIGS. 3 ˜ 15 , but may be available as many as one wishes by combinations of the different embodiments. That is, though not shown, an embodiment of the fastening means for the sensor including first fastening means having an extension member, and third fastening means having a third screw hole can be possible.
Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A sensor assembly is provided for an automatic drying machine having a rotatable drum containing a load of wet clothes to be dried wherein at least one sensing element is disposed on a surface of an elongated sensor body and is exposed to inside of the drum so as to make contact with the wet clothes. The sensor body is secured directly to a bulkhead having an air outlet opening and is provided at the air outlet opening for effective engagement with the wet clothes. | 3 |
RELATED CASES
Cross reference is made to the following applications filed concurrently and incorporated by reference herein: Ser. No. 09/362,022 entitled “Improved Digital Halftone With Auxiliary Pixels” by Robert J. Meyer and Allen T. Retzlaff, Jr., Ser. Nos. 10/707,572, 10/707,577 and 10/707,574 entitled “Improved Font Print Quality with Auxiliary Pixels” by Robert J. Meyer and Allen T. Retzlaff, Jr.
BACKGROUND OF THE INVENTION AND MATERIAL DISCLOSURE STATEMENT
The present invention relates to improving images produced by electrostatographic, electrophotographic or ionographic printers and reprographic copiers. More particularly, methods and apparatus are disclosed for solving the image problems of edge delineation and edge placement for shapes in an image. Such edge delineation and placement problems manifest as phenomena often referred to as line shrinkage, halo and white gap artifacts. These artifacts are also sometimes referred to as “slow toner”.
Heretofore a number of patents have disclosed various approaches to the manipulation and enhancement of the edges of image shapes. The primary focus of the various approaches has been upon the line and edge smoothing of “jaggies” and other artifacts generated by digitization. A summary follows.
In U.S. Pat. No. 4,847,641 to Tung, print enhancement circuitry to enhance the printed image produced by a laser beam printer is interposed between the character generator circuits and the laser drive circuits to modify the laser drive signals provided by the character generator circuits. Bit data representing successive lines of the bit map for a desired image are stored in a first-in first-out (FIFO) buffer. The bit pattern sample window having a central cell (bit) and a selected (arbitrary) number of neighboring bits is compared to a number of matching bit patterns or templates, each of which is associated with an error element or cell. When a logic matching network detects a match, a modification signal associated with a unique compensation cell (bit) is generated. The sample window central bit is then replaced (modified) with the unique compensation bit required by the matching template. In this manner, all bits in a desired bit map, or set of bit maps, are examined and their corresponding laser drive signals modified to compensate for the errors associated with the matched templates in a piece-wise manner.
U.S. Pat. No. 4,544,264 to Bassetti et al. discloses an electrophotographic printing machine with circuits to enhance the printing of fine lines, such as lines of a single picture element (pel) in width. Provision is made for broadening such lines in one dimension by adding small “black” areas to each edge of the fine line in order to broaden it. In a second dimension, perpendicular to the first dimension, lines are broadened by placing gray pels next to black pels. The disclosure also discusses specific cases in which it may be considered desirable to inhibit the enhancement signals.
U.S. Pat. No. 5,029,108 to Lung discloses an edge enhancement method and apparatus for dot matrix devices wherein a group of gradient mask matrices are applied to a “current matrix”, wherein a target pixel is surrounded by neighboring pixels, to determine if the target pixel is at a location where a change of brightness occurs. From this matrix operation, a conclusion is derived as to the existence or non-existence of an edge and the direction of the brightness change. The current matrix and a predetermined number of previously evaluated and yet to be evaluated pixels are then compared to a set of reference bit patterns which depict possible segment changes to be corrected. If the result indicates that the target pixel is on an edge of a changing edge segment, a corresponding code will be generated to modify the target pixel to enhance the smoothness of a segment transition. In the case of an electrophotographic printing machine, the specific code will change either the location or the size of the target pixel; whereas in the case of a monochrome screen display, the specific code will change the intensity of the target pixel.
In U.S. Pat. No. 4,544,922 to Watanabe et al., a desired character mainly composed of standard width dots selected from a matrix of orthogonally disposed rows and columns is displayed on a screen during scanning of the screen in horizontal and vertical directions. The display is smoothed by a circuit responsive to data stored in a memory. The smoothing involves the selected addition or removal, to or from particular portions of the character, of a small dot having a width one-third of the standard dot width.
U.S. Pat. No. 4,625,222 to Bassetti et al. discloses print enhancement circuits for an electrophotographic printing machine are placed between the character generator and the printhead to modify drive signals for the printhead. Modifications include smoothing the digitized edges of slanted lines; broadening single pel width lines in the direction perpendicular to the scan direction as well as in the direction parallel to scan. Inhibiting circuits are provided to prevent passage of enhancement signals under certain conditions. Generally, leading and trailing edge gray signals are provided next to all black data in a direction parallel to scan while expanded black signals are provided for the single pel data in a direction perpendicular to scan by adding to the black signal on both its leading and trailing edges. When a single picture element (pel) area contains two added black signals, both are passed; when a single pel area contains one added black signal and one gray signal, both are passed; when a single pel area contains two gray signals, only the leading gray signal is passed; and when a single pel area contains two added black signals and a gray signal, only the gray signal is passed.
The U.S. Pat. No. 5,479,175 to Cianciosi et al. is a an apparatus for enhancing the output along edges of discharged area developed regions in a tri-level imaging system employing a pulse width and position modulated signal ROS for exposure. The invention enables the identification and selective alteration of video data used to drive the ROS so as to extend the developed regions by a selected amount and eliminate digitization artifacts present in the image to be printed. The extension of the discharged area developed regions is accomplished by extending the width of, or adding separate, exposure pulses in adjacent areas to enable development within a portion of those regions.
In U.S. Pat. No. 5,193,008 to Frazier et al., the output of a conventional laser printer having a resolution of 300×300 dots per inch (dpi), and a predetermined threshold level for forming image dots, is enhanced by selectively providing interleaved image dots between the normal scan lines of the laser printer. Such interleaved image dots between scan lines may be achieved by appropriately energizing the two pixels directly above and directly below that desired interleaved dot, with the energizations at one or both pixels being selectively below the threshold level for producing a dot on the scan line, but with the combined energization at the desired interleaved point being above the threshold level to produce the desired interleaved dot. An input 600×600 bit map may be stored in a random access memory, and three vertically aligned bits from one main scan line and adjacent 600 dpi lines above and below are drawn from the RAM and are supplied to a logic and video output circuit which produces variable pulse width modulated pulses to the laser printer to produce the enhanced image.
U.S. Pat. No. 3,784,397 discloses a method for forming images by providing an electrostatographic imaging member bearing an electrostatic latent image on a recording surface. Then positioning the recording surface spaced from and facing a development electrode. This is followed with contacting the recording surface with toner particles whereby at least a portion of the toner particles deposit on the recording surface to form at least a partially imaged recording surface. Then maintaining the field strength of the development electrode as weak during the initial period of development and then increasing the field strength of the development electrode during the latter period of development, to form a substantially uniform developed image substantially free of streak, halo, edge effect, and background deposits.
In conventional xerography, electrostatic latent images are formed on a xerographic surface by first uniformly charging a photoreceptor. The photoreceptor is advanced to a development station where toner is attracted to the areas not discharged on the exposed charge retentive surface. In the development station there is a developer housing which is typically an inch or two (or more) long in the process direction. However, development doesn't occur throughout this length, but only over a restricted region. Typically this is a region where the photoreceptor belt or drum comes very close to the developer agent, whether it is a magnetic brush roll (which is roughly circular in cross section), or a donor roll. This area of closest approach or actual contact is called the nip. It is typically a few millimeters or so long (in the process direction). This is the region where all of the toner is actually transferred to the photoreceptor. Typically there is an air gap between the source of the toner and the photoreceptor.
A toner cloud is used to span the air gap between the source of toner and the photoreceptor surface. A method and apparatus for producing such a cloud of toner in an air gap between a toner donor and the photoreceptor is described in detail in U.S. Pat. No. 4,868,600, which is herein incorporated in its entirety by reference. Toner is detached from the toner donor and a powder cloud is generated by AC electric fields supplied by self-spaced electrode structures positioned within the development nip between the toner donor and the photoreceptor. The electrode structure is placed in close proximity to the toner donor within the gap between the toner donor and image receiver or photoreceptor. The toner cloud is used to span the gap between the source of toner and the photoreceptor surface as the photoreceptor passes through the development station. As through-put requirements drive the passing of the exposed photoreceptor surface though development station at ever greater speeds, this toner cloud is directed and modulated by the field charge pattern that results on the photoreceptor after exposure. Thus it is the speed and the presence of a gap that allows fringe fields in the latent image to strongly influence the deposition of toner. This is exacerbated in scavengeless systems where a cleaning field is utilized to repel toner from the photoreceptor.
The observed result of this toner cloud modulation is a propensity for depositing large amounts of toner where there is uninterrupted expanse of charged area (such as toward the middle of large image shapes), and to starve toner from locations where there is a strong or sudden change in charge (as found with narrow lines or shapes and on the edges of larger shapes). The result for thin lines and narrow shapes is line shrinkage. The effect on large shapes causes them to exhibit a defect called halo, which manifests itself most clearly at the interfaces of solid colors. Halo in color systems appears as white lines at interfaces which should otherwise be a perfect match between two colors. This defect is also observable in single color images as an edge distortion or displacement and line shrinkage dependent on the size of the printed object. Line shrinkage of course leads to poor line and text quality due to an erosion or shrinkage of the line edges and corners.
Therefore, there exists a need for techniques which will solve these halo and slow toner effects. Further, there exists a demand for increasing the throughput of printing and digital imaging systems without incurring or exacerbating these problems. Thus, it would be desirable to provide a means for satisfying such needs or demands by solving the aforesaid and other deficiencies and disadvantages.
SUMMARY OF THE INVENTION
The present invention relates to auxiliary pixels which do not print, either singly or in combination but aid in the satisfactory printing of the image and to the placing of auxiliary pixels within an image.
In accordance with the present invention, there is provided a digital imaging system which receives and processes a document image, in an image processing system or digital front end. This is done so as to embed auxiliary pixels in the document image and thereby improve the rendition of the document image.
More particularly, the present invention relates to a method of morphologically manipulating image data. The morphological sequence being to first store the source image in a first memory space. Then replicating that stored source image as a working image in a new memory space. Followed by dilating the working image and, then outlining that result. This will produce outline pixels as a second resultant working image. The outline pixels are then substituted for auxiliary pixels. Finally, an OR operation is performed of the outline pixel pattern of auxiliary pixels, with the original source image as stored in memory, to thus produce auxiliary pixels in the source image at those pixel locations corresponding to the outline data in the second resultant working image.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is part of a line, hypothetically rendered at 300×300 dpi.
FIG. 2 the line from FIG. 1 smoothed by templates and rendered at 600×600 dpi.
FIG. 3 the line from FIG. 2 with non-printing auxiliary dots.
FIG. 4 is a graph of empirically observed line growth for parallel positive lines.
FIG. 5 is a sectional, elevational view taken through an intended bit map for a large shape in the image at its edge depicting the deposited toner resulting on the photoreceptor.
FIG. 6 is a sectional, elevational view and bit map of the shape depicted in FIG. 5 with the addition of auxiliary pixels.
FIG. 7 is a sectional, elevational view taken through an intended bit map for a line in the image depicting the deposited toner resulting on the photoreceptor.
FIG. 8 is a sectional, elevational view and bit map of the line depicted in FIG. 7 with the addition of auxiliary pixels.
FIG. 9 is an auxiliary pixel pattern to control negative line growth in parallel lines.
FIG. 10 is an auxiliary pixel pattern to control negative line growth in parallel lines and halo effects for image shapes.
FIG. 11 is an alternative auxiliary pixel pattern cluster for controlling the negative line growth and halo effects of an image shape.
FIG. 12 is a general representation of a suitable system-level embodiment for the invention.
DESCRIPTION OF THE INVENTION
For a general understanding of the present invention, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements. In describing the present invention, the following term(s) have been used in the description.
An “image” is a pattern of physical light. It is understood that an image may be further comprised of shapes. An image as such, may include characters, words, and text as well as other features such as graphics. An image may be divided into “segments” or “regions”, each of which is itself an image. A region of an image may be of any size up to and including the whole image.
An item of data “defines” an image when the item of data includes sufficient information to produce the image. For example, a two-dimensional array can define all or any part of an image, with each item of data in the array providing a value indicating the color of a respective location of the image.
Each location in an image may be called a “pixel.” A “pixel” is the smallest segment of an image whose value is indicated in an item of data defining the image. In an array defining an image in which each item of data provides a value, each value indicating the color of a location may be called a “pixel value”. Each pixel value is a bit in a “binary form” of an image, a gray scale value in a “gray scale form” of an image, or a set of color space coordinates in a “color form” of an image, the binary form, gray scale form, and color form each being a two-dimensional array defining an image.
An “edge” occurs in an image when two neighboring pixels have sufficiently different pixel values according to an appropriate criterion for the occurrence of an edge between them. The term “edge pixel” may be applied to one or both of two neighboring pixels between which an edge occurs.
An “image characteristic” or “characteristic” is a measurable attribute of an image. An operation can “measure” a characteristic by producing data indicating the characteristic using data defining an image. A characteristic is measured “for an image” if the characteristic is measured in a manner that is likely to produce approximately the same result each time it occurs.
A “version” of a first image is a second image produced using an item of data defining the first image. The second image may be identical to the first image, or it may be modified, such as by image processing operations.
An “image input terminal” (IIT) is a device that can receive an image and provide an item of data defining a version of the image. A “scanner” is an image input device that receives an image by a scanning operation, such as by scanning a hardcopy document. An “image output terminal” (IOT) is a device that can receive an item of data defining an image and provide the image as a visual output. A “xerographic marking engine” is an image output device that provides the output image in hardcopy document form.
A “lead edge deletion” is an image defect which occurs on the leading or first-printing edge of a solid area. It is an edge displacement in a direction opposite to the process motion of the deposited toner as with respect to the lead edge of the latent electrostatic image pattern on the photoreceptor.
An operation performs “image processing” when it operates on an item of data that relates to part of an image. A “morphological” or “logic-based” operation operates using logical operators (e.g., AND, OR, INV, NOT) applied to a digital image. In particular, the logic operations are typically applied in association with a “structuring element” such as an aperture having a predefined shape or other set of characteristics.
A number of morphological operations map a source image onto an equally sized destination image according to a rule defined by a pixel pattern called a structuring element (SE). The SE is defined by a center location and a number of pixel locations, each having a defined value (ON or OFF for the binary case, with Grey-scale morphology all intermediate levels are allowed). The pixels defining the SE do not have to be adjacent each other. The center location need not be at the geometrical center of the pattern; indeed it need not even be inside the pattern.
“Erosion” is a morphological operation wherein a given pixel in the destination image is turned ON if and only if the result of superimposing the SE center on the corresponding pixel location in the source image results in a match between all ON pixels in the SE and On pixels in the underlying pixels in the source image.
“Dilation” is a morphological operation wherein a given pixel in the source image being ON causes the SE to be written into the destination image with the SE center at the corresponding location in the destination image.
Turning to FIG. 1 , depicted is a region of an image as at a diagonal edge 100 on an image shape 102 . For this image in the original data a pixel is 300 by 300 dots per inch (dpi). At that resolution diagonals will exhibit distinct jagged stair-case transitions in the edge 100 of the image shape 102 .
FIG. 2 shows a possible result to the data in FIG. 1 after expansion to 600×600 dpi by means of pattern matching templates and application of Resolution Enhancement Technology (RET). RET is a technique used in various Hewlett Packard and Xerox printers. It smoothes out the jagged stair-case transition resulting from digitization by inserting an added pixel 104 . This new added pixel is at the higher dpi resolution.
In FIG. 3 there is an example of the present invention as applied to the data found in FIG. 2 . The RET generated added pixel 104 is retained. However, ultra fine pixels herein referred to as “non-printing” pixels, or “auxiliary” pixels as substituted into the bitmap, have been placed close to the edge of, but both interior and exterior to the image shape. A “black” type of non-printing auxiliary pixel 106 is placed exterior to the image shape and a “white” type of non-printing auxiliary pixel 108 is placed interior to the image shape. It should be noted that the RET generated pixel 104 was retained in FIG. 3 for illustrative purposes only, it is not required for the present invention and in a preferred embodiment may in fact be replaced by a suitable auxiliary pixel. The auxiliary pixels 106 & 108 (and patterns of them in a preferred embodiment) are used to modulate the toner cloud density and distance from the photoreceptor during development.
These auxiliary pixels 106 & 108 may be above the frequency for printing on the MTF curve or they may be of sub-critical density, that is below the normal density threshold for printout in their respective regions so that they are non-printing in effect. This may be achieved typically in two ways; first in a laser based system for example, the laser may be modulated in a manner such that the laser intensity is so reduced that the auxiliary pixel location is substantially under-exposed. As a result, much more charge is retained on the photoreceptor at that location than there would be for a normal fully developed pixel at that location. Second, in the alternative or in combination with laser intensity modulation, the pulse width may be modulated to such a high frequency and thereby down to such a small size that no toner (or an insufficient amount of toner to survive transfer to a substrate) adheres to the photoreceptor sufficient to allow printing. A pulse width and position modulator (PWPM) may be used in a preferred embodiment to accomplish this. PWPM techniques are well known in the art. U.S. Pat. No. 5,184,226 and U.S. Pat. No. 5,504,462, which are both incorporated by reference herein for their teaching, provide exemplary examples.
The addition of such small non-printing pixels to a digital image will move the toner cloud toward or away from the photoreceptor in the neighborhood of an area to be developed. The auxiliary pixels may be either 106 “black” or “on” pixels in an otherwise “off” area, or 108 “white” (that is, “off” pixels in an otherwise “on” area). Depending on the system needs, the actual laser intensity or MTF frequency may be the same for both the “white” 108 and “black” 106 auxiliary pixel. In that case there is really only a single type of auxiliary pixel placed both within and without the image shape. When two types of auxiliary pixel are employed, their density or frequency is different but they are still always non-printing in and of themselves, whether employed singly or adjacently clumped together in an group of auxiliary pixels. By that we mean that all pixel locations that are originally “on” in the bit map will still print as black, regardless that an auxiliary pixel has been substituted at that location. All pixel locations that are “off” will also still not print, regardless that an auxiliary pixel has been substituted at that location. So while a 108 “white” auxiliary pixel taken and placed in isolation might actually print, when used as per the invention and substituted in an “on” printing area, there is no effective change relative to the intended input image bitmap. Thus it is non-printing in effect in and of itself, even when used in a clustered combination or directly adjacent any number of other auxiliary pixels.
The auxiliary pixels will produce small attractively biased or reversed biased areas on the photoreceptor. The attractively biased 106 areas will not develop toner on the photoreceptor, or develop so little, that it will not appear in the final print, because they are beyond the critical frequency on the development (or transfer) MTF. What they will do however, is encourage a toner cloud close enough to the photoreceptor to mitigate the spreading effect of the surrounding cleaning field. Of course, a corresponding statement in the alternate is true for the reverse biased areas 108 ; they will discourage or repel toner away from the photoreceptor. Thus, auxiliary pixels will have a printing effect upon original pixels which they neighbor. The result is that the development cloud (or a development brush) will not be repelled as much from surrounding white areas due to “black” non-printing auxiliary pixels 106 , and the development field will not be so strong near the sharp edges, due to non-printing “white” auxiliary pixels 108 . In this way auxiliary pixels will enhance the printing of original pixels in a manner as intended by the original bit map by mitigating the edge displacement and halo problems endemic to increased printing system speed and throughput. Numerous options exist for placement of non-printing pixels to use this effect.
FIG. 4 depicts the experimentally observed negative line growth found with parallel positive lines. This data substantiates the progressive line narrowing for positive (that is, black on white background) parallel lines. The wider the line, the greater the amount of line shrinkage. There are two effects in operation here causing the negative line growth. First, the MTF of the cleaning field spreads the white background area across the black line, thus displacing the edge inward. Second, the strong demand for toner in the middle of the line “recruits” toner from the edge of the line, thus further reducing supply at the edge. In order to control line growth, the invention proposes inserting non-printing black auxiliary pixels 106 around the line and non printing white pixels 108 within the line.
In FIG. 5 we have depicted a bitmap slice 500 of a pixel pattern for a solid shape at it's edge. Cross-sectioning through the bitmap slice 500 at line 501 , and looking at the photoreceptor 502 as on edge at that location corresponding to the bitmap slice 500 data, display is made of a typical resulting toner accumulation as found on a photoreceptor 502 . There we can see lead edge deletion by the edge displacement 504 of the toner from the intended edge 100 . Also note toner excess buildup 506 as in contrast to an area of desired toner coating 508 .
The origin of edge displacement 504 and the resulting lead edge deletion image defect is best understood in terms of the physics of the toner cloud development process. When a toner cloud developer subsystem is not printing, the toner cloud is repelled from the photoreceptor by a cleaning field. When the latent image on the photoreceptor changes from background (i.e., no developed toner) to image (developed toner desired), the directions of the fields in the space above the photoreceptor change directions, from a repelling or cleaning field to an attractive or developing field. This is accompanied by the usual fringe field effects. Since the toner cloud is initially some distance from the photoreceptor, there is a finite time that it takes the cloud to respond to the field and reach the photoreceptor. This cloud motion time depends on the tribo of the toner in the cloud and the development field strength. During this finite time no toner is being developed on the latent image, and the lead edge deletion results. The length of the lead edge deletion (edge displacement 504 ) on the image then increases as the product of this cloud motion time, and the speed of the photoreceptor with respect to the developer housing. Thus, the lead edge deletion problem becomes worse as the process speed increases.
With FIG. 6 the input data of FIG. 5 is rendered with the insertion of auxiliary pixels in a manner exemplary of a preferred embodiment of the present invention. The bitmap slice 600 comprises the input data of bitmap slice 500 with the addition of non-printing “black” pixels 602 and non-printing “White” pixels 604 . Again photoreceptor 502 is displayed on edge at the location corresponding to the cross-section line 601 through bitmap slice 600 . This shows how a preferred embodiment of auxiliary pixels yields an even coating of toner 508 in all intended areas, and the absence of any edge displacement 504 from the intended edge 100 .
There is a corresponding image defect on the trailing edge of solid area images, image drag-out. In this case, the edge displacement corresponds to toner moved into the background area which should remain with-out toner. This results both from Coulomb repulsion between charged toner particles, and from fringe field effects. Image drag-out is more endemic to liquid development systems, and is minimized by the use of “white” auxiliary pixels 604 dispersed within the solid image near the trailing edge. This has the purpose of decreasing the amount of toner deposited along this trailing edge. As the height of the toner pile 506 near this trail edge decreases, the lateral fringe fields forcing toner into the neighboring background area decreases.
FIG. 7 presents a similar situation as depicted in FIG. 5 . However, the image data portrayed is for a line rather than a solid shape taken at its edge. Cross-sectioning through the bitmap slice 700 at line 701 , and looking at the photoreceptor 502 as on edge at that location corresponding to the bitmap slice. 700 data, display is made of a typical resulting toner accumulation as found on a photoreceptor 502 . There we can see the edge displacement 504 of the toner from the intended edge 100 , and toner excess buildup 506 .
In FIG. 8 the input data of FIG. 7 is rendered with the insertion of auxiliary pixels in a manner exemplary of a preferred embodiment of the present invention. The bitmap slice 800 comprises the input data of bitmap slice 700 with the addition of non-printing “black” pixels 602 and non-printing “white” pixels 604 . Again, photoreceptor 502 is displayed on edge at the location corresponding to the cross-section line 801 through bitmap slice 800 . This suggests how a preferred embodiment of auxiliary pixels yields an even coating of toner 508 in all intended areas, and negates any edge displacement effects relative to the intended edge 100 .
There are two actions associated with negative line growth to be overcome. First, the MTF of the cleaning field spreads the white background area across the black line, thus displacing the edge inward. Second, the strong demand for toner in the middle of the line recruits toner from the edge of the line, thus further reducing the supply at the edge. The positive “black” auxiliary pixels 602 diminish the cleaning field, while the “white” auxiliary pixels 604 reduce demand in the middle of line. Since there is less toner deposited in the middle of the line, it is now available for development at the edge, and thus the line will be widened. This widening occurs at the cost of optical density in the middle of the line, which will be small, and the marginal increase in optical density with respect to DMA (developed mass per unit area) is less than at lower DMAs.
FIG. 9 is provided as an alternative example and preferred embodiment, of auxiliary pixels applied as a pattern to an image line shape data. Non-printing “black” auxiliary pixels 602 are provided outside of the desired line data 900 , though in close proximity to that line 900 , and non-printing “White” auxiliary pixels 604 are substituted within the line 900 data. While non-printing “black” auxiliary pixels 602 are in this embodiment, only in close proximity to the edge, there may be situations in various systems where the auxiliary pixel is best placed directly adjacent to the edge of a shape or at some other distance or pattern from the shape edge. Further, while here in FIG. 9 the non-printing “black” auxiliary pixels 602 are arranged adjacent to one another, in another embodiment, only every other pixel location may receive an auxiliary pixel in a skip pattern fashion along the edge of the desired image shape.
Image morphology is utilized to accomplish the addition or placement of auxiliary pixels into the input data of an original image. For a preferred example of an auxiliary pixel pattern as found in FIG. 9 , a morphological dilation followed by a morphological outlining operation will create the bitmap of pixel locations for the placement of the “black” auxiliary pixels. The “white” auxiliary pixel locations in FIG. 9 are determined by performing a morphological erosion followed by a morphological outlining operation. The morphological dilation and erosion are of from one to two pixels in operation, so as to realize a result like that found in FIG. 9 . Such morphological operations are well understood by those skilled in the art.
For example, a morphological outlining operation is essentially an erosion operation where the objects in the image data are shrunk by one pixel around their perimeter. Use is then made of a dual-image point process to subtract the eroded image from the original image. This is the same as performing a Boolean NOT operation upon the original data with the eroded image. The result is an image showing only the outline of the objects.
In an alternative embodiment, a diffuse pattern or array of auxiliary pixels as clustered about the edge of a shape is preferred. This pattern is typically a dispersed or dispersing patter. Clusters of auxiliary pixels are grouped around the edge of image areas most likely to be starved for toner or where it's anticipated slow toner problems may occur. This is most typically in areas of fine image detail or where there are narrow lines, but also includes the edges of larger image shapes when halo problems are to be anticipated. In accommodation of large image shapes where toner pileup may occur, particularly near the shape periphery, auxiliary pixels may be placed within the image shape to reduce any toner pileup as well. This is most appropriate in anticipation of toner shrinkage problems, where the greater the mass of toner, the greater the amount of edge shrinkage and resulting halo to be expected. The “clusters” comprise diffuse patterns or arrays of auxiliary pixels, so called because of the tight arrangement of the auxiliary pixels as clustered about their respective shapes and lines. The exact pattern will vary from printing system to printing system and must be determined either empirically or by simulation. In a preferred embodiment, the pattern of auxiliary pixels is disperse but typically located in close proximity to an image edge. Examples of preferred pattern clusters are presented in FIGS. 10 and 11 . At all times, the auxiliary pixels are non-printing in effect themselves, either singly or clustered in any pattern or combination. Auxiliary pixels are simply an adjunct to the original image pixels as found within an original image bitmap. Though substituted within an image for select original pixels they never cause a change to the image pattern from the intended original bitmap other than to more faithfully render that intended original bitmap.
As explained above, the length of the lead edge deletion, as identified by edge displacement 504 , is minimized by pre-positioning the toner cloud close to the photoreceptor through the use of auxiliary pixels. Just how far in advance of an image edge this pre-positioning should be performed by the placement of auxiliary pixels is dependent upon the particulars of a given printing system. The faster the system through-put, the more in advance the pre-positioning needs to be. The above preferred embodiment anticipates usage with more typical present day printing and copying systems. However for higher speed systems, clustered or diffuse array arrangements of auxiliary pixels are anticipated. In such high speed systems, a preferred limiting density would correspond to one pixel on, one pixel off, one pixel on, etc. in a checkerboard pattern. This auxiliary pixel pattern would pre-position the cloud as close to the photoreceptor as possible without printing. Remember, as the cloud distance from the photoreceptor decreases, the length of the lead edge deletion decreases. But, as the system speed increases, the lead edge deletion increases. In anticipation of such high speed systems, FIGS. 10 and 11 depict appropriate further preferred embodiments, where a diffuse array 1010 of non-printing attractive (black) auxiliary pixels 1020 is employed. The array is clustered in front of the leading edge 1030 of a solid area 1040 in the bitmap so as to effectuate manipulation of charge in the latent image in a more gradual and anticipatory manner. Since the toner cloud is subjected the attractive field from these pixels 1020 , it will move closer to the photoreceptor. The denser the array of auxiliary pixels 1020 , the closer the cloud moves toward the photoreceptor.
Turning now to FIG. 12 , there is shown an embodiment of a digital imaging system 1200 that incorporates the features of the present invention. Digital imaging system 1200 includes image source 1210 that may include scanner 1212 , computer 1214 , network 1216 or any similar or equivalent image input terminal (IIT) to generate original input image data 1220 . Image data 1220 , representing an image to be printed, is supplied to an image processing system 1230 , that may incorporate what is known in the art as a digital front end (DFE). Image processing system 1230 process the received original image data 1220 to produce print ready binary data 1240 that is supplied to print engine 1250 . In response to print ready data 1240 , print engine 1250 generates an output document or print image on suitable media. Print engine 1250 is preferably a electrostatographic or electrophotographic engine; however, engine 1250 may include an equivalent alternative, for example ionographic. The present invention is directed towards aspects of image processing system 1230 depicted in FIG. 12 . In particular, the present invention is directed to embedding auxiliary pixels into image data 1220 .
There are a variety of approaches apparent to those skilled in the art that may be taken in image processing system 1230 for processing received original image data 1220 so as to produce binary data 1240 with embedded auxiliary pixels. It will also be appreciated by those skilled in the art that the exact type and pattern of auxiliary pixel utilized will vary depending upon the particulars of print engine 1250 . A preferred approach comprises essentially the steps of storing the incoming data 1220 in a buffer or memory; replicating or copying incoming data 1220 in a memory work space; performing a dilation upon the work space data followed by; a morphological outline to that result, then; substituting the appropriate auxiliary pixel for all “on” pixels in the outline data as contained in the work space, and; finally performing a morphological Boolean OR operation of that work space result upon the original incoming data 1220 as stored in a buffer memory (or upon a copy of the original incoming data 1220 ). By changing the dilation operation referred to above for an erosion and substituting the appropriate auxiliary pixel type, “white” auxiliary pixels may be embedded.
Thus by introducing non-printing auxiliary pixels into the bitmap of an image, local control of the image development is obtained by modification of local average voltage in the development nip. Using auxiliary pixels positions the toner cloud by modulating it and may also compensate for cleaning field and toner supply effects. Auxiliary pixels in combination with the methods and apparatus discussed above can better position the toner cloud and ensure adequate toner supply to all parts of the image so that the desired printing pixels will print as intended and in this way overcome edge displacement, image halo, and slow toner problems.
While the embodiment disclosed herein is preferred, it will be appreciated from this teaching that other variations or examples may be made by those skilled in the art. For example other embodiments would include: ionographic systems; brush roller toner delivery systems; and CEP—Contact Electrostatic Printing or similar charged cake toner delivery systems. However, these examples are not exhaustive, nor is there any intent to exclude various alternative, modifications, variations or improvements therein from being encompassed by the following claims. | Utilization of non-printing high-spatial-frequency auxiliary pixels are introduced into the bitmap of an image to obtain local control of the image development by modification of local average voltage in the development nip. These auxiliary pixels embody frequencies or levels of charge that are past the threshold for printing on the Modulation Transfer Function (MTF) curve, and therefore by themselves result in no toner deposition on the resultant page. These auxiliary pixels will however, position the toner cloud by modulating it and to compensate for cleaning field and toner supply effects. This will better position the toner cloud to ensure adequate toner supply to all parts of the image so that the desired printing pixels will print as intended. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an actuator powered apparatus that has application for clamping, welding and other assembly functions that are common in the manufacture and assembly of vehicles, such as automobiles. More particularly, the invention is related to a dual action actuator powered apparatus that is equipped with two elongate arms that are spaced apart from one another. The elongate arms each have a rack gear that meshes with a pinion gear that is interengaged with both rack gears. The elongate arms are positioned within a common housing that supports fluid driven cylinders that are attached to each elongate arm.
2. Description of the Prior Art
The prior art discloses a variety of devices that employ the rack and gear combination to change arcuate motion to a translatory function, or vice versa. In general, most of the prior art devices utilize the pinion gear shaft to supply power to the device or else take power out via the pinion shaft. The prior art devices employ a rack gear that is formed from plate or bar stock as well as a cylindrical rod.
The present invention differs from the rack and pinion gear driven load grip device that is shown and described in U.S. Pat. No. 2,595,131 entitled "Load Grip Means for Trucks and the Like" issued Apr. 29, 1952, to Leslie G. Ehmann. FIG. 1 of the Ehmann patent depicts a pair of spaced apart cylinders 26 that are oriented parallel to one other. In cross section, the cylinders are square in configuration and have a cylindrical bore located along the longitudinal axis of the cylinder. One of the four sides of each cylinder contains a rack gear. The rack gears of the cylinders mesh with the teeth of a pinion gear that is attached to a flange. Each one of the cylinders is powered by a piston that is connected to a piston rod. The piston and the piston rod are contained within the cylinder in the usual fashion, with only the end of the piston rod protruding from the cylinder. The ends of the piston rods are fixed, thus, when fluid pressure is applied to the piston head, the cylinder with its attached rack gear moves in a linear direction. The pinion gear is fixed against rotation by its attached flange. Consequently, when fluid pressure is applied to the piston heads, the rack gear containing cylinders walk around the teeth of the fixed pinion gear. In this manner, a torque is developed to rotate the entire plate t which the cylinders and their accompanying pistons are attached.
The present invention differs from the above described device in that the power generating fluid driven cylinders are separate from the rods or elongated arms that contain the rack gear teeth. Thus, any malfunction of the piston head, or its seals, does not affect the block assembly that houses the elongated arms.
In U.S. Pat. No. 3,018,885 entitled "Extrusion and Stretch-Straightening Apparatus and Method" issued Jan. 30, 1962, to Leonard H. Trautman, there is shown an apparatus for stretching a metal rod subsequent to its formation by an extrusion process. The metal rod is grasped at both ends and then elongated to remove any non-linear sections that ma have resulted because of the extrusion process. The grasping of the rod is achieved by a pair of jaws that move into engagement with opposed sides of the rod. As shown in FIG. 3 of the drawings, the jaws are each attached to an elongated bar that has a rack gear formed on the end of the bar that is remote from the clamp jaw. The rack gears are positioned opposed to one another in spaced apart relationship with an idler pinion gear positioned therebetween. One of the elongate bars is attached to a fluid driven cylinder 42. The reciprocating action of the fluid cylinder 42 causes the jaws, which are attached to the elongate bars, to move into and out of engagement with the workpiece.
Thus, the present invention differs from the previously described metal stretching apparatus in that the elongate arms are linear in configuration and are confined within a block that has precisely aligned grooves.
In a somewhat similar application, the rack and pinion gear assembly shown in FIG. 5 of U.S. Pat. No. 3,752,062 entitled "Apparatus for Bonding Brake Linings" issued Aug. 14, 1973, to Thomas E. Morgan, Sr. et al, utilizes a pair of opposed elongated rods to control the movement of bars 134 and 136. The elongated rods each have rack gears that engage a common idler pinion gear. A lever having a centrally disposed fulcrum is attached to an end of one elongated rod. The lever is also attached to a fluid driven cylinder 168. Thus, movement of the actuator rod in the fluid driven cylinder 168 will cause the attached elongated rod and rack gear to move in the opposite direction. The present invention is an improvement over the aforementioned apparatus in that there is no lever arm positioned between the fluid driven cylinder and the rack gear. Then, too, the present invention provides for rapid disengagement of the cylinder rod from the rack gear assembly.
SUMMARY OF THE PRESENT INVENTION
The present invention is a dual action fluid actuated device for use in a variety of applications where a generally linear equal and opposite compressive or tensile force is applied to shape, form or hold a workpiece.
The invention includes a housing of elongated block configuration that contains two spaced apart elongated arm guides in the form of grooves. The elongated ar guides traverse the entire length of the housing and are open at their opposite ends. Each one of the elongated arm guides within the housing contains an elongate arm. The elongate arms each contain a gear segment in the form of a rack gear that extends over a portion of the longitudinal extent of the elongate arms. A pinion gear is mounted for rotation within the housing and is positioned intermediate the two elongated arm guides. The teeth of the pinion gear extend into each of the elongated arm guides within the housing and mesh with the teeth of each elongate arm rack gear. At least one end of one elongated arm protrudes from the housing and contains one or more tools affixed thereto. A fluid driven cylinder is attached to the housing in line with the elongate arm. A cylinder rod is coupled to the elongate arm to control the linear motion thereof. A fluid ingress and egress is provided for the cylinder so that fluid pressure will cause the cylinder rod to move which in turn controls the movement of the elongate arm. The movement of one elongate arm in one direction causes an equal and opposite movement in the other elongate arm because of the interconnection of the pinion gear. Reversal of the fluid pressure within the cylinder causes the elongate arms to reverse their directions and either engage o retract one or more tools from contact with a workpiece.
A primary object of the present invention is to provide a force generating dual action apparatus that is accurate and can function with a variety of tools attached thereto.
Another object of the present invention is to provide an apparatus that uses a double rack and pinion gear to produce equal and opposite forces to move tools into and out of engagement with a workpiece.
A further object of the present invention is to provide a force generating dual action apparatus that can be driven by different fluid mediums.
Another object of the present invention is to provide an apparatus that contains two elongate arms that move in opposite directions when a force generated by a fluid cylinder is applied to at least one of the elongate arms.
Still another object of the present invention is to provide a tool carrying apparatus that contains a minimum of moving parts and seals.
A further object of the present invention is to reduce the work cycle time in that both elongate arms move tools or clamps simultaneously into and out of engagement with a workpiece.
Another object of the present invention is to eliminate the whipping or arcing movements associated with non-linear motion devices.
A further object of the present invention is to provide an apparatus having increased smoothness of performance.
Further objects and advantages of the present invention will become apparent from the following description and the appended claims, reference being made to the accompanying drawings forming a part of this specification, wherein like reference characters designate corresponding parts in several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view that shows the dual action apparatus of the present invention;
FIG. 2 is a cross-sectional side view, showing the rack containing elongate arms and their interconnection to one another;
FIG. 3 is a top plan view of the apparatus depicted in FIG. 2;
FIG. 4 is a fragmented cross-sectional view taken along section lines 4--4 of FIG. 3 that shows the coupling between the cylinder rod and the elongate arm;
FIG. 5 is a cross-sectional view taken along section lines 5--5 of FIG. 2 that shows the pinion gear, its support shaft and the elongate arms within their respective arm guides;
FIG. 6 is a cross-sectional view taken along section lines 6--6 of FIG. 2 that shows the two piece configuration of the housing block; and
FIG. 7 is a simplified side view of the present invention that permits the apparatus to move into and out of engagement with a workpiece.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and more particularly to FIG. 1, there is illustrated in perspective a dual action apparatus 10 in the form of a self-equalizing work tool.
FIG. 1 shows a tool that is adapted for a top support such as suspension from a cable system, or a pivotable side mount system. A platform or floor suspension system of the present invention will be described hereinafter.
With reference to FIG. 1, a housing block 12 of the overall apparatus 10 is shown in elongated form. The housing block 12 is essentially of a two part construction in that a milled portion 14 contains a cover plate 16 attached by a plurality of fasteners, such as bolts 18. The assembly formed by the milled portion 14 and the cover plate 16 contains a top elongate arm 20 and a bottom elongate arm 22 positioned juxtaposed thereto. The top and bottom elongate arms 20 and 22 are positioned longitudinally within the housing block 12 and are spaced from one another in generally parallel relationship. An end cap 24 is attached to one end of the housing block 12 by fasteners (not shown). The end cap 24 not only prevents the ingress of dirt into the interior of the overall apparatus 10, but the end cap 24 also serves as a mounting plate for a power source, such as a fluid actuated cylinder 26. The fluid actuated cylinder 26 contains a flange 28 that is bolted to the exterior of the end cap 24 with bolts 30. The fluid actuated cylinder 26 has a plurality of fluid coupling ports 32 and 33 that permit the introduction of a fluid medium to both sides of a piston that is integral with the fluid actuated cylinder 26. The fluid actuated cylinder 26 is also equipped with a pair of position sensors 34. Since the fluid actuated cylinder 26 must have communication with the interior of the housing block 12, an aperture 35 is provided in the end cap 24 (as best shown in FIG. 2). A pivotal support member 36 is attached to each side of the housing block 12 by a plurality of bolts 38. The overall apparatus can be suspended from a flexible support system by utilizing a series of mounting taps 40 that are positioned in the housing block 12. In addition to carrying the fluid actuated cylinder 26, the end cap 24 also has a motion attenuator in the form of a shock absorber 42 attached thereto in cantilevered fashion by fasteners (not shown). In FIG. 1, the top elongate arm 20 contains an attachment plate 44 attached to its free end. In a similar manner, an attachment plate 46 is attached to the free end of the bottom elongate arm 22.
By way of illustration, a clamp bracket 48 is affixed to the attachment plate 44 at the end of the top elongate arm 20. The clamp bracket 48 carries as an attachment or an integral part thereof a clamp pad 50. In a similar manner, the bottom elongate arm 22 has attached at its free end a clamp bracket 52. A clamp pad 54 is attached to the clamp bracket 52 so that the clamp pad 54 is in axial alignment with the clamp pad 50. Other tool combinations such as welding fixtures and punch and die combinations can also be used in place of the clamping arrangement above described.
FIG. 2 is a cross-sectional side view of the overall apparatus 10 that shows the arrangement of the top and bottom elongate arms 20 and 22 and their interrelationship to one another. The milled portion 14 of the housing block 12 contains a top groove 56. The top elongate arm 20 is positioned within the top groove 56. The top groove 56 extends from end to end of the milled portion 14 and has dimensional tolerances such that the top elongate arm 20 can slide freely therein. In a similar manner, the housing block 12 contains a bottom groove 58 that extends over the longitudinal expanse of the milled portion 14 and is oriented generally parallel to the top groove 56. The bottom elongate arm 22 also slides freely within the confinement of the bottom groove 58. Thus, the top and bottom grooves 56 and 58 provide guides for the top and bottom elongate arms 20 and 22.
The top elongate arm 20 is generally rectangular in cross-sectional configuration. One side of the top elongate arm 20 contains an array of teeth 60 in the form of a rack gear 62. In a similar manner, the bottom elongate arm 22 also contains an array of teeth 64 in the form of a rack gear 66.
A cylindrical bore 68 is located in the center of the milled portion 14. The cylindrical bore 68 is oriented transversely with respect to the axial extent of the top and bottom elongate arms 20 and 22. A pinion gear 70 is positioned within the cylindrical bore 68. The pinion gear 70 is contained on a pinion shaft 72 that is journaled in the milled portion 14 and the cover plate 16. The pinion gear 70 can be either fixed on the pinion shaft 72 so that it rotates simultaneously therewith or the pinion gear 70 can rotate about the pinion shaft 72. The pinion gear 70 is equipped with an arcuate array of teeth 74 that circumscribes the pinion gear 70. The teeth 74 of the pinion gear 70 are meshed with the teeth 60 and 64 of the respective top and bottom elongate arms 20 and 22.
The fluid actuated cylinder 26 is attached to the housing block 12 so that its longitudinal axis 76 coincides with the longitudinal axis of the top elongate arm 20. The fluid actuated cylinder 26 has a cylinder rod 78 that is extendible from one end thereof. The end of the cylinder rod 78 has attached thereto a fitment 80. The fitment 80 has a reduced section or neck 82 adjacent to an enlarged head 84 that is cylindrical in configuration. The actual coupling of the fitment 80 to the top elongate arm 20 will be discussed hereinbelow. The shock absorber 42 is attached to the end cap 24 by appropriate fasteners (not shown). An aperture 86 extends through the end cap 24 and a portion of the shock absorber 42 is installed therethrough. The shock absorber 42 has a cantilevered plunger rod 88 that extends through the aperture 86 toward the end of the bottom elongate arm 22. The plunger rod 88 is biased toward an extended position under the influence of a compression spring 90. The outboard end of the compression spring 90 rests against a head section 92. The head section 92 has a overall diameter that is considerably larger than the diameter of the plunger rod 88 and slightly larger than the diameter of the compression spring 90.
Attention is now directed toward the right-hand side of FIG. 2. A cantilevered end 94 of the top elongate arm 20 has the attachment plate 44 coupled thereto by bolts 96. A collapsible shield 98 is attached to the attachment plate 44 and to the housing block 12 by fasteners (not shown). The collapsible shield 98 can be of metallic construction or a high temperature fiber composite or a combination of both. The main purpose of the collapsible shield 98 is to protect the surface of the top elongate arm 20 from particulate matter, such as the airborne fallout from an adjacent welding operation. The bottom elongate arm 22 is likewise protected at its cantilevered end 100 by a collapsible shield 98. As depicted in FIG. 2, the attachment plate 46 is firmly attached to the end 100 of the bottom elongate arm 22 by bolts 102. In order to provide a positive stop for the top and bottom elongate arms 20 and 22, a stop block 104 is attached to a center section 108 of the milled portion 14 of the housing block 12 by fasteners (not shown). Thus, the stop block 104 serves to limit the retractable movement of both the top and bottom elongate arms 20 and 22.
FIG. 3 is a top plan view of the overall apparatus 10 that is shown in FIG. 2. The position sensors 34 are shown at each end of the fluid actuated cylinder 26. The position sensors 34 are attached to the fluid actuated cylinder 26 by means of bolts 106. The series of mounting taps or tapped holes 40 are positioned in vertical alignment at each end of the housing block 12. The tapped holes 40 provide means for attaching a vertical lift mechanism, such as a cable sling, that would be utilized during production use of the overall apparatus 10.
FIG. 4 is a fragmented cross-sectional view taken along the section lines 4--4 of FIG. 3. The milled portion 14 is shown with the top thereof at the right-hand side of FIG. 4. The top elongate arm 20 is shown in position within the top groove 56. The top elongate arm 20 is held captive within the top groove 56 by means of the cover plate 16. However, the cover plate 16 does not interfere with the axially slidable feature of the top elongate arm 20 within the top groove 56. The end of the top elongate arm 20 adjacent the fluid actuated cylinder 26 has a milled slot 110 that extends downward from a top surface 112 of the top elongate arm 20 to a position past the longitudinal axis 76. The bottom of the milled slot 110 is undercut to provide a reentrant section 114. The reentrant section 114 provides a ledge for interaction with the head 84 of the fitment 80. This arrangement provides for rapid connection of the fluid actuated cylinder 26 and its cylinder rod 78 to the end of the top elongate arm 20. As the top elongate arm 20 is moved to an extended position, the head 84 of the fitment 80 pushes against the end of the top elongate arm 20 in a positive manner. When the direction of motion of the top elongate arm 20 is reversed or retracted, the enlarged head 84 of the fitment 80 engages the reentrant section 114 of the milled slot 110, therefore, providing a positive engagement. Thus, it becomes evident that the fitment 80 acts as a quick disconnect coupling.
FIG. 5 is a cross-sectional view taken along the section lines 5--5 of FIG. 2. The housing block 12, which is formed by the coupling of the milled portion 14 and the cover plate 16, is depicted with the top and bottom elongate arms 20 and 22 within the respective top and bottom grooves 56 and 58. The pinion shaft 72 is journaled at one end in a bore 116 which is located in the sidewall of the milled portion 14 and is journaled at the other end in a bore 118 which is located in the cover plate 16. The pinion shaft 72 can be cradled in needle bearings 120, as depicted, or in the alternate sleeve bearings may be utilized. The pinion gear 70 can be fixed to the pinion shaft 72 by means of a key or other immobilization techniques. In the embodiment shown in FIG. 5, the pinion shaft 72 need not be attached to the pinion gear 70; however, when the pinion shaft is extended in length as depicted by the dotted lines associated with an extended pinion shaft 122, the extended pinion shaft 122 must rotate with the pinion gear 70. As will be seen in FIG. 7, the extended pinion shaft 122 is used to rotate an additional gear.
FIG. 6 is a cross-sectional view taken along the section lines 6--6 of FIG. 2. The milled portion 14 is shown with the top groove 56 and the bottom groove 58 milled therein. As previously pointed out, the top and bottom grooves 56 and 58 provide slideways for the top and bottom elongate arms 20 and 22. A rib 124 remains within the milled portion 14 after the top and bottom grooves 56 and 58 have been milled. The rib 124 is continuous from end to end of the milled portion 14 except for the cylindrical bore 68 that accommodates the pinion gear 70. The rib 124 provides extra rigidity for the overall apparatus 10.
FIG. 7 is a simplified side view of the present invention that enhances the mobility of the overall apparatus 10. The overall apparatus 10 is shown with the clamp bracket 48 attached to the free end of the top elongate arm 20. The clamp pad 50 is shown in its generally horizontal attitude. Likewise, the clamp bracket 52 is attached to the free end of the bottom elongate arm 22. A workpiece 126 is shown between the clamp pads 50 and 54. Immobilization of the workpiece 126, whether it is a single unit or a plurality of units, is important to the accurate positioning of welds, crimps, drilled holes and similar production manipulative operations. After a given operation is performed on the workpiece 126, it is important to be able to remove the tools therefrom.
In order to enhance the mobility of the overall apparatus, it has been provided with base support structure as shown in FIG. 7. A base plate 128 is anchored to a solid substrate. A pair of support plates 130 are cantilevered in a vertical direction from the base plate 128. The support plates 130 are spaced one from the other in order to provide adequate room for the overall apparatus to fit therebetween. The extended pinion shaft 122 extends through a slot 132 that is positioned in at least one of the support plates 130. A drive gear 134 is attached to the end of the extended pinion shaft 122. The drive gear 134 and the internally positioned pinion gear 70 are both fixed so that they rotate in unison with the extended pinion shaft 122. An externally mounted rack gear bar 136 is positioned so that an array of teeth 138 on the rack gear bar 136 mesh with an arcuate array of teeth 140 spaced around the circumference of the drive gear 134. The rack gear bar 136 is journaled for sliding motion through a pair of brackets 142 and 144. The brackets 142 and 144 are held in position against the exterior of the support plate 130 by bolts 146. A small elongated aperture 148 is positioned in the rack gear bar 136. A pin 150 is attached to the exterior of the support plate 130. The pin 150 extends through the aperture 148 in the rack gear bar 136. The aperture 148 moves freely with respect to the pin 150 and the rack gear bar 136 slides along the surface of the support plate 130.
Assembly and Operation
The assembly of the overall apparatus 10 of the present invention is not complicated which is an asset when repairs must be performed. The top elongate arm 20 and the fluid actuated cylinder 26 are coupled by installing the head 84 of the fitment 80 into engagement with the milled slot 110. The top elongate arm 20 is then inserted into the top groove 56 and the flange 28 of the fluid actuated cylinder 26 is attached to the end cap 24 by means of the bolts 30. The shock absorber 42 is likewise attached to the end cap 24. The bottom elongate arm 22 is installed in the bottom groove 58. The top and bottom elongate arms 20 and 22 are positioned as shown in FIG. 2, then the pinion gear 70 and the pinion shaft 72 are installed with care being taken to assure proper meshing of the teeth 60, 64 and 74. The cover plate is then secured by the installation of the bolts 18. The protective shields 98 are then telescoped over each of the cantilevered ends 94 and 100 of the top and bottom elongate arms 20 and 22. The shields 98 are held in place by fasteners (not shown).
During the operation of the overall apparatus 10, with the illustrative clamp tooling shown in FIG. 1, the top elongate arm 20 is moved to an extended position as shown in FIGS. 2 and 3. The movement of the top elongate arm 20 is achieved by the introduction of a fluid medium, such as air or oil, through the fluid coupling port 32. This of course creates a desirable pressure behind the piston head within the fluid actuated cylinder 26. The pressure created by the ingress of the fluid medium behind the piston within the fluid actuated cylinder 26 causes an extension of the cylinder rod 78. As the cylinder rod 78 moves to an extended position, the top elongate arm 20 also moves until it reaches its maximum extent as depicted in FIGS. 2 and 3. The rack gear 62 also moves with the top elongate arm 20. The rack gear 62 causes rotation of the pinion gear 70 which in turn causes the bottom elongate arm 22 to move in a direction opposite to the movement of the top elongate ar 20. As the bottom elongate arm 22 nears the end of its travel to the left, as viewed in FIG. 2, its end contacts the head section of the plunger rod 88. The metered resistance afforded by the shock absorber 42 prevents a sudden stop in the movement of the top and bottom elongate arms 20 and 22. When it becomes necessary to reverse the direction of travel of the top and bottom elongate arms 20 and 22, a fluid medium is then introduced to the fluid actuated cylinder 26 through the fluid coupling port 33. The fluid medium thus introduced to the front of the piston within the fluid actuated cylinder causes a retraction of the cylinder rod 78. The top elongate arm 20 follows the cylinder rod 78 because of the aforementioned coupling. The top elongate arm 20 moves toward the left as viewed in FIG. 2 until its attachment plate 44 has reached the dotted location 152. The movement of the top elongate arm 20 causes an equal and opposite travel in the bottom elongate arm 22. At the end of its travel, the attachment plate 46 reaches a terminal position depicted by the dotted location 154.
In the embodiment of the present invention shown in FIG. 7, a way has been devised to move the overall apparatus 10 away from any possible interference with a workpiece as it is moved into and out of a work station. The overall apparatus 10 is shown in FIG. 7 in the fully clamped position, that is, the clamp pads 50 and 54 are in compressive contact with the workpiece 126. After the particular work function has been performed on the workpiece 126, the overall apparatus 10 must be disengaged from the workpiece 126. As a fluid medium is introduced to the fluid actuated cylinder 26 through the fluid coupling port 32, the top elongate arm 20 begins to move to the right in the direction of the arrow 156. During this initial movement of the top elongate arm 20, the bottom elongate arm 22 also moves away from the workpiece 126 as depicted by the arrow 158. Also, during the initial movement of the top elongate arm 20 the pinion gear 70 is caused to rotate. Since the pinion gear 70, the extended pinion shaft 122, and the drive gear 134 are coupled together in a rigid subassembly, the rotation of the pinion gear 70 causes a similar rotation in the drive gear 134.
The rotation of the drive gear in a clockwise direction as depicted by arrow 162 causes the rack gear bar 136 to move toward the right or in the direction of arrow 160. The rack gear bar 136 has the freedom of slight lateral movement because of the pin 150 and the aperture 148 arrangement. The free travel of the rack gear bar 136 stops as the left-hand end of the aperture 148 engages the pin 150. Since the rack gear bar 136 can no longer travel in the direction of the arrow 160, the continued revolving of the drive gear causes it to begin translating or moving in the direction of the arrow 164. As the drive gear begins to translate, the extended pinion shaft 122 also moves along the slot 132. Thus, the entire overall apparatus 10 moves to the left with respect to the workpiece 126. As the overall apparatus 10 moves to the left, it can be further removed from the vicinity of the workpiece 126 by rotating the overall apparatus 10 in the direction of arrows 166 about its extended pinion shaft and accompanying external support, such as the pivotal support member 36 as shown in FIG. 1.
While the illustrative embodiments of the present invention have been described in considerable detail for the purpose of setting forth practical operative structures whereby the invention may be practiced, it is to be understood that the particular apparatus described is intended to be illustrative only, and that the various novel characteristics of the invention may be incorporated in other structural forms without departing from the spirit and scope of the invention defined in the appended claims. | An apparatus for providing a reciprocating motion. The apparatus has a housing block that contains two movable arms in spaced apart relationship to one another. The movable arms each contain a rack gear connected to a common pinion gear. One movable arm is driven by a fluid actuated cylinder. The driven movable arm then produces an equal and opposite motion in the other arm because of the interconnection of the pinion gear. Tools for altering of a workpiece may be attached to one or both ends of the movable arms. An embodiment utilizes the rotation of the pinion gear shaft to cause a translation of the entire apparatus away from a workpiece. | 1 |
FIELD OF THE INVENTION
[0001] The field of the invention is plug and perforate methods of sequential zone fracturing and more particularly devices and methods that allow retrieval of a frack plug occluding object designed to selectively plug an isolation device in the event the guns misfire and new guns need to be run in after the original guns are removed.
BACKGROUND OF THE INVENTION
[0002] In typical plug and perforate systems the bottom hole assembly (BHA) comprises an isolation device with a passage through it and a surrounding seat on the passage for an object to land on the seat and obstruct the passage. The object can be delivered with the isolation device or pumped to the isolation device after the perforating guns are shot and removed from the borehole with the setting tool for the isolation device. Delivering the object with the isolation device has the advantage of saving time to get the passage in the isolation device closed as compared to pumping down an object from the surface. However, this prior method has a drawback if the guns misfire. In essence, if the guns misfire they must be removed and new guns run in to the desired location which is frequently in a horizontal portion of the wellbore. Thus, gravity is not much help in running in the replacement guns. Furthermore, if the object was run in with the isolation device, then the object would be forced against the seat in the passage of the isolation device if any effort to use pressure or flow to deliver the replacement guns was employed. The closing off of the passage in the isolation device means the replacement guns cannot be delivered on wireline with a pressure or flow assist and that alternative means such as coiled tubing or tractors have to be used to get the guns into position. This adds enormous expense to the operation and creates issues of delay. Even if the object is dropped after the misfired gun is removed, it still takes time to pump the object from the surface to the seat on the isolation device that is thousands of meters away costing time and additional fluid displacement.
[0003] In the past one way to cut the time to get an object seated on a seat in an isolation device was to include a ball release device above the guns. The idea in US 2013/0175053 was to release the object into the annulus from above the fired gun and have the object make its way around the fired gun and the isolation device setting tool to a seat on a passage in the isolation device. A physical pull on the wireline sheared an unnumbered pin and allowed a ball 24 to escape through a lateral opening 28 to make its way toward the isolation device 14 . There are many issues with this design. Frequently the guns 18 have very low clearance around them to the casing 12 , which means the ball 24 will not fit in the annular space or would have to be so small that the passage in the isolation device 14 would also have to be small. A smaller passage in the isolation device could mean delays if a replacement gun has to be delivered with flow after an original gun misfires. The spent perforating gun could also have burrs and sharp edges that could hang up or damage the object so badly that it might not seal at all when landing in the seat. Finally, in a horizontal run the object may not actually land on the seat if the seat surrounding the passage in the isolation device is considerably smaller than the casing inside diameter, a condition made necessary by the object being small enough to travel past the gun in the surrounding annulus around the gun.
[0004] Generally related to operation of lateral passages that can be selectively opened in a fracking context are US2013/0024030 and US2013/0020065.
[0005] What is needed is a device and method that allows retention of the object that is designed to go onto a seat for a passage in an isolation until such time as the gun actually fires. The reason is that if the guns misfire and need to be replaced, it will still be possible to deliver the replacement guns with pressure or flow because the passage in the isolation device will be open because the object has been retrieved with the misfired guns. What is also provided is a launcher for the object that is placed in close proximity of the isolation device which allows the use of a larger object than when the launcher is above the guns and has to deliver the object into an annulus between the gun and the casing after the gun fires. What is also provided is an object launching device that responds directly or indirectly to the concussive pressure shock created by the guns initially firing so that the object is only released if the guns actually fire. This allows for the object to be retrieved without release if the guns misfire so that the replacement guns can be delivered with flow through the still open passage in the isolation device. On the other hand, if the guns fire then the pressure that is built up from the firing will release the object allowing the start of fracturing after the guns and setting tool for the isolation device are pulled out. Those skilled in the art will further appreciate additional aspects of the invention from a review of the description of the preferred embodiment and the associated drawings while recognizing that the full scope of the invention is to be determined by the appended claims.
SUMMARY OF THE INVENTION
[0006] In a fracking context the object that will ultimately block a passage in an isolation device is introduced into the zone with the bottom hole assembly. The object is not released until the guns fire to create a pressure spike in the borehole that triggers the object retaining device to release the object. The retaining device is placed in close proximity to the isolation device and its setting tool to allow a larger object and passage in the isolation device to be used. If the guns misfire, the object is not released and comes out with the guns. The replacement guns can be pumped in because the passage in the isolation device has stayed open during the misfire. Direct and indirect object release in response to pressure created from the firing of the guns is contemplated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a prior art section view of a cemented production tubing in a horizontal portion of a borehole;
[0008] FIG. 2 is the view of FIG. 1 showing the bottom hole assembly in position;
[0009] FIG. 3 is the view of FIG. 2 with the frack plug set and the guns separated from the set plug while the ball for the plug is also released and floating;
[0010] FIG. 4 is the view of FIG. 3 shows the guns being fired;
[0011] FIG. 5 is the view of FIG. 4 showing the BHA removed;
[0012] FIG. 6 is the view of FIG. 5 showing the ball seated in the frack plug as pressure is built up to fracture the perforations created by the guns;
[0013] FIG. 7 is a prior art view of a horizontal portion of a borehole with cemented casing to illustrate the problem of gun misfire;
[0014] FIG. 8 is the view of FIG. 7 showing the BHA run into position;
[0015] FIG. 9 is the view of FIG. 8 showing the frack plug set and the frack ball released;
[0016] FIG. 10 is the view of FIG. 9 showing the guns having misfired;
[0017] FIG. 11 is the view of FIG. 10 with the BHA removed and the frack ball on the seat of the frack plug preventing a replacement gun from being delivered on wireline with a pressure assist;
[0018] FIG. 12 shows the present invention with the BHA in position and the ball release tool between the setting tool and the frack plug;
[0019] FIG. 13 is the view of FIG. 12 with the frack plug set;
[0020] FIG. 14 is the view of FIG. 13 with the guns being pulled after a misfire with the frack ball still in the release tool;
[0021] FIG. 15 is the view of FIG. 14 with the substituted guns in the hole and where the shock wave from firing is starting to migrate from the guns;
[0022] FIG. 15 a is a detailed view of the ball releasing tool in a direct pressure actuated embodiment;
[0023] FIG. 16 is the view of FIG. 15 with the shock wave migrating to the release tool for a ball release;
[0024] FIG. 16 a shows the ball release tool just as the shock wave reaches it;
[0025] FIG. 17 is the view of FIG. 16 with the guns fired and the ball released from the ball release tool;
[0026] FIG. 17 a shows a detail of the ball release tool in the ball released position;
[0027] FIG. 18 is the view of FIG. 17 showing the BHA removed;
[0028] FIG. 19 is the view of FIG. 18 showing fracking with the plug ball on the seat of the frack plug; and
[0029] FIGS. 20 a - 20 b are an alternative embodiment to the ball release tool that responds to a pressure spike by moving other parts from a breakable barrier to drive the ball from the ball release tool.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] FIGS. 1-6 illustrate a known way of doing a plug and perforate fracturing technique in a horizontal cemented production casing 10 . FIG. 2 shows the BHA 12 in the desired location of the casing 10 . The BHA 12 comprises perforating guns 14 followed by a setting tool 16 and a frack plug 18 . The BHA 12 is run in on wireline 20 . In FIG. 3 the setting tool 16 has set the frack plug 18 and released from the frack plug 18 so that the frack ball 22 is released. The wireline 20 provides power to the setting tool 16 which can be an E- 4 setting tool sold by Baker Hughes Incorporated. The BHA 12 that is suspended by wireline 20 is aided in travelling into the horizontal portion of the well by pressure from the surface that creates flow to carry the BHA 12 into the horizontal portion of the borehole. At this time the frack plug is unset and flow can get past it and into an already perforated zone that is lower or into the formation if it is the initial zone to be perforated. The frack plug 18 has a through passage and surrounding ball seat 24 on which ball 22 lands to close the passage when there is flow urging the ball 22 toward the seat around passage 24 . FIG. 4 shows the guns 14 being fired to create the perforations 26 . FIG. 5 shows the BHA 12 removed from the casing 10 . Note that the ball 22 is still floating because there is no applied pressure from the surface that creates flow in the direction of arrow 28 . In FIG. 6 the pressure represented by arrows 28 is applied that forces ball 22 against the ball seat on passage 24 so that pressure is built up onto the perforations 26 to frack them.
[0031] The sequence of FIGS. 7-11 represent an illustration of what can go wrong if the guns 14 misfire. FIG. 7 is the same as FIG. 1 showing the cemented casing 10 in a horizontal portion of the well 30 . The same BHA 12 is run in as in FIG. 2 as is shown in FIG. 8 . The frack plug 18 is set in FIG. 9 and an attempt to fire the guns 14 after a release of the setting tool 16 from the plug 18 results in a misfire of the guns. However, the ball 22 is released in this separation process between the setting tool 16 and the frack plug 18 . The problem now created when the BHA 12 is pulled out is evident by looking at FIG. 11 . There is a need to run in a replacement BHA 12 ′ into the position formerly occupied by the original BHA 12 that had the guns 14 that misfired. The problem is that the ball 22 is blocking the passage 24 by sitting on the associated seat if there is any pressure applied in the casing 10 . With the misfire there are no perforations 26 and the zone below is effectively isolated by the frack plug 18 . What this means is that it will not be possible to use pressure that creates a flow to carry the BHA 12 ′ into the lateral or horizontal portion 30 . This means that the alternative is to deliver the BHA 12 ′ with coiled tubing or a tractor (not shown). Delivering the BHA 12 ′ using either of these techniques is slow and therefore expensive. In the case of coiled tubing, there may also be issues of space for the coiled tubing unit at the wellsite particularly in offshore applications. Tractors are far slower than a delivery on wireline with a flow assist. A flow assist is not possible in an unperforated section of a casing that has a frack plug 18 in a set position with a ball 22 landed on the seat surrounding its passage 24 .
[0032] With the above as a background, the present invention will be described in greater detail starting with FIG. 12 where the BHA 40 that comprises perforating guns 42 , a plug setting tool 44 and a ball release tool 46 are disposed above the frack plug 48 . In FIG. 13 the frack plug 48 is set as before. In FIG. 14 the release tool separates from the frack plug 48 while still retaining the frack ball 50 . If the guns 42 misfire at this point then the frack plug 48 has a clear through passage 52 because the ball 50 has not obstructed it. The BHA 40 with the ball 50 can be pulled from the casing 54 with wireline 56 .
[0033] On the other hand if the guns fire as shown in FIG. 15 then the perforations 58 are made. The operation of the guns creates a pressure wave 60 that migrates in the direction of arrow 62 toward the ball release tool 46 that is disposed between the setting tool 44 and the frack plug 48 . FIG. 16 shows the pressure wave 60 reaching the ball releasing tool 46 so that the ball 50 is released from the release tool 46 . Preferably the ball 50 is in alignment with the passage 52 in the frack plug 48 to facilitate seating the ball on a seat that surrounds the passage 52 . This is shown in FIG. 17 . The BHA 40 is now removed as shown in FIG. 18 and the perforations 58 are fracked as represented by pressure arrows 64 .
[0034] Thus one aspect of the present invention is a method that allows retention of an object that can be a ball or plug or other shape that is designed to land in the passage of a frack plug, in the event the guns do not fire, and despite the fact that portions of the BHA have released from the frack plug 48 when that plug was set by the setting tool 44 . The release of the frack ball 50 is dependent on the guns firing to create a signal that allows the ball release tool 46 to release the ball 50 . Thus if the guns fire there is no problem in releasing the ball because there will be a flow path to allow a replacement gun to be wireline delivered with a flow assist. The gun can have multiple stages that sequentially fire so it possible to get one or more but not all stages to fire. In that event the gun has to be pulled and a new gun or the same gun redressed have to be run in later. In either case the method allows the completion process to continue. A misfire on the initial stage firing will not result in a ball release so that the next gun can be delivered on wireline with a flow assist with flow going through the frack plug that has an open passage. If at least one stage fires the ball is released but a subsequent gun can still be delivered on a wireline with a flow assist because the stage that did fire creates a fluid path for the flow assist to move the replacement gun into position.
[0035] In another aspect of the invention the placement of the ball release tool 46 immediately adjacent the frack plug 48 allows the use of a larger passage 52 through the frack plug 48 as well as a larger associated ball, or plug or dart 50 . This is because unlike Madero US 2013/0175053 the ball does not need to travel in an annular space past the guns. The ball 50 is delivered below the guns 42 so it can be larger than a ball that has to travel in an annular gap which can be very small. The ability to use a larger passage in the frack plug 48 also speeds the delivery of a replacement gun if the original gun misfires because there is less pressure drop for the flow going through the passage of the frack plug 48 when the replacement gun is delivered. The release tool 46 can be up against the frack plug 48 or spaced from frack plug 48 with no intervening equipment in between. Alternatively, the ball can drop through another tool disposed between the release tool 46 and the frack plug 48 .
[0036] Referring to FIG. 15 a a direct responding release tool 46 is shown. Direct means the pressure wave 60 has enough force to break a breakable member 70 such that well pressure in the surrounding annulus 72 can be brought to bear on the piston 74 that has a surrounding seal 76 so that an upper sealed variable volume chamber is defined and grows in volume as pressure from annulus 72 displaces the piston 74 and its associated push rod 78 to contact the ball 50 and push it past a retainer 80 . Piston 74 pushes against variable volume chamber 75 that is initially at atmospheric pressure. When barrier 70 breaks there is a pressure differential on the piston 74 that is enhanced by the low pressure in chamber 75 . FIG. 16 a shows the shock wave 60 arriving at the breakable member 70 and breaking through and FIG. 17 a shows the resulting movement of all the parts that will launch the ball 50 in the manner described above. Those skilled in the art will appreciate that FIGS. 15 a - 17 a are schematic and intend to portray both direct and indirect actuation using the developed pressure from the discharge of the guns. In an indirect system, the generated pressure from shooting off the guns is sensed with a sensor that is powered with a stored energy source such as a battery to then take action to get parts moving to eject the ball 50 . This can be accomplished by forcibly breaking the breakable member 70 or actuating a motor that moves piston 74 or in other ways getting part movement sufficient to expel the ball 50 so that it lands on the passage 52 of the frack plug 48 to allow subsequent pressure buildup for fracking represented by arrows 64 . FIGS. 20 a - 20 b generically illustrates an indirect system which processes the existence of the pressure wave to either harness it for part movement or to trigger part movement in other ways that release the ball. Thus an indirect system can still employ wellbore hydrostatic but the opening of access to the hydrostatic pressure is done with a sensed pressure signal that opens access to annulus pressure. In FIG. 20 a instead of barrier 70 there is a pressure sensing module 100 to sense the presence of the pressure wave 60 and use that signal to operate a valve 102 that opens passage 104 to drive the piston 74 in the manner previously described. Alternatively, such a sensed pressure can provide power to a motor from a stored power supply that moves a mechanical element that expels the ball 50 .
[0037] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below: | In a fracking context the object that will ultimately block a passage in an isolation device is introduced into the zone with the bottom hole assembly. The object is not released until the guns fire to create a pressure spike in the borehole that triggers the object retaining device to release the object. The retaining device is placed in close proximity to the isolation device and its setting tool to allow a larger object and passage in the isolation device to be used. If the guns misfire, the object is not released and comes out with the guns. The replacement guns can be pumped in because the passage in the isolation device has stayed open during the misfire. Direct and indirect object release in response to pressure created from the firing of the guns is contemplated. | 4 |
This application claims priority to Australian Provisional Application No. 2011902602, filed Jun. 30, 2011, the entirety of which is incorporated by reference herein.
TECHNICAL FIELD
The present invention relates to conveyors that convey a flowable substance in granular (including powder) form, and more particularly but not exclusively to conveyors that deliver the flowable substance for the purposes of coating product on another conveyor to which the substance is delivered.
BACKGROUND OF THE INVENTION
In the snack food industry many snack foods are coated with a flavouring. There are machines that provide for the coating of the snack food, such as the machine described in U.S. Pat. No. 7,878,142.
A disadvantage of some previous machines is that they do not uniformly coat the snack food and/or have significant waste.
A further disadvantage of some previous machines is that they can be complex and therefore unreliable.
A still further disadvantage of some previous machines is that they are frequently difficult to clean.
Object of the Invention
It is the object of the present invention to overcome or substantially ameliorate at least one of the above disadvantages.
SUMMARY OF THE INVENTION
There is disclosed herein a conveyor assembly to deliver a flowable substance in granular form, said assembly including:
an elongated tray having a longitudinal axis and a floor provided to receive the substance, the floor sloping downward from a substance receiving portion to a substance delivery portion;
an actuator to cause vibration of the tray to cause the substance to travel along the floor from the receiving portion to the delivery portion at which the substance is delivered from the floor; and wherein
said delivery portion includes an edge of the floor so the substance falls from the floor, and said actuator vibrates the floor at a frequency with an amplitude with a vertical component, with said frequency being at least 20,000 hz.
Preferably, the frequency is less than 70,000 hz.
Preferably, the frequency is 30,000 hz to 40,000 hz.
More preferably, the frequency is 36,000 hz to 38,000 hz.
Preferably, said amplitude has effectively a negligible horizontal component.
Preferably, said horizontal component is approximately zero.
There is still further disclosed herein a conveyor assembly to deliver a flowable substance in granular form, said assembly including:
an elongated tray having a longitudinal axis and a floor provided to receive the substance, the floor sloping downwardly from the substance receiving portion to a substance delivery portion;
an actuator to cause vibration of the tray to cause the substance to travel along the floor from the receiving portion to the delivery portion at which the substance is delivered from the floor; and wherein
the floor at the delivery portion including an edge so that the substance falls from the floor, and said actuator vibrates the floor at a frequency with an amplitude extending generally perpendicular to said axis.
Preferably, said frequency is at least 20,000 hz.
Preferably, said frequency is less than 70,000 hz.
Preferably, the frequency is 30,000 hz to 40,000 hz.
More preferably, the frequency is 36,000 hz to 38,000 hz.
Preferably, the amplitude is l μm to 130 μm.
Preferably, the amplitude is 2.5 μm to 5 μm.
Preferably, the amplitude has affectively no component parallel to said axis.
Preferably, said amplitude has approximately zero component parallel to said axis.
Preferably, said actuator is attached to said tray by a coupling member, with said tray having a bottom surface to which the coupling member is directly attached.
Preferably, the tray and coupling member have a resonant frequency at approximately the frequency provided by the actuator.
Preferably, said edge is generally linear so as to have a direction of extension transverse of said axis and parallel to said axis.
Preferably, the edge has a length in the direction of extension parallel to said axis and a length in the direction transverse of said axis that is less than the length in the direction of extension parallel to said axis.
Preferably, the tray is inclined by 1° to 10° to the horizontal.
Preferably, the tray is inclined by 3° to 5° to the horizontal.
There is further disclosed herein, the above assembly and a further conveyor, and wherein said edge extends generally transverse of further conveyor so that the substance is spread transversely across the further conveyor.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred forms of the present invention will now be described by way of example with reference to the accompanying drawings wherein:
FIG. 1 is a schematic isometric view of portion of an assembly to deliver a flowable substance in granular form to a conveyor;
FIG. 2 is a schematic top plan view of the machine of FIG. 1 ;
FIG. 3 is a schematic front elevation of the machine of FIG. 1 ; and
FIG. 4 is a schematic rear elevation of the machine of FIG. 1 ;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the accompanying drawings there is schematically depicted a conveyor assembly 10 . The assembly 10 delivers flavouring to a conveyor 11 upon which there is conveyed a product to be coated. The flavouring would be in granular forms, this includes the flavour being a powder. As a particular example, the assembly 10 may deliver a flavouring to a snack food being conveyed by the conveyor 11 . Although many types of different conveyors may be employed, typically the conveyor 11 would be a slip conveyor having a longitudinally extending tray 13 that includes a pair of longitudinally extending side walls 12 between which a tray floor 14 extends. The tray 13 would be reciprocated in the direction 15 so as to convey product in the longitudinal direction 16 . Typically the snack food would be distributed transversely across the tray 13 .
The assembly 10 includes a conveyor 17 consisting of a longitudinally elongated tray 23 that is vibrated by an actuator 19 . Preferably the actuator 19 is electrically operated and provides a vibration in the frequency range of 20,000 hz to 70,000 hz, most preferably about 36,000 hz to 38,000 hz. Supporting the tray 23 is a shaft 20 that is fixed to the tray 23 . The shaft 20 is supported by a collar 21 , with the collar 21 being mounted on a bracket 22 . The actuator 19 is also mounted on the bracket 22 so as to be supported thereby.
The tray 23 includes a pair of longitudinally extending sides 24 between which there is located a longitudinally extending floor 25 . The sides 24 extend upwardly from the tray floor 25 . The shaft 20 is fixed to the bottom surface of the tray 23 .
The actuator 19 vibrates the floor 25 so that the floor 25 has an amplitude with a vertical component, and most preferably with a vertical component and essentially negligible or zero horizontal component. In an alternative preferred from, the actuator 19 vibrates so as to vibrate the floor 25 so as to have an amplitude with a component perpendicular to the longitudinal axis 30 , and most preferably with a component perpendicular to the axis 30 with essentially negligible or zero component parallel to the axis 30 . When vibrated at the above frequency, the flavouring delivered to the tray 13 is essentially “fluidised”. Preferably, the actuator 19 is a ultra high frequency (ultra-sonic frequency) “Sonotrode” actuator. Typically the actuator 19 would be a piezo electric motor with a vertical amplitude (or an amplitude perpendicular to the axis 30 ) of between 1.0 μm and 130 μm, preferably 2.5 μm to 5 μm.
Preferably, the floor 25 is inclined to the horizontal by an acute angle of 1° to 10° , preferably about 3° to 5°.
The tray 23 has a receiving portion 26 to which the flavouring is delivered, and a delivery portion 27 . The delivery portion 27 includes an edge 28 of the floor 25 , the edge 28 extending at an acute angle 29 to the longitudinally axis 30 of the tray 23 . The edge 28 has a major direction of extension parallel to the axis 30 as well as a direction of extension in a lateral direction perpendicular to the axis 30 so as to be inclined by the angle 29 . The length of the edge 28 is greater in the longitudinal direction than the length of the edge 28 in the lateral direction, i.e. the angle 29 is less than 45°.
Vibration of the tray 23 (floor 25 ) causes the flavour to travel in the direction 31 from the receiving portion 26 to the delivery portion 27 as the floor slopes downwardly at an acute angle from the receiving portion 26 to the delivery portion 27 . Ultimately product passing along the tray 23 reaches the edge 28 at which time it falls from the edge 28 to be deposited on product on the floor 25 of the tray 13 . The product is coated by the flavouring. As the edge 28 extends substantially across the entire width of the floor 25 , product scattered across the floor 25 is coated.
Preferably, the direction 31 is generally perpendicular to the direction 16 .
The flavour is delivered to the tray 23 from a flavour delivering assembly 32 . The assembly 32 includes a hopper 33 that stores a volume of the flavouring in granular or powder form. The hopper 33 communicates with an auger assembly 34 that delivers the flavouring to a tube 35 via which the flavouring is delivered to the tray 23 at the delivery portion 26 . The auger assembly 34 would include an auger that passes through the lower end of the hopper 33 , or is in communication with the lower end of the hopper 33 , with the auger being driven by a motor and gearbox assembly 36 . | A conveyor assembly to deliver flavoring to a conveyor upon which a product to be coated is conveyed. The flavoring is typically in granular form such as a powder. The assembly includes a conveyor including a longitudinally elongated tray that is vibrated by an actuator. The tray and actuator are adapted to distribute the flavoring transversely across the conveyor. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Art
This invention relates to a saponin-containing galenical extract and a product isolated therefrom and more particularly to an absorption adjuvant composition for aiding adsorption of drugs to be absorbed or administered through the alimentary system. This invention is based on a finding relating to the pharmacological characteristics of this galenical extract capable of aiding, particularly promoting, absorption of a pharmacologically active substance administered through or into the alimentary system, e.g., orally or by insertion into the rectum.
2. Prior Art
Because of the difficulty in isolation by purification of saponin and its complicated structure, it has not been very long ago, only about ten and some years ago, when marked progress in research on saponin appeared.
As typical characteristics of saponins, they foam when shaken with water, act as powerful hemolytics by dissolving red blood corpuscles, are poisonous toward fish, and can form complexes with cholesterol (a steroid). As pharmaceuticals, they have been found to have pharmacological activities such as expectorant, antibechic, antiinflammatory, central nervous system blocking, antifatigue, antiulcer, cholesterol metabolism promoting, lipid metabolism promoting and nucleic acid or protein synthesis promoting activities. In addition, it has also recently been found that they have anti-infective and antitumor activities. Saponin-containing galenicals with relatively higher saponin contents listed in the Japanese Pharmacopoeia may include Senega, Polygala Root, Platycodon Root, Glycyrrhiza, Achyranthes Root, Bupleurum Root, Panax Rhizome, Ginseng, Ophiopogon Tuber, Akebia Stem, etc.
Saponins can be classified according to the chemical structures of the sapogenin or aglycone moieties thereof into steroid saponins and triterpenoid saponins. Triterpenoid saponins containing hederagenin as aglycone are obtained from various plants such as Akebia guinata Decne. (Chem, Pharm, Bull. 24, 1021 (1976)), Caulophyllum robustum Maxim. (C.A. 85, 106644h (1976), Fatsia japonica. Decne. (Phytochemistry 15, 781 (1976)), Sapindus mukurossi Gaertn. (C.A. 73, 77544, 110062m, 110071p (1970) and C.A. 74, 13384f (1971)), Lecaniodiscus cupanioides Planch. ex Benth (Phytochemistry 20, 1939 (1981)). But no systematic pharmacological research has been developed so far. Bupleurum root saponin, which is one of triterpenoid saponins, has very potent hemolytic and local excitory actions, exhibiting sedative, antalgic, hypothermal, antipyretic actions and anti-inflammatory effect, and it is also effective for digestive ulcer. As for a saponin from the peels of Sapindus mukurossi Gaertn., which is another triterpenoid saponin, it has not previously been used for medical purpose, but investigations about its anti-inflammatory action have been made due to similarlity in chemical structure. There is a report that it exhibited inhibitory effect in carragheenin edema and adjuvant arthritis of rats.
In spite of discovery of various pharmacological activities of saponin as mentioned above, systematic pharmacological research has just begun, and it can be expected in the future that a novel pharmacological effect not known in pharmaceuticals of prior art will be discovered.
On the other hand, in the administration of an antibacterial preparation, there is known the concept of minimal effective concentration in blood. At a level lower than such concentration, a drug is not effective even if it may exist persistently for a long time in a body. For this reason, the utilization percentage by absorption of a drug to be absorbed through the alimentary system is very important, and there have heretofore been investigations on methods for maintaining effective concentrations in blood with smaller amounts of drugs by enhancement of the absorption efficiency of drugs from the standpoint of either preparation or administration technique.
However, it would be greatly beneficial, if the absorption utilization percentage could be enhanced by administration of a conventional drug for oral administration according to a conventional oral administration method.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an expendient for solving the above problem. This object has been achieved by the use of a saponin-containing galenical extract or a product isolated therefrom as an absorption adjuvant composition.
Thus, the adsorption adjuvant composition for a drug to be absorbed through the alimentary system according to the present invention, which is useful for aiding absorption of a pharmacologically active substance administered through or into the alimentary system, comprises a saponin-containing galenical extract or an isolated product therefrom and, optionally, a pharmaceutically acceptable vehicle.
In a specific embodiment of the invention, the isolated product has the form of a triterpenoid saponin represented by the following formula. ##STR1## wherein R is ##STR2##
These triterpenoid saponins can be obtained by subjecting the peels of Sapindus mukurossi Gaertn. (hereinafter referred to as mukurossi peel), without or after defatting treatment, to extraction with a lower aliphatic alcohol or a mixture of water with a lower aliphatic alcohol and further separating the triterpenoid saponin represented by the above formula from the resulting extract fractions.
According to the present invention in another aspect thereof, there is also provided a pharmaceutical composition for administration through the alimentary system, comprising a combination of a safe and effective quantity of a saponin-containing galenical extract or a product isolated therefrom and a safe and effective amount of a pharmacologically active substance.
Further, the present invention also provides a method of administering through the alimentary system a pharmacologically active substance improved in absorption property, which comprises administering a pharmacologically active substance in combination with a saponin-containing galenical extract or a product isolated therefrom through alimentary system, especially, orally or into the rectum.
DETAILED DESCRIPTION OF THE INVENTION
1. Galanical extract
The galenical extract utilized in the present invention is an extract of a galenical containing a saponin component.
(1) Galenical
A large number of galenicals containing saponin components are known in the art, and any one of them can be employed in the present invention.
Typical examples of galenicals containing saponin components suitable for use in the present invention are enumerated below. In the present invention, the term "galenical" is used with the same meaning as or interchangeably with the corresponding "plant".
(1) (Pharm.) Akebia quinata Decne. or plants belonging to the same family (Lardizabalaceae).
(2) Fatsia japonica Decne. et Pianch.
(3) Caulophyllum robustum Maxim.
(4) Hedera rhombea Bean.
(5) Clematis chinensis Osbeck.
(6) Pulsatilla cernua Spreng.
(7) Sapindus mukurossi Gaertn.
(8) (Pharm.) Panax japonicum C. A. Meyer.
(9) (Pharm.) Glycyrrhiza glabra L. var. glandulifera Regel et Herder, Glycyrrhiza uralensis Fisher or plants belonging to the same family (Leguminosae).
(10) (Pharm.) Polygala senega L. or Polygala senega. L. var. Latifolia Torrey et Gray.
(11) (Pharm.) Platycodon grandiflorum A.D.C.
(12) (Pharm.) Polygala tenuifolia Willd.
(13) (Pharm.) Achyranthes fauriei Lev. et Van or Achyranthes bidentata Blume.
(14) Cyclamen europaeum.
(15) Primula officinalis.
(16) (Pharm.) Bupleurum falcatum L. or its varieties (Umbelliferae).
(17) (Pharm.) Panax ginseng C. A. Meyer.
(18) Panax notoginseng Burkill.
(19) Panax quinquefolium L.
Remarks
(1) Plants 1-7 contain saponins containing hederagenin as aglycone.
(2) A plant designated (Pharm.) is an original plant giving galenical listed in the Japanese Pharmacopoeia, 9th Edition.
(3) Root of Bupleurum falcatum L. is hereinafter referred to as Bupleurum root. This Bupleurum root and the mukurossi peel are famous galenicals from olden times.
(2) Extraction
The saponin-containing galenical extract to be utilized in the present invention can be obtained according to a conventional method using the above plants as starting materials from the galenicals thereof. That is, for example, the starting galenical, without being defatted or after being defatted with a conventional lipid-soluble organic solvent, is subjected to extraction of its effective ingredients with an extracting reagent such as water, a lower aliphatic alcohol, especially C 1 -C 4 monohydric alcohol, or a mixture of water with a lower aliphatic alcohol. In addition to these extracting reagents, there may also be used a lower ketone such as acetone, a lower ether such as diethylether, an ester of a lower mono-carboxylic acid with a lower alcohol such as ethyl acetate and others.
In the present invention, the extract can be utilized as such or after concentration. Ordinarily, however, it is subjected to purification to some extent before use. According to one example of purification, the concentrated extract is suspended in water, the suspension with addition of n-butanol is shaken and, after separation of the n-butanol layer, the aqueous layer is evaporated to dryness.
The plants are not necessarily required to be naturally occurring; a product obtained by tissue culture of cells from the starting plant may also be employed. When the tissue cultured product is still in the undifferentiated state but already contains saponin components, it is also possible to apply an extraction operation on such a cultured product.
(3) Extract
The thus prepared extract contains saponin components.
The saponins contained in the extract to be used in the present invention have chemical structures which have not yet completely been elucidated. The critical specific feature which must be possessed commonly by the extracts of the present invention is that each must be an n-butanol-soluble component of a galanical containing a saponin and has an absorption promoting capability with respect to a pharmacologically active substance for oral administration.
The isolated mukurossi peel saponins have chemical structures (four kinds corresponding to four types of sugar moieties respectively bonded to hederagenin) as reported by us in "Abstracts of Lectures in 101th Annual Symposium of Pharmacological Society of Japan", and the use thereof as drug absorption aids is one embodiment of the present invention as will be described in detail hereinafter. The Bupleurum root saponin has a chemical structure as reported in J. C. S. Perkin I, 2043 (1975), Tetrahedron Letters No. 46, 4167 (1976) and Tetrahedron Letters No.14, 1227 (1977). The mukurossi peel saponins prepared by the present inventors are substances all in the form of white powders, irrespective of the difference in the sugar moieties, which are readily soluble in methanol and hardly soluble in water. On the other hand, the Bupleurum root saponins (including Bupleurum root saponins, a, c, d and etc.) are hygroscopic substances in the form of brown powders, which are readily soluble in methanol and hardly soluble in water.
The term "extract" as used herein refers comprehensively to both the extract in the state of a solution and the solid or powders obtained therefrom by removal of the solvent (that is, substantially saponin).
2. Isolated saponin product
The isolated mukurossi peel saponins as one embodiment of the isolated saponin products of the present invention include the three kinds of saponins A, B and C, depending on the kinds of R in the above formula, as shown below.
______________________________________Saponin R______________________________________ ##STR3##B ##STR4##C ##STR5##
Saponin A is a known substance (Phytochemistry, 20, 1939 (1981). That is, Saponin A is 3-O-[α-L-arabinopyranosyl-(1→3)-α-L-rhamnopyranosyl-(1.fwdarw.2) -α-L-arabinopyranosyl]-hederagenin.
(2) Saponin B
Saponin B is a known substance (C. A. 73, 77544v (1970)). That is, Saponin B is 3-O-[β-D-xylopyranosyl-(1→3)-α-L-rhamnopyranosyl-(1.fwdarw.2)-α-L-arabinopyranosyl]-hederagenin.
(3) Saponin C
Saponin C is a known substance (Phytochemistry, 20, 1939 (1981). That is, Saponin C is 3-O-[α-L-arabinofuranosyl-(1→3)-α-L-rhamnopyranosyl-(1.fwdarw.2)-α-L-arabinopyranosyl]-hederagenin.
(4) Preparation of Saponins A, B and C
Saponins A, B and C can be prepared from the mukurossi peel.
The preparation steps according to one embodiment of the invention are described in detail below.
The mukurossi peel, without defatting or after being defatted with the use of a conventional lipid-soluble organic solvent, is subjected to extraction with an extracting reagent selected from a lower aliphatic alcohol, particularly C 1 -C 4 monohydric alcohol and a mixture of water with a lower aliphatic alcohol. The extract is conducted by normal phase chromatography using adsorbent (preferably silica gel) with the use of an eluant, which is a solvent mixture of an insoluble organic solvent (e.g., ethyl acetate, chloroform, n-butanol), an alcohol (e.g., methanol, ethanol) and water to obtain saponin fractions. The fractions are then subjected to purification operation such as recrystallization, if possible, to obtain the desired isolated saponin product.
3. Drug absorption adjuvant composition
The drug absorption adjuvant composition contains a galenical extract or a product isolated therefrom as described above That is, the drug absorption adjuvant composition may comprise either a single kind of a galenical extract or a product isolated therefrom or a mixture of plural kinds of such galenical extracts or isolated products. Alternatively such a composition may further contain optionally any pharmaceutically acceptable liquid or solid vehicle. As the dosage form, there may be included powders, pills, tablets, emulsions, capsules, species, granules, parvules, solutions (including also fluidextracts and syrups), troches, and any other form administrable orally or by insertion into the rectum.
The composition may be administered in any desired dosage, as long as the effect of promoting drug absorption can be recognized. Most saponin-containing galenicals are known in the art as starting materials for herb medicines, and therefore suitable levels of dosage are already empirically known. Thus, in the present invention, the optimum dosage for a given pharmacologically active substance to give a desired absorption improvement effect can easily be determined on the basis of such empirically known dosage levels. As described above, the extract utilized in the present invention has also a physiological activity well known in the art and it will sometimes be necessary to take such an activity into consideration in determining the dosage in the practice of the present invention. However, as a measure for producing a desirable drug absorption promoting effect, a galenical extract or a product isolated therefrom may be administered generally at a level of 2.5 to 250 mg, preferably 20 to 50 mg per dose for a human adult.
The drug absorption adjuvant composition according to the present invention is ordinarily prepared separately from the preparation of a pharmacologically active substance to be promoted in its absorption. In this case, the commercially available product will take the form of a kit comprising a preparation of the pharmaceutically active substance and a preparation of the absorption adjuvant composition. However, if desired, the composition can also be made into a preparation integrally combined with an objective pharmacologically active substance.
As mentioned above, triterpenoid saponins containing hederagenin as aglycone are obtained from various kinds of plants. But, it can be said that the pharmacological activity of a saponin depends greatly on the kinds of sapogenins as described, for example, in "Biologically Active Natural Substances" edited by Shoji Shibata, 418, 1978). Therefore, it may be possible to analogize that the saponins contained in the extracts of the starting materials other than the mukurossi peel having the drug absorption promoting effect of the present invention are triterpenoid saponins similarly as the above saponins A, B and C, and some of them may be triterpenoid saponins containing hederagenin as aglycone similarly as said saponins A, B and C.
4. Pharmacologically active substances
The pharmacologically active substances to be promoted in absorption with the use of a saponin-containing galenical extract or a product isolated from the extract are drugs to be administered orally or into the rectum, the concentrations of which in the blood are desirably held persistently for a long time at a level of minimal effective concentration in the blood or higher.
Examples of such pharmacologically active substances are β-lactam type antibiotics, especially penicillins and cephalosporins, and physiologically active peptides. Among these, typical examples are β-lactam type antibiotics, especially penicillins and cephalosporins as set forth below.
As penicillins, there are Ampicillin, Ciclacillin, Cloxacillin, Benzylpenicillin, Carbenicillin, Piperacillin, Mezolocillin, Sulbenicillin, Ticarcillin, Apalcillin, Amoxicillin, Hetacillin, Talampicillin and sodium salts thereof.
As cephalosporins, Cefalexin, Ceftezole, Cefapirin, Cefalotin, Cefoxitin, Cefmetazole, Cefazolin, Cefaloridine, Cefacetrile, Cefotiam, Ceforanide, Cephanone, Cefaclor, Cefadroxil, Cefatridine, Cefradine, Cefaloglycin, Cefoperazone (T-1551) and sodium salts thereof may be mentioned.
5. Experimental example (I): Galenical extract
Experimental method A
Rats weighing 180 to 220 g were anesthetized with 30 mg/kg of pentobarbital sodium and fixed by supination on a water bed made of a metal through which water regulated at a constant temperature of 39° C. was circulated. A duodenal loop of 10 cm length was prepared in a conventional manner with the point 1 cm under the pyloric part of the stomach as the starting point. Into the loop was injected a solution of ampicillin sodium and a galenical extract dissolved in a phosphate buffer of pH 6.5 in a proportion of 0.5 ml per 200 g of body weight of the rat. The rats were bled from jugular veins 10, 20, 40, 60, 90, 120, 180 and 240 minutes after injection and activity concentration in the blood in each case was measured according to biological assay.
That is, according to The Japan Antibiotic Drug Standards, using Bacillus subtilis as test microorganism, cultivation assay was performed by the paper disc method at 37° C. for 15 to 20 hours.
The composition of the solution had the following composition:
Ampicillin sodium: 20 mg/ml
Galenical extract: 2 mg/ml-20 mg/ml
Examples according to the experimental method A are shown in Examples 1A through 4A.
Experimental method B
Rats weighing 200 to 230 g under anesthesia with ether were intubated with polyethylene tube (PE-10) at the femoral artery with ligation. The other end of PE-10 was passed subcutaneously to be led to the cervicodorsal part, at which it was drawn out of the skin and fixed with capping. After restoration of the vulnus at the operated portion (about 24 hours), each rat was provided for the experiment.
A solution having ampicillin sodium (5 mg/ml) and a galenical extract (1 mg/ml) dissolved in purified water was administered by means of a stomach probe in a proportion of 1 ml per 200 g of rat body weight, and the blood was sampled periodically with elapse of time for measurement of activity concentration according to biological assay.
The test microorganism used was Bacillus subtilis, and the assay was performed by the paper disc method according to The Japan Antibiotic Drug Standards.
An example according to the experimental method B is given in Example 5B.
EXAMPLE 1A
Table 1 shows the results obtained when using n-butanol extract of Bupleurum falcatum L.
TABLE 1______________________________________Conc. of PharmacologicallyActive Substance in BloodConc.ofBup-leurumfal- Concentration in Blood (μg titer/ml)catum Rat 10 20 40 60 90 120 180 240extract No. min. min. min. min. min. min. min. min.______________________________________20 1 6.9 17.5 18.4 14.2 9.0 4.1 2.5 2.1mg/ml 2 5.8 16.0 15.5 14.0 8.0 4.1 2.3 1.75 1 3.2 9.0 9.0 6.3 4.7 3.3 1.5 1.0mg/ml 2 2.4 7.5 7.7 5.5 2.9 1.6 0.5 0.50 1 0.6 0.9 1.1 1.2 0.9 0.9 0.5 0.5(Con-trol)______________________________________
EXAMPLE 2A
Table 2 shows the results when a mukurossi peel extract TN-4-Bu was used in a concentration of 2 mg/ml.
TABLE 2______________________________________Conc. of PharmacologicallyActive Substance in BloodConcentration in Blood (μg titer/ml)Rat 10 20 40 60 90 120 180 240No. min. min. min. min. min. min. min. min.______________________________________1 3.8 12.0 19.2 17.1 14.5 12.7 8.7 7.72 5.7 20.4 23.0 18.4 17.6 14.5 11.3 7.73 3.5 11.2 14.0 12.4 7.6 5.3 3.7 3.84 9.4 16.5 14.3 8.5 4.7 2.6 1.2 0.55 0.6 0.9 1.1 1.2 0.9 0.9 0.5 0.5(Control)______________________________________
EXAMPLE 3A
Table 3 shows the results when a mukurossi peel extract TN-4-E 3-5 was used in a concentration of 2 mg/ml.
TABLE 3______________________________________Conc. of PharmacologicallyActive Substance in BloodConcentration in Blood (μg titer/ml)Rat 10 20 40 60 90 120 180 240No. min. min. min. min. min. min. min. min.______________________________________1 10.3 22.1 27.5 20.0 -- 10.3 7.1 --2 5.4 14.5 19.7 18.1 -- 10.9 9.2 8.13 13.6 20.6 24.9 22.0 -- 14.4 11.1 11.04 6.3 15.4 19.2 17.6 -- 4.3 3.7 3.15 0.6 0.9 1.1 1.2 0.9 0.9 0.5 0.5(Control)______________________________________
EXAMPLE 4A
Table 4 shows the results when a mukurossi peel extract TN-4-E 2 was used in a concentration of 2 mg/ml.
TABLE 4______________________________________Conc. of PharmacologicallyActive Substance in BloodConcentration in Blood (μg titer/ml)Rat 10 20 40 60 90 120 180 240No. min. min. min. min. min. min. min. min.______________________________________1 5.6 13.7 19.5 15.0 -- 5.5 4.9 --2 5.5 20.3 25.5 12.8 -- 3.1 2.6 2.13 5.5 21.1 26.5 16.9 -- 5.9 2.6 2.24 7.8 20.7 25.0 14.3 -- 5.4 3.1 2.85 0.6 0.9 1.1 1.2 0.9 0.9 0.5 0.5(Control)______________________________________
EXAMPLE 5B
TABLE 5______________________________________Conc. of PharmacologicallyActive Substance in BloodConcentration in Blood (μg titer/ml)Rat 10 20 40 60 90 120 180 240No. min. min. min. min. min. min. min. min.______________________________________1 + 0.4 0.9 2.0 1.7 1.0 0.6 0.4 tr. - 0.4 0.8 1.2 0.8 0.3 tr. tr. tr.(Control)2 + 0.8 1.8 2.1 1.7 1.2 0.8 0.2 tr. - 0.3 0.6 1.3 0.5 tr. tr. tr. tr.(Control)______________________________________ Note: tr.: trace
In the above Examples, the extract samples were prepared according to the methods described below.
(1) Bupleurum falcatum L. extract
500 g of minces of a biennial Bupleurum falcatum L. was employed.
Extraction was performed for aliquots each of 50 g with 500 ml of methanol/50 g using a mixer at room temperature, and extraction was repeated three times for each aliquot. (Consequently, 500 g of Bupleurum falcatum L. was extracted with 15 liters of methanol.) The methanol layer was subjected to evaporation to obtain 122 g of a methanol extract. The methanol extract was suspended in 750 ml of water, and the suspension was extracted (defatted) twice with 750 ml of diethyl ether to obtain 3 g of an ether extract. In the second time extraction, an emulsion was formed and the emulsion was made into aqueous layers. These aqueous layers were extracted 5 times with n-butanol saturated with water (total quantity, 1.8 liter) and evaporated at 38° to 40° C. (to prevent decomposition of Bupleurum root saponin by heat) to produce 52 g of a butanol extract.
The butanol extract was lyophilized, and 3 g of the product was used as a sample for pharmacological test (this sample was hygroscopic).
(2) Mukurossi peel extract
Mukurossi peel (100 g) was broken into pieces by hand and defatted by dipping in cold benzene (room temperature, 400 ml×3 times).
The defatted galenical was extracted by dipping in hot methanol (70° C., 400 ml×5). The methanol extract layer was subjected to evaporation to produce 65.6 g of a methanol extract (TN-4-M). Of the methanol extract, 11.4 g was reserved for storage, and 54.3 g was suspended in 350 ml of water and extracted with ethyl acetate (300 ml×5 times). During this operation, the emulsion portion was formed into an aqueous layer. After evaporation of the ethyl acetate layer, there were obtained 1.26 g (TN-4-E) as the first extract, 0.64 g (TN-4-E 2 ) as the second extract, and 1.21 g (TN-4-E 3-5 ) as the third to fifth extracts, respectively, making a total of 3.11 g. The aqueous layer after extraction with ethyl acetate was further subjected to extraction with n-butanol saturated with water (300 ml×once), followed by evaporation of the butanol layer, to produce 16.42 g (TN-4-Bu).
Experimental example (II) Isolated saponin product
(1) Extraction
Mukurossi peel (370 g) was broken into pieces by hand and defatted by dipping in cold methanol (room temperature, one liter). The defatted galenical was extracted by dipping in hot methanol (70° C., one liter×2). The methanol extract layer was subjected to evaporation to obtain 200 g of a methanol extract. Of the methanol extract, 140 g was reserved for storage, and 60.0 g was suspended in 200 ml of water and extracted with n-hexane. During this operation, in order to prevent emulsion formation, 8 ml of ethanol was added. After evaporation of the n-hexane layer, 290 mg of an extract was obtained. The aqueous layer after extraction with n-hexane was subjected to extraction with ethyl acetate (200 ml×6 times). The ethyl acetate layer was evaporated to produce 2.7 g of the first through the third extracts and 1.0 g of the fourth through the sixth extracts, respectively. The aqueous layer after extraction with ethyl acetate was further subjected to extraction with n-butanol saturated with water (200 ml×once), which step was followed by evaporation of the butanol layer to obtain 11.4 g of a butanol extract (TN-3-Bu).
(2) Isolation
The extract TN-3-Bu (11.4 g) prepared in the foregoing operation was subjected to column chromatography using a column of silica gel with an eluant of ethyl acetate-ethanol-water (15:2:0.8→15:3:1.2) to obtain fractions Nos. 1 through 50.
Evaporation of the solvent from the fraction No. 31 produced 350 mg of a residue, which was further subjected to recrystallization from methanol/ethyl acetate to obtain 110 mg of saponin A.
Evaporation of the solvent from the fractions Nos. 19 through 22 produced 1.32 g of a residue, which was subjected to chromatography through a column of silica gel with an eluant of ethyl acetate-ethanol-water (8:2:1) to obtain fractions Nos. 51 through 100. From 330 mg of the residue after evaporation of the solvent from the fractions Nos. 80 and 81, 270 mg of saponin B was obtained by recrystallization from a dilute methanol solution.
The residue (630 mg) obtained by evaporation of the solvent from the fractions Nos. 16, 18 and 19 was subjected to column chromatography using silica gel with an eluant of ethyl acetate-ethanol-water (16:2:1) to obtain fractions Nos. 101 through 110. The residue (170 mg) obtained by evaporation of the solvent from the fraction No. 17 was also subjected to chromatography through a silica gel column with an eluant of ethyl acetate-ethanol-water (45:10:1) to obtain fractions Nos. 111 through 120. From the residue after evaporation of the solvent from the fractions Nos. 103 and 112, there was obtained 210 mg of saponin C.
(3) Pharmacological tests
Experimental method A was repeated except that saponins A, B and C were respectively used in a concentration of 5 mg/liter in place of the galenical extract in a solution to be administered.
Examples according to the above experimental method are shown in the following Examples 6, 7 and 8. In each of the Examples, there was no damage of mucosa (e.g. mucosa ablation) or abnormality such as hemorrhagic spot by observation of the duodenum employed in the experiment. This may be ascribed to low acute toxicity of the drug absorption promoter of the present invention, as can readily be understood from the fact that the galenicals used in the present invention have been widely accepted as herb medicines or the like.
EXAMPLE 6
Table 6 shows the results when isolated saponin A was used.
TABLE 6__________________________________________________________________________Conc. of PharmacologicallyActive Substance in BloodConcentration in Blood (μg titer/ml)Rat 10 20 40 60 90 120 180No. min. min. min. min. min. min. min.__________________________________________________________________________1 2.08 6.23 6.64 6.79 5.41 4.58 2.342 0.90 3.91 4.43 4.46 2.47 2.07 1.153 4.93 7.02 7.32 5.15 2.78 2.34 2.854 1.06 2.22 3.93 4.35 3.60 2.67 2.535 1.35 4.06 3.52 2.03 1.10 0.89 0.576 2.01 5.63 5.15 3.79 2.88 2.07 2.01(Control)0.55 ± 0.04 0.89 ± 0.07 1.28 ± 0.09 1.41 ± 0.16 1.42 ± 0.04 1.25 ± 0.12 0.85 ± 0.11__________________________________________________________________________
EXAMPLE 7
Table 7 shows the results when isolated saponin B was used.
TABLE 7__________________________________________________________________________Conc. of PharmacologicallyActive Substance in BloodConcentration in Blood (μg titer/ml)Rat 10 20 40 60 90 120 180No. min. min. min. min. min. min. min.__________________________________________________________________________1 3.18 6.34 4.08 2.62 1.61 1.04 1.112 3.18 9.25 8.63 6.23 2.58 1.72 1.193 1.73 4.63 5.98 4.28 3.07 2.70 3.14(Control)0.55 ± 0.04 0.89 ± 0.07 1.28 ± 0.09 1.41 ± 0.16 1.42 ± 0.04 1.25 ± 0.12 0.85 ± 0.11__________________________________________________________________________
EXAMPLE 8
Table 8 shows the results when an isolated saponin C was used.
TABLE 8__________________________________________________________________________Conc. of PharmacologicallyActive Substance in BloodConcentration in Blood (μg titer/ml)Rat 10 20 40 60 90 120 180No. min. min. min. min. min. min. min.__________________________________________________________________________1 2.2 5.97 5.44 4.27 3.00 2.07 1.482 1.15 4.11 5.28 5.32 3.92 3.63 3.083 0.40 2.44 3.38 3.75 2.28 2.06 1.79Control0.55 ± 0.04 0.89 ± 0.07 1.28 ± 0.09 1.41 ± 0.16 1.42 ± 0.04 1.25 ± 0.12 0.85 ± 0.11__________________________________________________________________________
(4) Suppository tests (Examples 11-15)
The effectiveness of the saponins A, B and C when they were formulated into suppositories was tested in a method similar to the above Experimental method A.
Thus, rats weighing 180 to 220 g were anesthetized with 30 mg/kg of pentobarbital sodium and fixed by supination on a water bed made of a metal through which water regulated at a constant temperature of 39° C. was circulated. A suppository in a proportion of 1 g/kg of body weight of the rat was inserted through the anus and pushed by a glass bar until it reached the connecting point of the pubes.
The suppositories tested had the following compositions:
Ampicillin sodium: 50 mg/kg-rat,
Saponin A, B or C: 0.5-2 mg/kg-rat, and
Vehicle*: remainder for giving 1 mg of suppository/kg-rat.
The kind of the saponin and the amount thereof used in each of the examples were as follows:
Example 11: Saponin A 0.5 mg/kg-rat
Example 12: Saponin A 1.0 mg/kg-rat
Example 13: Saponin A 2.0 mg/kg-rat
Example 14: Saponin B 1.0 mg/kg-rat
Example 15: Saponin C 1.0 mg/kg-rat
Each of the rats to which a suppository was administered as mentioned above was bled from jugular veins at predetermined points of time after the administration shown in the Table 8A appearing hereinbelow and the concentration of the ampicillin sodium in the sample blood was measured according to biological assay. Thus, the assay was performed by the paper disc method according to The Japan Antibiotic Drug Standards using Bacillus subtilis as the test microorganism.
The results of the above assay are summarized in the following Table 8A.
TABLE 8A__________________________________________________________________________Conc. of Pharmacologically Active Substance in BloodConcentration in Blood (μg/ml)__________________________________________________________________________ 5 min. 10 min. 15 min. 35 min. 60 min. 100 min.__________________________________________________________________________Example 11 5.91 ± 3.08 8.13 ± 3.29 7.57 ± 2.36 4.28 ± 1.89 2.49 ± 1.38 0.92 ± 0.90(n = 6)Example 12 8.27 ± 3.37 12.03 ± 3.20 10.41 ± 3.06 5.71 ± 1.49 3.16 ± 0.93 1.85 ± 0.64(n = 6)Example 13 13.56 ± 3.12 14.43 ± 3.48 12.61 ± 2.96 6.30 ± 0.97 2.76 ± 0.40 1.02 ± 0.11(n = 4)Control (n = 8) 3.12 ± 1.66 3.98 ± 1.89 3.74 ± 1.80 1.91 ± 0.89 0.93 ± 0.54 trace__________________________________________________________________________ 10 min. 20 min. 30 min. 50 min. 100 min. 150 min.__________________________________________________________________________Example 14 10.73 ± 5.42 9.39 ± 5.27 6.30 ± 3.22 3.16 ± 0.87 1.58 ± 0.91 1.28 ± 1.21(n = 3)Example 15 11.72 ± 4.57 9.33 ± 0.88 6.30 ± 1.22 3.37 ± 1.31 1.15 ± 0.53 0.54 ± 0.37(n = 4)__________________________________________________________________________
The saponins A, B and C as prepared above have physical and chemical properties as shown in Table 9. The results of 13 C-NMR are shown in Table 10.
TABLE 9__________________________________________________________________________ Saponin A Saponin B Saponin C__________________________________________________________________________Appearance White powder White powder White powderm.p. 227-230° C. 239-240° C. indefinite (MeOH--EtOAc) (aq. MeOH)Optical [α].sub.D.sup.15° = +12.1° [α].sub.D.sup.18° = +5.96° [α].sub.D.sup.15° = -14.3° 4Rotation (c = 1.03, MeOH) (c = 1.36, MeOH) (c = 0.58, MeOH)IR ν .sub.max.sup.KBr cm.sup.-1--COOH 1690 1690 1690--OH 3400 3400 3400El-Mass (m/z) 259 (ara.) 259 (xyl.) 259 (terminal ara)(acetate) 489 (rha-ara) 489 (rha-xyl) 489 (rha-ara) 705 (ara-rha- xyl)__________________________________________________________________________
TABLE 10______________________________________ Saponin P.sub.G (Akebia quinata Saponin A Saponin B Saponin C Decne)______________________________________aglycone C-1 38.9 38.9 38.8 38.82 26.1 26.1 26.1 26.13 81.2 80.9 81.3 80.94 43.5 43.5 43.4 43.45 47.7 47.5 47.8 47.56 18.2 18.4 18.3 18.37 33.2 33.2 33.2 33.28 39.7 39.6 39.7 39.69 48.1 48.1 48.1 48.010 36.8 36.8 36.8 36.811 23.7 23.7 23.7 23.712 122.5 122.3 122.6 122.313 144.6 144.4 144.7 144.414 42.0 42.0 42.0 42.015 28.2 28.2 28.3 28.116 23.7 23.7 23.7 23.717 46.5 46.5 46.6 46.518 42.0 41.8 42.0 41.819 46.5 46.5 46.6 46.520 30.9 30.8 30.9 30.821 34.2 34.1 34.2 34.222 33.2 33.2 33.2 33.223 64.1 63.9 64.1 64.024 14.0 14.1 13.9 14.025 16.0 16.1 16.0 16.026 17.4 17.4 17.4 17.427 26.1 26.1 26.1 26.128 180.1 179.8 180.2 179.729 33.2 33.2 33.2 33.230 23.7 23.7 23.7 23.7ara 1' 104.4 104.3 104.4 104.22' 75.2 75.4* 75.4 75.33' 74.6 74.8 74.6 74.74' 69.3 69.4 69.4 69.45' 65.8 65.9 65.8 65.8rha 1" 101.2 101.1 101.2 101.02" 71.7 71.7 71.6 71.73" 82.5 82.6 82.2 82.64" 72.9 72.7 72.3 72.65" 69.3 69.4 69.4 69.46" 18.2 18.3 18.3 18.3terminal ara xyl ara(fur) xylmonose1"' 107.0 107.1 110.8 107.02"' 72.9 75.2* (79.2) 75.33"' 74.3 78.1 (78.7) 78.04"' 69.3 70.8 87.2 70.85"' 66.9 67.1 62.7 67.1______________________________________
On the basis of the results of 13 C-NMR, saponins A, B and C were identified to have structures as determined according to the following procedure.
From the 13 C-NMR as shown above, each compound was found to have three sugars since the number of anomers was three. Subsequently, each compound was subjected to acid hydrolysis, and the sugars were identified by TLC and GLC to obtain the results shown below.
TABLE 11______________________________________Saponin A arabinose, rhamnoseSaponin B arabinose, rhamnose, xyloseSaponin C arabinose, rhamnose______________________________________
Aglycone contained in each saponin was found to be hederagenin, as determined by 13 C-NMR.
The measurement of FD-MS in which m/z 905 (M+Na) + appeared suggested that saponin A has two molecules of arabinose and one molecule of rhamnose bonded to hederagenin.
On the other hand, enzymatic partial hydrolysis was accomplished with the use of crude pectinase I, and prosapogenin (called prosapogenin A) was separated by silica gel column chromatography. From measurement of 13 C-NMR, it was found to be completely identical with saponin Po (Kawasaki et al, Chem. Pharm. Bull. 24, 1021 (1976)) obtained from peels of Akebia quinata Decne. Table 12 shows comparison between the data of both compounds.
TABLE 12______________________________________ Saponin Po (Akebia quinata Pro-Sapoqenin A Decne)______________________________________aglycone C-1 38.9 38.92 26.1 26.13 81.1 81.04 43.5 43.45 47.7 47.76 18.2 18.17 32.8 32.88 39.7 39.79 48.1 48.110 36.9 36.811 23.8 23.812 122.7 122.513 144.7 144.714 42.1* 42.115 28.3 28.316 23.8 23.817 46.6 46.618 42.0* 42.119 46.6 46.420 31.0 30.921 34.2 34.222 33.2 33.223 64.0 63.924 14.0 13.925 16.1 16.026 17.5 17.427 26.1 26.128 180.2 180.129 33.2 33.230 23.8 23.8ara C-1' 104.2 104.32' 75.8 75.83' 74.4 74.64' 69.1 69.25' 65.3 65.5rha C-1" 101.5 101.62" 72.3 72.53" 72.3 72.34" 74.1 74.15" 69.7 69.76" 18.4 18.5______________________________________
Thus, prosapogenin A was identified to be hederagenin 3-O-α-L-rha.pyra-(1→2)-α-L-ara.pyranoside. The terminal sugar cleaved by enzymatic partial hydrolysis was identified by TLC and GLC to be arabinose.
From the above results, peaks of 13 C-NMR were assigned as shown in Table 10, and saponin A was identified to have the above structural formula.
Saponin B was found to exhibit 13 C-NMR which was completely identical with that of saponin P G of Akebia quinata Decne (which is also listed in Table 10) as reported by R. Higuchi et al (Chem. Pharm. Bull. 24, 1021 (1976)) and therefore identified to have the above structural formula.
Saponin C, after enzymatic partial hydrolysis, exhibits the spot with an R f value identical with that of said prosapogenin A on TLC. Also from the fact that terminal cleavage occurs with naringinase or hesperiginase similarly as pectinase I, saponin C was found to have terminal sugars different from saponin A.
On the other hand, for investigation on the location of sugars bonded, permethylation was conducted according to the Hakomori method (J. Biochem. (Tokyo) 55, 205 (1964)), which was followed by methanolysis and GLC, whereby the presence of arabinose as terminal sugar was confirmed.
From the above results, saponin C was found to have the above structural formula. | An extract from a saponin-containing galenical has the effect of promoting absorption of a pharmacologically active substance or drug such as β-lactam antibiotic administered through the alimentary system. In particular, saponin components are isolated from the extract of Sapindus mukurossi Gaertn. and recognized to have similar promotion effect of drug absorption. Thus, it has been made possible to increase absorption of a drug and hence its pharmacological effect by administering these substances in combination with a pharmacologically active substance orally or into the rectum. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to the provision of computer services and more specifically to the integration of computer application programs and e-business capabilities.
BACKGROUND
[0002] As enterprises the world over continually seek to comply with legislated requirements (e.g. taxation laws) and current business practices (e.g. Internet-based e-business capability), the advantages of integration with supplier's systems to improve Supply Chain Management (SCM) represents just one challenge faced in a competitive environment.
[0003] ERP systems are accounting-oriented information systems for identifying and planning the resources necessary to process customer orders. ERP systems typically differ from MRPII system in technical requirements such as graphical user interface, relational database, use of 4GL language, and computer assisted software engineering tools and development, client/server architecture and open system portability. ERP systems support a method for effective planning and control of an enterprise's resources necessary to accept, process, ship and account for customer orders in a manufacturing, distribution or service company. ERP is considered to be an integral part of Supply Chain Management (SCM) and often serves as the transaction backbone for other Supply Chain applications. Many ERP solution providers are adding other Supply Chain functions such as Advanced Planning and Scheduling to their application suites. SCM extend the method to reach trading partners, transportation and logistics suppliers, and other supporting functions.
[0004] Larger enterprises normally have the resources to adopt to the changing environment, mainly by implementing Enterprise Resource Planning (ERP) packages such as SAP™, BAAN™ and PeopleSoft™. However, smaller enterprises frequently do not have the resources to implement a dedicated world-class system to achieve a competitive advantage or to simply stay in business.
[0005] Application Service Providers (ASP's) deploy, host, manage and rent access to applications over the Internet from a centrally managed facility. However, ASP's typically concentrate on providing one or more individual applications, rather than integration of multiple applications. Furthermore, ASP's offer only a very limited degree of integration with client's existing systems.
[0006] e-commerce can be defined as buying and selling over digital media. e-business, in addition to encompassing e-commerce, includes both front- and back-office applications that form the engine for modem business. e-business is about redefining old business models, with the aid of technology, to maximise customer value. e-business involves the convergence of Internet and information technologies, thus allowing more effective and efficient communications both internally and externally for companies and organizations.
[0007] In the light of current developments, most specifically the proliferation of the Internet, a need exists to provide a comprehensive platform for a business to become an e-business.
SUMMARY OF THE INVENTION
[0008] The gist of the present invention revolves around a business offering to provide computer services. The offering comprises any combination of hosting computer application programs, providing e-business capability and providing integration capability.
[0009] According to an aspect of the present invention, a business method is provided for offering computer services to a plurality of vendors, by a service provider. The method comprises offering one or more services, which are supplied to the vendors substantially simultaneously, selected from the group consisting of:
[0010] hosting a computer application program;
[0011] providing an e-business capability for on-line business transactions between the vendors and other parties; and
[0012] providing an integration capability for integration of computer applications.
[0013] According to another aspect of the present invention, there is provided a system for providing, by a service provider, computer services to a plurality of vendors comprising:
[0014] processor means to host a computer application program for a plurality of vendors;
[0015] processor means to provide an e-business capability for on-line business transactions between the vendors and other parties; and
[0016] processor means to provide, to a plurality of vendors substantially simultaneously, an integration capability for integration of computer applications.
[0017] The processor means to host a computer application program for a plurality of vendors, the processor means to provide an e-business capability for on-line business transactions between said vendors and other parties, and the processor means to provide, to a plurality of vendors substantially simultaneously, an integration capability for integration of computer applications are configured in accordance with a vendor selection from an offering comprising one or more services selected from the group consisting of:
[0018] hosting a computer application program;
[0019] providing an e-business capability for on-line business transactions between the vendors and other parties; and
[0020] providing an integration capability for integration of computer applications.
[0021] In specific embodiments of the present invention, the computer application program is an Enterprise Resource Planning (ERP) system (such as the SAP™ ERP system). Preferably, integration of an ERP system with an ebusiness capability is provided as an eERP solution. However, vendors are able to select various alternative combinations in accordance with their specific needs.
DESCRIPTION OF THE DRAWINGS
[0022] Features and preferred embodiments of the present invention are hereinafter described with reference to the accompanying drawings in which:
[0023] [0023]FIG. 1 shows a general framework of a hosting infrastructure that supports integration of a computer application program and an e-business application program;
[0024] [0024]FIG. 2 shows a general framework for hosting computer application programs and providing computer services;
[0025] [0025]FIG. 3 shows a block diagram of an embodiment of the data centre of FIG. 2;
[0026] [0026]FIG. 4 shows a process flow for application program hosting;
[0027] [0027]FIG. 5 shows a process flow for Business-to-Customer (B 2 C) e-commerce transactions;
[0028] [0028]FIG. 6 shows a process flow for Business-to-Business (B 2 B) procurement by means of a browser;
[0029] [0029]FIG. 7 shows a process flow for Business-to-Business (B 2 B) procurement directly from a vendor's system;
[0030] [0030]FIG. 8 shows a block diagram of a specific embodiment of an integrated ERP and e-business system, being an overview of the mysap.com architecture; and
[0031] [0031]FIG. 9 shows the framework of FIG. 1 in additional detail.
DETAILED DESCRIPTION
[0032] The principles of the preferred method and/or system described herein have general applicability to any computer-based application programs and e-business application programs. For ease of explanation, the preferred method and/or system are/is described with reference to an Enterprise Resource Planning (ERP) application and, even more specifically, the SAP™ ERP Application. Similarly, the e-business application program is described with specific reference to the WebSphere™ Commerce Suite. However, it is not intended that the present invention be limited to any of the specifically described application programs.
[0033] For purposes of this disclosure, “vendors” are defined as those parties that offer their goods and services for sale on-line, typically over the Internet. Accordingly, “vendors” represent customers of an ASP.
[0034] “Customers”, on the other hand, are defined as “customers of vendors”. Accordingly, “customers” avail themselves of goods and services offered by vendors on-line, typically over the Internet.
[0035] A “front-end” is defined as an interface for access to an application program. In this way, an e-business “front-end” provides on-line access, for multiple customers simultaneously, to the goods and/or services offered for sale by vendors, typically over the Internet.
[0036] Similarly, a “back-end” is defined as a system or application program that is connected behind a front-end. In the present context, an ERP application program represents a “back-end” to the e-business front-end.
[0037] A “workplace server” is defined by SAP™ as the server that collects the user roles from the various application systems and builds the role-based and personalized portal Web page. In addition, a workplace server can be used for centralized user administration.
[0038] An “eMarketplace”, in this context, is defined as an electronic trading hub that facilitates commercial transactions. To be successful, it is essential that an eMarketplace can interpret messages sent to the eMarketplace by all trading partners and that the eMarketplace is capable of producing messages which can be processed by all trading partners.
General Embodiment of Offering to Vendors by a Service Provider
[0039] Referring to FIG. 1, use of a hosting infrastructure 100 , that supports integration of a computer application program and an e-business application program, is offered to vendors 110 and 120 by a service provider (not shown). The hosting infrastructure 100 includes an e-business layer 102 , an application layer 106 and an integration layer 104 . The e-business layer 102 provides a complete framework to conduct e-commerce that attracts customers 170 and drives sales. The e-business layer 102 typically provides a comprehensive set of integrated software components for the building, maintenance and hosting of electronic (on-line) stores and malls so that the vendors 110 and 120 can sell goods and services via the Internet. The e-business layer 102 can be tightly or loosely integrated with an application layer 106 , such as an ERP system back-end. Vendors 120 with legacy systems (i.e. non-ERP systems) who use the application hosting component of the offering, transact with their customers 170 through the e-business layer 102 by connection to the hosting infrastructure 100 through an application layer 106 . The e-business layer 102 and the application layer 106 are coupled via the integration layer 104 .
[0040] Vendors 110 already have an ERP system and access the e-business layer 102 and the integration layer 104 via the Internet or a dedicated communications link. Vendors 120 with legacy systems, on the other hand, are using the ERP system of the service provider and access the system 100 via the application layer 106 , also via the Internet or a dedicated communications link. Customers 170 , of vendors 110 and 120 , access the hosting infrastructure 100 through the e-business layer 102 via the Internet. Business partners 160 , of the vendors 110 and/or 120 , access the e-business layer 102 and/or the integration layer 104 , also via the Internet or a dedicated communications link.
[0041] In order to process commercial transactions, a bank 130 is accessible through the integration layer 104 . The bank 130 is in turn connected to the banking network 140 and may thus transact with other banks 150 , being banks of vendors 110 and 120 , customers 170 , and business partners 160 .
[0042] Examples of business scenarios that can be provided by the offering include:
[0043] 1. Application Hosting Only
[0044] The service provider hosts a computer software application on behalf of vendors 120 , serviced by the application layer 106 . For the exemplary case of a hosted ERP Application, each vendor typically has a dedicated production system and access to development and test environments that are shared by multiple vendors. Access to the ERP Application is usually via an Internet website, portal or workplace. Industry segment templates are employed to shorten the implementation lifecycle of the application for each particular vendor.
[0045] 2. Application Hosting with Integration
[0046] In this scenario, a vendor 120 selects integration capability, serviced by the integration layer 104 , in conjunction with application hosting. For the exemplary case of a hosted ERP Application, this option enables integration of the ERP Application with an existing legacy application of the vendor 120 . Alternatively, integration of the hosted ERP Application and a vendor's own e-business application is possible.
[0047] 3. e-business Only
[0048] The service provider builds, maintains and hosts electronic stores and malls for vendors 110 and/or 120 to sell their goods and services on the Internet. The exact functionality of the e-business capability is determined by vendor requirements and can include a secure e-commerce environment, secure Internet payment methods and support of third party connectivity for Business-to-Business (BSB) transactions. In this instance, vendors 110 and/or 120 provide their own integration facilities, at their end, for integration of e-business services provided by the service provider with their existing computer software application (e.g. legacy or ERP system).
[0049] 4. e-business with Integration
[0050] In this scenario, non-ERP-enabled vendors 120 and/or ERP-enabled vendors 110 can select integration capability, serviced by the integration layer 104 , in conjunction with e-business capability, serviced by the e-business layer 102 . This option enables integration of e-business capability, provided by the service provider, with existing applications, such as legacy or ERP systems, of the vendors 110 and/or 120 .
[0051] 5. Application Hosting with Integration and e-business (eERP)
[0052] In this scenario, vendors 120 select a hosted computer application program, such as an ERP system, integrated with e-business capability. Thus, all three layers 102 , 104 and 106 of the hosting infrastructure 100 are employed. Integration of ERP and e-business simplifies the use of ERP systems and makes the systems reusable and more financially attractive to vendors. Numerous vendors and customers of those vendors utilize a common infrastructure to access an ERP system via an e-business front-end interface. The full suite of possible options are available by this EERP offering.
[0053] 6. Integration Hosting Only
[0054] An Integration Hub, represented by integration layer 104 , can serve as a standalone offering. In this instance, the integration hub can be used to integrate a computer application program and an e-business application program, both of which are not hosted by the service provider. Additionally, the hub can be used to support more general integration requirements such as distributed vendor applications or connecting of vendors 110 and/or 120 to business partners 160 .
[0055] 7. Hosting Infrastructure
[0056] The infrastructure necessary to support the above solutions can also be used to provide a general hosting service. The data centre and system management facilities can be utilized by the service provider and offered to other parties. For instance, an application provided and supported by a partner of the service provider can be hosted on the partner's behalf.
[0057] 8. Electronic Marketplace (eMarketplace)
[0058] Vendors 110 and 120 , customers 170 and other business partners 160 can use the eERP solution as a trading eMarketplace to conduct business transactions. The inclusion of the integration layer 104 ensures minimum compliance costs for all parties.
[0059] [0059]FIG. 2 shows a general framework for hosting computer application programs. The data centre 210 and the implementation team 244 of FIG. 2 implement and maintain the application programs and e-business application programs hosted by the hosting infrastructure 100 of FIG. 1.
[0060] A vendor 222 accesses the data centre 210 via a dedicated communications link 220 , such as an Integrated Services Digital Network (ISDN) link. Alternatively, a vendor 234 accesses the data centre 210 via the Internet 232 . Similarly, a customer 236 of a vendor 222 or ERP customer 234 accesses the data centre 210 via the Internet 232 . Vendors 222 and 234 and customers 236 use browser software applications that execute on computer systems such as Personal Computers (PC's) and Personal Digital Assistants (PDA's) to access the data centre 210 .
[0061] The implementation team 244 , responsible for implementation and maintenance of the data centre 210 , accesses the data centre 210 via an intranet 242 and a communications link 240 .
[0062] The data centre 210 is also connected to the banking network 252 , via a dedicated communications link 250 , for processing transactions between the vendors 222 and 234 and customers 236 of the vendors 222 and 234 , electronically.
[0063] [0063]FIG. 3 shows a detailed block diagram of the data centre 210 of FIG. 2. Direct communications link 220 access to the data centre 210 is via a router 302 and a firewall 304 . Internet access 230 to the data centre 210 is via a router 312 and a firewall 314 . Traffic is routed via a dedicated ring and thus remains isolated from the intranet 242 of the service provider at all times. A Web Server 324 is connected to an Internet Transaction Server (ITS) 322 , a Workplace Server 330 , an e-business server 340 and an Integration server 350 . The Web Server 324 and the ITS 322 constitute what SAP™ call a middleware component of the mysap.com architecture.
[0064] The communications link 240 provides access for the ERP application implementation and maintenance team 244 via an intranet 242 of the service provider. The communications link 240 provides access via the Server 310 .
[0065] FIGS. 4 to 7 show various transaction process flows occurring in the general framework shown in FIGS. 2 and 3. The numerals accompanying the individual process flows in FIGS. 4 to 7 indicate the sequence of the overall process flow for a particular transaction type.
Application Hosting Process Flow
[0066] [0066]FIG. 4 shows a process flow for application hosting of an ERP system by a service provider.
[0067] A browser 410 , located at a vendor's site, communicates with a host data centre 430 via the Internet (not shown) or a dedicated link 420 , such as an Integrated Services Digital Network (ISDN) link.
[0068] Internet communications, at the host data centre 430 , are processed by a Web Server 432 that is connected to a Middleware Server 434 . The Middleware Server 434 is configured as an Internet Transaction Server (ITS). The ITS is in turn connected to a Workplace Server 436 that provides an operating environment, such as an Internet website, portal or workplace, for access by an ERP customer. The Workplace Server 436 accesses the ERP components hosted on the ERP Application Server/s 438 .
B 2 C e-commerce Transaction Process Flow
[0069] [0069]FIG. 5 shows a process flow for e-commerce transactions between a business and a customer (B 2 C). The ERP application program is hosted at a data centre 530 , by a service provider, on behalf of a vendor.
[0070] A browser 510 , of a customer, communicates with the host data centre 530 via the Internet (not shown).
[0071] Internet communications, at the host data centre 530 , are processed by a Web Server 532 that is connected to an e-business Server 534 . The e-business Server 534 is configured as an online marketplace, using software such as IBM's WebSphere™ Commerce Suite. The e-business Server 534 is in turn connected to a Integration Server 536 , such as a MQ Series Server, that integrates the marketplace and the ERP components hosted on the ERP Application Server/s 538 .
B 2 B e-commerce Transaction Process Flow—Procurement via the Internet
[0072] [0072]FIG. 6 shows a process flow for e-commerce transactions between businesses (B 2 B). Specifically, the transactions involve procurement from a vendor, by a customer of the vendor, via the Internet.
[0073] A browser 610 , of a customer, communicates with a host data centre 630 via the Internet (not shown).
[0074] Internet communications, at the host data centre 630 , are processed by a Web Server 632 that is connected to an e-business Server 634 . The e-business Server 634 is configured as an online marketplace, using software such as IBM's WebSphere™ Commerce Suite. The e-business Server 634 is in turn connected to an Integration Server 636 , such as a MQ Series Server, that integrates the marketplace and the ERP components hosted on the ERP Application Server/s 638 . The Integration Server 636 also integrates the ERP components with a Procurement Application Server 614 , at the site of the customer. The Integration Server 636 is connected to the Procurement Application Server 614 via the Internet (not shown).
B 2 B e-commerce Transaction Process Flow—Procurement directly from ERP Customer's Backend System
[0075] [0075]FIG. 7 shows a process flow for e-commerce transactions between businesses (B 2 B). Specifically, the transactions involve procurement from a vendor, by a customer of the vendor, directly from the customer's back-end system. The back-end system may be a legacy system (i.e. different to the ERP application provided by the service provider).
[0076] The customer's Procurement Application Server 710 is connected to an Integration Server 722 , such as a MQ Series Server, at a data centre 720 , via the Internet. The Integration Server 722 is connected to an e-business Server 724 , which is configured as an online marketplace, using software such as IBM's WebSpherer™ Commerce Suite. The Integration Server 722 is also connected to the ERP Application Server/s 726 . In this configuration, the e-business Server 724 is not directly connected to the ERP Application Server/s 726 and must thus communicate with the ERP Application Server/s 726 via the Integration Server 722 . The Integration Server 722 is connected to the customer's Procurement Application Server 710 via the Internet (not shown).
eERP Embodiment
[0077] Referring to the previously described eERP business scenario 5 and FIG. 1, a vendor 120 places a catalogue of the products on to a web site, which is hosted at the e-business layer 102 level. Catalogues are built using material master records stored in the application layer 106 and are fully synchronised. A customer 170 can browse those catalogues and purchase items from the catalogues. A purchasing transaction is passed to the service provider bank 130 via the integration layer 104 . If the service provider's bank 130 is different from a customer bank 150 , a debit transaction is passed to the customer bank 150 via the banking network 140 . The transaction is also recorded in the ERP system at the application layer 106 . A confirmation message is sent to the customer 170 if there are sufficient inventory levels and the payment transaction was successful. If transportation of the purchased good is required, a freight company business partner 160 of the vendor 120 is notified. Communications between the vendor 120 , their house bank 130 and their business partner 160 occur with the facilitation of MQ Series messaging and communication software.
[0078] [0078]FIG. 9 shows the framework of FIG. 1 with additional detail and is now used to describe a transaction process, as a sequence of steps, in this eERP embodiment:
[0079] 1. Sales catalogues are published in the e-business suite 103 . The catalogues can be synchronised with a vendor material master of an ERP system. The synchronisation occurs using the Integration Hub (refer to the diagram below). A vendor 120 can control the catalogue publishing process using a standard web browser 121 .
[0080] 2. Customers 170 browse the vendor's site using a standard web-enabled browser 171 and can choose to purchase one or more items from the catalogue.
[0081] 3. Once a purchase transaction is recorded in the e-business suite 103 , a sales order document is generated and passed on to the MQ Series Client 920.
[0082] 4. The MQ Series Client 920 passes on the message to a message queue in the MQ Series Server 900 , which forms part of the integration layer 104 . The message is then processed by the MQ Series Integrator 910 , which maps the received file to the sales order format of the ERP System 107 .
[0083] 5. Once the sales order file in the ERP system format has been generated and passed back to the MQ Series server 900 , the sales order file is placed in a message queue of the MQ Series Server 900 for transfer to the application layer 106 .
[0084] 6. The MQ Series Client 184 , setup in the application layer 106 passes the message to the ERP system 109 where a sales order is recorded and a confirmation message is generated.
[0085] 7. The confirmation message is sent back to customer's browser 171 using the same route, but in the reverse direction.
[0086] 8. If payment details were collected (applicable to B 2 C transactions and some B 2 B transactions), payment instructions are sent to the vendors' house bank 130 . Alternatively, payment instructions can be processed using payment processing functionality built into the e-business suite 103 (WebSphere™ Commerce Suite for example).
[0087] The MQ Series integration solution is a publicly available product for integration of various application programs and software suites. In simplified terms, MQ Series translates information between applications and requires some implementation at the integration layer 104 , the application layers 102 and 106 and other parties connected to the eERP system. Specific MQ Series ‘connectors’ are commonly available for translation of information into formats necessary for specific applications (e.g. SAP™). The MQ Series Integrator 910 incorporates an MQ Series Integrator Library that is specific to an application (e.g. SAP™).
[0088] Notwithstanding, alternative integration solutions are available. Custom solutions and connectors can be employed, however, off-the-shelf solutions incorporating relevant libraries and connectors (such as MQ Series) are generally more cost effective.
mySAP.com Application Hosting
[0089] [0089]FIG. 8 shows a block diagram of a specific embodiment of an integrated ERP and e-business system. The ERP system used is SAP™ R/3 and the integrated system is accessible through the mySAP Workplace enterprise portal (mySAP.com), on the Internet.
[0090] The SAP system consists of three components (not shown) namely Development (DEV), Test (TST), and Production (PRD). Additional components may be added as necessary. The DEV and TST components are shared by multiple vendors. The PRD component can either be provided on a shared basis or a dedicated vendor basis.
[0091] A user (e.g. a customer of a service provider) accesses the SAP™ system real time by means of a browser 810 , connected to Workplace Middleware 820 . The Workplace Middleware 820 consists of a Web Server and an Internet Transaction Server (ITS). The ITS consists of two components—Web GATE (WGATE) and Application GATE (AGATE). AGATE is the main component of the SAP™ ITS and is responsible for session management including the mapping of R/3 screens or function modules to Hypertext Markup Language (HTML), Web session time-out handling, R/3 connection management and the generation of HTML documents. The WGATE component encapsulates the various Hypertext Transfer Protocol (HTTP) server interfaces such as Common Gateway Interface (CGI), Netscape™ Server Applications Programming Interface (NSAPI) and Internet Server Applications Programming Interface (ISAPI), transparently. The WGATE component passes the requested data to the AGATE component, and receives the HTML pages from the AGATE component. The separation of AGATE and WGATE components minimises the security risk by only having the necessary code on the HTTP server which is relevant to the SAP™ Internet Transaction Server function for the Web server.
[0092] The Workplace Server 830 collects the user roles from the component systems and builds a role-based and personalised portal Web page. In addition, this information can be used for centralised user administration. The Workplace Server 830 is usually a relatively small system with moderate system loading, because the actual business functions are carried out in the component systems 840 without any participation of the Workplace Server 830 . SAP™ have a number of different component systems apart from R/3 ( 844 ). Other systems include Business Warehouse (BW) 842 , Automated Planning and Optimiser (APO), CRM, BBP (SAP's B 2 B app), etc. The database of the Workplace Server is small, because it holds no actual business data. The Workplace Server 830 enables actual SAP™ transactions to be executed via a web browser 810 .
[0093] Two different implementation approaches can be taken with respect to the physical location of the Workplace Middleware 820 and the Workplace Server 830 . In the centralised approach, the Workplace Middleware 820 and the Workplace Server 830 are located at the service provider's site, while in the distributed approach, either one or both of the Workplace Middleware 810 and Workplace Server 830 are located at the customer's site.
[0094] Customers of the vendor using the integrated e-business and ERP (e ERP) capabilities can utilise the provided e-business capability. The e-business component consists of IBM's WebSphere™ Commerce Suite, tightly integrated with the SAP™ back-end. Customers connect to the WebSphere™ Server via the Internet. Multiple customers may thus utilize this server and the associated configuration, simultaneously.
[0095] Vendors can be connected to the hosting data centre either via a dedicated line (direct connection to the data centre) or via the Internet. A dedicated connection can be serviced by either a frame relay or an ISDN link. In either case a router, which supports both ISDN and frame relay connections (such as CISCO 2503) is necessary at the vendor's site. Vendors can also access their ERP system via the Internet, providing sufficient Internet connection bandwidth is available. If the available bandwidth is insufficient, or the customer does not have a permanent Internet connection, sufficient bandwidth can be obtained by connecting to an Internet Service Provider (ISP) using ISDN, satellite or Digital Subscriber Line (DSL) methods.
[0096] In order to access the system the incoming network traffic will have to pass through one of two firewall configurations. If the traffic is coming from a dedicated line, it is routed via a Secure Network Interface (SNI) firewall. A dedicated port is setup for vendors wishing to access their system via a dedicated link. Vendors connecting via the Internet require an additional firewall before the traffic can be routed to their ERP system.
[0097] The foregoing describes only a few arrangements and/or embodiments of the present invention, and modifications and/or changes can be made thereto without departing from the scope and spirit of the invention, the arrangements and/or embodiments being illustrative and not restrictive. | The present invention comprises a business offering to provide computer services and a system to provide a selection of those services. The offering comprises any combination of hosting computer application programs, providing e-business capabilities and providing integration facilities. The services are provided substantially simultaneously to a plurality of parties. In specific embodiments of the present invention, the computer application program is an Enterprise Resource Planning (ERP) system (such as the SAP™ ERP system). The ebusiness capability provides a means for online business transactions between vendors and other parties and the integration capability enables integration of computer applications. Preferably, integration of an ERP system with an ebusiness capability is provided as an eERP solution. However, vendors are able to select various alternative combinations in accordance with their specific needs. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a process for impregnating threads in the form of spools with a liquid composition such as a crosslinkable resin. The invention is particularly suitable for pre-impregnating reinforcing threads for use in crosslinkable plastics.
It is well known to reinforce plastics using textiles of various forms to give end products which are sometimes known as "laminates". In general, the impregnation of the textile material is carried out just before product manufacturing step, that is to say either in the mould itself, where the product is moulded to shape, or on a mandrel where tubes, containers or other hollow articles are being made. Although very widespread, these techniques do exhibit disadvantages. Firstly, since rotating or rubbing members are often used, there is often a large proportion of bubbles in the laminate which leads to imperfections in the finished product. Moreover, since the impregnation time is relatively short, the fibre to plastic bond is sometimes defective, and the impregnation capacity is fairly limited so that thorough and homogeneous impregnation is difficult to carry out. Finally, the composition of the resulting laminate tends not to be homogeneous, within or between laminates, which quite obviously limits their applications.
It has also been proposed to impregnate the threads by passage through a tank of suitable resin, but in this technique, it is necessary to pass the threads over numerous guides, and this causes the fretting and sometimes even breaking of the individual strands.
it has also been suggested to wind the threads onto a mandrel and then to spray the resin thereon, but in this case, the resulting laminate again possesses numerous bubbles, which detracts from its properties and spoils its appearance.
Finally, in all these techniques in which the impregnation is carried out from the outside towards the inside, the installations are generally bulky, expensive and rather impractical.
It has also been proposed to carry out the treatment from the inside towards the outside (see, for example, Swiss Pat. Nos. 374,046 and 561/74) by placing the textile as a reel on a perforated mandrel. Unfortunately, this technique as developed thus far, which is satisfactory for dyeing or moistening reels, is not suitable for resin impregnation because the resin disposition is not sufficiently uniform and the installation frequently becomes clogged.
The present invention aims to overcome these disadvantages.
SUMMARY OF THE INVENTION
According to the present invention there is provided a process for impregnating a reel of thread with a liquid composition, for instance of crosslinkable resin in which the thread to be impregnated is arranged as a uniform reel of which the open volume approximately corresponds to the desired volume of resin on a perforated rigid mandrel to form a spool, the mandrel having perforations which are staggered and spaced along the entire length of the mandrel except at the ends thereof, and each spool is then gripped at its ends, and the said composition is injected under pressure into the perforated mandrel.
The process of the invention is easier to operate and more economical to carry out than previous processes, and the resulting laminates possess to a reduced extent the defects listed above.
Advantageously, the perforations in the mandrel are circumferential slots which are arranged uniformly and are staggered relative to one another along the mandrel.
In practice, several spools are preferably superposed, separated from one another by means of a rigid support plate, and pressure is applied to each end.
The invention is particularly suitable for treating chemical threads intended for reinforcing laminates. High performance carbon threads, boron threads and aromatic polyamide threads may be mentioned. "Roving" glass threads can advantageously be treated, according to the invention, in which the individual filaments are arranged side by side, without twist, in the form of a ribbon.
The mandrel used in the process of the invention can be made of any rigid material which is insensitive to the treatment conditions, such as, for example, metal or plastic (pvc and the like). As already stated, the mandrel must be perforated, it being possible for these perforations advantageously to be circumferential slots or holes. Slots which are arranged radially and staggered relative to one another in the axial sense are preferably used so as to assist the penetration of the resin. In practice, the two ends of the mandrel are left free of any slots in order to avoid preferential leakage of resin at the ends. It has been found that, with mandrels of usual dimensions, good results are obtained if each end has a portion of approximately 30 mm length without slots.
In a known manner, a reel with straight sides is formed on this mandrel, the travel, i.e. length, of the reel corresponding to the length of the mandrel. The spooling conditions are defined so as to obtain a spool density which leaves an open volume, i.e. spaces, corresponding to the desired volume of resin. In practice the ratio of weight of resin to the weight of thread is preferably one sixth to one third, as opposed to one third (1/3) to a half (1/2) for the conventional processes mentioned above. Moreover, the conditions of formation of the reel must be suitable for enabling the impregnated spool to be easily unwound. For example, with a glass roving, it has been determined that good results are obtained if:
the bulk density of the reel (that is to say of the roving on the spool) is between 1.35 and 1.75,
the crossing is between 2.5 and 3.5, preferably of the order of 3.25 (the crossing being the number of turns of thread per length of spool), and
the laying index is of the order of 0.5 to 0.6 (the laying index being the space, expressed in width of thread, which separates two turns which lie in the same direction but belong to successive layers; in other words, a laying index of 0.55 means that the turn, lying in the same direction, of the layer following the reference layer is laid at a distance of 0.55 times the width or the diameter of the thread).
As already stated, in practice, the ends of the spool are preferably straight, that is to say they form a plane which is approximately perpendicular to the generatrices of the mandrel. However, it is understood that the use of other shapes of reel, such as to give biconical spools, is not excluded. Thus, because of the spooling, these sides are composed of a circular reel which is produced when the crossing is inverted, and this leads to a higher density of the spool on these sides and hence to a lower loss of pressure and consequently a better lateral leaktightness.
Pure resins which are commonly used for the manufacture of laminates can be used as the impregnation resin. Examples which may be mentioned are polyesters, unsaturated polyene-esters and epoxy, furane and acrylic resins. The liquid composition of resin also contains various catalysts and various known adjuvants (an accelerator, promoter, inhibitor, photosensitiser, dyestuff or the like). The viscosity of the composition can vary as a function of the treatment conditions. Good results are obtained with acrylic resins based on oxyethyleneated bisphenol A dimethacrylate (OBDMA).
DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, the following description is given by way of example only, with reference to the accompanying drawings in which one embodiment of the invention is described and in which:
FIG. 1 schematically shows, in section, a reel of thread on a mandrel in accordance with the invention;
FIG. 2 shows a side view of a pre-impregnation installation for use in performing the process of the invention;
FIG. 3 is a front view of the installation of FIG. 2; and
FIGS. 4 to 6 respectively illustrate, in section, the lower, intermediate and upper plane rigid plates in the installation of FIGS. 2 and 3.
DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to FIG. 1, which is a schematic representation only, shown at 1 is a rigid mandrel, for example made of rigid pvc, having, for example, the following dimensions:
internal diameter: 76 millimeters
external diameter: 90 millimeters
length: 270 millimeters;
Indicated at 2 are some of a plurality of slots which are 2 mm wide and which are cut, for example, with a saw so as to include at the centre an angle of about 120°. The slots are staggered relative to one another by about 60° and are spaced 10 to 15 millimeters apart along the entire length of the mandrel 1 except at the two ends 3 and 4 which are each free of slots for a distance of about 30 mm. Slots 5 in the wall of the mandrel at its ends are for centering the spool in order to ensure ease of subsequent unwinding; while the reel of textile is shown at 6, this being formed by individual turns 7 of thread. At 8 and 9 are straight ends of the spool, which are flush with each end of the mandrel 1 and are perpendicular to the mandrel axis.
In a particular embodiment, the spools are formed by winding a 4,720 Tex roving glass thread, which is without twist and is formed by continuous individual 13.5 μ filaments (origin Owens Corning Fibreglass (OCF), sizing type 891), with a crossing of 3.37, a laying index of 0.55 and a density of 1.35. As already stated, the travel of this spool is 270 millimeters. Each individual spool weighs about 17 kilograms and has a proportion of resin of 25% by weight.
Other embodiments have been produced with the following reels:
1,200 Tex glass roving (origin OCF), 17.5 μ filaments; crossing 2.54; laying index 0.55; density of the reel before treatment 1.75; proportion of resin deposited (OBDMA) 17%.
2,400 Tex glass roving (origin OCF), 13.5 μ filaments; crossing 2.55; laying index 0.5; density of the reel before treatment 1.56; proportion of resin deposited (OBDMA) 22.50%.
In performing the process of the invention, a plurality of spools are stacked on a carriage (see FIG. 2) which is mounted on slides or on wheels or the like, and these spools are separated from one another by a plane rigid support plate on which their ends rest. With reference to FIG. 2, at 10 is the ground or floor; 11 and 12 denote two vertical metal struts; 13 and 14 denote L-shaped support angle-bars; 15, 16 and 17 denote horizontal crosspieces; 18 denotes a conduit arranged on the crosspiece 17 in order to form a recovery trough; 19 denotes a pipe for the resin to flow in to the recovery tank 20; 21 denotes a pipe for feeding the resin under pressure with an isolation valve 22 connected to a container, not shown, of pressurised resin; 23 denotes a liquid-dispensing manifold with an inlet valve 24 for each position of the spools or stacks of spools. At 25 is a lower rigid plate (see detail in FIG. 4) on which the spools 26, and, more precisely, the mandrel 27 and the bottom ends 28 of the reels, rest; this plate 25 is surmounted by a tenon 29 which is pierced at 30 to allow the passage of a support and centering bar 31, consisting, for example, of a square tube closed at its two ends; the external diameter of this tenon 29 approximately corresponding to the internal diameter of the mandrel 1. At 32 is an intermediate rigid plate (see detail in FIG. 5) on the bottom of which rests the upper end of the lower spool, and on the top of which rests the lower end of the upper spool; this plate, which, like the above mentioned plate 25 is made of a rigid material which is insensitive to the treatment conditions (for example made of polypropylene), has an orifice at its centre for the passage of the centering tube 31. A solid upper rigid plate 33 (see datail in FIG. 6) surmounts the upper of the two spools, while a pneumatic jack 35, for example to give a thrust of 7 kg/cm 2 has a bearing 38, a thrust rod 36 and a force-distributing plate 37, for example made of metal, which rests on the upper rigid plate 33. The jack 35 is connected in conventional manner to a compressed air supply which is not shown.
In the side view (see FIG. 3), 40 shows the fixing base plate and 41-42 show bores in a strut for the passage of the resin inlet pipe 21. As shown in FIG. 3, the installation is of the so-called "double-face" type and, in practice, comprises four superposed spools per row, although, for the clarity of the drawing, only two spools have been shown in each row.
In FIGS. 4 to 6, which show the three plates 25, 32 and 33 respectively, numeral 43 in each case denotes a gasket, for example made of elastomer, on which the end of the mandrel 27 rests, and 44 denotss the branch on the pipe 21 extending into the lower plate 25.
The diameters of the tenons 29, 45, 46 and 47 are slightly greater than the internal diameter of the mandrel 27, and the diameters of the plates 23, 32 or 33 are slightly greater than the diameter of the spool 26 to be treated.
This installation functions as follows.
The resin composition, together with its sensitiser, is placed in a pressurised container which is not shown. Several spools are stacked in rows on top of one another with the plates contacting their ends, and the centering bar 31 being placed at the centre of the mandrel and of the various rigid plates, namely the lower plate 25, the intermediate plate 32 and the upper plate 33. The jacks 25 are then placed under pressure by means of a compressed air circuit which is not shown.
The carriage and the container of resin are then placed in a conventional over and heated to 50°-55° C. by means of recycled air. The initial viscosity of the resin, typically 23 poises is thus reduced to one poise. The container of resin is then connected at its bottom to the pipe 21 and at its top to a compressed air supply which is not shown (for example of 3 kg/cm 2 ).
The various valves 22-24 are then opened so as to initially drive the air from the circuit through the reels 26. Gradually, the expelled air is replaced by the resin which diffuses through the spools 26. Excess resin which comes out of the spools is recovered by gravity in the conduit 18 and then in the tank 20 via the pipe 19.
By virtue of the windings of the reels 26, each spool behaves as an individual valve. In fact, the winding of the threads gives a homogeneous loss of pressure from the mandrel to the exterior curved surface surface of the spool and thus enables the resin to diffuse uniformly to fill all voids throughout the spool.
Moreover, since the ends of the mandrel do not possess slots, there are no leakages from the ends of the spool during impregnation, and the impregnation thus takes place homogeneously.
The impregnation operation is terminated when no more small bubbles are seen on the surface of the reels. In practice, this operation can take between five and seven hours.
The pressure of the compressed air on the resin is then cut off, the jacks 35 are then released and, finally, the carriage is removed from the oven.
The spools impregnated or pre-impregnated in this way exhibit numerous advantages compared with spools obtained with the techniques described in the introduction. There may be mentioned, inter alia;
small losses of starting materials during the operation, constant and precise proportion of resin deposited, homogeneous and uniform deposit on the spool and, in particular, on the thread itself, that is to say that the resin homogeneously penetrates between the filaments of the thread itself, by virtue of this homogeneity, a smaller amount of resin deposits than in the conventional techniques, which improves the mechanical properties of the laminates, a small proportion of bubbles (less than 0.5%), and compact, simplified and practical equipment.
The laminates produced using these pre-impregnated spools are uniform and homogeneous and possess excellent mechanical properties. These impregnated spools can advantageously be used in the techniques of lamination on a mandrel or by "extrusion/spraying", that is to say techniques of the type in which the impregnated threads travel continuously. The manufacture of tubes, poles or hollow containers may be mentioned by way of example. | In a process for impregnating a reel of thread in the form of a spool with a liquid resin composition, the thread is arranged on a perforated rigid mandrel so as to form a uniform reel in which the volume of open space approximately corresponds to the desired volume of resin to be impregnated, each spool is then gripped and completely sealed against resin leakage from its ends and, finally, the composition is injected under pressure into the interior of the perforated mandrel whereby there is a homogeneous loss of pressure from the mandrel to the spool's entire exterior curved surface and the resin diffuses uniformly to fill all voids through the spool. | 3 |
[0001] This application is related to and claims the priority of U.S. Provisional Application No. 60/652,693 filed on Feb. 14, 2005, which is hereby expressly incorporated by reference in its entirety.
BACKGROUND OF THE DISCLOSURE
[0002] The present disclosure relates to technologies using plasma and thermal spray processes for the deposition of thin films and coatings in addition to related types of manufacturing processes. In particular, the present disclosure relates to improvement of High Velocity Oxy Fuel (HVOF) tapes used with industrial manufacturing methods including, but not limited to, plasma and thermal spray processes for alloys, ceramics, and related types of materials generally functioning to surmount the issues of excessive wear and high stress on surfaces.
[0003] Tapes for HVOF thermal processes, for example, characterized by temperatures which can exceed 600 degrees Fahrenheit and greater than 21,000 miles per hour for fuel velocity, are a longstanding need yet to be adequately addressed in aircraft, automobiles, and metal finishing industry terms.
[0004] Common among known high temperature tapes are breakdowns or related mechanical integrity challenges such as unravelings, separation from their own backings, and the like unacceptable failure modes. No known tapes including those made with high temperature carriers are effective to withstand the above noted conditions. Further, metal deposition in unwanted areas, and related contaminations are not industrially accepted and require increased cost, time, and reworking efforts.
SUMMARY OF THE DISCLOSURE
[0005] A finished HVOF tape used, for example, during known HVOF processing imparts high temperature silicone pressure sensitive adhesives that provide enhanced adhesion strength to provide a firm adhesion to its own backing and unexpectedly leave no residue upon removal from metals. The novel enhanced HVOF tapes are made up of coated or uncoated, woven or non-woven glass cloth and ceramic based fabric laminated to at least one side of a metal foil using a silicone based laminating adhesive, which is then laminated with another layer of a pre-selected combination of the same materials and coated with a high temperature silicone pressure sensitive adhesive and wound to itself to make a self wound HVOF tape or covered adhesive assembly with a release liner to make a laminated sheet for die cut samples, among other things. Applications including military and commercial aircraft, automobiles, and metal finishing usages leverage off of the unique and inherent benefits of the novel enhanced HVOF tapes of the instant teachings.
[0006] According to features of the present disclosure, there is provided a multilayered laminated HVOF tape comprising, in combination a plurality of layers including having at least: a first layer; a third layer, further comprising any one of the group consisting of: aluminum foil, steel foil, copper foil, wool paper, polyamide paper, and polyamide woven fabric; a first adhesive layer; a glass cloth layer, wherein the glass cloth layer is a glass or ceramic fiber that is either woven or felt; a second adhesive layer; wherein the resulting HVOF tape which provides for high strength and non-flammable resistance to high temperature, high velocity, and high pressure when used during an HVOF process.
[0007] According to features of the present disclosure, there is provided a multilayered laminated HVOF tape comprising, in combination: a plurality of layers including having at least: a glass cloth layer; a first layer; a third layer, further comprising any one of the group consisting of: aluminum foil, steel foil, copper foil, wool paper, polyamide paper, and polyamide woven fabric; a second adhesive layer; wherein the resulting HVOF tape which provides for high strength and non-flammable resistance to high temperature, high velocity, and high pressure when used during an HVOF process.
[0008] According to features of the present disclosure, there is provided a multilayered laminated HVOF tape comprising, in combination: a first release liner; a first high temperature silicone pressure sensitive adhesive; one of a first high temperature fabric and a high temperature silicone foam; a first laminating adhesive; one of a metal foil and a silicone foam; a second laminating adhesive; a second high temperature fabric; a second high temperature silicone pressure sensitive adhesive; and a second release liner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:
[0010] FIG. 1 is a pictorial representation of the present disclosure.
[0011] FIG. 2 is a schematized view of an embodiment of the teachings of the present disclosure, showing the same as used in conjunction, for example, with conventional HVOF processing.
[0012] FIG. 3 is a schematized view of an embodiment of the teachings of the present disclosure, showing the same as used in conjunction, for example, with conventional HVOF processing.
[0013] FIG. 4 is a schematized view of an embodiment of the teachings of the present disclosure, showing the same as used in conjunction, for example, with conventional HVOF processing.
DETAILED DESCRIPTION
[0014] The present inventor has discovered that laminated materials preventing the types of failures detailed above can be simply and elegantly generated to address the longstanding needs existing among the prior art. The laminates of the instant teachings include more than one layer of coated or uncoated glass cloth laminated with a metal foil with high temperature inorganic silicone based adhesives—both pigmented and unpigmented.
[0015] What is unexpectedly better than dictated by empirical data are the excellent conformability and sealing properties, including the self-attachment achieved with the instant laminates. An ability to withstand extreme high temperatures and high fuel velocity up to a magnitude of at least about 21,000 miles per hour is likewise believed to differentiate the instant teachings from known art in novelty terms, as discussed herein, illustrated by the schematic and exemplary versions of the embodiments presented as figures and defined by the claimed appended. According to embodiments of the teachings of the present disclosure, there is disclosed a silicone pressure sensitive adhesive which, used according to the instant processes retained physical properties like adhesion to surfaces and to its own backing after being exposed to extreme conditions in testing.
[0016] The composition of silicone pressure sensitive adhesives (PSA) is similar to many common organic PSAs. However, silicone PSAs are appropriate in high temperature applications in which organic PSAs fail. The characteristics that dictate the performance of silicone PSAs are high molecular weight linear siloxane polymers and a highly condensed silicate tackifying resin, such as MQ resin. An example of a typical silicone polymer used in the present disclosure is:
Typical commercially available silicone PSAs are polydimethylsiloxane (PDMS) polymer, polydiphenylsiloxane (PDPS) polymer, and polydimethyldiphenylsiloxane (PDMDPS) polymer, which have silanol or vinyl functional groups at the polymer chain ends.
[0017] MQ is a silicate resin commercially available as a solid suspended in a hydrocarbon solvent and is disclosed in U.S. Pat. No. 5,330,747, which is hereby expressly incorporated by reference as if fully set forth herein. It comprises a core of SiO 4/2 “Q” units, which are surrounded by a shell of Me 3 SiO “M” units. MQ units undergo a condensation reaction with a siloxane polymer due to silanol functional groups in the shell, forming a covalent bond between the MQ resin and the siloxane polymer. The ratio of resin to polymer must optimized for each application, but can done without undue experiments by a person of ordinary skill in the art.
[0018] Adhesion of PSAs in a pressure sensitive manner occurs by removing solvents. To increase and reinforce the adhesion network, the PSAs may be cured. PSA curing systems are commercially available. One system is a peroxide-catalyzed free-radical cure system. It uses either benzoyl peroxide or 2,4-dichlorobenzoyl peroxide. The details of these systems are well known in the art. Another common system contemplated by the present disclosure for curing PSAs is a platinum-based system, which is also commercially available and well-known in the art. The advantage of platinum-based systems are the lack byproducts and the ability to cure while evaporating the solvent at low temperature.
[0019] The present disclosure is a process for making a multilayered laminated HVOF tape which comprises, attaching a plurality of layers of glass cloth laminated with metal foils, aramid paper, or ceramic papers with high temperature inorganic silicone based adhesives, and finishing a resulting HVOF tape which provides for high strength and non-flammable resistance to high temperature, high velocity, and high pressure when used during an HVOF process. Using this process, it is further understood that in certain instances of the process above, the attaching step further includes a first silicone rubber coating, followed by a woven or non-woven high temperature fabric, a laminating adhesive, a metal foil, another layer of laminating adhesive, and a woven or non-woven high temperature fabric, a silicone pressure sensitive adhesive and an optional release liner. Similarly, the product, produced by the process of described above works whereby the plurality of layers in the attaching step further includes a first silicone rubber coating, followed by a laminating adhesive, a metal foil, another layer of laminating adhesive, a woven or non-woven high temperature fabric, a silicone pressure sensitive adhesive, and an optional release liner.
[0020] The present disclosure likewise contemplates that in a product, produced by the above process, the plurality of layers in the attaching step further includes a first silicone rubber coating, followed by a woven or non-woven high temperature fabric; a laminating adhesive; a metal foil, ceramic paper, polyamide paper; a silicone pressure sensitive adhesive; and an optional release liner.
[0021] In another and alternative construction, a laminated assembly is disclosed wherein there is a laminated HVOF tape comprised of at least coated and uncoated glass cloth and ceramic based fabric laminated to one or both sides of at least one foil selected from the group consisting of copper, steel, aluminum, and other metal foils with a silicone laminating adhesive, which is then again laminated with another layer of woven or nonwoven glass cloth or ceramic based fabric which is coated with a high temperature silicone pressure sensitive adhesive and wound to itself to make a self wound HVOF tape.
[0022] Yet still another embodiment according to the present disclosure is shown, wherein the laminated HVOF tape product is comprised of at least one of coated and uncoated glass cloth and ceramic based fabric laminated to one or both sides of at least one foil selected from the group consisting of copper, steel, aluminum, and other metal foils with a silicone laminating adhesive which is then again laminated with another layer of woven or non woven glass cloth or ceramic based fabric which is coated with a high temperature silicone pressure sensitive adhesive and wound to itself to make a laminated sheet, or to make an assembly from which die cut samples may be made.
EXAMPLE 1
[0023] FIG. 2 demonstrates an embodiment of HVOF tape 100 construction. According to FIG. 2 , HVOF tape 100 construction comprises a plurality of layers: first layer 102 , second layer 104 , third layer 106 , first adhesive 108 , glass cloth 110 , second adhesive 112 , and release liner 114 .
[0024] First layer 102 is a pressure sensitive layer made from a polydimethylsiloxane (PDMS) polymer, polydiphenylsiloxane (PDPS) polymer, or a polydimethyldiphenylsiloxane (PDMDPS) polymer. In an embodiment, MQ resin may optionally be added as a tackifying agent. Moreover, a release liner (not shown) is optional in the configuration where first layer 102 is a pressure sensitive adhesive.
[0025] Optionally, first layer 102 may be a pressure insensitive (pressure insensitive defined to be not pressure sensitive) silastic coating, which is a non-tacky silicone rubber or elastomer coating. Additionally, first layer 102 may be a PDMS, PDPS, or PDMDPS polymer having a nonorganic fire resistant filler. Nonorganic fire resistant fillers may be ceramic powder, metal, glass, metal oxides, or combinations of ceramic powder, metal, glass, or metal oxide fillers. Examples of fire resistant fillers contemplated by the present disclosure are ferro oxide, titanium oxide, boron nitride, zirconium oxide, sodium silicate, and magnesium silicate, although others are suitable as well.
[0026] First layer 102 may also be a nonthermally conductive material, in embodiments. An example of a nonthermally conductive material is zirconium woven cloth or felt. Zirconium is defined to be a material comprising 50% to 100% ZrO 2 . A more effective embodiment comprises 70% to 100% ZrO 2 .
[0027] In another embodiment, the nonthermally conductive material is a siloxane-based foam that is either pressure sensitive or pressure insensitive, comprising the siloxane-based foam with a density of about 0.01 to about 1.00 g/cm 3 . The foam may optionally include at least one non-flammable filler, which may be ceramic powder, metal, glass, metal oxides, or combinations of ceramic powder, metal, glass, or metal oxide fillers. Examples of fire resistant fillers contemplated by the present disclosure are ferro oxide, titanium oxide, boron nitride, zirconium oxide, sodium silicate, and magnesium silicate, although others are suitable as well.
[0028] Second layer 104 is an optional laminating layer depending on how well first layer 102 adheres to third layer 106 . However, when included, second layer comprises an adhesive bonding first layer to third layer, such as a PDMS, PDPS, PDMDPS-based pressure sensitive adhesive or a PDMS, PDPS, PDMDPS-based adhesive that is pressure insensitive at room temperature.
[0029] Third layer 106 is also an optional layer comprising a metal film or foil. The present disclosure contemplates using an aluminum foil, steel foil, copper foil, or other types of metal foil. In other embodiments, metal foil is substituted with wool paper, polyamide paper, carbon paper, ceramic paper, or polyamide felt. The layer should be about 0.1 mm to about 5.00 mm thick. In a particularly effective embodiment, copper foil of thickness of about 0.025 mm to about 0.13 mm is used.
[0030] First adhesive 108 is a PDMS, PDPS, or PDMDPS polymer based adhesive. It must be able to adhere to whatever components form first layer 102 , second layer 104 , or third layer 106 and glass cloth 110 . First adhesive 108 works well as both a pressure sensitive adhesive or a pressure insensitive adhesive. The adhesive may optionally include at least one non-flammable additive, which may be ceramic powder, metal, glass, metal oxides, or combinations of ceramic powder, metal, glass, or metal oxide additives. Examples of fire resistant additives contemplated by the present disclosure are ferro oxide, titanium oxide, boron nitride, zirconium oxide, sodium silicate, and magnesium silicate, although others are suitable as well.
[0031] Glass cloth 110 is a woven or felt cloth made of glass fiber, silicate fiber, ceramic fiber, aramid fiber, polyamide fiber, or carbon fiber.
[0032] Like first adhesive 108 , second adhesive 112 is a PDMS, PDPS, or PDMDPS polymer based adhesive. It may either be a pressure sensitive adhesive or a pressure insensitive adhesive. A particularly effective embodiment is a pressure sensitive adhesive uses a PDPS polymer based adhesive. The adhesive may optionally include at least one non-flammable additive, which may be ceramic powder, metal, glass, metal oxides, or combinations of ceramic powder, metal, glass, or metal oxide additives. Examples of fire resistant additives contemplated by the present disclosure are ferro oxide, titanium oxide, boron nitride, zirconium oxide, sodium silicate, and magnesium silicate, although others are suitable as well.
[0033] Finally, release liner 114 may take a number of forms in embodiments. For example, it may be a thin layer web that covers second adhesive 112 . Alternately, it may be corrugated or embossed film, such as polyolefin or PVC. It may also be a smooth plastic film or paper coated with a flourosilicone coated release layer that does not bond to second adhesive 112 . Release liner 114 should be able to be easily and manually removed from second adhesive 112 without changing the physical or functional properties of second adhesive 112 . Other release liners having similar properties are similarly contemplated as would be known to those skilled in the art.
EXAMPLE 2
[0034] FIG. 3 shows an alternative embodiment of an HVOF tape 100 . The alternative embodiment comprises: glass cloth 110 , first layer 102 , second layer 104 , third layer 106 , first adhesive 108 , glass cloth 110 , second adhesive 112 , and release liner 114 . The exemplary embodiment is the same as the exemplary embodiment disclosed in EXAMPLE 1, with the exception that glass cloth layer 110 , as previously defined, comprises the top-most layer rather than first layer 102 .
[0035] Because glass layer is the topmost layer, first layer 102 is modified to be a pressure sensitive adhesive layer made from PDMS polymer, PDPS polymer, or PDMDPS polymer serving as an adhesive binding glass cloth 110 to the other layers. In an embodiment, MQ resin may optionally be added to first layer 102 as a tackifying agent. Optionally, first layer may be a PDMS, PDPS, or PDMDPS polymer having a nonorganic fire resistant additive. Nonorganic fire resistant additives may be ceramic powder, metal, glass, metal oxides, or combinations of ceramic powder, metal, glass, or metal oxide additives. Examples of fire resistant additives contemplated by the present disclosure are ferro oxide, titanium oxide, boron nitride, zirconium oxide, sodium silicate, and magnesium silicate, although others are suitable as well. First layer 102 may also be a pressure insensitive silastic coating, which is a non-tacky silicone rubber or elastomer coating.
EXAMPLE 3
[0036] FIG. 4 demonstrates a third embodiment for constructing HVOF tape 100 . The exemplary embodiment comprises glass cloth 110 , first layer 102 , second layer 104 , third layer 106 , second adhesive 112 , and release liner 114 . The embodiment is the same as that of EXAMPLE 2, except that third layer 106 is must be included and glass cloth 110 layer and its laminating adhesive, first adhesive 108 , are excluded. All other features are the same as in EXAMPLE 2.
EXAMPLE 4
[0037] A fourth embodiment exemplified by FIG. 5 of the present disclosure comprises HVOF tape 100 identical to the embodiment taught in EXAMPLE 1, except that first layer 102 comprises both a high temperature silicone PSA. Moreover, between first layer 102 and second layer 104 is high temperature fabric or foam 116 , as previously described. Release liners 114 are used on both sides of the HVOF tape bordering high temperature silicone PSA layers 102 and 112 .
[0038] The present inventor has disclosed that the material characteristics necessary to transform conventional tapes into HVOF tape, which provides interesting and useful results when optimized. Unexpectedly improved products have consequently been developed using the results set forth in the following tables in the process of optimizing the instant teachings.
TABLE 1 Tape Example Code 1259A 1259B 1260 1261 1262 Tape Glass fiber Glass fiber cloth Glass fiber cloth Glass fiber Glass fiber cloth Construction cloth Silastic Rubber Silicone cloth Silastic Rubber Silastic Coating lamination Silastic Coating Rubber Silicone adhesive Rubber Silicone Coating lamination 2 mil aluminum Coating lamination Silicone adhesive foil Silicone adhesive lamination 2 mil aluminum Silicone lamination 2 mil aluminum adhesive foil Silicone adhesive foil 2 mil Silicone lamination 2 mil PDMDPS aluminum foil lamination adhesive aluminum foil pressure Silicone adhesive Glass fiber cloth PDMS sensitive lamination Glass fiber cloth PDMDPS pressure adhesive adhesive PDMDPS pressure sensitive Fluorosilicone Glass fiber pressure sensitive adhesive PET release cloth sensitive adhesive liner PDMS adhesive pressure sensitive adhesive Adhesion to 53 61 60 63 48 Steel (oz/in) Adhesion to 31 40 28 29 35 Backing (oz/in) Probe tack 950 1500 1000 1440 1200 (grams) Rolling Ball 0.35 0.35 0.4 0.55 0.4 Tack (inches) Oxy/Propane good good fair-good fair fair-good thermal test (3 minutes)
[0039] Table 1 shows exemplary embodiments and their respective strengths with respect to key parameters of the instant disclosure. Table 2 demonstrates variations in the formulation of silicone adhesive and silastic silicone rubber layers reviewed in completion of the teachings of the instant disclosure. Units of the layers are in parts per total weight (e.g. the total weight of HVOF tape example 1043 is 105 parts, wherein 100 parts are PDMP Silicone PSA and 5 parts benzoyl peroxide).
TABLE 2 The following describes possible silicone adhesive and Silastic silicone rubber formulations. Tape Example Code Tape Construction Components 1043 A 1043A1 1043 B Adhesive Layer PDMDP Silicone PSA 100 100 PDP Silicone PSA PDM Silicone PSA 100 Benzoyl Peroxide 5 10 5 Silastic silicone Silicone rubber A rubber Layer Ferro Oxide Silicone rubber B Titanium Oxide Boron Nitride Zirconium Oxide Sodium Silicate Magnesium Silicate Tape Construction glass fiber cloth glass fiber cloth glass fiber cloth Silicone adhesive Silicone adhesive Silicone adhesive 3 mil aluminum foil 3 mil aluminum foil 3 mil aluminum foil Silicone adhesive Silicone adhesive Silicone adhesive glass fiber cloth glass fiber cloth glass fiber cloth Silicone PSA Silicone PSA Silicone PSA Tape Properties Adhesion to Steel (oz/in) 55 50 65 Adhesion to Backing (oz/in) 31 30 45 Probe tack (grams) 950 900 860 Rolling Ball Tack(inches) 0.35 0.45 0.45 Oxy/Propane thermal test (3 good good good minutes) Tape Example Code Tape Construction Components 1043 B1 1044 C 1044 D Adhesive Layer PDMDP Silicone PSA PDP Silicone PSA PDM Silicone PSA 100 100 100 Benzoyl Peroxide 10 10 10 Silastic silicone Silicone rubber A 100 rubber Layer Ferro Oxide 50 Silicone rubber B 100 Titanium Oxide 50 Boron Nitride Zirconium Oxide Sodium Silicate Magnesium Silicate Tape Construction glass fiber cloth Silastic silicone Silastic silicone Silicone adhesive rubber rubber 3 mil aluminum foil glass fiber cloth glass fiber cloth Silicone adhesive Silicone adhesive Silicone adhesive glass fiber cloth 3 mil aluminum foil 3 mil aluminum foil Silicone PSA Silicone adhesive Silicone adhesive glass fiber cloth glass fiber cloth Silicone PSA Silicone PSA Tape Properties Adhesion to Steel (oz/in) 60 62 60 Adhesion to Backing (oz/in) 43 38 40 Probe tack (grams) 910 900 910 Rolling Ball Tack(inches) 0.4 0.4 0.4 Oxy/Propane thermal test (3 good good good minutes) Tape Example Code Tape Construction Components 1044 E 1044 D 1045 D Adhesive Layer PDMDP Silicone PSA 100 PDP Silicone PSA 100 100 PDM Silicone PSA Benzoyl Peroxide 10 10 10 Silastic silicone Silicone rubber A 100 rubber Layer Ferro Oxide 50 Silicone rubber B 100 100 Titanium Oxide 20 100 Boron Nitride Zirconium Oxide Sodium Silicate Magnesium Silicate Tape Construction Silastic silicone Silastic silicone Silastic silicone rubber rubber rubber glass fiber cloth glass fiber cloth glass fiber cloth Silicone adhesive Silicone adhesive Silicone adhesive 3 mil aluminum foil 3 mil aluminum foil 3 mil aluminum foil Silicone adhesive Silicone adhesive Silicone adhesive glass fiber cloth glass fiber cloth glass fiber cloth Silicone PSA Silicone PSA Silicone PSA Tape Properties Adhesion to Steel (oz/in) 53 55 54 Adhesion to Backing (oz/in) 32 30 35 Probe tack (grams) 900 850 880 Rolling Ball Tack(inches) 0.3 0.35 0.3 Oxy/Propane thermal test (3 good good good minutes) Tape Example Code Tape Construction Components 1046 D 1047 D 1048 D Adhesive Layer PDMDP Silicone PSA PDP Silicone PSA 100 100 100 PDM Silicone PSA Benzoyl Peroxide 10 10 10 Silastic silicone Silicone rubber A rubber Layer Ferro Oxide Silicone rubber B 100 100 100 Titanium Oxide Boron Nitride 20 100 Zirconium Oxide 20 Sodium Silicate Magnesium Silicate Tape Construction Silastic silicone Silastic silicone Silastic silicone rubber rubber rubber glass fiber cloth glass fiber cloth glass fiber cloth Silicone adhesive Silicone adhesive Silicone adhesive 3 mil aluminum foil 3 mil aluminum foil 3 mil aluminum foil Silicone adhesive Silicone adhesive Silicone adhesive glass fiber cloth glass fiber cloth glass fiber cloth Silicone PSA Silicone PSA Silicone PSA Tape Properties Adhesion to Steel (oz/in) 52 53 55 Adhesion to Backing (oz/in) 29 33 35 Probe tack (grams) 800 790 820 Rolling Ball Tack(inches) 0.29 0.3 0.33 Oxy/Propane thermal test (3 good good good minutes) Tape Example Code Tape Construction Components 1049 D 1050 D 1051 D Adhesive Layer PDMDP Silicone PSA PDP Silicone PSA 100 100 100 PDM Silicone PSA Benzoyl Peroxide 10 10 10 Silastic silicone Silicone rubber A rubber Layer Ferro Oxide Silicone rubber B 100 100 100 Titanium Oxide Boron Nitride Zirconium Oxide 100 Sodium Silicate 20 100 Magnesium Silicate Tape Construction Silastic silicone Silastic silicone Silastic silicone rubber rubber rubber glass fiber cloth glass fiber cloth glass fiber cloth Silicone adhesive Silicone adhesive Silicone adhesive 3 mil aluminum foil 3 mil aluminum foil 3 mil aluminum foil Silicone adhesive Silicone adhesive Silicone adhesive glass fiber cloth glass fiber cloth glass fiber cloth Silicone PSA Silicone PSA Silicone PSA Tape Properties Adhesion to Steel (oz/in) 58 52 55 Adhesion to Backing (oz/in) 36 30 32 Probe tack (grams) 810 790 830 Rolling Ball Tack(inches) 0.34 0.3 0.32 Oxy/Propane thermal test (3 good good good minutes) Tape Example Code Tape Construction Components 1052 D 1053 D 1054 D Adhesive Layer PDMDP Silicone PSA PDP Silicone PSA 100 100 100 PDM Silicone PSA Benzoyl Peroxide 10 10 10 Silastic silicone Silicone rubber A rubber Layer Ferro Oxide Silicone rubber B 100 100 100 Titanium Oxide Boron Nitride Zirconium Oxide Sodium Silicate Magnesium Silicate 20 100 50 Tape Construction Silastic silicone Silastic silicone Silastic silicone rubber rubber rubber glass fiber cloth glass fiber cloth 5 mil copper foil Silicone adhesive Silicone adhesive Silicone adhesive 3 mil aluminum foil 3 mil aluminum foil 3 mil aluminum foil Silicone adhesive Silicone adhesive Silicone adhesive glass fiber cloth glass fiber cloth glass fiber cloth Silicone PSA Silicone PSA Silicone PSA Tape Properties Adhesion to Steel (oz/in) 51 56 57 Adhesion to Backing (oz/in) 33 33 34 Probe tack (grams) 820 850 850 Rolling Ball Tack(inches) 0.33 0.35 0.35 Oxy/Propane thermal test (3 good very good good minutes) Tape Example Code Tape Construction Components 1055 D 1056 D 1057 D Adhesive Layer PDMDP Silicone PSA PDP Silicone PSA 100 100 100 PDM Silicone PSA Benzoyl Peroxide 10 10 10 Silastic silicone Silicone rubber A rubber Layer Ferro Oxide Silicone rubber B 100 100 100 Titanium Oxide Boron Nitride Zirconium Oxide Sodium Silicate 50 100 Magnesium Silicate 100 Tape Construction Silastic silicone Silastic silicone Silastic silicone rubber rubber rubber 2 mil copper foil 3 mil aluminum foil 5 mil aluminum foil Silicone adhesive Silicone adhesive Silicone adhesive 4 mil aluminum foil 5 mil aluminum foil 6 mil aluminum foil Silicone adhesive Silicone adhesive Silicone adhesive glass fiber cloth glass fiber cloth glass fiber cloth Silicone PSA Silicone PSA Silicone PSA Tape Properties Adhesion to Steel (oz/in) 57 50 52 Adhesion to Backing (oz/in) 32 30 31 Probe tack (grams) 840 780 790 Rolling Ball Tack(inches) 0.33 0.3 0.3 Oxy/Propane thermal test (3 very good very good very good minutes) Tape Example Code Tape Construction Components 1058 D 1059 D 1060 D Adhesive Layer PDMDP Silicone PSA 100 100 100 PDP Silicone PSA PDM Silicone PSA Benzoyl Peroxide 10 10 10 Silastic silicone Silicone rubber A 100 100 100 rubber Layer Ferro Oxide Silicone rubber B Titanium Oxide Boron Nitride Zirconium Oxide Sodium Silicate 50 50 50 Magnesium Silicate Tape Construction Silastic silicone Silastic silicone 10 mil copper foil rubber rubber Silastic silicone 5 mil copper foil 6 mil copper foil rubber Silicone adhesive Silicone adhesive 3 mil aluminum foil glass fiber cloth 4 mil aluminum foil Silicone adhesive Silicone PSA Silicone PSA glass fiber cloth Silicone PSA Tape Properties Adhesion to Steel (oz/in) 50 52 66 Adhesion to Backing (oz/in) 34 30 34 Probe tack (grams) 850 810 860 Rolling Ball Tack(inches) 0.35 0.32 0.35 Oxy/Propane thermal test (3 good good very good minutes) Tape Example Code Tape Construction Components 1060 D Adhesive Layer PDMDP Silicone PSA 100 PDP Silicone PSA PDM Silicone PSA Benzoyl Peroxide 10 Silastic silicone Silicone rubber A 100 rubber Layer Ferro Oxide Silicone rubber B Titanium Oxide Boron Nitride Zirconium Oxide Sodium Silicate 50 Magnesium Silicate Tape Construction 10 mil copper foil Silastic silicone rubber 6 mil aluminum foil Silicone adhesive glass fiber cloth Silicone PSA Tape Properties Adhesion to Steel (oz/in) 68 Adhesion to Backing (oz/in) 32 Probe tack (grams) 850 Rolling Ball Tack(inches) 0.35 Oxy/Propane thermal test (3 good minutes)
[0040] While the apparatus and method have been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all embodiments of the following claims. | A finished high velocity oxy fuel (HVOF) tape used with, for example, during known HVOF processing imparts high temperature silicone pressure sensitive adhesives that provide enhanced adhesion strength to provide a firm adhesion to its own backing and unexpectedly leave no residue upon removal from metals. The novel enhanced tapes are made up of coated or uncoated, woven or non-woven glass cloth and ceramic based fabric laminated to at least one side of a metal-foil using a silicone based laminating adhesive, which is then laminated with another layer of a pre-selected combination of the same materials and coated with a high temperature silicone pressure sensitive adhesive and wound to itself to make a self wound tape or covered adhesive assembly with a release liner to make a laminated sheet for die cut samples, among other things. Applications including military and commercial aircraft, automobiles and metal finishing usages leverage of on the unique and inherent benefits of the novel enhanced tapes of the instant teachings. | 2 |
CROSS-REFERENCE OF RELATED APPLICATIONS
This application is a Continuation-in-Part of U.S. patent application Ser. No. 14/043,160, filed on Oct. 1, 2013, now U.S. Pat. No. 9,271,947, which is incorporated herein by reference in its entirety. This application is related to European Patent Application No. EP13186923.2, filed Oct. 1, 2013, and also Patent Cooperation Treaty Application No. PCT/IB2014/002548, filed on Sep. 30, 2014, both are also incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to aquaculture and, more particularly, to the prevention and reduction of parasites in aquatic animals.
Description of the Related Art
Aquaculture, also known as fish or shellfish farming, refers to the breeding, rearing, and harvesting of plants and animals in all types of water environments, including ponds, rivers, lakes, and oceans. Issues associated with aquaculture can include the propagation of invasive species, waste handling, side-effects of antibiotics, and competition between farmed and wild animals. In addition, the welfare of the animals in aquaculture can be impacted by stocking densities, behavioral interactions, diseases, and parasitosis.
Fish may be infected with numerous parasites belonging to various zoological groups. The most common types of infestation are caused by protozoans, like dinoflagellates ectoparasites, ciliates, and zooflagellates. Another species of interest in aquaculture is represented by helminth parasites, such as monogeneans, trematodes, cestodes and nematodes. In addition, parasites affecting aquaculture also include ectoparasites, such as mollusks, crustaceans, and sea lice.
The conventional strategies for controlling parasites and the resulting infections are expensive since they are based on chemoprophylaxis. Furthermore, the hardening of the regulations and the banning of the use of certain drugs, such as malachite green and gentian violet, against parasites in farms requires new approaches and strategies for parasite disease control.
BRIEF SUMMARY OF THE INVENTION
Embodiments of the present invention address deficiencies of the art in respect to the prevention and reduction of parasites in aquatic animals and provide a novel and non-obvious method for reducing parasites in aquatic animals. In an embodiment of the invention, propyl propane thiosulfinate (PTS) having the formula R—SOa-S—R, where R represents n-propyl group (—CH 2 —CH 2 —CH 3 ) and a is 1, can be administered to aquatic animals including fish, crustaceans, and molluscs, to reduce multiple, different parasites, including crustaceans, in the aquatic animals. Further, the concentration of PTS can be between at least one and no more than five thousand parts per million (1-5000 ppm).
In a different embodiment of the invention, propyl propane thiosulfonate (PTSO) having the formula R—SOa-S—R, where R represents n-propyl group (—CH 2 —CH 2 —CH 3 ) and a is 2, can be administered to an aquatic animal to reduce multiple, different parasites, such as crustaceans, in the aquatic animal. Further, the concentration of PTSO can be between at least one and no more than five thousand parts per million (1-5000 ppm).
In yet a different embodiment of the invention, a compound including both propyl propane thiosulfonate (PTSO) having a formula R—SOa-S—R, where R represents n-propyl group (—CH 2 —CH 2 —CH 3 ) and a is 2, and also propyl propane thiosulfinate (PTS) having a formula R—SOa-S—R, where R represents n-propyl group (—CH 2 —CH 2 —CH 3 ) and a is 1, can be administered to a aquatic animal to reduce multiple, different parasites, such as crustaceans, in the aquatic animal.
In even yet a different embodiment of the invention, a compound including both propyl propane thiosulfonate (PTSO) having a formula R—SOa-S—R, where R represents n-propyl group (—CH 2 —CH 2 —CH 3 ) and a is 2, and also propyl propane thiosulfinate (PTS) having a formula R—SOa-S—R, where R represents n-propyl group (—CH 2 —CH 2 —CH 3 ) and a is 1, can be administered to a fish to prevent multiple, different parasites from infecting the aquatic animal. In yet a different embodiment of the invention, PTS can be administered to an aquatic animal to prevent multiple, different parasites from infecting the aquatic animal. In another embodiment, PTSO can be administered to an aquatic animal to prevent multiple, different parasites from infecting the aquatic animal.
Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
FIG. 1 is a pictorial illustration of a method for reducing parasites in aquatic animals;
FIG. 2A is a flow chart illustrating a method for reducing parasites in aquatic animals;
FIG. 2B is a flow chart illustrating a method for preventing parasites in aquatic animals;
FIG. 3 illustrates the survival probability of Caligus rogercresseyi copepodites at different concentrations of PTS and PTSO;
FIG. 4 illustrates the survival probability of Caligus rogercresseyi Nauplius I at different concentrations of PTS and PTSO;
FIG. 5 illustrates the survival probability of Caligus rogercresseyi Nauplius II at different concentrations of PTS and PTSO;
FIG. 6 illustrates the survival probability of Caligus rogercresseyi adults at different concentrations of PTS and PTSO;
FIG. 7 illustrates assay effectiveness at different concentrations of PTSO on the control of Icthyobodo necator in rainbow trout;
FIG. 8 illustrates in vitro activity of PTS, PTSO, and a mixture of both (1:1) against L3 larvae of Hysterotylacium aduncum at the concentration tested (75 ppm), where activity is expressed as mortality; and,
FIG. 9 illustrates in vitro activity of PTSO against L3 larvae of Anisakis type I at the concentrations tested (200, 300 and 500 ppm), where activity is expressed as mortality.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention provide for combating parasites in aquatic animals, including fish, mollusks, and crustaceans. Specifically, propyl propane thiosulfonate (PTSO) and propyl propane thiosulfinate (PTS) can be used alone or in combination with each other as an anti-parasitic against a variety of parasites, such as flagellate protozoan, helminths, mollusks, crustaceans, and bloodsuckers, in aquatic animals, such as fish, mollusks, and crustaceans, so that parasites invading fish, mollusk, and crustaceans can both be reduced as well as prevented.
In further illustration of the invention, FIG. 1 pictorially shows a process for reducing parasites in aquatic animals. Of note, in addition to reducing parasites in aquatic animals, it is contemplated that the invention can also be used to eliminate parasites in aquatic animals. Upon the detection of a plurality of parasites on and/or in infected aquatic animals 105 , such as in and/or on fish 805 A, crustaceans 805 B, and mollusks 805 C, propyl propane thiosulfonate (PTSO) 150 B as well as propyl propane thiosulfinate (PTS) 150 A can be used alone or in combination with each other 150 to reduce the number of parasites in or/and on the aquatic animals 105 .
More specifically, upon the detection of a parasite, PTS and/or PTSO 150 can be administered 115 to an infected aquatic animal 105 . The administration of PTS and/or PTSO 150 to an infected aquatic animal 105 can be accomplished via an injection 115 A, a bath treatment 115 B, incorporation with a pharmacological composition and orally administered 115 C, incorporation with a pharmacological composition and injected 115 D, or incorporated with food and then orally administrated 115 E. In this way, after the administration of PTS and/or PTSO 150 , the parasites in and/or on the infected aquatic animal 105 are reduced (and/or eliminated).
In yet further illustration of the invention, FIG. 2A is a flow chart illustrating a process for reducing parasites in aquatic animals. Beginning in block 212 , an aquatic animal can be selected. The aquatic animal can be a fish (a member of a paraphyltic group of organisms that includes gill-bearing aquatic craniate animals), a crustacean, or a mollusk. The selected aquatic animal can be tested for the presence of parasites whether on and/or in the selected aquatic animal, as shown in block 222 , by any method now known or later developed. Of note, testing can also include the visual inspection of the aquatic animal. As illustrated in block 232 , upon the detection of a parasite, such as endoparasites and ectoparasites, including, but not limited to, flagellated protozoan, helminth, nematodes, trematodes, cestodes, bloodsuckers, copepods (such as sea lice), crustaceans, and mollusks, a determination as to what to administer to the infected aquatic animal can be made, as indicated in block 242 . Of note, with reference to the parasite being a crustacean as well as a copepod, the parasite can include those having a scientific classification of Class Maxillopoda and Subclass copepod, which act as ectoparasites.
Specifically, a determination can be made as to whether PTS, PTSO, or a combination of both should be administered. In addition, as shown in block 252 , an optional determination as whether PTS, PTSO, or both can be administered in conjunction with a pharmacological composition, such as drugs and other anti-parasitic products, can be made. Further, a determination can be made as to how to administer PTS, PTSO, or both, as shown in block 262 . For instance, administration of PTS, PTSO, or both can be accomplished via an injection, a bath treatment, or incorporated with food and then orally administrated in the aquatic animal. Further, if a pharmacological composition is also selected to be added, then PTS, PTSO, or both can be incorporated with the pharmacological composition and orally administered or incorporated with the pharmacological composition and injected.
In yet further illustration of the invention, FIG. 2B is a flow chart illustrating a process for preventing parasites in aquatic animals. As illustrated in FIG. 2B , an aquatic animal can be selected, as shown in block 218 . As before, the aquatic animal can be a fish (a member of a paraphyltic group of organisms that includes gill-bearing aquatic craniate animals), a crustacean, or a mollusk. Optionally, an aquatic animal can be tested, by any method now known or later developed, including by visual inspection, to determining whether the selected aquatic animal is infected by a parasite (or multiple, different parasites), as illustrated in block 228 . Regardless of whether it is determined that the selected aquatic animal is infected by parasites, as shown in block 248 , a determination can be made as to what to administer to the selected aquatic animal—PTS, PTSO, both. In addition, as shown in block 258 , an optional determination as whether PTS, PTSO, or both can be administered in conjunction with a pharmacological composition, such as drugs and other anti-parasitic products, can be made.
Also, a determination can be made as to how to administer PTS, PTSO, or both, as shown in block 268 . For instance, administration of PTS, PTSO, or both can be accomplished via an injection, a bath treatment, or incorporated with food and then orally administrated to the aquatic animal. Even yet further, if a pharmacological composition is also selected to be added, then PTS, PTSO, or both can be incorporated with the pharmacological composition and orally administered or incorporated with the pharmacological composition and injected. In this way, PTS, PTSO, or both, can be used in the prevention of parasites in aquatic animals.
Of note, as indicated herein the use of propyl propane thiosulfonate (PTSO) as well as propyl propane thiosulfinate (PTS) can be used alone or in combination with each other. In other words, PTS and PTSO can be used alone or in combination with each other in any relative percentage (in any ratio). In addition, PTS and PTSO can be used in combination with other anti-parasitic methods and products, including natural products or synthetic drugs, where PTS and/or PTSO can be in any ratio. The parasites can include endoparasites and ectoparasites, including, but are not limited to, flagellated protozoan, helminth, nematodes, trematodes, cestodes, bloodsuckers, copepods (such as sea lice), crustaceans, and mollusks. The aquatic animals being treated by PTS and/or PTSO can include, but are not limited to, fish (including fresh water and saline (marine) water species) such as salmon, trout, bass, seabream, fishbase, tilapia, turbot, cod, carp, sturgeon, flatfish, eel, tuna, catfish, coho, lobster, crab, mussel, clam, shrimp and prawn, mullet, shell, and oyster.
PTS and PTSO each correspond to the following formula:
R—SO a -S—R,
in which R represents n-propyl group (—CH 2 —CH 2 —CH 3 ), and a is 1 for PTS and 2 for PTSO. Of note, PTSO is also known as dipropyl thiosulfonate (CAS Number 1113-13-9) and PTS is also known as dipropyl thiosulfinate (CAS Number 1948-52-3). The concentration of PTS used in an embodiment of the invention to reduce a plurality of parasites in and/or on a fish (and also in crustaceans and mollusks) can be between one and five thousand parts per million (1-5000 ppm). In a different embodiment, the concentration of PTS can be between five and one thousand parts per million (5-1000 ppm). In yet a different embodiment, the concentration of PTS can be between ten and three hundred fifty parts per million (10-350 ppm).
In yet even a different embodiment, the concentration of PTS can be between 10 and four hundred parts per million (10-400 ppm). The concentration of PTSO used in an embodiment of the invention to reduce a plurality of parasites in fish (as well as on fish) can be between one and five thousand parts per million (1-5000 ppm). In a different embodiment, the concentration of PTSO compound can be between five and one thousand parts per million (5-1000 ppm). In yet a different embodiment, the concentration of PTSO can be between ten and three hundred fifty parts per million (10-350 ppm). In yet even a different embodiment, the concentration of PTSO can be between 10 and four hundred parts per million (10-400 ppm).
In addition, PTS and/or PTSO can be administered to a healthy aquatic animal or an infected aquatic animal by an immersion treatment, such as a bath. In other words, PTS and/or PTSO can be used to reduce the number of parasites in and/or on an aquatic animal as well as PTS and/or PTSO can be used in the prevention of parasites in aquatic animals. In addition, PTS and/or PTSO can be incorporated into feed; the feed can then be administered to either a healthy aquatic animal or an infected aquatic animal. To that end, in a different embodiment, PTS and/or PTSO can be administered orally. For example, PTS and/or PTSO can be incorporated into a pharmacological composition (including drugs and other anti-parasitic products) and then the pharmacological composition can be orally administered to the aquatic animal.
In another embodiment, PTS and/or PTSO can be incorporated into a pharmacological composition (including drugs and other anti-parasitic products) and then the pharmacological composition can be injected into the aquatic animal. In addition, PTS and/or PTSO can be administered to an aquatic animal directly by injection alone (with just PTS, just PTSO, or only a mixture of PTS and PTSO).
In further illustration of the invention, the following examples are presented. Of note, as will be understood by one skilled in the art, the invention is not limited to just these examples.
EXAMPLE 1
The parasiticide efficacy of a mixture of propyl propane thiosulfinate (PTS) and propyl propane thiosulfonate (PTSO) was measured in vitro against Caligus rogercresseyi.
Upon receipt in the laboratory, the wild adult females and males were kept in filtered seawater (125 μm membranes) in absolute darkness inside a thermo-regulated chamber at 12° C. The egg sacs were removed gently from females using a fine-tipped forceps and placed in separate beakers with 500 mL of filtered seawater in the conditions described above until spawning. The fish were then separated into the different stages: Nauplius I, Nauplius II, Copepodite and Adult for subsequent in vitro susceptibility studies.
In order to evaluate effectiveness, several bioassays were performed in triplicate with different concentrations of propyl propane thiosulfinate (PTS) and propyl propane thiosulfonate (PTSO) at each stage: Nauplio I, Nauplio II, Copepodite and Adult. In total, 40 Caligus were used per test and placed at a rate of 10 individuals per sterile petri plate. A mixture of propyl propane thiosulfinate (PTS) and propyl propane thiosulfonate (PTSO) at concentrations of 100, 200 and 300 ppm was added to each plate over a 30-minute exposure period. After that, the water was changed and the fish were incubated at 12° C. during a 12-hour photoperiod. A control group was also included. In order to estimate the effective lethal concentration and the survival ratio, observations were registered after treatment using the Kaplan-Meir function for each of the stages and treatments studied.
EXAMPLE 2
In this example, a study of oral treatments of Ichthyobodosis in rainbow trout with different concentrations of Propyl propane thiosulphonate (PTSO) administered into feed was conducted.
Rainbow trout Oncornynchus mykiss were obtained from a local fish farm and acclimatized for at least 10 days before assay in 100 l tanks with aeration in closed systems of water (15±2° C., pH 7-7.5). The natural light-dark cycle was simulated (12 h light: 12 h dark). Fish were fed twice per day with a commercial feed (EFICO, Biomar, Spain). Parasite-free fish were experimentally infested by holding the parasite-free fish 25 days in a 100 l tank that also contained fish showing high-intensity infestation (20 uninfected fish to 10 infected fish). Twenty (20) fish were then sampled at random for determination of infestation intensity, which was determined to be a high intensity infestation in at least 50% of fish.
Fish were anaesthetized by immersion in bath with 100 ppm of Tricaine methanesulfonate until respiration became weak. A mucus sample was then taken by gently scraping the body surface after examination of a sample area of 24×32 mm. The sample was mixed with 30 μl of distilled water on a slide, cover-slipped and examined to optic microscopy (400×).
Each treatment was assayed in 20 infected fish maintained in 100 L tanks with aeration in closed systems of water. The fish received feed containing three different treatments. The first group received a diet with 100 ppm of Propyl propane thiosulphonate (PTSO), the second received a diet supplemented with 300 ppm of PTSO, and the third received a diet with 300 ppm of metronidazole. All treatments were applied during a 10 day period. In all cases, feed was supplied at 2% of total body weight per day. Simultaneously, a positive control assay (also on 20 infected fish treated identically, but without any PTSO) and negative control assay (with 20 uninfected animals) were performed. Tanks conditions were identical to those during the acclimatization period.
Throughout the assay period the fish were monitored regularly to ensure that the fish were eating the food, and to check for signs of toxicity.
EXAMPLE 3
The objective of example 3 was to examine the activity of propyl propane thiosulphonate (PTSO) and propyl propane thiosulfinate (PTS) against L3 larvae of type I Anisakis and Hysterotylacium aduncum to explore the possible use of these compounds for prophylaxis treatments.
L3 of Anisakis type I and Hysterotylacium aduncum were collected by dissecting the fish Micromesistius poutassou (blue whiting) and Trachurus trachurus (mackerel) fished in the Cantabric sea, and selecting only larvae with a length greater than (>) 2.0 cm in the case of Anisakis , and greater than 0.8 cm for Hysterotylacium.
Larvae were axenised in antibiotic solution (Iglesias et al., 1997), introduced into polystyrene plate wells with 2 ml of sterile solution of 0.9% NaCl and the different concentrations of PTS alone, PTSO alone, and both PTS and PTSO (75, 200, 300 and 500 ppm) and then incubated at 36° C. in a 5% CO 2 atmosphere. As controls, larvae were assayed without test compound under identical experimental conditions, and using only the solvent DMSO 1% (Dimethyl sulfoxide). Larvae were examined under stereoscopic microscope at 4, 8, 24, and 48 hours to test the biocidal effect of the compounds. Larvae with no mobility at all were considered dead. Each dilution was tested three times on larvae from fish captured on different days.
EXAMPLE 4
One hundred fifty (150) parasitic copepods ( Caligus rogercresseyi ) were collected from parasitized trout, which had been previously sedated with methanesulfonate. The parasitic copepods were kept in water extracted from an aquaculture farm. For the experiment, thirty (30) adult trout ( Onchorhynchus mykiss ) were used and distributed in three (3) tanks (with ten (10) fish per tank), of three hundred liters (300 L) of water in each tank with supplemental aeration, closed circuit and controlled physico-chemical parameters.
In each tank, fifty (50) adult copepods were distributed and maintained for twenty four hours (24 h) in contact with the trout. After the twenty four hours the adult copepods were removed. To assess the anti-parasitic effect of a PTSO/PTS combination, at a total concentration of one part per million (1 ppm) with equal parts of MO and PTS, the trout where exposed to the PTSO/PTS combination in a bath (in a different tank) for one hour (1 h), following the experimental model:
Tank 1 : Control. Fish without treatment, exposed to a single bath in fresh water without additives for one hour (1 h). Tank 2 : Fish exposed to a single bath with PTSO/PTS in equal parts having a total concentration of one part per million (1 ppm) for one hour (1 h). Tank 3 : Fish treated in PTSO/PTS in equal parts having a total concentration of one part per million (1 ppm) for one hour (1 h), repeating the treatment once a day for three (3) days.
After the treatments, the trout were returned to the tanks. After twenty four hours (24 h), the load of copepods was measured, evaluating the survival and infection capacity of the copepods (sea lice). Results showed that a reduction of the parasitic copepods viability on the treated trout for those trout treated with a combination of PTSO/PTS. More specifically, for the trout in tank 3 , there was only a twenty percent (20%) recover of the parasitic copepods on the trout and for the trout in tank 2 , there was a fifty seven percent (57%) recover of the parasitic copepods on the trout. However, for the trout in tank 1 , there was a one hundred percent (100%) recover of the parasitic copepods on the trout. Of note, the recover and, in particular, the percent of recover, is based on a visual inspection of the trout's body, as where there are parasitic copepods present on the trout can be visually determined. Further, the percent of recover is calculated by determining the number of fish showing signs of the presence of parasitic copepods divided by the total number of fish in the tank.
Exemplary Results
The administration of PTS and PTSO demonstrated anti-parasitic activity against stages of the life C. rogercresseyi . For example, FIG. 3 illustrates the survival probability of Caligus rogercresseyi copepodites at different concentrations of PTS and PTSO.
In addition, FIG. 4 illustrates the survival probability of Caligus rogercresseyi Nauplius I at different concentrations of PTS and PTSO.
In further illustration of the exemplary results, FIG. 5 illustrates the survival probability of Caligus rogercresseyi Nauplius II at different concentrations of PTS and PTSO.
Finally, FIG. 6 illustrates the survival probability of Caligus rogercresseyi adults at different concentrations of PTS and PTSO.
It is further noted that PTSO demonstrated antiparasitic activity against Icthyobodo necator in rainbow trout with significant reduction of infestation intensity as shown in Table 1. For each treatment and each dosage tested, infestation intensity 24 hours after the end of the assay is shown for each of the 20 fish included in each assay. Also shown is infestation intensity: high, moderate, low, minimal and zero (i.e. no Icthyobodo necator detected in body scrapings).
TABLE 1
% infestation
High
Moderate
Low
minimal
zero
Positive control
53
41
6
0
0
PTSO (100 ppm)
35
30
18
12
5
PTSO (300 ppm)
25
7
8
5
55
Metronidazole (300 ppm)
15
20
7
12
46
Of note, infestation intensity was based on a 5-point scale, as follows: Zero equals Ichthyobodo necator not being detected in the sample; Minimal equals only 1 individual of I. necator being detected in the sample; Low equals more than 1 individual of parasite being detected in the sample, the average number per microscope field being less than 10; Moderate equals an average number of individuals per microscope field of 10 to 50; High equals an average number of individuals per microscope field of more than 50.
Further, FIG. 7 illustrates assay effectiveness at different concentrations of PTSO on the control of Icthyobodo necator in rainbow trout.
In addition, PTS and PTSO demonstrated significant anti-parasitic activity against L3 larvae of Hysterotylacium aduncum and Anisakis type I, as shown in FIG. 8 .
Specifically, FIG. 8 illustrates in vitro activity of PTS, PTSO, and a mixture of both (1:1) against L3 larvae of Hysterotylacium aduncum at the concentration tested (75 ppm), where activity is expressed as mortality. In addition, in FIG. 9 , in vitro activity of PTSO against L3 larvae of Anisakis type I at the concentrations tested (200, 300 and 500 ppm), where activity is expressed as mortality is illustrated.
Having thus described the invention of the present application in detail and by reference to 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 as follows: | A method for reducing parasites in aquatic animals is provided. The method includes administering to the aquatic animal a compound comprising propyl propane thiosulfonate (PTSO) having the formula R—SOa-S—R, where R represents n-propyl group (—CH 2 —CH 2 —CH 3 ) and a is 2 and also propyl propane thiosulfinate (PTS) having the formula R—SOa-S—R, where R represents n-propyl group (—CH 2 —CH 2 —CH 3 ) and a is 1, so that a combination of PTS and PTSO is administered to the aquatic animal resulting in the reduction of a plurality of crustaceans infecting the aquatic animal in response to administering the combination of PTS and PTSO to the aquatic animal. | 0 |
This application is a continuation-in-part of application Ser. No. 07/878,978, filed May 6, 1992, now pending.
BACKGROUND OF THE INVENTION
The present invention relates to a catalyst which is used for wet oxidation treatment for wastewater containing organic compounds etc. and used for decomposing them and also relates to a process for producing the catalyst and a process for treating wastewater with the wet oxidation under the presence of the catalyst.
There have been hitherto known methods for treating wastewater, such as a biochemical method called the activated-sludge method, a wet oxidation treatment called the Zimmerman method.
The activated-sludge method requires a long time to decompose organic compounds and also requires to dilute wastewater up to a concentration suitable for the growth of algae and bacteria so that it has a defect that a large scale of area is required to set treating facilities.
The Zimmerman method comprises treating wastewater in the presence of an oxygen gas under a high temperature and high pressure and decomposing organic compounds in the wastewater. In this method, there has been proposed a method which comprises a use of various kinds of oxidation catalysts in order to accelerate a reaction rate. The oxidation catalyst used here is a catalyst with a compound of a noble metal such as palladium, platinum or the like supported on a carrier such as alumina, silica, silica gel, active carbon or the like.
In general, it is rare that the chemical species included in wastewater to be treated is always the same. Thus, there are many cases where a nitrogen-containing compound is included besides a nitrogen-free organic compound.
However, wastewater including a nitrogen-containing compound such as an amine compound, an amide compound, an amino acid compound or the like is not treated with satisfactory efficiency by the above-mentioned methods.
Wastewater including an amine is usually treated by a cohesive treating method in which an anionic macromolecule cohesive agent is used. This method comprises gathering an amine by the anionic macromolecule cohesive agent and eliminating a formed precipitate (or sludge) from wastewater. Also, there has been attempted an adsorbent method which comprises bringing wastewater in contact with various kinds of adsorbents such as active carbon, activated clay, a silica gel, a complex oxide gel and the like, and adsorbing the amine to the adsorbent for eliminating it from the wastewater
Since sludge formed by the cohesive treating method contains amines, it should not be abolished without a following treatment. Because of this, a treatment to decompose the amines in the sludge becomes necessary. In addition, the macromolecular cohesive agent is expensive, so a cost for the treatment becomes high.
Concerning the adsorbent method, the elimination percentage of amines is not satisfactory enough. Since the adsorbing power of an adsorbent easily decreases, there is a problem in durability of the adsorbent.
Since the wet oxidation process is unavoidable in the wastewater treatment, it will be convenient if an arrangement is made so as to decompose a nitrogen-containing compound included in the wastewater in the course of the wet oxidation process.
On the other hand, a treatment for wastewater including a sulfur-containing compound has been so far carried out by a respectively different method depending upon the state and nature of the sulfur-containing compound. For example, in a case of wastewater including an organic sulfur compound, a biological treatment is generally carried out. However, in a case where a compound containing thiophene and the like is treated, which affects badly upon organisms in sludge, a biological treatment can not be applied and, accordingly, a combustion treatment etc. are carried out.
Wastewater containing a sulfide such as sodium sulfide or the like: for example, wood digestion wastewater in paper- and pulp manufacture, wastewater coming out from a coke oven in steel manufacture, wastewater after fiber-washing, wastewater from a plant of petroleum chemical products such as ethylene, BTX and the like, as well as wastewater from a coal gasification plant, a petroleum-refining plant, a rayon factory and a dyeing plant; has been mostly treated by a method which comprises adding iron chloride into wastewater to solidify sulfur ions, removing solid iron sulfide by solid-liquid separation, adjusting pH of the separated solution, carrying out a biological treatment of the solution, and then discharging the treated wastewater. Also, wastewater containing a sulfite salt and thiosulfate salt: for example, wastewater coming out from a wood kiln of pulp-making factory, wastewater from photograph-developing, wastewater from metal treatment as well as alkaline wastewater used to absorb sulfur dioxide and the like; is treated by a method which comprises subjecting wastewater to neutralization-precipitation treatment followed by biological treatment and then discharging the treated wastewater.
When wastewater containing a sulfur-containing compound is treated by either one or both of biological treatment and combustion treatment, there exist the undermentioned problems to be solved. In the biological treatment, it is necessary to adjust a wastewater source solution by diluting it with water so that organisms are not badly affected. Therefore, wastewater to be treated becomes a large amount and facilities for the biological treatment must be arranged in a large scale, so that there is a serious problem is in the necessary cost and so forth.
Also, in the combustion treatment, when a heal amount generating from wastewater is low, a supplementary fuel must be added and also, because a large amount of sulfur is usually included in the wastewater, a large amount of sulfur oxides are formed and, therefore, it is necessary to arrange a desulfurizer.
Next, when wastewater including a sulfur-containing compound such as sulfide is treated, if a method which comprises removing the sulfur-containing compound as iron sulfide by adding iron chloride is applied, sludge having iron sulfide as a main component is formed and also, this method is complicate as a treating procedure, because it consists of the following steps: injection of solution of chemicals, solid and liquid separation, pH control and biological treatment
The organic halogeno compounds have been used for various kinds of usage because of their stability. Since they are nonflammable and has great capability to degrease, they have been used in a large amount as a degreasing cleaner in metal, machinery and electronics industries as well as a cleaner for dry cleaning. On the other hand, the compounds have brought about problems on various fields. In general, since the organic halogeno compounds are difficult in decomposition, they are seriously accumulating in the natural environment and, as a result, ground water pollution has emerged everywhere. Furthermore, some of the organic halogeno compounds have been found to have carcinogenic nature against human bodies and, thus, trichloroethylene, tetrachloroethylene, 1,1,1-trichloroethane and the like have been designated as regulation items of the water-pollution preventive law on 1989, because of concern about influence on the human health.
Concerning treatment of the organic halogeno compounds, various methods have been proposed or used, and if the methods are roughly classified, there are a degradation method and a nondegradation method. Concerning the degradation method, there are listed a packed tower stripping method, a volatilizing method by means of exposing to air or heating, and an adsorption method using active carbon or macromolecules. Concerning the volatilizing method, the operation itself is very simple and at a low cost, but the method comprises only evaporating organic halogeno compounds in a liquid phase or a solution and scattering them in air and, therefore, basically it does not settle environmental pollution caused by organic halogeno compounds. Concerning the adsorption method, a secondary processing such as a recovering process after adsorption and a process to treat an adsorbent becomes necessary.
Concerning the degradation method, there are listed an irradiation method, a microorganism degradation method, a redox method and so forth. The irradiation method, of which representative examples are a photodecomposition method using a semiconductor as a catalyst and a radiation-irradiating method using a radiation, is still on an experimental stage and can not be adopted for a practical use. The microorganism degradation method takes a long time for treatment and its efficiency in treatment is unstable and, therefore, there exist many problems for a practical use. Concerning the redox method, a method of using an oxidizing agent such as ozone, hydrogen peroxide or the like and a method of reductive degradation method using iron have been attempted.
However, in a case where an organic halogeno compound exists in a high concentration, a method of highly efficient treatment has not yet been invented either as a nondegradation method or as a degradation method. In the volatilizing method, a large amount of organic halogeno compounds are discharged into air and, therefore, the method is not fundamental solution for the organic halogeno compounds to be-treated. The adsorption method is short in the break-through time in a case of high concentration, so it is not practical. Concerning the degradation method, highly effective decomposition has not yet been a practical one, and also, there exists a problem that harmful decomposition products are secondarily generated. In short, a practical and fundamental method to remove the organic halogeno compounds is not yet developed at a present stage.
SUMMARY OF THE INVENTION
Accordingly, it is the first object of the present invention to provide a catalyst for treating wastewater which not only decomposes an organic compound not containing nitrogen, sulfur or halogen, but also decomposes effectively a nitrogen-containing compound, a sulfur-containing compound and an organic halogeno compound, whereby the wastewater treatment can be carried out with good efficiency for a long period of time. The second object of the present invention is to provide a process for producing an above type catalyst for treating wastewater with good efficiency. In addition, the third object of the present invention is to provide a process for treating wastewater with good efficiency for a long period of time, whether the wastewater includes a nitrogen-containing compound, a sulfur-containing compound or an organic halogeno compound or not.
To solve the first object, the present invention first provides a catalyst for treating wastewater, comprising: an oxide of iron as an A component; and at least one kind of element as a B component, which is selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium. The present invention second provides a catalyst for treating wastewater, comprising: an oxide as an A component, which contains iron and at least one kind of element selected from a group consisting of titanium, silicon and zirconium; and at least one kind of element as a B component, which is selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium.
To solve the second object, the present invention first provides a process for producing a catalyst for treating wastewater, comprising the following steps: obtaining a coprecipitate containing iron and at least one kind of element selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium; and calcinating the coprecipitate. The present invention second provides a process for producing a catalyst for treating wastewater, comprising the following steps: obtaining an oxide of iron; and making this oxide contain at least one kind of element selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium. The present invention third provides a process for producing a catalyst for treating wastewater, comprising the following steps: obtaining a coprecipitate containing iron and at least one kind of element selected from a group consisting of titanium, silicon and zirconium; calcinating the coprecipitate, in order to obtain an oxide containing iron and at least one kind of element selected from a group consisting of titanium, silicon and zirconium; and making this oxide contain at least one kind of element selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium.
To solve the third object, the present invention first provides a process for treating wastewater, comprising wet oxidation treatment of the wastewater by using a solid catalyst under a condition that an oxygen gas is supplied at a pressure maintaining the wastewater in a liquid phase; being characterized in that a catalyst used as said solid catalyst contains the following two components: an oxide of iron as an A component; and at least one kind of element as a B component, which is selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium. The present invention second provides a process for treating wastewater, comprising wet oxidation treatment of the wastewater by using a solid catalyst under a condition that an oxygen gas is supplied at a pressure maintaining the wastewater in a liquid phase; being characterized in that a catalyst used as said solid catalyst contains the following two components: an oxide as an A component, which includes iron and at least one kind of element selected from a group consisting of titanium, silicon and zirconium; and at least one kind of element as a B component, which is selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium.
Wastewater to be treated in this invention includes a nitrogen-free organic compound, a nitrogen-containing compound, a sulfur-containing compound, an organic halogeno compound or the like. The nitrogen-free organic compounds are, for example, aldehydes; alcohols; lower organic acids such as acetic acid, formic acid and the like. The nitrogen-containing compounds are, for example, amine compounds, amide compounds, amino acid compounds and the like.
The amine compound, as far as it is a compound having an amino group in the molecule, may be any one of a primary amine, a secondary amine, a tertiary amine, and a quarternary amine salt. Practical examples are alkyl amines such as methylamine, dimethylamine, trimethylamine, propylamine and the like; alkylene diamines such as ethylenediamine, trimethylenediamine and the like; alkanol amines such as ethanolamine, triethanolamine and the like, all of which are aliphatic amines. In addition, the examples are aromatic amines such as aniline and the like; and nitrogen-containing heterocyclic compounds such as pyridine, picoline and the like.
The amide compound is a compound containing a group (RCONH--) made by combining an amino group with an acid group in its molecule. Practical examples are formamide, methylformamide, acetoamide, ethylformamide, methylpropionamide, dimethylformamide, diethylformamide, dimethylacetoamide, N-methylpyrroline and the like.
The amino acid compound is a compound containing a carboxyl group and an amino group in the same molecule and, it is called as an α-amino acid, β-amino acid, γ-amino acid or the like. Practical examples are aliphatic amino acids such as glycine, alanine, valine, leucine, serine, cystine, aspattic acid, glutamic acid, lysine, alginine and the like; amino acids having an aromatic ring such as phenylalanine, tyrosine and the like; amino acids having a heterocyclic ring such as histidine, tryptophan, proline and the like; and others.
However, the nitrogen-containing compound, with which this invention deals, is not limited to the above-mentioned examples. The nitrogen-containing compound needs not to be under a condition of dissolving in water and, even if it is under a condition of floating and suspending and so forth, it can be decomposed by a treating process of this invention.
A nitrogen-containing compound in wastewater may exist in form of either a sole compound or a mixture of plural kinds. The nitrogen-containing compound in wastewater for which the present invention can be applied is not especially limited, but its concentration is usually in a range of from 10 to 100,000 mg/l.
The sulfur-containing compound in the present invention is an inorganic or organic compound containing at least one sulfur atom other than sulfuric acid (SO 4 2- ). The compound includes, for example, a sulfide such as hydrogen sulfide, sodium sulfide, potassium sulfide, sodium hydrogen sulfide, sodium polysulfide and the like; thiosulfuric acids and their salts such as sodium thiosulfate, potassium thiosulfate and the like; sulfurous acids and their salts such as sodium sulfite and the like; trithionic acid, tetrathionic acid, and their salts such as sodium trithionate; thiols such as ethylmercaptan, thiophenol, 3,4-mercaptotoluene, dimercaptol, cystein and the like; thioacetals such as diethylthioacetal , 1-ethoxy-1-(methylthio)cyclopentane cyclopentane and the like; thiosulfites such as methyl thiosulfite, ethyl thiosulfite and the like; sulfides such as ethylsulfide, 1-(methylthio)propane, methionine and the like; thiins such as 4H-thiin and the like; thiocarbonates and their derivatives such as trithiocarbonate, sodium S-methyldithiocarbonate, diethyl trithiocarbonate, potassium O-ethyldithiocarbonate, S-methyl hydrogen thiocarbonate and the like; thio-acids and their derivatives such as sodium thiosulfate, hexanethio-acid, 1-piperidinecarbodithio-acid, hexanedithio-acid, O-thioacetic acid, S-thioacetic acid, dithiobenzoic acid, sodium dithioacetic acid, a S-ethyl ester of hexanethio-acid, an O-ethyl ester of hexanethio-acid, hexanethioyl chloride, 2-thiophenecarbothioamide, dibenzoic acid thioanhydride, di(thiobenzoic acid) anhydride and the like; thiocyans, thiocyanic acids and their salts such as rhodan, thiocyanic acid, potassium thiocyanic acid, ammonium thiocyanic acid and the like; thiocyanic acid esters such as methyl thiocyanate, ethyl thiocyanate, allyl thiocyanate and the like; thiosaccharides such as 1-thioglucose, S-methyl-5-thio-D-ribose and the like; thiazyl compounds such as fluorinated trithiazyl and the like; thiazines such as 1,2-thiazine, 1,3-thiazine, methylene blue and the like; thiazoles such as 1,3,4-thiadiazole, 1,3-thiazole, thioflavin, primuline and the like; thiocarbamides such as thiocarbamide, thiosemicarbamide, dithizone and the like; thiopyranes such as α-thiopyran, γ-thiopyran, 3-methyl-4H-thiopyran and the like; thiophenes such as thiophene, methylthiophene, thionaphthene, thiophthene and the like; polysulfides such as diphenyltrisulfide, diphenyldisulfide, 1,4-bis(methyldithio)cyclohexane and the like; thioaldehyde and the like; thioketones such as cyclohexanethione, 1,3-dithiorane-2-thione, 2,4-pentanedithione and the like; sulfinyl compounds such as thionyl chloride, diethylsulfoxide and the like; sulfonium compounds such as trimethylsulfonium iodide and the like; sulfonyl compounds such as sulfuryl chloride, sulfonylamide, diethylsulfone, thiophene-1,1-dioxide and the like; sulfonic acids and their salts such as dodecylbenzenesulfonic acid, sodium p-toluenesulfonate, naphthalinesulfonic acid, sulfanilic acid, sulfobenzoic acid, methyl orange, benzenedithiosulfinic acid and the like; sulfinic acid derivatives such as ethyl methanesulfonate and the like; sulfinic acids and their derivatives such as 1-piperidinesulfinic acid and the like; sulfates such as dimethylsulfate, methyl hydrogen sulfate and the like; sulfamides and their derivatives such as phenylsulfamide and the like. These compounds may be soluble in an aqueous medium or exist as a suspending substance in an aqueous medium. Also, even if sulfuric acid is contained in wastewater, there is no problem for treating it.
The organic halogeno compound in this invention is an organic compound containing at least one or more of a halogen atom in its molecule. Preferable examples for this are an aliphatic organic chloro compound such as methyl chloride, ethyl chloride, dichlorethylene, trichloroethylene, tetrachloroethylene, 1,1,1-trichloroethane, vinyl chloride and the like; an aliphatic organic bromo compound such as methyl bromide, ethyl bromide, vinyl bromide and the like; an aromatic organic chloro compound such as monochlorobenzene, dichlorobenzene, benzyl chloride and the like; an aromatic organic bromo compound such as benzyl bromide, benzylidene bromide and the like; flon such as trichlorofluoromethane, dichlorofluoromethane and the like, but the example is not limited to the above-described compounds.
Hereinafter, the first catalyst for treating wastewater, which relates to the present invention, is explained in detail.
A feature of the first catalyst for treating wastewater of this invention is that, as an A component, an oxide of iron is used and, as a B component, at least one kind of element selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium is used. A preferable form of this catalyst is such as a coprecipitate being calcinated, which is obtained from a solution containing elements of the catalyst A and B components, rather than a simple mixture of a powder oxide of the catalyst A component with a metal or compound of the catalyst B component. This calcinated product of the coprecipitate is not such as an oxide of the catalyst A component and a metal or compound of the catalyst B component being simply blended, but the product is a compound formed by that the catalyst A component and catalyst B component are well blended at a microscopic level and, accordingly, it is considered that novel properties not recognized in a metal or compound alone in each of the A and B components has emerged. Meanwhile, from a viewpoint that capability of decomposing the nitrogen-containing compounds, sulfur-containing compounds and organic halogeno compounds are superior, a preferable B component is a metal or compound containing at least one kind of element selected from a group consisting of platinum, palladium, rhodium, ruthenium and iridium.
Preferable proportions of each catalyst component in the first catalyst of this invention are, for the catalyst A component, in a range of from 0.05 to 99.95% by weight as an oxide, further preferably from 50 to 99.95% by weight as an oxide and, for the catalyst B component, in a range of from 0.05 to 99.95% by weight as a metal or compound, further preferably from 0.05 to 50% by weight. If the catalyst's A component or B component is out of the above range, catalytic activity may be insufficient. Or heat resistance and acid resistance may be inferior, which is unfavorable from a viewpoint of catalyst durability.
Although in this invention it is preferred to make the catalyst A and B components using a coprecipitation method, the A and B components may be prepared as complex oxides by another production process. A method to make the catalyst A and B components using the coprecipitation method is hereinafter explained by taking the Fe 2 O 3 --CoO compound as an example (as described above, an oxide which the Fe 2 O 3 --CoO makes in a closely blended form).
A precipitate is made by dissolving iron nitrate and cobalt nitrate in water followed by mixing them sufficiently, and then, adding aqueous ammonia to form a precipitate, which is taken by filtration, washed, dried, and calcinated at a temperature in a range of from 300° to 900° C. This method is practically carried out, for example, as follows. The iron and cobalt source compounds (iron nitrate and cobalt nitrate) are taken in order to have a defined value in a weight ratio of Fe 2 O 3 and CoO and, under a condition of an acidic aqueous solution, to have the concentration in a range of from 1 to 100 g per liter upon converting into the oxides or iron and cobalt (Fe 2 O 3 and CoO), and a solution obtained as described above is maintained at a temperature in a range of from 10° to 100° C. With stirring, into this solution is added dropwise an aqueous ammonia as a neutralizing agent and, then, an obtained mixture is allowed to react for a time in a range of from 2 to 10, whereby a coprecipitated compound (a precipitate) comprising iron and cobalt is formed. A thus-formed coprecipitate is taken by filtration, well washed, dried at a temperature in a range of from 80° C. to 140° C. for a period of time in a range from 1 to 10 hours, and calcinated at a temperature in a range of from 300° to 900° C. for a period of time in a range from 1 to 10 hours, whereby a Fe 2 O 3 --CoO compound is obtained.
In this invention, to obtain a catalyst by the coprecipitation method, it is necessary to dissolve elements of the catalyst A and B components in water. To dissolve an element of the catalyst A component, that is iron, into water, a water-soluble iron compound may be dissolved into water. To dissolve an element of the catalyst B component into water, for example, a water-soluble compound or sol of the element may be dissolved into water.
A preferable water-soluble iron compound (an iron source) can be selected from, for example, inorganic iron compounds such as iron nitrate, iron sulfate, iron chloride and the like as well as organic iron compounds such as iron oxalate, iron citrate and the like.
A preferable starting material of the catalyst B component is an oxide, a hydroxide, an inorganic acid salt, an organic acid salt or the like and, for example, it is selected from an ammonium salt, oxalate, a nitrate, halogenide and the like.
Slight amounts of impurities and admixtures may be contained among these materials. However, as far as the impurities and admixture do not significantly affect properties of an obtained compound, such materials do not cause trouble.
There are dissolved in water an iron source and a water-soluble salt of at least one kind of element selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium, and to this aqueous solution is added a basic compound such as aqueous ammonia, urea, sodium hydroxide, potassium hydroxide and the like to adjust the pH, whereby a precipitate is formed. The formed precipitate is a coprecipitate containing elements of the catalyst A and B components, which is usually a hydroxide. This precipitate is dried and then calcinated to convert it into an oxide. If required, the obtained oxide may be crushed and molded. This calcination is carried out, for example, in a temperature range of from 300° to 900° C. for a period of time in a range of from 1 to 10 hours, preferably, from 2 to 6 hours under an air stream.
Using a compound containing the catalyst A and B components (for example, a Fe 2 O 3 --CoO compound) prepared according to the forementioned process, a completed catalyst is obtained, for example, by the following procedure. One example of the procedure involves that a molding additive is added to a powder of the Fe 2 O 3 --CoO compound and an obtained mixture is well mixed with adding a proper amount of water, then kneaded, and molded by a molding device into a proper type such as a pellet, sphere, honeycomb type, etc.
The moldings is dried at a temperature in a range of from 50° to 120° C. and calcinated at a temperature in a range of from 300° to 1000° C., preferably from 350° to 900° C. for a period of time in a range from 1 to 10 hours, preferably form 2 to 6 hours, whereby a catalyst is obtained.
On the other hand, it is possible that to an oxide obtained from calcinating an iron-containing compound is added an aqueous solution of a metal salt of the forementioned B component together with a molding additive and, an obtained mixture is kneaded, molded, then dried and calcinated. The calcinating condition is, for example, similar to a case of calcinating the forementioned moldings.
Hereinafter, the second catalyst for treating wastewater, which relates to the present invention, is explained in detail.
The feature of the second catalyst for treating wastewater of this invention is using an oxide as an A component in the catalyst, which includes iron (hereinafter, referred to as "component (i)") and at least one kind of element (hereinafter, referred to as "component (ii)") selected from a group consisting of titanium, silicon and zirconium. The catalyst A component is, for example, a mixture of an oxide powder of the component (i) with an oxide powder of the component (ii). In a preferable case, a precipitate obtained from a solution containing an element in either one member of the components (i) and (ii) is well mixed with a salt slightly soluble in water containing an element in the other member of the components (i) and (ii) (which may be a precipitate obtained from a water-soluble salt containing an element in the other member or may be an oxide containing an element in the other member), and the obtained mixture is calcinated to convert into an oxide, which is then used as the catalyst A component. The calcinated product of the mixture is an oxide, which is derived from a form of the components (i) and (ii) mixed at a microscopic level more intimately than the each other's mixture of the forementioned oxide powders. A further preferable catalyst A component is an oxide obtained by calcinating a coprecipitate which is lead from a solution containing the components (i) and (ii).
This calcinated compound of the coprecipitate is not a simple mixture consisting of an oxide of the component (i) and an oxide of the component (ii), but it is a compound in which the components (i) and (ii) are well mixed at a microscopic level to form an oxide. It can be recognized that novel physical properties emerge, which are not observed in an oxide of each consisting component alone.
In the second catalyst of this invention, a preferable proportion of each component is 90 to 99.95% by weight for the catalyst A component and 0.05 to 10% by weight in form of a metal or a compound for the B component. If the B component is out of the above range, the oxidation activity may be insufficient. In addition, if the A component is out of the above range, the hot water resistance and acid resistance may be insufficient, so it is unfavorable in a viewpoint of catalysis durability. Furthermore, it is preferred that, in the catalyst A component, the component (i) is in a range of from 4.95 to 95% by weight as an oxide and the component (H) is in a range of from 4.95 to 95% by weight as an oxide (here, a total of the components (i) and (ii) is in a range of from 90 to 99.95% by weight). If they deviate from these ranges, the hot water resistance and acid resistance may be insufficient and it is unfavorable in a point of catalyst durability.
In this invention, although it is preferable that the catalyst A component is prepared using coprecipitation method, the A component may be made as a complex oxide or the like by other production processes. A method of preparing the A catalyst component by a coprecipitation method is hereinafter explained by taking, as an example, a case where the A component is a TiO 2 --Fe 2 O 3 compound this TiO 2 --Fe 2 O 3 compound is, as described above, an oxide that TiO 2 and Fe 2 O 3 make in a closely blended form and, hereinafter, the same).
A precipitate is made by dissolving titanium sulfate (a titanium source compound) and iron nitrate (an iron source compound) in water and mixing them sufficiently, and by adding an aqueous ammonia. This precipitate is taken by filtration, washed, dried, and calcinated at a temperature in a range of from 300° to 750°. To present a concrete example, this method is carried out as follows. That is, the above-described titanium source compound and iron source compound are taken so that a weight ratio of TiO 2 and Fe 2 O 3 is in a specific value, and under a condition of an aqueous acidic solution, the titanium and iron are adjusted to a concentration of from 1 to 100 g per liter upon converting into oxides, and the aqueous acidic solution is maintained at a temperature in a range of from 10° to 100° C. Into this solution is added dropwise with stirring an aqueous ammonia as a neutralizing agent and, an obtained solution is stirred for a period of from further 10 minutes to 3 hours at a pH in a range of from 2 to 10, whereby a coprecipitated compound (a coprecipitate) consisting of titanium and iron is formed. The formed precipitate is taken by filtration, well washed, dried at a temperature in a range of of from 80° to 140° C. for a period of from 1 to 10 hours, and calcinated at a temperature in a range of from 300° to 750° C. for a period of from 1 to 10 hours, whereby a TiO 2 --Fe 2 O 3 compound is obtained.
In this invention, in order to obtain the catalyst A component by a coprecipitation method, it is necessary to dissolve elements of the components (i) and (ii) in water. To dissolve an element of the component (i) in water, for example, a water-soluble iron compound may be dissolved in water. To dissolve an element of the component (H) in water, for example, a water-soluble compound or sol of the element may be dissolved in water.
A preferable water-soluble iron compound (an iron source) is selected from, for example, inorganic iron compounds such as iron nitrate, iron sulfate, iron chloride and the like; and organic iron compounds such as iron oxalate, iron citrate and the like.
A preferable water-soluble titanium compound or sol (a titanium source) is selected from, for example, inorganic titanium compounds such as titanium chlorides, titanium sulfate and the like; and organic titanium compounds such as titanium oxalate, tetraisopropyl titanate and the like.
A preferable water-soluble silicon compound or sol (a silicon source) is selected from, for example, inorganic silicon compounds such as colloid type silica, water glass, silicon tetrachloride and the like; and organic silicon compounds such as tetraethyl silicate and the like.
A preferable water-soluble zirconium compound or sol (a zirconium source) is selected from, for example, inorganic zirconium compounds such as zirconium oxychloride, zirconium nitrate, zirconium sulfate and the like; and organic zirconium compounds such as zirconium oxalate and the like.
In a group of these raw materials, although there exist such a member as containing slight amounts of impurities and mingling compounds, the impurities and mingled compounds in a raw material cause no problem as far as they do not affect on physical properties of an obtaining compound.
In the group of raw materials, at least one kind of source among the titanium, silicon and zirconium sources is dissolved with an iron source in water and, a precipitate is formed by varying pH with adding a base such as ammonia, urea, sodium hydroxide, potassium hydroxide or the like. The precipitate formed is a coprecipitate containing elements of the components (i) and (ii) and is usually a hydroxide. This precipitate is dried and calcinated to convert it into an oxide. If necessary, the oxide obtained may be crushed and molded. It is preferred that the calcinating is carried out at a temperature in a range of from 300° to 750° C. for a period of from 1 to 10 hours (more preferably for 2 to 6 hours) with an air stream.
Using the A component (for example, a TiO 2 --Fe 2 O 3 compound) prepared by the forementioned process, a completed catalyst is obtained, for example, from the following process. A molding additive is added to a TiO 2 --Fe 2 O 3 compound powder and, an obtained mixture is further mixed with adding a proper amount of water, kneaded, and molded by a molding device to a proper shape such as a pellet, sphere, honeycomb type or the like.
A molded product is dried at a temperature in a range of from 50° to 120° C., and calcinated at a temperature in a range of from 300° to 750° C., preferably at a temperature in a range of from 350° to 700° C., for a period of from 1 to 10 hours, preferably for a period of from 2 to 6 hours with an air stream, whereby a carrier is obtained.
An obtained carrier is soaked in an aqueous solution of a respective metal salt of the catalyst B component to carry the metal salt, then dried and calcinated, whereby a catalyst for treating wastewater of this invention is obtained. Or an aqueous solution of a metal salt of the forementioned B component together with a molding additive may be added to the A component (for example, a TiO 2 --Fe 2 O 3 compound powder), and a mixture obtained above may be kneaded, molded, then dried and calcinated. The calcination condition is, for example, similar to a case of calcinating the forementioned moldings.
Or again, a metal salt of the B component may be added before or after coprecipitation of the A component.
A preferable starting material of the catalyst B component is an oxide, a hydroxide, an inorganic acid salt, an organic acid salt or the like of at least one kind of element selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium. For example, it is selected from an ammonium salt, an oxalate, a nitrate, a sulfate, a halogenide or the like of said element.
An element of the B component is carried in a condition of a metal, a compound or the like.
Concerning the shape of a catalyst of the present invention, although any one of a pellet, sphere, honeycomb, ring type and the like can be used , because blocking in a catalyst layer by a solid, a precipitate or the like may occur in a case of treating wastewater containing a suspension, the honeycomb type is especially preferred.
A preferable catalyst used in this invention is such as having a specific composition as mentioned above. A preferable shape of the catalyst is one-body structure such as a pellet, particle and honeycomb type or other several types of structure. A catalyst of the particle type has an average diameter in a range of from 1 to 10 mm, preferably from 2 to 7 mm. If the average diameter is less than 1 mm, pressure loss increases. If it is larger than 10 mm, the geometric surface area is not enough and sufficient treating capability can not be obtained, so that this is unfavorable. Relative surface area by the BET method is in a range of from 5 to 200 m 2 per gram, preferably, 10 to 80 m 2 per gram.
If it is less than 5 m 2 per gram, contact efficiency between molecules to be treated and a catalyst lowers and, if it is larger than 200 m 2 per gram, the mechanical strength of a solid catalyst becomes weak, so that this is unfavorable. A catalyst of the pellet type has an average diameter in a range of from 1 to 10 mm, preferably from 3 to 8 mm and a length in a range of from 2 to 15 mm, preferably from 3 to 10 mm. If the average diameter is less than 1 mm or the length is shorter than 2 mm, pressure loss may increase and, if the average diameter is larger than 10 mm or the length is longer than 15 mm, the geometric surface area is not enough, the contact efficiency diminishes, and sufficient treating capability may not be obtained, so that this is unfavorable. It is preferred that relative surface area by the BET method of the pellet type catalyst is in a range similar to that in a case of the particle type. A preferable shape of a honeycomb type catalyst has a penetrating hole-corresponding diameter in a range of from 2 to 20 mm, a cell wall thickness in a range of from 0.1 to 3 mm, and an opening ratio in a range of from 50 to 90%. A further preferable shape has a penetrating hole-corresponding diameter in a range of from 2.5 to 15 a cell wall thickness in a range of from 0.5 to 3 mm and an opening ratio in a range of from 50 to 90%. If the penetrating hole-corresponding diameter is less than 2 mm, pressure loss is large and, if it exceeds 20 mm, although the pressure loss becomes small, the contact percentage diminishes and the catalyst activity lowers. In a case where the cell wall thickness is less than 0.1 mm, although there is an advantage that the pressure loss is small and a catalyst can be converted into a light weight one, the mechanical strength of the catalyst may diminish. In a case where the cell wall thickness exceeds 3 mm, the mechanical strength is enough, but the pressure loss may become large. From the same reason to the above-described, a preferable opening ratio is in a range of from 50 to 90%.
To carry out a process for treating wastewater of this invention, for example, there is used a single cylindrical tube reactor for wet oxidation reaction or the like which is commonly used in a hitherto-known process for treating wastewater. A multiple tube reactor for wet oxidation reaction or the like is used depending upon wastewater to be treated.
In these reactors, for example, a catalyst for treating wastewater of this invention is arranged in a manner similar to a previous manner, and then wastewater is subjected to a wet oxidation process.
Next, one example of treatment condition for wastewater is explained.
First, in a case of wastewater including a nitrogen-containing compound, the temperature in the course of wastewater treatment is required to be set at a temperature lower than a critical temperature in order to maintain a liquid phase condition off, the wastewater. A temperature lower than the critical one is properly selected, the atmosphere pressure is set at a pressure higher than a pressure under which the wastewater keeps its liquid phase at said temperature. A pressure of this sort is, for example, in a range of from 1 to 200 kgf/cm 2 . According to this invention, the temperature necessary for treating wastewater can be set, for example, in a range of from 100° to 370° C., but it is possible to set it at a temperature which is about 50° C. lower compared with a case of previous wet oxidation treatment, and in this temperature range, decomposition of an organic compound or the like into carbon dioxide, water or the like as well as decomposition of nitrogen in a nitrogen-containing compound into a nitrogen gas are achieved.
Although existence of an oxygen gas is necessary for the reaction of wastewater treatment, air is preferable owing to its cheap cost, except a special case where apparatus-compacting or the like is wanted. A preferable amount of the oxygen gas is from 1 to 1.5 times of the theoretically required oxygen amount.
The pH of wastewater necessary for wet oxidation treatment may be set case by case between an acidic region and an alkaline region, and it is, for example, from 1 to 14.
Next, in a case of wastewater including a sulfur-containing compound, the wet oxidation process is carried out in the presence of the above-described catalyst at a temperature of 350° C. or lower under a pressure that the wastewater has a liquid phase, preferably, at a temperature lower than 180° C. under a pressure less than 10 kg/cm 2 G and also, in the presence of an oxygen gas in an amount of 1 to 5 times of a theoretical oxygen amount which is required for oxidative decomposition of an inorganic compound containing a sulfur atom into an inorganic salt, a carbon dioxide gas, water, a nitrogen gas or the like. Besides, in a case where an organic compound contained in the wastewater is simultaneouly converted into a harmless compound, a theoretical oxygen amount required for oxidative decomposition of the organic compound should be added. It is considered that the sulfur atom constituting an inorganic sulfur compound becomes harmless by being oxidized to a sulfate ion with the wet oxidation.
In the present invention, it is preferable to adjust the pH in a range of from a neutral to an alkaline region, after treatment of wastewater including a sulfur-containing compound is finished, by supplying an alkaline component before or during the treatment. This is because the oxidation reaction by a solid catalyst of the sulfur-containing compound is especially accelerated in a range of from a neutral to an alkaline region. Also, that is because in a wet oxidation process under an acidic condition that sulfuric acid exists, the material of the wet oxidation reaction tube corrodes very much, so that it is afraid that the apparatus durability is damaged very much.
Finally, in a case of wastewater including an organic halogeno compound, the wet oxidation reaction in this invention is carried out in the presence of a specific catalyst, by keeping the wastewater at a temperature in a range of from 100° to 370° C., under a pressure which maintains the wastewater in a liquid phase, and in the presence of an oxygen gas in an amount equal to or more than the theoretically required amount to oxidize the organic halogeno compounds being contained in wastewater into carbon dioxide, water, water-soluble salts, ashes and others. In a case where oxygen-consuming substances (hereinafter, referred to as "TOD components") such as other organic compounds etc. exists, that is a pollution factor of the wastewater, a theoretical amount of oxygen required for oxidative degradation of the TOD component should be added.
In a case where the organic halogeno compounds are treated by the present invention, the halogen atom in the wastewater becomes harmless by being converted into a halide ion. That is, the chlorine atom in an organic chloro compound, the fluorine atom in an organic fluoro compound, and the bromine atom in an organic bromo compound are converted into the Cl - ion, F - ion, and Br - ion, respectively, so that said halogen atoms become harmless.
In this invention, it is preferred to make salts by adding beforehand into wastewater an equivalent amount or more of cations which make pairs with halide ions generating from the wet oxidation. In adding cations, it is further preferred that alkali metal ions such as sodium, potassium or other ions are added. By adding the alkali metal ions into wastewater, durability decrease of a reaction tube caused by that wastewater becomes acidic in the course of treatment is prevented, and in addition, the reaction rate is accelerated, so that faster treatment becomes possible. As far as the alkali metal ions show an alkaline character by dissolving them into wastewater, any kind of the ions can be used and, for example, there are listed for use sodium hydroxide, potassium hydroxide, sodium carbonate, sodium acetate and the like. In a case where a salt containing an organic acid moiety such as sodium acetate or the like is added into wastewater, the acetate ion is decomposed up to carbon dioxide and water, similarly to the case of organic halogeno compounds.
Concerning the oxygen-containing gas in this invention, a gas having any oxygen concentration may be used. As the oxygen concentration in an oxygen-containing gas becomes higher, the reaction rate is more accelerated and faster treatment becomes possible. However, since sufficient efficiency on treatment is obtainable even by the air, the oxygen concentration of an oxygen-containing gas may be properly determined depending upon factors such as cost and the like.
The first catalyst for treating wastewater of this invention contains, as an A component, an oxide of iron and, as a B component, at least one kind of element selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium. This catalyst maintains its catalytic activity for a long period of time even if wastewater includes a nitrogen-containing compound, a sulfur-containing compound or an organic halogeno compound when the wastewater being treated with wet oxidation.
In the second catalyst for treating wastewater relating to this invention, the B component is at least one kind of element selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium. The A component is an oxide containing iron and at least one kind of element selected from a group consisting of titanium, silicon and zirconium. This catalyst maintains its catalytic activity for a long period of time even if wastewater includes a nitrogen-containing compound, a sulfur-containing compound or an organic halogeno compound when the wastewater being treated with wet oxidation.
Wastewater can be treated with excellent efficiency for a long period of time, even if the wastewater includes a nitrogen-containing compound, a sulfur-containing compound or an organic halogeno compound, by subjecting the wastewater to wet oxidation treatment using such a catalyst as stated above, similar to a case where the wastewater does not include said compounds. In addition, since nitrogen in the nitrogen-containing compound is decomposed up to a nitrogen gas, post-treatment as carried out in previously known conventional methods becomes unnecessary.
A catalyst for treating wastewater of this invention not only decomposes a nitrogen-free organic compound, but also decomposes nitrogen in a nitrogen-containing compound up to a nitrogen gas. By using this catalyst, whether wastewater includes a nitrogen-containing compound or not, the wastewater treatment can be carried out for a long period of time with excellent efficiency.
According to a catalyst for treating wastewater of this invention, a compound containing sulfur and other pollution substances in wastewater can be decomposed by oxidation with excellent efficiency and, it is possible to convert them into inorganic salts, carbon dioxide, water, ash or the like. Then, biological treatment is not required as a post-treatment at all and treated wastewater may be directly discharged, or even if the biological treatment is required as a post-treatment, a substance which may affect badly on an organism has already been decomposed and it is unnecessary to regulate wastewater on which the wet oxidation process has been carried out, except for a pH adjustment. Therefore, an amount of the treated wastewater becomes small and biological treatment facilities are not necessary at all or they can be very small compared with previous facilities, and treatment process is simplified. Consequently, an advantage comes on the investment and running cost of facilities.
According to this invention, it is possible to convert an organic halogeno compound, which is included in wastewater, into carbon dioxide, water, soluble salts, ash or the like with excellent efficiency and whereby to make the compound harmless without secondary forming of harmful substances.
According to a process for producing a catalyst for treating wastewater of this invention, a superior catalyst for treating wastewater as described above can be produced with excellent efficiency.
According to a process for treating wastewater of this invention, whether the wastewater includes a nitrogen-containing compound, a sulfur-containing compound or an organic halogeno compound or not, it is possible to treat wastewater for a long period of time with excellent efficiency.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, catalyst preparation examples and wastewater treatment examples relating to practical examples of the present invention and comparative catalyst preparation examples and comparative wastewater treatment examples are shown, but the present invention is not limited to the below-described examples.
Preparation example 1
A compound consisting of iron and ruthenium was prepared by the undermentioned process.
Into 50 liter of water were dissolved 4.81 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O] and an obtained solution was well mixed with adding 500 cc of an aqueous ruthenium nitrate solution (100 g/l as Ru). To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 10 hours. Then, it was calcinated at 700° C. for 5 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of Fe 2 O 3 and Ru, in which the weight ratio between Fe 2 O 3 and Ru was 95 versus 5 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets of paticle diameter 5 mm φ and length 6 mm, dried at 120° C. for 6 hours and then, calcinated at 500° C. for 3 hours.
Preparation example 2
Into 50 liter of water were dissolved 3.54 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O], 1.09 kg of cobalt nitrate and 200 cc of an aqueous platinum nitrate solution (100 g/l as Pt), and an obtained solution was well mixed. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 10 hours. Then, it was calcined at 700° C. for 5 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of Fe 2 O 3 , CoO and Pt, in which the weight ratio among Fe 2 O 3 , CoO and Pt was 70:28:2 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets of paticle diameter 5 mm and length 6 mm, dried at 120° C. for 6 hours and then, calcinated at 500° C. for 3 hours.
Preparation example 3
Into 50 liter of water were dissolved 2.53 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O], 1.21 kg of cerous nitrate Ce(NO 3 ) 3 ·6H 2 O] and 200 cc of an aqueous palladium nitrate solution (100 g/l as Pd), and an obtained solution was well-mixed. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 10 hours. Then, it was calcinated at 700° C. for 5 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of Fe 2 O 3 , CeO 2 and Pd, in which the weight ratio among CeO 2 and Pd was 50:48:2 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets of paticle diameter 5 mm φ and length 6 mm, dried at 120° C. for 6 hours and then, calcinated at 500° C. for 3 hours.
Treatment examples 1 to 3
Using each of the catalysts obtained from the preparation examples 1 to 3, wastewater treatment was carried out by wet oxidation according to the following procedure.
Each of the catalysts (1000 cc) was filled in a reaction tube made of a stainless steel of a wet oxidation column and, from a down part of tile reaction tube, preheated wastewater blended with air containing oxygen in a concentration of about 21% was continuously introduced for 5,000 hours, the COD (Cr) concentration and total nitrogen amount were measured at an entrance and exit of the reaction tube to calculate their elimination percentages. Meanwhile, wastewater to be treated contained 15,000 mg/l of dimethylformamide and showed 20,000 mg/l in the COD (Cr) concentration.
The reaction conditions were 200° C. at a reaction temperature, 40 kg/cm 2 G at a reaction pressure, 2 liter per hour at the rate of supplying wastewater, and 230N liter per hour at the rate of supplying air. Obtained results are shown in Table 1.
TABLE 1______________________________________ elimination percentage elimination of total percentage nitrogen kind of of COD (Cr) amount catalyst (%) (%)______________________________________treatment preparation 99.0 99.5example 1 example 1treatment preparation 99.5 99.1example 2 example 2treatment preparation 99.5 99.0example 3 example 3______________________________________
As seen in Table 1, in a continuous operation for 5,000 hours under the forementioned conditions, decrease in the elimination percentages of the COD (Cr) and total nitrogen amount was not recognized.
Treatment examples 4 to 6
According to the treatment example 1, wastewater treatment was carried out by wet oxidation using each of the catalysts obtained from the preparation examples 1 to 3. Wastewater to be treated contained 20,000 mg/l of glycine and showed 19,000 mg/l in the COD (Cr) concentration.
The reaction conditions were 200° C. at a reaction temperature, 40 kg/cm 2 G at a reaction pressure, 2 liter per hour at the rate of supplying wastewater, and 160N liter per hour at the rate of supplying air. Obtained results are shown in Table 2.
TABLE 2______________________________________ elimination percentage elimination of total percentage nitrogen kind of of COD (Cr) amount catalyst (%) (%)______________________________________treatment preparation 98.5 99.0example 4 example 1treatment preparation 99.0 99.0example 5 example 2treatment preparation 98.9 98.7example 6 example 3______________________________________
As seen in Table 2, In a continuous operation for 3,000 hours under the forementioned conditions, decrease in the elimination percentages of the COD (Cr) and total nitrogen amount was not recognized.
Treatment examples 7 to 9
According to the treatment example 1, wastewater treatment was carried out by wet oxidation using each of the catalysts obtained from the preparation examples 1 to 3.
Wastewater to be treated contained 10,000 mg/l of ethanolamine and showed 12,000 mg/l in the COD (Cr) concentration.
The reaction conditions were 200° C. at a reaction temperature, 40 kg/cm 2 G at a reaction pressure, 2 liter per hour at the rate of supplying wastewater, and 140N liter per hour at the rate of supplying air. Obtained results are shown in Table 3.
TABLE 3______________________________________ elimination percentage elimination of total percentage nitrogen kind of of COD (Cr) amount catalyst (%) (%)______________________________________treatment preparation 98.8 99.0example 7 example 1treatment preparation 98.5 98.5example 8 example 2treatment preparation 98.5 98.5example 9 example 3______________________________________
As seen in Table 3, in a continuous operation for 3,000 hours under the forementioned conditions, decrease in the elimination percentages of the COD (Cr) and total nitrogen amount was not recognized.
Preparation example 4
Into 50 liter of water were dissolved 10 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O]. To an obtained solution maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 16 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 16 hours. Then, it was calcinated at 700° C. for 6 hours under an air atmosphere. According to a X-ray diffraction analysis, an obtained powder consisted of Fe 2 O 3 .
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets having a particle diameter 5 mmφ and length 6 mm, and calcinated at 500° C. for 4 hours under an air atmosphere.
The pellets thus-obtained were soaked in an aqueous ruthenium nitrate solution, dried at 120° C. for 6 hours, and calcinated at 400° C. for 4 hours.
An obtained, completed catalyst showed composition having a 99.3 versus 0.7 ratio by weight between Fe 2 O 3 and ruthenium, according to a fluorescence X-ray analysis.
Treatment example 10
Using the catalyst obtained from preparation example 4, wastewater having the below-mentioned composition was continuously treated for 1000 hours under the reaction conditions of 130° C. at a reaction temperature, 9 kg/cm 2 G at a reaction pressure, 1 liter per hour at the rate of supplying wastewater, and 667N liter per hour at the rate of supplying air [ratio of O 2 /TOD (amount of oxygen in air theoretical oxygen demand) is 2].
______________________________________pH 13Na.sub.2 S 8%NaSH 3%Na.sub.2 CO.sub.3 3%TOD 100,000 mg/l______________________________________
Such a treatment resulted in that COD (Cr) was 3500 mg/l or less, sulfide ion was 0.1 mg/l or less, and thiosulfate ion was 5000 mg/l or less.
Comparative preparation example 1
Into 100 liter of water were gradually dissolved 7 kg of titanium tetrachloride(TiCl 4 ). To an obtained solution maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 16 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 16 hours. Then, it was calcinated at 600° C. for 5 hours under an air atmosphere. According to a X-ray diffraction analysis, an obtained powder consisted of TiO 2 .
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to a spherical shape of an average particle diameter 6 mm, and calcinated at 500° C. for 4 hours under an air atmosphere.
A thus-obtained, spherically molded product was soaked in an aqueous iridium chloride solution, dried at 140° C. for 3 hours, and calcinated at 450° C. for 4 hours.
An obtained, completed catalyst showed composition having a 99.8 versus 0.2 ratio by weight between TiO 2 and Ir, according to a fluorescence X-ray analysis.
Comparative treatment example 1
The catalyst of comparative preparation example 1 obtained by the above-mentioned process was filled in a reaction tube. Treatment of wastewater similar to the wastewater used in treatment example 10 was carried out according to treatment example 10 under the conditions similar to treatment example 10. As a result, COD (Cr) was 11,000 mg/l or less, sulfide ion was 50 mg/l or less, and thiosulfate ion was 14,000 mg/l or less.
Preparation example 5
The pellet-like molded product of the oxide of iron obtained from preparation example 4 was soaked in an aqueous chloroplatinic acid solution, dried at 150° C. for 4 hours, and calcinated at 450° C. for 3 hours.
An obtained, completed catalyst showed composition having a 99.7 versus 0.3 ratio by weight between the oxide of iron and platinum, according to a fluorescence X-ray analysis.
Treatment example 11
The catalyst, 500 cc, obtained from preparation example 5 was filled in a reaction tube. Treatment of wastewater having the below-mentioned composition was carried out according to treatment example 10 under the conditions of 200° C. at a reaction temperature, 50 kg/cm 2 G at a reaction pressure, 1 liter per hour at the rate of supplying wastewater, and 220N liter per hour at the rate of supplying air [ratio of O 2 /TOD (amount of oxygen in air/theoretical oxygen demand) is 1.2]. In addition, other conditions were as follows.
______________________________________Thiophene: 0.1%Sodium rhodanide: 3.0%Dimethyl sulfoxide: 1.5%TOD: 55 g/l______________________________________
The above-mentioned treatment resulted in that treated wastewater containing 40 mg/l or less of thiophene, 10 mg/l or less of sodium rhodanide and 20 mg/l or less of dimethyl sulfoxide was stably obtained. In addition, TOC treatment efficiency was 83%.
Comparative preparation example 2
γ-alumina (spherical; average particle diameter 5 mm) was soaked in an aqueous palladium nitrate solution, dried at 120° C. for 5 hours, and calcinated at 400° C. for 4 hours.
An obtained, completed catalyst showed composition having a 99.5 versus 0.5 ratio by weight between the alumina and palladium, according to a fluorescence X-ray analysis.
Comparative treatment example 2
The catalyst, 500 cc, obtained from comparative preparation example 2 was filled in a reaction tube. Treatment of wastewater similar to the wastewater used in treatment example 11 was carried out, according to treatment example 11, under the conditions similar to treatment example 11.
The above-mentioned treatment resulted in that treated wastewater containing 100 mg/l or less of thiophene, 1200 mg/l or less of sodium rhodanide and 900 mg/l or less of dimethyl sulfoxide was stably obtained. In addition, TOC treatment efficiency was 61%.
Preparation examples 6 to 11
The pellet type molded product of the oxide of iron obtained from preparation example 4 was soaked in an aqueous solution of one kind among ruthenium nitrate, chloroauric acid, palladium nitrate, iridium chloride, silver nitrate and rhodium nitrate. Then, the soaked product was dried at 120° C. for 5 hours and calcinated at 400° C. for 4 hours.
Treatment examples 12 to 17
Each of the catalysts, 500 cc, obtained from preparation examples 6 to 11 was filled in a reaction tube. Treatment of wastewater similar to the wastewater used in treatment example 11 was carried out under the conditions similar to treatment example 11.
Results obtained were shown in Table 4.
TABLE 4______________________________________ kind of metal Amount of treatment soaked-in B component efficiencykind of (B compo- in catalyst of TOCcatalyst nent) (wt %) (%)______________________________________treatment preparation Ru 0.5 80example 12 example 6treatment preparation Au 0.5 76example 13 example 7treatment preparation Pd 0.5 81example 14 example 8treatment preparation Ir 0.3 82example 15 example 9treatment preparation Ag 3.0 77example 16 example 10treatment preparation Rh 0.2 82example 17 example 11______________________________________
Preparation examples 12 to 14
Similarly to preparation example 1, into 100 liter of water were dissolved ferric nitrate and other metal nitrates. To this solution, sodium hydroxide was added until pH 8.5 being indicated to form a precipitate. Then, oxides of iron and added metals were obtained by carrying out the procedure similar to preparation example
These oxides were molded by the procedure similar to preparation example 1. Whereby, pellet type molded products (catalysts) of paticle diameter 5 mm φ and length 6 mm were obtained.
Treatment examples 18 to 20
Each of the catalysts, 500 cc, obtained from preparation examples 12 to 14 was filled in a reaction tube. Treatment of wastewater similar to the wastewater used in treatment example 10 was carried out under the conditions similar to treatment example 10.
Results obtained were shown in Table 5.
TABLE 5______________________________________ amount of COD (Cr) kind of oxide of concen- metal left-described tration in added- metal in treatedkind of metal in catalyst watercatalyst solution (wt %) (mg/l)______________________________________treatment preparation Co 31.9 6,500example 18 example 12treatment preparation Ni 23.8 8,200example 19 example 13treatment preparation Ce 21.2 6,200example 20 example 14______________________________________
Preparation example 15
Into 100 liter of water were dissolved 24.87 kg of ferrous sulfate [FeSO 4 ·7H 2 O] and 2.00 kg of cerous nitrate [Ce(NO 3 ) 3 ·6H 2 O]. An obtained solution was well mixed. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 9 being indicated, and an obtained mixture was still stood for 24 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 16 hours. Then, it was calcinated at 600° C. for 5 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of Fe 2 O 3 and CeO 2 , in which the Weight ratio between Fe 2 O 3 and CeO 2 was 9 versus 1 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to a spherical shape of average paticle diameter 6 mm and calcinated at 500° C. for 4 hours under an air atmosphere.
Treatment example 21
The catalyst, 500 cc, obtained from preparation example 15 was filled in a reaction tube. Treatment of wastewater similar to the wastewater used in treatment example 11 was carried out under the conditions similar to treatment example 11.
The above-mentioned treatment resulted in that treated wastewater containing 100 mg/l or less of thiophene, 10 mg/l or less of sodium rhodanide and 200 mg/l or less of dimethyl sulfoxide was stably obtained. In addition, TOC treatment efficiency was 69%.
Preparation example 16
The spherical molded product of the iron-cerium oxide obtained from preparation example 15 was soaked in an aqueous ruthenium solution. Then, this soaked product was dried at 130° C. for 3 hours and calcinated at 400° C. for 4 hours.
An obtained, completed catalyst showed composition having a 99.3 versus 0.7 ratio by weight between the iron-cerium oxide and ruthenium, according to a fluorescence X-ray analysis.
Treatment example 22
The catalyst, 500 cc, obtained from preparation example 16 was filled in a reaction tube. Treatment of wastewater similar to the wastewater used in treatment example 11 was carried out under the conditions similar to treatment example 11.
The above-mentioned treatment resulted in that treated wastewater containing 30 mg/l or less of thiophene, 10 mg/l or less of sodium rhodanide and 10 mg/l or less of dimethyl sulfoxide was stably obtained. In addition, TOC treatment efficiency was 84%.
Comparative preparation examples 3 to 8
Similarly to preparation examples 6 to 11, the pellet-like molded product of the oxide of titanium obtained from comparative preparation example 1 was soaked in each of the aqueous metal salt solutions and calcinated. Whereby, catalyst were obtained.
Comparative treatment examples 3 to 8
Each of the catalysts obtained from comparative preparation examples 3 to 8 was filled in a reaction tube. Treatment of wastewater similar to the wastewater used in treatment example 10 was carried out under the conditions similar to treatment example 10.
Results obtained were shown in Table 6.
TABLE 6______________________________________ amount of COD (Cr) left-described concen- kind of metal tration metal component in treated kind of soaked- in catalyst water catalyst in (wt %) (mg/l)______________________________________comparative comparative Ru 0.5 14,000treatment preparationexample 3 example 3comparative comparative Au 0.5 18,000treatment preparationexample 4 example 4comparative comparative Pd 0.5 12,000treatment preparationexample 5 example 5comparative comparative Ir 0.3 11,000treatment preparationexample 6 example 6comparative comparative Ag 3.0 19,000treatment preparationexample 7 example 7comparative comparative Rh 0.2 12,000treatment preparationexample 8 example 8______________________________________
Comparative preparation examples 9 to 11
Similarly to preparation example 1, into 100 liter of water were added a titanyl sulfate solution and a metal nitrate. To this solution, sodium hydroxide was added until pH 8.5 being indicated to form a precipitate. Then, an oxide of the titanium and added metal was obtained by carrying out the procedure similar to preparation example 1.
This oxide was molded by the procedure similar to preparation example 1. Whereby, a pellet-like molded product (catalysts) of paticle diameter 5 mm φ and length 6 mm was obtained.
Comparative treatment examples 9 to 11
Each of the catalysts, 500 cc, obtained from comparative preparation examples 9 to 11 was filled in a reaction tube. Treatment of wastewater similar to the wastewater used in treatment example 11 was carried out under the conditions similar to treatment example 11.
Results obtained were shown in Table 7.
TABLE 7______________________________________ amount of kind of oxide of metal left-described treatment in added- metal efficiency kind of metal in catalyst of TOC catalyst solution (wt %) (%)______________________________________comparative comparative Co 31.9 46treatment preparationexample 9 example 9comparative comparative Ni 23.8 47treatment preparationexample 10 example 10comparative comparative Ce 21.2 58treatment preparationexample 11 example 11______________________________________
Preparation examples 17 to 19
Into 50 liter of water were dissolved 10 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O]. To this solution maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8.5 being indicated, and an obtained mixture was still stood for 16 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 16 hours. Then, it was calcinated at 600° C. for 8 hours under an air atmosphere. According to a X-ray diffraction analysis, an obtained powder consisted of Fe 2 O 3 .
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets having a particle diameter 5 mm φ and length 6 mm, and calcinated at 500° C. for 4 hours under an air atmosphere.
The pellets thus-obtained were soaked in an aqueous solution of iridium nitrate, platinum nitrate or ruthenium nitrate. These soaked products were dried at 120° C. for 6 hours and then calcinated at 400° C. for 4 hours.
Treatment examples 23 to 25
Using each of the catalysts obtained from the preparation examples 17 to 19, treatment of wastewater containing 500 mg/l of trichloroethylene was carried out by wet oxidation according to the following procedure.
Each of the catalysts (500 cc) was filled in a reaction tube and, from a down part of the reaction tube, preheated wastewater blended with air was continuously introduced for 1,000 hours, the trichloroethylene concentration was measured at an entrance and exit of the reaction tube to calculate the elimination percentage of trichloroethylene.
The reaction conditions were 250° C. at a reaction temperature, 70 kg/cm 2 G at a reaction pressure, 0.5 liter per hour at the rate of supplying wastewater, and 10N liter per hour at the rate of supplying air. Obtained results are shown in Table 8.
TABLE 8______________________________________ elimination kind of percentage metal amount of of soaked-in B component trichloro-kind of (B compo- in catalyst ethylenecatalyst nent) (wt %) (%)______________________________________treatment preparation Ir 0.3 94example 23 example 17treatment preparation Pt 0.3 96example 24 example 18treatment preparation Ru 1.0 92example 25 example 19______________________________________
Preparation example 20
A compound consisting of titanium and iron was prepared by the undermentioned process and, as a titanium source, an aqueous sulfuric acid having the following composition was used.
TiOSO 4 . . . 250 g/l (as TiO 2 )
total H 2 SO 4 . . . 1,100 g/l
Into 100 liter of water were dissolved 5.41 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O] and an obtained solution was well mixed With adding 5 liter of an aqueous sulfuric acid solution of titanyl sulfate (titanium oxysulfate) which has the above composition. To this mixture maintained about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 10 hours. Then, it was calcinated at 700° C. for 5 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of TiO 2 and Fe 2 O 3 , in which the weight ratio between TiO 2 and Fe 2 O 3 was 53.9 versus 46.1 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process,
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets of paticle diameter 5 mm φ and length 6 mm and calcinated at 500° C. for 3 hours under an air atmosphere.
The pellets thus-obtained were soaked in an aqueous palladium nitrate solution, dried at 120° C. for 6 hours, and calcinated at 400° C. for 3 hours.
An obtained, completed catalyst showed composition having a 98 versus 2 ratio by weight between a TiO 2 --Fe 2 O 3 compound and palladium, according to a fluorescence X-ray analysis.
Preparation example 21
Into 80 liter of water were dissolved 6.57 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O] and 2.17 kg of zirconium oxynitrate (zirconium nitrate) [ZrO (NO 3 ) 2 ·2H 2 O ] with well mixing. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 10 hours. Then, it was calcinated at 700° C. for 5 hours under an air atmosphere. According to a X-ray diffraction analysis, an obtained powder consisted of ZrO 2 and Fe 2 O 3 , in which the weight ratio between ZrO 2 and Fe 2 O 3 was 43.5 versus 56.5 according to a fluorescence X-ray analysis.
Using this obtained powder a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets having a particle diameter 5 mm φ and length 6 mm, and calcinated at 500° C. for 3 hours under an air atmosphere.
The pellets thus-obtained were soaked in an aqueous ruthenium nitrate solution, dried at 120° C. for 6 hours and calcinated at 400° C. for 3 hours.
An obtained, completed catalyst showed composition having a 95 versus 5 ratio by weight between a ZrO 2 --Fe 2 O 3 compound and ruthenium, according to a fluorescence X-ray analysis.
Preparation example 22
Into 100 liter of water were dissolved 6.07 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O] and an obtained solution was well mixed with dissolving 4 liter of an aqueous sulfuric acid solution of titanyl sulfate (titanium oxysulfate) having the composition used in the preparation example 20 and 1.34 kg of zirconium oxynitrate (zirconium nitrate) [ZrO (NO 3 ) 3 ·2H 2 O]. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 10 hours. Then, it was calcinated at 700° C. for 5 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of TiO 2 , ZrO 2 and Fe 2 O 3 , in which the weight ratios among TiO 2 , ZrO 2 and Fe 2 O 3 were 35.5, 21.9 and 42.6, respectively, according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets having a particle diameter 5 mmφ and length 6 mm and calcinated at 500° C. for 3 hours under an air atmosphere.
The pellets thus-obtained were soaked in an aqueous platinum nitrate solution, dried at 120° C. for 6 hours, and calcinated at 400° C. for 3 hours.
An obtained, completed catalyst showed composition having a 99 versus 1 ratio by weight between a TiO 2 --ZrO 2 --Fe 2 O 3 compound and platinum, according to a fluorescence X-ray analysis.
Preparation examples 23 and 24
The procedure of preparation example 20 was repeated except that the ratio between TiO 2 and Fe 2 O 3 was varied as follows.
______________________________________TiO.sub.2 versus Fe.sub.2 O.sub.3 (weight ratio)______________________________________Preparation example 23 80 versus 20Preparation example 24 15 versus 85______________________________________
Preparation examples 25 to 27
Pellets of the TiO 2 --ZrO 2 --Fe 2 O 3 compound obtained from the preparation example 22 were soaked in each of an aqueous chloroauric acid solution, aqueous rhodium nitrate solution and aqueous iridium nitrate solution, dried at 120° C. for 6 hours, and calcinated at 400° C. for 3 hours.
Obtained, completed catalysts had the below-described composition by weight ratios, according to a fluorescence X-ray analysis.
______________________________________Preparation example 25 (TiO.sub.2 --ZrO.sub.2 --Fe.sub.2 O.sub.3 compound) versus Au = 90 versus 10Preparation example 26 (TiO.sub.2 --ZrO.sub.2 --Fe.sub.2 O.sub.3 compound) versus Rh = 99 versus 1Preparation example 27 (TiO.sub.2 --ZrO.sub.2 --Fe.sub.2 O.sub.3 compound) versus Ir = 95 versus 5______________________________________
Treatment examples 26 to 33
Using each of the catalysts obtained from the preparation examples 20 to 27, wastewater treatment was carried out by wet oxidation according to the following procedure.
Each of the catalysts (1000 cc) was filled in a reaction tube made of a stainless steel and, from a down part of the reaction tube, preheated wastewater blended with air containing oxygen in a concentration of about 21% was continuously introduced for 5,000 hours, the COD (Cr) concentration and total nitrogen amount were measured at an entrance and exit of the reaction tube to calculate their elimination percentages. Meanwhile, before treatment, wastewater contained 15,000 mg/l of dimethylformamide and showed 20,000 mg/l in the COD (Cr) concentration.
The reaction conditions were 200° C. at a reaction temperature, 40 kg/cm 2 G at a reaction pressure, 2 liter per hour at the rate of supplying wastewater, and 230N liter per hour at the rate of supplying air. The obtained results are shown in Table 9.
TABLE 9______________________________________ elimination percentage elimination of total percentage nitrogen kind of of COD (Cr) amount catalyst (%) (%)______________________________________treatment preparation 99.9 99.5example 26 example 20treatment preparation 99.9 99.1example 27 example 21treatment preparation 99.9 99.0example 28 example 22treatment preparation 99.9 99.4example 29 example 23treatment preparation 99.9 99.6example 30 example 24treatment preparation 99.6 99.0example 31 example 25treatment preparation 99.7 98.5example 32 example 26treatment preparation 99.5 98.3example 33 example 27______________________________________
As seen in Table 9, in a continuous operation for 5,000 hours under the forementioned conditions, decrease in the elimination percentages of the COD (Cr) and total nitrogen amount was not recognized.
Treatment examples 34 to 38
According to the treatment example 26, wastewater treatment was carried out by wet oxidation using each of the catalysts obtained from the preparation examples 20 to 24. Wastewater to be treated contained 20,000 mg/l of glycine and showed 19,000 mg/l in the COD (Cr) concentration.
The reaction conditions were 200° C. at a reaction temperature, 40 kg/cm 2 G at a reaction pressure, 2 liter per hour at the rate of supplying wastewater, and 160N liter per hour at the rate of supplying air. The obtained results are shown in Table 10.
TABLE 10______________________________________ elimination percentage elimination of total percentage nitrogen kind of of COD (Cr) amount catalyst (%) (%)______________________________________treatment preparation 99.8 99.5example 34 example 20treatment preparation 99.9 99.1example 35 example 21treatment preparation 99.9 99.0example 36 example 22treatment preparation 99.9 99.3example 37 example 23treatment preparation 99.9 99.4example 38 example 24______________________________________
As seen in Table 10, in a continuous operation for 3,000 hours under the forementioned conditions, decrease in the elimination percentages of the COD (Cr) and total nitrogen amount was not recognized.
Treatment examples 39 to 43
According to the treatment example 26, wastewater treatment was carried out by wet oxidation using each of the catalysts obtained from the preparation examples 20 to 24. Wastewater to be treated contained 10,000 mg/l of ethanolamine and showed 12,000 mg/l in the COD (Cr) concentration.
The reaction conditions were 200° C. at a reaction temperature, 40 kg/cm 2 G at a reaction pressure, 2 liter per hour at the rate of supplying wastewater, and 140N liter per hour at the rate of supplying air. Obtained results are shown in Table 11.
TABLE 11______________________________________ elimination percentage elimination of total percentage nitrogen kind of of COD (Cr) amount catalyst (%) (%)______________________________________treatment preparation 99.0 99.0example 39 example 20treatment preparation 98.8 98.8example 40 example 21treatment preparation 98.8 98.9example 41 example 22treatment preparation 99.0 98.6example 42 example 23treatment prreparation 99.0 98.8example 43 example 24______________________________________
As seen in Table 11, in a continuous operation for 3,000 hours under the forementioned conditions, decrease in the elimination percentages of the COD (Cr) and total nitrogen amount was not recognized.
Comparative preparation example 12
The procedure of preparation example 20 was repeated to obtain a catalyst except that an aqueous solution of ferric nitrate was not used. Composition of an obtained, completed catalyst showed a weight ratio of 98 versus 2 between TiO 2 and palladium.
Comparative preparation example 13
Into 4 liter of an aqueous sulfuric acid solution of titanyl sulfate (titanium oxysulfate) having the composition used in the preparation example 20 was added with mixing 1.44 kg of zirconium oxynitrate [ZrO(NO 3 ) 2 ·2H 2 O]. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 10 hours. Then, it was calcinated at 700° C. for 5 hours under an air atmosphere. Composition of an obtained powder showed a weight ratio of 60.2 versus 39.8 between TiO 2 and ZrO 2 .
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets having a particle diameter 5 mmφ and length 6 mm and calcinated at 500° C. for 3 hours under an air atmosphere.
The pellets thus-obtained were soaked in an aqueous iron nitrate solution, dried at 120° C. for 6 hours, and calcinated at 400° C. for 3 hours.
An obtained, completed catalyst showed composition having a 85 versus 15 ratio by weight between a TiO 2 --ZrO 2 compound and Fe 2 O 3 .
Comparative treatment examples 12 and 13
Wastewater treatment by wet oxidation was carried out by the procedure of treatment example 26 except that each of the catalysts obtained from the comparative preparation examples 12 and 13 was used.
Results obtained are shown in Table 12.
TABLE 12__________________________________________________________________________ initial after 500 hours elimination elimination elimination percentage elimination percentage percentage of total percentage of total of nitrogen of nitrogen kind of COD (Cr) amount COD (Cr) amount catalyst (%) (%) (%) (%)__________________________________________________________________________comparative comparative 72.0 75.0 42.0 36.0treatment preparationexample 12 example 12comparative comparative 50.5 47.5 37.0 25.5treatment preparationexample 13 example 13__________________________________________________________________________
As seen in Table 12, in the comparative treatment example 12 where a catalyst not containing the component was used as well as in the comparative treatment example 13 where a catalyst containing iron as a B component, the COD (Cr)-elimination and total nitrogen-elimination percentages are both lower than the cases where the catalysts of this invention were used, and furthermore, a large decrease in the COD(Cr)-elimination and total nitrogen-elimination percentages was observed in a continuous operation of 500 hours.
Preparation example 28
Into 100 liter of water were added 9 liter of an aqueous titanyl sulfate solution (which has the same composition as the solution used in preparation example 20) and 4 liter of an aqueous ferrous sulfate [FeSO 4 ; 500 g/l solution, and these solutions were well mixed each other. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 7 being indicated, and an obtained mixture was still stood for 20 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 12 hours. Then, it was calcinated at 700° C. for 6 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of TiO 2 and Fe 2 O 3 , in which the weight ratio between TiO 2 and Fe 2 O 3 was 75.0 versus 25.0 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to a spherical shape of average paticle diameter 5 mm and calcinated at 500° C. for 3 hours under an air atmosphere.
The thus-obtained, spherical molded product was soaked in an aqueous ruthenium nitrate solution, dried at 120° C. for 6 hours, and calcinated at 400° C. for 4 hours.
An obtained, completed catalyst showed composition having a 99.7 versus 0.3 ratio by weight between a TiO 2 --Fe 2 O 3 compound and Ru, according to a fluorescence X-ray analysis.
Treatment example 44
Using the catalyst obtained from preparation example 28, wastewater having the below-mentioned composition was treated.
______________________________________pH 13Na.sub.2 S 8%NaSH 3%NaCO.sub.3 3%TOD 100,000 mg/l______________________________________
The catalyst (500 cc) was filled in a reaction tube made of a stainless steel of a wet oxidation column and, from a down part of the reaction tube, preheated wastewater blended with air was continuously introduced for 1,000 hours, the concentrations of sulfide ion (S 2- ), thiosulfate ion and COD (Cr) were measured at an entrance and exit of the reaction tube.
The reaction conditions were 150° C. at a reaction temperature, 9 kg/cm 2 G at a reaction pressure, 0.5 liter per hour at the rate of supplying wastewater, and 200N liter per hour at the rate of supplying air [ratio of O 2 /TOD (amount of oxygen in air/total amount of consumed oxygen) is 1.2].
As a result, treated water was stably obtained, which contained COD (Cr), sulfide ion and thiosulfate ion in concentrations of 3000 mg/l or less, 0.1 mg/l or less and 4500 mg/l or less, respectively.
Comparative treatment example 14
The procedure of treatment example 44 was repeated except that any catalyst was not filled in a wet oxidation column and the column was empty.
As a result, treated water contained COD (Cr), sulfide ion and thiosulfate ion in concentrations of 23,000 mg/l, 20 mg/l and 30,000 mg/l, respectively.
Treatment example 45
Wastewater having the below-mentioned composition was treated by the procedure similar to treatment example 44, except that the catalyst in a wet oxidation column was changed.
______________________________________ pH 13 Na.sub.2 S.sub.2 O.sub.3 1.7% NaOH 1.0% TOD 8,600 mg/l______________________________________
A catalyst used in the present treatment example was the catalyst obtained from preparation example 28. This catalyst (500 cc) was filled in a wet oxidation column.
The above-mentioned treatment resulted in that treated water containing 70 mg/l or less of COD (Cr), 100 mg/l or less of thiosulfate ion was stably obtained.
Comparative treatment example 15
The procedure of treatment example 45 was repeated except that any catalyst was not filled in a wet oxidation column and the column was empty.
As a result, 4300 mg/l of COD (Cr) and 6,000 mg/l of thiosulfate ion remained in treated water.
Treatment example 46
Wastewater having the below-mentioned composition was treated by the procedure similar to treatment example 44, except that the catalyst in a wet oxidation column was changed.
______________________________________pH 13Na.sub.2 S 2.4%Na.sub.2 S.sub.2 O.sub.3 0.9%Na.sub.2 SO.sub.2 0.2%NaOH 0.5%TOD 25,000 mg/l______________________________________
A catalyst used in the present treatment example was the catalyst obtained from preparation example 28. This catalyst (500 cc) was filled in a wet oxidation column.
The above-mentioned treatment resulted in that treated water containing 230 mg/l or less of COD (Cr), 350 mg/l or less of thiosulfate ion was stably obtained. In addition, both sulfide ion and sulfite ion were 0.01 mg/l or less.
Comparative treatment example 16
The procedure of treatment example 46 was repeated except that any catalyst was not filled in a wet oxidation column and the column was empty.
As a result, 7,200 mg/l of COD (Cr), 5 mg/l of sulfide ion and 10,000 mg/l of thiosulfate ion remained in treated water. In addition, sulfite ion was 0.01 mg/l or less.
Preparation example 29
Into 100 liter of water were added 7 liter of an aqueous titanyl sulfate solution (which has the same composition as the solution used in preparation example 20) and 3.80 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O], and these were well mixed. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 7 being indicated, and an obtained mixture was still stood for 16 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 20 hours. Then, it was calcinated at 700° C. for 6 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of TiO 2 and Fe 2 O 3 , in which the weight ratio between TiO 2 and Fe 2 O 3 was 70.0 versus 30.0 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to a spherical shape of average paticle diameter 6 mm and calcinated at 500° C. for 4 hours under an air atmosphere.
The thus-obtained, spherical molded product was soaked in an aqueous chloroplatinic acid solution, dried at 120° C. for 6 hours, and calcinated at 400° C. for 6 hours.
An obtained, completed catalyst showed composition having a 99.6 versus 0.4 ratio by weight between a TiO 2 --Fe 2 O 3 compound and Pt, according to a fluorescence X-ray analysis.
Treatment example 47
Using the catalyst obtained from preparation example 29 and according to the below-mentioned procedure, wastewater was treated by a wet oxidation. The catalyst (3,000 cc) was filled in a reaction tube made of a stainless steel and from a down part of the reaction tube, preheated wastewater blended with air was continuously introduced for 500 hours, a COD (Cr) concentration, an amount of thiophene and an amount of sodium dodecyl sulfate were measured at an entrance and exit of the reaction tube to calculate treatment efficiency.
Here, conditions of wastewater provided for treatment were 3.5 g/l in an amount of thiophene, 20 g/l in an amount of sodium dodecyl sulfate, 16.2 g/l in other oil content, 21.7 g/l in TOC, and before treatment, caustic soda had been added to the wastewater until pH 13 being indicated. The reaction conditions were 240° C. at a reaction temperature, 70 kg/cm 2 G at a reaction pressure, 0.9 per hour at space velocity of wastewater (empty column standard), 6 m per hour at linear velocity of wastewater. Air was introduced to the reaction tube in such an amount that the ratio of O 2 /TOD (amount of oxygen in air/total amount of consumed oxygen) is 1.0.
As a result, elimination percentages of thiophene, sodium dodecyl sulfate, and TOC were 97.0%, 89.5%, and 82.0%, respectively. In addition, pH of treated water was 8.
Comparative treatment example 17
The procedure of treatment example 47 was repeated except that any catalyst was not filled in a wet oxidation column and the column was empty.
As a result, elimination percentages of thiophene, sodium dodecyl sulfate, and TOC were 42.0%, 37.0%, and 34.5%, respectively. In addition, pH of treated water was 11.
Preparation example 30
Into 100 liter of water were added 5 liter of an aqueous titanyl sulfate solution (which has the same composition as the solution used in preparation example 20). 10.66 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O] and 1.32 kg of cerous nitrate [Ce(NO 3 ) 3 ·6H 2 O], and these were well mixed. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 24 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 16 hours. Then, it was calcinated at 700° C. for 6 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of TiO 2 , Fe 2 O 3 and CeO 2 , in which the weight ratio among TiO 2 , Fe 2 O 3 and CeO 2 was 31.2:52.6:16.2 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to a spherical shape of average paticle diameter 5 mm and calcinated at 500° C. for 4 hours under an air atmosphere.
The thus-obtained, spherical molded product was soaked in an aqueous ruthenium nitrate solution, dried at 120° C. for 6 hours, and calcinated at 450° C. for 4 hours.
An obtained, completed catalyst showed composition having a 99.4 versus 0.6 ratio by weight between a TiO 2 --Fe 2 O 3 --CeO 2 compound and Ru, according to a fluorescence X-ray analysis.
Treatment example 48
Using the catalyst obtained from preparation example 30, wastewater containing 100 mg/l of ethyl bromide was treated by the below-mentioned process.
The catalyst (500 cc) was filled in a reaction tube made of titanium of a wet oxidation column and, from a down part of the reaction tube, preheated wastewater blended with air was continuously introduced for 1,000 hours, the concentrations of ethyl bromide and bromide ion were measured at an entrance and exit of the reaction tube.
The reaction conditions were 270° C. at a reaction temperature, 80 kg/cm 2 G at a reaction pressure, 0.5 liter per hour at the rate of supplying wastewater, and 10N liter per hour at the rate of supplying air.
As a result, the elimination percentage of ethyl bromide was 99%, and any organic bromine compound except ethyl bromide was not detected in treated water by GC-ECD method. In addition, the bromide ion concentration in the treated water was 73 mg/l and ethyl bromide was not detected at all in waste gas.
Preparation example 31
Into 100 liter of water were added 5 liter of an aqueous titanyl sulfate solution (which has the same composition as the solution used in preparation example 20) and 7.56 kg of ferric nitrate [Fe(NO 3 ) 3 ·9H 2 O], and these were well mixed. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 7 being indicated, and an obtained mixture was still stood for 16 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, and dried at 120° C. for 20 hours. Then, it was calcinated at 700° C. for 6 hours under an air atmosphere. According to a X-ray diffraction analysis, the obtained powder consisted of TiO 2 and Fe 2 O 3 , in which the weight ratio between TiO 2 and Fe 2 O 3 was 45.5 versus 54.5 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to honeycomb structure having a penetrating hole-corresponding diameter of 10 mm, a cell wall thickness of 1 mm and an opening ratio of 83%, and then calcinated at 500° C. for 4 hours under an air atmosphere.
The thus-obtained, honeycomb type molded product was soaked in an aqueous palladium nitrate solution, dried at 120° C. for 6 hours, and calcinated at 400° C. for 4 hours.
An obtained, completed catalyst showed composition having a 99.3 versus 0.7 ratio by weight between a TiO 2 --Fe 2 O 3 compound and Pd, according to a fluorescence X-ray analysis.
Treatment example 49
According to treatment example 48, the catalyst obtained from preparation example 31 was filled in a wet oxidation column, and wastewater containing 50 mg/l of dichlorobenzene was treated. However, in the present treatment example, a temperature at an entrance of a reaction vessel was 230° C. , a reaction pressure was 60 kg/cm 2 G, and an air amount was 5 liter per hour. Other conditions were similar to treatment example 48.
As a result, the elimination percentage of dichlorobenzene was 89%, and any organic chlorine compound except dichlorobenzene was not detected in treated water. In addition, the chloride ion concentration in the treated water was 21 mg/l and dichlorobenzene was not detected at all in waste gas.
Treatment example 50
The procedure of treatment example 49 was repeated except that a gas containing oxygen in concentration of 70% was used.
As a result, the elimination percentage of dichlorobenzene was 94%, and any organic chlorine compound except dichlorobenzene was not detected in treated water. In addition, the chloride ion concentration in the treated water was 54 mg/l and dichlorobenzene was not detected at all in waste gas.
Preparation example 32
The honeycomb type molded product of a titanium-iron n oxide obtained from preparation example 31 was soaked in an aqueous rhodium nitrate solution, dried at 120° C. for 6 hours, and calcinated at at 400° C. for 3 hours to obtain a catalyst.
Treatment example 51
The catalyst obtained from preparation example 32 was filled in a wet oxidation column, and wastewater treatment was carried out. In addition, wastewater containing 500 mg/l of trichloroethylene was used as model wastewater. The model wastewater did not contain chloride ion. The reaction was carried out under the conditions of 250° C. and 70 kg/cm 2 G. Other conditions and flow were similar to treatment example 48. As a result, the elimination percentage of trichloroethylene was 95%.
Comparative treatment example 18
According to treatment Example 51, wastewater similar to the wastewater used in treatment example 51 was treated under the conditions similar to treatment example 51. However, any catalyst was not filled in a wet oxidation column and the column was empty. As a result, the elimination percentage of trichloroethylene was 32%.
Preparation example 33
Into 100 liter of water, were added 4 liter of an aqueous titanyl sulfate solution (which has the same composition in the solution used in preparation example 20), and these were well mixed each other. To this mixture maintained at about 30° C. with well stirring, an aqueous ammonia was gradually added dropwise until pH 8 being indicated, and an obtained mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration and washed with water.
To the gel, 1.67 kg of a hydroxide of iron (α-FeOOH) were added and these were mixed and well kneaded by a kneader and dried at 120° C. for 10 hours. Then, the resulting kneaded mixture was calcinated at 700° C. for 5 hours under an air atmosphere to obtain a powder. According to a X-ray diffraction analysis, the obtained powder consisted of TiO 2 and Fe 2 O 3 in which the weight ratio between TiO 2 and Fe 2 O 3 was 40 versus 60 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
Water, the obtained powder and starch were mixed and well kneaded by a kneader. This kneaded product was molded by a molding device to pellets of particle diameter 5 mm φ and length 6 mm and calcinated at 500° C. for 3 hours under an air atmosphere.
The pellets thus-obtained were soaked in an aqueous ruthenium nitrate solution, dried at 120° C. for 6 hours, and calcinated at 400° C. for 3 hours.
An obtained, completed catalyst showed composition having a 98 versus 2 ratio by weight between a TiO 2 --Fe 2 O 3 compound and ruthenium, according to a fluorescence X-ray analysis.
Treatment example 52
Using the catalyst obtained from the preparation example 33, wastewater treatment was carried out by wet oxidation according to the following procedure.
The catalyst (1000 cc) was filled in a reaction tube made of a stainless steel and, from a down part of the reaction tube, preheated wastewater blended with air containing oxygen in concentration of about 21% was continuously introduced for 5,000 hours, the COD (Cr) concentration and total nitrogen amount were measured at an entrance and exit of the reaction tube to calculate their elimination percentages. Meanwhile, before treatment, wastewater contained 15,000 mg/l of dimethylformamide and showed 20,000 mg/l in the COD (Cr) concentration.
The reaction conditions were 200° C. at a reaction temperature, 40 kg/cm 2 G at a reaction pressure, 2 liter per hour at the rate of supplying wastewater, and 230N liter per hour at the rate of supplying air. The obtained results are shown in Table 13.
According to the treatment example 26, wastewater treatment was carried out by wet oxidation using the catalyst obtained from the preparation example 33. Wastewater to be treated contained 20,000 mg/l of glycine and showed 19,000 mg/l in the COD (Cr) concentration.
The reaction conditions were 200° C. at a reaction temperature, 40 kg/cm 2 G at a reaction pressure, 2 liter per hour at the rate of supplying wastewater, and 160N liter per hour at the rate of supplying air. The obtained results are shown in Table 13.
Treatment example 54
According to the treatment example 26, wastewater treatment was carried out by wet oxidation using the catalyst obtained from the preparation example 33. Wastewater to be treated contained 10,000 mg/l of ethanolamine and showed 12,000 mg/l in the COD (Cr) concentration.
The reaction conditions were 200° C. at a reaction temperature, 40 kg/cm 2 G at a reaction pressure, 2 liter per hour at the rate of supplying wastewater, and 140N liter per hour at the rate of supplying air. Obtained results are shown in Table 13.
TABLE 13______________________________________ Elimination Elimination percentage percentage of total Kind of of COD (Cr) nitrogen catalyst % amount (%)______________________________________Treatment Preparation 99.0 98.7example 52 example 33Treatment Preparation 98.5 98.5example 53 example 33Treatment Preparation 98.0 98.5example 54 example 33______________________________________
Preparation example 34
Into 30 liter of water was added 2.4 liter of the same aqueous sulfuric acid solution of titanyl sulfate (titanium oxysulfate) as that for the preparation example 20 with well mixing. To the resulting mixture maintained at about 30° C. with well stirring, aqueous ammonia was gradually added dropwise until pH 8 being indicated, and the resulting mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration and washed with water. To the resulting gel was added 2.67 kg of a hydroxide of iron (α-FeOOH), and they were mixed and well kneaded by a kneader, dried at 120° C. for 10 hours, and calcined at 700° C. for 5 hours under an air atmosphere to obtain a powder. According to a X-ray diffraction analysis, the obtained powder consisted of TiO 2 and Fe 2 O 3 in which the weight ratio of TiO 2 : Fe 2 O 3 was 20:80 according to fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
To the powder were added 0.6 liter of an aqueous ruthenium nitrate solution (Ru content: 50 g/l), 0.15 liter of an aqueous palladium nitrate solution (Pd content: 100 g/l), water and starch, and they were mixed and well kneaded by a kneader. The resulting kneaded product was molded by a molding device to pellets of particle diameter 5 mmφ and length 6 mm and calcined at 400° C. for 3 hours under an air atmosphere.
The resulting completed catalyst showed composition in which the weight ratio of TiO 2 : Fe 2 O 3 : Ru: Pd was 19.7:78.8:1:0.5 according to a fluorescence X-ray analysis.
Preparation example 35
Into 100 liter of water were added 5 liter of the same aqueous sulfuric acid solution of titanyl sulfate (titanium oxysulfate) as that for the preparation example 20 and 5.41 kg of ferric nitrate [Fe(NO 3 ) 3 --9H 2 O)] with well mixing. To the resulting mixture maintained at about 30° C. with well stirring, aqueous ammonia was gradually added dropwise until pH 8 being indicated, and the resulting mixture was still stood for 15 hours to make a precipitate (gel).
This gel was taken by filtration, washed with water, dried at 120° C. for 10 hours, and calcined at 700° C. for 5 hours under an air atmosphere to obtain a powder. According to a X-ray diffraction analysis, the obtained powder consisted of TiO 2 and Fe 2 O 3 ; in which the weight ratio of TiO 2 : Fe 2 O 3 was 53.9:46.1 according to a fluorescence X-ray analysis.
Using this obtained powder, a catalyst was prepared by the undermentioned process.
To the powder were added 0.46 liter of an aqueous palladium nitrate solution (Pd content: 100 g/l), water and starch, and they were mixed and well kneaded by a kneader. The resulting kneaded product was molded by a molding device to pellets of particle diameter 5 mm φ and length 6 mm and calcined at 400° C. for 3 hours under an air atmosphere.
The resulting completed catalyst showed composition in which the weight ratio of TiO 2 : Fe 2 O 3 : Pd was 52.9:45.2:1.9 according to fluorescence X-ray analysis.
Treatment example 55
The procedure of the treatment example 52 was repeated to carry out wastewater treatment by wet oxidation except that the catalyst obtained from the preparation example 34 was used instead of the catalyst obtained from the preparation example 33. Obtained results are shown in Table 14.
Treatment example 56
The procedure of the treatment example 53 was repeated to carry out wastewater treatment by wet oxidation except that the catalyst obtained from the preparation example 34 was used instead of the catalyst obtained from the preparation example 33. Obtained results are shown in Table 14.
Treatment example 57
The procedure of the treatment example 54 was repeated to carry out wastewater treatment by wet oxidation except that the catalyst obtained from the preparation example 34 was used instead of the catalyst obtained from the preparation example 33. Obtained results are shown in Table 14.
Treatment example 58
The procedure of the treatment example 52 was repeated to carry out wastewater treatment by wet oxidation except that the catalyst obtained from the preparation example 35 was used instead of the catalyst obtained from the preparation example 33. Obtained results are shown in Table 14.
Treatment example 59
The procedure of the treatment example 53 was repeated to carry out wastewater treatment by wet oxidation except that the catalyst obtained from the preparation example 35 was used instead of the catalyst obtained from the preparation example 33. Obtained results are in Table 14.
Treatment example 60
The procedure of the treatment example 54 was repeated to carry out wastewater treatment by wet oxidation except that the catalyst obtained from the preparation example 35 was used instead of the catalyst obtained form the preparation example 33. Obtained results are shown in Table 14.
TABLE 14______________________________________ Elimination Elimination percentage percentage of total Kind of of COD (Cr) nitrogen catalyst % amount (%)______________________________________Treatment Preparation 99.5 99.0example 55 example 34Treatment Preparation 99.2 99.0example 56 example 34Treatment Preparation 98.8 98.5example 57 example 34Treatment Preparation 98.0 97.5example 58 example 35Treatment Preparation 97.6 97.2example 59 example 35Treatment Preparation 97.5 96.4example 60 example 35______________________________________ | The present invention provides a catalyst used in wastewater treatment process wherein not only an organic compound not containing nitrogen, sulfur or halogen is decomposed, but also a nitrogen-containing compound, a sulfur-containing compound and an organic halogeno compound are effectively decomposed, thereby wastewater are treated with excellent efficiency for a long period of time. The invention also provides a production process for the catalyst and said wastewater treatment process. The first catalyst comprises: an oxide of iron as an A component; and at least one kind of element as a B component selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium. The second catalyst comprises: an oxide as an A component containing iron and at least one kind of element selected from a group consisting of titanium, silicon and zirconium; and at least one kind of element as a B component selected from a group consisting of cobalt, nickel, cerium, silver, gold, platinum, palladium, rhodium, ruthenium and iridium. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of German Application No. 10237270.5, filed Aug. 14, 2002, and PCT Application No. PCT/EP03/08784, filed Aug. 7, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to the use of silane-crosslinkable coating formulations having good curing properties, which produce scratch resistant coatings.
2. Background Art
At present there is a great need for scratch-resistant coatings for a wide variety of applications. Particular mention might be made here of scratch-resistant topcoat materials for motor vehicles. In this context it is necessary in addition to differentiate between OEM coating materials and refinish coating materials. These coating materials differ primarily in their process temperature: while OEM coating materials are generally baked at 130-140° C.; refinish coating materials must be able to be processed at not more than 80° C.—even better would be 50° C., or even ambient temperature.
The great majority of the present commercial coatings for OEM and refinish are systems composed of isocyanate oligomers, in some cases the isocyanate groups of which are blocked, and hydroxy-functional polymers. These systems, however, still have a large number of various disadvantages.
For instance, on the one hand, the achievable scratch resistance is still not sufficient, so that, for example, in a car wash particles in the washing water cause noticeable scratching of the finish. Over time this permanently damages the gloss of the finish. Formulations would be desirable here that allow higher finish hardnesses to be achieved.
A further disadvantage of conventional automobile topcoat materials lies in the fact that they are solvent-based systems whose solids fraction is in some cases even below 60%. Because of the high molar masses of the uncrosslinked prepolymers and the correspondingly high viscosities and/or glass transition points thereof, it is virtually impossible to do without a solvent.
Finally, isocyanate-based systems possess the critical disadvantage that the isocyanate-containing components are not toxicologically unobjectionable and, moreover, have a strong sensitizing action. In the course of their use it is therefore necessary to take extensive precautionary measures in order to prevent inhalation of vapors or aerosols and to prevent skin contact. This is very inconvenient and expensive, particularly in the case of refinish applications. Replacing isocyanate-based coating materials by a more toxicologically unobjectionable system is desirable in any case.
The potential applications of scratch-resistant coatings are not restricted, however, to clearcoat materials for motor vehicles, but extend to many further areas: particularly for the scratch-resistant finishing of plastics, especially for transparent plastics such as corresponding polymethacrylates or polycarbonates, there is a high demand for coatings possessing superior scratch resistance.
On account of these disadvantages of the conventional isocyanate-based coating materials presently available commercially there is a keen search for new coating systems which no longer have the abovementioned disadvantages. In the case of one very promising approach the starting-point compounds are organic oligomers or polymers which possess hydrolyzable silyl groups of the general formula (1).
—Si(OR) 3-x R′ x (1)
where:
R=alkyl or acyl radical R′=alkyl, cycloalkyl or aryl radical x=0 or 1.
These silyl groups are able in the presence of water—e.g., from atmospheric humidity—to undergo hydrolysis, with the formation of Si—OH functions, and subsequently to undergo condensation, with the formation of Si—O—Si bridges, as a result of which the coating cures. The silyl groups are attached in terminal or lateral position on the otherwise organic main chain of the oligomer or polymer, with bonding being via a hydrolysis-stable Si—C bond.
Polymers or oligomers which are able to crosslink to three-dimensional networks by groups of the general formula (1) are also referred to below as prepolymers.
In recent years a variety of coatings have been developed on the basis of such prepolymers, said coatings being distinguished not only by high hardness but also, in particular, by outstanding chemical resistance and weathering stability.
The hydrolyzable silane groups of the corresponding prepolymers are generally trimethoxysilyl groups or alkyldimethoxysilyl groups (general formula 1: R=methyl, x=0 or 1). For the preparation of the pre-polymers provided with these silane units it is possible to take a variety of pathways.
Thus, inter alia, EP-A-44 049, EP-A-267 698, EP-A-549 643 and U.S. Pat. No. 4,043,953 describe coating formulations which comprise prepolymers which have pendent silane groups. These prepolymers are prepared by copolymerizing ethylenically unsaturated alkoxysilanes with other unsaturated compounds. Preferably silanes containing (meth)acrylic groups are copolymerized with other (meth)acrylates to give alkoxysilane-functional polymethacrylates. In such a reaction it is of course possible for further unsaturated compounds such as styrene, for example, to be copolymerized as well. Disadvantageous features of this process include the high molar masses which are obtained, meaning that the corresponding polymers can be handled only in solution form.
EP-A-1 123 951 describes coatings which in addition to the above-described alkoxysilane-functional polymethacrylates, and further coating constituents, also comprise silane-terminated prepolymers which have been prepared from a polyol or alcohol having at least 2 OH functions and from an isocyanate-functional alkoxysilane. The coating materials prepared in that patent, however, are not solvent-free.
EP-A-571 073 describes silane-crosslinking coatings wherein the silane-terminated prepolymers are obtained by reacting isocyanates having tertiary isocyanate groups and amino-functional silanes. One of the disadvantages here is the difficulty of obtaining the tertiary isocyanates.
All of these attempts at producing coatings of high hardness which are suitable for producing scratch-resistant coatings and which crosslink via condensation of alkoxysilyl groups additionally have, without exception, a further critical disadvantage. Thus the preparation of the silane-functional polymers or oligomers starts exclusively from vinylsilanes of the general formula (2) or else from silanes containing groups corresponding to the general formula (3) which possess a propyl spacer between a heteroatom and the silyl group.
vinyl-Si(OR) 3-x R′ x (2)
—X—(CH 2 ) 3 —Si(OR) 3-x R′ x (3)
where:
R=methyl radical, R′=alkyl, cycloalkyl, aryl or alkylaryl radical, X=oxygen, sulfur or a group of the formula NR″, R″=hydrogen, alkyl, cycloalkyl, aryl, aminoalkyl or aspartate ester radical, x=0 or 1.
The reactivity of the silane-functional prepolymers obtained in this case, however, is no more than moderate. In order to achieve a sufficient cure rate with these components even at moderate temperatures of not more than 80° C. it is vital to add heavy metal catalysts—generally organotin compounds. Even at relatively high baking temperatures of 130-150° C. it is often not possible to do without heavy metal catalysts.
The avoidance of heavy metal catalysts—or at least a marked reduction in the amount of catalyst to be employed—would on the one hand be desirable from toxicological standpoints; on the other hand, the catalyst may also lower the storage stability of the coating formulation and the resistance of the cured coating material. For the same reasons the catalysis of film curing by strong organic bases such as 1,4-diazabicyclo[5.4.0]undec-7-ene (DBU) is likewise disadvantageous.
Furthermore, using the moderately reactive silanes of the general formulae (2) or (3), only methoxy-crosslinking prepolymers can be prepared, in other words prepolymers which give off methanol as they cure. Ethoxy-crosslinking systems, which give off the less toxicologically objectionable ethanol as they cure, are not possible, since compounds of the general formulae (2) or (3) with R=ethyl lack sufficient reactivities even in the presence of high concentrations of catalyst.
WO 92/20463 proposes adding the curing catalyst not to the topcoat material, with the silane-functional prepolymers present therein, but instead to a basecoat material. In a two-coat system first of all the basecoat, containing catalyst, is applied, and is subsequently covered with the topcoat material. Both coating films are dried or cured jointly, and the catalyst diffuses from the basecoat material into the topcoat film. Although this does allow the problem of the moderate storage stability of a one-component topcoat solution to be solved, it is not possible in this way to forego heavy metal catalysts or to achieve a reduction in the amount of catalyst.
DE-A-21 55 258 describes silane-terminated prepolymers which possess crosslinkable end groups of the general formula (4)
—Y—CO—NH—Q—NH—CO—NR″—CH 2 —Si(OR) 3-z R′ z (4)
where:
Q=alkylene, cycloalkylene, arylene or alkylarylene radical, R=alkyl radical, preferably methyl or ethyl radical, R′=alkyl, cycloalkyl, aryl or alkylaryl radical, R″=hydrogen, alkyl, cycloalkyl, aryl or aminoalkyl radical, Y=oxygen or a group of the formula NR″, x=0 or 1.
These prepolymers are distinguished by very high reactivity on the part of the alkoxysilyl groups, so that these prepolymers cure in air even in the absence of heavy metal catalysts. Ethoxy-crosslinking pre-polymers containing such end groups are also described. The prepolymers described in DE-A-21 55 258, however, are suitable merely for producing elastic coatings, but not for producing scratch-resistant coatings. Thus in the case of these materials each crosslinkable silyl group is attached to the prepolymer either by way of two urea units or else by way of one urea unit and one urethane unit. Urea units and, albeit to a lesser extent, urethane units as well, however, have a capacity to form hydrogen bonds which increases the viscosity and also the glass transition point of the corresponding polymers. Consequently prepolymers having crosslinkable end groups of the general formula (4) either possess only a low crosslinkable alkoxysilyl group density or because of their high urea and urethane group density are vitreous solids and can be handled only in highly dilute solution. Accordingly all of the prepolymers described in DE-A-21 55 258, with end groups of the general formula (4), either possess only a very low fraction of alkoxysilyl groups, of less than 3% by weight, or are prepared and used only in high dilution, as a 30% strength toluenic solution. For producing highly crosslinked and hence scratch-resistant coatings from low-solvent coating formulations, these prepolymers are unsuitable.
Moreover, the compounds described in DE-A-21 55 258 with crosslinkable end groups of the general formula (4) have considerable stability problems. Although the reactivity of these alkoxysilyl groups is high it can be neither controlled nor modulated. Accordingly these compounds are storage-stable and handleable in air only with severe problems and also only in solutions containing alcohol and acid anhydride. Their further processing presents similar problems.
SUMMARY OF THE INVENTION
It was therefore an object of the invention to provide a hard coating with good scratch resistance, which can be produced from alkoxysilane-functional prepolymers and which does not have restrictions corresponding to those of the prior art. These and other objects are achieved by coating a substrate with crosslinkable prepolymer(s) bearing 2 or 3 reactive silyl groups —OR, bonded to the prepolymer through an intervening methylene group via —O—, —S—, or a single urethane linkage. Coating compositions employing the prepolymers can be used in low-solvent or solvent-free form, and cure readily at low temperatures to form coatings of high hardness values.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention provides coating formulations (B) which are curable to coatings having a pencil hardness according to ISO 15184 of at least HB, which comprise prepolymers (A) which possess alkoxysilane functions of the general formula (6)
—X—CH 2 —Si(OR) 3-x R′ x (6)
in which
R is hydrogen, alkyl, cycloalkyl or aryl radical having in each case 1 to 6 carbon atoms, the carbon chain being uninterrupted or interrupted by non-adjacent oxygen, sulfur or NR″ groups, R′ is alkyl, cycloalkyl, aryl or arylalkyl radical having in each case 1 to 12 carbon atoms, the carbon chain being uninterrupted or interrupted by nonadjacent oxygen, sulfur or NR″ groups, R″ is hydrogen, alkyl, cycloalkyl, aryl, aminoalkyl or aspartate ester radical, X is oxygen, sulfur or a group of the general formula (20)
—O—CO—NR″— (20) and
x is 0 or 1.
The curable coating formulations (B) can be used in low-solvent or solvent-free form. They can be formulated for high reactivity and cure to a scratch-resistant coating which has a pencil hardness according to ISO 15184 of at least HB.
In particular the preparation of the prepolymers (A) does not start from aminosilanes of the general formula (5)
NHR″—CH 2 —Si(OR) 3-x R′ x (5)
where R, R′, R″ and x have the definitions described in connection with the general formula (6). In the case of applications of economic interest these aminosilanes would always be attached to the prepolymer through a reaction with isocyanate groups, with the formation of a urea unit.
The invention is based on the following, surprising discoveries. Firstly, it has been found that prepolymers (A) having alkoxysilyl groups of the general formula (1) which are attached via a methyl spacer to a heteroatom can have extremely high reactivities toward moisture. Surprisingly, however, these high reactivities occur only when acidic or basic compounds—such as, for example, aminosilanes of the general formula (5) are present, even if present only in traces. Although an extremely high reactivity of the prepolymers (A) is entirely advantageous in the context of the curing of the prepolymer-containing coatings, the handleability of these highly reactive mixtures is extremely problematic. In the absence of any acids or bases, however, the prepolymers (A) have virtually no reactivity and can therefore be handled and stored without problems. This also allows effective modulability and/or controllability of the reactivity of the prepolymers (A) by means of the addition of suitable—e.g., weakly basic or acidic—catalysts.
A second, likewise surprising discovery is that solvent-free or low solvent coating formulations (B) can be produced with mixtures of prepolymers (A) having a very high density of alkoxysilyl groups of the general formula (1) which are attached via a methyl spacer to a heteroatom, while providing low viscosities, if the heteroatom is not a nitrogen atom that is part of a urea group. As a result of the low viscosity, these prepolymers (A) can be used effectively in low-solvent or even in solvent-free coating systems. Coating formulations (B) of this kind, with mixtures of prepolymers (A) having a high density of alkoxysilyl groups of the general formula (1), in the course of their curing, form networks having a high network density, thereby resulting in very hard materials which are highly suitable for scratch-resistant coatings.
The group R preferably comprises methyl or ethyl radicals. The group R′ preferably comprises a methyl, ethyl or phenyl radical. The group X preferably comprises oxygen or a group of the general formula (20). R″ preferably has 1 to 12 carbon atoms. R″ preferably comprises hydrogen.
The main chains of the alkoxysilane-terminated polymers (A) can be branched or unbranched. The average chain lengths may be adapted arbitrarily in accordance with the particular desired properties both of the uncross-linked mixture and of the cured coating. They may be composed of different building blocks. Thus the polymers in question may be, for example, polyethers, polyesters, polyurethanes, polyureas, polyacrylates and polymethacrylates, polycarbonates, polystyrenes, polysiloxanes, polysiloxane-urea/urethane copolymers, polyamides, polyvinyl esters, polyvinyl hydroxides or polyolefins such as, for example, polyethylene, polybutadiene, ethylene-olefin copolymers or styrenebutadiene copolymers. It is of course also possible to use any desired mixtures or combinations of polymers having different main chains. Similarly it is also possible to use any desired monomeric or oligomeric molecules having one or more alkoxysilane functions of the general formula (6) as prepolymers (A). Here as well arbitrary mixtures are possible.
The alkoxysilane groups of the general formula (6) may be situated terminally at the chain ends of the branched or unbranched main chains of the prepolymers (A). All or only some of the chain ends may be provided with alkoxysilane groups of the general formula (6). It is also possible, furthermore, for the alkoxysilane groups of the general formula (6) to be located laterally at the sides of the branched or unbranched main chains of the prepolymers (A).
In one preferred version of the invention the silane-functional prepolymers (A) are prepared using silanes of the general formulae (7) and (8):
CH 2 ═CHW—CO—O—CH 2 —Si(OR) 3-x R′ x (7),
propylene oxide-O—CH 2 —Si(OR) 3-x R′ x (8),
where W is a CH 3 group or hydrogen and where R, R′ and x have the definitions described in connection with the general formula (6).
From the silane of the general formula (7) it is possible to prepare prepolymers (A) having lateral alkoxysilane groups of the general formula (6) by copolymerization with other unsaturated compounds, such as acrylic esters, methacrylic esters or styrene, for example.
From the silane of the general formula (8) it is possible to prepare prepolymers (A) having lateral alkoxysilane groups of the general formula (6) by copolymerization with other epoxides, such as ethylene oxide or propylene oxide. From the same silane it is possible to prepare prepolymers having terminal alkoxy-silane groups of the general formula (6), by reacting this silane with polyols having terminal OH groups or with monomeric alcohols, preferably having at least two OH groups.
In one particularly preferred version of the invention the silane-functional prepolymers (A) are prepared using silanes (A1) of the general formula (9):
OCN—CH 2 —Si(OR) 3-x R′ x (9),
where R, R′ and x have the definitions described in connection with the general formula (6).
The isocyanatosilane (A1) is reacted with an OH-functional prepolymer (A2). In terms of the chain length and the degree of branching of the OH-functional prepolymers (A2) there are no restrictions whatsoever.
Where the OH-functional prepolymer (A2) is a polymeric or oligomeric compound having lateral OH functions, prepolymers (A) having pendent alkoxysilane groups of the general formula (6) are obtained. Where, in contrast, the OH-functional prepolymer (A2) is a polymeric or oligomeric compound having terminal OH functions, prepolymers (A) are obtained which are terminated with alkoxysilane groups of the general formula (6). For the synthesis of the prepolymers (A) it is possible to use, in addition to the silane (A1), any desired mixtures of OH-functional prepolymers (A2) and/or monomeric alcohols.
If the molar amount of silane (A1) used is smaller or else the same size as the molar number of OH terminations of the prepolymer (A2), then NCO free prepolymers (A) are obtained.
If the OH-functional prepolymer (A2) has been synthesized from one or more polyols (A21)—preferably having at least two OH functions—and also from di- and/or polyisocyanates (A22), then it is not absolutely necessary to use these building blocks (A21, A22) to first prepare the OH-functional prepolymer (A2) which is subsequently reacted with the silane (A1) to form the finished prepolymer (A). But in this case as well it is possible to reverse the reaction steps, by reacting the polyols (A21) first with the isocyanatosilane (A1), and only subsequently reacting the resulting compounds with the di- or polyisocyanate (A22) to give the finished polymer (A).
Examples of customary diisocyanates (A22) are hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), diisocyanatonaphthalene (NDI), diisocyanatodiphenylmethane (MDI), both in the form of crude or technical MDI and in the form of pure 4,4′ and/or 2,4′ isomers or mixtures thereof, and also tolylene diisocyanate (TDI) in the form of its various regioisomers. Examples of polyisocyanates (A22) are polymeric MDI (p-MDI), triphenylmethane triisocyanate, biuret triisocyanates and all of the isocyanurates of the abovementioned diisocyanates. Particular preference is given to aliphatic diisocyanates such as IPDI or HDI and also to isocyanurates or biuret compounds formed from these diisocyanates.
Particularly suitable polyols (A2 or A21) for preparing the prepolymers (A) include aromatic and aliphatic polyester polyols and polyether polyols and also hydroxyl-containing polyacrylates, such as are widely described in the literature. In principle, however, any polymeric, oligomeric or even monomeric alcohols having two or more OH functions can be used. Instead of or alongside the OH-functional prepolymers (A2) and/or (A21) it is also possible to use all monomeric alcohols having one or—preferably—at least two OH functions in the preparation of the prepolymers (A). Examples that might be mentioned here include compounds such as ethylene glycol, glycerol, the various propane-, butane-, pentane- or hexanediol isomers, the various pentoses and hexoses, and also derivatives thereof, or else petaerythrotetraol. It is of course also possible to use mixtures of different polymeric and/or monomeric alcohols as polyol components (A2) and/or (A21).
Moreover, as well as the OH-functional polyols (A2, A21), in the preparation of the prepolymers (A) it is also possible to use polymeric or monomeric amines, preferably having at least two NH functions. The use of hydroxyalkyl- or aminoalkyl-terminated polydiorganosiloxanes is a further possibility.
In the preparation of the prepolymers (A) from isocyanatosilanes (A1) and OH-functional prepolymers (A2) it is preferred to use catalysts. Suitable catalysts in this case are all compounds known from polyurethane chemistry which catalyze the addition of alcohols to isocyanates. It is also possible, however, to do without a catalyst entirely when preparing the prepolymers (A) from isocyanatosilanes (A1) and OH-functional prepolymers (A2). In that case, however, it is advantageous to carry out the prepolymer preparation at elevated temperatures, in order to avoid excessively long reaction times.
In the case of one particularly preferred process the polymers (A) are prepared from isocyanatosilanes (A1) and OH-functional prepolymers (A2) in the presence of a tin catalyst. Examples of tin catalysts are organo tin compounds, such as dibutyltin dilaurate, dioctyltin dilaurate, dibutyltin diacetylacetonate, dibutyltin diacetate or dibutyltin dioctoate. Preference is given to using dibutyltin dilaurate. Preferably extremely small concentrations of tin catalysts are used, so that the tin content of the resulting polymers (A) is <500 ppm, preferably <100 ppm and more preferably <50 ppm.
The use of a tin catalyst in the synthesis of the polymers (A) is based on the surprising discovery that tin catalysts are only very poor catalysts of the curing reaction of the polymers (A). This finding is especially conspicuous on account of the fact that in the case of conventional silane-terminated polymers with silane terminations other than those of the general formula (6) tin compounds represent particularly efficient catalysts. The polymers (A), in contrast, are sufficiently slow to react even in the presence of the indicated concentrations of tin catalyst, and are activated only by the addition of a suitable basic catalyst.
In order to achieve rapid curing of the coating formulations (B) it is possible for them to include not only the alkoxysilane-functional prepolymers (A) but also catalysts (K) which accelerate the condensation reactions of the alkoxysilane groups of the general formula (6). Besides the tin catalysts already described above suitability is also possessed here by titanates, e.g., titanium(IV) isopropoxide, iron(III) compounds, e.g., iron(III) acetylacetonate, or else amines, particularly organic amines, e.g., aminopropyltri(m)ethoxysilane, N-(2-aminoethyl) aminopropyltri(m)ethoxysilane, N-alkylaminopropyltri(m)ethoxysilanes, N,N-dialkylaminopropyltri(m)ethoxysilanes, N,N-dialkylaminomethyltri(m)ethoxysilanes, triethylamine, tributylamine, 1,4-diazabicyclo[2.2.2]-octane, bis(N,N-dimethylaminoethyl) ether, N,N-bis(N,N-dimethyl-2-aminoethyl) methylamine, N,N-dimethylcyclohexylamine, N,N-dimethylpiperazines, tris(3-N,N-dimethylaminopropyl)amine, N,N-dimethylphenylamine, N,N-dimethylenthanolamine, N-ethylmorpholinine, N-methylmorpholinine, 2,2-dimorpholinodiethyl ether, etc. Numerous further organic and inorganic heavy metal compounds and also organic and inorganic Lewis acids or bases, however, can be used here as well.
Naturally it is possible for the same catalysts already added during the synthesis of the prepolymer (A) to serve as curing catalysts (K).
Particularly preferred catalysts (K) are tertiary amines, examples being the tertiary amino compounds listed above. Because of the steric hindrance on the nitrogen atom, these tertiary amines possess a moderate catalytic activity, so that coatings having good curing properties combined with high storage stabilities and good processing properties result. By way of the extent of the steric shielding on the nitrogen atom it is possible here to control the catalytic activity of the catalyst (K).
The catalysts (K) are used preferably in concentrations of 0.01%-10% by weight, more preferably in concentrations of 0.01%-1% by weight, based on the coating formulation (B). The various catalysts can be used both in pure form and also as mixtures of different catalysts.
A further possibility is for the coating formulations (B) to also include one or more reactive diluents (R) in order to produce the coatings. Suitable reactive diluents (R) are in principle all low molecular mass compounds having a viscosity of preferably not more than 5 Pas, in particular not more than 1 Pas at 20° C., and which possess reactive alkoxysilyl groups via which they are incorporated into the nascent three-dimensional network as the coating cures. The reactive diluent (R) in this context may where appropriate serve not only to reduce the viscosity but also to enhance the properties of the cured coating. Thus it may also lead, for example, to a further increase in the alkoxysilyl group density in the coating formulation (B) and hence to a further increase in the network density in the cured coating. This may possibly result in an even higher hardness on the part of said coating. Additionally the reactive diluent (R) may serve simultaneously as an adhesion promoter and so enhance the adhesion of the coating on the respective substrate.
Preferred reactive diluents (R) are the inexpensive alkyltri(m)ethoxysilanes, such as methyltrimethoxysilane, methyltriethoxysilane and also vinyltrimethoxysilane, vinyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane and also tetraethylsilane. Partial hydrolysates of these compounds can also be used as reactive diluents (R).
Likewise preferred are reactive diluents (R) which possess alkoxysilane functions of the general formula (6), e.g. reactive diluents (R) in the general formulae (10) or (11):
R″O—CH 2 —Si(OR) 3-x R′ x (10),
R″—O—CO—NH—CH 2 —Si(OR) 3 —R′ x (11),
where R, R′, R″ and x have the definitions indicated in connection with the general formula (6).
The reactive diluents (R) may be added only during the formulation of the coating formulations (B) or else as early as during the synthesis of the prepolymers (A).
The coating formulations (B) may comprise as binders exclusively the prepolymers (A) and, if desired, one or more reactive diluents (R). In that case it is also possible for different types of prepolymers (A) to be mixed with one another, examples being prepolymers (A) having a backbone based on poly(meth)acrylates, prepared using a (meth)acryloylsilane of the general formula (7), with prepolymers (A) prepared using an isocyanatosilane of the general formula (9).
Besides the prepolymers (A) and, where appropriate, one or more reactive diluents (B) it is also possible for the coating formulations (B) to include further binders (D) without alkoxysilane functions of the general formula (6). Suitable binders (D) include all of the binders known from paint preparation, examples being binders based on polyurethanes, polyacrylates or melamine resins and also binders which possess alkoxysilane groups that are not of the general formula (6).
The coating formulations (B) may either include solvent or be solvent-free. Suitable solvents in the first case are all of the solvents and solvent mixtures known from paint preparation. In one preferred version of the invention the coating formulations (B) are solvent-free.
The coating formulations (B) may further include the additives and additions that are customary in coating formulations. Mention might be made here, among others, of flow assistants, surface-active substances, adhesion promoters, light stabilizers such as UV absorbers and/or free-radical scavengers, thixotropic agents and also solids such as, for example, fillers or nanoparticles. In order to produce the particular desired profiles of properties both of the coating formulations (B) and also of the cured coatings such additions are generally unavoidable. Also, of course, the coating formulations (B) may comprise pigments.
The cured coating formulations (B) possess a high level of hardness, and so possess suitability for use as scratch-resistant coatings, e.g., as vehicle finishes, as scratch-resistant coatings on plastics or else as scratch-resistant coatings on wood. On the basis of their moderate crosslinking conditions the coating formulations (B) can be used as OEM coating materials and also as refinish coating materials.
Through the use of prepolymers (A) having a relatively low density of alkoxysilane groups of the general formula (6), however, it is also possible to produce coatings which as well as having a high level of hardness possess in particular high elasticity and good abrasion resistance.
A particular advantage of the coating formulations (B) lies in the reactivity—on the one hand controllable, on the other hand very high if required—of the prepolymers (A). Thus by adding suitable curing catalysts (K) it is possible to obtain coating formulations (B) which cure completely even at 50-80° C. or—with particular preference—even at as low as room temperature (20° C.). Through the use of different types of curing catalyst (K) and different concentrations of curing catalyst it is possible to adjust the respective curing time, in accordance with the requirement, between a few minutes and several hours.
A further important advantage of the adjustable—on demand—high reactivities of the prepolymers (A) lies in the fact that with these prepolymers ethoxy-crosslinking coating formulations (B) as well are possible, i.e., formulations which possess ethoxysilyl groups (R=ethyl in the general formula (6)). These formulations, on curing, release only ethanol and no methanol or only small quantities thereof. Ethoxy-crosslinking coating formulations (B) of this kind are likewise preferred.
The coating formulations (B) can be applied to the respective substrate by means of the customary methods, such as spraying, dipping, flow coating, knife coating or else spin coating techniques, for example.
All of the symbols in the above formulae exhibit their definitions in each case independently of one another. In all formulae the silicon atom is tetravalent.
Unless otherwise indicated all amounts and percentages in the examples below are by weight, all pressures are 0.10 MPa (abs.) and all temperatures are 20° C.
EXAMPLE 1
Preparation of Isocyanatomethyltrimethoxysilane:
Starting from chloromethyltrimethoxysilane methylcarbamatomethyltrimethoxysilane was synthesized by a known process (U.S. Pat. No. 3,494,951).
It was pumped in a stream of argon gas into a quartz pyrolysis tube packed with quartz wool. The temperature in the pyrolysis tube was between 420 and 470° C. The crude product was condensed at the end of the heated section by means of a condenser and collected. The colorless liquid was purified by distillation under reduced pressure. The desired product passed overhead at about 88-90° C. (82 mbar) in a purity of more than 99%, while the unreacted carbamate was reisolated at the bottom. It was passed back again directly to the pyrolysis.
In this way, starting from 56.9 g (273 mmol) of methylcarbamatomethyltrimethoxysilane, 33.9 g (191 mmol) of the desired isocyanatomethyltrimethoxysilane were obtained in a purity >97%. This corresponds to a yield of 70% of theory.
EXAMPLE 2
Preparation of the Prepolymers (A) from a Polyol and a Silane of the General Formula (9):
A 250 ml reaction vessel with stirring, cooling and heating facilities was charged with 34.63 g (133.2 mmol) of a polyoxypropylated glycerol having an average molar mass of 260 g/mol, which was dewatered by heating at 100° C. under a membrane pump vacuum for one hour. Subsequently it was cooled to about 60° C. and at this temperature 0.025 g of dibutyltin dilaurate 64.49 g (400 mmol) of isocyanatomethyl trimethoxysilane were added under nitrogen. The temperature during this addition ought not to rise above 85° C. After the end of the addition stirring was continued at a temperature of 60° C. for a further 60 minutes. In the course of this procedure only the isocyanate function of the isocyanatomethyl trimethoxysilane reacted with the OH groups of the polyol. The reaction of the OH functions of the polyol with the trimethoxysilyl groups of the isocyanatomethyl trimethoxysilane, although conceivable in principle, could not be found within the bounds of measurement accuracy (NMR, HPLC-MS).
In the resulting prepolymer mixture no further isocyanate groups were detectable by IR spectroscopy. A clear, transparent mixture of methoxysilane-terminated prepolymers was obtained which had a viscosity of approximately 2.9 Pas at 20° C. Without the addition of a further catalyst this mixture exhibited a skin-forming time of several hours in air, and so could be handled and processed further without problems.
EXAMPLE 3
Preparation of the Prepolymers (A) from a Polyol and a Silane of the General Formula (9):
The procedure described in Example 2 was repeated but with the addition of only 47.27 g (266.7 mmol) of isocyanatomethyltrimethoxysilane. At the stoichiometric ratio between the polyoxypropylated glycerol and the isocyanatomethyltrimethoxysilane it was possible on average for only two of the three OH functions of the polyol to react with an isocyanatomethyltrimethoxysilane to form a urea unit.
In the resulting prepolymer mixture no further isocyanate groups were detectable by IR spectroscopy. A clear, transparent mixture of methoxysilane-terminated prepolymers was obtained which had a viscosity of approximately 20 Pas at 20° C. Without the addition of a further catalyst this mixture exhibited a skin-forming time of several hours in air, and so could be handled and processed further without problems.
EXAMPLE 4
Preparation of the Prepolymers (A) from an OH-terminated Polyurethane and a Silane of the General Formula (9):
A 250 ml reaction vessel with stirring, cooling and heating facilities was charged with 30.00 g (115.4 mmol) of a polyoxypropylated glycerol having an average molar mass of 260 g/mol, which was dewatered by heating at 100° C. under a membrane pump vacuum for one hour. Subsequently it was cooled to about 60° C. and at this temperature 0.03 g of dibutyltin dilaurate and 7.30 g (43.4 mmol) of hexamethylene diisocyanate (HDI) were added under nitrogen. The temperature during this addition ought not to rise above 80° C. After the end of the addition stirring was continued at a temperature of 60° C. for a further 60 minutes.
This mixture was added at 60° C. under a nitrogen atmosphere to 45.97 g (259.4 mmol) of isocyanatomethyltrimethoxysilane; the temperature during the addition again ought to remain below 80° C. The mixture was subsequently stirred at 60° C. for 60 minutes. In the course of this procedure only the isocyanate function of the isocyanatomethyltrimethoxysilane reacted with the OH groups of the polyol. The reaction of the OH functions of the polyol with the trimethoxysilyl groups of the isocyanatomethyltrimethoxysilane, although conceivable in principle, could not be found within the bounds of measurement accuracy (NMR, HPLC-MS).
In the resulting prepolymer mixture no further isocyanate groups were detectable by IR spectroscopy. A clear, transparent mixture was obtained which had a viscosity of approximately 9 Pas at 20° C. Without the addition of a further catalyst this mixture exhibited a skin-forming time of several hours in air, and so could be handled and processed further without problems.
EXAMPLE 5
Preparation of the Prepolymers (A) from an OH-terminated Polyurethane and a Silane of the General Formula (9):
The procedure described in Example 4 was repeated but in the first reaction step no HDI was used; instead, 9.65 g (43.4 mmol) of isophorone diisocyanate (IPDI) were added.
In the resulting prepolymer mixture no further isocyanate groups were detectable by IR spectroscopy. A clear, transparent mixture was obtained which had a viscosity of approximately 43 Pas at 20° C. Without the addition of a further catalyst this mixture exhibited a skin-forming time of several hours in air, and so could be handled and processed further without problems.
EXAMPLE 6
Preparation of Prepolymers (A) having Ethoxysilane Functions from an OH-terminated Polyurethane and a Silane of the General Formula (9):
The procedure described in Example 4 was repeated but in the second reaction step no isocyanatomethyltrimethoxysilane was used; instead, 56.89 g (259.4 mmol) of isocyanatomethyltriethoxysilane were added.
In the resulting prepolymer mixture no further isocyanate groups were detectable by IR spectroscopy. A clear, transparent mixture was obtained which had a viscosity of approximately 30 Pas at 20° C. Without the addition of a further catalyst this mixture exhibited a skin-forming time of several hours in air, and so could be handled and processed further without problems.
COMPARATIVE EXAMPLE 1
Preparation of Noninventive Prepolymers (A) from a Polyol and a γ-isocyanatopropylsilane:
The procedure described in Example 2 was repeated but in this case no isocyanatomethyltrimethoxysilane was used; instead, 82.11 g (400 mmol) of γ-isocyanatopropyltrimethoxysilane were added.
In the resulting prepolymer mixture no further isocyanate groups were detectable by IR spectroscopy. A clear, transparent mixture was obtained which had a viscosity of approximately 1.6 Pas at 20° C. This mixture had virtually no reactivity and can be handled in air for several hours without problems.
COMPARATIVE EXAMPLE 2 (NONINVENTIVE)
Preparation of Prepolymers (A) having from an OH-terminated Polyurethane and a γ-isocyanatopropylsilane:
The procedure described in Example 4 was repeated but in the second reaction step no isocyanatomethyltrimethoxysilane was used; instead, 53.25 g (259.4 mmol) of γ-isocyanatopropyltrimethoxysilane were added.
In the resulting prepolymer mixture no further isocyanate groups were detectable by IR spectroscopy. A clear, transparent mixture was obtained which had a viscosity of approximately 32.32 Pas at 20° C. This mixture had virtually no reactivity and can be handled in air for several hours without problems.
COMPARATIVE EXAMPLE 3 (NONINVENTIVE)
Preparation of Prepolymers (A) from an NCO-terminated Polyurethane and an Aminosilane:
A 250 ml reaction vessel with stirring, cooling and heating facilities was charged with 30 g (70.6 mmol) of a polypropylene glycol having an average molar mass of 425 g/mol, which was dewatered by heating at 100° C. under a membrane pump vacuum for one hour. Subsequently it was cooled to about 50° C. and at this temperature 23.75 g (141.2 mmol) of hexamethylene diisocyanate (HDI) were added under nitrogen at a rate such that the temperature did not climb above 80° C. After the end of the addition stirring was continued at 80° C. for 15 minutes.
The mixture was cooled to about 50° C. and 5 ml of vinyltrimethoxysilane were added as reactive diluent. This was followed by the dropwise addition of 32.95 g (141.2 mmol) of N-cyclohexylaminomethyltrimethoxysilane and subsequent stirring at 80° C. for 60 minutes.
In the resulting prepolymer mixture no further isocyanate groups were detectable by IR spectroscopy. However, in spite of the addition of vinyltrimethoxysilane, the viscosity was already >>100 Pas at 20° C. Also the mixture was of such high reactivity that it could no longer be processed. Coatings could not be produced with this material.
EXAMPLE 6
Production of Coatings:
The prepolymers in the preceding examples were diluted in accordance with the figures in Table 1, where appropriate, with a solvent (2K diluent; Herberts) or with methyltrimethoxysilane (M-TMO), vinyltrimethoxysilane (V-TMO) or tetraethoxysilane (TES), and admixed where appropriate with bis(2-dimethylaminoethyl) ether as a curing catalyst. All of the amounts indicated in Table 1 refer to the amounts by weight that were used.
The finished coating materials were then coated onto aluminum test panels (Pausch Messtechnik) using an Erichsen “Coatmaster 509 MC” film drawer, with a wet film thickness of 120 μm. The resulting coating films were dried at room temperature or at 80° C. in accordance with the indications in Table 1.
The coatings comprising prepolymers (A) from Examples 2-5 were fully cured without exception after 20-30 minutes. A corresponding listing of the coatings produced is found in Table 1. In contrast, from the prepolymers of the noninventive Comparative Examples 1 and 2, irrespective of the drying temperature and the amounts of catalyst used, the coatings obtained were without exception still soft and tacky even after several days.
TABLE 1
Coating
Reactive
Curing
number
Prepolymer
diluent
Solvent
Catalyst
temperature
2-80-
Ex. 2
V-TMO
—
0.5 p
Room
Cat-RT
80 p
20 p
temperature
2-68-
Ex. 2
V-TMO
—
0.5 p
Room
Cat-Rt
68 p
32 p
temperature
2-80-
Ex. 2
V-TMO
—
0.5 p
80° C.
Cat-80
80 p
20 p
2-80L-
Ex. 2
—
2K diluent
0.5 p
Room
Cat-Rt
80 p
20 p
temperature
3-80-
Ex. 3
V-TMO
—
0.5 p
60° C.
Cat-Rt
80 p
20 p
4-60-Rt
Ex. 4
V-TMO
—
—
Room
60 p
40 p
temperature
4-60-60
Ex. 4
V-TMO
—
—
60° C.
60 p
40 p
4-80-
Ex. 4
V-TMO
—
0.5 p
Room
Cat-Rt
80 p
20 p
temperature
4-60-
Ex. 4
V-TMO
—
0.5 p
Room
Cat-Rt
60 p
40 p
temperature
4-60-
Ex. 4
V-TMO
—
0.5 p
60° C.
Cat-60
60 p
40 p
4-60M-
Ex. 4
M-TMO
—
0.5 p
60° C.
Cat-60
60 p
40 p
5-80-
Ex. 5
V-TMO
—
0.5 p
60° C.
Cat-60
80 p
20 p
5-80L-
Ex. 5
—
2K diluent
0.5 p
60° C.
Cat-60
80 p
20 p
6-50-
Ex. 6
TES
Ethanol
0.5 p
Room
Cat-Rt
50 p
25 p
25 p
temperature
p = part(s)
EXAMPLE 7
Determining the Pencil Hardnesses of the Coatings:
The pencil hardnesses of the above-described coatings were performed along the lines of ISO 15184. The hardness test was carried out using an Erichsen scratch hardness tester model 291. In the course of this test pencils with graded levels of hardness were advanced over the test layer at a fixed angle of attack and with a defined load. The film hardness was determined by the two levels of hardness at the boundary between scribe effect and penetration effect.
The results are divided into the following degrees of hardness:
6B-5B-4B-3B-2B-B-HB-F-H-2H-3H-4H-5H-6H-7H-8H-9H softer harder
The corresponding measurements were carried out both with coatings 1 day old and with coatings 2 weeks old. The values obtained are listed in Table 2. In coatings with an age of more than 2 weeks it was no longer possible to detect any changes.
EXAMPLE 8
Determining the Coating Adhesion to Aluminum:
The adhesion of the coatings of the invention to aluminum and steel were performed along the lines of DIN 53151.
The adhesion test was carried out using an Erichsen cross hatch cutter model 295 with a 1 mm blade spacing. Using the cross hatch tester, 2 cuts down to the substrate were made at right angles to one another, to form a cross hatch. Using a manual brush, brushing was carried out 5 times back and forth in a diagonal direction or loose parts were removed with adhesive tape. The processed area was examined using a magnifying glass.
The degree of adhesion was classified by comparison in accordance with different characteristic values:
5B—The cut edges are completely smooth, no segment of the coating has flaked off. 4B—Small fragments of the coating material have flaked off at the points where the cross hatch lines intersect. About 5% 3B—The coating material has flaked off along the cut edges and/or at the intersection points of the cross hatch lines. About 5-15% 2B—The coating material has flaked off in some cases completely or in broad strips along the cut edges. About 15-35% 1B—The coating material has flaked off in some cases completely or in broad strips along the cut edges. About 35 to 65%
The corresponding measurements were carried out both with coatings 1 day old and with coatings 2 weeks old. The values obtained are listed in Table 2. In coatings with an age of more than 2 weeks it was no longer possible to detect any changes.
TABLE 2
Pencil
Pencil
Degree of
Degree of
hardness
hardness
adhesion
adhesion
after 1
after 14
after 1
after 14
Coating number
day
days
day
days
2-80-Cat-RT
3H
5H
5B
5B
2-68-Cat-Rt
3H
4H
5B
5B
2-80-Cat-80
4H
5H
5B
5B
2-80L-Cat-Rt
3H
3H
4B
4B
3-80-Cat-60
3H
3H
5B
5B
4-60-Rt
B
H
5B
5B
4-60-60
F
H
5B
5B
4-80-Cat-Rt
2H
3H
5B
5B
4-60-Cat-Rt
2H
4H
5B
5B
4-60-Cat-60
3H
4H
5B
5B
4-60M-Cat-60
3H
3H
5B
5B
5-80-Cat-60
3H
4H
5B
5B
5-80L-Cat-60
3H
3H
5B
5B
6-50-Cat-Rt
3H
4H
5B
5B
For comparison purposes the pencil hardnesses of a number of commercially available topcoat materials were also measured. In the case of conventional polyurethane OEM coating materials—produced at baking temperatures of 130-150° C.—pencil hardnesses between HB and H were found. In the case of conventional refinish materials—produced at dry temperatures of 80° C.—pencil hardnesses of between B and HB were found. | The invention relates to coating formulations (B) which can be hardened to form coatings having a pencil hardness according to ISO 15184 of at least HB. Said formulations contain prepolymers (A) having alkoxysilane functions of general formula (6) —X—CH 2 —Si(OR)3- x R′ x , wherein R represents hydrogen, an alkyl, cycloalkyl or aryl radical respectively having between 1 and 6 atoms, and the carbon chain can be broken by non-adjacent oxygen, sulphur or NR″ groups; R′ represents an alkyl, cycloalkyl, aryl or arylalkyl radical respectively having between 1 and 12 C atoms, and the carbon chain can be broken by non-adjacent oxygen, sulphur or NR″ groups; R″ represents hydrogen, an alkyl, cycloalkyl, aryl, aminoalkyl, or aspartate acid ester radical; X represents oxygen, sulphur or a group of general formula (20) —O—CO—NR″—; and x represents 0 or 1. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from Japanese Patent Application No. 2006-018742, filed on Jan. 27, 2006, the disclosure of which are incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an ink-droplet ejecting apparatus of an ink-jet type.
[0004] 2. Description of the Related Art
[0005] In hitherto known ink-jet printers, which are ink-droplet ejecting apparatuses, an ink-jet head is used which ejects an ink droplet from a nozzle by changing a volume of a pressure chamber in which an ink is filled, by displacing an electromechanical transducer (transducer element) such as a piezoelectric element by applying a driving pulse signal.
[0006] In the above mentioned ink-jet head, a gradation control in which, a dot diameter is changed is carried out. For forming one dot by a plurality of ink droplets, the driving pulse signal is set such that a plurality of pulses is applied continuously. Moreover, for suppressing an effect on a subsequent ejection of a vibration which is remained (residual vibration) in the ink after the ink droplets are ejected, a stabilizing pulse (canceling pulse) is output after a main pulse for ejecting the ink. For example, an ink jetting apparatus described in U.S. Pat. No. 6,412,923 (corresponds to Japanese Patent Application Laid-open No. 2001-18388), for forming one dot, outputs one after another, an ejecting pulse for a first droplet (a first-droplet ejecting pulse), an ejecting pulse for a second droplet (a second-droplet ejecting pulse), a stabilizing pulse, an ejecting pulse for a third droplet (a third-droplet ejecting pulse), an ejecting pulse for a fourth droplet (a fourth-droplet ejecting pulse), and another stabilizing pulse, and drives these pulses as one set.
[0007] Incidentally, in recent years, speed up of a recording speed (high-speed recording) in the ink-jet printers has been sought. For speed up the recording speed, it is necessary to increase a drive frequency, or in other words, to shorten a driving cycle for forming one dot. When the stabilizing pulse is output not only in between the plurality of ejecting pulses, but also at an end as in the ink jetting apparatus described in U.S. Pat. No. 6,412,923, an overall pulse width (width of all pulses) made of a plurality of pulse signals becomes long. As a result, the driving cycle becomes long, and it is not possible to increase the recording speed.
SUMMARY OF THE INVENTION
[0008] An object of the present invention is to realize an ink-droplet ejecting apparatus which is an ink ejecting apparatus ejecting a plurality of ink droplets for one dot, and which is capable of increasing the drive frequency by making short (shortening) the entire pulse width, and increase the recording speed. It should be noted that parenthesized reference numerals assigned to elements shown below are only examples of the elements, and are not intended to limit the elements.
[0009] According to a first aspect of the present invention, there is provided an ink-droplet ejecting apparatus ( 101 ) which ejects a plurality of ink droplets of an ink to form one dot onto a recording medium (P), including a pressure chamber ( 36 ) in which the ink is filled and a piezoelectric actuator ( 2 ) which faces the pressure chamber ( 36 ), and which changes a volume of the pressure chamber ( 36 ) according to a driving pulse signal for ejecting the ink droplets to form one dot, wherein the driving pulse signal includes a plurality of main pulses (Pm) which are successive with intervals to eject the ink droplets, and a stabilizing pulse (Ps) which is inserted between the main pulses (Pm), and which suppresses a residual vibration of the ink, in the pressure chamber ( 36 ), generated by one of the main pulse (Pm) applied before the stabilizing pulse, and a last main pulse, among the main pulses, is adjusted to suppress the residual vibration of the ink in the pressure chamber ( 36 ), generated by a main pulse applied before the last main pulse, and to prevent vibration generated by the last main pulse from remaining.
[0010] In order to shorten a driving cycle for forming one dot, it is necessary to shorten an one-way propagation time (a time in which a pressure wave generated due to a displacement of the piezoelectric actuator ( 2 ) is propagated in one way through an ink channel) with respect to a pulse width of each of a plurality of pulse signals. As a method for shortening the one-way propagation time, it is possible to shorten ink channels including the pressure chamber ( 36 ). However, in this case, since a length of the pressure chamber ( 36 ) which is affected by the displacement of the piezoelectric actuator ( 2 ) becomes short, it is necessary to increase a driving voltage applied to the piezoelectric actuator ( 2 ) to impart the same ejecting pressure. However, there are limitations on increasing the driving voltage. On the other hand, in the ink-droplet ejecting apparatus ( 101 ) of the present invention, at the time of forming one dot, a plurality of ink droplets is ejected by the plurality of main pulses (Pm), and by inserting the stabilizing pulse (Ps) between the main pulses (Pm), the residual vibration of the ink is suppressed. Furthermore, since the last main pulse among the plurality of main pulses (Pm) suppresses the residual vibration of the ink in the pressure chamber generated by the main pulses which were applied before the last main pulse, and has the pulse width such that no vibration by the last main pulse is remained, it is possible to suppress effectively the residual vibration of the ink by less number of the stabilizing pulses (Ps) as compared to the number of the main pulses (Pm). As a result, it is possible to shorten an overall pulse width, and to drive with a short cycle, thereby enabling to increase the recording speed. Furthermore, since it is not necessary to shorten the ink channel to shorten the driving cycle, it is not necessary to shorten a length of the pressure chamber ( 36 ). Consequently, it is not necessary to increase a driving voltage to impart the same ejecting pressure.
[0011] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, the main pulses (Pm) may include a first main pulse (Pm 1 ), a second main pulse (Pm 2 ), and a third main pulse (Pm 3 ), and the stabilizing pulse (Ps) may be inserted between the first main pulse (Pm 1 ) and the second main pulse (Pm 2 ). In this case, by inserting the stabilizing pulse (Ps) between the first main pulse (Pm 1 ) and the second main pulse (Pm 2 ), it is possible to suppress effectively the residual vibration of the ink, and to shorten the overall pulse width.
[0012] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, the second main pulse (Pm 2 ) and the third main pulse (Pm 3 ) may have a short pulse width with respect to an one-way propagation time AL of a pressure wave generated due to the change in the volume of the pressure chamber ( 36 ). In this case, it is possible to suppress effectively the residual vibration in the ink after ejecting a plurality of ink droplets, and to shorten the overall pulse width.
[0013] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, a pulse width Ts 1 of the stabilizing pulse with respect to an one-way propagation time AL of a pressure wave generated due to the change in the volume of the pressure chamber ( 36 ) may be 0.15 AL≦Ts 1 ≦0.40 AL. In this case, it is possible to suppress effectively the residual vibration in the ink during the ejection, and to suppress the residual vibration after ejection of a plurality of droplets early.
[0014] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, each of the main pulses (Pm 1 , Pm 2 , and Pm 3 ) may have a pulse width sufficiently large for a voltage applied to the actuator ( 2 ) to change from a voltage of one of two predetermined voltages, to be the other voltage of the two predetermined voltages, and the stabilizing pulse (Ps) may have a pulse width which is insufficient for the voltage to change from the one of the two predetermined voltages, to be the other voltage of the two predetermined voltages. In this case, by applying the stabilizing pulse (Ps) immediately after the main pulse (Pm) which is immediately before the stabilizing pulse, it is possible to suppress effectively in a short time the residual vibration of the ink during the ejection. Moreover, it is possible to form favorably one dot by the previous main pulses and the subsequent main pulses.
[0015] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, a pulse width Tm 1 of the first main pulse (Pm 1 ), a pulse width Ts 1 of the stabilizing pulse (Ps), a pulse width Tm 2 of the second main pulse (Pm 2 ), a pulse width Tm 3 of the third main pulse (Pm 3 ), an interval W 1 between a tail end of the first main pulse (Pm 1 ) and a lead end of the stabilizing pulse (Ps), an interval W 2 between a tail end of the stabilizing pulse (Ps) and a lead end of the second main pulse (Pm 2 ), an interval W 3 between a tail end of the second main pulse (Pm 2 ) and a lead end of the third main pulse (Pm 3 ) may satisfy following relationships with respect to an one-way propagation time AL of a pressure wave generated due to the change in the volume of the pressure chamber ( 36 ): 0.7 AL≦Tm 1 ≦1.3 AL, 0.8 AL ≦W 1 ≦2.2 AL, 0.15 AL≦Ts 1 ≦0.4 AL, 0.8 AL≦W 2 ≦1.8 AL, 0.4 AL≦Tm 2 ≦0.8 AL, 0.8 AL≦W 3 ≦1.4 AL, and 0.5 AL≦Tm 3 ≦1.0 AL. Furthermore, the Tm 1 , the Ts 1 , the Tm 2 , the Tm 3 , the W 1 , the W 2 , and the W 3 may satisfy following relationships: 0.9 AL ≦Tm 1 ≦1.05 AL, 1.0 AL≦W 1 ≦2.0 AL, 0.2 AL≦Ts 1 ≦0.35 AL, 1.0 AL≦W 2 ≦1.5 AL, 0.5 AL≦Tm 2 ≦0.75 AL, 0.95 AL≦W 3 ≦1.1 AL, and 0.65 AL≦Tm 3 ≦0.8 AL. In these cases, it is possible to suppress effectively the residual vibration of the ink, and to shorten the overall pulse width. Consequently, it is possible to drive with a short cycle, and to increase the recording speed.
[0016] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, a pulse width Ts 1 of the stabilizing pulse (Ps) with respect to an one-way propagation time AL of a pressure wave generated by the change in the volume of the pressure chamber ( 36 ) may be 1.7 AL≦Ts 1 ≦1.8 AL. In this case, it is possible to suppress effectively the residual vibration of the ink during the ejection, and to suppress the residual vibration after a plurality of droplets is ejected early.
[0017] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, a pulse width Tm 1 of the first main pulse (Pm 1 ), a pulse width of Ts 1 of the stabilizing pulse (Ps), a pulse width Tm 2 of the second main pulse (Pm 2 ), a pulse width Tm 3 of the third main pulse (Pm 3 ), an interval W 1 between a tail end of the first main pulse (Pm 1 ) and a lead end of the stabilizing pulse (Ps), an interval W 2 between a tail end of the stabilizing pulse (Ps) and a lead end of the second main pulse (Pm 2 ), and an interval W 3 between a tail end of the second main pulse (Pm 2 ) and a lead end of the third main pulse (Pm 3 ) satisfy following relationships with respect to an one-way propagation time AL of a pressure wave generated due to the change in the volume of the pressure chamber ( 36 ): 0.95≦Tm 1 ≦1.25 AL, 1.0 AL≦W 1 ≦1.25 AL, 1.7 AL≦Ts 1 ≦1.88 AL, 0.87 AL≦W 2 ≦1.13 AL, 0.5 AL≦Tm 2 ≦0.88 AL, 1.12 AL≦W 3 ≦1.38 AL, and 0.75 AL≦Tm 3 ≦0.88 AL. In this case, it is possible to suppress effectively the residual vibration of the ink, and to shorten the overall pulse width. Consequently, it is possible to drive with a short cycle, and to increase the recording speed.
[0018] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, the volume of the pressure chamber ( 36 ) may be increased at lead ends of the stabilizing pulse (Ps) and the main pulses applied to the actuator ( 2 ), and may be decreased at tail ends of the stabilizing pulse (Ps) and the main pulses (Pm) applied to the actuator ( 2 ).
[0019] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, the actuator ( 2 ) may be a piezoelectric element which is displaced with respect to the pressure chamber ( 36 ), by application of a voltage.
[0020] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, the actuator ( 2 ) may further include a surface electrode ( 48 ) to which the driving pulse signal is applied.
[0021] The ink-droplet ejecting apparatus ( 101 ) of the present invention may further include a signal control unit ( 200 ) which supplies the driving pulse signal to the surface electrode ( 48 ).
[0022] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, the signal control unit ( 200 ) may adjust a pulse width of the stabilizing pulse (Ps) such that the ink droplets are not ejected.
[0023] In the ink-droplet ejecting apparatus ( 101 ) of the present invention, the signal control unit ( 200 ) may adjust a pulse width of the stabilizing pulse (Ps) to be shorter than a pulse width of each of the main pulses (Pm).
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of an ink-jet head used in an ink-droplet ejecting apparatus of the present invention;
[0025] FIG. 2 is an exploded perspective view of the ink-jet head;
[0026] FIG. 3 is a cross-sectional view taken a long a line III-III in FIG. 1 ;
[0027] FIG. 4 is a block diagram of a control unit;
[0028] FIG. 5A is a schematic diagram showing a relationship between a pulse and a voltage in a driving pulse signal;
[0029] FIG. 5B is a schematic diagram showing a practical relationship between the pulse and the voltage in the driving pulse signal;
[0030] FIG. 6 is a schematic diagram showing the driving pulse signal;
[0031] FIG. 7A is a table showing experiment results of the driving pulse signal;
[0032] FIG. 7B is a table showing a continuation of the experiment results shown in FIG. 7A ;
[0033] FIG. 8 is a table showing other experiment results of the driving pulse signal; and
[0034] FIG. 9 is a schematic perspective view of the ink-droplet ejecting apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] A basic embodiment of the present invention will be described below by referring to FIG. 1 to FIG. 9 .
[0036] As shown in FIG. 9 , an ink-droplet ejecting apparatus 101 includes a carriage 102 which is movable in a scanning direction (left and right direction in FIG. 9 ), an ink-jet head 100 which is movable along with the carriage 102 , and which jets an ink onto a recording paper P, paper transporting rollers 103 which transport the recording paper P in a paper feeding direction (paper-surface frontward direction in FIG. 9 ), and the like. Moreover, the ink-jet head 100 , while moving integrally with the carriage 102 in the scanning direction, performs printing on the recording paper P from nozzles 4 arranged on a lower surface thereof (refer to FIG. 3 ). The recording paper P with the printing performed thereon by the ink-jet head 100 is discharged in the paper feeding direction by the paper transporting rollers 103 .
[0037] Next, the ink-jet head 100 will be described below. As shown in FIG. 1 , in the ink-jet head 100 of the present invention, a plate-type piezoelectric actuator 2 is joined to a cavity unit 1 which includes a plurality of plates. A flexible flat cable 3 which connects with a control unit is joined to an upper surface of the plate-type piezoelectric actuator 2 . The ink is ejected in a downward direction in FIG. 3 from nozzles 4 opening on a lower surface of the cavity unit 1 (refer to FIG. 3 ).
[0038] The cavity unit 1 , as shown in FIG. 2 , includes totally eight thin and flat plates namely a nozzle plate 11 , a spacer plate 12 , a damper plate 13 , two manifold plates 14 a and 14 b , a supply plate 15 , a base plate 16 , and a cavity plate 17 , and has a structure in which these plates are stacked in layers to face the surfaces mutually. The plates are mutually joined by adhesive.
[0039] Each of the plates 11 to 17 has a thickness of about 40 μm to 150 μm. The nozzle plate 11 is made of a synthetic resin (material) such as polyimide, and the other plates 12 to 17 are made of 42% nickel alloy steel plate. The nozzles 4 having a substantially small diameter (of about 20 μm) are formed and arranged at substantially small (short) intervals in the nozzle plate 11 . The nozzles 4 are arranged in five rows along a longitudinal direction (X direction) of the nozzle plate 11 .
[0040] Each of the nozzles 4 , as shown in FIG. 3 , is connected to a pressure chamber 36 in the cavity plate 17 , via a through channel 38 which is formed through the spacer plate 12 , the damper plate 13 , the two manifold plates 14 a and 14 b , the supply plate 15 , and the base plate 16 .
[0041] In the cavity plate 17 , the pressure chamber 36 is provided as a plurality of pressure chambers and arranged in five rows parallel to a longitudinal direction (X direction) of the cavity plate 17 as shown in FIG. 2 . Each of the pressure chambers 36 has a long and slender shape in a plan view, and is drilled through the cavity plate 17 such that a longitudinal direction of the pressure chamber 36 is along a short side direction (Y direction) of the cavity plate 17 . Each of the pressure chambers 36 is formed to be long and slender in shape, such that a longer side is along a direction of flow of ink. As shown in FIG. 3 , one end 36 a in the longitudinal direction of each of the pressure chambers 36 communicates with a common ink chamber 7 via a connecting channel 40 and a communicating hole 37 which will be described later, and the through channel 38 is connected to the other end 36 b of the pressure chamber 36 .
[0042] The connecting channel 40 which supplies the ink from the common ink chamber 7 to the pressure chamber 36 is provided as a plurality of the connecting channels 40 to the supply plate 15 which is adjacent to a lower surface of the cavity plate 17 via the base plate 16 . Each of the connecting channels 40 , as shown in FIG. 3 , is provided with an inlet port 40 a through which the ink enters (flows in) from the common ink chamber 7 , an outlet port 40 b which is connected to the pressure chamber 36 via the communicating hole 37 of the base plate 16 , and an aperture 40 c which is positioned between the inlet port 40 a and the outlet port 40 b , and which is formed to make a cross-sectional area small such that a channel resistance is the maximum among the connecting channel 40 . This aperture 40 c is provided for preventing a back flow of the ink to the common ink chamber 7 , and for allowing the ink to advance efficiently toward one of the nozzles 4 , when an ejecting pressure for ejecting the ink from the nozzle 4 is exerted on the pressure chamber 36 .
[0043] In the two manifold plates 14 a and 14 b , the common ink chamber 7 is provided as five common ink chambers 7 , which are long along a longitudinal direction (X direction) of the two manifold plates 14 a and 14 b formed through the plates 14 a and 14 b , to extend along each of the rows of the nozzles 4 . In other words, the two manifold plates 14 a and 14 b are stacked, and an upper surface of the stacked manifold plates 14 a and 14 b is covered by the supply plate 15 and a lower surface thereof is covered by the damper plate 13 , thereby forming a total of five common ink chambers (manifold chambers) 7 . Each of the common ink chambers 7 , in a plan view from a direction of stacking of each plate, extends to be long in a direction of rows of the pressure chambers 36 (direction of the rows of the nozzles 4 ) overlapping with a part of each of the pressure chambers 36 .
[0044] As shown in FIG. 2 and FIG. 3 , on a lower surface side of the damper plate 13 adjacent to a lower surface of the manifold plate 14 a , a plurality of damper chambers 41 completely isolated from the common ink chambers 7 is formed as recesses. A position and a shape of each of the damper chambers 41 coincide with those of each of the common ink chambers 7 as shown in FIG. 2 . A ceiling in the form of a thin plate of the damper plate 13 , on an upper side of the damper chamber 41 is capable of free elastic vibrations both toward the common ink chambers 7 and toward the damper chambers 41 . At the time of ejection of the ink, even when a pressure fluctuation generated in the ink in the pressure chamber 36 is propagated to one of the common ink chamber 7 , since the ceiling is deformed elastically, a damper effect of absorbing and attenuating the pressure fluctuation is shown. Accordingly, it is possible to suppress a cross-talk which is a phenomenon in which the pressure fluctuation in one pressure chamber 36 is propagated to the other pressure chamber 36 .
[0045] Moreover, as shown in FIG. 2 , on an end portion on one short side of the cavity plate 17 , four ink supply ports 42 are formed as ink-inlets to the cavity unit 1 . Four connecting ports 43 are formed in each of the base plate 16 and the supply plate 15 , corresponding to the four ink supply ports 42 vertically. The ink from an ink supply source flows into one end portion in the longitudinal direction of each of the common ink chambers 7 via the ink supply ports 42 and the connecting ports 43 . A filter 20 having filter portions 20 a corresponding to openings of the ink supply ports is adhered to the four ink supply ports 42 by an adhesive, or the like.
[0046] In this embodiment, four ink supply ports 42 and four connecting ports 43 are provided, and on the other hand, five common ink chambers 7 are provided. Only the leftmost ink supply port 42 in FIG. 2 among the ink supply ports 42 is provided to supply the ink to two common ink chambers 7 . Since a frequency of use of a black ink is higher as compared to other color inks, the black ink is supplied to this ink supply port 42 . Inks of yellow, magenta, and cyan colors are supplied separately to the other ink supply ports 42 .
[0047] The piezoelectric actuator 2 has a structure similar to a structure of a hitherto known actuator disclosed in U.S. Pat. No. 6,595,628 (corresponds to Japanese Patent Application Laid-open No. 2002-254634). More specifically, a plurality of flat ceramics layers each having a size to cover all the pressure chambers 36 is stacked in a direction orthogonal to the flat direction, and individual electrodes 46 and common electrodes 47 are sandwiched alternately between the flat ceramics layers. The ceramics layers include a plurality of base piezoelectric layers 51 formed as active portions 54 , in which a portion of each of the ceramics layers sandwiched between the individual electrodes 46 and the common electrodes 47 is polarized in a facing direction of both of the electrodes, top layer 53 on an upper surface of the base piezoelectric layers 51 , and a bottom layer 52 on a lower surface of the base piezoelectric layers 51 . A lower surface of the bottom layer 52 is adhered to the cavity plate 17 by an adhesive. Each of the individual electrodes 46 is arranged to face one of the pressure chambers 36 , and each of the common electrodes 47 is arranged to cover the pressure chambers 36 . By applying a voltage between the individual electrodes 46 and the common electrodes 47 , the ceramics layers sandwiched between the individual electrodes 46 and the common electrodes 47 are deformed in a direction in which volumes of the pressure chambers 36 change.
[0048] A surface electrode 48 (refer to FIG. 1 ) which is electrically connected to the individual electrodes 46 and the common electrodes 47 via an electroconductive material is formed on an upper surface of the top layer 53 , and a flexible flat cable 3 is connected to the surface electrode 48 .
[0049] A structure of a control unit (signal control unit) 200 which generates a driving pulse signal to be applied to each of the electrodes will be described by referring to FIG. 4 . The control unit 200 includes a LSI (large scale integration) chip 60 (refer to FIG. 1 ) which is disposed on the flexible flat cable 3 . The surface electrode 48 corresponding to each of the individual electrodes 46 and the common electrodes 47 is connected to the LSI chip 60 . Moreover, a clock line 61 , a data line 62 , a voltage line 63 , and an earth line 64 extending from a main-body circuit not shown in the diagram are connected to the LSI chip 60 . On the data line 62 , data corresponding to each of the nozzles 4 is supplied serially in synchronization with a clock pulse supplied from the clock line 61 . A plurality of driving waveform data supplied from the main-body circuit via the voltage line 63 is output based on the data described above, and driving pulse signals of voltage suitable for driving the active portions 54 are generated. Accordingly, the driving pulse signals are applied to the surface electrode 48 corresponding to the desired pressure chambers 36 .
[0050] Each of the driving pulse signals, as shown in FIG. 5 A, is formed by a pulse which changes between voltages V 1 and V 2 , and in this embodiment, V 1 is set to be any positive voltage value (for example about 22 V) and V 2 is set to 0 V. Before the ink is ejected, a positive voltage V 1 is applied to all of the individual electrodes 46 , and the common electrodes 47 are connected to ground. Consequently, the active portions 54 between the individual electrodes 46 and the common electrodes 47 are extended, and the volumes of all of the pressure chambers 36 are contracted. When a voltage application to one of the individual electrodes 46 corresponding to one of the pressure chambers 36 to eject the ink is stopped (switched to V 2 ), the active portion 54 regains a contracted state, and the volume of the pressure chamber 36 is increased. As the volume of the pressure chamber 36 is increased, the ink in the pressure chamber 36 is subjected to a negative pressure, and a pressure wave is generated. When the voltage is applied again to the individual electrode 46 at a timing when the pressure of the pressure wave is changed to a positive pressure, a pressure due to the extension of the active portion 54 , and the pressure changed to the positive pressure are superimposed, and an ink droplet is ejected from the nozzle 4 .
[0051] The pulse, as it has been described above, changes between the voltage V 1 and V 2 set in advance. However, in practice, as shown in FIG. 5B , a rise and a fall of the waveform delay. This is because the piezoelectric layer sandwiched between the individual electrode 46 and the common electrode 47 acts as a condenser (C), and this is because there is a resistance (R) in a path from the control unit 200 , which outputs the driving pulse signal, up to the individual electrode 46 . In other words, even when the control unit 200 outputs a rectangular wave as a driving pulse signal, since an integrating circuit is formed by the C and R, the rise and the fall of the pulse delay in the individual electrode 46 . Therefore, by setting a pulse Pm to have a sufficient pulse width Tm including the delay, it is possible to make the voltage (to be) applied to the piezoelectric actuator 2 to change from the voltage V 1 to the voltage V 2 . On the other hand, by setting a pulse Ps to have a short pulse width Ts, the voltage (to be) applied to the piezoelectric actuator 2 does not change from the voltage V 1 to the voltage V 2 . In other words, it is possible to make a change in the voltage (to be) applied to the piezoelectric actuator 2 to be a low voltage difference.
[0052] However, contrary to the description above, as in the actuator disclosed in U.S. Pat. Nos. 6,257,686, 6,386,665, 6,412,896, and 6,416,149 (correspond to Japanese Patent Application Laid-open No. 2001-301161), the piezoelectric actuator of the present invention may be formed such that the volumes of the pressure chambers are increased by applying a voltage to driving electrodes, thereby generating a pressure wave, and by stopping applying the voltage at a point of time at which the pressure wave has reversed, the volumes of the pressure chambers are decreased, thereby ejecting the ink droplets.
[0053] In this ink-droplet ejecting apparatus, in order to carry out a gradational expression, in which a diameter (an area) of a dot formed on a recording medium is changed, a plurality of driving waveform data signals are set in advance such that volume of ink ejected to form one dot can be changed. In a case of controlling the dot diameter, the number of pulses for ejecting ink droplets is increased or decreased, as it has been known. As an example, a driving waveform for ejecting a plurality of ink droplets at the time of forming one dot is shown in FIG. 6 .
[0054] In FIG. 6 , the driving pulse signal is formed by four pulses including three main pulses, and these four pulses are applied in an order of a first main pulse Pm 1 , a stabilizing pulse Ps 1 , a second main pulse Pm 2 , and a third main pulse Pm 3 . Each pulse, as described in FIG. 5A and FIG. 5B , drives the piezoelectric actuator 2 to increase the volume of the pressure chambers 36 and then to decrease the volume of pressure chambers 36 . In a driving pulse signal of this structure, firstly, an ink droplet is ejected by imparting a substantial pressure to the ink in the pressure chamber 36 by the first main pulse Pm 1 , and after ejecting the ink, a residual vibration of the ink in the pressure chamber is suppressed by the stabilizing pulse Ps 1 . Next, ink droplets are again ejected continuously by the second main pulse Pm 2 and the third main pulse Pm 3 . The third main pulse Pm 3 , in addition to (performing) an ejection operation, also has a function to suppress the residual vibration of the ink in the pressure chamber generated due to the ejection. The stabilizing pulse Ps 1 does not eject an ink droplet.
[0055] Results of experiments carried out by inventors of the present invention are shown in FIG. 7A and FIG. 7B . The inventors let a pulse width (time series) of the first main pulse Pm 1 , the stabilizing pulse Ps 1 , the second main pulse Ps 2 , and the third main pulse Ps 3 to be Tm 1 , Ts 1 , Tm 2 , and Tm 3 respectively, and an interval between a tail end of the first main pulse Pm 1 and a lead end of the stabilizing pulse Ps 1 to be W 1 , an interval between a tail end of the stabilizing pulse Ps 1 and a lead end of the second main pulse Pm 2 to be W 2 , and an interval between a tail end of the second main pulse Pm 2 and a lead end of the third main pulse Pm 3 to be W 3 , and carried out experiments by changing these values (unit: μsec). At this time, a series of pulses in FIG. 6 was treated as one set, and this set was driven in a plurality of continuous cycles with a drive frequency of 26 KHz, and stability when the ink droplets were ejected continuously was analyzed.
[0056] In FIG. 7A and FIG. 7B , the “stability” is based on results of observation whether a splash or ink mist was generated in an ejecting state. A state of the highest stability, in which the residual vibration was sufficiently suppressed even when the inks were continuously ejected and there was no splash or ink mist, is indicated as “+”. A state, in which the stability was declined compared to the highest stability but there was no practical problem, is indicated as “±”. A state in which the stability was low and was not practical is indicated as “−”.
[0057] It is possible to express the pulse width and the interval by using a time AL, which the pressure wave generated in the ink in the ink channel including the pressure chamber 36 is propagated one-way in a longitudinal direction in the ink channel (one-way propagation time of the pressure wave generated due to the change in the volume of the pressure chamber). In other words, AL means ½ of a cycle of the pressure fluctuation of the ink. In the ink-jet head 100 used in this experiment, AL is 4 μsec. Consequently, from the results of the experiments, it is possible to indicate appropriate practical ranges of the pulse widths and the intervals taken margins, or the like into consideration.
[0058] 0.7 AL≦Tm 1 ≦1.3 AL (2.8 μsec≦Tm 1 ≦5.2 μsec), 0.8 AL≦W 1 ≦2.2 AL (3.2 μsec≦W 1 ≦8.8 μsec), 0.15 AL≦Ts 1 ≦0.4 AL (0.6 μsec≦Ts 1 ≦1.6 μsec), 0.8 AL≦W 2 ≦1.8 AL (3.2 μsec≦W 2 ≦7.2 μsec), 0.4 AL≦Tm 2 ≦0.8 AL (1.6 μsec≦Tm 2 ≦3.2 μsec), 0.8 AL≦W 3 ≦1.4 AL (3.2 μsec≦W 3 ≦5.6 μsec), 0.5 AL≦Tm 3 ≦1.0 AL (2.0 μsec≦Tm 3 ≦4.0 μsec). Each of the first main pulse Pm 1 , the second main pulse Pm 2 , and the third main pulse Pm 3 , similarly as the pulse Pm in FIG. 5B , has a time sufficient for making the voltage to be applied to the piezoelectric actuator 2 to change from the voltage V 1 to the voltage V 2 . The stabilizing pulse Ps 1 , similarly as the pulse Ps in FIG. 5B , does not make the voltage to be applied to the piezoelectric actuator 2 to change from the voltage V 1 to the voltage V 2 . In other words, the voltage to be applied to the piezoelectric actuator 2 is let to be a low voltage. When the stabilizing pulse Ps 1 is in a range lower than 2 μsec, the voltage does not change completely from the voltage V 1 to the voltage V 2 .
[0059] Moreover, it was revealed that even more preferable results are achieved with driving pulse signals shown in A to E in FIG. 8 , by further experiments based on the experiment results shown in FIG. 7A and FIG. 7B . More optimum ranges shown below were derived, based on the results of A to E in FIG. 8 , the margin, and the like. The ranges shown below are indicated by using the one-way propagation time AL.
[0060] 0.9 AL≦Tm 1 ≦1.05 AL (3.6 μsec≦Tm 1 ≦4.2 μsec), 1.0 AL≦W 1 ≦2.0 AL (4.0 μsec≦W 1 ≦8.0 μsec), 0.2 AL≦Ts 1 ≦0.35 AL (0.8 μsec≦Ts 1 ≦1.4 μsec), 1.0 AL≦W 2 ≦1.5 AL (4.0 μsec≦W 2 ≦6.0 μsec), 0.5 AL≦Tm 2 ≦0.75 AL (2.0 μsec≦Tm 2 ≦3.0 μsec), 0.95 AL≦W 3 ≦1.1 AL (3.8 μsec≦W 3 ≦4.4 μsec), 0.65 AL≦Tm 3 ≦0.8 AL (2.6 μsec≦Tm 3 ≦3.2 μsec). Moreover, by repeating the experiments, it was revealed that favorable results are achieved even with driving pulse signals including stabilizing pulses Ps 1 each having a comparatively longer pulse width, as shown in F to I in FIG. 8 . Based on the results of F to I in FIG. 8 , the margin, and the like, another optimum ranges different from the ranges described above were derived. The ranges shown below are indicated by using the one-way propagation time AL.
[0061] 0.95 AL≦Tm 1 ≦1.25 AL (3.8 μsec≦Tm 1 ≦5.0 μsec), 1.0 AL≦W 1 ≦1.25 AL (4.0 μsec≦W 1 ≦5.0 μsec), 1.7 AL≦Ts 1 ≦1.88 AL (6.8 μsec≦Ts 1 ≦7.5 μsec), 0.87 AL≦W 2 ≦1.13 AL (3.48 μsec≦W 2 ≦4.5 μsec), 0.5 AL≦Tm 2 ≦0.88 AL (2.0 μsec ≦Tm 2 ≦3.5 μsec), 1.12 AL≦W 3 ≦1.38 AL (4.48 μsec≦W 3 ≦5.5 μsec), 0.75 AL≦Tm 3 ≦0.88 AL (3.0 μsec≦Tm 3 ≦3.5 μsec). In the driving pulse signal which has above described optimum ranges, each of the first main pulse Pm 1 , the second main pulse Pm 2 , and the third main pulse Pm 3 is for ejecting an ink droplet by generating a substantial pressure wave in the ink. It was revealed that, among these main pulses, by setting the pulse width of the second main pulse Pm 2 and the third main pulse Pm 3 to be shorter with respect to the one-way propagation time AL, the second main pulse Pm 2 and the third main pulse Pm 3 also have a function of suppressing the residual vibration due to ejection. Moreover, the pulse width of the second main pulse Pm 2 and the third main pulse Pm 3 being short, it is possible to shorten a length of the entire driving pulse signal. Consequently, there is shown an effect that the driving cycle does not become long, while the driving pulse signal ejects a plurality of ink droplets.
[0062] The stabilizing pulse Ps 1 is for suppressing the residual vibration of the ink by being applied in a phase which practically offset the pressure wave in the pressure chamber after ejection of the ink. It is preferable to set this pulse width to be short such that the voltage applied to the piezoelectric actuator 2 does not change from one voltage to the other voltage. Accordingly, it is possible to avoid the length of the entire driving pulse signal being long. Consequently, it is possible to increase the drive frequency, and to increase the recording speed. Moreover, due to the pulse width becoming short, it is possible to suppress a fatigue and a heat generation in the piezoelectric actuator 2 , and to perform a high quality recording operation stably over a long period of time.
[0063] The embodiment described above is an example in which the present invention is applied to an ink-droplet ejecting apparatus of an ink-jet type. However, embodiments to which the present invention is applicable are not restricted to the embodiment described above, and the present invention is also applicable to apparatuses used in various fields such as a medical treatment and analysis, without restricting to the ink-droplet ejecting apparatus. | A driving pulse signal for forming one dot includes a first, a second, and a third main pulses applied intermittently with an intervals to eject an ink droplet, and a stabilizing pulse which is inserted between the main pulses, and which suppresses a residual vibration of an ink in a pressure chamber, generated by a main pulse applied previously. The third main pulse suppresses the residual vibration of the ink generated by the second main pulse, and also a pulse width of the third pulse is adjusted such that there is no residual vibration remained, due to application of the last main pulse. Consequently, it is possible to suppress effectively the residual vibration of the ink by the less number of the stabilizing pulses compared to the number of main pulses. As a result, an overall pulse width becomes short, and it is possible to increase the recording speed. | 1 |
[0001] This application claims priority on U.S. provisional patent application No. 61/866,414, filed on Aug. 15, 2013, entitled FLASHLIGHT AND DEFENSIVE SPRAY APPARATUS, in the name of inventor Michael H. Teig, which application is hereby incorporated herein in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a flashlight and defensive spray apparatus, such as a flashlight and pepper spray combination apparatus. The apparatus includes activation buttons for both the flashlight and the defensive spray component in close proximity to one another so as to facilitate activation of both components by a single thumb or finger of the operator, which may be desirable in emergency situations.
BACKGROUND OF THE INVENTION
[0003] The present invention is particularly intended for use in situations where use of a flashlight and a defensive spray device may both be desirable, such as by police and/or military personal, and such as by civilians in self defense situations. In previous situations, a flashlight and a pepper spray device may each be carried separately by police and/or military personnel, or by civilians in self defense situations. In some prior art devices, a flashlight and a defensive spray component may be integrated into a single device. However, these devices generally include activation buttons positioned on opposite ends of the device, which makes simultaneous activation of the two components impractible or at least difficult. Such prior art devices, therefore, may not provide the effective and efficient defensive action required in emergency situations. There is a need therefore for a device that may allow activation of the two components simultaneously, and preferably, which allows for activation of both components by a single thumb or finger of the operator.
SUMMARY OF THE INVENTION
[0004] The present invention provides a flashlight and defensive spray apparatus, such as a flashlight and pepper spray combination apparatus. The apparatus includes activation buttons for both the flashlight and the defensive spray component in close proximity to one another so as to facilitate activation of both components by a single thumb or finger of the operator, which may be desirable in emergency situations. In particular, the activation buttons may be positioned next to each other in an arrangement such that a single thumb of an operator may activate or deactivate both buttons individually without moving their thumb on the device. More particularly, the operator may rock or pivot the end of their thumb on the two buttons to activate or deactivate either of the two buttons as desired, without loosening or adjusting their grip on the device. This time efficient and effective arrangement of the activation buttons of the present device may mean the difference between life and death for the operator in hostile situations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a front isometric view of one example embodiment of a flashlight spray apparatus.
[0006] FIG. 2 is a front view of the apparatus of FIG. 1 .
[0007] FIG. 3 is a back view of the apparatus of FIG. 1 .
[0008] FIG. 4 is a side view of the apparatus of FIG. 1 .
[0009] FIG. 5 is an exploded side view of the apparatus of FIG. 1 .
[0010] FIG. 6 is a detailed cross-sectional side view of the apparatus of FIG. 1 .
[0011] FIG. 7 is a front isometric view of a second example embodiment of a flashlight spray apparatus.
[0012] FIG. 8 is a back view of the apparatus of FIG. 7 .
[0013] FIG. 9 is a detailed cross-sectional side view of another example embodiment of a flashlight spray apparatus.
[0014] FIG. 10 is a detailed cross-sectional side view of yet another example embodiment of a flashlight spray apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] The invention discloses a combination flashlight and defensive spray device that includes two activation buttons arranged to allow individual activation or deactivation by movement of a single thumb of an operator, without requiring shifting of the operators hand during use.
[0016] FIG. 1 is a front isometric view of a first example embodiment of a flashlight spray apparatus 10 . The flashlight/pepper spray combination apparatus 10 incorporates a self-defense flashlight 12 with concealed chemical self-defense spray 14 . The spray canister 16 is positioned parallel to the battery compartment 18 of the flashlight with the actuator 20 of the spray being positioned parallel to and slightly above the light switch 22 . The light switch 22 is an “end switch” and is positioned on the butt end off the flashlight, opposite the end where the LED 24 is located. Both the spray switch 20 and the light switch 22 are operated with a single thumb of the operator.
[0017] The spray actuator 20 is located behind and slightly above the button 22 on the light and is accessed by inserting the thumb over the top of the light switch and resting it on the spray button 20 or “actuator.” The relationship of the spray actuator 20 and the lights multi-mode switch button 22 , as well as the actuation pressure of each, has been designed to allow the operator to either move his thumb easily from one button to the other or the operator (user) can position his thumb on the spray actuator to enable an immediate self-defense response without having to move his thumb. Thus the thumb can be kept in the spray position while still being able to operate the multi-mode light button 22 by simply arching his thumb but not moving it from its position above the spray actuator 20 . This simple action causes or allows the upper knuckle of the thumb to press down on the light button without applying pressure on the spray button.
[0018] A hood 26 over the spray button 20 is designed to prevent accidental or unintentional actuation of the spray by foreign objects. Additionally, a safety tab can be inserted under the actuator between the actuator button 20 and the top of the canister to prevent actuation while not in use.
[0019] The light function provides a unique sequencing feature with a “panic” mode that, regardless of the last mode the light was in, when initially turned on, it assumes a threat and goes into a high intensity blinding strobe designed to surprise and disorient the attacker. The user can bypass the panic mode and go to constant high beam by pushing the switch 22 down twice within approximately one-second. This can be done whether in momentary or click mode. In momentary mode, the user only has to push the button 22 partially down without clicking it. If left in that position for more that a second, it will go off when released. If left in that position for less than a second and pushed down again, partially or all the way, it will go to the next mode. There are four modes that include panic strobe, High, Low and SOS.
[0020] FIG. 2 is a front view of apparatus 10 of FIG. 1 .
[0021] FIG. 3 is a back view of apparatus 10 of FIG. 1 .
[0022] FIG. 4 is a side view of apparatus 10 of FIG. 1 .
[0023] FIG. 5 is an exploded side view of apparatus 10 of FIG. 1 .
[0024] FIG. 6 is a detailed cross-sectional side view of apparatus 10 of FIG. 1 .
[0025] FIG. 7 is a front isometric view of a second example embodiment of a flashlight spray apparatus 10 . In this embodiment the shape of the outer casing of apparatus 10 is slightly modified from the embodiment shown in FIG. 1 . The functional parts of the apparatus remain the same as in FIG. 1 , however, this embodiment includes a more rounded, less angular external design.
[0026] FIG. 8 is a back view of the apparatus of FIG. 7 .
[0027] FIG. 9 is a detailed cross-sectional side view of another example embodiment of a flashlight spray apparatus 10 . This third embodiment uses either a sleeve 28 ( FIG. 10 ) or two strap-like fasteners 30 ( FIG. 9 ) to secure the pepper spray portion 14 of the apparatus 10 to a variety of third party flashlights 32 that may vary slightly in size but are close to the size of the flashlight compartment 12 in the apparatus shown in FIGS. 1 and 2 . This is done by using either a rubber sleeve 28 , or bands 30 , that slips over the pepper spray portion which houses the pepper spray and the pepper spray actuator, and secures it to the third party flashlight, holding them securely together in a position that the combination may be used essentially the same as the apparatus shown in FIGS. 1 and 2 . The two fasteners 28 and/or 30 may be made of a variety of materials including plastic, rubber, leather, vinyl or any other material that may effectively secure the pepper spray compartment 16 to the third party flashlight 32 .
[0028] FIG. 10 is a detailed cross-sectional side view of yet another example embodiment of a flashlight spray apparatus utilizing a sleeve 28 .
[0029] Because the embodiments shown in FIGS. 9 and 10 utilize a typical tactical flashlight design with an end switch rather than a side switch and add the elements necessary to convert it to a self-defense device with concealed pepper spray or other chemical agents, it is adaptable to all similar lights and will be manufactured and sold also as a modification to other tactical lights to convert them to the type of apparatus shown in FIG. 1 .
[0030] FIG. 10 shows first activation button 40 and second activation button 42 both positioned on the same end 36 of the body of apparatus 10 such that both buttons may simultaneously be depressed by an operator's thumb 38 to simultaneously activate the spray and light functions of apparatus 10 . Buttons 40 and 42 may be referred to as positioned adjacent to one another, positioned on the same end of the body of apparatus 10 , positioned substantially in the same plane 44 , positioned next to each other, and/or positioned in a single operational or activation location, which individually all mean that an operator may activate two distinct functions of apparatus 10 without shifting their hand on the device 10 . In other words, thumb 38 of an operator can activate both buttons simultaneously or individually without shifting the position of their thumb 38 on apparatus 10 , which may be very important in stressful defensive situations.
[0031] In the above description numerous details have been set forth in order to provide a more through understanding of the present invention. It will be obvious, however, to one skilled in the art that the present invention may be practiced using other equivalent designs. | A flashlight and defensive spray apparatus, such as a flashlight and pepper spray combination apparatus, includes activation buttons for both the flashlight and the defensive spray component in close proximity to one another so as to facilitate activation of both components by a single thumb or finger of the operator, which may be desirable in emergency situations. | 5 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to a method for handling handovers in a cellular radio system where a mobile terminal, having a connection to at least one first base station, is about to establish a new connection to a second base station.
[0002] It also relates to a device for handling handovers in a cellular radio system where a mobile terminal, having a connection to at least one first base station, is about to establish a new connection to a second base station, the at least two base stations being connected to the network via at least one node.
[0003] Furthermore it relates to a node in a network in a cellular radio system, the node being connectable to at least one base station, which can connect to and receive branches of signals from at least one mobile terminal.
[0004] The invention also relates to a mobile communication network comprising base stations.
RELATED ART
[0005] Code Division Multiple Access (CDMA) is a multiple access method that is based on spread spectrum technique. It is applied in cellular radio systems in addition to the FDMA (Frequency Division Multiple Access) and TDMA (Time Division Multiple Access) methods. In the CDMA method the narrow-band data signal from the user is multiplied to a relatively wide band by a spreading code. The CDMA technique enables all users to transmit on the same frequency simultaneously. A separate spreading code is used for each connection between a base station and a mobile station, and the signals of the different users can be distinguished from one another in the receivers on the basis of the spreading code of each user. The data signal is restored in the receiver to the original band by multiplying it again by the same spreading code that was used during the transmission. To avoid the signals disturbing each other the codes allocated to the downlinks (radio links from base station to mobile terminal) from each base station are typically, mutually orthogonal.
[0006] The number of orthogonal codes is however limited and the number is dependent on the data rate. When the average used data rate increases in a cell the number of available orthogonal codes decreases.
[0007] Thus, a base station has limited resources regarding codes that can be used in the downlink direction. The base station may also have limited resources regarding the total amount of transmitted power and regarding the signal processing resources required for transmitting and receiving.
[0008] When a user enters a new cell in a CDMA-system the handover from the first base station to the base station of the entered cell can be performed in, in principal, two ways. The normal way in CDMA-systems is a soft handover where the mobile station stays on the original frequency and adds towards the new base station another branch, which uses the same frequency as the original branch. During soft handover the mobile station keeps the “old” branch/branches so that it has at least two branches to different base stations. Another way to enter a new cell is via hard handover. This means that the branch used before the handover is dropped when a new branch to a new base station is added. The new branch can have a different frequency from the first used branch, but the frequencies can also be the same. Thus a frequency shift is possible for the hard handover.
[0009] In the co-pending US-application with application number U.S. Ser. No. 09/461.030 soft and hard handover in a CDMA-system is described.
[0010] One problem with the hard handover is that during the shift to a new branch and maybe to a new frequency, the quality of the connection may decrease or the connection may even be broken.
SUMMARY
[0011] The object of the invention is to increase the reliability of connections in a cellular radio system.
[0012] This is achieved by a method of the initially defined kind, comprising the steps described hereafter. The first step is determining a priority value indicative of a priority assigned to the connection between the mobile terminal and the at least one first base station. The next step is deciding from the priority value which type of handover the mobile terminal should be exposed to and then the decided type of handover is performed.
[0013] It is also achieved by a device of the initially defined kind characterised in that the device is arranged to be placed in the node. The device comprises determining means for determining a priority value indicative of a priority assigned to the at least one connection between the mobile terminal and the at least one first base station. It comprises also controlling means, connected to the determining means, adapted to make a decision according to the determined priority value about which type of handover this connection should be exposed to and to perform the handover.
[0014] Furthermore it is achieved by a node of the initially defined kind, characterised in that it comprises such a device.
[0015] It is also achieved by a mobile communication network of the initially defined kind, characterised in that the base stations is connected to the network through such a node.
[0016] This method, device, node and mobile communication network ensure that there will not be any unnecessary quality degradations of the connections and that high priority connections not will be exposed to hard handovers if connections with lower priority instead could be exposed to hard handovers.
[0017] Preferably the method comprises monitoring by monitoring means the frequencies used for the connections between the mobile terminals and the base stations to determine when there is, or is about to be, a congestion in a used frequency. Suitably it comprises also deciding, in the controlling means connected to the monitoring means, from the information about the status of the frequencies together with the information about the priority value of the connection which type of handover the mobile terminal should be exposed to. Hereby the statuses of the different frequencies are considered when deciding about type of handover.
[0018] Suitably the determining step is performed in a node connected to the base stations.
[0019] The monitoring of the frequencies, the deciding of which type of handover and the performing of the handover are preferably controlled from the node.
[0020] The method comprises preferably sending, from a Home Location Register (HLR) connected to the node, information about which type of customer the at least one concerned subscriber is. This information is suitably received in the node in receiving means and the information is preferable used in the determining of a value indicative of the priority assigned to the at least one subscriber. Thus the determining means suitably is connected to the receiving means.
[0021] Preferable the method comprises using information about which type of service the subscriber uses in the determining of a value indicative of the priority assigned to the at least one connection.
[0022] The deciding step could comprise deciding in the controlling means whether the handover should be a hard or soft handover.
[0023] Preferably the node is a Radio Network Controller (RNC).
[0024] Suitably the network is adapted to operate according to the CDMA technique.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 shows schematically a mobile terminal, which is in contact with three base stations.
[0026] [0026]FIG. 2 shows schematically the mobile terminal in FIG. 1.
[0027] [0027]FIG. 3 shows a mobile terminal connected to three base stations, which are connected to a network.
DETAILED DESCRIPTION OF EMBODIMENTS
[0028] In a CDMA-system mobile terminals receive and combine branches from many base stations at the same time. This is possible since different base stations use the same frequency for their branches to one and the same mobile terminal. In the following description each base station corresponds to one cell.
[0029] [0029]FIG. 1 shows schematically a mobile terminal 1 , which has established radio links to a first, a second and a third base station 3 , 5 and 7 , respectively. There is also shown a fourth, a fifth and a sixth base station 9 , 11 and 13 , respectively, located relatively near the mobile terminal, but not having established radio links to the mobile terminal 1 .
[0030] The mobile terminal 1 thus has an active set 15 of base stations 3 , 5 , 7 from which the mobile terminal 1 receives radio signals and a monitored set 17 of base stations 9 , 11 , 13 from which the mobile terminal 1 should be ready to receive radio signals. The mobile terminal 1 receives a pilot signal from all base stations in a region around the mobile terminal, this region comprising both the active set 15 and the monitored set 17 .
[0031] Pilot signals are used in the CDMA system to estimate the quality of the downlinks from the base stations. A pilot signal is a data-unmodulated spreading-coded signal, which is continuously transmitted by each base station to its coverage area. A rake receiver (not shown) in a mobile terminal indicates when it has received power on a specific code corresponding to a pilot signal from a specific base station. The mobile terminal receives these pilot signals from the base stations and reports measurement values to a node, RNC (Radio Network Controller), in the network connected to the base stations. The node uses the pilot signal measurements to instruct the mobile terminal to receive or not receive downlinks from the different base stations. The pilot signals giving the strongest measurement values form the active set 15 of the base stations 3 , 5 , 7 in the mobile terminal. From the base stations 9 , 11 , 13 comprised in the monitored set 17 the mobile terminal 1 receives nothing but these pilot signals.
[0032] The rake receiver in each mobile terminal continuously measures pilot signals. Each rake receiver maintains a measurement list of the base stations and the corresponding spreading codes of the pilot signals that are situated near the mobile terminal and that are possible candidates for handover or connection establishment. The base stations on the measurement list form a group of candidates, which may become members of the active set.
[0033] When a mobile terminal moves, the measurement list is updated. The rake receiver receives radio signals from a new base station when the RNC instructs the mobile terminal to do so. The instructions from the RNC are based on the strengths of the pilot signals received in the mobile terminal.
[0034] The mobile terminal repeatedly sends information to the base stations about, for example, how strong the different received pilot signals are. This information could be sent periodically or only when a change in the signal has been recorded. The information is forwarded from the base stations to the RNC. The RNC also knows the sending effect of the pilot signals and thus it knows the attenuation between the base station and the mobile terminal for each downlink (radio links from the base stations to the mobile terminals). It can thus from this information derive which downlinks that are most important in the different connections.
[0035] Accordingly, in FIG. 1, the base stations 3 , 5 , 7 in the active set 15 are located “close” to the mobile terminal 1 and the base stations 9 , 11 , 13 in the monitored set 17 are located “next” to the active set base stations. This “close” and “next” corresponds rather to the needed power for a good connection than to a geographical distance. When the mobile terminal moves some of the monitored set base stations 9 , 11 , 13 are moved from the monitored set 17 to the active set 15 and vice versa. Both sets 15 , 17 are thus currently updated as the mobile 1 moves between the cells of the base stations.
[0036] [0036]FIG. 2 shows schematically the mobile terminal 1 in FIG. 1. The mobile terminal 1 comprises a rake receiver 20 . A similar device is placed in all mobile terminals and also in each base station. The rake receiver 20 receives radio signals 22 , 24 and 26 , respectively, from the base stations 3 , 5 and 7 , respectively, (see FIG. 1) that are comprised in the above-mentioned active set 15 . These signals 22 , 24 , 26 have each different codes. The rake receiver 20 decodes the signals 22 , 24 , 26 and combines them into one signal 28 . The fact that the end signal 28 is combined from many signals 22 , 24 , 26 gives an increased signal quality thanks to diversity. The signal from one base station is also divided into many radio paths during the transmission between the base station and the rake receiver due to reflections. The different radio paths will propagate along different paths and thus they will arrive at the rake receiver 20 in different times. The rake receiver 20 combines also these radio paths and quality in the connection is once again gained because of diversity.
[0037] As mentioned above there are in principal two ways for handover in a CDMA system. The normal way in CDMA is soft handover. During a soft handover the mobile terminal connects to a new base station without dropping the previous connections. The mobile terminal is thus connected to more than one base station at the same time. The other way is hard handover where the first branch is dropped when a new is added to the new base station. The hard handover normally involves a frequency shift. The soft and hard handovers can also be combined in different ways. For example a handover could be performed as a soft handover but almost immediately after the soft handover the first branch is removed and the new branch is moved to another frequency. These combined methods will hereafter be included in the expression hard handover.
[0038] A hard handover is sometimes needed when the first used frequency is, or is about to be, congested in the cell the mobile station is about to leave. A hard handover with a frequency shift is needed when the first used frequency is, or is about to be, congested in the cell the mobile terminal is about to enter.
[0039] The decisions of when a mobile terminal should make a handover and if the mobile terminal that should make a hard or soft handover are taken by the RNC connected to the base stations. The factors that are considered for these decisions are for example how many base stations the different mobile terminals are connected to, reported noise level from the mobile terminals and maybe the resource situation in the different base stations.
[0040] According to the invention different types of connections should be treated differently. The different connections should be divided into different priority groups. The high priority connections should not be exposed to hard handovers if a low priority connection instead could make a hard handover since there is a risk of a decreased quality during the hard handover.
[0041] The division into different priority groups could be based on different facts. One possibility is to divide the subscribers into different priority groups depending on how good customers they are or how much they pay, i.e. which category of customer they belong to. The priority division could also be based on how the different connections, depending on which type of service they are using, are influenced by a hard handover or, also the other way around, how the system is influenced by a hard handover of a certain service. This means that different types of services are placed in different priority groups. Packet users should for example be placed in a low priority group since they will not experience any extra disturbance due to a hard handover. It is also possible to decide that all connections using a certain service, i.e. packet users, should make hard handovers even if soft handover is the normal way for handover in CDMA. Statistics of how frequently the subscriber uses different services may also be used for the division into priority groups. The division may also be based on all these mentioned alternatives, or maybe on some of them.
[0042] [0042]FIG. 3 shows a mobile terminal 40 in contact with a first base station 42 . A second and a third base station 41 and 43 respectively are shown in the vicinity of the mobile terminal. The base stations 41 , 42 , 43 are all connected to a node 45 , called RNC, in the network. A Home Location Register (=HLR) 47 located higher in the network is also shown. The RNC 45 comprises, according to the invention, a device 57 , here called a priority device.
[0043] In the HLR 47 information about every subscriber is stored. This information comprises, according to the invention, which category of customer each subscriber belongs to. There could for example be four categories of customers where the different categories correspond to how the subscribers are prioritised.
[0044] When a mobile terminal for the first time enters a cell served by one of the base stations 41 , 42 , 43 connected to the RNC 45 information about which category of customers this subscriber belongs to is sent by sending means 48 in the HLR 47 to the RNC 45 . A receiving means 49 in the priority device 57 in the RNC 45 receives this information. In a determining means 50 , connected to the receiving means 49 , this information about category of customer and/or information about which type of service the subscriber uses is combined to a resulting value indicative of the priority assigned to the connection. This value could either be a specific value for each connection or one of a predefined number of values corresponding to different priority groups. In a first embodiment of the invention this resulting value is based on a combination of which type of service the subscriber uses and which type of customer it is. In a second embodiment only the information from the HLR 47 about the type of customer is used and in a third embodiment of the invention only the information about which type of service the subscriber uses is used. Also other kind of information could be used to make the prioritisation. For example stored statistics of the subscribers, such as how frequently they use the service, could be used.
[0045] The RNC 45 monitors, continuously or repeatedly, by monitoring means 51 the frequencies used by the base stations 41 , 42 , 43 connected to this RNC 45 to be able to recognise when congestion occurs, or is about to occur, in a frequency. When the mobile terminal 40 is going to establish a new connection to for example the second base station 41 and a handover is to be done, information from the monitoring means 51 about the status of the frequencies together with information from the determining means 50 about the priority of the connection is used in a controlling means 53 , connected to the monitoring means 51 and the determining means 50 , for making a decision about whether this mobile terminal 40 should make a hard or soft handover to the second base station 41 . A hard handover should be done if the priority of the connection is low and/or the currently used frequency for the connection is, or is about to be, congested in the first and/or second base station. The controlling means 53 then performs the handover according to the decision.
[0046] The receiving means 49 , the determining means 50 , the monitoring means 51 and the controlling means 53 are all comprised in the priority device 57 in the RNC 45 . | A method and a system for handling handovers in a cellular radio system where a mobile terminal ( 40 ), having a connection to at least one first base station ( 42 ), is about to establish a new connection to a second base station ( 41 ).
According to the invention the method comprises the steps:
determining a priority value indicative of a priority assigned to the connection between the mobile terminal ( 40 ) and the at least one first base station ( 42 );
deciding from the priority value which type of handover the mobile terminal ( 40 ) should be exposed to;
performing the decided handover. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a concentration gradient test reagent kit and a testing method for use in bacterial/fungal drug susceptibility testing and falls within the technical field of drug assay apparatuses and assay methods.
[0003] 2. Description of Related Art
[0004] Common methods for use in performing susceptibility testing on antimicrobial drugs include a paper method, a dilution method, and an E-test method. The paper method for performing drug susceptibility testing is a qualitative testing method which is convenient but provides little information to compare and choose between susceptible drugs. The dilution method includes broth dilution method and agar dilution method. The broth method includes the tube dilution method and the microdilution method. The tube dilution method often requires intricate operations and thus not suitable in voluminous or batch tests. Although the microdilution method requires smaller amounts of reagents and specimens than the tube dilution method, the microdilution method is not only more complicated but also less clear in result reading than the tube dilution method. The agar dilution method is more suitable for tests involve large amounts of specimen, but is not suitable for occasional tests of sporadic clinical specimen, requires the preparation of a drug-containing culture plate and at the time of testing, and quite cumbersome. Although the E-test method has certain advantages of both the paper method and the dilution method, e.g., the convenience of the paper method, and the ability to determine MIC of the dilution method, it is expensive and not as accurate in terms of MIC results. Thus, common methods for performing antimicrobial drug susceptibility testing according to the prior art no longer meet people's needs.
SUMMARY OF THE INVENTION
[0005] The objective of the present invention is to provide a concentration gradient test reagent kit and a testing method for use in bacterial/fungal drug susceptibility testing that meet current clinical needs, is applicable to both single specimen tests as well as batch specimen operations, is accurate and convenient, and allows different antibiotics and agar to be premade and freely combined as needed, and enables qualitative and quantitative determination of MIC, thereby addressing an otherwise unattended issue in this technical field, meeting the market's urgent needs, and overcoming the drawbacks of the prior art.
[0006] The present invention is implemented by a technical solution described below.
[0007] A concentration gradient test reagent kit for use in bacterial/fungal drug susceptibility testing is provided. The reagent kit comprises a test strip unit(s). A test strip unit comprises a strip-shaped culture medium container and a strip-shaped drug container. The culture medium container and the drug container comprise axially-arranged culture medium cells and drug cells, respectively. The culture medium cells are insertable into the corresponding drug cells. The culture medium cells each have therein a pre-fabricated solid culture medium. The inner wall of the bottom of each drug cell has a convex surface, on which an antimicrobial drug is disposed.
[0008] In certain specific embodiments, a mid-section of the inner wall of each culture medium cell is defined with a waist line which is a protrusion projecting in the direction of a central axis.
[0009] In certain specific embodiments, the concentration gradient test reagent kit further comprises a box-shaped culture holder which has a hollowed-out channel(s) with which the test strip unit(s) can be engaged and fitted.
[0010] In certain specific embodiments, sheet-shaped, separable plastic films are disposed on the top and bottom of the culture medium container, respectively.
[0011] In certain specific embodiments, a control mark panel is disposed on one side of the box-shaped culture holder.
[0012] In certain specific embodiments, the control mark panel comprises a positive control mark, a negative control mark, and numeric graduation marks.
[0013] The present invention further provides a method of manufacturing a concentration gradient test reagent kit for use in bacterial/fungal drug susceptibility testing, characterized in that the method comprises the steps of:
(1) manufacturing a drug container, a drug container lid, a body of a culture medium container, a bottom of a culture medium container, a box-shaped culture holder, and a culture medium package case by compression molding; (2) sterilizing the drug container, the drug container lid, the body of the culture medium container, and the bottom of the culture medium container; (3) in a relatively sterile environment, introducing an amount of an antimicrobial drug solution into cells of the drug container, and vacuum drying the drug container cells; (4) adhering a plastic film to the bottom of the culture medium container; (5) using a liquid culture medium as a solute to prepare a sol of a predetermined concentration in a sterile condition, and introducing the sol into cells of the culture medium container, solidifying the sol so as to form a solid culture medium, and sealing a plastic film on the upper surface of the culture medium container; (6) in a sterile environment, packaging the drug container and the drug container lid in a plastic bag or plastic box; (7) placing a plurality of the culture medium containers in a culture medium package case; and (8) sterilizing the plastic box containing the drug container and drug container lid, and the packaged case containing culture medium containers with cobalt-60 irradiation.
[0022] The beneficial technical effects of the present invention are as follows: the drug container and the culture medium container are stable, easy to preserve and transport, and can be included into a reagent kit for long-term storage; the kit allows for easy and convenient testing operations; testing results are easy to observe and interpret; the kit can be used in drug susceptibility testing on slow-growing fungi and anaerobic bacteria; testing procedures and waste processing is biologically very safe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an exploded view of a test reagent kit of the present invention;
[0024] FIG. 2 is a schematic view of the operation steps for a culture medium container and plastic films;
[0025] FIG. 3 is a partial enlarged view of cells after the culture medium container has been inserted into a drug container (i.e., after a test strip unit has been assembled); and
[0026] FIG. 4 is a partial enlarged view of the drug container.
DETAILED DESCRIPTION OF EMBODIMENTS
[0027] Embodiments of the present invention are described below to help the general public understand the present invention, but the specific embodiments described herein by the applicant cannot and should not be regarded as limitations on the technical solution of the present invention, as any changes made to the definitions of technical features or components of the present invention and/or any alterations made to the overall structure that are merely formal but non-substantive should be deemed to be within the scope of protection defined by the technical solution of the present invention.
[0028] References in the drawings include: drug container lid 1 , top plastic film 2 , culture medium container 3 , bottom plastic film 4 , drug container 5 , positive control mark 6 , numeric graduation marks 7 , negative control mark 8 , box-shaped culture holder 9 , culture medium 10 , waist line 11 , antimicrobial drug 12 , convex surface 13 , drug concentration gradient 14 , drug name mark 15 , venting groove 16 .
[0029] A concentration gradient test reagent kit for use in bacterial/fungal drug susceptibility testing is provided. The test reagent kit comprises a test strip unit. The test strip unit comprises a strip-shaped culture medium container 3 and a drug container 5 . The culture medium container 3 and the drug container 5 comprise axially-arranged culture medium cells and drug cells, respectively. The culture medium cells are insertable into the corresponding drug cells. The test reagent kit further comprises a box-shaped culture holder 9 . The box-shaped culture holder 9 has a hollowed-out channels with which the test strip units can be engaged and fitted. The test reagent kit has thereon a drug container lid 1 . A control mark panel is disposed on one side of the box-shaped culture holder 9 . The control mark panel comprises a positive control mark 6 , a negative control mark 8 , and numeric graduation marks 7 . Each test strip unit measures an MIC of a drug. The test strip units can be grouped as needed and disposed in the box-shaped culture holder 9 , and placed in a certain culture environment, where the MIC of a test strain can be measured with respect to a multitude of drugs. The box-shaped culture holder 9 is a box-shaped object with a rectangular profile. The test strip units, each of which comprises a drug container 5 and a culture medium container 3 , can be transversely placed on the culture holder 9 . Each box-shaped culture holder 9 can accommodate 5 test strips. A lateral periphery of the upper surface of the culture holder 9 is marked with signs “+”, “−” and numerals. A foolproof design is included at longitudinal ends of the upper surface of the box-shaped culture holder 9 , such that the test strip units can be inserted into the box-shaped culture holder 9 only in a specific direction. The box-shaped culture holder 9 may be reusable.
[0030] In this embodiment, the cells of culture medium container 3 and drug container 5 are arranged in a row and form cell groups, where neighboring cells are closely juxtaposed. Certainly, in other embodiments, the number and configuration of the cells may be varied as needed to meet the needs in different situations. Therefore, this embodiment is not restrictive of the present invention. Sheet-shaped, separable plastic films are disposed on the top and bottom of the culture medium container 3 , respectively. The plastic films include a top plastic film 2 and a bottom plastic film 4 . The top and bottom plastic films 2 , 4 are fixed to the upper and lower surfaces of the culture medium container 3 by adhesion, respectively. The culture medium cells each have therein a pre-fabricated solid culture medium. The inner wall of the bottom of each drug cell includes a convex surface. An antimicrobial drug is disposed on the convex surface. A mid-section of the inner wall of each culture medium cell is defined with a waist line 11 which is a protrusion projecting in the direction of a central axis.
[0031] In this embodiment, the drug container 5 is technically characterized in that the drug container cells each hold a drug with different concentrations which have been pre-calculated and prepared in advance, and that the drug of different concentrations is physically separated. The bottom of each drug container cell has a convex surface and holds a dry antimicrobial drug. The amounts of the antimicrobial drug in the consecutively-arranged drug container cells are arranged in an ascending (or descending) order. The inner wall of each cell includes a plurality of venting grooves 16 such that, upon insertion of the culture medium container 3 , air can be pushed out through the venting grooves 16 . A drug name mark 15 is included at one end of the drug container 5 . The drug name mark 15 bears colors and alphabets which not only indicate the name of the drug contained in the drug container 5 but also ensure that a user can correctly discern the direction of the drug concentration gradient. Antibiotics of different types are denoted by different chromatic system signs, respectively. Different antibiotics of the same type are denoted by different color signs of the same chromatic system, respectively.
[0032] In this embodiment, the culture medium container 3 is technically characterized in that: the culture medium container 3 comprises independent culture medium cells; the culture medium cells each have therein a pre-fabricated solid culture medium (which mainly comprises agar); the bottom of each culture medium cell can be removed; the inner wall of each culture medium cell is configured with waist line 11 which prevents the agar from coming off when the bottom is removed; after the bottom has been removed, the cells of the culture medium container can be inserted into the cells of the drug container, respectively; and, due to the design of the culture medium container, the pressure generated by the inward sliding of the drug container lid 1 causes the agar culture medium to come into contact with the antimicrobial drug disposed at the bottom of the drug container cells while maintaining the breathability of the culture medium. The culture medium container 3 is preloaded with a culture medium. The volume of the culture medium container 3 is designed to allow the antibiotic disposed in the drug cell to attain a predetermined concentration when dissolved. The composition of the culture medium can be selected to be suitable for different bacteria and/or fungus having varying requirements for growth, and can be stored for a long period of time. One culture medium container 3 and one drug container 5 together can form a drug susceptibility test strip unit, and each test strip unit can be used to determine a drug's MIC. Multiple test strip units may be grouped as needed.
[0033] Pre-fabrication of an antimicrobial concentration gradient: a strip-shaped plastic drug container has a series of divisions (drug container cells), and ascending (or descending) amounts of an antimicrobial drug solution are added to the bottoms of the divisions (drug container cells). The antimicrobial drug solution is dried under a negative pressure and then covered with a lid so as to be preserved at 4° C. for later use.
[0034] Pre-fabrication of a culture medium based in agar (or another gel): a sol solution is prepared from a broth culture medium for culturing bacteria, and then the sol solution is added to the series of cells of a strip-shaped culture medium container. The sol is then solidified physically (such as by lowering the temperature) or chemically, and the solid gel is packaged and sealed, and preserved at 4° C. for later use.
[0035] Combination of the pre-fabricated antimicrobial drug and pre-fabricated culture medium to form a test strip unit: the films are removed from the bottom and top of the culture medium container, and the cells of the culture medium container can be inserted into the corresponding cells of the drug container. Then, the drug container is covered with a lid, and the pressure created in the process causes the antimicrobial drug at the bottoms of the cells to come into contact with the solid culture medium, and therefore dissolved in the agar culture medium to reach a specific concentration. To use the solid culture medium, a bacterial culture solution can be applied on the upper surface of the solid culture medium in each cell of the culture medium container. Then the culture medium container is covered with a lid, and then kept at 35° C. for 16-20 hours before the culture result is visually checked. When the drug concentration is higher than the MIC for the bacteria, no bacteria is observed on the surface of the gel. When the drug concentration is lower than the MIC, the bacteria grows on the surface of the culture medium and eventually develops a bacterial colony thereon. The lowest drug concentration at which no bacteria is observed on the gel surface is considered as the MIC of the antimicrobial drug for the strain under test.
[0036] A method of manufacturing a test strip unit includes the following steps:
1) manufacturing a drug container 5 , a drug container lid 1 , the body of a culture medium container 3 , the bottom of a culture medium container 3 , a box-shaped culture holder 9 , and a culture medium package case by compression molding; 2) sterilizing the drug container 5 , the drug container lid 1 , the body of the culture medium container 3 , and the bottom of the culture medium container 3 ; 3) in a relatively sterile environment, introducing an amount of an antimicrobial drug solution into cells of the drug container, and vacuum drying the drug container cells; 4) adhering a plastic film to the bottom of the culture medium container 3 ; 5) using a liquid culture medium as a solute to prepare a sol of a predetermined concentration in a sterile condition, and introducing the sol into cells of the culture medium container 3 , solidifying the sol so as to form a solid culture medium, and sealing a plastic film on the upper surface of the culture medium container 3 ; 6) in a sterile environment, packaging the drug container 5 and the drug container lid 1 in a plastic bag or plastic box; 7) placing a plurality of the culture medium containers 3 in a culture medium package case; and 8) irradiating the large-packaged drug container 5 and culture medium container with cobalt-60 to sterilize them and then storing them at a room temperature or 4° C.
[0045] Embodiments of a method of performing concentration gradient measurement for use in bacterial/fungal drug susceptibility testing are described below.
Embodiment 1
[0046] A concentration gradient measurement method for use in bacterial/fungal drug susceptibility testing is provided. The method comprises the steps of:
1) irradiating drug container and culture medium container manufactured by compression molding to sterilize them; 2) adding Cefotaxime with concentrations of 3.75, 7.5, 15.0, 30.0, 60.0, 120.0, 240.0, 480.0, 960.0, 1920.0 μg/ml into the second to eleventh cells (and not the first and twelfth cells) of the drug container, 13 μl of Cefotaxime each, and drying the drug container under a negative pressure for later use; 3) adding 1.2% agar to MH broth, dissolving the agar by boiling water insulated from the agar, sterilizing the agar under high pressure at 121° C. for 15 minutes; 4) pipetting a 1.2% hot agar solution to a culture medium container under a sterile condition, the culture medium container having round cells each with internal dimensions of a bottom's radius of 3.25 mm and a height of 6 mm, with gel strips each being of a thickness of about 6 mm, wherein, after the agar solution has cooled and solidified, the solid agar is packaged in a culture medium package case for later use; 5) inoculating a nutrient agar plate with various test strains (see Table 1), cultivating the test strains at 35° C. overnight, taking 4 or 5 colonies having the same pattern from the pure culture plate in the following day, making a uniform bacterial suspension from the colonies with normal saline and adjusting its turbidity to 0.5 McFarland standard; 6) removing the film from the bottom of the agar culture medium container, inserting the agar culture medium container into the drug container so that the antibiotic in the drug container disperses into the agar, thereby allowing the drugs in the drug-containing cells to reach final concentrations of 0.25, 0.5, 1.0, 2.0, 4.0, 8.0, 16.0, 32.0, 64.0 and 128.0 μg/ml, respectively; 7) dipping a swab in a bacterial solution of 0.5 McFarland standard to apply the bacterial solution to the surface of the agar block in each cell in a direction from the left to the right, with increasing concentrations of the bacterial solution; sliding close the drug container lid in a direction from the right to the left, and then placing the test strip unit into a moist box to incubate at 37° C. for 16-20 hours before visually observing the result, wherein the lowest drug concentration in a cell where there is no bacterial growth is considered the MIC value of the drug. The bacterial lawn on the drug-free control agar blocks is expected to grow well; and 8) in the meantime, performing an MIC assay on the test strains with tube broth dilution method.
Embodiment 2
[0055] This embodiment still uses a drug container with 12 round cells, and each round cell has internal dimensions of 4 mm×6 mm (bottom's radius×height). However, the experimental strains in use are Streptococcus pneumoniae . The related manufacturing and testing processes are as follows:
1) irradiating drug container and culture medium container, which are manufactured by compression molding, to sterilize them; 2) putting Amoxicillin with concentrations of 0.9, 1.8, 3.75, 7.5, 15, 30, 60, 120, 240, 480 μg/ml in the second to eleventh cells, rather than the first and twelfth cells, of the drug container, 13 μl of Amoxicillin each, drying the drug container under a negative pressure for later use; 3) adding 1.2% agar to CAMHB broth, dissolving the agar by boiling the broth while being insulated from water, sterilizing the agar under a high pressure at 121° C. for 15 minutes, sterilizing the agar as soon as its temperature drops to 50° C., mixing the sterilized agar with 2.5% LHB, wherein the CAMHB broth is a regulated cation concentration MH broth; 4) pipetting a hot agar solution to a culture medium container in a sterile condition, wherein each round cell of the culture medium container has internal dimensions of a bottom's radius 3.25 mm×a height of 6 mm, and each gel strip is 6 mm thick approximately, wherein, after the agar solution has cooled and solidified, the solid agar is packaged in a culture medium package case for later use; 5) inoculating a sheep blood agar plate with various test strains (see Table 2), cultivating the test strains at 35° C. with 5% CO 2 overnight, taking 4 or 5 colonies having a same pattern from the pure culture plate the following day, making a uniform bacterial suspension from the colonies with normal saline, and adjusting its turbidity to 0.5 McFarland standard; 6) removing the film from the bottom of the agar culture medium container, inserting the agar culture medium container into the drug container so that the antibiotic in the drug container disperses into the agar, thereby allowing the drugs in the drug-containing cells to reach final concentrations of 0.06, 0.12, 0.25, 0.5, 1.0, 2.0, 4.0, 8.0, 16 and 32 μg/ml, respectively; 7) dipping a swab in a bacterial solution of 0.5 McFarland standard to apply the bacterial solution to the surface of the agar block in each cell in a direction from the left to the right, with increasing concentrations of the bacterial solution, sliding close the drug container lid in a direction from the right to the left; and then placing the test strip unit into a moist box to incubate at 37° C. for 16-20 hours before visually observing the result; wherein the lowest drug concentration in a cell where there is no bacterial growth is considered the MIC value of the drug. The bacterial lawn on the drug-free control agar blocks is expected to grow well; and 8) performing an MIC assay on the test strains with the tube broth dilution method.
[0064] The measurement results of the two methods are shown in Table 2.
[0000]
TABLE 1
Comparison of the results (mg/L) of MIC assays performed on
30 pathogens by this method and tube broth dilution method
with Cefotaxime
Concentration
Concentration
(tube broth
(gradient agar
dilution
Strain No.
Strain Name
strip method)
method)
1
Klebsiella
pneumoniae
4.0
4.0
2
Klebsiella
pneumoniae
4.0
4.0
3
Klebsiella
pneumoniae
4.0
2.0
4
Klebsiella
pneumoniae
2.0
2.0
5
Klebsiella
pneumoniae
2.0
2.0
6
Klebsiella
pneumoniae
4.0
4.0
7
Klebsiella
pneumoniae
8.0
8.0
8
Klebsiella
pneumoniae
4.0
4.0
9
Escherichia
coli
8.0
8.0
10
Escherichia
coli
1.0
1.0
11
Escherichia
coli
2.0
4.0
12
Escherichia
coli
4.0
4.0
13
Escherichia
coli
4.0
4.0
14
Escherichia
coli
8.0
8.0
15
Escherichia
coli
2.0
4.0
16
Escherichia
coli
4.0
4.0
17
Escherichia
coli
4.0
4.0
18
Klebsiella
pneumoniae
16.0
16.0
19
Escherichia
coli
16.0
16.0
20
Escherichia
coli
4.0
4.0
21
Klebsiella
pneumoniae
8.0
8.0
22
Klebsiella
oxytoca
8.0
8.0
23
Escherichia
coli
8.0
8.0
24
Klebsiella
pneumoniae
4.0
4.0
25
Klebsiella
oxytoca
8.0
8.0
26
Escherichia
coli
4.0
4.0
27
Proteus
mirabilis
8.0
4.0
28
Enterobacter
cloacae
16.0
16.0
29
Enterobacter
cloacae
16.0
16.0
30
Escherichia
coli
8.0
8.0
[0000]
TABLE 2
Comparison of the results (μg/ml) of MIC assays performed on
20 strains of Streptococcus pneumoniae by this method and tube
broth dilution method with Amoxicillin
Concentration
Concentration
(tube broth
(gradient agar
dilution
Strain No.
Strain Name
strip method)
method)
1
Streptococcus
pneumoniae
0.12
0.12
2
Streptococcus
pneumoniae
0.12
0.12
3
Streptococcus
pneumoniae
0.25
0.12
4
Streptococcus
pneumoniae
0.25
0.25
5
Streptococcus
pneumoniae
0.5
0.5
6
Streptococcus
pneumoniae
0.12
0.12
7
Streptococcus
pneumoniae
0.25
0.25
8
Streptococcus
pneumoniae
1.0
0.5
9
Streptococcus
pneumoniae
0.25
0.25
10
Streptococcus
pneumoniae
2.0
2.0
11
Streptococcus
pneumoniae
0.12
0.12
12
Streptococcus
pneumoniae
0.06
0.06
13
Streptococcus
pneumoniae
0.06
0.12
14
Streptococcus
pneumoniae
2.0
2.0
15
Streptococcus
pneumoniae
0.12
0.12
16
Streptococcus
pneumoniae
0.12
0.12
17
Streptococcus
pneumoniae
1.0
1.0
18
Streptococcus
pneumoniae
0.5
1.0
19
Streptococcus
pneumoniae
0.25
0.12
20
Streptococcus
pneumoniae
0.12
0.12
[0065] Explanation of the results: as shown in Table 1 and Table 2, this method (concentration gradient agar strip method) yields mostly the same result as the tube broth dilution method, except for an occasional difference of a titer of 1:2. However, since the methodological permissible errors for the broth dilution method fall within the range of a titer of 1:2 lower to a titer of 1:2 higher, the results of the concentration gradient agar strip method are consistent with the results of the dilution method.
Embodiment 3
[0066] a drug container which has 12 round cells each with internal dimensions of 4 mm×6 mm (bottom's radius×height), and a culture medium container which has 12 round cells each with internal dimensions of 3.25 mm×6 mm (bottom's radius×height). The gel strips are made of agar gel.
Embodiment 4
[0067] a drug container which has 12 round cells each with internal dimensions of 4 mm×6 mm (bottom's radius×height), and a culture medium container which has 12 round cells each with internal dimensions of 3.25 mm×6 mm (bottom's radius×height). The gel strips are made of polyacrylamide gel.
Embodiment 5
[0068] a drug container which has 12 round cells each with internal dimensions of 4 mm×6 mm (bottom's radius×height), and a culture medium container which has 12 round cells each with internal dimensions of 3.25 mm×6 mm (bottom's radius×height). The gel strips are made of plant protein adhesive.
Embodiment 6
[0069] a drug container which has 12 round cells each with internal dimensions of 4 mm×6 mm (bottom's radius×height), and a culture medium container which has 12 round cells each with internal dimensions of 3.25 mm×6 mm (bottom's radius×height). The gel strips are made of gelatin gel.
[0070] The present invention also has some other embodiments. Persons skilled in the art can make various changes and modifications to the present invention without departing from the spirit and essential features of the present invention. However, the changes and modifications are deemed covered by the appended claims of the present invention. | The present invention discloses a concentration gradient test reagent kit and a testing method for use in bacterial/fungal drug susceptibility testing. The reagent kit includes a test strip unit. The test strip unit includes a strip-shaped culture medium container and a drug container. The culture medium container and the drug container comprise axially-arranged culture medium cells and drug cells, respectively. The culture medium cells can be inserted into corresponding drug cells. The drug container and the culture medium container are stable, easy to preserve and transport, and can be included into a reagent kit for long-term storage. The kit allows for easy and convenient testing operations. Testing results are easy to observe and interpret. The kit can be used in drug susceptibility testing on slow-growing fungi and anaerobic bacteria. Testing procedures and waste processing is biologically very safe. | 2 |
FIELD OF THE INVENTION
[0001] This invention relates to manhole structures. In particular, it relates to a method and device for sealing a manhole structure.
BACKGROUND OF THE INVENTION
[0002] Manholes are used to provide street-level access to sewer lines and other underground structures. Most often, the top portion of the manhole has the form of a cylindrical frame (or casting) with a lid. The lower portion of the casting, which is not generally seen after installation, often resembles a hat with a brim. This hat-shaped casting rests on a concrete cone leading to a sewer line. The upper portion of the casting defines an opening that may be closed with a lid. The elevation of the manhole casting and lid may be raised to the level of the surrounding surface grade by placing one or more concrete adjusting rings between the bottom of the casting and the cone. A manhole structure is thus created by stacking a number of components on top of each other. After the manhole structure is installed, the space around it is typically filled in with earth so that the lid at the top portion of the manhole casting is conveniently accessible at street-level.
[0003] Manholes created by such stacking of components are vulnerable to leaks. Water and other contaminants may enter through gaps between the stacked components after installation. Once the manhole structure has been installed and earth has been filled in around it, gaps below the ground level become difficult to reach. It is thus desirable to seal the manhole structure during installation to prevent future leaks at the interfaces between the stacked components.
[0004] Various methods and devices are known for sealing the external surfaces of manhole structures. One method employs an elastomeric band positioned around the top portion of the cone and extending over the adjusting rings to the base of the manhole casting. Because the cone and the adjusting rings have generally the same outer perimeter, one or more sealing bands may be used to provide an external seal for the gaps between these components. A band extends over the cone (and any adjusting rings) to the casting base as in U.S. Pat. No. 5,876,533 or may extend in tapered form to the upper portion of the casting as in U.S. Pat. No. 7,150,580.
[0005] To reduce the risk of accumulating water or contaminants between the inner layer of the seal and the outer layer of the manhole, methods have been devised for keeping the external seal snugly fitted to the manhole structure. A heat-sealing method, for example, is known whereby the sealing band is heated before fitting so that it may be secured tightly to the manhole structure, thereby reducing bulges and air pockets. But methods that use heat require a heat source, often torches and other special tools that involve hazards to the user.
[0006] What is needed in the industry is a device and method for sealing a manhole structure so that the seal is retained in close proximity to the external surfaces of manhole structure without the use of heat-sealing methods.
SUMMARY OF THE INVENTION
[0007] The problems described above are solved in substantial part by a band for sealing a manhole structure that has an L-shaped corner with that is more rigid than the rest of the band. The band includes first and second portions extending from the L-shaped corner at a generally 90-degree angle to each other. The L-shaped corner may extend equal or unequal distances in the direction of the first and second portions. The band may be integrally molded or formed by from separate pieces of material.
[0008] The rigidity of the L-shaped corner may be enhanced by making it from a thicker material than the first or second portions. The thickness of the L-shaped corner may be at least twice the thickness of the first and second portions.
[0009] A method for using a band with an L-shaped corner includes rolling the band over the exterior of the casting and the upper margin of a manhole structure and fitting the L-shaped corner to the upper margin defining a corner such that the first portion extends toward the casting and the second portion covers at least part of the upper margin. The L-shaped corner may be fitted to either a corner defined by the upper margin of a cone (when no adjusting rings are used) or to a corner defined by the uppermost adjusting ring. An adhesive may be applied to the band's inner surface to enhance the seal formed against the manhole structure. A butyl mastic adhesive may be used, either alone or in conjunction with a primer applied to the surfaces of the manhole structure that will contact the adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is cut-away plan view of an embodiment of the invention in place around a manhole structure.
[0011] FIG. 2 is a cross-section view of an embodiment of the invention in place around a manhole structure.
[0012] FIG. 3 is a detailed cross-sectional view showing an embodiment of the invention in place around the upper margin of a manhole structure.
[0013] FIG. 4A is a cross-sectional view of the embodiment of the band of the invention.
[0014] FIG. 4B is a detailed cross-sectional view of an embodiment of the corner of the band of the invention.
[0015] FIG. 5 is an exploded cross-sectional view of a manhole structure and an embodiment of the invention.
DETAILED DESCRIPTION
[0016] As shown in FIGS. 1-5 , sealing band 10 is generally L-shaped, with a first portion 12 that extends horizontally in relation to a manhole structure, a second portion 14 that extends vertically, and a corner 34 linking the first and second portions.
[0017] In FIG. 1 , band 10 is shown in position around a cross section of manhole structure 16 . Manhole structure 16 includes a cone 18 and a casting 20 . Cone 18 has a lower portion 22 that extends downward to a sewer (not shown) and an upper margin 24 on which casting 20 is disposed. The casting 20 is generally hat shaped and includes a brim portion 26 , an upper portion 28 , and a lid-receiving portion 30 .
[0018] Band 10 is positioned around the exterior periphery of the upper margin 24 of cone 18 and overlaps with part of brim portion 26 of casting 20 . In the embodiment shown in FIG. 1 , cone 18 is shown without adjusting rings.
[0019] The positioning of band 10 around manhole structure 16 is shown in greater detail in FIG. 2 , which shows a cut-away view of manhole structure 16 . In FIG. 2 , manhole structure 16 includes cone 18 and casting 20 as in FIG. 1 , but also includes adjusting rings 32 . As shown in FIG. 2 , band 10 extends around the periphery of cone 18 and adjusting rings 32 . When adjusting rings 32 are stacked on cone 18 , one or more adjusting ring, 32 may be used. In such embodiments, corner 34 of band 10 corresponds to a corner 35 defined by the uppermost adjusting ring 32 .
[0020] In an embodiment, the material used to form corner 34 of band 10 is thicker than the material that forms first and second portions 12 , 14 . As shown in FIG. 3 , which provides a detail of the cross-sectional view of band 10 , the inner side 36 of corner 34 is reinforced with more material than the other portions of band 10 .
[0021] As shown in FIG. 4A , first and second portions 12 , 14 of band 10 may be unequal in length. Referring back to FIGS. 1 and 2 , it can be seen that first portion 12 extends from corner 34 to cover the interface between the uppermost adjusting ring 32 (or upper margin 24 of cone 18 ) and the brim portion 26 of casting 20 . Second portion 14 extends beyond the height of the stacked adjusting rings 32 . First and second portions 12 , 14 may also extend the same distance from corner 34 .
[0022] For example, where cone 18 in FIG. 1 is 39¼″ in diameter and casting 20 is 29″ in diameter, there are 5⅛″ of material from corner 32 to the end of first portion 12 and 16″ of material from corner 34 to the end of second portion 14 . In this embodiment, band 10 has an outer circumference of 123¼″ and an inner circumference of 91″.
[0023] In the embodiment shown in FIG. 4B , corner 34 is thicker than the rest of band 10 , which is shown in FIG. 4B by the curvature of the inner side 36 of corner 34 . In this embodiment, corner 34 is made from the same material as first and second portions 12 , 14 . Corner 34 may extend equally in both directions. In the embodiment shown in FIG. 1 , corner 34 extends 1″ toward each of the first and second portions 12 , 14 . In other embodiments, corner 34 may extend unequally.
[0024] Corner 34 may be formed integrally, for example, by molding. Or first and second portions 12 , 14 may be attached to corner 34 . In a preferred embodiment, first and second portions 12 , 14 are made of a resilient material that can be rolled over a manhole structure and has sufficient thickness to withstand the environmental conditions generally found at manhole-construction sites. For example, band 10 may be constructed from ethylene propylene diene monomer (EPDM) rubber. The thickness of the first and second portions is approximately 65 mili-inches (mils). The thickness of the preformed corner portion is approximately twice that, or 130 mils.
[0025] Alternatively, a more rigid material may be used to form corner 34 than is used for the rest of band 10 . In this alternative embodiment, the thickness of corner 34 may not be different than the thickness of the rest of band 10 , and may even be less, depending on the material used.
[0026] In use, band 10 is preformed in generally the shape shown in FIG. 5 and brought to a site where a manhole structure is being installed. As shown in FIG. 1 , manhole structure 16 may be created by placing casting 20 directly on cone 18 . Frequently, however, the elevation of cone 18 alone is insufficient to reach the desired surface grade. Thus, one or more adjusting rings 32 are added to the top of cone 18 , as best shown in FIG. 5 . Band 10 is positioned so that corner 34 is fitted to the topmost adjusting ring 32 , if adjusting rings 32 are used, or to the upper margin 24 of cone 18 , if no adjusting rings 32 are used. In this position, first portion 12 extends to cover brim portion 26 of casting 20 while second portion 14 extends to cover either the upper margin of cone 24 (if no adjusting rings 32 are used, or adjusting rings 32 .
[0027] In an alternative embodiment, as shown in FIG. 6 , an adhesive 37 is applied around either the inner side 38 of first portion 12 or the inner side 40 of second portion 14 , or both. For example, as shown in FIG. 4A , butyl mastic 37 a may be applied all the way around the underside of first portion 12 . The adhesive may be applied in different proportions, for example, where the first portion 12 is 5⅛″, the adhesive 37 a may be applied as a strip 5″ wide. This arrangement will enhance the seal created by first portion 12 against uppermost adjusting ring 32 and brim portion 26 of casting 20 . Near the bottom edge 42 of second portion 14 , a 2″ wide strip of adhesive 37 b may be used to provide an enhanced seal around lower portion 22 of cone 18 . Strips of other sizes may also be used to seal first portion 12 or second portion 14 to manhole structure 16 . A primer 43 may also be applied to the external surfaces of manhole structure 16 to enhance the seal formed by the adhesive. For example, when a butyl mastic adhesive is placed on first or second portions 12 , 14 , a primer-delivery device 44 may be used to apply primer 43 in aerosol form to the corresponding portions of the manhole structure. | The invention relates to a device and method for sealing a manhole structure. A band with a relatively rigid angled corner engages the upper margin of a manhole structure. Adhesives may also be used with the band to enhance the seal with the manhole structure. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a diaphragm-operated pressure control valve assembly and, more particularly, to improvements in a pressure control valve assembly of the type used in conjunction with a negative pressure source as well as fluid pressure source and including at least one diaphragm, on one surface of which fluid medium pressure is applied and on the other surface of which negative pressure is applied. The valve assembly of the present invention is, moreover, especially designed for use in systems wherein the fluid medium such as gas contains some ingredients such as condensed water.
2. Description of the Prior Art
A diaphragm-operated valve assembly within which variable control pressure is admitted to effect the valve operation has been conventionally proposed. When the gas containing various ingredients is utilized as the variable control pressure applied onto the rubber diaphragm, any objectionable materials contained in the gas should not gather on the diaphragm in order to prevent the possible oxidation or corrosion thereof due to such materials or ingredients.
One system employing such diaphragm-operated valve assembly is, typically, an exhaust gas recirculation system for the internal combustion engines of automotive vehicles. Exhaust gas recirculation is, as is well known, one of the effective means for reducing the emission of oxides of nitrogen (commonly represented as NOx) by the exhaust systems of internal combustion engines. The exhaust gas is, in the exhaust gas recirculation system, employed as fluid medium for actuating the diaphragm of the valve assembly. However, the conventional diaphragm-operated valve assembly leaves much to be desired because the gas ingredients, such as condensed water, are likely to gather within the valve assembly, particularly on the diaphragm; with the results that the diaphragm is subjected to corrosion or oxidation. U.S. Pat. No. 3,802,402 granted on Apr. 9, 1974 to Mr. Peter Phillimore Swatman or U.S. Pat. No. 3,834,366 granted on Sept. 10, 1974 to General Motors Corporation, for instance, disclose the diaphragm-operated valve assembly, but are silent as to the problems caused by the gas ingredients as mentioned above.
SUMMARY OF THE INVENTION
It is, therefore, one of the objects of the present invention to provide a diaphragm-operated valve assembly which may overcome the drawbacks of the prior art.
It is another object of the present invention to provide a diaphragm-operated valve assembly wherein the form of the diaphragm operable in response to negative pressure as well as fluid pressure is improved so as to gather no fluid ingredients on the diaphragm, thereby avoiding objectionable oxidation or corrosion thereof.
It is a further object of the present invention to provide a diaphragm-operated valve assembly wherein a single diaphragm comprises two partition members to constitute three chambers in order to effect an easy mounting of the diaphragm.
It is still another object of the present invention to provide a diaphragm-operated valve assembly which is particularly designed for use as an exhaust gas recirculation system for internal combustion engines.
According to the diaphragm-operated valve assembly of the present invention, an inner surface of the diaphragm member subjected to fluid medium containing various ingredients includes a gradual descent from an inner periphery associated with a valve member to an outer periphery secured to a valve assembly body. Therefore, the fluid ingredients such as condensed water may be expelled outside via a port provided on the body adjacent to the said outer periphery of the diaphragm member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of an exhaust gas recirculation system employing a valve assembly of the present invention;
FIG. 2 is an enlarged sectional view of one embodiment of the valve assembly used in the exhaust gas recirculation system; and
FIG. 3 is a view similar to FIG. 2 but showing another embodiment of the valve assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1 of the drawings, an exhaust gas recirculation system in which a pressure control valve assembly 10 according to the present invention is being employed is schematically shown. The exhaust gas recirculation system further comprises an internal combustion engine 11, a carburetor 12 and a recirculation control valve assembly 13. A recirculation conduit 15 in open communication with an exhaust manifold 14 may be, through means of the valve assembly 13, connected to a recirculation conduit 17 in open communication with an intake manifold 16. The valve assembly 13 determines when exhaust gas recirculation is to take place as will be hereinafter explained, and includes a casing 80, a diaphragm 18 for partitioning the interior of casing 80, and a valve piston 20 associated with the diaphragm 18 and biased downwards by means of a spring 19 to interrupt pneumatic communication between the recirculation conduits 15 and 17. The valve piston 20 of valve assembly 13 will be moved up in accordance with the negative pressure within a chamber 23 which is through a negative pressure conduit 22 in communication with a negative pressure outlet port 81 controllable by a throttle valve 21 of carburetor 12.
The pressure control valve assembly 10 of the present invention is disposed within the negative pressure conduit 22. A first embodiment of the pressure control valve assembly 10 as shown in FIG. 2 includes a first body 24, a second body 25 secured to the first body 24, and a third body 26 secured to the second body 25.
A single diaphragm 27 disposed within the interior constituted by the bodies 24, 25 and 26 is provided with an upper partition member 28, an outer periphery 82 which is fixedly held between the first and the second bodies 24 and 25, a lower partition member 29, and an outer periphery 83 which is fixedly held between the second and the third bodies 25 and 26. Consequently, the interior of the valve assembly 10 is divided into three chambers: an atmospheric air chamber 30, an exhaust gas chamber 31 and a negative pressure chamber 32. The function of each chamber in the exhaust gas recirculation system will be described in more detail below.
Each of the upper and the lower partition members 28 and 29 of diaphragm 27 is at the surface confronting the exhaust gas chamber 31 formed with a gentle curve, i.e., the shape of the inner surface of each partition member is an almost circular arc between the outer periphery thereof and the integral main boss 33 of a larger thickness of diaphragm 27. It is to be particularly noted that the lower partition member 29 is formed with the gentle descent shape in which the main boss 33 is the highest portion while the outer periphery 83 thereof is the lowest portion as illustrated, thereby forming no portion which is lower than the outer periphery 83. As a result, any objectionable material contained within the exhaust gas such as condensed water will flow out along the curved partition member 29 descending from the main boss 33 to the outer periphery 83 so as not to be gathered in the exhaust gas chamber 31. It should be recognized that the gently spherical or circular shape of the lower partition member 29 at the inner surface thereof is not essential in the present invention but the lower partition member 29 of diaphragm 27 may be formed with a straight line descending from the main boss 33 to the outer periphery 83 thereof in order to prevent the gathering of condensed water or other exhaust gas ingredients thereon.
The atmospheric air chamber 30 is in the permanent communication with the atmospheric air by way of a hole 34 formed through the first body 24 and a gap 36 formed between the first body 24 and a cover cap 35 secured thereto. Foreign materials contained in the atmospheric air admitted to the chamber 30 may be excluded by means of air filter 37 interposed between the cover cap 35 and the first body 24.
The exhaust gas chamber 31 is connected at an inlet 38 thereof to a branch conduit 39 of the recirculation conduit 15, thereby being admitted with the exhaust gas pressure which essentially corresponds to the engine rotation. The negative pressure chamber 32 is connected at an inlet 40 thereof to a conduit 41 which is in turn connected to a negative pressure outlet port 84 of intake manifold 16.
The single diaphragm 27 is urged to move down due to the force exerted by a leaf spring 42 mounted on the first body 25 while pressure to move up is provided by a helical spring 43. That is to say, the diaphragm 27 is moved downwards by the leaf spring 42 and the negative pressure in the negative pressure chamber 32, and moved upwards by the helical spring 43 and the gas pressure in the exhaust gas pressure 31. The outer periphery of the leaf spring 42 is secured to the first body 24 through means of a screw 44 while the inner periphery thereof imparting the downward urging force is engaged with a metal boss 45 made integrally with the diaphragm boss 33. It will be seen that the axial movement of the screw 44 adjusts the urging force of leaf spring 42 onto the diaphragm 27.
A movable valve member 47 disposed within the boss 45 is urged to move up by a coiled spring 46 so as to engage a valve seat 49 which is formed at the edge of an axial extension 48 of the first body 24. Thus, the communication between the atmospheric air chamber 30 and a passage 52 in the first body 24, formed between an inlet port 50 of the first body 24 and an outlet port 51 thereof and connected to the negative pressure conduit 22, may be controlled. More specifically, the valve member 47 engages a shoulder or flange 54 of diaphragm metal boss 45 during the inoperative condition in which the diaphragm 27 is being brought to engagement with a stopper 73 mounted on the second body 25 as seen in FIG. 2. Therefore, the valve member 47 is released from the valve seat 49 so that the passage 52 is connected to the atmospheric chamber 30 via clearance between the first body 24 and the diaphragm metal boss 45. Between the inlet port 50 and the outlet port 51 of passage 52, is provided an orifice 55 for restricting the admission of atmospheric air to the inlet port 51 when the valve member 47 is open, thereby ensuring the atmospheric air pressure at the outlet port 51. A plug 56 is fitted in the axial hole of the first body 24 to constitute the T-shaped passage 52.
In operation, the pressure control valve assembly 10 is actuated in accordance with the exhaust gas pressure which is substantially proportional to the engine rotational number and the intake manifold pressure which is responsive to the operational load condition of the engine. The diaphragm 27 is moved down due to the negative pressure in the negative pressure chamber 32 against the spring 43 and the exhaust gas pressure when the vehicle engine is in a small load operation such as during idling or during deceleration. Therefore, the valve member 47 is released from the valve seat 49. In small load operating conditions such as above, the negative pressure conduit 22 is in communication with the atmospheric air via passage 52 and outlet port 51, to maintain the valve piston 20 at the closed position. The intake manifold negative pressure prevailing in the negative pressure chamber 32 is low when the vehicle engine is in full load operation such as during running at high speed or during the climbing slopes. In such full load operations, while the exhaust gas pressure in the exhaust gas chamber 31 is lower than the urging force of leaf spring 42 the valve member 47 is released from the valve seat 49 to bleed the atmospheric air in the conduit 22. When the exhaust gas pressure is increased, due to the increase in engine rotation, to overcome the urging force of leaf spring 42 the diaphragm 27 is moved up to seat the valve member 47 on the valve seat 49. Therefore, no air is bled to the negative pressure conduit 22. However, it is to be understood that the advance port pressure of the carburetor 12 is small enough to keep the valve piston 20 of assembly 13 in the closed position by the spring 19. As will be apparent from the foregoing description, when the vehicle engine is in the small or full load operation, no exhaust gas recirculation may be achieved irrespective of the exhaust gas pressure.
When the engine is in average load condition such as when running at constant speed, the negative pressure generated at the advance port 81 and admitted to the chamber 23 of valve assembly 13 through the negative pressure conduit 22 will prevail to open the valve piston 20. The intake manifold pressure admitted to the negative pressure chamber 32 of the control valve assembly 10 is relatively low although higher than in the full load condition of the engine. As a result the exhaust gas recirculation is effected in accordance with the intake manifold pressure and the exhaust gas pressure. More specifically, when the exhaust gas pressure overcomes the negative pressure in the chamber 32 and the influence of leaf spring 42, the valve member 47 as well as the diaphragm 27 is lifted to engage the valve seat 49. The negative pressure conduit 22 is thus isolated from the atmospheric chamber 30 and the negative pressure at the advance port 81 causes the valve pistion 20 of assembly 13 to move up, thereby effecting the recirculation.
However, when the exhaust gas pressure is decreased due to the decrease of engine rotation, the diaphragm 27 is moved down by means of the intake manifold pressure in the negative pressure chamber 32 and the force of the leaf spring 42. The valve member 47 is thus released from the seat 49 to bleed the atmospheric air into the negative pressure conduit 22, thereby closing the valve piston 20 of the assembly 13; with the result that exhaust gas recirculation is precluded.
Referring now to FIG. 3, a modified embodiment of the invention wherein those components which are constructed and arranged in the same manner as in FIG. 2 are identified by the same reference numerals with the affix "a", is shown.
According to the pressure control valve assembly 10a depicted in FIG. 3, a first or upper diaphragm 57 and a second or lower diaphragm 58 are provided separate from each other in order to constitute an atmospheric air chamber 30a, an exhaust gas pressure chamber 31a and a negative pressure chamber 32a. The upper diaphragm 57 is at the outer periphery thereof secured by a first body 24a and a second body 25a while at the inner periphery thereof is secured by a first movable member 59 and a second movable member 60, the said first and second members being fixed to each other. Similarly, the lower diaphragm 58 is at the outer periphery thereof secured by the second body 25a and a third body 26a while at the inner periphery thereof is secured by the second movable member 60 and a support member 61 fixed thereto. An underside 72 of the upper diaphragm 57 is in contact with the second body 25a while recirculation is not necessary. It should be recognized that each inner surface 62, 63 of the first and the second diaphragms 57, 58 is formed substantially in the same manner as in FIG. 1.
The first movable member 59 is urged to move down by the exerting force of spring 64 disposed in the atmospheric air chamber 30a while no recirculation is to take place. Therefore, a valve member 47a is released from a valve seat 49a due to engagement with a shoulder 65 of the first movable member 59. Between the support member 61 and a spring retainer 67 in the negative pressure chamber 32a a helical spring 66 is interposed which will function in the same manner as the spring 43 of FIG. 1.
A screw-threaded bolt 69 is fitted in the third body 26a together with a silicone seal 68. The axial movement of the bolt 69 adjusts the exerting force of spring 66. Relatively coarse foreign materials contained in the atmospheric air may be filtered by an upper filter 70, whilst relatively fine foreign materials may be filtered by a lower filter 71 arranged in series to the upper filter 70.
The operation of the valve assembly 10a is substantially the same as that of the valve assembly 10 and will be readily understood to those skilled in this art, so that the detailed description thereof may be omitted. | A pressure control valve assembly comprising a rubber diaphragm to which is applied the negative pressure of the engine intake manifold and the exhaust gas pressure of the engine exhaust manifold. The diaphragm of the present invention is formed with a gradual descent sloping down from a valve-actuating central portion to an outer periphery. Adjacent to one portion of the outer periphery of the diaphragm a port opening to the outside of the valve assembly is provided. Thus, any gas ingredients such as condensed water can be expelled along the descent of the diaphragm via the port without gathering on the diaphragm surface which will therefore be free from objectionable oxidation or corrosion. | 5 |
BACKGROUND OF THE INVENTION
A “flat box” is a standard drywall finishing tool for applying drywall compound, also called “mud,” to joints between sheets of drywall after taping the joints. Often the drywall compound is applied in three coats, called the base coat, finish coat and skim coat, using flat boxes of different sizes.
The device is the general shape of an approximately 30 degree partial cylinder. One flat side, the back plate, has a slot for expelling drywall compound. Side plates and a radius plate combine with the back plate to form an open box-like enclosure. Another flat side, called the pressure plate, completes the enclosure and is pivotably attached to the back plate so it may be pressed toward the back plate, squeezing out the drywall compound through the slot. A long handle attaches to the pressure plate so the operator may move the box along the wall and assert the pressure needed to squeeze out the compound. A flexible polymer wiper blade attached to the free end of the pressure plate provides a flexible seal that pushes the drywall compound out as the plates are pressed together.
A disadvantage of prior art flat box designs is that the edge of the wiper blade extends beyond the edge of the pressure plate, so in operation the pressure plate must be stopped short of flattening against the back plate in order to prevent damage to the wiper. Incorporation of a stop mechanism protects the wiper but leaves a volume of drywall compound inside the box when the operator stops to reload the box.
The current invention addresses this disadvantage by permitting the device to expel almost all its contents before reloading the box. Improvements shown in additional embodiments provide a variable spring tension applied to the pressure plate and independently suspended wheels for moving the box against the wall.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . is a perspective view of an embodiment of the current invention facing toward the radius plate.
FIG. 2 . is a view of the embodiment of FIG. 1 facing toward the pressure plate.
FIG. 3 . is a view of embodiment of FIG. 1 facing toward the back plate.
FIG. 4 . is a close view of a wheel assembly in one embodiment of the invention.
FIG. 5 . is the wheel suspension spring in one embodiment of the invention.
FIG. 6 . is an exploded perspective view of the pressure plate and wiper assembly in one embodiment of the invention.
FIG. 7 . is a cross section of the pressure plate of FIG. 6 with the wiper in place.
FIG. 8 . is a transverse cross section of the pressure plate of FIG. 6 with the wiper in place.
FIG. 9 . is a perspective view of a wiper of the present invention.
FIG. 10 . is an end view of a wiper of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-3 show various perspectives of an embodiment of the present invention. The flat box comprises a back plate or pivot plate 2 , left and right side plates 3 and 4 , a pressure plate 5 , and a radius plate 6 . The pressure plate is pivotably attached at the pivot end 7 to the pivot end 8 of the back plate 2 with an axle assembly 9 .
Back plate 2 includes a slot 10 for expulsion of drywall compound onto the wall. A trowling blade 11 is attached above slot 10 to distribute the drywall compound as it comes out of the unit. An adjustable crown spring 12 and dial 13 , known in the art, are attached at radius plate 6 to adjust the arc of the trowling blade 11 .
Pressure plate 5 is preferably an anodized aluminum rectangular plate fitted to the dimensions of the box. The pressure plate incorporates handle mounting screws 14 for attachment of a long handle (not shown).
In one embodiment, a pressure plate handle spacer 15 , comprising a raised area of the plate 5 the size of a standard flat box handle mounting plate (not shown) is integrally manufactured with the pressure plate. To save weight, the handle spacer may have one or more channels 16 , decreasing the amount of plate material but maintaining the structural strength needed to sustain the pressure applied by the operator.
The pressure plate 5 also incorporates one or more pressure plate springs 17 . These springs 17 supply a counterforce that tends to pull the pressure plate 5 away from the back plate 2 when the operator is not exerting force against the pressure plate 5 , so the drywall compound does not come out of the box while it is being moved to the next location. If the spring 17 pulls the pressure plate 5 all the way back, as the fixed springs of the prior art do, drywall compound falls back into the box and requires extra exertion to be pushed back to the slot 10 . The springs 17 of one embodiment of the invention are adjustable. One end 18 of the spring 17 is held in place by a spring anchor nut 19 attached to a spring anchor bolt 20 . The other end 21 of the spring 17 , near the pivot axle 9 , is attached to a turnbuckle-type spring tension adjuster 22 that attaches through an aperture 23 in an extension 24 of the back plate. Turning the barrel of the turnbuckle 22 permits the operator to set the tension on either or both springs 17 . Optimally, the tension can be set so that the pressure plate 5 pulls back the minimum amount required to keep the mud from coming out of the box while the unit is moved. Other spring tension assemblies may be used for this function.
In another embodiment, the flat box includes independently suspended wheels parallel to the back plate. For each wheel 45 , as shown in FIGS. 4 and 5 suspension spring 30 is a stainless steel clip with a tubular channel 31 at one end and a pair of wheel mounting apertures 32 at the ends of flex legs 33 . Shoulder bolt 34 passes through the wheel mounting apertures 32 and is secured by nut 35 to form an axle for wheel 45 . Mounting shoulder bolt 36 passes through the tubular channel 31 and an aperture 37 in side plate 3 and is secured by nut 38 , holding the spring in place. Retaining screw 39 threads through a small aperture 40 in the side plate 3 , positioned so that the retaining screw 39 sits above the spring 30 and inhibits the spring 30 from flopping around. A tension adjuster bolt 41 with a lock nut 42 fits in slotted opening 43 in the side plate 3 and sits under the spring 30 . The tension bolt 41 may be positioned toward the front of the flat box, whereby the wheel 45 is on a more flexible mount, or positioned toward the rear of the flat box, whereby a shorter length of the spring 30 is available, thus making the wheel 45 stiffer.
The wheels 45 decrease the friction as the flat box is dragged across the wall. With independent suspension, either of the wheels 45 can ride over a rough spot on the wall without disturbing the balance of the flat box or the position of the trowling blade against the wall.
As seen in FIGS. 6-10 , a wiper 50 , made of a flexible material such as polymer rubber substitute such as the nitrile copolymer known as Buna-N, or other materials known in the industry, is attached to the pressure plate 5 by inserting ridges 51 in the wiper into slot 53 in the pressure plate. The wiper prevents backward escape of drywall compound as the pressure plate is pushed toward the back plate, and cleans drywall compound off the interior surface of the radius plate, pushing it toward the slot. The leading edge 52 of wiper 50 does not extend beyond the interior surface 54 of pressure plate 5 into the enclosure formed by the surrounding plates. This configuration allows the pressure plate to be pushed flat against the back plate 2 without damaging the wiper 50 , and permits expulsion of nearly all the drywall compound from the flat box.
As seen more particularly in FIGS. 6-8 , wiper 50 fits into a recess or slot 53 created by a raised extension 57 across the width of the pressure plate 5 . Left and right wiper retainers, 54 , 55 , are clamped over the wiper 50 and held to the pressure plate with nuts and bolts 56 . Wiper edge 52 extends peripherally beyond pressure plate 5 just enough to create a seal with the side plates 3 , 4 and the radius plate 6 sufficient to keep the drywall compound beneath the pressure plate as the pressure plate moves against the back plate, squeezing compound out through the exit slot 10 .
Although the invention has been described with respect to specific embodiments, persons of ordinary skill in the art will readily understand that the inventive concepts may be applied to a variety of configurations including, without limitation, variations in the adjustable pressure spring assemblies or the independent wheel suspensions. | A drywall finisher's flat box is disclosed, having an adjustable pressure plate spring, independent suspension for guide wheels on the back plate, and a wiper configured so that the pressure plate can be pushed flat against the back plate, thus expelling nearly all of the drywall compound from the flat box. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a rotary machine with orbiting twin blades, especially for expansion drive units and compressors, which can also be utilized for the field of pumping technology and other work machinery.
[0003] 2. Description of Related Art
[0004] From the U.S. Pat. No. 1,940,384 to Arnold Zöller, there is known a rotary compressor that operates with orbiting twin blades, and more particularly with planar sliders. These planar sliders are forced to move, during rotation, in guiding grooves of an eccentrically supported rotor, and are guided by friction blocks secured therein. As a consequence of the mutual connection of the oppositely located sliders into a single twin blade, there is avoided an increase of the centrifugal forces acting on the blade and, as a result, an increase in the friction work between the blade and the orbit-determining surface of the stator. The filling efficiency of the compressor described there is very high and amounts to 75 to 95%. However, the mechanical efficiency is low as a result of the friction work, ranging between 35 and 65%. This compressor, when operated as a blower, is suited for operation at high rotary speeds, and the filling curve exhibits a linear behavior up to 6000 r.p.m. This compressor was previously used, as the case may be, in the function of a blower, for turbocharging the motors of racing cars.
[0005] A significant disadvantage of this type of a compressor is the considerable friction work that is generated in the course of rotation during the rapid forced movement of the blades on the eccentric drum and on the stator wall, which results in a rapid wear of its components.
[0006] A multitude of other technical approaches has subsequently concerned itself with the solution of these tribological problems of the aforementioned machine by presenting various alternative constructions that make it possible to accomplish the forced movement of the twin blades situated in the internal space of the rotor, with the aim of reducing the friction work and achieving circular orbiting trajectory of the twin blades.
[0007] So, for instance, in the patent documents of JP 56-44489, the twin blades are guided in lateral grooves, as a result of which, however, centrifugal forces increase with increasing rotary speeds and, simultaneously, increase the frictional work. In this solution, moreover, the implementation of only one twin blade is optimized, similarly to another known solution according to the Austrian patent document AT 920009.
[0008] In further documents U.S. Pat. No. 3,001,482, DE-PS 433,963 and U.S. Pat. No. 3,294,454, the blades are again guided in lateral grooves; that brings about high frictional resistance during rotation. In the U.S. Pat. No. 2,070,662, the movement of the freely inserted blades is forced by an eccentrically supported rotor entraining member.
[0009] The solution in accordance with the patent document FR-A 1091637 is characterized by blades that are pressed against the orbit-determining surface, which again results at higher rotary speeds in an increased friction work.
BRIEF SUMMARY OF THE INVENTION
[0010] An important object of the invention is to avoid the aforementioned drawbacks of the preceding solutions, which reside primarily in the creation of undesirable frictional forces at the contact locations between the end portions of the blades and the orbit-determining surface of the stator.
[0011] Another object of the present invention is to provide a kind of a rotary support for the twin blades that would be structurally simple.
[0012] Still another object of the invention is to construct the above support in such a manner that it would totally eliminate the frictional work between the end portions and the orbit-determining surface of the stator.
[0013] Yet another object of the invention is so to design the above support that it would reduce the frictional work between the twin blades and the rotor to a minimum value even at high rotational speeds.
[0014] Last but not least, it is an object of the present invention to provide the possibility of incorporation of a significant number of twin blades into the novel structural solution of the rotary machine with orbiting twin blades.
[0015] In keeping with these objects and others which will become apparent hereafter, one feature of the present invention resides in a rotary machine with orbiting twin blades, especially for expansion drive units and compressors. This machine includes a stator housing having an inner peripheral surface circumferentially delimiting an enclosed internal chamber extending along a stator axis; a rotor part received in the stator housing for rotation about a rotor axis parallel to and radially offset from the stator axis and including at least two entraining rings axially spaced from one another and at least four entraining bars extending substantially parallel to the rotor axis at a radial distance therefrom, interconnecting the entraining rings, and defining respective slots between themselves; and means for mounting the rotor part for rotation in the internal chamber about the rotor axis. According to the invention, there is further provided a carrier shaft mounted in the internal chamber for rotation about a carrier shaft axis parallel to the rotor axis and extending over the entire axial length of the stator housing; at least two pairs of eccentric members provided on the carrier shaft for joint rotation therewith and centered on respective axes that are transversely offset from the carrier shaft axis in different radial directions; at least two twin blades each supported on one of the pairs of eccentric members for relative turning therebetween and including two blade portions passing through oppositely located associated ones of the slots of the rotor part into close proximity of the inner peripheral surface of the stator housing. Furthermore, there is provided means for transmitting torque between the rotor part and the carrier shaft in a permanent 1:2 transmission ratio such that the carrier shaft with the eccentric members turns in the same direction as but at twice the speed of the rotor part when the rotary machine is in operation such that the eccentric members force the twin blades to conduct movements relative to the rotor part that cause such blades to follow the inner peripheral surface of the stator housing at the aforementioned close proximity therefrom.
[0016] An important advantage of the implementation of the rotary machine according to the invention may be seen in the effective elimination of frictional forces which, in the previous devices, come into being at the contact regions of the freely supported blades with the contact stator surface delimiting the working space where, due to the influence of centrifugal forces, there is encountered, especially at high rotational speeds of the rotor, considerable frictional work and, in extreme cases, even catastrophic failure of the machine.
[0017] Another advantage is the stable mounting of the individual twin blades on the carrier shaft in accordance with the invention described here, which ensures a constant distance of the end portion of the twin blade from the internal working surface of the stator housing in any working regimen, and which makes it possible to utilize the machine in the region of high rotational speeds simultaneously with an increase in its longevity.
[0018] A significant further advantage of this machine is a continuous flow of the working medium in one and the same direction, which renders possible the ganging of several such machines in series for the achievement of multiple expansion or multiple compression of the working medium.
[0019] According to another advantageous aspect of the present invention, the stator housing includes an assembly of plate-shaped modules individually connected to one another, at least some adjacent ones of which have internal bores that together constitute the internal chamber of the stator housing. This feature provides for easy manufacture and assembly of the rotary machine.
[0020] It is particularly advantageous when the transmission means includes a pinion with external teeth on one of the rings, a carrier shaft gear wheel mounted on the carrier shaft for joint rotation therewith, a countershaft supported on the stator housing and centered on a countershaft axis, a first countershaft gear wheel supported on the countershaft and having external teeth that are in permanent meshing relationship with the external teeth of the pinion, and a second countershaft gear wheel supported on the countershaft, connected with the first countershaft gear wheel for joint rotation therewith about the countershaft axis and having external teeth that are in permanent meshing relationship at the aforementioned transmission ratio of 1:2 with the external teeth of the carrier shaft gear wheel. An advantage of this approach is that it reduces the complexity of the transmission means to a minimum while assuring its reliability and constant maintenance of the predetermined transmission ratio.
[0021] Advantageously, stator housing includes an end module that supports the countershaft and accommodates at least the pinion of the one ring and the first countershaft gear wheel. This results, on the one hand, in a stable support for the countershaft and hence the components supported thereon and, on the other hand, in protection of the components accommodated in this end module from the environment of the rotary machine and vice versa.
[0022] The carrier shaft has one end portion close to and another end portion remote from the pinion, and there is provided, according to the present invention, a power transmission gear wheel mounted on the other end portion of the carrier shaft for joint rotation therewith. This makes it possible to supply power to the machine when used, for instance, as a compressor, and derive power from the machine when utilized as an expansion motor, in a very simple manner.
[0023] A further utilization of this rotary machine can be found in the area of industrial evacuation pumps and rotary pumps or, as the case may be, in modified internal combustion engines or thermal machines of the Stirling type.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0024] The present invention will be explained in more detail below with reference to the accompanying drawing in which:
[0025] FIG. 1 is an axial sectional view of the rotary machine of the present invention in its assembled condition, taken on line B-B of FIG. 2 ;
[0026] FIG. 2 is a cross-sectional view, taken on line A-A of FIG. 1 , of the construction of the rotary machine with two twin blades in an immediate basic configuration;
[0027] FIGS. 3 a to 3 c are an axial sectional view, flanked by respective cross-sectional views taken on line F-F and on line E-E, of the implementation of two rings of the rotary part of the machine with entraining bars;
[0028] FIG. 4 is a partially exploded axonometric view of the rotary part of the machine with the entraining rings and entraining bars as shown in FIGS. 3 a to 3 c;
[0029] FIGS. 5 a and 5 b and FIGS. 6 a and 6 b are respective end and side elevational views of an example of the implementation of the twin blades and their connecting-rod eyes for a rotary machine with two twin blades;
[0030] FIG. 7 , is a view similar to FIG. 1 but depicting, in a longitudinal sectional view taken on line B′-B′ of FIG. 8 , an alternative construction of the rotary machine adapted for the mounting of eight twin blades;
[0031] FIG. 8 is a view corresponding to FIG. 2 but taken on line A′-A′ of FIG. 7 , of an applied construction of the rotary machine with the configuration of channels for the function of the rotary machine as an expansion drive machine with the utilization of the rotary machine with eight twin blades;
[0032] FIG. 9 is a view similar to that of FIG. 8 but taken on line A″-A″ of FIG. 7 , of the implementation of the rotary machine with eight twin blades and with the configuration of the channels for the function of the rotary machine as a compressor;
[0033] FIG. 10 is a partially sectioned view through the working part of the machine akin to that of FIG. 9 , for the application with an expansion drive unit for the utilization of low-potential heat from a geothermal system;
[0034] FIG. 11 is a view corresponding to that of FIG. 10 but for the application of the machine for the utilization of low-potential heat from solar energy;
[0035] FIG. 12 is a highly diagrammatic view of the instantaneous configuration and position of the twin blades of the implementation FIGS. 1 to 6 b in the bore in the working central module of the stator housing, taken basically on line A-A of FIG. 2 ;
[0036] FIG. 13 is a graphic representation showing the derivation of the conchoidal curve of the movement of the end points of the axis of the twin blade during the rotation, with the indicated comparison circle;
[0037] FIG. 14 is another graphic representation individually illustrating the conchoidal curve together with mathematical quantities introduced into the parametric equation; and
[0038] FIGS. 15 a to 15 d are views corresponding to FIG. 13 but at a reduced scale and showing the positions of one of the twin blades relative to the inner surface of the stator housing and to the rotor part in four different consecutive phases of rotation of the rotor part.
DETAILED DESCRIPTION OF THE INVENTION
[0039] Referring now to the drawing in detail, and first to FIG. 1 . thereof, it may be seen that it depicts an example of the implementation of the machine according to the invention that is arranged for two twin blades. The machine includes a stator housing 1 , which is constituted by individual plate-shaped modules that are connected to one another. A pair of plate-shaped end modules 1 . 1 , 1 . 2 axially terminates the stator housing 1 . A carrier shaft 4 centered on an axis o 2 is supported in the housing 1 by means of a pair of carrier shaft bearings 4 . 5 , 4 . 6 . On the carrier shaft 4 , there is formed a central first pair of eccentric members 4 . 2 centered on an axis o 3 for a second twin blade 3 . 1 supported by means of a pair 3 . 4 of connecting-rod eyes of the second twin blade 3 . 1 , and a second, axially spaced pair 4 . 1 of eccentric members flanking the first pair of eccentric members 4 . 2 and centered on an axis o 1 for a first twin blade 3 supported by means of a pair 3 . 3 of connecting-rod eyes of the first twin blade 3 . A pair of annular modules 1 . 3 , 1 . 4 , as well as a central working module 1 . 5 are situated between the pair of the end modules 1 . 1 , 1 . 2 . A pair of entraining rings 5 , 5 . 1 is supported, on a pair of annular bearings 5 . 2 , 5 . 3 , in the pair of annular modules 1 . 3 , 1 . 4 , The entraining rings 5 , 5 . 1 are mutually interconnected by entraining bars 6 , which are on both sides in sliding contact with each of the end surfaces of the pair of twin blades 3 , 3 . 1 .
[0040] A pinion 8 is formed on the entraining ring 5 . 1 . The pinion 8 is equipped with external teeth that are in a permanent meshing relationship with external teeth of an inner countershaft gear wheel 7 . The gear wheel 7 is supported on a countershaft 7 . 1 that is supported in the plate-shaped end module 1 . 2 by means of a pair of countershaft bearings 7 . 2 . The countershaft 7 . 1 is provided at its outer end with an outer countershaft gear wheel 7 . 3 with external teeth that are in permanent meshing relationship, in a transmission ratio of 1:2, with external teeth of an outer gear wheel 4 . 3 of the carrier shaft 4 . The carrier shaft 4 is provided at the opposite end that is remote from the pinion 8 with an external gear wheel 4 . 4 serving, depending on the use of the rotary machine, as a power input or a power output member. For simplification, reference will be had throughout this application merely to “power” or “torque”, regardless of whether they constitute the input or the output of the machine.
[0041] FIG. 2 shows the rotary part 2 and the instantaneous basic or initial position of the pair of twin blades 3 , 3 . 1 in the working space 1 . 6 of the central working module 1 . 5 , and also indicates a direction s of rotation of the rotary part 2 .
[0042] In FIGS. 3 a to 3 c , there is visible, in FIG. 3 a , the arrangement of entraining bars 6 on an entrainment ring 5 , and in FIG. 3 c , the construction of an entraining ring 5 . 1 on the side facing toward the working space 1 . 6 . Between FIGS. 3 a and 3 a , there is situated the axial sectional view of FIG. 3 b that shows the construction of the entraining rings 5 , 5 . 1 and their support on the entraining ring bearings 5 . 2 and 5 . 3 .
[0043] FIG. 4 depicts the arrangement of the entraining rings 5 , 5 . 1 and the construction of the entraining bars 6 in an axonometric projection, between which there are visible respective guiding slots for the twin blades 3 and 3 . 1 .
[0044] FIGS. 5 a and 5 b , and FIGS. 6 a and 6 b show in detail a currently preferred implementation of the twin blades 3 and 3 . 1 , wherein the first twin blade 3 with a supporting first blade connecting-rod eye 3 . 3 is visible in FIGS. 5 a and 5 b and the detailed construction of the second twin blade 3 . 1 with a supporting second blade connecting-rod eye 3 . 4 is visible in FIGS. 6 a and 6 b.
[0045] In FIG. 7 , there is depicted, in a longitudinal section, an example of the embodiment of the rotary machine of the present invention with a carrier shaft 4 . 7 equipped for the support of eight twin blades in a central working module 1 . 5 . 1 .
[0046] FIG. 8 and FIG. 9 represent applications of the rotary machine according to the invention with eight twin blades, which are determined by the desired technical solutions, where, in FIG. 8 , an arrangement is depicted for the use of the machine as an expansion drive unit with an inlet channel V, the main output channel V. 1 and an auxiliary output channel V. 2 , and in FIG. 9 , here is depicted the arrangement for the utilization of the machine in the function of a compressor, with a compressor input channel V. 3 and a compressor output channel V. 4 .
[0047] In FIG. 10 , there is depicted a rotary machine with eight twin blades, placed as an expansion drive unit utilizing the low-potential thermal energy of a hot spring 9 , wherein there is visible a closed circulating circuit 11 of the working medium and a cooler 10 of the geothermal working medium.
[0048] FIG. 11 illustrates a rotary machine with eight twin blades, placed as an expansion drive unit utilizing solar energy obtained by means of an array of focusing devices 12 for the solar energy in a closed circuit 11 . 1 of the working medium with a cooler 10 . 1 of the solar energy working medium.
[0049] FIG. 12 represents the instantaneous configuration and initial position of a pair of twin blades 3 , 3 . 1 , wherein the first twin blade 3 is situated in its initial position M, N, where respective points M and N are the points of intersection of an axis o of the first twin blade 3 with a conchoid curve k ch and with a curve k k of a comparison circle. In all other positions, for instance even in the position angularly displaced by 45° in the direction s of rotation into a position M′, N′, the intersection point of the angularly displaced axis o′ of the first twin blade 3 remains on the conchoid curve k ch, but it does not follow the curve k k of the comparison circle any more. Simultaneously, the second twin blade 3 . 1 gets in the same manner into the position M″. N″.
[0050] FIG. 13 depicts the geometric derivation of the shape of the working space 1 . 5 . 2 formed in the central working module 1 . 5 of the stator housing 1 , wherein the outline curve k ch of the conchoid reveals its conchoidal shape and where there is evident the curve k k of the comparison circle with its center at a point A situated on the axis o 1 and having a diameter d/2. This shows the difference between its actual shape corresponding to the curve k ch of the conchoid and the comparison curve k k with a diameter d=MN that simultaneously corresponds to the length of the twin blade as taken on its axis o. Simultaneously, there is indicated here a controlling circle k k of the curve k ch of the conchoid with a center located at the point B situated on the axis o 2 of the carrier shaft 4 . The initial position of the respective twin blade represents, on the one hand, the length d that simultaneously corresponds to the dimension MN on its axis o, and at the same time the limiting diameter of the curve k ch of the conchoid of the same diameter as the length d, wherein d=length of the twin blade=diameter of the curve k k of the comparison circle=diameter of the curve k ch of the conchoid in the initial position of the twin blade with the end points M, N. The controlling circle k r of the curve k ch of the conchoid has a diameter e, wherein 2 e represents the length of the maximum protrusion of the twin blade out of the rotor part. The point P represents the intersection of all of the axes of the twin blades in all positions and lies on the axis o 3 .
[0051] In FIG. 14 , there is individually illustrated the mathematical derivation of the conchoidal curve k ch, the parametric equation of which in polar coordinates P (ρ, φ) is
ρ= e .cos φ+/−½ d
wherein ρ denotes the distance on the curve k ch of the conchoid from the pole P, φ denotes the instantaneous turning angle of the axis o of the twin blade, wherein φ=45° for this illustrated instantaneous example, and P denotes the point of origin of the set of polar coordinates (ρ, φ) of the axis o of the twin blade that moves on the curve k ch of the conchoid. The axes of all of the twin blades in all possible turning angles always pass through the point P which may thus be referred to as the pole.
[0052] The function of the machine according to the invention can be explained with the aid of FIG. 1 . FIG. 2 and FIG. 12 , wherein during the turning of the symmetrical twin blade 3 out of the initial position M, N in the direction of rotation s, there occurs a deviation of the center of the twin blade 3 along the controlling circle k r of the conchoid in dependence on the corresponding turning of the eccentric member 4 . 1 formed on the carrier shaft 4 . As a result of this, there occurs the projection of the twin blade 3 out of the rotor part 2 and back in such a manner that the end points M′, N′ of the axis o of the twin blade 3 always precisely track the curve k ch of a conchoid that is identical with the conchoidal curve k ch formed in the central working module 1 . 5 of the stator housing 1 . The pair of twin blades 3 , 3 . 1 then subdivides the work space 1 . 5 . 2 into four compartments that, owing to the eccentric support of the rotor part 2 , continuously change their volume during the rotation of the rotor part 2 , wherein the volume of each of such compartments increases at first in the sense of expansion and, after the respective end portion of the twin blade 3 has reached the lower turning point corresponding to the maximum volume of the compartment, the volume of the respective compartment decreases in the sense of compression. In the course of repeated turning of the rotor part 2 , there is obtained uninterrupted retrieval of expansion work out of the energy medium in the event of the utilization as an expansion drive unit and/or consumption of input work for obtaining a compressed medium in the event of the utilization in the function of a compressor.
[0053] FIGS. 15 a to 15 d , from which most of the alphanumeric reference characters have been omitted in order not to unnecessarily clutter the drawing, depict the positions of one of the twin blades (such as the twin blade 3 referred to previously), that such blade assumes relative to the stator housing and to the rotor part as the latter turns in the direction indicated by the arrow s. In this diagrammatic representation, the blade in question is represented by a thick black line, while the position of the center of the respective twin blade is indicated by a white area on that thick black line.
[0054] In FIG. 15 a , the blade is in its initial (vertical) position and its center (which is always situated on the controlling circle k r ) is at the lowest point of that circle. The next phase of the movement of the rotor part and of the twin blade is shown in FIG. 15 b . In this position, the rotor part had moved in the direction of rotation s by 45°, but the center of the twin blade has moved, due to the double angular velocity of the carrier shaft with respect to the rotor part, into a position on the right of the controlling circle k r that corresponds to the angular displacement of 90°. In the next phase shown in FIG. 15 c , it is the twin blade that has been displaced by 90° out of its initial position, but at this time the center of the twin blade has reached the top of the controlling circle k r , that is a position corresponding to 180°. Another 45° increment of movement brings the blade into the position shown in FIG. 15 d and its center to the right of the controlling circle k r , that is into the position corresponding to 270°. Another 45° displacement would then bring the blade into a position corresponding to that shown in FIG. 15 a , except that the blade would now be, inasmuch as the rotor part has conducted an angular displacement of only 180° by this time, in an upside down position. In all other respects, however, the process of moving through the four phases—and the positions inbetween them—would be repeated on the further turning of the rotor part, so long as the rotary machine is in operation.
[0055] It may be seen from FIGS. 15 a to 15 d that the movement of the center of the twin blade on the controlling circle k r coincides with the withdrawal of one end portion of the twin blade into, and the corresponding projection of the other end portion of the twin blade out of, the rotor part. This is consistent with the movement of the ends of such end portions along the conchoidal curve k ch . However, it is to be realized that this kind of movement along the curve k ch is not accidental. Rather, it is caused, or forced, by the action on the twin blade of the respective eccentric member carried on the carrier shaft for joint rotation with it. This means that the in-and-out movement of the twin blade relative to the rotor part, and its consequent movement relative to the stator housing, is determined not by a sliding contact of any part of the twin blade with either some sliding support contained within the rotor part or, worse yet, with the surface bounding the internal chamber of the stator housing, but rather solely by the cooperation of the twin blade with the respective associated eccentric members of the carrier shaft. That, however, is an area where any frictional losses can be kept to a minimum by the use of anti-friction or even friction bearings. At the same time, this solution makes it possible to avoid any contact of the ends of the twin blades with the internal surface of the stator housing, where frictional losses encountered in prior constructions are tremendous and even exacerbated if springs are used in addition to centrifugal forces to press the blade ends against the internal surface of the stator. Thus, the ends of the twin blades need not actually come in contact with the internal surface of the stator housing but can move at a minimum distance therefrom, i.e. in the immediate or close proximity of the internal surface.
[0056] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by using merely ordinary skill in the art, readily adapt it to various applications in various fields and environments.
[0057] While the present invention has been described and shown as embodied in several implementations and possible applications, it is to be understood that various modifications of the structure, as well as other uses, of the machine may be made without leaving the realm of the invention as defined in the following claims. | A rotary machine with orbiting twin blades, especially for expansion drive units and compressors, includes a stator housing bounding an internal chamber, a rotor part received in the chamber for rotation and including at least two entraining rings axially spaced from one another and at least four entraining bars interconnecting the entraining rings and defining respective slots between themselves. A carrier shaft is mounted in the internal chamber for rotation and carries for joint rotation therewith at least two pairs of eccentric members. At least two twin blades are each supported on one of the pairs of eccentric members for relative turning therebetween and each includes two blade portions passing through oppositely located associated ones of the slots into close proximity of the inner peripheral surface of the stator housing. A transmission is provided that transmits torque between the rotor part and the carrier shaft in a permanent 1:2 transmission, causing the carrier shaft to rotate in the same direction as but at double the speed of the rotor part and causing the eccentric members mounted thereon to force the twin blades to follow the inner surface of the stator housing still at the aforementioned close proximity thereof. | 5 |
RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 14/176,735 entitled “LOCATION BASED NOTIFICATION SERVICES”, filed Feb. 10, 2014, which is a continuation of Ser. No. 13/118481, (U.S. Pat. No. 8,686,852), entitled “LOCATION-BASED NOTIFICATION SERVICES”, filed May 30, 2011, both of which are incorporated herein in their entireties.
BACKGROUND
[0002] There are numerous cases when people want to know when children, employees, friends, vehicles (e.g., buses, trains, cars, etc.), etc., arrive or depart or just linger at a specific location, and also want to be notified immediately when the arrival, departure, or lingering event occurs. However, in all other cases, the location could remain private. For example, parents want to know if a child left the school perimeter in the middle of the day (e.g., during workdays only), a parent wants to know if a son is driving on the highway on a rainy night, or a teenager wants to know when a friend arrives at any mall during weekends.
SUMMARY
[0003] The following presents a simplified summary in order to provide a basic understanding of some novel embodiments described herein. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
[0004] The disclosed architecture can generate a notification when a user arrives at, lingers in, or departs from a location--with or without exposing the location information. Exposure of the location information can be managed according to permissions or privileges. Moreover, the notification can be generated and transmitted at any and all times.
[0005] The architecture provides the capability to run on a mobile phone (e.g., with geo-location capabilities), and manages user requests and user approvals for location based notifications, alerts a requesting user (e.g., via a mobile phone, desktop computer, a portable computer, and/or other suitable device) that target user arrived at one of previously-specified points of interest. Similarly, a general category or class of location can be specified, such as “malls in the city of Seattle” (the point of interest does not need to be specific but can be a member of the class).
[0006] The architecture can comprise a reminder service that manages all reminder requests and approvals (for privacy issues), a notification engine that notifies a requesting user when target user arrived at a specific location or one of a general category of location, and a user interface that allows the user to set reminders that are displayed when the target user arrives at the destination and approves other user reminder requests.
[0007] To the accomplishment of the foregoing and related ends, certain illustrative aspects are described herein in connection with the following description and the annexed drawings. These aspects are indicative of the various ways in which the principles disclosed herein can be practiced and all aspects and equivalents thereof are intended to be within the scope of the claimed subject matter. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as they are better understood by reference to the following description when taken in conjunction with the following drawings, wherein:
[0009] FIG. 1 illustrates a notification system in accordance with the disclosed architecture.
[0010] FIG. 2 illustrates a more detailed embodiment of a notification system in accordance with the disclosed architecture.
[0011] FIG. 3 illustrates a system that includes components and entities for reminder management, notification management, geo-location processes, and client operations.
[0012] FIG. 4 illustrates a computer-implemented notification method in accordance with the disclosed architecture.
[0013] FIG. 5 illustrates further aspects of the method of FIG. 4 .
[0014] FIG. 6 illustrates a block diagram of a computing system that executes notification and reminders in accordance with the disclosed architecture.
[0015] FIG. 7 illustrates a schematic block diagram of an exemplary smart mobile device that processes notification and reminders in accordance with the disclosed architecture.
DETAILED DESCRIPTION
[0016] The disclosed architecture includes a notification system that sends one or more notifications and reminders to requesting users based on geographic location of a target user relative to one or more points of interest (geographical locations). The system and methods can run on computing devices such as mobile phones, portable computers, desktop computers, and so on, and can utilize online services.
[0017] Generally, the architecture can include a reminders component (e.g., a service) that provides user interfaces (UIs) which enable the creation and configuration of reminder requests and approvals, and a notification component that communicates one or more notifications when the target user reaches, enters, and/or exits the specified point of interest and maintains fresh data about the points of interest that satisfies refreshable queries.
[0018] The UIs enable the user to set reminders that are displayed when the target user meets the geo-location criteria for the location (and any other defined filters such as time, date, speed, weather, prior locations visited, etc.), and approve other user reminder requests.
[0019] The disclosed architecture can be employed for a wide variety of purposes that include ensuring the safety of children and adults, identifying geolocation for taxation purposes (e.g., mileage), identifying geolocation for job performance (e.g., electronic time card for arrival at a construction site), identifying geolocation information of property movement and utilization, and so on.
[0020] Reference is now made to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the novel embodiments can be practiced without these specific details. In other instances, well known structures and devices are shown in block diagram form in order to facilitate a description thereof. The intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the claimed subject matter.
[0021] FIG. 1 illustrates a notification system 100 in accordance with the disclosed architecture. The system 100 can include a reminder component 102 that manages configuration and approval of a reminder 104 related to (via a geographical relationship 106 ) the geographic location of a target device 108 relative to a point of interest (POI) 110 . The relationship 106 between the target device 108 and the point of interest 110 can be defined according to proximity of the target device 108 to the point of interest 110 , if the target device 108 is detected to have entered the point of interest 110 , if the target device 108 has exited the point of interest 110 , and/or lingered (dwell time) at the point of interest 110 , for example.
[0022] A notification component 112 of the system 100 monitors the geographical location of the target device 108 and communicates a notification 114 (denoted NOTIF) to a requesting device 116 according to the reminder 104 when the geographic location of the target device 108 meets geo-location criteria (e.g., near, in, or exiting) related to the point of interest 110 . Although showing only a single requesting device 116 , it is within contemplation of the disclosed architecture that there can be multiple requesting devices, as is described herein below.
[0023] The target device 108 can be a mobile device (e.g., a cellphone) the geographical location of which is monitored, and the requesting device 116 can be a mobile device (e.g., a cellphone) to which the notification 114 is communicated. Alternatively, the target device can be a mobile phone and the requesting devices can include one or more of a computing device (e.g., portable computer, desktop computer, tablet computer, etc.), a web server, a mobile phone, etc. The point of interest 110 can be a single geographic location specified in association with the reminder 104 .
[0024] The point of interest 110 can be one of a class of locations (e.g., all restaurants, all shopping malls in a five mile radius, etc.) specified in association with the reminder 104 and the notification 114 is communicated when the target device 108 meets the geo-location criteria for one location (e.g., POI 110 ) of the class. In other words, a query provided to the system 100 can be “all shopping malls”. Thus, when the target device 108 (as carried by a user) enters any shopping mall, such as the point of interest 110 , the notification 114 and reminder 104 are triggered for communication to all intended and approved requesting devices (e.g., requesting device 116 ).
[0025] In this embodiment, the notification component 112 can receive geo-location information 118 that determines the geographical relationship 106 between the target device 108 and the point of interest 110 . The geo-location information 118 can be obtained from a technology that identifies location of an entity, such as global positioning system (GPS), triangulation, access points, and other techniques used to ascertain the geographical location of the entity (e.g., cell phone).
[0026] Geo-fencing technology can be employed to determine the proximity relative to a point of interest. A geo-fence is a predefined virtual perimeter (e.g., within a two mile radius) relative to a physical geographic area. When the geo-location of the target device 108 matches the geo-location information that defines the virtual perimeter (denoted by the dotted line object surrounding the POI 110 and other POIs), specified events can be triggered to occur, such as sending the notification 114 to the requesting device 116 .
[0027] FIG. 2 illustrates a more detailed embodiment of a notification system 200 in accordance with the disclosed architecture. In this implementation, the notification component 112 can include a geo-location component 202 that identifies geo-location points of interest (e.g., POI 110 ) relative to a query (e.g., all shopping malls). The query can be refreshed to include added points of interest (e.g., POI 204 ) and removed points of interest (e.g., POI 206 ) associated with a geo-fence. The reminder 104 is then processed based on the refreshed query.
[0028] The reminder component 102 can include a user interface (UI) 208 that facilitates creation of the reminder 104 (and other reminders), approval of the reminder 104 from the requesting device 116 , and an action associated with the reminder 104 . In other words, the UI 208 can be included as part of the client user interface of the target device 108 , or any suitable client device (e.g., desktop computer). Alternatively, or in combination therewith, the capabilities of the UI 208 can be made accessible via a web service that the use of the target device 108 . For example, a user may log into the web service to access the functionality to create and/or approve the reminder 104 . Likewise, the requesting device 116 can access the web service (via the UI 208 ) to create the reminder 104 and define associated actions. It is to be understood that the reminder component 102 can include additional functionality, including, but not limited to, performing actions related to the notification component 112 , as well as accessing the geo-location information 118 . In an alternative embodiment, the notification component 112 can be part of the reminder component 102 such that the geo-location information 118 is received into the reminder component 102 .
[0029] The system 200 can further comprise a filter component 210 that applies a filter parameter to the geo-location criteria. The notification 114 is communicated to the requesting device 116 based on the filter parameter.
[0030] The system 200 can further comprise a permissions component 212 that processes a request by the requesting device 116 to access identification of location of the target device 108 and an approval of the target device 108 to allow geolocation identification by the requesting device 116 .
[0031] FIG. 3 illustrates a system 300 that includes components and entities for reminder management, notification management, geo-location processes, and client operations. The system 300 comprises a reminder component (e.g., service) that manages all reminder requests and approvals (e.g., for privacy issues) as well as reminder actions. The notification component 112 sends one or more notifications to the requesting device. A user interface enables the user to set reminders that will be displayed when the target device triggers geographical events (e.g., arrives at the point of interest). The user interface further enables the target device user to approve reminder requests from one or more requesting users (devices).
[0032] The system 300 illustrates a reminder settings UI 302 that further includes user interfaces such as a reminder creation UI 304 , a reminder removal UI 306 , and an actions UI 308 . Other user interfaces can be designed and utilized as desired. The reminder creation UI 304 enables the user to create one or more reminders for a single geo-fence event (the target device intersecting the virtual perimeter) or multiple events entering a point of interest and then exiting the point of interest. The reminder approval UI 306 enables the user to allow geolocation identification or to not allow geolocation identification. The actions UI 308 enables the user to set and associate actions with the reminder.
[0033] The reminder actions 310 include, but are not limited to, notifying contacts 312 (send one or messages such as an SMS (short message service) message to a specified list of contacts, an email to a specified list of contacts), call a user 314 (call a specified phone number or an emergency phone number (e.g., 9-1-1)), send geo-location identifier data 316 (send specific GPS trails (geolocation information in an emergency situation)), and record sensor data 318 (e.g., audio signals such as voices in the immediate vicinity of the target device (e.g., phone) and then sending some or all of this data to a designated entity or system).
[0034] The reminder component (the reminder settings UI 302 and reminder actions 310 ) can be a network service (a server side application that communicates with the clients, including target and requesting devices) and enables the following additional functionalities: the target user of the target device can give permission to other users (requesting users of requesting devices) to obtain the target user's location (e.g., obtain the target user's location at specific times); the requesting user can add and/or modify reminders (e.g., when the target user device is leaving a school perimeter or area); requesting users can maintain reminders from different machines (e.g., smartphones, computers, etc.); maintains a user base with privacy-related data; and provides fresh data for refreshable queries (e.g., “restaurants in Seattle”).
[0035] Additionally, the actions 310 can include activating one or more sensors on the target device to capture data which can be used to measure speed of the target device. The speed can indicate if the target device is moving according to a walking speed, jogging speed, running speed, driving speed, varying speed sequences (e.g., indicate approaching the point of interest, then slowing down to park followed by walking to access the point of interest), and so on.
[0036] The system 300 also includes the notification component 112 , which in this embodiment, further includes a geo-fencing engine 320 , a filter confirmation component 322 and query refresh component 324 . The notification component notifies the requesting device (User X) when the target device (User Y) triggered the geo-fence and/or arrived at a point of interest.
[0037] The geo-fencing engine 320 provides the capability to employ geo-fencing technology to signal when the target device (and user) reaches specified geographic locations such as a specific point of interest, enters the point of interest, exits the point of interest, and so on. The geo-fencing engine 320 notifies the requesting user when a target user has entered and/or exited one of the specified points of interest, and can store all the geo-fence data (e.g., geo-location information of the virtual fence associated with an area, geo-location of the target device, etc.).
[0038] The filter confirmation component 322 enables the creation and application of filter parameters. The parameters can include, but are not limited to, time filter (e.g., prefer the reminder only in association with a specific time), places filter (e.g., prefer one location over another location, only certain points of interest, etc.), the time and date, user speed, user heading, and/or environmental conditions (e.g., weather, road conditions, route conditions, traffic conditions, etc.).
[0039] The query refresh component 324 enables a standing query to be applicable to not only the original points of interest at the time the query was created and presented, but over time, to changes in the points of interest related to the query. In other words, original points of interest at the time the query was created can change due to the construction of new points of interest (e.g., a new shopping mall) and due to points of interest that no longer exist (e.g., police check points). The points of interest relevant to the standing query are then updated automatically (e.g., dynamically) based on the changes to an area or region of interest. This further dynamically changes the locations form which the reminder(s) will be triggered. For example, if a reminder was originally created to execute based on discovery of a shopping mall that includes Vendor X, the construction of a new shopping mall at a different location in the region of interest that includes a new location of Vendor X can also trigger a reminder (a new reminder) or the same reminder as for the original Vendor X.
[0040] In an implementation for a mobile device, a mobile operation system 326 of the mobile device can include a location subsystem 328 that facilitates determination of the geographical location of the mobile device. The operation subsystem 326 can further include an orientation and motion subsystem 330 which includes sensors (e.g., accelerometer) that facilitate the determination of speed and heading, for example, of the associated mobile device. A voice subsystem 332 can include the hardware and software for receiving and processing voice signals (e.g., speech).
[0041] It is to be understood that where user information (e.g., identifying geo-location information) may be made available to and utilized by others, the user is provided the option to opt-in or to opt-out of allowing this information to be captured and utilized. Accordingly, a security component can be provided which enables the user to opt-in and/or opt-out of identifying geolocation information as well as personal information that may have been obtained and utilized thereafter. The user can be provided with notice of the collection of information, for example, and the opportunity to provide or deny consent to do so. Consent can take several forms. Opt-in consent imposes on the user to take an affirmative action before the data is collected. Alternatively, opt-out consent imposes on the subscriber to take an affirmative action to prevent the collection of data before that data is collected. This is similar to implied consent in that by doing nothing, the user allows the data collection after having been adequately informed. The security component ensures the proper collection, storage, and access to the user information while allowing for the dynamic selection and presentation of the content, features, and/or services that assist the user to obtain the benefits of a richer user experience and to access to more relevant information.
[0042] Put another way, a notification system is provided that comprises a reminder component that includes a user interface which facilitates management of a reminder to a requesting device based on location of a target device relative to a point of interest, a permissions component that processes a request from the requesting device to access geo-location information associated with the target device and an approval from the target device to allow identification of geolocation by the requesting device, a geo-location component that identifies the geographic location of the target device relative to the point of interest based on a query, and a notification component that communicates a notification to the requesting device when the geographic location of the target device matches a virtual perimeter defined in association with the point of interest.
[0043] The query can define a single geographic point of interest or a class of points of interest, the notification is communicated when the target device matches the virtual perimeter. The notification component refreshes the query to include added points of interest associated with the virtual perimeter and removed points of interest associated with the virtual perimeter, and the reminder and notification are processed based on the refreshed query. The system can further comprise a filter component that applies a filter to information associated with the reminder, the notification is communicated to a user and/or multiple users defined in the reminder. The reminder includes reminder actions that when processed, at least one of notify contacts, call a user device, send geo-location information, or sense and record surrounding information. The notification component validates that the target device is at the point of interest based on conditions that include at least one of time, date, speed of the target device, heading of the target device, or environmental conditions.
[0044] Included herein is a set of flow charts representative of exemplary methodologies for performing novel aspects of the disclosed architecture. While, for purposes of simplicity of explanation, the one or more methodologies shown herein, for example, in the form of a flow chart or flow diagram, are shown and described as a series of acts, it is to be understood and appreciated that the methodologies are not limited by the order of acts, as some acts may, in accordance therewith, occur in a different order and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all acts illustrated in a methodology may be required for a novel implementation.
[0045] FIG. 4 illustrates a computer-implemented notification method in accordance with the disclosed architecture. At 400 , a query is input to monitor a target computing device relative to a geographical point of interest. At 402 , a reminder is configured to be associated with the target computing device. At 404 , the geographical location of the target computing device is monitored relative to the geographical point of interest. At 406 , the reminder is processed based on the geographical location of the target computing device relative to the geographical point of interest. At 408 , a notification is automatically communicated to a requesting computing device based on the geographical location of the target computing device relative to the point of interest.
[0046] FIG. 5 illustrates further aspects of the method of FIG. 4 . Note that the flow indicates that each block can represent a step that can be included, separately or in combination with other blocks, as additional aspects of the method represented by the flow chart of FIG. 4 . At 500 , approval is requested from the target computing device to monitor associated sensed data of the target computing device. At 502 , actions are defined associated with the reminder, the actions processed in response to execution of the reminder. At 504 , the query is refreshed to include new points of interest not previously included in the query. At 506 , the notification is communicated to multiple requesting computing devices. At 508 , actions of the reminder are filtered based on filter criteria.
[0047] As used in this application, the terms “component” and “system” are intended to refer to a computer-related entity, either hardware, a combination of software and tangible hardware, software, or software in execution. For example, a component can be, but is not limited to, tangible components such as a processor, chip memory, mass storage devices (e.g., optical drives, solid state drives, and/or magnetic storage media drives), and computers, and software components such as a process running on a processor, an object, an executable, a data structure (stored in volatile or non-volatile storage media), a module, a thread of execution, and/or a program. By way of illustration, both an application running on a server and the server can be a component. One or more components can reside within a process and/or thread of execution, and a component can be localized on one computer and/or distributed between two or more computers. The word “exemplary” may be used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs.
[0048] Referring now to FIG. 6 , there is illustrated a block diagram of a computing system 600 that executes notification and reminders in accordance with the disclosed architecture. However, it is appreciated that the some or all aspects of the disclosed methods and/or systems can be implemented as a system-on-a-chip, where analog, digital, mixed signals, and other functions are fabricated on a single chip substrate. In order to provide additional context for various aspects thereof, FIG. 6 and the following description are intended to provide a brief, general description of the suitable computing system 600 in which the various aspects can be implemented. While the description above is in the general context of computer-executable instructions that can run on one or more computers, those skilled in the art will recognize that a novel embodiment also can be implemented in combination with other program modules and/or as a combination of hardware and software.
[0049] The computing system 600 for implementing various aspects includes the computer 602 having processing unit(s) 604 , a computer-readable storage such as a system memory 606 , and a system bus 608 . The processing unit(s) 604 can be any of various commercially available processors such as single-processor, multi-processor, single-core units and multi-core units. Moreover, those skilled in the art will appreciate that the novel methods can be practiced with other computer system configurations, including minicomputers, mainframe computers, as well as personal computers (e.g., desktop, laptop, etc.), hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like, each of which can be operatively coupled to one or more associated devices.
[0050] The system memory 606 can include computer-readable storage (physical storage media) such as a volatile (VOL) memory 610 (e.g., random access memory (RAM)) and non-volatile memory (NON-VOL) 612 (e.g., ROM, EPROM, EEPROM, etc.). A basic input/output system (BIOS) can be stored in the non-volatile memory 612 , and includes the basic routines that facilitate the communication of data and signals between components within the computer 602 , such as during startup. The volatile memory 610 can also include a high-speed RAM such as static RAM for caching data.
[0051] The system bus 608 provides an interface for system components including, but not limited to, the system memory 606 to the processing unit(s) 604 . The system bus 608 can be any of several types of bus structure that can further interconnect to a memory bus (with or without a memory controller), and a peripheral bus (e.g., PCI, PCIe, AGP, LPC, etc.), using any of a variety of commercially available bus architectures.
[0052] The computer 602 further includes machine readable storage subsystem(s) 614 and storage interface(s) 616 for interfacing the storage subsystem(s) 614 to the system bus 608 and other desired computer components. The storage subsystem(s) 614 (physical storage media) can include one or more of a hard disk drive (HDD), a magnetic floppy disk drive (FDD), and/or optical disk storage drive (e.g., a CD-ROM drive DVD drive), for example. The storage interface(s) 616 can include interface technologies such as EIDE, ATA, SATA, and IEEE 1394, for example.
[0053] One or more programs and data can be stored in the memory subsystem 606 , a machine readable and removable memory subsystem 618 (e.g., flash drive form factor technology), and/or the storage subsystem(s) 614 (e.g., optical, magnetic, solid state), including an operating system 620 , one or more application programs 622 , other program modules 624 , and program data 626 .
[0054] The operating system 620 , one or more application programs 622 , other program modules 624 , and/or program data 626 can include entities and components of the system 100 of FIG. 1 , entities and components of the system 200 of FIG. 2 , the reminder component and mobile operation system 326 of system 300 of FIG. 3 , and the methods represented by the flowcharts of FIGS. 4-5 , for example.
[0055] Generally, programs include routines, methods, data structures, other software components, etc., that perform particular tasks or implement particular abstract data types. All or portions of the operating system 620 , applications 622 , modules 624 , and/or data 626 can also be cached in memory such as the volatile memory 610 , for example. It is to be appreciated that the disclosed architecture can be implemented with various commercially available operating systems or combinations of operating systems (e.g., as virtual machines).
[0056] The storage subsystem(s) 614 and memory subsystems ( 606 and 618 ) serve as computer readable media for volatile and non-volatile storage of data, data structures, computer-executable instructions, and so forth. Such instructions, when executed by a computer or other machine, can cause the computer or other machine to perform one or more acts of a method. The instructions to perform the acts can be stored on one medium, or could be stored across multiple media, so that the instructions appear collectively on the one or more computer-readable storage media, regardless of whether all of the instructions are on the same media.
[0057] Computer readable media can be any available media that can be accessed by the computer 602 and includes volatile and non-volatile internal and/or external media that is removable or non-removable. For the computer 602 , the media accommodate the storage of data in any suitable digital format. It should be appreciated by those skilled in the art that other types of computer readable media can be employed such as zip drives, magnetic tape, flash memory cards, flash drives, cartridges, and the like, for storing computer executable instructions for performing the novel methods of the disclosed architecture.
[0058] A user can interact with the computer 602 , programs, and data using external user input devices 628 such as a keyboard and a mouse. Other external user input devices 628 can include a microphone, an IR (infrared) remote control, a joystick, a game pad, camera recognition systems, a stylus pen, touch screen, gesture systems (e.g., eye movement, head movement, etc.), and/or the like. The user can interact with the computer 602 , programs, and data using onboard user input devices 630 such as a touchpad, microphone, keyboard, etc., where the computer 602 is a portable computer, for example. These and other input devices are connected to the processing unit(s) 604 through input/output (I/O) device interface(s) 632 via the system bus 608 , but can be connected by other interfaces such as a parallel port, IEEE 1394 serial port, a game port, a USB port, an IR interface, short-range wireless (e.g., Bluetooth) and other personal area network (PAN) technologies, etc. The I/O device interface(s) 632 also facilitate the use of output peripherals 634 such as printers, audio devices, camera devices, and so on, such as a sound card and/or onboard audio processing capability.
[0059] One or more graphics interface(s) 636 (also commonly referred to as a graphics processing unit (GPU)) provide graphics and video signals between the computer 602 and external display(s) 638 (e.g., LCD, plasma) and/or onboard displays 640 (e.g., for portable computer). The graphics interface(s) 636 can also be manufactured as part of the computer system board.
[0060] The computer 602 can operate in a networked environment (e.g., IP-based) using logical connections via a wired/wireless communications subsystem 642 to one or more networks and/or other computers. The other computers can include workstations, servers, routers, personal computers, microprocessor-based entertainment appliances, peer devices or other common network nodes, and typically include many or all of the elements described relative to the computer 602 . The logical connections can include wired/wireless connectivity to a local area network (LAN), a wide area network (WAN), hotspot, and so on. LAN and WAN networking environments are commonplace in offices and companies and facilitate enterprise-wide computer networks, such as intranets, all of which may connect to a global communications network such as the Internet.
[0061] When used in a networking environment the computer 602 connects to the network via a wired/wireless communication subsystem 642 (e.g., a network interface adapter, onboard transceiver subsystem, etc.) to communicate with wired/wireless networks, wired/wireless printers, wired/wireless input devices 644 , and so on. The computer 602 can include a modem or other means for establishing communications over the network. In a networked environment, programs and data relative to the computer 602 can be stored in the remote memory/storage device, as is associated with a distributed system. It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers can be used.
[0062] The computer 602 is operable to communicate with wired/wireless devices or entities using the radio technologies such as the IEEE 802.xx family of standards, such as wireless devices operatively disposed in wireless communication (e.g., IEEE 802.11 over-the-air modulation techniques) with, for example, a printer, scanner, desktop and/or portable computer, personal digital assistant (PDA), communications satellite, any piece of equipment or location associated with a wirelessly detectable tag (e.g., a kiosk, news stand, restroom), and telephone. This includes at least Wi-Fi (or Wireless Fidelity) for hotspots, WiMax, and Bluetooth™ wireless technologies. Thus, the communications can be a predefined structure as with a conventional network or simply an ad hoc communication between at least two devices. Wi-Fi networks use radio technologies called IEEE 802.11x (a, b, g, etc.) to provide secure, reliable, fast wireless connectivity. A Wi-Fi network can be used to connect computers to each other, to the Internet, and to wire networks (which use IEEE 802.3-related media and functions).
[0063] FIG. 7 illustrates a schematic block diagram of an exemplary smart mobile device 700 that processes notification and reminders in accordance with the disclosed architecture. In order to provide additional context for various aspects thereof, FIG. 7 and the following discussion are intended to provide a brief, general description of a suitable environment in which the various aspects of the innovation can be implemented. While the description includes a general context of computer-executable instructions, those skilled in the art will recognize that the innovation also can be implemented in combination with other program modules and/or as a combination of hardware and software.
[0064] Generally, applications (e.g., program modules) can include routines, programs, components, data structures, etc., that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the inventive methods can be practiced with other system configurations, including single-processor or multiprocessor systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like, each of which can be operatively coupled to one or more associated devices.
[0065] The smart device 700 (e.g., a cell phone, PDA) can typically include a variety of computer-readable media. Computer-readable media can be any available media accessed by the handset systems and includes volatile and non-volatile media, removable and non-removable media. By way of example, and not limitation, computer-readable media can comprise device storage media and communication media. Storage media includes volatile and/or non-volatile, removable and/or non-removable media implemented in any method or technology for the storage of information such as computer-readable instructions, data structures, program modules or other data. Storage media can include, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital video disc (DVD) or other optical disk storage, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by the mobile device systems.
[0066] The smart device 700 includes a processor 702 for controlling and processing onboard operations and functions. A memory 704 interfaces to the processor 702 for the storage of data and one or more applications 706 (e.g., a video player software, user feedback component software, etc.).
[0067] The applications 706 can include the reminder component (settings UI 302 and reminder actions 310 ) of the system 100 of FIG. 1 , one or more of the entities and components of the system 200 of FIG. 2 , the mobile operation system 326 of system 300 of FIG. 3 , and methods as provided herein in FIGS. 4-5 , for example. The applications also facilitate direct (e.g., wired and/or wireless) communications with the external systems.
[0068] The applications 706 can also include a user interface (UI) application 708 that operates with a client 710 (e.g., operating system) to facilitate user interaction with handset functionality and data, for example, answering/initiating calls, entering/deleting data, configuring settings, address book manipulation, multimode interaction, etc. The applications 706 can include other applications 712 that came installed with the device 700 and/or can be installed as add-ons or plug-ins to the client 710 and/or UI 708 , for example, or for other purposes (e.g., processor, firmware, etc.).
[0069] The other applications 712 can include voice recognition of predetermined voice commands that facilitate user control, call voice processing, voice recording, messaging, e-mail processing, video processing, image processing, music play, as well as subsystems or components described infra. Some of the applications 706 can be stored in the memory 704 and/or in a firmware 714 , and executed by the processor 702 from either or both the memory 704 or/and the firmware 714 . The firmware 714 can also store code for execution in power-up initialization and control during normal operation of the smart device 700 .
[0070] A communications component 716 can interface to the processor 702 to facilitate wired/wireless communications with external systems, for example, cellular networks, VoIP (voice-over-IP) networks, local wireless networks or personal wireless networks such as Wi-Fi, Wi-Max, and so on. Here, the communications component 716 can also include a multimode communications subsystem for providing cellular communications via different cellular technologies. For example, a first cellular transceiver 718 (e.g., GSM) can be one mode and an Nth transceiver 720 can provide cellular communications via an Nth cellular network (e.g., UMTS), where N is a positive integer. The communications component 716 can also include a transceiver 722 for unlicensed communications (e.g., Wi-Fi, Wi-Max, Bluetooth, etc.) for corresponding communications. The communications component 716 can also facilitate communications reception from terrestrial radio networks (e.g., broadcast), digital satellite radio networks, and Internet-based radio services networks.
[0071] The smart device 700 can process IP data traffic via the communications component 716 to accommodate IP traffic from an IP network such as, for example, the Internet, a corporate intranet, a home broadband network, a personal area network, etc., via an ISP or broadband cable provider. Thus, VoIP traffic can be utilized by the smart device 700 and IP-based multimedia content can be received in an encoded and/or decoded format.
[0072] The smart device 700 includes a display 724 for displaying multimedia that include text, images, video, telephony functions (e.g., a Caller ID function), setup functions, menus, etc. The display 724 can also accommodate the presentation of multimedia content (e.g., music metadata, messages, wallpaper, graphics, etc.).
[0073] An input/output (I/O) interface 726 can be provided for serial/parallel I/O of data and/or signals (e.g., USB, and/or IEEE 1394 ) via a hardwire connection, and other I/O devices (e.g., a keyboard, keypad, mouse, interface tether, stylus pen, touch screen, etc.). The I/O interface 726 can be utilized for updating and/or troubleshooting the smart device 700 , for example.
[0074] Audio capabilities can be provided via an audio I/O component 728 , which can include a speaker for the output of audio signals related to, for example, indication that the user pressed the proper key or key combination to initiate the user feedback signal, call signals, music, etc. The audio I/O component 728 also facilitates the input of audio signals via a microphone to record data and/or telephony voice data, and for inputting voice signals for telephone conversations.
[0075] The smart device 700 can include a slot interface 730 for accommodating a subscriber identity system 732 that can accommodate a SIM or universal SIM (USIM), and interfacing the subscriber identity system 732 with the processor 702 . However, it is to be appreciated that the subscriber identity system 732 can be manufactured into the smart device 700 and updated by downloading data and software thereinto, such as the access information described herein.
[0076] An image capture and processing system 734 (e.g., a camera) can be provided for decoding encoded image content. Additionally, as indicated, photos can be obtained via an associated image capture subsystem of the image system 734 . The smart device 700 can also include a video component 736 for processing video content received and, for recording and transmitting video content.
[0077] Optionally, a geolocation component 738 (e.g., GPS-global positioning system) facilitates receiving geolocation signals (e.g., from satellites via the communications component 716 ) that define the location of the smart device 700 . Alternatively, or in combination therewith, the geolocation component 738 can facilitate triangulation processing for locating the smart device 700 .
[0078] The smart device 700 also includes a power source 740 in the form of batteries and/or an AC power subsystem, which power source 740 can interface to an external power system or charging equipment (not shown) via a power I/O component 742 .
[0079] What has been described above includes examples of the disclosed architecture. It is, of course, not possible to describe every conceivable combination of components and/or methodologies, but one of ordinary skill in the art may recognize that many further combinations and permutations are possible. Accordingly, the novel architecture is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. | Architecture that generates a notification when a user arrives at a location, but without exposing identity of the location. Moreover, the notification can be generated and transmitted at all times. The architecture comprises a reminder service that manages all reminder requests and approvals, a notification engine that notifies a requesting user when target user arrived at a specific location or one of a general category of location, and a user interface that allows the user to set reminders that are displayed when the target user arrives at the point of interest and approves other user reminder requests. The architecture can be run on a mobile phone, and manages user requests and user approvals for location based notifications, alerts a requesting user the target user arrived at one of previously-specified points of interest. Similarly, a general category of destination can be specified, rather than a specific point of interest. | 6 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The Present Application claims priority to U.S. Provisional Patent Application No. 61/235,614, filed On Aug. 20, 2009.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The field of the invention generally relates to electronic devices which utilize the global positioning system (“GPS”) to determine locations and distances, and more particularly to a GPS device for determining distances to features on a golf course, and displaying the distances to features, golf course animations, and/or other golf related data. The invention also relates to systems and methods for supporting such a GPS device.
[0005] 2. Description of the Related Art
[0006] In golf, there is always a need for more information. Knowing more information about the course being played gives players of all abilities a better chance to improve their game or make the right shot choice. Standard golf GPS provides distance to the front, middle and back of the green. This is typically not enough information for players to make the best choices. Having the ability to measure to or from anything on the golf course provides detailed information which quickly becomes indispensable.
[0007] Currently, the only competing solutions allow either movement limited only to the Green, or in another case, allows movement of a measurement point around a representation of the hole however does not allow measurement to or from anything on the course. In the former case, a crosshair can be moved around the area of the green, allowing limited functionality. In the latter case, the cursor movement covers the whole course, however the measurement is always from the current user location to the cursor, and from the cursor to a selected point on the green.
[0008] Various golf GPS devices, both handheld and golf cart-mounted, have been previously disclosed and described in the prior art. Generally, these devices comprise a GPS receiver and processing electronics (the “GPS system”), a display such as a liquid crystal display (“LCD”) or cathode ray tube (“CRT”), and a user input device such as a keypad. Golf course data is input and stored in the golf GPS device, including for example, the coordinates for locations of greens, bunkers and/or other course features. These types of devices use the GPS system to determine the location of the device. Then, the device calculates and displays the distances to the various golf course features, such as the distance to the front, middle and back of the green, or the distance to a bunker or water hazard. Accordingly, by placing the device at or near the golfer's ball, the device can relatively easily and accurately provide the golfer with important distance information usable while playing golf. For example, the distance information is used by the golfer to formulate strategy for playing a hole (sometimes called “course management”) and for club selection.
[0009] As an example of a golf GPS device, U.S. Pat. No. 5,507,485 (“the '485 patent”), which is hereby incorporated by reference herein in its entirety, purports to disclose a golf GPS device which can display depictions of a golf hole including multiple, selectable views of each hole such as the approach to the green and the green itself. The '485 patent describes that the device is configured to automatically determine the location of the device using a GPS receiver and then automatically display the golf hole view that would be of immediate interest to the golfer. Although the '485 patent discloses that the distance to displayed features may be indicated on the display, there is no description of how or where such information is displayed. The '485 patent also describes that the device may include other features such as means for receiving climate (i.e. temperature and humidity) and weather (i.e. wind speed and direction) conditions, means for recording and computing scores, bets and handicaps, means for recording details of a golf game sufficient to later replay and analyze a round of golf, means for suggesting shot and club selections to the golfer, clubs used and distances obtained for shots, and means for updating daily tee and hole positions on a removable integrated circuit (“IC”) card. The course data for each particular course is also described as being stored on removable IC cards which are interchangeable between a host computer and the golf computer.
[0010] However, the '485 patent does not describe how the course data is generated, or how daily tee and hole positions are determined. The means for updating and supplying course data through removable IC cards which are programmed on a host computer and then inserted into the golf computer is clumsy and inconvenient. Moreover, the '485 patent only describes a cart-based golf computer, and although the '485 patent suggests that portions of the device (the display and input means) could be implemented on a handheld unit such as the Apple Computer Company's NEWTON™, there is no enabling disclosure of a fully integrated, standalone, handheld golf GPS device.
[0011] U.S. Pat. No. 6,456,938 (“the '938 patent”), which is hereby incorporated by reference herein in its entirety, describes a handheld golf GPS device. The handheld device is described as software executed on a palm-held computer (PC) saddled into and connected directly to a dGPS (differential global positioning system or differential GPS) receiver. The handheld device of the '938 patent has a modular construction comprising a dGPS receiver module which receives and accommodates a display module. The display module is described as being any of a variety of handheld, multifunctional computing devices having a display screen and a processor running an operating system. Suitable display modules disclosed include Personal Data Assistants (PDAs), such as a Pocket PC, PALM® PDA, or similar palm held computing device. The screen is split into two distinct sections, a course display section for displaying a graphic representation of an area of a golf course, and a separate data and menu display section for displaying touch sensitive menu buttons and data (including distances). In the disclosed embodiment, the majority of the screen includes the first section, and a thin, left column of the screen shows a vertical menu column of touch sensitive menu buttons and data, such as distances.
[0012] The '938 patent also describes that the handheld golf GPS device could be constructed so that the modules are integrated into one unit, but does not describe the construction of such an “integrated” unit in any detail.
[0013] The '938 patent describes various functionality of the handheld golf GPS device, methods of creating golf course maps, and methods of distributing the golf course maps to the handheld golf GPS devices. For example, to use the device of the '938 patent during a round of golf, course data is first loaded onto the device. This may be accomplished by mapping the course using the device and using that course data file, as discussed below, or by connecting the device to a personal computer (PC) or directly to an interne connection and downloading the course data file onto the device. There is a setup menu for setting player preferences such as: club selection and data gathering; lie and stroke tracking enabled/disabled; marking of green strokes; and setting the green reference point, system units, and course, tee and starting hole selections. Once the course, tee and starting hole have been selected, the device displays a graphical (icon) representation of the selected hole, and certain distances to features whose locations are pre-stored in the course data file is displayed only in the data and menu section of the display. For example, the distance to the center of the green may be displayed in one of the boxes in the data and menu section of the display. The graphical representation includes simple icons for various features to be shown on the display, as shown in FIG. 29 of the '938 patent. At any time, the location of the device is determined using the dGPS receiver.
[0014] The device of the '938 patent also includes a club selection feature, in which the average distance for the player's clubs is displayed for each shot during play. The device also includes features for distance measuring from the location of the device to a target marked on the display by the user. Another described feature of the device is a shot tracking method which allows the user to store the location of each shot and the club used for the stroke at such location. Several other features are described in the '938 patent, including display functions such as pan and zoom, score keeping, statistics tracking, and the ability to upload game shot data to a web site or PC and then view a replay of a round with the speed of replay being adjustable.
[0015] Another example of a handheld golf GPS device is the Skycaddie™ line of devices from Skygolf®. At present, there are four models of Skycaddies with various levels of functionality and features. Like the devices described in the '485 patent and the '938 patent, the golf course data is loaded into the Skycaddie device. As described by Skygolf, the golf course data is generated by mapping each course on the ground using GPS and survey equipment. The database of golf course data is accessible through the internet on Skycaddie's website. The golf course data is downloaded onto a PC and then may be loaded onto the Skycaddie device by connecting the device to the PC. In addition, the Skycaddie devices allow a user to map a course, or additional course features, in the event a course or feature of interest is not included in the Skygolf database.
[0016] Another example of a handheld golf GPS device is the Skycaddie™ line of devices from Skygolf®. At present, there are four models of Skycaddies with various levels of functionality and features. Like the devices described in the '485 patent and the '938 patent, the golf course data is loaded into the Skycaddie device. As described by Skygolf, the golf course data is generated by mapping each course on the ground using GPS and survey equipment. The database of golf course data is accessible through the internet on Skycaddie's website. The golf course data is downloaded onto a PC and then may be loaded onto the Skycaddie device by connecting the device to the PC. In addition, the Skycaddie devices allow a user to map a course, or additional course features, in the event a course or feature of interest is not included in the Skygolf database.
[0017] Certain models of the Skycaddies may also display an outline of the green for a selected hole with the distances to the front, center and back of green displayed to the side of the displayed outline. Some models also display an icon representation of certain features, such as a creek, bunker or green, in one section of the display and the distances to such features in a different section of the display next to the icons. The Skycaddie devices can only measure distance to locations which are not pre-stored in the course data by marking a starting location and then moving the device to the measured location and marking the ending location. The device will then display the distance between the two locations. However, this requires walking all the way to the measured location. The Skycaddie devices are configured to automatically advance to the next hole of play based on the location of the device.
[0018] However, none of the previously described golf GPS devices provides a convenient, pocket-sized form factor, a high-resolution color display capable of storing data for tens of thousands of golf courses, flexible calibration to improve accuracy, or the functionality and ease of use to take full advantage of such features. Accordingly, there is a need for an improved golf GPS device which overcomes the deficiencies and drawbacks of previous devices and systems.
BRIEF SUMMARY OF THE INVENTION
[0019] The present invention allows for a single device to store data for a plurality of golf courses and then render animations of portions of the golf course based on the data to display on a screen of a device for a golfer to determine the distance to points of interest on the portions of the golf course. The device preferably stores data for 1000 to 50,000 golf courses, more preferably data for 10,000 to 40,000 golf courses and most preferably data for 30,000 golf courses.
[0020] The device allows the golfer to truly measure to or from anything on the course. When entering Anypoint, a cursor is positioned in the center of the current viewport. This cursor is moveable by the user using any number of input methods. Initially, when the user moves the cursor, the measurement takes place from the current user location to the cursor. This measurement gets updated as both the user location moves, and the position of the cursor changes. If the user presses the select button, this starts a new measurement. There will then be two measurements on the screen at the same time. One measurement will still be from the cursor to the current user location. The other measurement will be from the cursor to the point where the user pressed the select button. A second press of the select button stops the 2 nd measurement, and leaves the measurement on the screen. Using this sequence of events, the user can easily perform layup measurements by putting the cursor at the approximate pin location on the green, then pressing the select button and moving the cursor to whatever their favorite yardage is into the green. They will then have two measurements showing—one from their current location so they know what club to hit, and another measurement showing their ideal yardage into the green. Also using this sequence, a user can measure things like the width of a fairway, different characteristics of hazards, and anything else that they need additional information on. This is superior to competing solutions both in terms of the level of information supplied, but also in usability.
[0021] The present invention comprises a portable golf GPS device and system which is simple, accurate, and easy to use, yet provides excellent functionality and features in a compact, lightweight form factor. The portable golf GPS device of the present invention generally comprises a microprocessor operably coupled to a GPS unit, an input device such as a keypad (or touch screen) operably coupled to the microprocessor, and a display such as a liquid crystal display (“LCD”) operably coupled to the microprocessor. A program memory system which contains at least some of the software and data to operate the device is also operably coupled to the microprocessor. The device also comprises various firmware and software configured to control the operation of the device and provide the device functionality as described in more detail below. In addition, data utilized by the device, such as golf course data and type region animations, may be stored in the program memory or other memory module such as Secure Digital memory card (“SD Card”), USB based memory devices, other types of flash memory, or the like.
[0022] For portability, the golf GPS device of the present invention is self-contained, compact and lightweight. For example, the device is preferably battery operated. The portable golf GPS device is preferably contained in a housing such that the entire device has a very compact and lightweight form factor, and is preferably handheld and small enough to fit comfortably in a pocket of a user's clothing. For example, the entire golf GPS device may be 4 inches long ( 4 ″), by 2 inches wide ( 2 ″), by 0.6 inches thick (0.6″), or smaller in any one or more of the dimensions. The entire golf GPS device may weigh 3.5 ounces or less, including the battery.
[0023] The microprocessor may be any suitable processor, such as one of the MX line of processors available from Freescale Semiconductor or other ARM based microprocessor. The GPS unit may be any suitable GPS microchip or chipset, such as the NJ1030/NJ1006 GPS chipset available from Nemerix, Inc. The LCD is preferably a high resolution (e.g. 320 pixels by 240 pixels, QVGA or higher resolution), full color LCD, having a size of about 2.2″ diagonal
[0024] The program memory may include one or more electronic memory devices on the golf GPS device. For example, the program memory may include some memory contained on the microprocessor, memory in a non-volatile memory storage device such as flash memory, EPROM, or EEPROM, memory on a hard disk drive (“hdd”), SD Card(s), USB based memory devices, other types of flash memory, or other suitable storage device. The program memory stores at least some of the software configured to control the operation of the device and provide the functionality of the golf GPS device.
[0025] The components of the portable golf GPS device are preferably assembled onto a PCB, along with various other electronic components used to control and distribute the battery power, thereby providing the electronic connections and operability for a functional electronic device.
[0026] The hardware and software of the portable golf GPS device are configured to determine, track, and display useful golf related information, before, during and after a round of golf. For example, the GPS device is configured to store golf course data for a particular golf course of interest which is loaded onto the GPS device. The golf course data includes geographic location coordinates for various golf course features, such as bunkers, greens, water hazards, tees, and the like. The golf course data may also include golf hole data such a par, handicap, daily tee and hole locations, etc.
[0027] The use of the GPS device during play of a round of golf is referred to herein as “Play Golf” mode. In Play Golf mode, the basic functionality of the device is as follows. First, the golf course being played is selected on the GPS device, for example, from a list of courses displayed on the display. Then, the user should locate the GPS device at a location of play (e.g. the location of the user's ball, or a tee box). The GPS device determines the location of the device, and then displays various golf hole information on the display. For example, the device may display the number of the particular golf hole being played, par for the hole, the length of the hole, and the handicap of the hole. The device may also display information regarding the distance to various features of the golf hole being played and an identification of the type of feature. For example, the display may show the front and carry distance of bunkers, the front, middle and back of the green, the front and carry distance of water hazards, and the like.
[0028] Accordingly, a portable golf GPS device and system is provided. Additional aspects and features of the portable golf GPS device and system of the present invention will become apparent from the drawings and detailed description provided below.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0029] FIG. 1 is a schematic block diagram of a golf GPS device according to one embodiment of the present invention.
[0030] FIG. 2 is a four view showing the front, left side, right side, top and bottom of a golf GPS device according to one embodiment of the present invention.
[0031] FIG. 3 is front, elevational view of a GPS device with a Main Menu displayed on the display according to one embodiment of the present invention.
[0032] FIG. 4 is front, elevational view of a GPS device with a Golf Menu displayed on the display according to one embodiment of the present invention.
[0033] FIG. 5 is front, elevational view of a GPS device with golf hole information displayed on the display according to one embodiment of the present invention.
[0034] FIG. 6 is front, elevational view of a GPS device with a Hazard view in Basic Mode displayed on the display according to one embodiment of the present invention.
[0035] FIG. 7 is front, elevational view of a GPS device with a Pro Mode view displayed on the display according to one embodiment of the present invention.
[0036] FIG. 8 is front, elevational view of a GPS device with another Pro Mode view displayed on the display according to one embodiment of the present invention.
[0037] FIG. 9 is front, elevational view of a GPS device with a zoomed in Pro Mode view displayed on the display according to one embodiment of the present invention.
[0038] FIG. 10 is front, elevational view of a GPS device in a Measure mode displayed on the display according to one embodiment of the present invention.
[0039] FIG. 11 is front, elevational view of a GPS device with another aspect of the Measure mode displayed on the display according to one embodiment of the present invention.
[0040] FIG. 12 is a flow chart of a method.
[0041] FIG. 13 is a representation of pre-rendering latitude and longitude coordinate points for a region of a portion of a golf course.
[0042] FIG. 14 is an animation of a portion of a golf course that is rendered on a screen of the device.
[0043] FIG. 15 is an animation of a portion of a golf course that is rendered on a screen of the device with overlapping data.
[0044] FIG. 16 is an illustration of distance data on a screen of the device.
[0045] FIG. 17 is an illustration of distance data and animations on a screen of the device.
DETAILED DESCRIPTION OF THE INVENTION
[0046] Referring to FIG. 1 , a schematic block diagram of the major electronic components of a golf GPS device 10 according to one embodiment of the present invention will be described. The golf GPS device 10 comprises a microprocessor 12 which is operably coupled to a GPS chipset 14 , a user input device 16 , an LCD display 18 ; a program memory 20 , a voice recognition module 22 , an audio output 24 , a data transfer interface 26 , and a battery and power management unit 28 . As understood by one of ordinary skill in the art, the device 10 also comprises other electronic components, such as passive electronics and other electronics configured to produce a fully functional GPS device as described herein. In addition, the device 10 comprises various firmware and software configured to control the operation of the device 10 and provide the device functionality as described in more detail below.
[0047] The microprocessor 12 is preferably an ARM based microprocessor, such as one of the MX line of processors available from Freescale Semiconductor, but may be any other suitable processor. The microprocessor 12 executes instructions retrieved from the program memory 20 , receives and transmits data, and generally manages the overall operation of the GPS device 10 .
[0048] The GPS chipset 14 is preferably an integrated circuit based GPS chipset which includes a receiver and microcontroller. The GPS chipset may be a single, integrated microchip, or multiple microchips such as a processor and a separate receiver which are operably coupled to each other (for example, on a printed circuit board (“PCB”)). For instance, the GPS chipset 14 may be a NJ1030 GPS chipset available from Nemerix, Inc., or any other suitable GPS chipset or microchip. The GPS chipset includes a GPS receiver, associated integrated circuit(s), firmware and/or software to control the operation of the microchip, and may also include one or more correction signal receiver(s) (alternatively, the correction signal receiver(s) may be integrated into a single receiver along with the GPS receiver). As is well known, the GPS unit 14 receives signals from GPS satellites and/or other signals such as correction signals, and calculates the positional coordinates of the GPS unit 14 . The GPS device 10 utilizes this positional data to calculate and display distances to features or selected locations on a golf course, as described in more detail below.
[0049] The display 18 may be any suitable graphic display, but is preferably a high resolution (e.g. 320 pixels by 240 pixels, QVGA or higher resolution), full color LCD. The display 18 is preferably the largest size display that can be fit into the form factor of the overall device 10 , and preferably has a diagonal screen dimension of between about 1.5 inches and 4 inches. For example, for the form factor described below with reference to FIG. 2 , the display may be a 2.2″ diagonal, QVGA, full color LCD. In addition, since the display 18 is intended to be used outside under sunlit conditions, the display 18 should provide good visibility under brightly lit conditions, such as with a transflective LCD.
[0050] The program memory 20 stores the software and data used to control and operate the device 10 . For example, the program memory 20 stores the operating system (such as LINUX or Windows CE), the application software (which provides the specific functionality of the device 10 , as described below), and the golf course data. The program memory 20 broadly includes all of the memory of the device 10 , including memory contained on the microprocessor, memory in a non-volatile memory storage device such as flash memory, EPROM, or EEPROM, memory on a hard disk drive (“hdd”), SD Card(s), USB based memory devices, other types of flash memory, or other suitable storage device, including one or more electronic memory devices on the golf GPS device, including an additional removable memory unit 30 .
[0051] The user input device 16 may comprise a plurality of buttons, a touch screen, a keypad, or any other suitable user interface which allows a user to select functions and move a cursor. Referring to the embodiment shown in FIG. 2 , an example of a user input device comprises a directional pad 16 a and plurality of buttons 16 b , 16 c , 16 d , 16 e and 16 f . The device 10 is configured such that directional pad 16 a may be used to move a cursor around the display, while the buttons 16 b - 16 f may be used to make selections and/or activate functions such as activating the voice recognition or switching between modes (as described in more detail below).
[0052] In order to provide portability, the golf GPS device 10 is preferably battery powered by a battery and power management unit 28 . The battery may be any suitable battery, including one or more non-rechargeable batteries or rechargeable batteries. For instance, a rechargeable, lithium-ion battery would work quite well in this application, as it provides relatively long life on a single charge, it is compact, and it can be recharged many times before it fails or loses significant capacity. The power management unit controls and distributes the battery power to the other components of the device 10 , controls battery charging, and may provide an output representing the battery life. The power management unit may be a separate integrated circuit and firmware, or it may be integrated with the microprocessor 12 , or other of the electronic components of the device 10 .
[0053] The voice recognition unit 22 comprises electronics and software (the term “software” as used herein shall mean either software or firmware, or any combination of both software and firmware) configured to receive voice or other sounds and convert them into software commands and/or inputs usable by the main application software. The voice recognition unit 22 may comprise a separate integrated circuit, electronics and/or software, or it may be integrated into the main microprocessor 12 . The voice recognition unit 22 includes a microphone 32 . The voice recognition unit 22 is configured to detect voice and/or other sound inputs from a user of the device 10 , and convert the sound inputs into electrical signals. The voice recognition unit 22 then digitizes the analog electrical signals and computes a command or other input representative of the digitized signal. For example, a command for switching between Pro Mode and Basic Mode may be input using the voice recognition unit 22 by speaking the term “Pro Mode” or “Basic Mode” into the microphone 32 . Of course, the main application software must also be configured to receive the inputs from the voice recognition unit 22 . The hardware and software for the voice recognition unit are relatively complex, but packaged solutions are available, such as the products available from Texas Instruments, Inc. or Wolfson Micro, Inc.
[0054] The audio output 24 comprises electronics and software to convert digital signals from the device into electrical signals for driving a speaker or headphones. The audio output 24 may comprise a phone jack 34 (also shown in FIG. 2 ) and/or a speaker 36 . The audio output 24 typically includes a digital-to-analog converter, a power amplifier, and may also include software for converting information or data into audible sounds. For instance, the audio output 26 may be configured to convert distances measured by the device 10 into an audibly replicated voice of the distance in words, such as “one-hundred fifty.” Additionally, the device 10 may be configured to also play digital music files (such as MP3 audio files) or digital video files (such as MPEG files), with the audio being output using the audio output 24 .
[0055] The voice recognition unit 22 and audio output 24 may be integrated together into a software and hardware unit. For example, such integrated products are available from Texas Instruments, Inc. and Wolfson Micro, Inc.
[0056] The data transfer interface 26 is configured to send and receive data from a computer or other electronic device (e.g. another golf GPS device 10 ). The interface 26 may be a physical connection such as a USB connection, a radio frequency connection such as Wi-Fi, wireless USB, or Bluetooth, an infra-red optical link, or any other suitable interface which can exchange electronic data between the GPS device 10 and another electronic device. As shown in one preferred embodiment in FIG. 2 , the interface 26 comprises a USB connection having a USB connector 26 a.
[0057] The electronic components of the golf GPS device 10 are preferably assembled onto a PCB, along with various other electronic components and mechanical interfaces (such as buttons for the user input device 16 ), thereby providing the electronic connections and operability for a functional electronic GPS device 10 .
[0058] Turning to FIG. 2 now, the golf GPS device 10 preferably comprises a housing 40 which houses the electronic components such that the entire device has a very compact, thin, and lightweight form factor. The housing 40 may be formed of any suitable material, but is preferably a plastic material which is substantially transparent to radio frequency signals from GPS satellites. Indeed, the golf GPS device is preferably handheld and small enough to fit comfortably in a pocket of a user's clothing. One example of the form factor for the GPS device 10 with dimensions is shown in FIG. 2 . In one preferred form, the GPS device 10 may have the following dimensions: a height 44 of about 4 inches or less, a width 46 of 1.9 inches or less and a thickness 42 of 0.6 inches or less. More preferably, the height 44 is 3.9 inches or less, the width 46 is 1.8 inches or less, and the thickness 42 is 0.55 inches or less. The entire golf GPS device 10 may weigh about 3.5 ounces or less, including the battery 28 .
[0059] An application software program is stored in the program memory 12 . The application software program is configured to operate with the microprocessor 12 and the other electronic components to provide the golf GPS device 10 with the functionality as described herein. Most generally, the hardware and software of the portable golf GPS device 10 are configured to determine, track, and display useful golf related information, before, during and after a round of golf. The GPS device 10 is configured to store golf course data for a particular golf course of interest.
[0060] The golf courses are mapped to create the golf course data using any suitable method. The mapping process produces golf course data which can be used by the GPS device 10 to determine the coordinates of golf course features of interest, such as the greens, bunkers, hazards, tees, pin positions, other landmarks, and the like. Generally, the perimeter of the golf course features will be mapped so that distance to the front and back of the feature may be determined. The captured data is used to create a data set comprising the coordinates for a plurality of points on the perimeter of the feature, or a vector-map of the perimeter, or other data, which can be used to calculate the distance to such feature from the location of the GPS device 10 . The golf course data preferably also includes golf hole data such as par, handicap, daily tee and hole locations, etc.
[0061] With reference now to FIGS. 3-11 , the operation and functionality of GPS device 10 according to one embodiment will be described. Referring to FIG. 3 , a “Main Menu” screen is displayed on the display 18 . The “Main Menu” screen has two options, “Play Golf” or “Settings.” The choices on the Main Menu screen (or any of the other menus and screen displays described herein) can be selected by changing the highlighted option using the up and down arrows on the directional pad 16 a of the user input device 16 . The button 16 b may function as an “Enter” key to make a selection. If a touch screen input device 16 is utilized, the user can simply touch the selection on the display 18 .
[0062] Selecting “Settings” will bring up a “Settings” menu which allows the user to set various device and player settings and preferences. For example, the “Settings” menu may allow the user to set such user preferences as system units (e.g. yards or meters), preferred display settings (e.g. text size, Pro Mode vs. Basic Mode, screen brightness and contrast), turning on/off functions (such as score keeping, voice recognition, shot tracking, etc.), and other device settings.
[0063] Selecting the “Play Golf” mode brings up a “Golf Menu” as shown in FIG. 4 for initializing the GPS device 10 for use during a round of golf. The course being played may be selected by selecting “Select Course” which may bring up a list of courses currently stored on the device 10 . Preferably, the golfer inputs a geographical region which is selected from a list of geographical regions. The list is preferably a list of the States of the United States. Alternatively, the list is a list of the nations of Europe. Alternatively, the list is a list of the Prefectures of Japan. One a region is selected, based on the GPS coordinates, the GPS device will provide a list of courses for selection by the golfer. The list of courses shown can be determined based on the location of the device as determined by the GPS device 10 , for example, a list of the two or three courses closest to the location of the device. Alternatively, the list can be generated as a simple alphabetical list, a list of favorites, or other suitable listing method. The “Golf Menu” also allows the user to choose the starting hole, for instance, if a player is going to start on a hole other than the 1st hole, such as starting on the 10th hole (the “back nine”).
[0064] Once the course and starting hole have been selected, GPS device 10 determines the location of the device 10 using the GPS chipset 14 , and then displays various golf hole information on the display. Turning to FIG. 5 , in this described embodiment, the GPS device 10 is configured to display the hole number 50 , the current time 52 (the device 10 may include a clock function which can be provided by the microprocessor 12 , the GPS chipset 14 , or other electronic device), the par for the hole 54 , a battery charge indicator 56 , and a GPS signal strength indicator 58 . The GPS device 10 further calculates the distance between the determined location of the device 10 and the front, middle and back of the green and displays the distance to the front 60 , the middle 62 and the back 64 of the green. As the device 10 is moved, the location of the device 10 is continually updated, and the distances (such as the front 60 , middle 64 , and back 64 of green) displayed are updated accordingly.
[0065] The golf GPS device 10 also may display the distances from the location of the device 10 to hazards and other features of interest as shown in FIG. 6 . As an example, the user may select the “Hazard” selection on the display shown in FIG. 5 using the button 16 d to bring up the screen as shown in FIG. 6 . The screen shown in FIG. 6 displays the “Hazard” information in what is referred to herein as “Basic Mode.” Basic Mode displays the “Hazard” information in a list using icons or text and respective measured distances. The example of FIG. 6 shows an icon for a right fairway bunker 66 and the distance to the front side of the bunker is 248 yards and the distance to carry the bunker is 264 yards. Similarly, the screen shows that the distance to the left greenside bunker 68 is 455 yards to reach and 472 yards to carry. Instead of easy to read icons, the features can alternatively be displayed using text, such as “Right Fairway Bunker” or using an abbreviation such as RtFwyBnkr, or the like.
[0066] In order to optimize the viewability of the golf course animations and displayed distances in the Pro Mode on a relatively small display 18 , the golf GPS device 10 may include a automatic, dynamic, viewport generation method. The ability to miniaturize the size of the device 10 is in many ways limited by the size of the display 18 , the major tradeoff being the desire to maximize the size of the display 18 in order to be able to display as much information and images at an easily viewable scale, while at the same time keeping the overall size of the device 10 as small as possible. Intelligent generation of the of the images and numbers being displayed can help to display the most relevant section of the golf hole being played with distances displayed at a font size that is easily readable.
[0067] The viewport generation may include one or more methods to determine the displayed viewport. First, the viewport generation method may include a method of determining the location and scale of the animation of the portion of the golf course to be displayed based on the location of the device (and therefore the location of play) and the characteristics of the golf hole. For example, the method of viewport generation method displays the section of the golf hole that will be most relevant to the golfer from the current location, which may be a yardage range such as the fairway which is between 150 and 250 yards from the current location. As one specific example, FIG. 7 shows a viewport which might be displayed if the user is on the tee box of the displayed hole. The viewport displays the fairway and area surrounding the fairway from about 200 yards to 375 yards from the tee. The graphic animation is automatically scaled (i.e. the zoom level is set) to display the relevant section of the hole so that it will fit on the display while maintaining viewability of relevant features (e.g. the bunkers) and distance to the fairway bunker. If the hole happens to be a par 3, or there is less than a certain distance (e.g. 250 yards) to the end of the hole, then the viewport generation method may display the rest of the hole at a maximum zoom level that can fit the rest of the hole on the display (see e.g. FIG. 8 ).
[0068] The golf GPS device 10 may also be configured to measure the distance between locations on the golf course using the animations displayed on the display. In order to measure a distance from the location of the device to a location as viewed on an animation on the display, the “Meas” button 16 c is selected (see FIG. 9 ), to enter “Measure” mode as shown in FIG. 10 . A cursor 70 (such as a “+”) and a marker 72 (such as the star shown in FIG. 10 ) will appear at the current location of the device 10 . The marker 70 indicates the current location of the device 10 , and the cursor indicates the point being measured to. At the outset, the marker 70 and cursor 72 are at the same location, so the distance is displayed as “0”. The directional pad is then used to move the cursor 72 to the location of interest. As the cursor 72 is moved, the distance between the cursor 72 and the marker 70 is calculated and displayed. As the cursor 72 reaches the edge of the display in the direction of interest, the display may automatically pan (and/or zoom), as shown in FIG. 11 . When the cursor is located at the location of interest, the desired distance will be displayed, as shown in the example of FIG. 11 . In a similar manner, the device 10 may also be configured to measure the distance between two locations of interest selected on display. The user simply selects the “Meas” mode. The cursor 72 is then positioned at a first point of interest, the button 16 b is pushed to set the first point of interest, and then the cursor 72 is moved to a second point of interest. As in the example above, the distance between selected first point of interest and the location of the cursor will be updated and displayed as the cursor is moved. The distance between a first location for the device 10 and a second location of the device 10 may also be measured by simply entering the “Meas” mode and then moving the device 10 to a new location. As the device 10 is moved, the distance between the original location of the device 10 and the new location of the device 10 will be calculated and displayed. The pan and zoom functions may be utilized automatically or manually during any of the above described measurement modes in order to select a location of interest.
[0069] FIG. 12 is a preferred method of the present invention. The method 1000 begins at block 1001 with the GPS device 10 retrieving latitude and longitude coordinates for the present location of the device. At block 1002 , the golfer selects a geographical region. At block 1003 , the golfer determines a golf course from a list of golf courses. At block 1004 , the golfer selects a portion of a golf course such as a green for display on a screen of the device 10 . At block 1005 , the device 10 renders an animation of the portion of the golf course based on latitude and longitude coordinate points which represent type regions of the green. At block 1006 , the device displays the animation of the portion of the golf course.
[0070] FIG. 13 is a representation of latitude and longitude coordinate points 1100 a - 1100 q for a type region 1100 which is a green for a golf course. The latitude and longitude coordinate points 1100 a - 1100 q are stored on the device as representing a particular green for a particular golf course that has been selected by a golfer. These latitude and longitude coordinate points 1100 a - 1100 q are stored as green grass such that the animation for the green 1100 is rendered and displayed on the screen of the device 10 when the golfer is at this location or chooses this location for display on the device. FIGS. 15-17 illustrate other information and animations that are shown on screen of the device 10 .
[0071] The foregoing illustrated and described embodiments of the invention are susceptible to various modifications and alternative forms, and it should be understood that the invention generally, as well as the specific embodiments described herein, are not limited to the particular forms or methods disclosed, but also cover all modifications, equivalents and alternatives falling within the scope of the appended claims. The invention, therefore, should not be limited, except to the following claims, and their equivalents. | A golf GPS device is disclosed herein. The device includes a GPS unit, a memory for storing data for a plurality of golf courses, a display for displaying animations of portions of golf courses, a user input for inputting a plurality of location points on the display, and a processor comprising means for rendering the animations of portions of golf courses from a plurality of latitude and longitude coordinate points. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/961,792, filed Sep. 24, 2001, which is incorporated by reference in its entirety to the extent not inconsistent with the disclosure herein.
BACKGROUND
[0002] Forms or mannequins that are models of the human body are well known in the art and are used to display clothing and other merchandise. Such forms and mannequins are often complete or partial human bodies and often are of life-sized proportions. “Forms” typically refers to human shapes with or without heads, and without appendages or limbs. “Mannequins” typically refers to human shapes with or without heads, and with some or all appendages. The terms “form” and “mannequin” are used interchangeably herein, and each term incorporates the other. It is desirable that limbs can be placed in natural poses.
[0003] Examples of mannequin joint structures in the prior art include those described in Ikeda (U.S. Pat. No. 5,180,086); Day (U.S. Pat. No. 5,098,213); Schoenhut (U.S. Pat. No. 982,096); Abbat (U.S. Pat. No. 5,257,873); Stringer (U.S. Pat. No. 4,630,762); Pansiera (U.S. Pat. No. 4,958,643); Kotlarsky and Gelman (U.S. Pat. No. 5,443,188); Bruce (U.S. Pat. No. 3,934,804); Strover and Strover (U.S. Pat. No. 5,967,790); Luke (U.S. Pat. No. 4,186,518); Miller (U.S. Pat. No. 4,955,844); Fogarty et al. (U.S. Pat. No. 5,308,276); Unalp and Kelley (U.S. Pat. No. 5,318,469); Glovier (U.S. Pat. No. 5,318,471); Toy (U.S. Pat. No. 4,545,514); Wiley et al. (U.S. Pat. No. 5,018,977); Jiang (U.S. Pat. No. 5,265,779); Neuschatz (U.S. Pat. No. 4,075,782); Breiden (U.S. Pat. No. 4,466,800); De Porteous (U.S. Pat. No. 5,044,960); Richards (U.S. Pat. No. 5,152,692); and Richards (U.S. Pat. No. 5,259,765).
[0004] A typical joint structure for mannequins uses a ball and socket connection means wherein a ball portion formed on a first limb member fits in and moves against the interior surface of a socket portion formed on a second limb member. The ball and socket are held in contact with each other by a locking mechanism, or fastener. Fastening the ball and socket together results in friction between the exterior ball surface and the interior socket surface. This friction allows the limbs to be placed and held in multiple positions.
[0005] One common type of fastener for a ball and socket joint is an eyehook-spring fixture where the spring and the eyehook are located on opposite sides of a bolt. The eyehook passes through a slot on the ball and is looped around a pivot-pin that is screwed into the center portion of the ball perpendicular to the long axis of the limb. The spring is threaded onto a rod that is located in the limb above the socket. Threading the spring onto the rod forces the ball and socket together, creating the friction used to position the limbs. The use of this type of fastener also results in the appearance of a gap on the ball portion of the joint at the slot and also permits movement of the limb having the ball portion to pivot, relative to the limb with the socket, by allowing the bolt to move through the slot.
[0006] Drawbacks of these types of prior art joints include:
[0007] 1. The entire limb is assembled in one step, which can be awkward.
[0008] 2. An unnatural looking slot, or gap, on the ball section of these joints.
[0009] 3. Poor anatomical shape of the limb.
[0010] The joint of this invention defines an improvement over the prior art in that the disclosed joint eliminates the unnatural gap on the ball section of the limb. Further, novel fastening means simplifies production and assembly of joint structures and the assembly of mannequins and forms.
SUMMARY OF THE INVENTION
[0011] In its most general form, this invention provides a mannequin having removable, positionable limb members attached thereto comprising a joint to join two of the limb members together. The joints of this invention comprise one or more assembly fixtures, located within or on a limb member to be joined, that contain elements for joining limb members. The assembly fixtures may contain elements of a locking mechanism, or fastener, and may contain other elements for joining members or creating friction or tension between limb members to bejoined. For example, a socket assembly fixture is positioned fixedly in the socket portion of a first member to be joined and comprises a chamber containing a tension-producing member and one half of a locking mechanism. A ball assembly fixture is positioned in the ball portion of a second member to be joined to said first member and comprises a second half of a locking mechanism, and means for attaching the second half of the locking mechanism to the ball portion of the second member to be joined. A joint structure is formed when two attachable limb members are joined together using one or more assembly fixtures.
[0012] This invention also provides methods for assembling the different embodiments of the joints and mannequins of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGS. 1 A-B show a mannequin of the invention with movable, detachable limbs. FIG. 1A shows a front view. FIG. 1B shows a side view.
[0014] FIGS. 2 A-C show a socket assembly fixture of this invention. FIG. 2A is an exploded view. FIG. 2B shows a cross-sectional view of the fixture in FIG. 2A through b-b. FIG. 2C shows a top view of a portion of the socket assembly fixture of FIG. 2A.
[0015] FIGS. 3 A-C show a ball assembly fixture of this invention. FIG. 3A is a side view of the ball assembly fixture. FIG. 3B shows a pivot pin. FIG. 3C shows a side view of the ball assembly fixture of FIG. 3A together with a pivot pin.
[0016] FIGS. 4 A-B show an exploded view of the joint structure of this invention, used to join an upper leg with a lower leg. FIG. 4A is a front view. FIG. 4B is a side view.
[0017] FIGS. 5 A-B show another embodiment of the joint structure of this invention at the wrist joint. FIG. 5A is a top view cross-section. FIG. 5B is an exploded side view.
[0018] FIGS. 6 A-B show another embodiment of the joint structure of this invention at the wrist joint. FIG. 6A is a top view cross-section. FIG. 6B is an exploded side view.
[0019] [0019]FIG. 7 shows another embodiment of the joint structure of this invention at the wrist joint. FIG. 7 is a top view cross-section.
[0020] [0020]FIG. 8 shows an exploded view of the joint structure of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
[0021] This invention describes novel joint structures for mannequins. In one embodiment of this invention, a joint structure is formed when a socket assembly fixture and ball assembly fixture are joined together.
[0022] For example, a socket assembly fixture is positioned fixedly in the socket portion of a first member to be joined and is comprised of a chamber containing a tension-producing member and one half of a locking mechanism. The tension-producing member may be made of any reversibly compressible material such as a spring, an elastomer, rubber, foam, or any other reversibly compressible material known in the art. Preferably, the tension-producing member is a spring. The locking mechanism can be a nut and bolt, a snap, a latch, dimples, a locking collar, or any other fastener or fastening means known in the art. Preferably, the locking mechanism is a threaded nut.
[0023] A ball assembly fixture is positioned in the ball portion of a second member to be joined to the first member and comprises a second half of a locking mechanism, and means for attaching the second half of the locking mechanism to the ball portion of the second member to be joined. Preferably, the second half of the locking mechanism is an eyebolt and the preferred means for attaching the eyebolt to the second member to be joined is via attachment to a disc. The disc may be molded with a groove on one of its flat surfaces to fixedly accept the eye portion of said eyebolt such that the eyebolt is held substantially in place relative to the disc surface. Alternatively, the eyebolt may be fixed to the disc using any means known in the art, including mechanical means and the use of adhesives.
[0024] The round disc is pivotally attached to the second member by any attachment means that allow the ball portion of the limb to pivot around the disc. Such attachment means are known in the art and include the use of a pivot pin and dimples. In a preferred embodiment, the attachment means is a pivot pin.
[0025] In another embodiment of this invention, a friction assembly fixture is recessed in the end of a first limb member to be joined, below the ball portion of the first limb member. A tab formed as part of, or attached to the socket surface of a second limb member, is inserted into the first limb member to contact the friction assembly fixture. Preferably, the tab is inserted into a slit formed in the first limb member. The first and second members may be held in pivotal contact using any attachment means known in the art, including a pivot pin passing through both members and dimples. Preferably, a pivot pin is inserted through both fixtures, perpendicular to the limb axis, to hold the first and second limb members in contact.
[0026] The friction assembly fixture comprises a chamber with one end open to the attaching end of the first member. This chamber contains a reversibly compressible material in its bottom and a bearing on top of the reversibly-compressible material. This reversibly-compressible material can include elastic materials such as rubber, elastomers, foam or other polymers, or may be a spring. Preferably the reversibly-compressible material is a spring. Also preferably, the spring is made of spring wire, also known as music wire or piano wire. The bearing may be made of any suitably rigid material, including plastics, metals, alloys, polymers, and the like. Preferably the bearing is made of plastic. More preferably the bearing is made of nylon.
[0027] The tab may be fixedly attached to the second limb member. The tab to be received by the friction assembly fixture may be molded as an integral part of the second limb member to be joined or it may be attached to the limb member using any attachment means known in the art, including adhesives, latches, clamps, pegs, or screws. Preferably, the tab is molded together with the second limb member to be joined.
[0028] Alternatively, the tab may be pivotally attached to the second limb member to allow rotation of the second limb member with respect to the tab. The rotation axis of the second limb member is parallel to the long axis of the second limb member. The tab may be pivotally attached by any means known to the art, including a rod fitting into a socket. The rod can be attached to the second limb member and the socket formed in the tab.
[0029] In a preferred embodiment the first and second limb members are held together with a pivot pin passing through the end of the first member and the tab of the second member to be joined such that the tab contacts the bearing in the socket assembly fixture enough to compress the reversibly compressible material. The resulting friction between the two limb members allows them to bend or to be moved relative to each other.
[0030] Optionally, one or more depressions, such as recessed dimples, grooves, or pits, are present on the surface of the tab. As the tab contacts the bearing in the socket, the bearing engages in a recessed dimple or groove on the surface of the tab. By slidably positioning the tab relative to the bearing to engage different recessed dimples or grooves, the limbs are held in one or more positions.
[0031] This invention also provides for a mannequin having the joints of this invention. “Mannequin” refers to human shapes with or without heads, and with some or all appendages. The mannequins of this invention may have one or all of the joint structures described herein. FIG. 1A shows a front view of a mannequin or form of this invention with removable, freely movable, positionable, and adjustable limbs. Joint structures are present between the torso 10 and the upper arms 15 at the shoulder joint 12 , between the upper arms 15 and the lower arms 20 at the elbow joint 18 , between the lower arms 20 and the hands 25 at the wrist joint 23 , between the torso 10 and the upper legs 30 at the hip joint 22 , between the upper legs 30 and the lower legs 35 at the knee joint 32 , and between the lower leg 35 and the feet 40 at the ankle joint 38 . FIG. 1B is a side view of FIG. 1A.
[0032] [0032]FIG. 2A shows an exploded view of a preferred embodiment of socket assembly fixture 50 . Socket assembly fixture 50 is located within a first limb member to be joined and adjacent to the molded socket surface of the first limb member (see FIG. 4B). Socket assembly fixture 50 consists of chamber 60 defining cavity 63 . Cavity 63 may be any shape such as square, round, oval, triangular, and the like. Preferably chamber 60 is defined by four walls 68 and is square. Chamber 60 is attached by tack welding at the corners of chamber 60 , or by other means known in the art, to the flat surface of washer 62 , which is stamped with a recessed shape 61 (FIG. 2C) to match and receive one end of chamber 60 . Washer 62 also has an opening 65 (FIG. 2C) in its center that has a diameter smaller than the diameter of spring 70 (FIG. 2A) so as to retain spring 70 within chamber 60 . Spring 70 fits in chamber 60 in contact with washer 62 . Nut 72 , having threads 71 is positioned on top of washer 62 in chamber 60 . Each wall 68 has a dimple 64 positioned on its surface such that the dimple is located above nut 72 . Optional cap 75 fits on top of chamber 60 such that it closes cavity 63 . FIG. 2B is a cross-sectional view of the socket assembly fixture 50 in FIG. 2A, through the axis b-b as it appears after assembly.
[0033] [0033]FIG. 3A shows a preferred embodiment of ball assembly fixture 55 in the ball portion of the limb members to be joined. Ball assembly fixture 55 consists of a disc 80 having surface 81 , a groove (not shown) molded in surface 81 , an edge surface 84 (FIG. 3 c ) and an opening 82 near the center of surface 81 . Ball assembly fixture 55 also consists of an eyebolt 74 having threads 76 and a looped portion 78 . The looped portion 78 of eyebolt 74 is positioned in the molded groove on surface 81 of disc 80 .
[0034] [0034]FIG. 3B shows pivot pin 90 having a recessed middle portion 92 having a smaller diameter than the two outer portions 87 and 89 of pivot pin 90 . Disc 80 is rotatably mounted on pivot pin 90 with the recessed middle portion 92 of the pin engaged upon and secured within opening 82 of disc 80 . This is shown in FIG. 3C, a side view of FIG. 3A through c-c with pivot pin 90 .
[0035] [0035]FIG. 4A is an exploded view of the knee joint 32 used to join upper leg 30 and lower leg 35 . Upper leg 30 has a socket 31 at its lower end with socket assembly fixture 50 recessed in the limb above the socket surface. Socket 31 has a hole 37 that is aligned with an opening 65 of washer 62 . Lower leg 35 has a slot 34 extending into lower leg 35 from the center of the ball surface 33 . Lower leg 35 also has a pin channel 36 that is perpendicular to and intersects with slot 34 . Pin channel 36 may pass completely through lower leg 35 or may begin on either the lateral or medial side of lower leg 35 and pass only partially through lower leg 35 . Preferably, pin channel 36 begins on the medial side of lower leg 35 and does not pass completely through to the lateral side of lower leg 35 .
[0036] There are at least two methods of assembling the fastener to join the two limbs. In a first method for joining upper leg 30 and lower leg 35 , the threaded portion 76 of eyebolt 74 (fixedly attached to disc 80 ) is inserted into socket hole 37 of upper leg 30 and opening 65 of washer 62 and passes through spring 70 . Dimples 64 and/or cap 75 retain nut 72 within chamber 60 . The eyebolt threads 76 are coupled with threads 71 of the nut 72 (FIG. 2A) of socket assembly fixture 50 . Joining these threads together pulls nut 72 towards the socket 31 and puts tension on spring 70 . Next, the disc 80 of ball fixture assembly 55 is inserted into slot 34 of lower leg 35 so that disc opening 82 is aligned with pin channel 36 on lower leg 35 (FIG. 2 a ). Finally, pivot pin 90 is inserted into pin channel 36 on lower leg 35 so that recessed portion 92 of the pivot pin 90 is located within and engages with opening 82 in the disc 80 . Thus engaged, pivot pin 90 is securely centered in disc 80 . Alternatively, lower leg 35 and ball fixture assembly 55 can be assembled as above prior to joining socket assembly fixture 50 with ball assembly fixture 55 .
[0037] Once upper leg 30 is joined to lower leg 35 , lower leg 35 is free to rotate about the axis c-c defined by eyebolt 74 (FIG. 4B), and can also pivot about pivot pin 90 . Also, disc 80 effectively fills the gap found in prior art joints in which a spring-topped eyebolt only (no disc) is used to pivotally attach a ball limb member to a socket limb member. Furthermore, the distance′f on disc 80 is ideally slightly smaller than the diameter ‘g’ of the ball portion of the limb (FIG. 4B). This allows the ball surface 33 to fully contact the socket surface 31 , which in turn results in greater friction between the two limb members than if only the disc edge surface 84 (FIG. 3C) contacted the socket surface. This allows the limbs to be more easily held in a variety of positions. Preferably, the difference between distances f and g is between 0.100 and 0.010 inches. More preferably, the difference is between 0.060 and 0.020 inches. Most preferably, the difference is 0.040 inches.
[0038] Another embodiment of this invention is shown in FIGS. 5A and 5B, which illustrate a top view cross-section and a side view, respectively, of wrist joint 23 between lower arm 20 and hand 25 . In this embodiment, lower arm 20 provides the ball portion 102 of the ball and socket connection means and hand 25 provides the socket portion 103 of the ball and socket connection means.
[0039] [0039]FIG. 5A shows an embodiment where tab 100 is fixedly attached to a hand. Referring to FIG. 5A, lower arm 20 has a chamber 94 extending into the center of lower arm 20 below the slit 104 of the ball portion 102 . Chamber 94 contains a friction-producing assembly fixture 105 , said friction-producing assembly fixture consisting of a spring 96 and a bearing 98 positioned on top of spring 96 . Ball portion 102 of lower arm 20 also has a cavity 97 that is perpendicular to the long axis of chamber 94 . Hand 25 has tab 100 fixedly attached to the interior surface of its socket portion 103 . Tab 100 also has a center hole 95 (FIG. 5B, pin 91 not shown in FIG. 5B). Optionally tab 100 has one or more surface depressions, shown as dimples 101 in FIGS. 6A and 6B.
[0040] To assemble the wrist joint, tab 100 is inserted into slit 104 such that center hole 95 lines up with cavity 97 . With center hole 95 and cavity 97 aligned, wrist pin 91 is inserted into cavity 97 and through center hole 95 to secure hand 25 to lower arm 20 . Wrist pin 91 pivotally attaches the tab to the lower arm so that the tab can rotate about an axis parallel to the thickness of the tab. The wrist pin 91 extends through the tab and at least partly through the first limb member. Pin 91 may or may not extend completely through the first limb member. Further, when tab 100 is thus secured in slit 104 , its lower surface 93 contacts bearing 98 . The resulting tension in spring 96 causes the bearing 98 to push up against the lower surface 93 of tab 100 . This pressure causes friction between tab 100 and wrist pin 91 that allows the limbs to be placed in a variety of positions.
[0041] Alternatively, bearing 98 registers with the optional tab surface depressions, shown as dimples 101 in FIGS. 6 A- 6 B (pin 91 not shown in FIG. 6B), to afford additional control over limb position. As seen in the previous embodiment, tab 100 also effectively fills the joint gap found in prior art joints. In different embodiments, the tab fills greater than or equal to about 80%, or about 85%, or about 90%, or about 95% of the width of the joint gap.
[0042] In another embodiment of the invention, tab 100 is pivotally attached to the second limb member to allow rotation of the second limb member with respect to the tab and to the first limb member. For example, for a wrist joint where the first limb member is a lower arm and the second limb member a hand, pivotal attachment of the hand to the tab allows rotation of the hand with respect to the tab, with the axis of rotation being parallel to the long axis of the hand. Once the joint is assembled, pivotal attachment of the hand to the tab also allows rotation of the hand with respect to the lower arm.
[0043] In a preferred embodiment, once the joint between the first and second limb member is assembled, the joint cannot be readily disassembled. For example, for a wrist, once the wrist joint is assembled the hand cannot be readily removed. This prevents loss of the hand from the mannequin.
[0044] [0044]FIGS. 7 and 8 illustrate a top view cross-section and an exploded view, respectively, of wrist joint 23 between lower arm 20 and hand 25 in which tab 100 is pivotally attached to hand 25 . The tab 100 is attached to hand 25 by a rod assembly.
[0045] The rod assembly comprises a rod 200 and socket 210 . The rod assembly is connected to tab 100 by rod 200 that fits into socket 210 in tab 100 (FIG. 8). As shown in FIGS. 7 and 8, rod 200 may be threaded and have head 205 . Rod 200 may be a headed screw. If rod 200 is threaded, socket 210 can be correspondingly threaded to receive rod 200 . Socket 210 may comprise a metal insert in tab 100 . The rod and socket may also be affixed to one another so that no rotation of the rod within the socket occurs after the joint is assembled (e.g. by gluing the rod within the socket or otherwise locking it in place).
[0046] The rod assembly is also connected to hand 25 . As shown in FIGS. 7 and 8, the rod assembly may comprise threaded bushing 250 which is adapted to receive threaded rod 200 . As shown in FIGS. 7 and 8, bushing 250 may be threaded both internally and externally. Bushing 250 may be attached to the second limb member (the hand in FIGS. 7 and 8) by inserting the bushing into a threaded portion of cavity 270 formed in the second limb member, as shown in FIGS. 7 and 8. The bushing is typically affixed to the hand so that the bushing does not rotate within the cavity after assembly of the joint.
[0047] The joint in FIGS. 7 and 8 is assembled by inserting the head end of rod 200 in cavity 270 , inserting bushing 250 into cavity 270 , and then inserting rod 200 into socket 210 of tab 100 . Tab 100 is inserted into slit 104 such that center hole 95 lines up with cavity 97 . With center hole 95 and cavity 97 aligned, wrist pin 91 is inserted into cavity 97 and through center hole 95 to secure hand 25 to lower arm 20 . Wrist pin 91 pivotally attaches the tab to the lower arm so that the tab can rotate about an axis parallel to the thickness of the tab. Further, when tab 100 is thus secured in slit 104 , its lower surface 93 contacts bearing 98 . The resulting tension in spring 96 causes the bearing 98 to register with the optional tab surface depressions, shown as grooves 120 , to afford additional control over limb position. This pressure causes friction between tab 100 and wrist pin 91 that allows the limbs to be placed in a variety of positions. Alternatively, if tab surface depressions are absent, the bearing may push up against the lower surface 93 of tab 100 . As seen in the previous embodiment, tab 100 also effectively fills the joint gap found in prior art joints. In different embodiments, the tab fills greater than or equal to about 80%, or about 85%, or about 90% or about 95% of the width of the joint gap.
[0048] The joint shown in FIGS. 7 and 8 can be operated by fixing rod 200 within socket 210 so that the rod does not rotate within the socket. The hand 25 can then be rotated with respect to the tab 100 by movement of bushing 250 along rod 200 . Travel of the bushing along the rod is limited by contact between head 205 and bushing 250 . This contact, in combination with the fixing of rod 200 within socket 210 and the fixing of bushing 250 to hand 25 , prevents easy removal of hand 25 once the joint is assembled. Travel of the bushing along the rod may also be limited by contact between head 205 and cavity 270 or contact between the ball 102 and socket 103 portions of the first and second limb. Preferably, the joint is designed so that rotation of the hand is limited to one and a half turns.
[0049] Prevention of easy removal of hand 25 once the joint is assembled can be achieved with other joint designs. For example, the rod 200 can be affixed to hand 25 and the rod and socket designed to prevent easy removal of the rod from the socket after assembly of the joint. For example rod 200 may have a head 205 placed within an enlarged portion of socket 210 or a c-ring may be inserted into the tab to prevent easy removal of rod 200 .
[0050] Throughout this specification, the term “limb member” refers to any movable member of a form and includes but is not limited to: head, neck, torso, upper and lower arms, hands, fingers (including all digits), upper and lower legs, feet, and toes (including all digits). The term “joint” refers to all the joints that commonly connect limb members and allow their relative movement and includes neck, shoulder, wrist, hip, knee, torso, ankle, and fingers and toes. The term “medial” refers to positions towards the center, or mid-line of the body, while the term “lateral” refers to positions towards the side of the body, opposite the medial position.
[0051] The present invention is not to be limited by the preferred embodiments described herein. Upon reading this specification, those skilled in the art will recognize various modifications thereof. Therefore, it is to be understood that such modifications are intended to fall within the scope of the appended claims.
[0052] All references cited herein are incorporated in their entirety to the extent that they are not inconsistent with the disclosure herein. | Joints for joining together limb members of mannequins and forms, and methods of assembly of joints and mannequins are provided. The joints and mannequins of this invention provide natural anatomical shape and ease of assembly. This is accomplished using one or more assembly fixtures, located within or on a limb member to be joined, that contain elements of a joining or locking mechanism to hold the limbs together and other elements for creating tension or friction between joined limb members. The assembly fixtures also comprise a tab or disk that provides a natural appearance to the joint and allows for ease of assembly. The invention provides a friction assembly fixture recessed in the end of a first limb member to be joined. A tab formed as part of, or attached to, a second limb member is inserted into the first limb member to contact the friction assembly fixture. The first and second limb members are held in pivotal contact. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] None.
BACKGROUND OF THE INVENTION
[0002] This invention relates to braking systems, in more particular, to brake control systems adapted to engage the brakes of a towed vehicles when the brakes of the towing vehicle are actuated so as to causes the brakes of the towed vehicle to assist the brakes of the towing vehicle in stopping the two vehicles. There are a number of patents and designs for braking systems intended to be employed with one vehicle being towed by another. When a vehicle is being towed by another vehicle, the braking system of the towing vehicle must function to stop both the towing vehicle and the towed vehicle, unless some auxiliary braking control is provided. The extra force of the towed vehicle on the braking system of the towing vehicle requires extra stopping distance and extra stopping time for the two vehicles. The extra weight of the towed vehicle also accelerates the wear and tear of the braking system of the towing vehicle thus increasing the frequency of repairs.
[0003] It has long been known that it is possible to provide a system that applies braking force to the towed vehicle in response to brake actuation in the towing vehicle. Trailers of various size and shape, intended for towing by a towing vehicle conventionally include brake systems that are either hydraulically or electrically operated. A number of prior art devices are intended to operate with the towed vehicle braking system. While these prior art devices are acceptable for their intended purposes, they have not solved a number of problems associated with towing a second vehicle. In particular, these systems generally do not function to cause the braking system of the towed vehicle to operate as quickly as is desirable in braking situations. In addition, the prior art designs do not function properly in a number of specific operating situations. Prior art systems in which we are aware of do not engage the brakes of the towed vehicle during backing up of the two vehicles. This can be especially important, for example, in situations in which the towed vehicle is a boat type trailer and it is desired to back the trailer down an extended boat ramp.
[0004] In general, there are two types of braking systems available for trailers. Legal requirement specify that all trailers that require brakes have means for activating the trailer brakes under trailer breakaway conditions. In hydraulic surge brake systems this is normally done by means of a cable or chain which is connected to the tow vehicle. Under trailer breakaway conditions, the connecting link is designed to provided mechanical activation of the master cylinder, and to maintain brake system operation as the trailer stops. If the trailer has an electric brake system, the emergency breakaway regulations require that the trailer be provided with an emergency battery back-up system that will provide electrical power to the brake magnets during trailer breakaways. In an electric breakaway system there is a breakaway switch with a pull pin and cable which, when attached to the tow vehicle provides electrical activation of the trailer brakes if the trailer disconnects from the tow vehicle during highway travel, for example. The components for this system are normally packaged as an emergency breakaway kit which has a battery and charger, emergency switch, and battery case in one package.
[0005] Hydraulic surge brakes are a totally trailer self-contained braking system, requiring no electrical, hydraulic or other connection of brake sensing components to the towed vehicle for automatic operation of the trailer brakes. In a hydraulic surge brake system, the differential pressure developed between the towing vehicle and the trailer, during the braking process, creates a mechanical pressure which is applied to the push rod of the master cylinder in a hydraulic surge brake coupler. This mechanical pressure is proportional to the difference in pressure between the two vehicles and therefore, the hydraulic output of the brake coupler, and resulting brake operation, is automatic, regulated, and proportional to the amount of braking being applied by the towing vehicle.
[0006] These various systems, though effective, are not without hidden problems. For example, the hydraulic surge brake system requires a certain amount of forward pressure to be effective. Backing a trailer up a hill puts pressure on the system and actuates the trailer brakes when the brakes are least needed. Backing a surge system down a hill takes away pressure and the trailer free wheels, leaving no chance of brake activation. Electric brakes work well in dry conditions, however, electric brakes are not recommended for boat trailers.
[0007] The brake control system of the present invention is intended for application with surge brake systems to increase their efficiency. Certain components of the system also can be applied to electrical brake systems to improve their operation. A particularly hazardous condition can exist with respect to rental trailers which are attached to a tow vehicle without really evaluating the safety features, and particularly the brake features of the vehicle being towed. In one embodiment of the invention, the braking system is self-contained and is installed on the towed vehicle, requiring only an interconnection to the brake light system of the towing vehicle for operation. Other embodiments of invention include a hard wire system intended for use with a single towing vehicle and trailer, for example, in the common recreational use of the system.
BRIEF SUMMARY OF THE INVENTION
[0008] In view of the foregoing, as an object of the present invention to provide a brake control system that selectively actuates and deactuates the brake system of a towed vehicle in response to the activation and unactivation of the brake system of a towing vehicle.
[0009] Another object of the present invention is to provide an auxiliary brake system that actuates and deactuates the brake system of a towed vehicle in response to an electric signal that is carried from the towing vehicle to the towed vehicle.
[0010] Still another object of the present is to provide a brake control system that uses the existing brakes and/or brake lines of the towed vehicle.
[0011] A further object of the present invention is to provide a brake control system that uses a hydrostatic pump to apply pressure to the existing brakes and brake lines of the towed vehicle to create braking forces.
[0012] Still a further object of the present invention is to provide an auxiliary brake actuator that may be easily retrofit on a variety of vehicles that are typically towed behind another vehicle.
[0013] Another object of this invention is to provide a brake control system which, in one exemplary design, is self-contained and is installed on the towed vehicle.
[0014] Yet another object of this invention is to provide a brake control system that is microprocessor controlled.
[0015] Another object of the present invention is to provide a brake control system that is of relatively simple construction, which achieves the stated objectives in a simple effective and inexpensive manner, and which solves the problems associated with known braking systems employed with towed vehicles.
[0016] In accordance with this invention, generally stated, a brake control system has a microprocessor control adapted for use in a variety of applications. In one embodiment, the system is self-contained and is intended for attachment to the towed vehicle, the towed vehicle having a hydraulic brake system. The control includes a motor driven hydrostatic pump. The motor and pump are attached to a reservoir of brake fluid and the unit is attached to the hydraulic system of the towed vehicle. A battery provides power to the motor. A microprocessor controls application of electrical energy to the pump motor, and controls charging current to the battery. Other embodiments of the invention distribute the components of the control system between the towing vehicle and the towed vehicle.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0017] The objects of the invention are achieved as set forth in the illustrative embodiments shown in the drawings which form a part of the specification.
[0018] [0018]FIG. 1 is a diagrammatic view of one illustrative embodiment of the brake control system of the present invention;
[0019] [0019]FIG. 2 is a diagrammatic view of the brake system of FIG. 1 showing a distribution of the system to a towed vehicle;
[0020] [0020]FIG. 3 is a diagrammatic view of the brake control system of a towing vehicle control unit adaptable for use with either electric or hydraulic brakes on a towed vehicle; and
[0021] [0021]FIG. 4 is diagrammatic view of a distribution system for permanently wired system intended for a single and user application.
[0022] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF INVENTION
[0023] The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention. It describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what we presently believe is the best mode of carrying out the invention. As various changes could be made in the these constructions without departing from the scope of the invention, it is intended that all matter contained in the description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0024] Referring now to FIG. 1, reference numeral 1 indicates one illustrative embodiment of the brake control system of the present invention. The brake control system 1 includes an enclosure 2 which functions to house a plurality of components, including a motor 3 and a pump 4 . Also mounted with the enclosure 2 are a battery 5 and a microprocessor 6 .
[0025] The system shown in FIG. 1 is the self-contained unit, and all components mentioned above fit and attach neatly to and/or into the enclosure 2 . Installation of the unit is as easy as mounting the enclosure 2 to a trailer (or other towed vehicle) 17 , and connecting the brake line of the trailer to a fluid fitting under the enclosure 2 , not shown. The motor 3 of the motor/pump combination is conventional and is driven by the battery 4 through the microprocessor 6 . The battery 5 is a conventional 12 volt battery, and the motor 3 is intended to operate from the 12 volts through a power modulator 7 associated with the microprocessor 6 .
[0026] The microprocessor 6 includes a relay time function 8 which is interposed between the processor 6 and the battery 5 . As seen in FIG. 1, the interconnection between the system 1 and the towing vehicle 10 is accomplished through a single interconnection 11 . The interconnection 11 includes a first line 12 and a second line 13 which provide electrical input to the microprocessor 6 and corresponds to the right turn signal/brake and the left turn signal/brake input from the brake lights of the vehicle 10 . A third line 14 is connected to a charging circuit 15 which in turn is connected to the microprocessor 6 and enables the microprocessor 6 to control charging to the battery 5 whenever at least the taillight switch of the vehicle 10 is on.
[0027] As shown in FIG. 1, a breakaway switch 16 is operatively connected between the towed vehicle 17 and the towing vehicle 10 and is connected to the enclosure 2 , in the embodiment illustrated. The breakaway 16 in turn is electrically connected to the microprocessor 6 and operates to cause the microprocessor 6 to apply braking signals to the motor 3 in the event of towing vehicle breakaway during use. Also shown in FIG. 1, is an on/off switch 17 which removes power from the system 1 .
[0028] Referring now to FIG. 4, a permanent single end user system as shown in which certain of the components of the system are distributed between the towing vehicle 10 and the towed vehicle 17 . In this particular embodiment, a relay box 18 is preferably mounted under the hood of the vehicle 10 , near the vehicle battery 5 ′. An on/off switch 60 of the relay box applies power to the pump 4 through leads 19 and 20 . Leads 21 and 22 are connected to the battery 5 ′ and the unit transmits the power from the battery 5 ′ to the motor 3 . A lead 23 is operatively connected to a brake pedal motion detector 61 .
[0029] The switch enclosure 18 may be replaced by an under dash unit 24 , if desired. The unit 24 may assume a variety of esthetic design configurations, and two such configurations as shown in FIG. 2 and FIG. 3, for example. Regardless of the configuration, the unit 24 is designed to operate with either hydraulic or electric brakes, and a mode switch 25 is provided to adjust the brake control system with the types of brakes being employed in the towed vehicle 17 . In the embodiment illustrated in FIGS. 2 and 3, a power dial position selector switch 26 also is provided.
[0030] Merely by way of example, the selector switch 26 may contain the following functions. For example, we have chosen the position 1 as being the off mode, which would be used when the towed vehicle is parked for any length of time. Switch selection No. 2 , is in the embodiment illustrated, the battery connection mode and shows the battery voltage on a scale 27 . This selection will also let the operator know when the battery should be charged. As indicated above, charging may be accomplished merely by turning on the vehicle lights so that the microprocessor 6 actuates the charging circuit for the battery 12 in those units in which the battery 12 is mounted on the towed vehicle 17 . Switch selection No. 3 is the back-up mode. As indicated above, this allows the user to back up any hydraulic trailer regardless of whether the backup is occurring up hill or down hill. This setting offers an on command of the brakes for the trailer 17 for as long as the brake pedal of the towing vehicle is depressed. This is an important feature for trailers employed with recreational boats, for example, in that it is common for such trailers to be backing down long extended boat ramps.
[0031] The next seven selections gives the user multiple power settings for the brakes. The dial starts from a minimum to maximum pressure setting. This allows the user to adjust for conditions in the towed vehicle 17 . This is particularly important to adjust the system operation between loaded and unloaded trailers or other towed vehicles, for example.
[0032] The relay timer circuit 8 is an important feature of our invention. This system allows braking pressure to be constant for 8 seconds from the time the brake pedal in the towing vehicle is depressed. Each time the pedal is depressed, the timing function resets and the brakes continue to operate. This feature allows a vehicle to travel down long steep grades without dragging the brakes. After 8 seconds of continuous braking, the timer circuit disengages the brakes, forcing the release and reapplication of the brake pedal of the towing vehicle. This action allows for improved operation of both the towing vehicle and the towed vehicle brakes.
[0033] Regardless of the configuration of the system, operation of the braking control system of the present invention is relatively simple to understand. Upon initial braking, the microprocessor 6 drives the motor pump into a spin up mode. The function insures a quick response from the electronic signal to the pressurizing of the brakes. Once spin up produces pressure to the brake lines, the pressure returns to the brake pressure setting that the driver has dialed on the control board. The control board, in the embodiment of FIG. 1, is located on the left side of the housing with LED light display and control adjust knob in plain view from the driver side of the vehicle. Operation of the system thereafter follows in tandem with the application of brakes in the first or towing vehicle.
[0034] One test conducted on the control system of the present invention, a truck having a weight of 5,400 lbs. with a trailer having a weight of 12,600 lbs. on a day with the temperature of 55° F., dry pavement showed the following results. From initial start of 55 M.P.H panic stop with ABS breaking and the towing vehicle. The trailer had two axles.
[0035] Braking with truck only 350 feet.
[0036] Braking with utilizing the trailer only 578 feet.
[0037] Braking with trailer and truck 262 feet.
[0038] It may thus be observed that the brake system of this invention provides substantially improved braking capability for vehicles being towed, while providing functionality not found in prior art designs.
[0039] Numerous variations, will be apparent to those skilled in the art in light of the foregoing description and accompanying drawings. For example, the location of various units of the equipment may be varied in other embodiments of the invention. As indicated, the design silhouettes for certain components may be altered. While hard wiring was indicated with respect to certain applications and signal transmissions between the towing vehicle and the towed vehicle, those skilled in the art will recognize that radio transmissions or infrared or other forms of electromagnetic or light transmissions may be employed in other embodiments of the invention. These variations are merely illustrative. | A brake control system for towed vehicles is disclosed which provides for controlled application of hydraulic brakes in a towed vehicle in response to the application of the brakes of the towing vehicle. The system is designed in two preferred embodiments. The first embodiment is a self-contained design adapted for use with rental trailers, for example, where a plurality of towed vehicles will be associated with a particular trailer. The second embodiment is intended for hard wiring in connection with the towed and towing vehicles. In each case, superior performance is obtained because the system operates the brake system of the towed vehicle in a unique manner. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of application Ser. No. 09/833,403 filed Apr. 11, 2001, now U.S. Pat. No. 6,704,331, entitled “Synthetic Guide Star Generation.”
The United States Government has rights in this invention pursuant to Contract No. W-7405-ENG-48 between the United States Department of Energy and the University of California for the operation of Lawrence Livermore National Laboratory.
BACKGROUND OF THE INVENTION
1. Field of Endeavor
The present invention relates to synthetic guide stars and more particularly to laser guide star generation.
2. State of Technology
Earth-bound astronomers have long sought to diminish the effects of the atmosphere on their observations. Stars that appear as sharp pinpricks to the eye become smeared “blobs” by the time they are imaged by large ground-based telescopes.
At the University of California's Lick Observatory on Mount Hamilton near San Jose, Calif., Laboratory researchers and their UC colleagues are installing a system on the 3-m Shane telescope that will correct these troublesome distortions. The system includes a dye laser that will create a “guide star” in the upper atmosphere and very sensitive adaptive optics that will measure and correct for atmospheric distortions. According to Scot Olivier, project scientist for the adaptive optics subsystem, the Shane is the first major astronomical telescope with such a laser system. Other groups have been using adaptive optics systems with natural guide stars. However, it turns out that not just any star will do. It must be bright enough; that is, generate enough light to serve as a reference. When observing at visible wavelengths, astronomers using adaptive optics require a fifth-magnitude star, one that is just bright enough to be seen unaided. For near-infrared observations, only a tenth-magnitude star is needed, which is 100 times fainter.
The problem, Olivier noted, is that even though there may be hundreds of thousands or even a million stars bright enough to be guide stars, they only cover a small fraction of the sky. “Many times, there just isn't a natural guide star in the area you want to observe,” he said. “This is the kind of situation where a telescope equipped with a laser guide star comes out ahead.”
Definition: Laser Guide Star—A man-made, star-like laser light source that permits an optical system (telescope) to be adjusted to cancel out the adverse effects of viewing through turbulent atmosphere. By detecting backscattered light from a laser beam fired upwards, computers and adaptive optics can compensate for the distorting effects of atmospheric turbulence on astronomical images.
Some rudimentary wavefront correction systems, which don't require lasers, are based on a mirror, which can be tilted in real-time in response to the wandering of the star image about a centroid. These minute deflections originate from the atmosphere acting like a giant prism, which varies over time bending the wavefront as a whole. It is much more difficult for such passive systems to adequately correct for higher order aberrations which change the shape of the point spread function due to multiple inhomogeneities in the atmospheric index of refraction along the light path. Laser guide star systems can offer an elegant solution to this problem by actively rather than passively sensing these inhomogeneities.
There are many prototype laser guide star systems currently in operation or in the testing phase such as the Lick Observatory system. Most are based on correcting the incoming optical wavefront using a laser to probe the index of refraction variations of the atmosphere along the path. With this knowledge, computers and high speed deformable or tiltable mirrors can be used to reverse these wavefront distortions.
Laser guide star efforts have generally focused on two methods of creating artificial stars. The first method uses visible or ultraviolet light to reflect off air molecules in the lower atmosphere from fluctuations (Rayleigh scattering), creating a star at an altitude of about 10 km. The other method uses yellow laser light to excite sodium atoms at about 90 km. The sodium-layer laser guide star turns out to be crucial for astronomy, because astronomers need large telescopes to see objects that are very far away and therefore very dim. These large telescopes require the laser guide star to be as high as possible so that the light from the laser star and the observed object pass through the same part of the atmosphere. With a guide star at the lower elevation, the system senses and corrects for only about half of the atmosphere affecting the light from a distant object.
U.S. Pat. No. 5,412,200 for a method and apparatus for wide field distortion-compensated imaging by Geoffrey B. Rhoads, patented May 2, 1995, provide the following information beginning at column 2, line 59: “Just as adaptive optics systems have recently employed “artificial beacons” to assist in the imaging of very dim objects, so too can this invention utilize various forms of this concept as described herein. Artificial beacons can be employed when the brightness of an object under study is insufficient or inappropriate to provide photons to a wavefront sensor. The beacons are generally laser beams directed along a close line of sight to the object, generating backscatter photons which will undergo largely similar phase distortions as the photons from the object under study, and thus they can be used to deduce the phase distortions applicable to the object photons.”
U.S. Pat. No. 5,448,053 for a method and apparatus for wide field distortion-compensated imaging by Geoffrey B. Rhoads, patented Sep. 5, 1995, provides the following abstract: “An imaging system for measuring the field variance of distorted light waves collects a set of short exposure “distorted” images of an object, and applies a field variant data processing methodology in the digital domain, resulting in an image estimate which approaches the diffraction limited resolution of the underlying physical imaging system as if the distorting mechanism were not present. By explicitly quantifying and compensating for the field variance of the distorting media, arbitrarily wide fields can be imaged, well beyond the prior art limits imposed by isoplanatism. The preferred embodiment comprehensively eliminates the blurring effects of the atmosphere for ground based telescopes, removing a serious limitation that has plagued the use of telescopes since the time of Newton.”
U.S. Pat. No. 6,084,227 for a method and apparatus for wide field distortion-compensated imaging by Geoffrey B. Rhoads, patented Jul. 4, 2000, provide the following information beginning at column 1, line 15: “The limitations on imaging system performance imposed by a turbulent media, most simply described as ‘blurring,’ are well known, particularly in applications using medium to large aperture telescopes in the open atmosphere. These limitations have not only led to a variety of system solutions that will be discussed as prior art, but have played a major role in the decision to launch space based telescopes and have led to serious postulations of lunar based observatories. For a large aperture telescope—generally greater than a 10 centimeter diameter for the visible light region—which is otherwise constructed to a precision commonly referred to as “near diffraction limited,” the overall ability to resolve objects obscured by a turbulent atmosphere is limited by the turbulence rather than by the instrument. For the visual band of light once more, it is quite typical for a 1 meter aperture telescope to have ten times worse resolving power due to the turbulence, while a 10 meter aperture telescope can be 100 times or more worse than its innate “diffraction limit.” The exact numbers for any given telescope on any given night are a function of many variables, but this general level of degradation is widely recognized. As importantly, this atmospheric blurring directly leads to a loss in effective sensitivity of these large aperture imaging systems, which either renders dim objects just too dim to be seen or forces greatly extended exposure times, ultimately limiting the number of objects that can be imaged during a given length of usage time. The prior art for addressing this problem and trying to alleviate it can be generally categorized into the following well known areas: 1) Telescope Placement; 2) Adaptive Optics Systems; and 3) Speckle Inferometric Systems.”
SUMMARY OF THE INVENTION
The present invention provides a system for assisting in observing a celestial object and providing synthetic guide star generation. The system includes a lasing system, a frequency-conversion system serving to mix the radiation and generate light at a separate frequency, and a system for directing the light toward the celestial object and providing synthetic guide star generation. The lasing system provides radiation at a frequency at or near 938 nm and radiation at a frequency at or near 1583 nm. A frequency-conversion system mixes the radiation at a frequency at or near 938 nm and the radiation at a frequency at or near 1583 nm and generates light at a frequency at or near 589 nm. A system directs the light at a frequency at or near 589 nm toward the celestial object and enables synthetic guide star generation. Other 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 specific 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 and by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated into and constitute a part of the specification, illustrate specific embodiments of the invention and, together with the general description of the invention given above, and the detailed description of the specific embodiments, serve to explain the principles of the invention.
FIG. 1 illustrates the general architecture for the cw all-fiber laser guide star.
FIG. 2 shows an etalon trace of the low-power frequency-mixed output near the guide-star wavelength.
FIG. 3 shows absorption and emission cross-section spectra of Nd:SiO 2 fiber, using germania in the core rather than alumina.
FIG. 4 shows output power of Nd:fiber as a function of seed power assuming 1080 nm ASE is suppressed.
FIG. 5 shows depiction of periodically-poled frequency conversion crystal.
FIG. 6 shows a plot of the 589 nm light output as a function of temperature of the periodically-poled frequency conversion crystal.
FIG. 7 shows a simple diagram of anomorphic focus represented as a means of scaling the power by about a factor of five.
FIG. 8 illustrates the lasing system, the frequency-conversion system serving to mix the radiation and generate light at a separate frequency, and the system for directing the light toward the celestial object and providing synthetic guide star generation.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, specific embodiments of the invention are shown. The detailed description of the specific embodiments, together with the general description of the invention, serve to explain the principles of the invention.
Synthetic guide stars can be produced by optical excitation of atoms contained in the mesosphere at an altitude of approximately 90 km. The generation of brightly-fluorescent guide stars for adaptive optics requires precise control of the laser frequency and bandwidth to maximize the return signal. Several laser technologies were investigated to generate 589 nm sodium D-line light for laser guide star applications. The sodium-laser embodiment of the present invention uses two fiber lasers operating at or near 938 nm and at or near 1583 nm, respectively. Very stable fiber oscillators followed by high-average-power double-clad fiber amplifiers are used to generate the frequency-stable cw output powers required for the nonlinear wave-mixing process. The output radiation from these two fiber lasers is then wave-mixed in a nonlinear crystal such as Periodically Poled Lithium Niobate (PPLN), Lithium Tantalate (PPLT), or Potassium Titanyl Phosphate (PPKTD) to generate an output at 589 nm. The resulting systems are simple, robust, efficient, and reliable, making them ideal for use in remote astronomical observatories. Similar fiber-laser technology generates the 765 nm light used for potassium resonance excitation, and for 570 nm bichromatic (with 589 nm) sodium excitation.
The present invention provides a new architecture for constructing laser guide stars, used to correct for atmospheric distortions with adaptive optics. These guide stars are based on fluorescence emitted from atoms resonantly pumped to excited states. The best-known example is 589 nm excitation of sodium. Other examples are, 765 nm excitation of potassium and multiple-color pumping (e.g., sequential absorption of 589 and 570 nm photons by sodium atoms).
The main approaches pursued in the past for pumping sodium include (1) dye lasers, and (2) frequency-mixed Nd:YAG lasers. Dye lasers generate the desired 589 nm wavelength directly using a MOPA architecture (master oscillator—power amplifier). It is therefore possible to amplify, the seed from an oscillator in a manner tailored to optimize the spectrum of the output beam (20 Watts at 2 GHz bandwidth for 10-100 nsec pulsed operation). Their disadvantages include potentially-flammable solvents, need for pumping and cooling cycles, and relatively-inefficient (<0.1%) operation.
At this time the bulk-solid-state-laser approach appears more compelling, since its efficiency is higher (−0.5%), it can probably be more compact, and flammable liquids are eliminated. In the original vision developed at MIT, 1064 nm and 1319 run beams were frequency-mixed to generate the desired 589 run wavelength. Nevertheless, very careful optical design is required to manage the substantial thermal aberrations expected in this type of laser, and such a system will probably require the maintenance services of a laser expert.
The present invention is based on the use of fiber pump lasers. Fiber lasers perform far more effectively when operating in the continuous wave (CW) mode than when generating pulses. To enable efficient frequency conversion of these CW lasers, the present invention relies on the benefits from recent advances in “quasi-phase-matched” nonlinear-optical crystals, based on periodic poling. The present invention uses these new crystals to achieve high conversion efficiency via single pass mixing. Resonant buildup cavities will not be required.
Fiber lasers have been developed as a new generation of compact, inexpensive and robust light sources. In essence, a fiber laser is an optically-pumped doped-fiber serving as the gain medium. As the gain exceeds the total optical loss in the resonator, a laser oscillation can be generated or an input seed input can be amplified. Many different dopants can be used to achieve laser oscillations at different wavelengths. Atomic transitions in rare-earth ions can be used to produce lasers from visible wavelengths to mid infrared wavelengths. Mode-locked fiber lasers can use various cavity is configurations such as linear, ring, and figure-eight geometries. See, for example, U.S. Pat. No. 5,008,887 to Kafka, et al. and U.S. Pat. No. 5,513,194 to Tamura et al which are incorporated herein by reference.
The general architecture for the cw all-fiber laser guide star is shown in FIG. 1 . The general architecture includes: DFB (“distributed feedback”) oscillators, Phase modulators, Cladding-pumped fiber amplifiers, and Quasi-phase-matched (PPLN, PPLT, PPKTP, etc.) sum-frequency-converters. The DFB oscillators determine the operating wavelengths of the pump lasers, which have been selected as 938 run for the Nd:SiO 2 fiber and 1583 nm for the Er:SiO 2 fiber. Since the fibers will each need to generate about 20 Watts, bandwidth must be added to the seed lasers to reduce the tendency for Stimulated Brillouin Backscatter (SBS). Using the formula to estimate the SBS threshold in Watts:
P crit =21( A eff /g 0 L )(1 +ΔV ‘nu’lase /ΔV Br ),
where the mode radius is taken as 5 microns, the Brillouin gain coefficient is g 0 =5×10 −11 m/W, the laser and Brillouin bandwidths are taken as ΔV=500 MHz and ΔV Br =17 MHz respectively, and fiber length is 10 meters (half the actual physical length to account for the growing amplitude of the intensity). We calculate the critical power for Brillouin scattering is P crit =100 Watts. Considering the requirements relating to the guide star, we note that a bandwidth of ␣500 MHz also has a favorable impact on the luminescence from the sodium layer, since it avoids saturation of the sodium atoms in the atmosphere. The fortuitous coincidence of the bandwidth requirements imposed by the fiber amplifiers and of the sodium layer saturation, enables the functionality of the current invention. Use of larger fiber core diameter and shorter fiber length would increase the power margin further. So, it is plausible to obtain 20 Watts of cw fiber laser power without interference from SBS losses, while meeting the guide star requirements for the atmospheric sodium layer.
FIG. 1 shows the components of the cw all-fiber laser guide star. The overall system is generally designated by the reference numeral 10 . The lasing system includes a Nd-doped fiber pump fiber laser operating near a frequency of 938 nm. The Nd-doped fiber pump fiber laser is composed of pump diodes 13 , distributed feedback oscillator (DFB) 14 , phase modulator (PM) 16 , and Nd doped fiber amplifier (NDFA) 18 . The Erbium-doped fiber pump fiber laser is composed of pump diodes 12 , distributed feedback oscillator (DFB) 11 , phase modulator (PM) 15 , and Erbium doped fiber amplifier (EDFA) 17 . The lasing system provides radiation at a frequency near 938 nm and radiation at a frequency near 1583 nm. The Nd doped fiber amplifier (NDFA) 18 and Erbium doped fiber amplifier (EDFA) 17 provide the radiation to sum frequency generation (SFG) frequency-conversion system 19 . The frequency-conversion system 19 mixes the radiation at a frequency near 938 nm and the radiation at a frequency near 1583 nm and generates light at a frequency near 589 nm. The frequency-conversion system 19 uses periodically poled frequency-conversion crystals (such as PPLN).
The desired wavelength of 589 nm can be generated by many pairs of wavelengths, that are available within the gain bandwidth of EDFA and NDFA fiber amplifiers. For example, stable pairs of wavelengths are: 1530.0 nm and 957 nm; 1550.0 nm and 950.0 nm; 1570.0 nm and 942.6 nm; 1590.0 nm and 935.6 nm; and 1610.0 nm and 928.7 nm. The recommended wavelength pair of 1583 nm and 938 nm provides desired performance at 589 nm.
DFB fiber oscillators have proven extremely stable, even without any wavelength-control feedback. An etalon trace of the low-power frequency-mixed output near the guide-star wavelength is shown in FIG. 2 and is stable over several minutes without any type of feedback loop. In this case, the DFB oscillator has a linewidth of <<50 MHz (instrument limited). Fiber-pigtailed phase modulators are standard components, readily procured with the necessary operating wavelength, RF frequency, and depth of modulation. Also shown in FIG. 2 is the usual pattern of side-band frequencies imposed on the oscillator output by the FM modulator.
Both of the fiber amplifiers employ cladding-pumped structures to produce adequate output power. Cladding-pumped structures will be applied to the 20 Watt 1583 nm Er:fiber. Fifteen (15) Watt modules are already on sale from IRE Polus (operating at 1555 nm). While 1583 nm is about halfway down the Er 3+ gain curve, sufficient flexibility in the amplifier design exists to achieve the desired output power. Furthermore, one of the strongest new directions (continuing the trend toward greater bandwidth) in the telecom industry is operation in the so-called long-wave region (L-band) of erbium-doped fiber amplifiers. Er 3+ is normally codoped with Yb 3+ to enhance the pumping efficiency and minimize the quasi-three-level losses. It is possible to maintain linear polarization of the fiber amplifier if its temperature is stabilized and it is firmly mounted to a fixture. Polarization-maintaining Er:fibers are being developed.
The 938 nm Nd:silica fiber is a somewhat more novel device, since the Nd 3+ ions must operate on the resonance transition (i.e. 4 F 3/2 − 4 I 9/2 ), while suppressing ASE losses at the more-conventional 1080 nm transition. The absorption and emission of the relevant transitions appears in FIG. 3 . Although the 1080 nm transition is the common operating mode of the laser, there have been several papers in which lasing at 900-945 nm was reported [for example, see A. Cook & H. Hendricks, Diode-laser-pumped tunable 896-939. 5-nm neodymium-doped fiber laser with 43-mw output power, Applied Optics 37, 3276-328 (1998). An important finding is that an alumina-free fiber core (using germania instead to raise the refractive index) assures that the Nd 3+ ions have the optimal emission spectrum, favoring resonance-band operation.
In FIG. 4 , the calculated output power of a Nd:silica fiber resonance amplifier (938 nm) is plotted as a function of the front-end input signal power. For this design (60 Watts of pump power, 10 20 cm −3 Nd doping, 250 μm inner [pump] cladding dimension, and 20 meters of fiber) will meet the 20-Watt goal. An issue for this type of fiber amplifier is self-saturation from 1080 nm ASE. With 100 mW of 938 nm input signal power, the 1080 nm gain is driven down to 57 dB, larger than the 40 dB practical limit. The 1080 nm ASE can be suppressed by separating the fiber into two catenated lower-gain segments with an intermediate dichroic filter to reject the 1080 nm radiation. Or, chirped long-period fiber Bragg gratings can direct the ASE from the core into the cladding, where there is greatly reduced gain because of poor overlap with the core. Another possibility is to systematically bend the fiber, since the bend losses are normally greater at longer wavelengths, thereby selectively reducing the gain at 1080 nm compared to 938 nm. See, for example, U.S. Pat. No. 6,118,575 which is incorporated herein by reference.
In another embodiment the fiber is cooled. This entails cooling the fiber to below ambient, perhaps to 100K, so that the ground state absorption at 938 nm is greatly reduced, essentially approximately equalizing the gain at 938 nm and 1080 nm.
Frequency conversion efficiency is dependent upon the magnitude of the nonlinear optical coefficient, the length of the crystal, and the square of the incident intensity. Traditionally, frequency conversion of CW laser sources is accomplished using external cavity techniques—resonantly enhancing the incident light at a cost of precisely monitoring and controlling the length of the optical cavity (also known as cavity locking). Periodically-poled crystals, and in particular PPLN (Periodically Poled Lithium Niobate), allow efficient frequency conversion through a 30× increase (over the nonlinear coupling of crystals such as LBO) in the magnitude of the nonlinear optical coefficient. With this tremendous increase in the nonlinear optical coupling, it is now possible to frequency-convert CW laser light in a single pass without the use of the external cavity. A CW single pass conversion efficiency exceeding 42% at an average power of 2 W has been demonstrated in PPLN. In addition, 6 Watts of second-harmonic power was produced with an Yb:silica fiber using periodically-poled KTP (purchased from Isorad). This result is within a factor of two of the guide-star requirements. Other periodically poled materials offering very promising performance are PPLT (LiTaO 3 ), as well as Mg-doped and stoichiometric LiNbO 3 and LiTaO 3 , and periodically-poled KTP.
FIG. 5 shows depiction of periodically-poled frequency conversion crystal and FIG. 6 shows a plot of the 589 nm light output as a function of temperature. FIG. 5 schematically depicts a periodically-poled material (PPLN in this example.) With 938 nm and 1583 nm light being summed to 589 nm using LiNbO 3 , the poling period must be 9.57 μm. Results utilizing PPLN have been successful. We include for illustration, the temperature-tuned 589 nm output power achieved by mixing 1319 nm and 1064 nm light in a PPLN crystal with 8.9 μm period (for about 100 mW of output.) The expected sinc-squared dependence on the temperature detuning is evidence of the high uniformity (needed for good mixing efficiency) in the poling period and in the oven temperature.
Another challenge to using this new class of periodically poled crystals is increasing their average power handling capabilities. Although improved materials will be able to handle 10 Watts of 589 nm output, in an embodiment we use anamorphic focussing as an alternative approach to the necessary power scaling. Our strategy is to employ a simple circular beam unless power handling becomes a problem, requiring an elliptical focus. The issue is that the crystals can typically be poled at thickness up to ˜1 mm, resulting in very high intensities if round spots of such diameters are used. Our resolution is to expand the focal spot in the crystal up to a 5× aspect ratio, as pictured in FIG. 7 .
A 100 mW 589 nm system has been built based on mixing relatively low power 1064 nm and 1319 nm light. The system is comprised of a NPRO single-frequency laser from Lightwave Electronics and an Yb:silica fiber (together with a modulator). Although this system offers less power (by about two orders of magnitude) than the guide-star requirements (since it was only intended to serve as a front-end laser), many of the basic physics issues were resolved in the course of its construction.
FIG. 8 illustrates the present invention of a synthetic laser guide star used to correct for atmospheric distortions with adaptive optics. A celestial object 21 is observed by a telescope through an atmosphere 22 . The synthetic laser guide star system, designated generally by the reference numeral 20 , includes a telescope-adaptive optics-laser system 23 . The system 23 includes a telescope, adaptive optics, and a laser system based on fluorescence emitted from atoms resonantly pumped to excited states. The laser light for the system 23 is provided by a lasing system and a frequency-conversion system serving to mix the radiation and generate light at a separate frequency.
Adaptive optics requires a reference source of light in the sky to measure wavefront aberration introduced by atmospheric turbulence. Natural stars are ideal for this purpose, but the density of bright stars is not sufficient to provide complete sky coverage. The problem can be overcome with an artificial beacon generated from resonant backscattering off mesospheric sodium atoms exited by a low-power laser. U.S. Pat. No. 5,412,200 for a method and apparatus for wide field distortion-compensated imaging by Geoffrey B. Rhoads, patented May 2, 1995, incorporate herein by reference, states “Just as adaptive optics systems have recently employed “artificial beacons” to assist in the imaging of very dim objects, so too can this invention utilize various forms of this concept as described herein. Artificial beacons can be employed when the brightness of an object under study is insufficient or inappropriate to provide photons to a wavefront sensor. The beacons are generally laser beams directed along a close line of sight to the object, generating backscatter photons which will undergo largely similar phase distortions as the photons from the object under study, and thus they can be used to deduce the phase distortions applicable to the object photons.”
The synthetic guide star 20 is produced by optical excitation of atoms contained in the mesosphere 22 at an altitude of approximately 90 km. The optical excitation of atoms generates sodium D-line light at or near 589 nm for laser guide star application. The sodium-laser embodiment of the present invention uses two fiber lasers operating at or near 938 nm and at or near 1583 nm, respectively. The frequency-conversion system 32 mixes the radiation at a frequency at or near 938 nm and the radiation at a frequency at or near 1583 nm and generates light at a frequency at or near 589 nm.
The lasing system includes a Nd-doped fiber pump fiber laser operating at or near a frequency of 938 nm. The Nd-doped fiber pump fiber laser is composed of pump diodes 24 , distributed feedback oscillator (DFB) 25 , phase modulator (PM) 26 , and Nd doped fiber amplifier (NDFA) 27 . The Erbium-doped fiber pump fiber laser is composed of pump diodes 28 , distributed feedback oscillator (DFB) 29 , phase modulator (PM) 30 , and Erbium doped fiber amplifier (EDFA) 31 . The lasing system provides radiation at a frequency at or near 938 nm and radiation at a frequency at or near 1583 nm. The Nd doped fiber amplifier (NDFA) 27 and Erbium doped fiber amplifier (EDFA) 31 provide the radiation to sum frequency generation (SFG) frequency-conversion system 32 . The frequency-conversion system 32 mixes the radiation at a frequency at or near 938 nm and the radiation at a frequency at or near 1583 nm and generates light at a frequency at or near 589 nm. The light is directed to the telescope-adaptive optics-laser system 23 . The synthetic guide star 20 is used to correct for atmospheric distortions. The telescope-adaptive optics-laser system 23 provides a reference source of light in the sky to measure wavefront aberration introduced by atmospheric turbulence.
While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims. | A system for assisting in observing a celestial object and providing synthetic guide star generation. A lasing system provides radiation at a frequency at or near 938 nm and radiation at a frequency at or near 1583 nm. The lasing system includes a fiber laser operating between 880 nm and 960 nm and a fiber laser operating between 1524 nm and 1650 nm. A frequency-conversion system mixes the radiation and generates light at a frequency at or near 589 nm. A system directs the light at a frequency at or near 589 nm toward the celestial object and provides synthetic guide star generation. | 6 |
FIELD OF THE INVENTION
The present invention relates to an electronic automatic energizing damping device which is connected to an electric power supply network to protect and safeguard continuously all the devices, instruments, equipment and systems, as well as the electric power supply network, by means of the following two basic function stages: I) a control stage which monitors the operating conditions of both the A.C. line and the load energized by it via the power stage, in order to detect irregularities in any of the programmed parameters of the voltage or the current and automatically acts to protect the load, the electric power supply network and itself, by supplying control signals that regulate the power stage; and II) a power stage which supplies the energy of the electric power supply network to the load, according to the commands of the control stage.
BACKGROUND OF THE INVENTION
Voltage regulators and line management instruments, and surge suppressors are basically the most important electronic devices used to protect the equipment operated with alternative current.
The operating principle of voltage regulators and line conditioners are used to protect equipment using a high amount of electric energy and, as a result, the projection provided is very limited because their slow response to transient surges, capacity of the energy to be managed and the restricted range of the operating voltages. Moreover, this equipment delivers instant electric energy, that is, without any delay or damping, and requires both constant monitoring by the user and continuous maintenance for its correct operation.
On the other hand, the surge suppressors can limit the wide amplitude variations generated by the electrical facilities only within a certain range, since their impedance changes according to the voltage detected between their terminals. This means that the transient peaks are suppressed as a result of a temporary short circuit between the said terminals, without affecting or altering the low voltages encountered beyond the normal range or triggering the poor functioning, including the breakdown and overheating of the equipment operated in these conditions.
As a result of this situation, the protection provided by devices of this nature is very limited, in addition to presenting a series of other shortcomings such as high weight, large volume and high cost. Moreover, since in critical operating conditions they act as highly reactive loads, without delaying or damping the load of the network, these devices may induce serious disorders in the installed network.
These and other shortcomings and limitations are widely and advantageously corrected by the device claimed by the present invention.
SUMMARY OF THE INVENTION
The present invention relates to a delayed-action automatic electronic energizing damper (AED) for alternating current which is connected to the tap of electric energy supplied by the public electric power supply network, after the meter (wattmeter) and the central switch with protecting fuses, in the electrical equipment that must be protected.
The AED checks the existence of electric energy at the entry terminals and verifies that the voltage supplied by the network is within a predetermined range, for example from about 95 volts to about 135 volts.
In the absence of alternating current, or if the latter exceeds the programmed range, the device automatically cuts off the delivery of power to the electric installation in question.
Upon the resumption of the alternating current, provided that the latter is stable for a certain period of time, preferably 5 seconds, AED automatically and slowly energizes the connected load and dampens it. In other words, it supplies gradually, in approximately 1 second, from 0% to 99% of the energy resulting from the first stable cycles and the next ones, without any detectable change in the supply of electric energy.
AED is designed such that, when connected to the public network of alternating current, it performs the following basic functions:
1) Continuous protection of all the devices, electrical equipment, equipment and systems operated with electric power supplied by the public network against transient surges of power generated during the resumption of the power supply following a cut or blackout in normal operating conditions. Moreover, it filters and attenuates the surges produced by atmospheric discharges, such as lightning, preventing the operation of the equipment in poor power supply conditions. Likewise, it is provided with a current sensing and limiting circuit which protects the installations against instant continuous overloads and continuous short circuits, automatically reestablishing the power following the cessation of the abnormal voltage or overcharge conditions.
2) Protects the public electric power supply network by damping the load applied to the network when the supply of current is resumed after a power failure, as well as any instability occurring during delivery. By preventing power surges or sudden overloads, it improves the operating conditions of the public power supply network, which results in the reduction of maintenance costs. It is also useful in reducing the size and electrical specifications of the distribution substations, in that it is no longer necessary to provide for excess design capacity which is usually required to withstand the overload generated when the network is energized.
Accordingly, the primary object of the present invention is to provide an automatic energizing damper which, when connected to the tap of electric power, provides total protection and safeguards with respect to everything connected before it (the public network), and after it (particular installation or user).
Another object of the present invention is to provide an automatic energizing damper which provides continuous protection within a wide range of voltage, both low and high.
Another object of the present invention is to provide an automatic energizing damper which energizes automatically the load, according to a gradual and dampening pattern, which reduces the maintenance costs of the equipment being protected.
Still another object of the present invention is to provide an automatic energizing damper that protects the equipment of the public power supply distribution network, in that it dampens and prevents the generation of surges in the network, and also filters and prevents the reflection of surges generated by atmospheric discharges.
Another object of the present invention is to provide an automatic energizing damper that generates digital control signals (TTL) for the relay in the supply of energy across the power generating plants.
Still another object of the present invention is to provide an automatic energizing damper the principle of which is applicable to various demands of electric energy, by selecting adequately the power stage according to the specific needs and also applicable to any type of equipment operated by alternating electrical current.
Another object of the present invention is to provide an automatic energizing damper of low energy consumption, without a load at its exit (approximately 6 Watts) and highly efficient at full load (approximately 98.8%), which provides protection at practically no operating cost.
An additional object of the present invention is to provide an automatic energizing damper which is also a system of protection against overload and acts when the limits established in the control circuit are exceeded or in continuous short circuit conditions.
Still another object of the present invention is to provide an automatic energizing damper compatible with various frequencies of the network by synchronizing automatically to the required frequency, in the range from 20 to 1000 Hz.
These and other objects of the present invention emerge more clearly from the detailed description of the invention, which is presented below.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram which illustrates the components of the automatic energizing damper according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The automatic energizing damper claimed by the present invention is characterized by the following two basic stages: I) a control stage and; II) a power stage.
The function of the control stage, which is the brain of the AED, is to monitor the operating conditions of both the AC line and the load energized by the power stage. When it detects any abnormal changes in programmed voltage or current parameters, it acts automatically to protect the load, the electric power supply network that supplies the electric energy and the device itself, by generating the command signals which control the power stage.
The power stage is responsible for the delivery of the load of energy received from the network, according to the commands of the control stage. In turn, each of the two basic stages of the AED device consists of a series of electronic circuits and elements which together and in combination account for the development of the overall function of the said device.
The control stage consists of the following elements and circuits:
an electronic power supply source circuit 1;
a voltage sensing circuit 2;
a current sensing circuit 3;
a comparison circuit 4;
an energy relay control circuit (TTL) 5;
a delay line circuit 6, that activates the solid state switch of the power stage;
a zero crossing detector circuit 7;
an alternating current detector circuit 8; and
a duty cycle control circuit 9 for controlling the duty cycle of the solid state switch. The power stage consists of the following electronic circuits:
an optical interface 10; and
solid state switch circuit and surge suppressor means 11.
In FIG. 1, the electronic power supply source 1 converts the energy of the alternating current received from the public network to a direct current of lower intensity, which supplies the control circuits of the AED, for its adequate operation. The feeding voltage to the circuits of the AED is indicated by +B. It also generates the proportional sampling signal M1 for sensing the amplitude and frequency of the operating voltage. This circuit also provides sufficient protection against the overvoltage and surges in the network to the control stage and to the power stage, as well as the power and load connected to AED. This is made possible by the protection network formed by varistors V1, V2 and V3 and fuses F1 and F2. Breaker S1 energizes the control stage and acts as a control master. The remote control of AED is achieved by means of a remote breaker S3.
When the operating voltage limits of AED is exceeded, or in the presence of surges of voltage from any of the three supply lines, live, V, neutral, N, and physical ground TF, an excessively high current flow through fuses F1 and/or F2, passing across V1, V2 or V3 and inducing the break of F1 and/or F2 much earlier than the break of the varistors. This results in the cut-off of the energy supply at the source and prevents the breakdown or malfunctioning of AED.
An indicator D18, such as a light-emitting diode, visually indicates to the user the condition of the open or molten fuses for their replacement. After replacing the fuses, AED is once more reactivated.
The cut-off of energizing in the control stage automatically triggers the operation of the damper and opens the solid state electronic switch S2 to allow the passage of the alternating current to the load, with subsequent de-energizing and protection.
It is important to point out that before the disabling effect resulting from operating beyond the operating range, in the form of fuse failure, for example, AED blocks the flow of energy to the load by detecting the high voltage conditions prevailing in the comparison circuit 4, thus providing timely and early protection to everything connected to it.
The voltage sensor circuit 2 receives the proportional signal M1 originating from the supply source and adapts it for transmission to the comparison circuit 4.
The adaption operation involves: a) limitation of the amplitude, so that it does not exceed the limits tolerated by the comparison circuit 4, thus protecting the control stage and assuring its adequate operation in critical conditions resulting from the presence of surges in the network; b) average out its amplitude, in order to prevent fluctuations and instability in the control stage, as compared to the references provided by the comparison circuit 4; c) delay the signal to be compared, in order to prevent false manifestations in the comparison circuit 4 in normal operating conditions, during the insertion of a surge of tolerable amplitude, thus assuring that the comparison circuit 4 is sensitive enough and providing a stable and adequate energy service, compatible with the standards; and d) divide the signal M1 to obtain two identical signals which are fed to the comparison circuit 4 through the pre-adjusted potentiometers P1 and P2, in order to achieve its adequate calibration in the comparison circuit 4 and to establish the range of the discharge of the comparison circuit 4 against the voltage variations on the line.
The current sensing circuit 3 detects the flow of current across the live feeding line V of AED and converts it to a proportional signal equal to 1/1000 smaller than the said current. This proportional current is converted to a voltage and is adequate for subsequent use as the overload signal SC in the comparison circuit 4 across the pre-adjustable potentiometer P3 for the calibration of the level that determines the overload condition, thus controlling the limitation of the current and protecting the AED.
The adaptation of the proportional current signal to the load involves the following steps: a) conversion of the sample current to a reflection voltage proportional to it, known as overload or SC current; b) rectification of the SC current to allow comparison; c) limit the SC signal, in order to prevent damage to the comparators of the comparison circuit 4 as a result of the great variation in its amplitude when it senses an excessive transient surge of current generated by atmospheric discharges, reactive loads or even a short circuit; d) averaging out of the SC signal to prevent oscillations and instability in the control stage, as compared to the reference values of the comparison circuit 4; e) delaying the SC signal to prevent the false discharge of the comparison circuit upon the appearance of power loads when leaving the previously energized AED, as it happens with the startup of induction motors or lighting networks.
These adjustments guarantee the continuous supply of the current, as well as reliable and accurate protection against overloads and continuous short circuits when leaving the AED.
It is important to note that, as indicated by reference 3' in FIG. 1, when the AED has several outlets and a more accurate control is required, independently of the current limitations prevailing at each outlet, the current can also be sensed when it leaves the device. This is one of the multiple combinations that can be implemented to comply with the particular requirements of each user.
Comparison circuit 4 confirms that the levels of the high voltage signal, VA, low voltage signal, VL, and overload signal, SC, are adequate. This is achieved by comparing a portion of these signals against a common reference. When any of these signals presents an alteration, the comparison circuit 4 generates an error signal E1 which flags the presence of an undesirable condition by means of low, D9, high, D11, and overload, D17, indicators.
Signal E1 triggers the cut-off of the energy at the solid state switch 52 of circuit 11, after being delayed by the delay line circuit 6, being transformed into E2 signal. The E2 signal will activate the duty cycle control circuit 9 in order to generate a command signal which controls the duty cycle of the power stage. Also, the duty cycle control circuit 9 is synchronized to the operating frequency of the electric power supply network through the CXO signal from the zero crossing detector circuit 7.
The low voltage, VL, high voltage, VA, and overload, SC, signals enter the comparison circuit 4 and calibrate the discharge levels of the error Signal E1 across the pre-adjusted potentiometers P1, P2 and P3.
The comparison circuit 4 also supplies the overload signal SC1 for consideration by the energy relay control circuit (TTL) 5, thus preventing the startup of an emergency plant in conditions of short circuit in the load. Each of the comparators in the comparison circuit 4 responds independently. The high voltage comparator can be calibrated to generate the fail signals preferably at 135 V.A.C. R.C.M. (Volts of Alternating Current, Average Square Root) and cancels it by lowering the voltage to 130 V.A.C. R.C.M., which implies a hysteresis of 5 V.A.C. R.C.M. in the alternating supply voltage. The low voltage comparator can be calibrated to generate the failure signal preferably at 95 V.A.C. R.C.M. to cancel it when exposed to a voltage of 102 V.A.C. R.C.M., which implies a hysteresis of 7 V.A.C. R.C.M.
The overload comparator acts when the nominal capacity of the current applicable to AED is exceeded by 30% and is reestablished automatically upon the cut-off of the flow, when the comparison circuit 4 is activated.
The hysteresis of the comparators in circuit 4 prevents the occurrence of fluctuations and instabilities in AED when the voltage conditions of the network are unstable, when the demand of power during the operation varies. It is important to note that all the calibration levels of the voltages and currents can be adjusted according to the specific needs and applications of the final user.
The circuit that controls the relay of power (TTL) 5 is the interface between AED and an electric power generating plant (not shown). Its function is to synchronize the startup of the emergency power generating plant with the AED and the public network, across a power relief circuit (not shown). This power development control circuit (TTL) receives the E1 and SC1 signals.
Signal SC1 is generated at the time of the detection of an overload condition, which results in the suppression of the flux of current across AED and the subsequent resumption of normal operating conditions, such that the overload condition lasts only a few fractions of a second.
Signal SC1 is delivered to the emergency plant instantly, in order to prevent its startup and operation in conditions of overload.
The power relay control circuit (TTL) 5 generates the following signals at its outlets: a) a CPG signal, the continuous control signal for the startup of the emergency plant; b) a PSC signal, the instant TTL pulse which indicates the presence of an abnormal overload condition, in order to prevent the operation of the emergency plant in these conditions; c) a CR signal, which is a TTL control signal for the energy relay (not shown) that commands the transfer of the sources between the public network and the emergency plant; d) a VVC signal, small source of direct current, delayed and stabilized to assist in the control of the energy reliever (not shown) and prevent the flow of current between the contacts of the reliever (not shown) during the said transfer. This guarantees the long life of the relay circuit (not shown), with minimum maintenance of its contacts and optimal transfer of the services; and e) a GND signal, which is a grounding point for direct current common to all the TTL control circuits with the same reference.
The delay line circuit 6 that activates the switch of the power stage delays the arrival of the E1 signal to the duty cycle control circuit 9 to about 5 seconds. The new delayed signal is E2.
This delay allows sufficient time for the electronic power supply source 1 and the rest of the circuits to stabilize before sending any instructions to the power stage, when the electric power arrives at the intake of AED after a cut-off.
In addition to the 5 second delay, energizing the load also results in the stabilization of the voltage in the network, thus preventing the application of transient surges to the load due to the decline of the power stage. p This circuit 6 does not induce a substantial delay in the delay line power cut-off control of the load, which protects instantaneously against any of the abnormal operating conditions.
The zero crossing detector circuit 7 guarantees the switching of the solid state switch S2 to the power stage, synchronizing the frequency of the supply voltage at the exact time when the amplitude of the alternating current is equal to zero. This minimizes the noise generated on the supply line by the commands directed to the solid state switch S2 when the power management is "zero" and assures better operation of AED and the least possible wear of the solid state switches.
The reference for the zero crossing detector circuit 7 is provided by the M1 signal which generates a synchronized TTL pulse level (zero point for CXO) at the very time when the value of signal M1 is zero volts. Since signal M1 is in phase at twice the frequency of the supply line, the pulse of the "zero point" is an accurate reference for the command of the power stage, solid state switch S2 switching at each half-cycle of the alternating supply current.
The alternating current detector circuit 8 senses or detects the existence of electric power at the entrance of AED across signal M1 and detects immediately (in about 1 second) the supply of direct current to the optical interface circuit 10 as soon as it detects the presence of the alternating supply current. This prevents the false discharge of the power stage at the start of AED energizing. At this time, the instant surges on their way to the load at this moment are filtered once more across the solid state switch S2.
The duty cycle control circuit 9 of the solid state switch S2 generates the dampened signal AM used to command the power stage. Upon receiving the error signal E2, circuit 9 synchronizes the slow and dampened startup of the power stage, according to the reference supplied by the zero crossing detectors circuit 7, such that the AM signal generated at its exit (TTL signal having a frequency twice as high as the power supply frequency of AED) varies its duty cycle from 100% to 1% and forwards it to the optical coupler or optical interface circuit 10 to control the reverse behavior of the duty cycle of the solid state switch S2, which ranges from 0% to 99%, in approximately 1 second. This happens as determined by signal E2, or following the initialization of the energizing process following a cut-off or discontinuation of the power to the load due to the detection of one or more conditions of failure.
This semi-slow and gradual energizing of the power stage gives the damping effect of the load to the electric power supply network at any request of current and prevents the generation of damaging transient surges caused by instant overloads during the initialization of the supply of current to the load. As a result, protection is obtained for the circuits compatible with the load, the public distribution network and the AED itself.
In continuation and with reference to FIG. 1, the optical interface circuit 10 is a high voltage optical coupling isolation circuit which connects the two stages (control II and power II) and isolates the TTL signals generated in the control state by the command of the solid stage switch S2, to provide polarization and sufficient protection to the said solid state switch S2 against reactive loads across a "Snubber" circuit.
The presence of the optical coupling circuit 10 prevents the occurrence of undesirable noise and interference generated by the loads in the power stage and reflected to the control stage, insulating electrically both stages.
The optical interface circuit 10 receives the AM signals originating from the duty cycle control circuit 9 and the DCA supply voltage originating from the alternating current detector circuit and generates 8, the GOB command signal which controls the solid state switch S2.
The components of the solid state switch and surge suppressor 11 are the solid state switch S2 and a metal oxide varistor, VOM. The solid state switch S2 allows the passage of the current towards the load, or not, depending on the orders received from the control stage, which are delivered across the optical interface circuit 10.
Varistor VOM limits the transient surges produced by reactive charges, preventing their reflection to the supply network, and, therefore, protecting the load, AED and source of power.
The power capacity managed by the said circuit 11 depends on the particular power requirements of the user.
The load is connected to the output line S of the power stage in order to receive the electric energy from the electric power supply network.
The electronic, delayed-action automatic energizing damper, or AED, for alternating current, consists essentially of the circuit described herein; the said circuits, together and in combination perform the following general operation:
When AED is energized for the first time, there is a delay of 5 seconds before the flow of alternating current is allowed to pass across it. During this period of time, the device senses the voltage supplied by the electric power supply network, such as the public supply network, for example, and keeps it within the range of the calibrated voltages (nominal calibration, depending on the specific application), allows the passage of the current to the load and, in about 1 second, supplies 0% to 99% of the power of the first stable cycles, without evidence of overload or voltage variations beyond the said range, in which case the delivery of the current to the load is discontinued and the initialization process is repeated after the lapse of stabilization period of 5 seconds.
This process is repeated automatically every time that the failure conditions are present, whether there is a question of overload or voltage variations beyond the predetermined range.
Although the present invention was described with reference to the circuit mentioned and a series of preferred embodiments, it is understood that qualified technical personnel can figure out other practical embodiments are necessarily compatible with the extent and spirit of the present invention which is limited only by the attached claims. | An electronic automatic energizing damping device for connection to a source of electrical energy to protect and safeguard continuously all the devices, instruments, equipment and systems, connected to the source. The device comprises a control stage and a power stage. The control stage monitors the operating conditions of both the A.C. line and the load energized by it via the power stage, in order to detect irregularities in any of the programmed parameters of the voltage or the current, and supplies control signals that regulate the power stage. The power stage supplies the energy of the network to the load, according to the commands of the control stage. The control stage features a voltage sensor circuit, a current sensing circuit, a comparison circuit to receive the output of the voltage sensor circuit and an energy relay control circuit. The power stage comprises a surge breaker and suppressor, and an optical interface circuit. An alternating current detector circuit and a zero detector circuit connect the power stage to the control stage. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This nonprovisional application claims priority under 35 U.S.C. §119(a) on Patent Application No.2001-007013filed in Japan on Jan. 15, 2001, the entirety of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. FIELD OF THE INVENTION
[0003] The present invention relates to a belt replacement timing annunciator, and more particularly to a belt replacement timing annunciator for informing the driver of a vehicle of the necessity of replacement of the endless belt in an automatic, belt-type transmission.
[0004] 2. DESCRIPTION OF THE BACKGROUND ART
[0005] Since the endless belt in a belt-type automatic transmission mounted on a vehicle of the background art is worn away by contact with a pulley during operation, the endless belt is indicated as requiring replacement when the integrated mileage of the vehicle exceeds a predetermined reference value in the service manual. A belt-type automatic transmission in which the change gear ratio of the automatic transmission is displayed on the meter panel is described in Japanese Patent Laid-Open No.53558/1989. In the stepless, variable power transmission system described in this patent publication, a potentiometer is provided for detecting the movement zone of a movable pulley for a drive pulley on which an endless belt is routed. The output of the potentiometer is converted into the change gear ratio, and the change gear ratio is displayed on the change gear ratio display provided on the meter panel.
[0006] Since the actual extent of wear of the endless belt varies depending on the vehicle operating conditions, and therefore differs significantly from the timing of belt replacement based on the integrated mileage indicated in the service manual, a system that can properly indicate the necessity of belt replacement based on the actual wear of the endless belt would be desirable in the background art.
[0007] The technology in the related art disclosed in the aforementioned patent publication is a system that simply displays the actual change gear ratio of the stepless, variable power transmission system, and the timing of replacement of the endless belt in relation to the gear ratio is not considered.
SUMMARY OF THE INVENTION
[0008] The present invention overcomes the shortcomings associated with the background art and achieves other advantages not realized by the background art.
[0009] An object of the present invention is to improve the maintainability of a vehicle by keeping track of the wear conditions of an endless belt in a belt-type, automatic transmission system.
[0010] A further object of the present invention is to accurately and clearly inform the driver of the proper timing for replacement of the belt in the aforementioned transmission system.
[0011] These and other objects are accomplished by a belt replacement timing annunciator for an automatic transmission mounted on a vehicle provided with an endless belt routed between a drive pulley connected to an output shaft of an engine and a driven pulley connected to an axle of a driving wheel, wherein a change gear ratio is shifted by changing radii of the endless belt according to operating conditions of the vehicle, the annunciator comprising means for detecting specific operating conditions of the vehicle; means for detecting an actual change gear ratio of the automatic transmission; means for determining that the endless belt requires replacement, wherein the means for determining outputs a determination if the actual change gear ratio exceeds a predetermined reference change gear ratio for the specific operating condition; and means for displaying the result of the determination of the means for determining.
[0012] These and other objects are further accomplished by a belt replacement timing annunciator for an automatic transmission mounted on a vehicle provided with an endless belt routed between a drive pulley connected to an output shaft of an engine and a driven pulley connected to an axle of a driving wheel, wherein a change gear ratio is shifted by changing radii of the endless belt according to operating conditions of the vehicle, the annunciator comprising an electronic control unit; a pair of revolution sensors providing a number of output shaft revolutions signals and a vehicle velocity signal; a throttle valve opening sensor for recording a degree of throttle valve opening signal; a microcomputer, the microcomputer processing the signals from the sensors, recording an integrated mileage value L and calculating an actual change gear ratio and comparing the actual change gear ratio to a predetermined reference change gear ratio; an LED display for indicating a belt replacement signal when the actual change gear ratio is abnormal to the predetermined reference change gear ratio; and a resetting device for clearing a belt replacement signal based upon an operator input.
[0013] Therefore, in contrast to the related art described above, the wear condition of the endless belt reflecting various operating conditions of the vehicle, which were heretofore difficult to identify from the integrated mileage alone, can be identified adequately and properly with the present invention. Accordingly, the endless belt can be replaced at proper intervals and the maintainability of the vehicle is improved.
[0014] The present invention prevents an erroneous determination of the timing of belt replacement based on the variable change gear ratios calculated during variations in operating condition of the vehicle. Accordingly, a reliable determination of belt replacement intervals is realized.
[0015] According to the an aspect of the invention, the reference change gear ratio is determined based on the minimum predetermined change gear ratio that is determined during operating conditions in which the effect on the predetermined change gear ratio is smaller than the operating conditions at other predetermined change gear ratios, and the actual change gear ratio is detected in that reliable operating condition.
[0016] Further scope of 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 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
[0017] 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:
[0018] [0018]FIG. 1 is a plan view in cross section of a power unit having an internal combustion engine and a belt-type automatic transmission according to an embodiment of the present invention;
[0019] [0019]FIG. 2 is a side view of the power unit of FIG. 1 viewed with the belt-type automatic transmission and a cover unit removed;
[0020] [0020]FIG. 3 is a cross sectional view taken along line III-III of FIG. 1;
[0021] [0021]FIG. 4 is a graphical view showing transmission properties of the belt-type automatic transmission shown in FIG. 1;
[0022] [0022]FIG. 5 is a frontal view of an instrument panel for a motorcycle on which the power unit shown in FIG. 1 is to be mounted according to an embodiment of the present invention; and
[0023] [0023]FIG. 6 is a flow chart of a belt replacement timing determination routine of the belt replacement timing annunciator according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The present invention will hereinafter be described with reference to the accompanying drawings. FIG. 1 is a plan view in cross section of a power unit having an internal combustion engine and a belt-type automatic transmission according to an embodiment of the present invention. FIG. 2 is a side view of the power unit of FIG. 1 viewed with the belt-type automatic transmission and a cover unit removed. FIG. 3 is a cross sectional view taken along line III-III of FIG. 1. FIG. 4 is a graphical view showing transmission properties of the belt-type automatic transmission shown in FIG. 1. FIG. 5 is a frontal view of an instrument panel for a motorcycle on which the power unit shown in FIG. 1 is to be mounted according to an embodiment of the present invention. FIG. 6 is a flow chart of a belt replacement timing determination routine of the belt replacement timing annunciator according to an embodiment of the present invention.
[0025] Referring to FIG. 1 and FIG. 2, a power unit P including an internal combustion engine E and a transmission system T including a belt-type automatic transmission M, a starting clutch C, and a decelerator D formed into a single unit is mounted on the motorcycle. Although not shown in these figures, the power unit is aligned horizontally with the laterally oriented crankshaft 5 .
[0026] The internal combustion engine E includes an engine body including a cylinder bock 2 , cylinder head 3 , and a head cover 4 superimposed in sequence on the crankcase 1 that can be divided into left and right halves. These components are formed into one unit by integrating all these four components together, and the unit is placed on the vehicle body in a forwardly tilted state in which the cylinders 21 , 22 face toward an upper, front portion of the vehicle body.
[0027] Hereinafter, the terms “front, rear, left and right” are indicative of the “front, rear, left and right” with respect to the vehicle body as viewed from the perspective of a vehicle operator.
[0028] The transmission system T disposed on the left side of the vehicle body is, as will be described hereinafter, supported so as to be capable of swinging vertically with respect to the internal combustion engine E. The transmission T is supported by the crankcase 1 with the axis of rotation of the crankshaft 5 as a center of swinging motion. The transmission T is rotatably supported at the rear end portion thereof by the rear portion of the vehicle body via a shock absorber. A rear wheel W, which is a drive wheel of the vehicle, is supported at the rear portion of the transmission system T with a shaft.
[0029] The internal combustion engine E is a two-cylinder, four-cycle internal combustion engine, in which reciprocating movements of the pistons 6 slidably fitted into two cylinders 21 , 22 of the cylinder block 2 are transmitted via a connecting rod to the crankshaft 5 . The crankshaft 5 is an output shaft rotatably supported by the crankcase 1 via a pair of left and right main bearings 7 , 8 .
[0030] The crankshaft 5 is provided with a drive gear 9 at a position adjacent to the right main bearing 8 on the left side thereof, and as shown in FIG. 3. The drive gear 9 engages with the driven gears 12 , 13 provided on a pair of balancer shafts 10 , 11 disposed above and below the crankshaft 5 , so that both of the balancer shafts 10 , 11 rotate in reverse directions with respect to each other at the same speed as the crankshaft 5 .
[0031] A pump driving pulley 15 for driving an oil pump 14 and a pulsar rotor 16 having a plurality of projections on the outer periphery thereof are connected to the right end portion of one of the balancer shafts 11 . A pick-up 17 is disposed at a position radially outward of the pulsar rotor 16 and opposed to the projections, so that the pulsar rotor 16 and the pick-up 17 constitute the revolution sensor 18 for detecting the number of revolution of the crankshaft 5 , e.g. the number of engine revolutions N via the balancer shaft 11 .
[0032] In addition, a drive sprocket 19 is provided on the right end portion of the crankshaft 5 projecting rightward of the right main bearing 8 and a AC generator 20 is provided on the right thereof. A drive pulley 40 is provided for the automatic transmission M at the left end portion of the crankshaft 5 projecting leftward of the left main bearing 7 . A timing chain 25 is routed around the drive sprocket 19 , and cam sprockets 23 , 24 interlocked with the intake camshaft 21 and an exhaust camshaft 22 (See FIG. 3) that are components of the motion valve mechanism provided on the cylinder head 3 respectively. Two intake valves and two exhaust valves provided correspondingly to the cylinders 21 , 22 are operated at prescribed opening and closing intervals by the timing action of cams respectively formed on both of the camshafts 23 , 24 rotated by the power of the crankshaft 5 transmitted via the timing chain 25 .
[0033] Then, fuel injected from the fuel injection valve 27 to the intake passage by the amount of injection determined based on a variety of detected signals. The detected signals are from the revolution sensor 18 , an opening sensor 26 for detecting the opening of the throttle valve, a pressure sensor for detecting the pressure of the intake passage, a temperature sensor for detecting the temperature of cooling water, and the like to be supplied to the electronic control unit (ECU) 80 (See FIG. 5) of the fuel injection control unit. The fuel is mixed with air sucked through the throttle valve and sucked into the combustion chamber through the intake valve, and then ignited by the ignition plug and burned. The combustion gases drive the piston 6 by its combustion pressure and is discharged through the exhaust valve to the exhaust passage.
[0034] A right case 30 is rotatably supported on the supporting shaft 29 fixed to the generator cover 28 joined to the right crankcase 1 R. The right case 30 is joined to the connecting member 32 disposed along the rear surface of the right crankcase 1 R, and a left case 31 is joined to the connecting member 32 . Accordingly, the right case 30 and the left case 31 are integrally joined via the connecting member 32 . An annular supporting member 33 connected to the left wall of the left crankcase 1 L so as to surround the crankshaft 5 rotatably supports the left case 31 . The left case 31 opens toward the left side, and the opened portion is covered by the cover unit U of dual structure having an inner cover 34 and an outer cover 35 . A sound absorption member 36 adheres to an inner surface of the outer cover 35 .
[0035] The automatic transmission M, the starting clutch C, and the decelerator D for transmitting the power of the crankshaft 5 to the rear wheel W are stored in the transmission chamber 37 constructed of the left case 31 and the cover unit U. The transmission system T is capable of swinging freely with respect to the crankcase 1 .
[0036] The automatic transmission M includes a drive pulley 40 of variable diameter, a driven pulley 46 of variable diameter, and an endless belt 45 formed for example of a V-belt routed around both pulleys 40 , 46 . The drive pulley 40 includes a fixed pulley strip 41 fixed so as not to move in the axial direction and in the direction of rotation with respect to the crankshaft 5 . The fixed pulley strip 40 also has a conical surface with which one side surface 45 a of the endless belt 45 is brought into contact.
[0037] A movable pulley strip 42 is joined so as to be capable of moving in the axial direction but not in the direction of rotation with respect to the crankshaft 5 and has a conical surface with which the other side surface 45 b of the endless belt 45 is brought into contact. The movable pulley strip 42 is provided with a plurality of weight rollers 43 for moving the movable pulley strip 42 in the radial direction along an axis of the back surface of the movable pulley strip 42 by the action of a centrifugal force generated by the rotation of the drive pulley 40 . A lamp plate 44 having guiding surfaces for guiding the radial movement of the weight roller 43 as a driving mechanism for the movable pulley strip 42 is also provided.
[0038] The driven pulley 46 is provided on the left portion of the driven shaft 50 oriented laterally with respect to the motorcycle. The right end portion of the driven shaft 50 is rotatably supported by the left case 31 , and the intermediate portion thereof is rotatably supported by a mission cover 54 , which will be described later. In addition, the driven pulley 46 comprises a fixed pulley strip 47 that is fixed with respect to the driven shaft 50 but rotatable, and a movable pulley strip 48 that is movable with respect to the fixed pulley strip 47 in the axial direction. The driven pulley 46 is also provided with a spring 49 for urging the movable pulley strip 48 toward the fixed pulley strip 47 as a driving mechanism for the movable pulley strip 48 .
[0039] The fixed pulley strip 47 includes an inner sleeve 47 a rotatably supported on the outer periphery of the driven shaft 50 , and a conical plate 47 b fixed to the inner sleeve 47 a and having a conical surface with which the other side surface 45 b of the endless belt 45 is brought into contact. The inner sleeve 47 b is rotatably supported by the inner cover 34 at its left end portion.
[0040] The movable pulley strip 48 includes an outer sleeve 48 a fitted on the outer periphery of the inner sleeve 47 a so as to be capable of sliding in the axial direction, and a conical plate 48 b fixed on the outer sleeve 48 a and having a conical surface with which one side surface 45 a of the endless belt 45 is brought into contact.
[0041] A starting clutch C comprising a centrifugal clutch is provided on the driven shaft 50 between the fixed pulley strip 47 and the mission cover 54 forming a mission chamber 55 for storing the decelerator D that will be described hereinafter. The starting clutch C includes a clutch outer 51 formed in the shape of a bowl and rotating integrally with the driven shaft 50 , and a drive plate 52 disposed inside of the clutch outer 51 and rotating integrally with the fixed pulley strip 47 .
[0042] When the driven pulley 46 rotates at the number of revolutions exceeding the predetermined number of revolutions for starting linkage, a plurality of clutch shoes 53 supported by the drive plate 52 so as to be capable of swinging motion swing radially outwardly by the action of a centrifugal force against a spring force of the clutch spring and abut against the inner peripheral surface of the clutch outer 51 . The starting clutch C is then brought into a connected state and the rotation of the driven pulley 46 is transmitted to the driven shaft 50 .
[0043] The driven shaft 50 is drivingly joined to the rear axle 57 on which the rear wheel W is mounted via the decelerator D having a speed reducing gear train. In the rear portion of the transmission chamber 37 , a mission chamber 55 defined by the rear portion of the left case 31 and a mission cover 54 that is disposed between the rear portion of the left case 31 and the starting clutch C is provided.
[0044] The decelerator D stored in the mission chamber 55 includes a first gear 58 of small diameter provided on the right end portion of the driven shaft 50 , a second gear 59 of a large diameter and a third gear 60 of a small diameter provided on the intermediate shaft 56 rotatably supported by the left case 31 . A fourth gear 61 of relatively large diameter is provided on the rear axle 57 and is rotatably supported by the left case 31 and a mission cover 54 . The first gear 58 engages the second gear 59 , and the third gear 60 engages the fourth gear 61 , and thus the rotation of the driven shaft 50 is decelerated to the second gear and transmitted to the rear axle 57 .
[0045] The left case 31 is provided with a pick-up 62 at a position radially facing toward the teeth of the fourth gear 61 mounted on the rear axle 57 . The fourth gear 61 acting as a pulsar rotor and the pick-up 62 include a revolution sensor 63 for detecting the number of revolutions of the driven shaft 50 , e.g. the number of revolutions of the driven pulley 46 in a state in which the starting clutch C is in a completely connected state via the rear axle 57 and the intermediate shaft 56 . Since the revolution sensor 63 detects the number of revolutions after gear change is made by the automatic transmission M, it also serves as a vehicle velocity sensor for detecting the vehicle velocity V of the motorcycle.
[0046] Referring now to FIG. 4, a graph showing the transmission properties in a state in which a new endless belt 45 , or an endless belt 45 that has little wear and has the same change gear ratio as that of the new endless belt is used in the transmission system T thus constructed. The change-gear action of the automatic transmission M will be described hereinafter. When the internal combustion engine E is operated and the number of engine revolutions N is not more than the first predetermined number of revolutions N 1 , the starting clutch is in the disconnected state and thus the motorcycle is in an immobilized state because the number of revolutions of the driven pulley 46 is not more than the number of revolutions for the starting linkage. At the drive pulley 40 , a centrifugal force of the weight roller 43 is not large enough it can move the movable pulley strip 42 in the axial direction since the number of engine revolutions N is low. Accordingly, the movable pulley strip 42 is away from the fixed pulley strip 41 , and the radius of the endless belt 45 wound thereon is minimized.
[0047] At the driven pulley 46 , the movable pulley strip 48 urged by the spring 49 is close to the fixed pulley strip 47 , and the radius of the endless belt 45 wound thereon is maximized. Therefore, the power of the crankshaft 5 is transmitted to the driven pulley 46 at the maximum change gear ratio RL.
[0048] When the throttle valve is gradually opened and the number of engine revolutions N slightly exceeds the first predetermined number of revolutions N 1 , the number of revolutions of the driven pulley 46 exceeds the number of revolutions for the starting linkage. The clutch shoe 53 swings by the action of centrifugal force and is brought into contact with the clutch outer 51 . Consequently, the power of the crankshaft 5 is transmitted to the driven shaft 50 and then to the rear axle 57 via the decelerator D, and the motorcycle starts moving.
[0049] When the number of engine revolutions N further increases and reaches the second prescribed number of engine revolutions N 2 , the vehicle velocity V increases in a state where the start clutch C is at a half clutch position and in a state in which the number of engine revolutions N is almost constant at more or less the second predetermined number of revolutions N 2 . The start clutch C is completely linked with the vehicle velocity V being near the first vehicle velocity V 1 , and the power of the crankshaft 5 is transmitted to the driven shaft 50 at the maximum change gear ratio RL.
[0050] The power of the crankshaft 5 is shifted at this predetermined constant maximum change gear ratio RL and is transmitted to the driven shaft 50 in the operating state of the motorcycle corresponding to the low rotational region or the low vehicle velocity region. This power transmission continues until the number of engine revolutions N reaches the third predetermined number of revolutions N 3 from the second predetermined number of revolutions N 2 or until the vehicle velocity V reaches the second vehicle velocity V 2 . The engine power is then transmitted to the rear axle 57 via the decelerator D, so that the motorcycle travels at the vehicle velocity V in proportion with the number of engine revolutions N.
[0051] When the throttle valve is further opened and the number of engine revolutions N slightly exceeds the third predetermined number of revolutions N 3 , at the drive pulley 40 , the movable pulley strip 42 is moved in the axial direction by the weight roller 43 that moves radially from the movable pulley strip 42 by the action of centrifugal force toward the fixed pulley strip 41 . The radius of the endless belt 45 wound thereon gradually increases.
[0052] At the driven pulley 46 , the movable pulley strip 48 moves in the axial direction away from the fixed pulley strip 47 while compressing the spring 49 against a spring force, and the radius of the endless belt 45 wound thereon gradually decreases. As a consequence, the change gear ratio is automatically changed in a state in which the number of engine revolutions N is almost constant at more or less the third predetermined number of revolutions N 3 , and the vehicle velocity V increases.
[0053] When the weight roller 43 abuts against the stopper provided on the back surface of the movable pulley strip 42 and the radial movement thereof is disturbed at the vehicle velocity V near the third vehicle velocity V 3 , the radius of the endless belt 45 wound around the drive pulley 40 is maximized, and the radius of the endless belt 45 wound around the driven pulley 46 is minimized. A constant minimum change gear ratio RT is then determined. At this time, the opening of the throttle valve is large, and the power of the crankshaft 5 is shifted at this minimum change gear ratio RT and is transmitted to the driven shaft 50 in the operating state of the motorcycle corresponding to the third predetermined number of revolutions N 3 . This operating state is the operating region in which the throttle valve is further opened to the fully opened state or to the high revolution region or the high vehicle velocity region is higher than the third vehicle velocity V 3 . The power is then transmitted to the rear axle 57 via the decelerator D, so that the motorcycle travels at the vehicle velocity V in proportion to the number of engine revolutions N.
[0054] When the endless belt 45 that comes into contact with the drive pulley 40 and the driven pulley 46 wears on both side surfaces 45 a, 45 b that are the areas coming into contact with both pulleys, and the width of the endless belt 45 gradually decreases as a result of long term use of the motorcycle, the actual change gear ratio increases. In other words, with the same number of engine revolutions N, when the width of the endless belt 45 decreases due to wear, the radius of the endless belt 45 wound around the drive pulley 40 that has a movable pulley strip 42 to be pressed by the weight roller 43 decreases in comparison with the state in which no wear has occurred.
[0055] At the driven pulley 46 having a movable pulley strip 48 on which a spring force of the spring 49 is exerted, the radius of the endless belt 45 wound thereon increases from the condition in which no wear has occurred. The actual change gear ratio increases gradually as wear progresses from the change gear ratio in the condition that the new endless belt 45 or the endless belt 45 with little wear is used. Therefore, even under the operating condition of the motorcycle in which the maximum change gear ratio RL and the minimum change gear ratio RT can be obtained, the change gear ratios will be the constant values R′L, R′T larger than those as shown by dotted lines in FIG. 4.
[0056] Therefore, a belt replacement timing annunciator for automatic transmissions M is provided on the motorcycle in order to keep track of the wear condition of the endless belt 45 by detecting the actual change gear ratio R of the automatic transmission M and simultaneously keeping track of the wear condition of the endless belt 45 from the integrated mileage L to visually inform the driver of the fact that the wear of the endless belt 45 progresses. Accordingly, the endless belt 45 is replaced at the right time.
[0057] The belt replacement timing annunciator includes a change gear detecting device for detecting the actual change gear ratio R, an operating condition detecting device for detecting the operating condition of the motorcycle, a determination device for determining a timing of replacement, and a display for informing the driver of the fact that the endless belt 45 is at a replacement interval based on the result of determination of the determination device.
[0058] The change gear ratio detecting device includes a revolution sensor 18 and a revolution sensor 63 both providing the number of revolutions. The actual change gear ratio R is calculated and detected based on the detected signals from the revolution sensors 18 , 63 . As seen from the change gear properties of the automatic transmitter M shown in FIG. 4, since the maximum change gear ratio RL and the minimum change gear ratio RT, which are constant stable change gear ratios in which the number of engine revolutions N and the vehicle velocity V are in direct proportion, can be obtained when the motorcycle is in a specific operating condition, it is preferable to detect the change gear ratio R in the operating condition in which the constant change gear ratio can be obtained in order to determine the wear condition of the endless belt 45 precisely from the actual change gear ratio R.
[0059] Therefore, based on the opening of the throttle valve detected by the opening sensor 26 and the vehicle velocity V detected by the revolution sensor 63 that also serves as a vehicle velocity sensor, the calculating means is used to calculate the change gear ratio R in the operating condition in which the minimum change gear ratio RT can be obtained. The reason is that the high rotation region or the high vehicle velocity region, which is the operating condition of the motorcycle predetermined as the minimum change gear ratio RT, are the operating conditions in which the effect on the change gear ratio resulting from variations in the operating conditions of the motorcycle is less than the operating conditions in which the maximum change gear ratio RL is determined.
[0060] Referring to FIG. 5, the instrument panel 70 of the motorcycle includes a microcomputer 71 for processing the signals from the various sensors, calculating the vehicle velocity V, the number of engine revolutions N, the integrated mileage L, and the like, and displaying them on the various meters. Among others, the function for calculating the integrated mileage L in the microcomputer 71 corresponds to the integrated mileage measuring means.
[0061] The instrument panel 70 is provided, e.g. as display means, with the display lamp 72 formed of a light-emitting diode that is turned on when the endless belt 45 is determined to be at a right timing to be replaced by the determination means for informing the driver of the fact that the endless belt 45 is ready to be replaced. Furthermore, a lens 73 of the instrument panel 70 is provided with a push-button switch 74 for setting the time of the day on the clock being integrated in the instrument panel 70 .
[0062] Referring now to the flow chart of the belt replacement timing determination routine in FIG. 6, the operation of the belt replacement timing annunciator will be described hereinafter. A series of processes in this routine is repeatedly performed at intervals of predetermined time period by the electronic control unit 80 as control means.
[0063] In Step S 1 , whether the determination authorizing flag F 1 for deciding the initiation of determination of the belt replacement timing is “1” or not is first determined. The determination authorizing flag F 1 is set to “1” when a predetermined time period has passed after the ignition switch is turned ON and the internal combustion engine E is actuated. After a few seconds have passed, and when the predetermined time period have not passed, it is set to “0.” When the predetermined time period has not passed, it goes to Step S 11 , where the replacement timing display flag F 3 for showing that the endless belt 45 is at the right timing to be replaced is set to “0,” and the timer tm is set to the predetermined time period to.
[0064] Subsequently, in Step S 12 , the extinction signal for turning OFF the display lamp 72 that indicates that the endless belt 45 is ready to be replaced is supplied, and the routine terminates. On the other hand, when the predetermined time period has passed, the routine proceeds to Step S 2 .
[0065] In Step S 2 , whether or not any failure occurred in both revolution sensors 18 , 63 and/or the opening sensor 26 is then determined. When the sensor failure flag F 2 is “1,” and a failure occurred in any one of the sensors, the routine jumps to Step S 11 , S 12 . When the sensor failure flag F 2 is “0,” and no detectable failure has occurred in any sensor, the routine proceeds to Step S 3 .
[0066] In Step S 3 , whether of not the integrated mileage L measured by the integrated mileage measuring means exceeds the reference distance LO that requires replacement of the endless belt 45 is then determined. When the integrated mileage L is not more than the reference distance LO, it goes to Step S 4 . When the mileage L exceeds the reference distance LO, the routine procees to Step S 9 and the timing of replacement display flag F 3 that indicates that the endless belt 45 is ready to be replaced is set to “1.” Subsequently, in Step S 10 , the illuminating signal that illuminates the display lamp 72 is supplied, and this routine terminates.
[0067] In Steps S 4 and S 5 , whether or not the operating condition of the motorcycle is the operating condition in which the change gear ratio is at the minimum change gear ratio RT is determined. In other words, in Step S 4 , whether or not the opening qTH of the throttle valve is larger than the predetermined opening qO, at which the throttle valve is highly opened, is then determined. When the degree of opening is larger than the predetermined opening qO, the routine procees to Step S 5 . Whether or not the vehicle velocity V is larger than the predetermined third vehicle velocity V 3 , which is a high vehicle velocity, is determined in Step S 5 . When the vehicle velocity V is higher than the third vehicle velocity V 3 , it goes to Step S 6 .
[0068] On the other hand, when the determination in Step S 4 or Step S 5 is No, the routine jumps to Step S 11 in either case, and then to Step S 12 to complete the routine. The functions in both steps S 4 , S 5 that are carried out in the electronic control unit 80 correspond to the operating state detecting means for detecting the specific operating condition described above.
[0069] In Step S 6 , the proportion between the number of revolutions of the drive pulley 40 (the number of engine revolutions N) detected by the revolution sensor 18 , and the number of revolution of the driven pulley 46 detected by the revolution sensor 63 , that also serves as a vehicle velocity sensor are detected, and the actual change gear ratio R is calculated. Accordingly, the actual change gear ratio R is detected.
[0070] Therefore, the function carried out in the electronic control unit 80 in Step S 6 corresponds to the calculating of the change gear ratio. Thereafter, it goes to Step S 7 and the progression of the wear condition of the endless belt 45 is determined. Since the change gear ratio increases as wear progresses as described above, whether or not the change gear ratio R calculated in Step S 6 is larger than the reference change gear ratio RO is determined. The reference change gear ratio RO is set to a value larger than the minimum change gear ratio RT by a predetermined value corresponding to the wear condition that requires replacement of the endless belt 45 with respect to the minimum change gear ratio RT obtained when the endless belt 45 is new and the same change gear ratio as that of the new endless belt 45 is obtained in the operating conditions described above. When the result of this determination is No, it is determined that the extent of wear is not as much as is required for replacement and thus it is not at the right timing to be replaced, and then it goes to Step S 11 and S 12 .
[0071] On the other hand, when it is determined that the change gear ratio R is larger than the reference change gear ratio RO, the endless belt 45 is ready to be replaced. The result of the determination in Step S 7 is Yes, and the routine proceeds to Step S 8 . In Step S 8 , the timer tm that is set to the prescribed time period starts counting down. When the time is up, the routine is terminated once, and the processes from Step S 1 to Step S 8 are carried out respectively in the next routine.
[0072] When the time being counted by the timer tm is up in Step S 8 , the routine proceeds to Step S 9 . The value “1” is set to the replacement timing display flag F 3 , which indicates that the endless belt 45 is ready to be replaced. In subsequent Step S 10 , a signal to illuminate the display lamp 72 is supplied, and the routine terminates. The reason why the timer tm is provided here is to prevent an erroneous determination of belt wear based on the change gear ratio R resulting from temporary variations in change gear ratio due to variations in operating condition or the like of the motorcycle. The timer tm enhances the reliability of determination of the proper replacement timing for the endless belt 45 .
[0073] The functions carried out in the electronic control unit 80 in Steps S 7 , S 8 , S 9 , and S 1 O correspond to the first determination means for determining that the belt is at the right timing to be replaced based on the actual change gear ratio R. The functions carried out in the electronic control unit 80 in Steps S 3 , S 9 , and S 10 correspond to the second determination means for determining that the belt is at a right timing to be replaced based on the integrated mileage L.
[0074] Here, data of the integrated mileage L and the timing of replacement display flag F 3 set in the step S 9 are both stored in the non-volatile memory of the microcomputer 71 provided on the instrument panel 70 . Therefore, the timing of replacement display flag F 3 and data of the integrated mileage L are not reset even when the battery to be mounted on the motorcycle is replaced. In addition, the data will not be deleted unless the reset operation that will be described hereinafter is made. As a consequence, when the timing of replacement display flag F 3 is set to “1,” the display lamp 72 is always illuminated as far as the ignition switch is in the ON state.
[0075] The resetting operation can be executed by turning the ignition switch from OFF to ON with the reset switch 75 that also serves as the pressing switch 74 . By keeping the reset switch 75 pressed for a predetermined time period, for example, longer than several seconds, the replacement interval is reset. By performing this resetting operation, the timing of replacement display flag F 3 and data of the integrated mileage L are reset, and the timing of replacement display flag F 3 is set to “b 0 ” and the display lamp 72 is turned OFF.
[0076] Operations and effects of the belt replacement timing annunciator according to the aforementioned embodiments will now be described hereinafter.
[0077] When the actual change gear ratio R of the belt-type automatic transmission M is detected and the actual change gear ratio R exceeds the reference change gear ratio RO it is determined that wear of the endless belt 45 has occurred and the belt is ready to be replaced. The reference change gear ratio RO is preset to the value larger than the minimum change gear ratio RT by a prescribed value based on the minimum change gear ratio RT. The presecribed value is determined during the operating conditions in which the throttle valve is set to the minimum change gear ratio RT, which is a constant change gear ratio, is highly opened, and the number of engine revolutions N is in the high revolution region, or the vehicle velocity V is in the high vehicle velocity region.
[0078] As opposed to the systems of the related art, the wear condition of the endless belt 45 even during various operating modes of the vehicle, which heretofore has been difficult to identify from the integrated mileage L alone, can be correctly identified. Accordingly, the proper timing of belt replacement can be accurately determined and detected by the vehicle operator. In addition, since the result of determination is displayed on the display lamp 72 , the driver is able to know that the belt is ready to be replaced by viewing the display lamp 72 . The maintainability of the motorcycle and the endless belt 45 are desirably increased.
[0079] In addition, since the reference change gear ratio Ro is set based on the minimum change gear ratio RT that is determined in the high revolution region or the high vehicle velocity region in which the effect on the predetermined change gear ratio resulted from variations in the operating conditions of the motorcycle, and the actual change gear ratio R is detected in this operating state, more accurate change gear ratios can be detected and thus more reliable determination of the timing of belt replacement can be made.
[0080] In addition, since the moment when the first determination means determines that the belt is ready to be replaced is when the actual change gear ratio R exceeds the reference change gear ratio Ro continuously for the predetermined period of time tO, e.g. until the time period preset to the timer tm is up, the timing of belt replacement is prevented from being determined based on an erroneously calculated change gear ratio R due to temporary variations in change gear ratio resulted from variations in the operating conditions of the motorcycle and the like. Accordingly, a reliable determination of the right timing for belt replacement can be made.
[0081] Since the display lamp 72 that indicates that the belt is at the right timing to be replaced is turned on based on the result of either one of the determinations made by the first determination means for determining that the belt is at the right timing to be replaced based on the actual change gear ratio R or the determination made by the second determination means for determining that the belt is at the right timing to be replaced based on the integrated mileage L, which is made earlier, a proper belt replacement interval may be determined according to the actual operating conditions, including the integrated mileage L of the motorcycle.
[0082] A display indicating that the belt is ready to be replaced appears on the common display lamp 72 irrespective of the fact that the determinations of the timing of replacement are made based on the different criterion such as the change gear ratio R and the integrated mileage L. Therefore, the driver can easily recognize a right timing of belt replacement and thus the maintainability is improved.
[0083] In addition, since the timing of replacement display flag F 3 and data of integrated mileage L are stored in the non-volatile memory, they are not reset even when the battery is replaced. The display lamp 72 that was turned on once when the timing of replacement display flag F 3 became “b 1 ” is always illuminated when the ignition switch is ON. Furthermore, as described hereinabove, since the reset operation of the timing of replacement display flag F 3 and data of the integrated mileage L must be done by the driver fairly consciously, the illuminated display lamp 72 cannot be turned off easily, and the driver is able to notice the fact that the belt is ready to be replaced.
[0084] Since the actual change gear ratio R can be detected by the use of the revolution sensor 18 for detecting the number of engine revolutions N to be supplied to the electronic control unit 80 for controlling the amount of fuel injection and the revolution sensor 63 that also serves as a vehicle velocity sensor, it is not necessary to provide a change gear ratio detecting means separately. The number of required components may be reduced and the maintenance/assembly costs may be eliminated/reduced.
[0085] An embodiment in which the structure of a part of the embodiment described above is modified will be described in conjunction with the modified structures. In the embodiment described above, the reference change gear ratio RO that is determined based on a constant predetermined change gear ratio in a specified operating condition of the vehicle is determined based on the minimum change gear ratio RT. However, it may be determined based on the maximum change gear ratio RL. It is also possible to use the revolution sensor 18 instead of the opening sensor 26 for detecting the operating conditions in which the minimum change gear ratio RT or the maximum change gear ratio RL.
[0086] In the embodiment described above, the driver is informed that the belt is ready to be replaced by the use of the display lamp 72 . However, it is also possible to turn on the display lamp 72 at the moment when the belt is ready to be replaced, and to lower the output of the internal combustion engine E by ignition time control or the fuel injection control so that the driver further recognizes that the belt replacement is necessary.
[0087] The engine used in the embodiment described above was an internal combustion engine E. However, it may be a motor other than an internal combustion engine, and the vehicle may be a vehicle other than a motorcycle. In the embodiment described hereinabove, the automatic transmission has a minimum change gear ratio RT and the maximum change gear ratio RL as constant change gear ratios. However, the present invention can be applied to an automatic transmission having an intermediate change gear ratio, which is a constant change gear ratio of a value between both of the change gear ratios RT and RL.
[0088] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | The present invention improves the maintainability of a vehicle by properly identifying a worn endless belt in a belt-type automatic transmission and informing a driver of the proper belt replacement interval. The belt replacement timing annunciator relies upon the radii of the endless belt wound around a drive pulley and around a driven pulley that vary to produce shifting change gear ratios. Various operating conditions and the actual change gear ratio for the specific operating condition are detected, and a comparison between a reference change gear ratio and the actual change gear ratio is made to determine if belt replacement is necessary. A timer device provides a predetermined observation interval for avoiding erroneous readings and a display is also provided for indicating the necessity of belt replacement. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Reference is made to commonly assigned U.S. patent application Ser. No. ______ filed concurrently herewith, entitled “Ink Tank Check Valve for Pressure Regulation”, the disclosure of which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to an ink tank for an inkjet printer, and more particularly to a method for regulating the pressure in the ink tank.
BACKGROUND OF THE INVENTION
[0003] An inkjet printer typically includes one or more printheads and their corresponding ink supplies. A printhead includes an array of drop ejectors, each ejector consisting of an ink pressurization chamber, an ejecting actuator and a nozzle through which droplets of ink are ejected. The ejecting actuator may be one of various types, including a heater that vaporizes some of the ink in the pressurization chamber in order to propel a droplet out of the nozzle, or a piezoelectric device which changes the wall geometry of the pressurization chamber in order to generate a pressure wave that ejects a droplet. The droplets are typically directed toward paper or other recording medium in order to produce an image according to image data that is converted into electronic firing pulses for the drop ejectors as the print medium is moved relative to the printhead.
[0004] In some printers an ink reservoir can be located remotely from an intermediate ink supply that is co-located with the printhead. The remote reservoir can be connected to the intermediate ink supply, for example, by tubing in order to replenish the ink used by the printhead. Alternatively in other printers, an ink supply can be directly coupled to the printhead. For the case of ink supplies being mounted on the carriage of a carriage printer, the ink supply can be permanently mounted onto the printhead, so that the printhead needs to be replaced when the ink is depleted, or the ink supply can be detachably mounted onto the printhead, so that only the ink supply itself needs to be replaced when the ink is depleted.
[0005] An ink supply should be capable of containing the ink without leakage during manufacture, storage, transportation, and the printing operation itself. The ink supply should be capable of containing the ink even under conditions where the pressure within the ink supply changes due to environmental conditions. Pressure variations can occur, for example, due to changes in ambient temperature or barometric pressure during storage or transportation. During the printing operation ink should be held at a suitably negative pressure relative to ambient so that ink does not drool out of the nozzles, and yet not at an excessively negative pressure that would lead to ink starvation and dropout during printing. Various designs for regulating pressure within an inkjet ink supply are known including spring-biased bags, capillary media, and bubble generators.
[0006] It has been found that pigment particles in a pigmented ink can settle out in ink supply designs where ink is stored in a capillary media pressure regulator, partly due to the restriction of motion of pigment particles within the small passages of the capillary media, as described in more detail in commonly assigned US Published Patent Application 20090309940. Such settling of pigments particles, especially for larger pigment particles (e.g. larger than 30 nanometers), can result in defective images during the printing process. As a result, an ink supply using capillary media to store ink can lead to a limitation in pigment particle size that can be used. Such a limitation can be disadvantageous, because such larger particles can be beneficial for providing higher optical density in printed regions.
[0007] In addition to compatibility with inks of interest, other evaluation metrics for ink supply and pressure regulation methods include extractable ink per volume of the supply and the amount of variation of pressure versus amount of ink extracted from the supply. What is needed is a method for regulating the pressure within an ink supply for a printhead that is capable of keeping the pressure substantially constant and within an acceptable range as ink is being used. For the case of ink supplies that are not replenished within the printer, the method should preferably facilitate the ink supply's ability to deliver a volume of ink that is a substantial fraction of the volume of the ink supply, in order to help keep the design of the printer compact.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to overcoming one or more of the problems set forth above. Briefly summarized, according to one aspect of the invention, the invention resides a method of regulating pressure in an ink tank, including biasing an aperture of the ink tank to a closed position, withdrawing ink from an outlet port of the ink tank to provide a reduced internal pressure in the ink tank. The aperture is opened in response to the reduced internal pressure in the ink tank. The aperture leads to ambient atmospheric pressure outside the ink tank. The biasing step can include using biasing a valve member with a predetermined force against a valve seat at a contact region between the valve member and the valve seat. Opening of the apertures can include moving the member away from the valve seat in response to a difference in pressure between ambient atmospheric pressure and the reduced internal pressure in the tank. The difference in pressure that forces the member away from the valve seat is proportional to the predetermined force and inversely proportional to the area of the contact region.
[0009] These and other objects, features, and advantages of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings wherein there is shown and described an illustrative embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above and other objects, features, and advantages of the present invention will become more apparent when taken in conjunction with the following description and drawings wherein identical reference numerals have been used, where possible, to designate identical features that are common to the figures, and wherein:
[0011] FIG. 1 is a schematic representation of an inkjet printer system;
[0012] FIG. 2 is a perspective view of a portion of a printhead chassis;
[0013] FIG. 3 is a perspective view of a portion of a carriage printer;
[0014] FIG. 4 is a schematic side view of an exemplary paper path in a carriage printer;
[0015] FIG. 5 is a cross sectional view of an ink tank according to an embodiment of the invention with the vent closed by a valve;
[0016] FIG. 6 is a cross sectional view of an ink tank according to an embodiment of the invention with the vent opened by a valve;
[0017] FIG. 7 is a graph of pressure at the outlet port of the ink tank versus time as ink is withdrawn at a constant rate;
[0018] FIG. 8 is an enlarged cross sectional view of a portion of the valve of FIG. 5 ;
[0019] FIG. 9 is a portion of a carriage printer according to an embodiment of the invention;
[0020] FIG. 10 is a cross sectional view of an ink tank according to an embodiment of the invention;
[0021] FIG. 11 is a cross sectional view of an ink tank according to an embodiment of the invention; and
[0022] FIG. 12 is a portion of a carriage printer with a remote ink supply connected to the ink tank of FIG. 11 according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring to FIG. 1 , a schematic representation of an inkjet printer system 10 is shown, for its usefulness with the present invention and is fully described in U.S. Pat. No. 7,350,902, and is incorporated by reference herein in its entirety. Inkjet printer system 10 includes an image data source 12 , which provides data signals that are interpreted by a controller 14 as being commands to eject drops. Controller 14 includes an image processing unit 15 for rendering images for printing, and outputs signals to an electrical pulse source 16 of electrical energy pulses that are inputted to an inkjet printhead 100 , which includes at least one inkjet printhead die 110 .
[0024] In the example shown in FIG. 1 , there are two nozzle arrays. Nozzles 121 in the first nozzle array 120 have a larger opening area than nozzles 131 in the second nozzle array 130 . In this example, each of the two nozzle arrays has two staggered rows of nozzles, each row having a nozzle density of 600 per inch. The effective nozzle density then in each array is 1200 per inch (i.e. d= 1/1200 inch in FIG. 1 ). If pixels on the recording medium 20 were sequentially numbered along the paper advance direction, the nozzles from one row of an array would print the odd numbered pixels, while the nozzles from the other row of the array would print the even numbered pixels.
[0025] In fluid communication with each nozzle array is a corresponding ink delivery pathway. Ink delivery pathway 122 is in fluid communication with the first nozzle array 120 , and ink delivery pathway 132 is in fluid communication with the second nozzle array 130 . Portions of ink delivery pathways 122 and 132 are shown in FIG. 1 as openings through printhead die substrate 111 . One or more inkjet printhead die 110 will be included in inkjet printhead 100 , but for greater clarity only one inkjet printhead die 110 is shown in FIG. 1 . The printhead die are arranged on a support member as discussed below relative to FIG. 2 . In FIG. 1 , first fluid source 18 supplies ink to first nozzle array 120 via ink delivery pathway 122 , and second fluid source 19 supplies ink to second nozzle array 130 via ink delivery pathway 132 . Although distinct fluid sources 18 and 19 are shown, in some applications it may be beneficial to have a single fluid source supplying ink to both the first nozzle array 120 and the second nozzle array 130 via ink delivery pathways 122 and 132 respectively. Also, in some embodiments, fewer than two or more than two nozzle arrays can be included on printhead die 110 . In some embodiments, all nozzles on inkjet printhead die 110 can be the same size, rather than having multiple sized nozzles on inkjet printhead die 110 .
[0026] Not shown in FIG. 1 , are the drop forming mechanisms associated with the nozzles. Drop forming mechanisms can be of a variety of types, some of which include a heating element to vaporize a portion of ink and thereby cause ejection of a droplet, or a piezoelectric transducer to constrict the volume of a fluid chamber and thereby cause ejection, or an actuator which is made to move (for example, by heating a bi-layer element) and thereby cause ejection. In any case, electrical pulses from electrical pulse source 16 are sent to the various drop ejectors according to the desired deposition pattern. In the example of FIG. 1 , droplets 181 ejected from the first nozzle array 120 are larger than droplets 182 ejected from the second nozzle array 130 , due to the larger nozzle opening area. Typically other aspects of the drop forming mechanisms (not shown) associated respectively with nozzle arrays 120 and 130 are also sized differently in order to optimize the drop ejection process for the different sized drops. During operation, droplets of ink are deposited on a recording medium 20 .
[0027] FIG. 2 shows a perspective view of a portion of a printhead chassis 250 , which is an example of an inkjet printhead 100 . Printhead chassis 250 includes three printhead die 251 (similar to printhead die 110 in FIG. 1 ), each printhead die 251 containing two nozzle arrays 253 , so that printhead chassis 250 contains six nozzle arrays 253 altogether. The six nozzle arrays 253 in this example can each be connected to separate ink sources (not shown in FIG. 2 ); such as cyan, magenta, yellow, text black, photo black, and a colorless protective printing fluid. Each of the six nozzle arrays 253 is disposed along nozzle array direction 254 , and the length of each nozzle array along the nozzle array direction 254 is typically on the order of 1 inch or less. Typical lengths of recording media are 6 inches for photographic prints (4 inches by 6 inches) or 11 inches for paper (8.5 by 11 inches). Thus, in order to print a full image, a number of swaths are successively printed while moving printhead chassis 250 across the recording medium 20 . Following the printing of a swath, the recording medium 20 is advanced along a media advance direction that is substantially parallel to nozzle array direction 254 .
[0028] Also shown in FIG. 2 is a flex circuit 257 to which the printhead die 251 are electrically interconnected, for example, by wire bonding or TAB bonding. The interconnections are covered by an encapsulant 256 to protect them. Flex circuit 257 bends around the side of printhead chassis 250 and connects to connector board 258 . When printhead chassis 250 is mounted into the carriage 200 (see FIG. 3 ), connector board 258 is electrically connected to a connector (not shown) on the carriage 200 , so that electrical signals can be transmitted to the printhead die 251 .
[0029] FIG. 3 shows a portion of a desktop carriage printer. Some of the parts of the printer have been hidden in the view shown in FIG. 3 so that other parts can be more clearly seen. Printer chassis 300 has a print region 303 across which carriage 200 is moved back and forth in carriage scan direction 305 along the X axis, between the right side 306 and the left side 307 of printer chassis 300 , while drops are ejected from printhead die 251 (not shown in FIG. 3 ) on printhead chassis 250 that is mounted on carriage 200 . Carriage motor 380 moves belt 384 to move carriage 200 along carriage guide rail 382 . An encoder sensor (not shown) is mounted on carriage 200 and indicates carriage location relative to an encoder fence 383 .
[0030] Printhead chassis 250 is mounted in carriage 200 , and multi-chamber ink supply 262 and single-chamber ink supply 264 are mounted in the printhead chassis 250 . The mounting orientation of printhead chassis 250 is rotated relative to the view in FIG. 2 , so that the printhead die 251 are located at the bottom side of printhead chassis 250 , the droplets of ink being ejected downward onto the recording medium in print region 303 in the view of FIG. 3 . Multi-chamber ink supply 262 , in this example, contains five ink sources: cyan, magenta, yellow, photo black, and colorless protective fluid; while single-chamber ink supply 264 contains the ink source for text black. Paper or other recording medium (sometimes generically referred to as paper or media herein) is loaded along paper load entry direction 302 toward the front of printer chassis 308 .
[0031] A variety of rollers are used to advance the medium through the printer as shown schematically in the side view of FIG. 4 . In this example, a pick-up roller 320 moves the top piece or sheet 371 of a stack 370 of paper or other recording medium in the direction of arrow, paper load entry direction 302 . A turn roller 322 acts to move the paper around a C-shaped path (in cooperation with a curved rear wall surface) so that the paper continues to advance along media advance direction 304 from the rear 309 of the printer chassis (with reference also to FIG. 3 ). The paper is then moved by feed roller 312 and idler roller(s) 323 to advance along the Y axis across print region 303 , and from there to a discharge roller 324 and star wheel(s) 325 so that printed paper exits along media advance direction 304 . Feed roller 312 includes a feed roller shaft along its axis, and feed roller gear 311 is mounted on the feed roller shaft. Feed roller 312 can include a separate roller mounted on the feed roller shaft, or can include a thin high friction coating on the feed roller shaft. A rotary encoder (not shown) can be coaxially mounted on the feed roller shaft in order to monitor the angular rotation of the feed roller.
[0032] The motor that powers the paper advance rollers is not shown in FIG. 3 , but the hole 310 at the right side of the printer chassis 306 is where the motor gear (not shown) protrudes through in order to engage feed roller gear 311 , as well as the gear for the discharge roller (not shown). For normal paper pick-up and feeding, it is desired that all rollers rotate in forward rotation direction 313 . Toward the left side of the printer chassis 307 , in the example of FIG. 3 , is the maintenance station 330 .
[0033] Toward the rear of the printer chassis 309 , in this example, is located the electronics board 390 , which includes cable connectors 392 for communicating via cables (not shown) to the printhead carriage 200 and from there to the printhead chassis 250 . Also on the electronics board are typically mounted motor controllers for the carriage motor 380 and for the paper advance motor, a processor and/or other control electronics (shown schematically as controller 14 and image processing unit 15 in FIG. 1 ) for controlling the printing process, and an optional connector for a cable to a host computer.
[0034] FIG. 5 shows a cross-sectional view of an ink tank 270 according to an embodiment of the invention. Ink tank 270 can be a chamber of multi-chamber ink supply 262 or single chamber ink supply 264 (see FIG. 3 ). Ink tank 270 can be replaceably removable from printhead chassis 250 (see FIGS. 2 and 3 ) or it can be permanently mounted on the printhead. Ink tank 270 includes a tank body 272 which contains a quantity of ink 274 . Above the ink 274 is an airspace 273 . Within the tank body 272 is an enclosure 275 that houses a valve 280 . Valve 280 (also sometimes referred to as a check valve herein) includes a closing member such as a ball 282 , and a valve seat 286 . Ball 282 is substantially spherical and can be made of a compliant material such as an elastomer. Similarly, valve seat 286 can include a compliant material. The compliancy of the closing member or the valve seat 286 can improve the quality of the seal of the valve when it is closed. A spring 284 biases the ball 282 against the valve seat 286 under normal operating conditions. An aperture serving as a vent 276 leading to ambient atmospheric pressure is also included in the tank body near one end of enclosure 275 . When check valve 280 is closed (i.e. when spring 284 pushes ball 282 into sealing contact against valve seat 286 ), air is not allowed to enter the tank body 272 through vent 276 . In other words, the valve is biased to close the vent.
[0035] Ink tank 270 also includes an outlet port 279 which provides ink to the printhead (not shown in FIG. 5 ), for example through a wick 271 . As ink 274 is extracted from ink tank 270 through outlet port 279 for printing or for printhead maintenance, the level of ink 274 in ink tank 270 decreases, as seen by comparing FIG. 6 to FIG. 5 . As a result, the volume of the airspace 273 increases. Since pressure of a quantity of air is inversely proportional to its volume, as the airspace 273 increases without adding more air (with vent 276 closed as in FIG. 5 ), the pressure inside the ink tank 270 and at the outlet port 279 decreases relative to ambient pressure outside ink tank 270 . As ink 274 continues to be extracted from ink tank 270 , the pressure within the ink tank 270 becomes sufficiently reduced relative to ambient pressure that the bias force of spring 284 is overcome and the ball 282 of valve 280 moves away from valve seat 282 to open vent 276 as shown in FIG. 6 . The incoming air enters enclosure 275 and can exit the enclosure 275 into the ink 274 through holes 277 in the end of the enclosure 275 that is in contact with the ink 274 . When sufficient air has entered the vent 276 , the spring 284 is again able to push ball 282 against valve seat 286 to close the vent 276 .
[0036] The check valve 280 and vent 276 in this embodiment act as a pressure regulator for ink tank 270 . The rate of change of pressure P port with time at outlet port 279 as ink 274 is extracted at an extraction rate Q port prior to the opening of valve 280 to open vent 276 is calculated below. In this analysis, P is the pressure of the air in airspace 273 , P o is the initial pressure of the air in airspace 273 before ink is extracted, ρ is the density of ink 274 , h is the height of the ink above the bottom of ink tank 270 , g is the acceleration due to gravity, V is the volume of the air in airspace 273 , V 0 is the volume of air in airspace 273 before ink is extracted, and A is the cross sectional area of ink tank 270 .
[0000]
P
port
=
P
air
+
ρ
gh
P
air
(
t
)
=
P
0
V
0
V
(
t
)
∂
P
air
∂
t
=
-
P
0
V
0
V
2
∂
V
∂
t
∂
V
∂
t
=
Q
port
,
∂
V
∂
t
=
-
A
∂
h
∂
t
∂
P
port
∂
t
=
∂
P
air
∂
t
+
ρ
g
∂
h
∂
t
-
=
P
0
V
0
V
2
∂
V
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+
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∂
h
∂
t
=
-
(
P
0
V
0
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+
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Q
port
[0037] During extraction of ink 274 at a constant rate Q port from outlet port 279 prior to the opening of valve 280 , the pressure in ink tank 270 decreases nearly linearly with time for typical tank configurations. This linear approach toward the designed operating pressure of about −5 inches of water relative to ambient pressure is shown as line 405 in FIG. 7 where the ink extraction rate Q port was 4 ml per minute. The valve 280 opens at point 410 in FIG. 7 . Once the opening pressure of valve 280 is reached, air is allowed to flow into the ink tank 270 , preventing further lowering of the pressure. Since the regulated air entering ink tank 270 is doing so at a fixed height (near the bottom of tank 270 ), the pressure at the outlet port 279 does not continue to change with decreasing ink level, but instead, remains at a substantially constant regulated pressure equal to the valve opening pressure, as shown by line 420 in FIG. 7 .
[0038] FIG. 8 shows an enlarged cross-sectional view of ball 282 in contact with valve seat 286 . Valve seat 286 is conically shaped in this example and has an annular contact region 288 with ball 282 . Contact region 288 has an area A c . For an annular shaped contact region 288 having a width w and an average or midpoint radius R, the area A G of contact region 288 is 2πRw. A compliant ball 282 and/or a compliant valve seat 286 will deform to an amount determined by the geometry, materials and load applied by spring 284 . The spring can be chosen with a spring constant and a compression displacement to provide a spring force F s to bias ball 282 against valve seat 286 that is approximately related to the opening pressure of the valve by P open ˜F s /A c =F s /2πRw. The opening pressure P open is the pressure difference between the ambient pressure and the reduced pressure within ink tank 270 that is sufficient to open check valve 280 , and is also substantially equal to the constant operating pressure illustrated in FIG. 7 by line 420 . Frictional forces in valve 280 , as well as compression forces that deform the compliant ball 282 and/or valve seat 286 can cause P open to deviate somewhat from F s /A c .
[0039] FIG. 9 show an embodiment of the present invention including individual ink tanks 270 mounted on a printhead chassis 250 that is mounted on a carriage 200 of an inkjet printer, a portion of which is shown. Many of the part numbers of this example are similar to parts shown in FIGS. 3 and 4 and will not be discussed further here. Each ink tank 270 includes a vent 276 . The valve and some other components of the ink tank 270 that are shown in FIG. 5 are not shown in FIG. 9 . In the embodiment shown in FIG. 9 , a platform 334 including a finger 336 is mounted on rotational mount 338 above the maintenance station 330 . The rotational mount 338 allows the platform to be rotated out of the way for normal operation. Since the sense of rotation of rotational mount 338 is similar to the forward direction 313 (and its reverse) of feed roller 312 , rotation of the rotational mount 338 can be achieved by transmitting power from the paper advance motor (not shown) when needed. The purpose of finger 336 is to protrude into vent 276 and forcibly push down ball 282 (or other closing member) away from valve seat 286 of valve 280 (see FIGS. 5 and 6 ) if the pressure becomes excessive within one or more of the ink tanks 270 . For example, if an ink tank 270 is partially depleted to the extent that the valve 280 has already opened to allow air to enter the tank through vent 276 , and subsequently the tank is exposed to a sufficiently elevated temperature, the pressure in the tank can become greater than ambient pressure. As a result, pressure at the outlet port 279 can become high enough that ink is forced out of the nozzles of the printhead. To avoid this occurrence, ink level in ink tank 270 and ambient temperature can be monitored. If the conditions of ink level below a predetermined level and temperature above a predetermined temperature are encountered, printer controller 14 can cause carriage 200 to move the tank below the position of finger 336 , and then rotate platform 336 to cause finger 336 to enter vent 276 and open valve 280 to relieve the excess pressure. Ink level can be monitored within the printer by knowing the initial fill level and tracking usage by counting ejected drops and multiplying by drop volume and counting maintenance operations and multiplying by volume of ink per maintenance operation. Temperature can be monitored within the printer by a temperature sensor that can be integrated into the printhead, or mounted on the printer electronics board 390 , for example.
[0040] In the embodiments described above, the check valve 280 is used to regulate pressure in the ink tank 270 during usage of ink within the printer. In addition, check valve 280 keeps the pressure from reaching excessively negative levels even when ink is not being used—for example, during manufacture, storage or transportation when the ink tank 270 is not even installed in the printer. FIG. 10 shows an embodiment where check valve 280 prevents pressure from reaching excessively negative levels when ink is not being used, but capillary member 278 is used to regulate pressure in the ink tank 270 when ink is being used in the printer. Capillary member 278 is disposed at an end of enclosure 275 that is in contact with ink 274 , i.e. opposite the end near which the vent 276 is located. In such an embodiment, pressure regulation is provided substantially as described in commonly assigned US Patent Application Publication 20090309940, incorporated herein in its entirety by reference.
[0041] In the embodiments described above the aperture located in the tank body 272 near valve 280 has been a vent 276 to ambient atmospheric pressure. In the embodiments shown in FIGS. 11 and 12 , the aperture is an inlet port 294 . A fitting 289 allows flexible tubing 292 to be connected to the ink tank 270 (see FIG. 12 , where, for clarity, tubing 292 is shown leading only to one ink tank 270 ). Tubing 292 leads to a remote ink supply 290 (sometimes called an off-axis ink supply) stationarily mounted on the printer chassis 300 . When a sufficient amount of ink 274 is withdrawn from ink tank 270 for printing and/or maintenance, the pressure within the tank body 272 of ink tank 270 becomes reduced relative to the external ink pressure in the tubing 292 and remote ink supply 290 . At a predetermined pressure within the ink tank 270 relative to the external ink pressure, valve 280 is configured to open (see FIG. 11 ), so that ink from the remote ink supply 290 can be replenished into ink tank 270 . The predetermined pressure is related to the spring force provided by spring 284 that biases valve 280 to a closed position.
[0042] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
PARTS LIST
[0000]
10 Inkjet printer system
12 Image data source
14 Controller
15 Image processing unit
16 Electrical pulse source
18 First fluid source
19 Second fluid source
20 Recording medium
100 Inkjet printhead
110 Inkjet printhead die
111 Substrate
120 First nozzle array
121 Nozzle(s)
122 Ink delivery pathway (for first nozzle array)
130 Second nozzle array
131 Nozzle(s)
132 Ink delivery pathway (for second nozzle array)
181 Droplet(s) (ejected from first nozzle array)
182 Droplet(s) (ejected from second nozzle array)
200 Carriage
250 Printhead chassis
251 Printhead die
253 Nozzle array
254 Nozzle array direction
256 Encapsulant
257 Flex circuit
258 Connector board
262 Multi-chamber ink supply
264 Single-chamber ink supply
270 Ink tank
271 Wick
272 Tank body
273 Airspace
274 Ink
275 Enclosure
276 Vent
277 Hole
278 Capillary member
279 Outlet port
280 Valve
282 Ball
284 Spring
286 Valve seat
288 Contact region
289 Fitting
290 Remote ink supply
292 Tubing
294 Inlet port
300 Printer chassis
302 Paper load entry direction
303 Print region
304 Media advance direction
305 Carriage scan direction
306 Right side of printer chassis
307 Left side of printer chassis
308 Front of printer chassis
309 Rear of printer chassis
310 Hole (for paper advance motor drive gear)
311 Feed roller gear
312 Feed roller
313 Forward rotation direction (of feed roller)
320 Pick-up roller
322 Turn roller
323 Idler roller
324 Discharge roller
325 Star wheel(s)
330 Maintenance station
332 Cap
334 Platform
336 Finger
338 Rotational mount
370 Stack of media
371 Top piece of medium
380 Carriage motor
382 Carriage guide rail
383 Encoder fence
384 Belt
390 Printer electronics board
392 Cable connectors
405 Line (pressure vs time before valve opens)
410 Point (time at which valve opens)
420 Line (pressure vs time after valve opens) | A method of regulating pressure in an ink tank including biasing an aperture of the ink tank to a closed position, withdrawing ink from an outlet port of the ink tank to provide a reduced internal pressure in the ink tank. The aperture is opened in response to the reduced internal pressure in the ink tank. The aperture leads to ambient atmospheric pressure outside the ink tank. The biasing step can include using biasing a valve member with a predetermined force against a valve seat at a contact region between the valve member and the valve seat. Opening of the aperture can include moving the member away from the valve seat in response to a difference in pressure between ambient atmospheric pressure and the reduced internal pressure in the tank. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a cube root calculation apparatus, namely to an apparatus for obtaining the cube root of an arbitrary number.
2. Description of the Prior Art
Generally, the cube root of an arbitrary number is obtained by either the method using a logarithmic function and exponential function and the method using Newton's successive-approximation equation.
In the former, the logarithm of a number from which the cube root is to be calculated (hereinafter, such a number is referred to as "a cube root extraction number") is obtained, and the exponent of the number obtained by dividing the logarithm by three is calculated.
In the latter, Newton's successive-approximation equation is applied to a cube root extraction number "A":
X.sub.n+1 =2·X.sub.n /3+A/X.sub.n.sup.2 (n=0, 1, 2, . . . )
Then, the values X 1 , X 2 , X 3 , . . . are successively calculated. When X m and X m+1 are equal to or approximately equal to each other, X m is determined as the cube root of the cube root extraction number "A".
The above-described methods of the prior art require the calculation of special functions such as logarithmic and exponential functions, and also repeated multiplications and divisions, with the result that the time required for the calculation of the cube root of a number in the prior art becomes extremely long. Moreover, the number of digits of the mantissa of a cube root obtained in the prior art depends on the computational accuracy of subroutines used to execute the calculation of the special functions, and also on that of the multications and divisions, so that the number of digits of the mantissa of a cube root cannot be arbitrarily specified.
SUMMARY OF THE INVENTION
The apparatus of this invention, which overcomes the above-discussed and numerous other disadvantages and deficiencies of the prior art, comprises: first memory means for initially storing a cube root extraction number from which the cube root is to be extracted; second memory means for initially storing a first number which is predetermined based on said cube root extraction number; third memory means for initially storing a second predetermined number; fourth memory means for initially storing a third predetermined number; fifth memory means for storing a number; judging means for judging the relation in size between the number stored in said first memory means and the number stored in said second memory means; first process means for, when said judging means judges that the number stored in said first memory means is not smaller than the number stored in said second memory means, subtracting the number stored in said second memory means from the number stored in said first memory means, adding a number generated from the number stored in said third memory means to the number stored in said second memory means, and adding a fourth predetermined number to the number stored in said fifth memory means; second process means for, when said judging means judges that the number stored in said first memory means is smaller than the number stored in said second memory means, subtracting a number generated from the number stored in said fourth memory means from the number stored in said second memory means, and shifting the number stored in said fifth memory means to the left; and control means for controlling said judging means, and said first and second process means, until predetermined conditions are met, and operating said judging means after the operation of said first process means and also after the operation of said process means.
In the appratus, said predetermined conditions may be that the number stored in said fifth memory means has a predetermined place number.
In the above configuration, when said predetermined conditions are met, the number stored in said fifth memory means may be determined as the cube root of said cube root extraction number.
In the apparatus, said apparatus may further comprise sixth memory means for initially storing said said first number, said process means, when said judging means judges that the number stored in said first memory means is smaller than the number stored in said second memory means, subtracting the number stored in said sixth memory means from the number stored in said second memory means, and shifting the number stored in said sixth memory means to the right.
In the above configuration, said predetermined conditions may be that the number stored in said sixth memory means is zero.
In the above configuration, when said predetermined conditions are met, the number stored in said fifth memory means may be determined as the cube root of said cube root extraction number.
Thus, the invention described herein makes possible the objectives of:
(1) providing a cube root calculation apparatus which can calculate the cube root of a number in a much shorter time than in the prior art; and
(2) providing a cube root calculation apparatus in which the number of digits of the mantissa of a cube root to be obtained can be arbitrarily specified.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings as follows:
FIG. 1 is a block diagram illustrating an apparatus according to the invention.
FIG. 2 is a flowchart illustrating the operation of the apparatus of FIG. 1.
FIGS. 3, 4A and 4B, and 5A to 5D are block diagrams illustrating the portions of the apparatus of FIG. 1 which are involved in each step of the operation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a cube root calculation apparatus according to the invention. In the embodiment, the internal calculations are executed using the decimal number system. According to the invention, the internal calculations can be executed using another number system in the essential same manner as in the embodiment except that some of the constants are adequately changed. When a cube root is obtained, the sign (+ or -) and decimal place of the cube root must be determined. The sign of a cube root extraction number is used as that of the cube root of the number. For the latter, if the cube root extraction number includes a decimal fraction part, the cube root extraction number may be made an integer the required number of times by multiplying it by 10 to the third power (when the cube root extraction number is a decimal number), and then the cube root of the integer number is obtained, and the exponent part of the obtained cube root is decreased to adjust the decimal place. To simplify the description, therefore, the cube root extraction number is assumed to be a natural decimal number.
The cube root calculation apparatus of FIG. 1 comprises eight memory devices 1-8 each for storing decimal a decimal number, a comparator 9, subtracters 11 and 13, adders 12 and 15-17, an adder-subtracter 14, right shift indicators 21-26, and a left shift indicator 27.
The stored contents of the memory devices 1-8 are designated as x, y, z, A, r 1 , r 2 , rc 1 and rc 2 , respectively. The cube root extraction number is inititially stored in the memory device 1, and the calculated cube root is finally obtained as the contents of the memory device 4. The inputs of the memory devices 1-8 are coupled to the components as summarized in Table 1 below.
TABLE 1______________________________________Memory Devices Supplied with Outputs of______________________________________1 (x) 1 and 112 (y) 2, 11, 13 and 143 (z) 34 (A) 175 (r.sub.1) 5 and 156 (r.sub.2) 6 and 167 (rc.sub.1) 78 (rc.sub.2) 8______________________________________
The memory devices 1, 2, 5 and 6 which have a plurality of inputs are controlled by a control device (not shown) so as to selectively select one of the inputs and store the data on the selected input. The memory devices 1, 2, 5, 6 and 4 correspond respectively to the first to fifth memory means stated in the accompanying claims.
The comparator 9 compares the contents (x) of memory device 1 with the contents (y) of memory device 2, and then supplies a signal "a" based on the relative size of the two contents to the control device mentioned above. The subtracter 11 subtracts the contents (y) of the memory device 2 from the contents (x) of the memory device 1 (x-y). The subtracter 13 subtracts the contents (r 2 ) of the memory device 6 from the contents (y) of the memory device 2 (y-r 2 ).
The adder 12 adds the contents (r 1 ) of the memory device 5 to the contents (y) of the memory device 2 (y+r 1 ). The adder 15 adds the contents (rc 1 ) of the memory device 7 to the contents (r 1 ) of the memory device 5 (r 1 +rc 1 ). The adder 16 adds the contents (rc 2 ) of the memory device 8 to the contents (r 2 ) of the memory device 6 (r 2 +rc 2 ). The adder 17 adds 1 to the contents (A) of the memory device 4 (A+1).
The adder-subtracter 14 adds the contents (z) of the memory device 3 to the contents (y) of the memory device 2 (y+z) when it receives a signal "b" from the above-mentioned control device, and, when the signal "b" is not supplied from the control device, it subtracts the contents (z) of the memory device 3 from the contents (y) of the memory device 2 (y-z).
The add and subtract timing of the adders 12, 15 and 16, subtracters 11 and 13, and adder-subtracter 14 is determined by the above-mentioned control device. As shown in FIG. 1 and Table 1, the calculation results obtained from the adders 12, 15 and 16 are stored in the memory devices 2, 7 and 8, respectively. The calculation results obtained from the subtracters 11 and 13, and adder-subtracter 14 are stored in the memory device 1.
The right shift indicators 21-26 indicate to shift the contents of the memory devices 2, 5, 6, 3, 7 and 8 with which they are associated as indicated by the arrows in FIG. 1, to the right; i.e., toward the lower place digits. The numbers in "R1", "R2" and "R3" appearing in the blocks of the right shift indicators are the number of places shifted each time when the corresponding right shift indicator instructs the shift operation. The left shift indicator 27 instructs to shift the contents of the memory device 4 to the left; i.e., toward the upper place digits, one place.
In order to make the description simple, one adder or subtracter is provided for each memory device in the embodiment of FIG. 1, but alternatively one adder or subtracter may be commonly provided to a plurality of memory devices. The cube root extraction calculation apparatus of this embodiment can be constructed so as to have only a hardware configuration, but alternatively it may have a configuration using a general-purpose microprocessor unit (MPU). In the latter case, the memory devices may be implemented using registers of the MPU or the main memory unit, and the other components may be implemented using commands from the MPU for performing the calculation of the contents of the register or main memory. The required commands in this case are mainly commands for adding, subtracting and shifting, which are generally used in a usual MPU. Also in an embodiment in which an MPU is used, therefore, the cube root extraction calculation can be performed extremely fast.
The operation of this embodiment will be described with reference to FIG. 2.
(a) First, the memory devices 1-8 are initialized (step S0). As described above, the natural number supplied as the cube root extraction number X is stored in the memory device 1. When the cube root extraction number X satisfies the equation:
10.sup.3(N+1) >X≧10.sup.3N,
10 3N is initially set in the memory device 2 (where N is an integer). In other words, the number set in the memory device 2 comprises "1" for the block corresponding to the upper most block when the cube root extraction number is divided up into blocks of three digits each beginning from the low place digit, and "0"s for the digits of the other blocks. The same number as the initial value in the memory device 2 is set in the memory device 3 at first. The initial values in the memory devices 4, 5 and 6 are "0". The numbers initially set in the memory devices 7 and 8 are a number six times and a number 27 times, respectively, the initial value in the memory device 2. In FIG. 1, the means which performs the above initial settings is not shown. In Tables 2 to 27 below, the contents of the memory devices 1-8 in each step are shown wherein the cube root extraction number X is 12,812,904 (=234 3 ).
TABLE 2______________________________________Step S0Memory Devices Contents of Memory Devices______________________________________1 (x) 128129042 (y) 10000005 (r.sub.1) 06 (r.sub.2) 07 (rc.sub.1) 60000008 (rc.sub.2) 270000003 (z) 10000004 (A) 0______________________________________
(b) After the above initial settings are made in step S0, it is determined whether or not x is greater than y (step S1). If x≧y, then the processes in steps S2 and S3 are performed. If x<y, then the processes in steps S4 to S7 are performed. The portion of the apparatus of FIG. 1 involved in the comparison process in step S1 is shown in FIG. 3. The signal "a" is output from the comparator 9 in accordance with the comparison result in step S1.
(c) In the example shown in Table 2, x is greater than y in step S1, then the operation proceeds to steps S2 and S3. In step S2, the processes in (1) to (4) below is performed: (1) y is subtracted from x; (2) rc 1 is added to r 1 ; (3) rc 2 is added to r 2 ; and (4) 1 is added to A.
TABLE 3______________________________________Step S2Memory Devices Contents of Memory Devices______________________________________1 (x) 118129042 (y) 10000005 (r.sub.1) 60000006 (r.sub.2) 270000007 (rc.sub.1) 60000008 (rc.sub.2) 270000003 (z) 10000004 (A) 1______________________________________
In step S3, r 1 is added to y. When the process of step S3 is completed, the operation returns to step S1. The portion of the apparatus involved in the step S2 calculation is shown in FIG. 4A, and that involved in the step S3 calculation is shown in FIG. 4B. After the completion of step S3, the operation returns to Step S1.
TABLE 4______________________________________Step S3Memory Devices Contents of Memory Devices______________________________________1 (x) 118129042 (y) 70000005 (r.sub.1) 60000006 (r.sub.2) 270000007 (rc.sub.1) 60000008 (rc.sub.2) 270000003 (z) 10000004 (A) 1______________________________________
(d) In step S1, x is greater than y again. The processes of steps S2 and S3 are repeated.
TABLE 5______________________________________Step S2Memory Devices Contents of Memory Devices______________________________________1 (x) 48129042 (y) 70000005 (r.sub.1) 120000006 (r.sub.2) 540000007 (rc.sub.1) 60000008 (rc.sub.2) 270000003 (z) 10000004 (A) 2______________________________________
TABLE 6______________________________________Step S3Memory Devices Contents of Memory Devices______________________________________1 (x) 48129042 (y) 190000005 (r.sub.1) 120000006 (r.sub.2) 540000007 (rc.sub.1) 60000008 (rc.sub.2) 270000003 (z) 10000004 (A) 2______________________________________
As a result of the above process in (c) and (d), "2" is obtained as the hundred place digit of the cube root.
(e) The operation returns again to step S1 wherein it is judged that x is smaller than y. Then, the processes of steps S4 to S7 are performed. In step S4, z is subtracted from y. The portion of the apparatus involved in the step S4 calculation is shown in FIG. 5A. When the step S4 calculation is performed, the signal "b" is not supplied to the adder-subtracter 14, and the adder-subtracter 14 functions as a subtracter.
TABLE 7______________________________________Step S4Memory Devices Contents of Memory Devices______________________________________1 (x) 48129042 (y) 180000005 (r.sub.1) 120000006 (r.sub.2) 540000007 (rc.sub.1) 60000008 (rc.sub.2) 270000003 (z) 10000004 (A) 2______________________________________
In step S5, y is shifted one place to the right, r 2 is shifted two places to the right, and z is shifted three places to the right. The portion of the apparatus involved in the step S5 calculation is shown in FIG. 5B.
TABLE 8______________________________________Step S5Memory Devices Contents of Memory Devices______________________________________1 (x) 48129042 (y) 18000005 (r.sub.1) 120000006 (r.sub.2) 5400007 (rc.sub.1) 60000008 (rc.sub.2) 270000003 (z) 10004 (A) 2______________________________________
In step S6, r 2 is subtracted from y. The portion of the apparatus involved in the step S6 calculation is shown in FIG. 5C.
TABLE 9______________________________________Step S6Memory Devices Contents of Memory Devices______________________________________1 (x) 48129042 (y) 12600005 (r.sub.1) 120000006 (r.sub.2) 5400007 (rc.sub.1) 60000008 (rc.sub.2) 270000003 (z) 10004 (A) 2______________________________________
In step S7, the processes in (5) to (9) below are performed: (5) z is added to y; (6) A is shifted one place to the left; (7) r 1 is shifted two places to the right; (8) rc 1 is shifted three places to the right; (9) rc 2 is shifted three places to the right. That portion of the apparatus involved in the step S7 calculation is shown in FIG. 5D. When the step S7 calculation is performed, the signal "b" is supplied to the adder-subtracter 14 so that the adder-subtracter 14 functions as an adder.
TABLE 10______________________________________Step S7Memory Devices Contents of Memory Devices______________________________________1 (x) 48129042 (y) 12610005 (r.sub.1) 1200006 (r.sub.2) 5400007 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 10004 (A) 20______________________________________
As a result of the above process in (e), the preparation of obtaining the 10's place of the cube root has been done. When the process of step S7 is completed, the operation returns to step S1.
(f) In step S1, x is greater than y. Hence the processes of steps S2 and S3 are performed with the result summarized in Tables 11 and 12.
TABLE 11______________________________________Step S2Memory Devices Contents of Memory Devices______________________________________1 (x) 35519042 (y) 12610005 (r.sub.1) 1260006 (r.sub.2) 5670007 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 10004 (A) 21______________________________________
TABLE 12______________________________________Step S3Memory Devices Contents of Memory Devices______________________________________1 (x) 35519042 (y) 13870005 (r.sub.1) 1260006 (r.sub.2) 5670007 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 10004 (A) 21______________________________________
(g) In step S1, x is again greater than y, and hence the processes of steps S2 and S3 are repeated.
TABLE 13______________________________________Step S2Memory Devices Contents of Memory Devices______________________________________1 (x) 21649042 (y) 13870005 (r.sub.1) 1320006 (r.sub.2) 5940007 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 10004 (A) 22______________________________________
TABLE 14______________________________________Step S3Memory Devices Contents of Memory Devices______________________________________1 (x) 21649042 (y) 15190005 (r.sub.1) 1320006 (r.sub.2) 5940007 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 10004 (A) 22______________________________________
(h) In step S1, x is again greater than y, and hence the processes of steps S2 and S3 are repeated with result summarized in Tables 15 and 16 below.
TABLE 15______________________________________Step S2Memory Devices Contents of Memory Devices______________________________________1 (x) 6459042 (y) 15190005 (r.sub.1) 1380006 (r.sub.2) 6210007 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 10004 (A) 23______________________________________
TABLE 16______________________________________Step S3Memory Devices Contents of Memory Devices______________________________________1 (x) 6459042 (y) 16570005 (r.sub.1) 1380006 (r.sub.2) 6210007 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 10004 (A) 23______________________________________
As a result of above (f), (g) and (h), the 10's place number "3" of the cube root is obtained.
(i) Next, x is smaller than y in step S1, and then the processes of steps S4 to S7 are sequentially performed to prepare for obtaining the 1's place of the cube root. The results of steps S4 to S7 are indicated in Tables 17 to 20, respectively.
TABLE 17______________________________________Step S4Memory Devices Contents of Memory Devices______________________________________1 (x) 6459042 (y) 16560005 (r.sub.1) 1380006 (r.sub.2) 6210007 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 10004 (A) 23______________________________________
TABLE 18______________________________________Step S5Memory Devices Contents of Memory Devices______________________________________1 (x) 6459042 (y) 1656005 (r.sub.1) 1380006 (r.sub.2) 62107 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 14 (A) 23______________________________________
TABLE 19______________________________________Step S6Memory Devices Contents of Memory Devices______________________________________1 (x) 6459042 (y) 1593905 (r.sub.1) 1380006 (r.sub.2) 62107 (rc.sub.1) 60008 (rc.sub.2) 270003 (z) 14 (A) 23______________________________________
TABLE 20______________________________________Step S7Memory Devices Contents of Memory Devices______________________________________1 (x) 6459042 (y) 1593915 (r.sub.1) 13806 (r.sub.2) 62107 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 230______________________________________
(j) In step S1, x is greater than y so that the operation proceeds to steps S2 and S3.
TABLE 21______________________________________Step S2Memory Devices Contents of Memory Devices______________________________________1 (x) 4865132 (y) 1593915 (r.sub.1) 13866 (r.sub.2) 62377 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 231______________________________________
TABLE 22______________________________________Step S3Memory Devices Contents of Memory Devices______________________________________1 (x) 4865132 (y) 1607775 (r.sub.1) 13866 (r.sub.2) 62377 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 231______________________________________
(k) In step S1, x is again greater than y so that the processes of steps S2 and S3 are repeated.
TABLE 23______________________________________Step S2Memory Devices Contents of Memory Devices______________________________________1 (x) 3257362 (y) 1607775 (r.sub.1) 13926 (r.sub.2) 62647 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 232______________________________________
TABLE 24______________________________________Step S3Memory Devices Contents of Memory Devices______________________________________1 (x) 3257362 (y) 1621695 (r.sub.1) 13926 (r.sub.2) 62647 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 232______________________________________
(1) In step S1, x is again greater than y so that the processes of steps S2 and S3 are again repeated.
TABLE 25______________________________________Step S2Memory Devices Contents of Memory Devices______________________________________1 (x) 1635672 (y) 1621695 (r.sub.1) 13986 (r.sub.2) 62917 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 233______________________________________
TABLE 26______________________________________Step S3Memory Devices Contents of Memory Devices______________________________________1 (x) 1635672 (y) 1635675 (r.sub.1) 13986 (r.sub.2) 62917 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 233______________________________________
(m) In step S1, x≧y is further valid, and the process of step S2 is further performed. As a result, the contents of the memory devices become as indicated in Table 27 below.
TABLE 27______________________________________Step S2Memory Devices Contents of Memory Devices______________________________________1 (x) 02 (y) 1635675 (r.sub.1) 14946 (r.sub.2) 63187 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 234______________________________________
The value "A" stored in the memory device 4 is equal to the cube root, and at this time x=0. In this way, it can be efficiently judged whether or not the cube root extraction calculation is completed, by checking the value of x (i.e., the contents of the memory device 1) upon completion of the process in step S2 and escaping from the loop when x is determined to be 0. However, since the condition x=0 is only valid when the cube root extraction number is exactly the cube of some number, this completion condition cannot be applied to all cube root extraction numbers. Therefore, escape from the loop and terminating cube root extraction calculation can generally be performed when, for example,
(1) the value of "A" (i.e., the contents of the memory device 4) reaches a predetermined number of places, or
(2) z=0 becomes valid.
For example, if the judgment of whether x=0 after step S2 is omitted and judgment of whether z=0 is performed after step S5, the following additional processes (n) and (o) become necessary in the calculation example described above.
(n) The process of step S3 is further performed after (m).
TABLE 28______________________________________Step S3Memory Devices Contents of Memory Devices______________________________________1 (x) 02 (y) 1649715 (r.sub.1) 14946 (r.sub.2) 63187 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 234______________________________________
(o) In step S1, it is judged that x<y to that the operation proceeds to steps S4 and S5. In step S4, since z is null, y is not changed. After step S5, it is judged that z=0, and then the cube root calculation is terminated.
TABLE 29______________________________________Step S4Memory Devices Contents of Memory Devices______________________________________1 (x) 02 (y) 1649715 (r.sub.1) 14946 (r.sub.2) 63187 (rc.sub.1) 68 (rc.sub.2) 273 (z) 14 (A) 234______________________________________
TABLE 30______________________________________Step S5Memory Devices Contents of Memory Devices______________________________________1 (x) 02 (y) 164975 (r.sub.1) 14946 (r.sub.2) 637 (rc.sub.1) 68 (rc.sub.2) 273 (z) 04 (A) 234______________________________________
As is apparent from the above description, cube roots can be calculated to any desired place.
Below is a supplemental description of the operation of this embodiment.
If the cube root extraction number X (the initial value of x) satisfies
10.sup.3(N+1) >X≧10.sup.3N,
then the initial value of y is 10 3N as described above. On the other hand, the initial value of rc 1 can be expressed using a natural number n as follows: ##EQU1##
When the processes in steps S2 and S3 are repeated n times while x≧ is valid, then ##EQU2## Then, x and A become as follows: ##EQU3## and A is obtained as the upper most place of the cube root.
Next, the processes in steps S4 to S7 are described. When the equation (3) is deformed,
y=10.sup.3(N-1) {(10n+10).sup.3 -(10n).sup.3 } (6)
The initial value of rc 2 is
rc.sub.2 =27·10.sup.3N (7)
so r 2 just before the process in step S4 is performed is expressed as
r.sub.2 =27n·10.sup.3N (8)
In step S4, y is replaced by ##EQU4## In step S5,
r.sub.2 =270n·10.sup.3(N-1) (10)
y=3·10.sup.2 (n.sup.2 +n)·10.sup.3(N-1) (11)
z=10.sup.3(N-1) (12)
After the processes of steps S6 and S7, y becomes as follows: ##EQU5## And r 1 expressed by equation (2) is changed by shifting two places to the right in step S7 to ##EQU6## In this way, preparation for seeking the next place of the cube root is performed.
Next, when the processes in steps S2 and S3 are repeated m times while x≧y is valid, then y, x and A become as shown below.
y=10.sup.3(N-1) [(10n+m+1).sup.3 -(10n+m).sup.3 ] (15)
x=X-10.sup.3(N-1) (10n+m).sup.3 (16)
A=10n+m (17)
And r 1 becomes ##EQU7##
Calculation proceeds in the sequence described above, and when x=0, then A becomes the cube root.
In this way, according to the invention, the cube root of any desired cube root extraction number with the desired precision (number of places) can be obtained extremely fast.
It is understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be construed as encompassing all the features of patentable novelty that reside in the present invention, including all features that would be treated as equivalents thereof by those skilled in the art to which this invention pertains. | An apparatus for calculating the cube root of a number has: a first memory for initially storing a cube root extraction number from which the cube root is to be extracted; a second memory for initially storing a first number which is predetermined based on said cube root extraction number; a third memory for initially storing a second predetermined number; a fourth memory for initially storing a third predetermined number; and a fifth memory for storing a number. The relation in size between the number stored in the first memory and the number stored in the second memory is judged. When the number stored in the first memory is not smaller than the number stored in the second memory, the number stored in the second memory from the number stored in the first memory, a number generated from the number stored in the third memory is added to the number stored in the second memory means, and a fourth predetermined number is added to the number stored in the fifth memory. When the number stored in the first memory is smaller than the number stored in the second memory, a number generated from the number stored in the fourth memory is substracted from the number stored in the second memory, and the number stored in the fifth memory is shifted to the left. Until predetermined conditions are met, the above processes are repeated, and the number stored in said fifth memory is determined as the cube root. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to building structure and in particular, to a structural insulating panel and flat roof structure employing the same.
BACKGROUND
[0002] Historically, flat or horizontal roofs on commercial and residential buildings have been common in warmer, drier climates where water accumulation as a result of precipitation is not a problem. More recently, flat roofs have become popular in cooler, wetter climates. Unlike sloped roofs, flat roofs have ineffective drainage characteristics making them prone to leakage problems. In wetter climates, to deal with this drainage issue, complex water proofing is typically required in flat roofs. In commercial buildings, drains are sometimes provided in the flat roofs to collect rainwater and melting snow and direct the water off of the roofs.
[0003] For example, U.S. Pat. No. 5,144,782 to Paquette et al. discloses a draining system for water which may collect between the upper and lower membranes of a flat insulated roof. Insulating panels located between the upper and lower membranes are provided at both their upper and lower faces with a network of intersecting grooves. The networks of grooves communicate with each other through passages made through the insulating panels or constituted at the insulating panel joints. The grooves and passages provide drainage channels for any water that has seeped under the upper membrane as a result of perforations in the upper membrane. A lower drain is sealed to and opens above the lower membrane to drain water collected by the drainage channels. Drainage of the water helps to prevent deterioration of the insulating panels and water accumulation which may provoke overload problems.
[0004] Although such drainage structures are effective in removing water from flat roofs, they add significant complexity to the building structures and hence, increase costs making them unsuitable in many environments. As will be appreciated, alternative techniques to improve drainage in flat roofs are desired.
[0005] It is therefore an object of the present invention at least to provide a novel structural insulating panel and roof structure employing the same.
SUMMARY
[0006] Accordingly, in one aspect there is provided a structural insulating panel for use in a flat roof structure comprising upper and lower structural layers and an intermediate layer between said upper and lower structural layers, the intermediate layer being shaped such that said upper structural layer is sloped relative to a horizontal plane when said structural insulating panel is installed in a flat roof structure.
[0007] In one embodiment, the intermediate layer is shaped such that the upper structural layer is sloped in multiple dimensions relative to the horizontal plane. The upper structural layer may slope generally linearly downwardly in generally orthogonal directions or may curve downwardly in different directions. In another embodiment, the intermediate layer is shaped such that the upper structural layer slopes generally linearly downwardly in a single direction.
[0008] In one form, the intermediate layer is sandwiched directly between the upper and lower structural layers. The thicknesses of the upper and lower structural layers are selected to give the structural insulating panel a desired fire rating. Each of the upper and lower structural layers may have a thickness in the range from about ⅛″ to about 1⅛″. The intermediate layer may have a minimum thickness of about 1″ and a maximum thickness of about 16″.
[0009] According to another aspect there is provided a flat roof structure comprising a plurality of abutting structural insulating panels, each structural insulating panel spanning at least a pair of adjacent rafters of the flat roof structure and defining an upper decking surface on which roofing is applied, the structural insulating panels being configured such that the upper decking surface is non-horizontal thereby to promote drainage.
[0010] The structural insulating panels in one form are arranged at least one of end-to-end and side-to-side with adjacent structural panels carrying mating formations. Sealant seals seams between the adjacent structural insulating panels.
[0011] According to yet another aspect there is provided a structural insulating panel comprising an intermediate layer sandwiched between and adhered to first and second structural layers, the intermediate layer varying in thickness such that the first and second structural layers are non-parallel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Embodiments will now be described more fully with reference to the accompanying drawings in which:
[0013] FIG. 1 is a top plan view of a flat roof structure employing structural insulating panels;
[0014] FIG. 2 is a side elevational view of the roof structure of FIG. 1 ;
[0015] FIG. 3 is an enlarged portion of FIG. 2 ;
[0016] FIG. 4 is a perspective view of a structural insulating panel forming part of the flat roof structures of FIG. 1 ;
[0017] FIG. 5 is a cross-sectional view of FIG. 4 taken along line 5 - 5 ;
[0018] FIG. 6 is a cross-sectional view of FIG. 4 taken along line 6 - 6 ;
[0019] FIG. 7 is a top plan view of an alternative structural insulating panel for use in a flat roof structure;
[0020] FIG. 8 is a cross-sectional view of FIG. 7 taken along line 8 - 8 ;
[0021] FIG. 9 is a cross-sectional view of FIG. 7 taken along line 9 - 9 ;
[0022] FIG. 10 is a top plan view of yet another structural insulating panel for use in a flat roof structure;
[0023] FIG. 11 is a cross-sectional view of FIG. 10 taken along line 11 - 11 ;
[0024] FIG. 12 is a cross-sectional view of FIG. 10 taken along line 12 - 12 ;
[0025] FIG. 13 is an enlarged side elevational view of a portion of adjacent structural insulating panels showing an alternative joint; and
[0026] FIG. 14 is an enlarged side elevational view of a portion of adjacent structural insulating panels showing yet another joint.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0027] Turning now to FIGS. 1 to 3 , a flat roof structure is shown and is generally identified by reference numeral 30 . The flat roof structure 30 comprises a plurality of abutting structural insulating panels 32 arranged in an array. In this embodiment, the array comprises six (6) rows and three (3) columns of panels 32 . Those of skill in the art will appreciate that the 6×3 array of panels 32 is shown for illustrative purposes only. The dimensions of the panel array can vary significantly depending on the overall size of the flat roof structure 30 and the dimensions of the individual panels 32 in the array. The longitudinal dimension of each panel 32 is selected so that each structural insulating panel 32 spans at least one pair of adjacent rafters 34 . Typically, each structural insulating panel 32 will have a lengthwise dimension in the range of from about eight (8) feet to about twenty (20) feet and a widthwise dimension equal to about four (4) feet. Suitable fasteners (not shown) such as screws or nails are used to secure the structural insulating panels 32 to the rafters 34 .
[0028] The upper surfaces 36 of the structural insulating panels 32 define the decking 38 of the flat roof structure 30 on which roofing (not shown) is applied. The structural insulating panels 32 are configured so that the decking 38 is pitched in multiple dimensions thereby to promote drainage towards the outer peripheral edges of the flat roof structure 30 . The pitch in each dimension is typically selected so that it does not exceed 1/12″. In the embodiment of FIG. 1 , the structural insulating panels 32 in column C 1 , rows R 1 to R 3 and in column C 3 , rows R 1 to R 3 are configured so that the flat roof structure 30 slopes linearly downwardly to the right as indicated by arrows 40 and slopes linearly downwardly from its central longitudinal axis 42 towards its peripheral side edge 44 as indicated by arrows 46 . The structural insulating panels 32 in column C 1 , rows R 4 to R 6 and in column C 3 , rows R 4 to R 6 are configured so that the flat roof structure 30 slopes linearly downwardly to the right as indicated by arrows 40 and slopes linearly downwardly from its longitudinal axis 42 towards its peripheral side edge 48 as indicated by arrows 50 . The structural insulating panels 32 in column C 2 , rows R 1 to R 3 are configured so that the flat roof structure 30 slopes linearly downwardly to the left as indicated by arrow 52 and slopes linearly downwardly from its longitudinal axis 42 towards its peripheral side edge 44 as indicated by arrow 46 . The structural insulating panels 32 in column C 2 , rows R 4 to R 6 are configured so that the flat roof structure 30 slopes linearly downwardly to the left as indicated by arrow 52 and slopes linearly downwardly from its longitudinal axis 42 towards its peripheral side edge 48 as indicated by arrow 50 .
[0029] Turning now to FIGS. 4 to 6 , one of structural insulating panels 32 is better illustrated. As can be seen, structural insulating panel 32 comprises an intermediate layer 60 sandwiched between and bonded to upper and lower structural layers 62 and 64 respectively by suitable adhesive. In this embodiment, the intermediate layer 60 is formed of expanded polystyrene (EPS) foam and comprises a core 70 typically having a thickness in the range of from about 1″ to about 16″, a top skin 72 on the core 70 having a thickness of about 7/16″ and a bottom skin 74 on the core 70 having a thickness of about ⅝″. The upper and lower structural layers 62 and 64 are formed of a suitable structural material such as for example plywood and have a thickness generally in the range of from about ⅛″ to about 1⅛″. The thicknesses of upper and lower structural layers 62 and 64 are selected to give the flat roof structure 30 its desired fire rating.
[0030] The core 70 varies in thickness to give the structural insulating panel 32 its desired pitch. As a result, the upper structural layer 62 which overlies the top skin 72 of the intermediate layer 60 conforms to the orientation of the intermediate layer and thus, provides the sloped upper decking surface onto which the roofing is applied. One side edge of the lower structural layer 64 has a groove 80 formed therein and the opposite side edge of the lower structural layer 64 has a tongue 82 formed thereon. The groove 80 is shaped to receive a tongue formed on an adjacent structural insulating panel 32 and the tongue 82 is shaped to be inserted into the groove formed in another adjacent structural insulating panel 32 .
[0031] Looking back to FIG. 3 , one of the seams 90 between two adjacent structural insulating panels 32 is shown. As can be seen, the tongue 82 on the lower structural layer 64 of one structural insulating panel is received in the groove 80 formed in the lower structural layer 64 of the other structural insulating panel. Adhesive caulking 92 is applied to the tongue 82 and/or groove 80 prior to insertion of the tongue into the groove to secure the lower structural layers of the adjacent structural insulating panels 32 together. A sealant 94 such as for example, a foam seal or sill seal gasket, is used to fill any gaps between the intermediate layers 60 and upper structural layers 62 of the adjacent structural insulating panels at the seam 90 .
[0032] In the above embodiment, the structural insulating panels 32 of the flat roof structure 30 are configured so that the flat roof structure 30 slopes linearly downward in two different directions. Those of skill in the art will appreciate however, that other structural insulating panel configurations can be used in flat roof structures 30 to promote drainage. For example, turning now to FIGS. 7 to 9 , another embodiment of a structural insulating panel for use in a flat roof structure is shown and is generally identified by reference numeral 132 . Similar to the structural insulating panel 32 , structural insulating panel 132 also comprises an intermediate EPS layer 160 sandwiched between upper and lower structural layers 162 and 164 respectively. In this embodiment, rather than sloping linearly downwardly in two different directions, the core 170 of the intermediate layer 160 has a parabolic shape and thus, curves downwardly from its center in all directions towards the edges of the intermediate layer.
[0033] FIGS. 10 to 12 show yet another embodiment of a structural insulating panel 232 for use in a flat roof structure. Similar to the structural insulating panels 32 and 132 , structural insulating panel 232 comprises an intermediate EPS layer 260 sandwiched between upper and lower structural layers 262 and 264 respectively. In this embodiment, the core 270 of the intermediate layer 260 slopes linearly downwardly in only one direction.
[0034] Although the embodiments described and shown above show adjacent structural insulating panels 32 as comprising mating formations in the form of tongues and grooves, those of skill in the art will appreciate that alternative joints between adjacent structural insulating panels can be used. For example, FIG. 13 shows adjacent structural insulating panels 32 interconnected via an overlap joint and FIG. 14 shows adjacent structural insulting panels interconnected via a butt spline joint.
[0035] Although dimensions for the structural insulating panels and components therefor, are provided above, those of skill in the art will appreciate that the dimensional information is exemplary. Depending on the environment in which the structural insulating panels are being deployed, the overall dimensions of the structural insulating panels and the dimensions of the panel components may vary from those discussed above.
[0036] In the embodiments described above, the upper and lower structural layers 62 and 64 are described as being formed of plywood. Those of skill in the art will appreciate that the upper and lower structural layers may be formed of other suitable structural material such as for example OSB, metal sheet, fire resistant board etc. Also, the intermediate layer 60 need not be formed of EPS. Other foam material such as for example urethane foam, polyurethane foam, isocyanurate foam etc. or other suitable non-foam material such as for example honeycomb board may be used.
[0037] While particular examples of structural insulating panels that provide pitched upper decking surfaces are described and illustrated above, those of skill in the art will appreciate that the structural insulating panels may take on other orientations to promote drainage. Of course, if desired the structural insulating panels can be used on wall structures for structural and/or decorative purposes.
[0038] Although embodiments have been described above with reference to the drawings, those of skill in the art will appreciate that variations and modifications may be made without departing from the spirit and scope thereof as defined by the appended claims. | A structural insulating panel for use in a flat roof structure comprises upper and lower structural layers and an intermediate layer between the upper and lower structural layers. The intermediate layer is shaped such that the upper structural layer is sloped relative to a generally horizontal plane when the structural insulating panel is installed in a flat roof structure. | 4 |
CLAIM OF PRIORITY
[0001] This Application is a continuation of International Application Number PCT/US2014/039602, filed May 27, 2014, the entire contents of which are incorporated herein by reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure is related to the field of anti-counterfeiting and authentication devices. More specifically, aspects of the present disclosure are related to nanostructured devices with anti-counterfeiting features and methods of fabricating the same.
BACKGROUND
[0003] This section describes background subject matter related to the disclosed embodiments of the present invention. There is no intention, either express or implied, that the background art discussed in this section legally constitutes prior art.
[0004] Nanostructuring is necessary for many present applications and industries and for new technologies which are under development. Improvements in efficiency can be achieved for current applications in areas such as solar cells and LEDs, next generation data storage devices, architectural glass and bio- and chemical sensors, for example and not by way of limitation.
[0005] Nanostructured substrates may be fabricated using techniques such as e-beam direct writing, Deep UV lithography, nanosphere lithography, nanoimprint lithography, near-field phase shift lithography, and plasmonic lithography, for example.
[0006] There is a need to identify nanostructures produced using specific equipment and process in order to protect and enforce Intellectual Property (IP) rights. Some desirable features for anti-counterfeiting features/systems are a) they should be quite difficult to find and/or replicate; b) they should be manufactured using mass production methods in order to keep added cost down; and c) flexibility to change the anti-counterfeiting system frequently to avoid adoption of the method or system by counterfeiters.
[0007] Various approaches have been proposed for counterfeit prevention and for authentication of documents or valuable articles. Some of these methods are clearly visible to the naked eye and are intended for the general public, while others are hidden and only detectable by the competent authorities, or by automatic devices. For example, some methods use special paper, special inks, watermarks, micro-letters, security threads, holograms, etc. Nevertheless, there is still an urgent need to develop and or embed anti-counterfeiting features or systems to a nanostructured device seamlessly and non-intrusively.
[0008] It is within this context that the present invention arises.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIGS. 1A-1C shows cross-sectional views of anti-counterfeiting devices according to aspects of the present disclosure.
[0010] FIG. 2A-2B shows top views of anti-counterfeiting patterns according to aspects of the present disclosure.
[0011] FIGS. 3A-3D are a sequence of cross-sectional schematic diagrams illustrating one possible method of fabrication of the device of FIG. 1A .
[0012] FIGS. 4A-4D illustrate an example of fabrication of metal mesh structures using a “lift-off” technique.
[0013] FIG. 5 is a schematic diagram illustrating use of a sheet resistance metrology system to image an anti-counterfeiting device according to an aspect of the present disclosure.
[0014] FIG. 6 is a screen shot of an example of a sheet resistance map a metal mesh imaged using a Terahertz imaging system equipment according to an aspect of the present disclosure.
[0015] FIG. 7 is an example of a covert anti-counterfeiting feature in the form of a company Logo as could be seen on a sheet resistance map according to an aspect of the present disclosure.
[0016] FIG. 8 is an example of a touch screen that incorporates a pattern of sheet resistance variation that can be revealed as an anti-counterfeiting pattern according to an aspect of the present disclosure.
DETAILED DESCRIPTION
[0017] The present disclosure generally relates to a device that incorporates an anti-counterfeiting pattern invisible to unaided human eyes but recognizable as anti-counterfeiting features by sheet resistance mapping metrology. Sheet resistance is a measure of resistance of thin films that are nominally uniform in thickness. It is commonly used to characterize materials made by semiconductor doping, metal deposition, resistive paste printing and glass coating.
[0018] Sheet resistance R s for a film of material of resistivity ρ and thickness t is given by the ratio
[0000]
R
s
=ρ/t
[0019] A common unit for sheet resistance is “ohms per square” (denoted “Ω/sq” or “Ω/□”), which is dimensionally equal to an ohm, but is exclusively used for sheet resistance. The name “ohms per square” reflects the fact that a square sheet with sheet resistance of, e.g., 10 ohm/square has an actual resistance of 10 ohm, regardless of the size of the square.
[0020] Several measuring methods have been implemented for sheet resistance measurement. For example, the four point measuring method uses a simple apparatus including a four point probe for measuring the resistivity of semiconductor samples. By passing a current through two outer probes and measuring the voltage through the inner probes allows the measurement of the substrate resistivity. Although possible in principle, four point probe measurements tend to be time consuming and limited in resolution. Moreover, four point probe techniques are impractical for samples (e.g., metal mesh) that are protected (e.g., covered) with a polymer/barrier, or disposed under a functional material.
[0021] In addition, non-contact and non-destructive methods have been widely used. Eddy current testing is one of the most extensively used non-destructive techniques for inspecting electrically conductive materials that does not require any contact between the sample and the sensor. Eddy currents are electric currents induced within conductors by a changing magnetic flux in the conductor. These circulating eddies of current have inductance and thus induce magnetic fields.
[0022] These fields can cause repulsion, attraction, propulsion, drag, and heating effects. The stronger the applied magnetic field, the greater the electrical conductivity of the conductor. The faster the field changes, the greater the currents that are developed and the greater the fields produced. For this method, a sample under test is placed between two coils. Such a configuration may provide two magnetic fields that penetrate the sample, and the interaction between the magnetic fields and the sample induces eddy currents in the sample. The sample is then subjected to a relatively evenly distributed field so as to obtain an accurate sheet resistance measurement. The measuring accuracy of standard Eddy current metrology may be about less than 2% accuracy for a sensor covering the sheet resistance range between 0.1-10 ohm/sq. The accuracy may be about less than 3% accuracy for a sensor covering the range between 10-100 ohm/sq. The accuracy may be about better than 5% for a sensor covering the range between 100-1000 ohm/sq. Eddy current metrology provides non-contact, proximity (few mm distance) measurements, can scan a sample area relatively quickly compared to four point probe techniques, and can sense sheet resistance properties through some functional/protective/films and coatings.
[0023] Terahertz (Thz) microprobe-based technology is another non-contact method that can be used for high-resolution measurements of sheet resistance distributions on large-scale areas. Specifically, AMO-GmbH, Germany proposed a measurement tool employing THz radiation in combination with contactless THz microprobes that enables micron-scale resolution and high-speed full wafer mapping. THz radiation penetrates fairly well through thin conductor layers with a thickness below skin-depth. In addition, the contactless THz microprobes can measure the sheet resistivity and thickness of large-area conductor films at very high speeds and up to 10 μm resolution. The term “Terahertz radiation” is used to describe electromagnetic radiation with frequencies between the high-frequency edge of the millimeter wave band, 300 gigahertz (3×10 11 Hz), and the low frequency edge of the far-infrared light band, 3000 GHz (3×10 12 Hz). Corresponding vacuum wavelengths of radiation in this band range from about 1 mm to about 0.1 mm (or 100
[0024] It should be noted that the above describes some example methods commonly used in the industry for sheet resistance mapping measurement. The term “sheet resistance mapping metrology” used in this disclosure is not limited to the measuring methods described above but also other methods applied for sheet resistance mapping measurement.
[0025] FIGS. 1A-1C show three examples of an anti-counterfeiting device according to aspects of the present disclosure. The anti-counterfeiting device generally includes a structure 110 with an anti-counterfeiting pattern 112 . In one example, the structure 110 may be a conductive material.
[0026] The anti-counterfeiting pattern 112 will be discussed in detail below. FIG. 1A shows an anti-counterfeiting device formed on top of a substrate 120 and a device layer 122 over the substrate. In one implementation, the substrate 120 may be a transparent conductive layer. By way of example and not by way of limitation, the substrate 120 may be a glass or polymer material. The device layer 122 may have device features 123 (e.g., integrated circuit structures) formed on it.
[0027] By way of example, the device layer 122 may include conductive materials, semiconductor materials, insulating materials, or some combination of two or more or even all three types of materials in the structures that form the device features.
[0028] As used herein, the term “substrate” generally refers to an object or structure onto which a layer is formed. In some contexts, the term substrate may refer to a single layer of material. In other contexts, the term substrate may refer to a structure made up of multiple layers.
[0029] FIG. 2A shows an anti-counterfeiting device formed in the same layer with the device features 123 over the substrate 120 . The structure 110 with the anti-counterfeiting pattern 112 may be placed in areas that do not affect the performance of a device. FIG. 1C shows another embodiment where the anti-counterfeiting structure 110 formed hidden among the device features 123 . The anti-counterfeiting structure 110 could be a non-functional structure hidden among the device features 123 . Alternatively, one or more functional device features 123 could be configured to also serve as the anti-counterfeiting structure 110 .
[0030] The size of the anti-counterfeiting structure 110 could be large or small. In one example, the anti-counterfeiting structure 110 may be large enough in a size to cover the entire area of the device. In other examples, the anti-counterfeiting structure 110 may be in a size less than 100 micron×100 micron. By way of example, and not by way of limitation, an anti-counterfeiting structure 110 having an area about 100 micron would be large enough to be detected by sheet resistance mapping that utilizes Thz microprobe-based technology with at least 10 micron resolution.
[0031] The anti-counterfeiting pattern 112 should be invisible to the unaided human eye. That is, the anti-counterfeiting pattern 112 should not be visible to the naked eye without conventional aids (e.g., viewing under ultravoilet light or with optical filters or tools/equipment, such as magnifying glasses, microscopes, and the like. In some implementations, the anti-counterfeiting pattern 112 could be invisible to a conventionally-aided human eye.
[0032] In one embodiment, the lines in the anti-counterfeiting pattern 112 are characterized by a linewidth less than 2 microns. Lines below 2 microns are generally invisible to the unaided human eye. The pitch and/or height in the anti-counterfeiting pattern are not critical as long as they are within reasonable limits. In one example, the pitch in the anti-counterfeiting pattern is about 2× the linewidth, and the height is about the same size of the linewidth or smaller. In addition, the anti-counterfeiting pattern 112 could be designed and made to have a very similar optical transmission, color and haze (below the sensitivity of the unaided human eye) to the substrate and/or surrounding materials, thus to be absolutely invisible to the human eye.
[0033] The anti-counterfeiting pattern 112 contains features that are distinguishable from the surrounding device features and thus identifiable as anti-counterfeiting features upon detection by sheet resistance mapping metrology. In one implementation, the anti-counterfeiting pattern 112 may be in the form of recognizable characters, such as letters, numbers, symbols, company logo, etc. In some implementations, the anti-counterfeiting pattern 112 may be a pattern similar to the surrounding device features that is deliberately shifted and/or rotated to make them stand out as shown in FIG. 2A . In some other implementations, the anti-counterfeiting pattern 112 may be in a distinctly different shape than the surrounding device features. In one example as shown in FIG. 2B , the anti-counterfeiting patterns may be ovals and the surrounding device features have a pattern of triangles. In certain implementations, the anti-counterfeiting pattern may be a bar code. In some other implementations, the anti-counterfeiting pattern may be any other coded structure or pattern. In one implementation, the anti-counterfeiting pattern has features in lower density comparing to the density of the surrounding device features. In some implementations, the anti-counterfeiting pattern is characterized by a specific gradient of sheet resistance, e.g., due to a thickness gradient. That is, the anti-counterfeiting pattern has unique pattern of sheet resistance that may have much larger variations of sheet resistance to be outside of measurement noise and may be identifiable as anti-counterfeiting features upon detection.
[0034] The anti-counterfeiting pattern 112 invisible to unaided human eyes is readily recognizable as anti-counterfeiting features that are provided deliberately on a device, when it is imaged with sheet resistance mapping metrology. The anti-counterfeiting structure should be sufficiently different in appearance from the surrounding device features so that the anti-counterfeiting pattern stands out in a sheet resistance map. Depending on the sensitivity of detection/interrogation equipment, the difference may be small but must be above the noise level. The interrogation may be performed by using sheet resistance mapping metrology tools to get a sheet resistance distribution map. Alternatively, the interrogation could be a combination of electrical and optical metrology. In one example, the anti-counterfeiting structure may be detected by utilizing sheet resistance mapping metrology tools in combination with optical tools (e.g., color filters, polarizers or optical metrology tools to detect optical transmission, haze and color).
[0035] Anti-counterfeiting devices according to aspects of the present disclosure may be very useful and advantageous in applications involving articles or documents that need to protect against illicit copying, such as credit cards, passports, driver licenses, valuable articles and/or nanostructured devices packaging for drugs, food, software, music, data CD and DVD, or other products, instrumentation and devices. Anti-counterfeiting devices according to aspects of the present disclosure may be placed on objects sensitive to light (so optical interrogation methods are not desirable or possible). Furthermore, no coding of anti-counterfeiting feature is necessary as long as an image of the feature can be clearly seen on a sheet resistance map. In another example, the device according to aspects of the present disclosure may be utilized as part of RFID tagging and a substrate (e.g., a transparent conductor) may be used as an antenna. The interrogation by sheet resistance mapping metrology tools may provide additional data about a product.
[0036] There are several ways for fabricating anti-counterfeiting device of the present disclosure. FIGS. 3A-3E are a sequence of cross-sectional schematic diagrams illustrating one possible method of fabrication of the device of FIG. 1A where the anti-counterfeiting device is formed on top of a substrate and a device layer. It should be understood that the anti-counterfeiting structure may be formed in the same layer with those device features over the substrate as in FIG. 1B or the anti-counterfeiting structure may be formed hidden within the device features as in FIG. 1C .
[0037] FIG. 3A depicts a structure 110 provided on a substrate 120 . The substrate 120 may be a transparent conductive layer. A patterned device layer with device features 123 is deposited over the substrate. The structure 110 may be a conductive layer. A layer of photo-sensitive material 124 may be deposited over the structure 110 as shown in FIG. 3B . The photosensitive material 124 could be a photoresist. The photoresist could be a positive resist or a negative resist. A positive resist is a type of photoresist in which the portion of the photoresist that is exposed to light becomes soluble to the photoresist developer. The portion of the photoresist that is unexposed remains insoluble to the photoresist developer. A negative resist is a type of photoresist in which the portion of the photoresist that is exposed to light becomes insoluble to the photoresist developer. The unexposed portion of the photoresist is dissolved by the photoresist developer.
[0038] The photosensitive layer 124 may be patterned utilizing conventional photolithography or rolling mask lithography (RML) and then developed. The developed photosensitive layer 124 includes a pattern of openings 126 that expose underlying portions of the structure 110 , as shown in FIG. 3C . The pattern of openings 126 is corresponding to an anti-counterfeiting pattern to be formed on the substrate 120 . The patterned photosensitive material 124 and the structure 110 can be subjected to an etch process that removes portions of the structure 110 exposed by the openings 126 in the resist layer, as shown in FIG. 3D . The etch process can be an anisotropic process, such as a plasma etch process or ion milling. Remaining portions of the photosensitive material 124 can then be removed leaving behind the anti-counterfeiting pattern 112 as shown in FIG. 1A .
[0039] In an alternative implementation, metal mesh structures may be formed by deposition of materials through a template can be followed by lift-off of template materials (photoresists, etc.), e.g., as shown in FIGS. 4A-4D . In this technique, a layer of photosensitive material 404 (e.g., a positive or negative resist) is formed on a substrate 402 , as shown in FIG. 4A . The substrate 402 can be, e.g., glass or a polymer material. The photosensitive layer 404 can be patterned using RML, e.g., as discussed above, and then developed. The developed photosensitive layer includes a pattern of openings 405 that expose underlying portions of the substrate 402 , as shown in FIG. 4B .
[0040] A layer of metal 401 is deposited over the patterned photosensitive material 404 as shown in FIG. 4C . Deposition of the metal layer 401 can be implemented using physical vapor deposition (PVD), sputtering, chemical vapor deposition (CVD), atomic layer deposition (ALD), MVD and other vacuum-based techniques. Non-vacuum methods can also be used, like sol-gel, electroplating, electroless plating, and the like. One preferred metal deposition technique that is useful for forming metal mesh structures is to deposit metal-containing materials from a liquid phase (e.g. as a metal ink) onto the substrate through the patterned photosensitive layer, e.g., using a roller. The metal material may also be sprayed onto the template and substrate. Also, other coating methods for liquid film deposition could be used such as, but not limited to, slot die and gravure coating. An example of such a technique is described, e.g., in U.S. Pat. No. 8,334,217, which is incorporated herein by reference. Metal-containing materials can be chosen to attach only to template materials or only to substrate material exposed through the template. The width and pitch of the metal mesh structures is determined by the corresponding pitch and width in the patterned rolling mask that is used to pattern the photosensitive layer. The thickness of the metal structures can be controlled by optimization of process transfer speed, viscosity of precursor, number of contact cycles with the roller, and other processing parameters.
[0041] The patterned photosensitive material 404 is then removed in a lift-off process taking with it overlying portions of the metal layer 401 . Portions of the metal layer that are in direct contact with the substrate remain behind following the liftoff process, leaving behind a pattern metal layer as shown in FIG. 4D . Some implementations that use a metal-containing ink to form the metal layer 401 include a sintering step to solidify the patterned metal layer. The sintering could take place before lift-off or afterwards.
[0042] Using lift-off in conjunction with RML does not require etching the metal layer, e.g., with plasma etch. Plasma etch is a vacuum process that is not compatible with processing of large area flexible substrates. Lift-off also allows for recycling of the metal portions that have been removed in the lift-off process.
[0043] Lift-off in conjunction with metal ink deposition is highly desirable because it removes any vacuum operation from the manufacturing process. Thus metal mesh fabrication can be implemented in a roll-to-roll process, as opposed to a batch process. In addition to being a vacuum process, etching can result in a roughened substrate and/or roughened metal line edges.
[0044] Another option for fabricating the anti-counterfeiting device is to form a pattern of conductive material on the substrate by conductive ink deposition using inkjet technology. For example, a pattern of metal ink could be formed with a conventional inkjet printer.
[0045] Another option for fabricating the anti-counterfeiting device is to form a pattern of conductive material on the substrate using gravure printing technology. In this type of printing a pattern of conductive ink, e.g., metal ink, is deposited onto a surface of the substrate using an engraved roller having a corresponding pattern engraved into its surface. In some gravure printing implementations, the substrate may pass between the engraved roller and a pressure roller as the ink is applied. The pattern of ink on the substrate surface may be dried or cured by a subsequent heating stage.
[0046] Another option for fabricating the anti-counterfeiting device is to deposit conductive material onto a surface of the substrate through a stencil mask. In this type of fabrication, a stencil mask having a desired pattern of openings is placed on a surface of the substrate or in close proximity to the surface of the substrate. The openings expose selected portions of the substrate. Conductive material may then be deposited over the stencil mask and onto the exposed portions of the substrate underlying the openings in the stencil mask. The material may be deposited using any suitable technique, e.g., metal ink printing, chemical vapor deposition (CVD), physical vapor deposition (e.g., laser-assisted metal deposition), and the like. The stencil mask may then be removed leaving behind a pattern of conductive material on the substrate surface.
[0047] Another option for fabricating the anti-counterfeiting device is metal layer ablation by scanning a laser beam across a layer of metal to ablate selected portions of the layer.
[0048] Another option for fabricating the anti-counterfeiting device is laser-assisted deposition. In this technique the conductive material is formed from an interaction between one or more reactant gases and a laser beam. The beam may be operated in a pulsed mode. The beam passes through the reactant gas(es) and impinges on a surface of the substrate either at perpendicular incidence or at an angle. A reaction between the gas, the substrate surface, and the laser beam forms a conductive material that adheres to the surface. If the beam spot is sufficiently small, a pattern of conductive material could be produced without a mask by selectively turning the beam on and off as the substrate moves relative to the beam or vice versa. Alternatively, a mask may be used in conjunction with laser-assisted deposition to form the pattern. By way of example, silicon can be deposited on a glass surface using Silane (SiH 4 ) as a reactant gas and a laser beam characterized by a vacuum wavelength of 193 nm. Such a beam of sufficient intensity could be produced, e.g., using a pulsed ArF laser.
[0049] Yet another option for fabricating the anti-counterfeiting device is to use laser-assisted etch. This technique uses a highly absorbing media in contact with the material being etched. By way of example, a metal target in contact with the material to be etched (e.g., quartz, glass, or semiconductor) may be used as an absorber. Removal of the material is assisted by the plasma generated by the metal target where the laser light is absorbed.
[0050] The laser etching of materials can be also assisted with a suitable liquid solution (for example CrO 3 ) in contact with the material to be etched. In such cases a temperature increase resulting from strong absorption of laser light at the thin interface between the liquid and the material enhances the etching. The rapid temperature increase leads to heating of the material and thermal decomposition of the solution into non-soluble Cr 2 O 3 deposits. The thin film of non-soluble Cr 2 O 3 formed on the substrate results in a further rise of the laser induced temperature that follows the absorption of subsequent laser pulses. Due to the difference in the thermal expansion coefficients between the Cr 2 O 3 film and material substrate the removal of the material is achieved.
[0051] FIG. 5 illustrates the use of a sheet resistance metrology system 500 to image an anti-counterfeiting pattern. The system 500 generally includes a sensor head 502 coupled to an imaging system 504 . The sensor head 502 produces an output signal in response to some form of input that is applied to a sample 501 that includes an anti-counterfeiting pattern 112 of the type described above. The output signal is related to the input signal in a way that depends on the sheet resistance of the sample 501 . The imaging system 504 interprets the output signal from the sensor head 502 and generates an image 503 of the sample 501 , which can be stored in electronic form or presented on a visual display. In the image 503 , differences in sheet resistance are made apparent, e.g., using a suitable color or intensity scale. In the illustrated example, the sample 501 includes multiple device structures 505 and the anti-counterfeiting pattern 112 (shown in phantom) is invisible to the unaided eye but visible in the image 503 , which may be in the form of a sheet resistance map of the sample 501 or a portion thereof.
[0052] The sample 501 can be any suitable product, device, or material that bears an anti-counterfeiting pattern. By way of example, and not by way of limitation, the anti-counterfeiting pattern may be integrated into a sample in the form of a touch screen sensor, smart window, electromagnetic interference (EMI) shield, transparent heater, or solar panel.
[0053] The system may include an optional stage 506 and controller 508 . The sample may be mounted to the stage 506 . The stage can translate and/or rotate the sample with respect to the sensor head 502 . The controller 408 may be a special purpose computer or a general purpose computer configured to control operation of one or more of the sensor head 502 , the imaging system 504 , and the stage 506 .
[0054] By way of example, and not by way of limitation, the sensor head 502 may include an element that detects terahertz (Thz) radiation. The system may include or work in conjunction with a source that directs Thz radiation toward the sample. In some configurations, the Thz radiation source may be integrated into the sensor head. In some implementations, the Thz radiation may be directed at a small portion 507 of the sample 501 and/or the sensor may only detect Thz radiation emitted from that small portion. In such cases, the stage 506 can translate the sample 501 with respect to the sensor head with respect to x, y, and z axes so that the sensor head 502 can collect TeraHertz (THz) radiation from different parts of the sample. The controller 508 can provide the imaging system 504 with stage position information that the imaging system can correlate with the output signal from the sensor head 502 to produce the image 503 .
[0055] In alternative implementations, the sensor head 502 may include electromagnets that produce a changing magnetic flux within the sample 501 or small portion 507 thereof and sensors that detect the effects of the resulting eddy currents within the sample. Again, the stage 506 can translate the sample 501 with respect to the sensor head with respect to x, y, and z axes so that the sensor head 502 can sense eddy currents from different parts of the sample.
[0056] By way of example, FIG. 6 is a screen shot of an example of a sheet resistance map a metal mesh imaged using a Terahertz imaging system equipment according to an aspect of the present disclosure. The image was obtained using a TeraSpike-800-X-HRS Terahertz imaging system from AMO GmbH of Aachen, Germany. The sheet resistance map in the image us for a metal mesh having about 3 Ohm/sq deviations of sheet resistance over an 80 mm×80 mm area.
[0057] There are many different possible configurations for anti-counterfeiting devices within the scope of the present disclosure. By way of example, and not by way of limitation, FIG. 7 shows an example of a covert anti-counterfeiting feature in the form of a company logo as could be seen on a sheet resistance map.
[0058] By way of alternative example, anti-counterfeiting devices of the type described in this disclosure may be implemented as integrated parts of a functional transparent metal mesh conductor element (electrode) in various devices. For example, the transparent conductor for capacitive touch sensor in a display, which is created on a glass (cover lens) or polymer film, can be engineered to have a specific and distinctive pattern of sheet resistance distribution (e.g., in the form of Logo, bar code, image, etc.). Such sheet resistance distribution could be designed to have a range that would not affect the basic performance of the device as a touch screen (e.g., few Ohm/sq deviations), and would add an anti-counterfeiting feature to the device. Similarly, such “integrated anti-counterfeiting conductors” could be used as EMI shields and transparent heaters (in displays and other products), electrodes in smart windows (electrochromic devices), solar panels, OLED lighting products, etc. etc.
[0059] Distribution of sheet resistance described in the example of a touch screen can be interrogated (revealed) by touch of a finger or stylus (multi-touch, slide, or other movement on the surface). The resulting image or trace could be revealed directly on the touch screen display (using some “drawing software”). By way of example as shown in FIG. 8 , when a touch sensor 802 is interrogated by passing a finger 801 over it in a pattern of straight lines 803 the variation in sheet resistance within the touch sensor results in curved traces 805 on a display 806 when the inputs are interpreted conventionally through a processor 804 . The “non-linearity” of the traces 805 shows the sheet resistance distribution in the touch sensor 802 . Such sheet resistance distributions may be engineered as a distinctive and recognizable pattern, such as a company logo image, bar code, QR code, number, etc.
[0060] The hardware and/or software of the processor 804 that interprets the touch sensor input is based on the assumption that the sheet resistance is uniform (or varies in some known way). Varying the sheet resistance of the touch sensor while maintaining conventional assumptions in the sensor interpretation software/hardware of the processor 804 causes straight traces to be interpreted and displayed as bent lines. In some implementations the processor may implement an algorithm that operates in two modes, a normal touch screen mode and an anti-counterfeiting mode. In the normal mode the algorithm recognizes any sheet resistance/capacitance values that fall within a specified range (+/−X) as the same values (uniform/linear response) and ignore fine variations within that range, e.g., by averaging the input data. In the anti-counterfeiting mode, by contrast, the algorithm treats fine variations of sheet resistance/capacitance as signal data and interprets such variations accordingly (e.g., by not averaging the input data).
[0061] As may be realized from the foregoing description, aspects of the present disclosure provide anti-counterfeiting that is relatively simple to fabricate but relatively difficult to detect.
[0062] More generally it is important to note that while the above is a complete description of the preferred embodiments of the present invention, it is possible to use various alternatives, modifications and equivalents. Therefore, the scope of the present invention should be determined not with reference to the above description but should, instead, be determined with reference to the appended claims, along with their full scope of equivalents. Any feature described herein, whether preferred or not, may be combined with any other feature described herein, whether preferred or not. In the claims that follow, the indefinite article “a”, or “an” when used in claims containing an open-ended transitional phrase, such as “comprising,” refers to a quantity of one or more of the item following the article, except where expressly stated otherwise. Furthermore, the later use of the word “said” or “the” to refer back to the same claim term does not change this meaning, but simply re-invokes that non-singular meaning. The appended claims are not to be interpreted as including means-plus-function limitations or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase “means for” or “step for.” | Aspects of the present disclosure include an anti-counterfeiting pattern that is identifiable by sheet resistance mapping metrology, a method of fabricating such an anti-counterfeiting device, and a method of detecting such an anti-counterfeiting device by imaging the pattern with sheet resistance mapping metrology. This abstract is provided to comply with rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. | 1 |
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