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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a condensed heterocyclic compound and a psychopharmaceutical composition containing the same.
The condensed heterocyclic compounds and salts thereof according to the present invention show activities specific to the σ-receptor, and therefore, are effective as remedies for treating psychoneurosis.
2. Description of the Related Art
The principal conventionally developed remedies for treating psychosis are D 2 -receptor antagonists such as butyrophenone derivatives represented by Haloperidol, phenothiazine, and thioxanthine, owing to the presence of dopamine in the brain.
Nevertheless, many cases have been known which cannot be improved by the use of these D 2 -receptor antagonists, and it is known that the use thereof is accompanied by side-effects such as extrapyramidal tract disorders. Accordingly, there is a need for the development of a specific remedy for treating psychosis, which is not accompanied by side-effects.
In this connection, it recently has been proved that the σ-receptor, which is a subtype of the opioid receptor, is closely involved in the development of various symptoms of psychosis, and remedies have been developed for treating psychosis based on the σ-receptor antagonism, as represented by Rimcazole and BMY 14802 having the following structures, respectively. ##STR3##
Nevertheless, the antipsychotic effect of these Rimicazole and BMY 14802 is inferior to those of existing remedies such as Haloperidol, and as a cause thereof, it is considered that the σ-receptor antagonism thereof is inferior to those of existing remedies such as Haloperidol.
SUMMARY OF THE INVENTION
Accordingly, the objects of the present invention are to eliminate the above-mentioned disadvantages of the prior art and to provide a novel compound having a strong affinity to the σ-receptor and a low affinity to the D 2 -receptor and a psychopharmaceutical composition containing the same.
Other objects and advantages of the present invention will be apparent from the following description.
In accordance with the present invention, there is provided a condensed heterocyclic compound having the formula (I): ##STR4## wherein A and B are both carbonyl groups or one thereof represents a methylene group and the other represents a carbonyl group; Z represents an oxygen atom, a sulfur atom, an unsubstituted or substituted imino group, or a methylene group; n is an integer ranging from 2 to 6; and R represents a group having the following formula: ##STR5## wherein R 1 represents a hydrogen atom or a hydroxyl group; R 2 represents a substituted or unsubstituted phenyl or 2-pyridyl group or salts thereof as well as a psychotropic drug containing the same as an effective component.
In accordance with the present invention, there is also provided a psychopharmaceutical composition comprising the above-mentioned a condensed heterocyclic compound having the formula (I) or a pharmacologically acceptable salt thereof, as an effective component, and a carrier therefor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present inventors conducted intensive studies into the developing of a pharmaceutically active compound having a stronger affinity for the σ-receptor and a lower affinity for the D 2 -receptor, and thus a higher selectivity to the σ-receptor, and as a result, found that the compounds having the above-mentioned formula (I) and salts thereof show a strong affinity for the σ-receptor and a low affinity for the D 2 -receptor, and thus completed the present invention.
The typical examples of the substituent in the substituted imino group in the formula (I) of the compounds according to the present inventions are C 1-5 alkyl group (for example, methyl, ethyl, propyl, butyl and pentyl group), aryl group (for example, phenyl, benzyl and phenethyl group) and heterocyclic group (for example, pyridyl group).
The preferable compound (I) according to the present invention are 4-(4-(4-phenyl)-1-piperidnyl) butyl-2,3,4,5-tetrahydro-1,4-benzodiazepine-3,5-dione (A,B=carbonyl group, Z=imino group, n=4, R=piperidinyl group, R 1 =hydrogen atom, R 2 =phenyl group), 4-(5-(4-phenyl)-1-piperidinyl)pentyl-2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one (A=carbonyl group, B=methylene group, Z=oxygen atom, n=5, R=piperidinyl group, R 1 =hydrogen atom, R 2 =phenyl group) and 2-(5-(4-(chlorophenyl)-1-piperidinyl)pentyl-1,3,4,5-tetrahydro-2-benzazepine-1,3-dione (A,B=carbonyl group, Z=methylen group, n=5, R=piperidinyl group, R 1 =hydrogen atom, R 2 =4-chlorophenyl group).
The compounds having the above-mentioned formula (I) according to the present invention can be prepared, for example, by the following methods:
1) Preparation of Intermediate Compounds (II): ##STR6## wherein A, B, Z and n are the same as defined above and X and Y may be the same or different and each represents a halogen atom.
2) Preparation of Final Compounds:
(II)+RH (V) →(I)
(wherein R is the same as defined above).
More specifically, a compound represented by the following general formula (Ia): ##STR7## i.e., a compound of the formula (I), wherein A is a carbonyl group, B is a methylene group and Z is an oxygen atom, can be prepared by forming a compound having the following formula (III): ##STR8## according to the method disclosed in the article of G. S. Sidhu, G. Thyagarajan and U. T. Bhalerao (J. Chem. Soc. (C), 1966, p. 969), reacting same with a dibromoalkane to form a compound having the formula (IV): ##STR9## and then condensing the resulting compound with an amine derivative of the formula (V) in the usual manner.
A compound having the following general formula (Ib): ##STR10## i.e., a compound of the formula (I) wherein A is a methylene group, B is a carbonyl group and Z is an oxygen atom, can be prepared by forming a compound having the following formula (VI): ##STR11## according to the method disclosed in the article of Kost. A. N., Stankevicius, A. (Khim. Geterotsiki. Soedin., 1971, 7 (9), p. 1288), reacting it with a dibromoalkane to give a compound having the following general formula (VII) ##STR12## and then condensing the resulting compound with an amine derivative (V) in a usual manner. A compound having the following general formula (Ic): ##STR13## i.e., a compound of the formula (I) wherein A and B each represents a carbonyl group and Z is an oxygen atom, can be prepared by forming a compound having the following formula (VIII): ##STR14## according to the method disclosed in the article of A. Cattaneo, P. Galimberti, M. Melandri (Boll. Chim. Farm., 1963, 102, p. 541), reacting it with a dibromoalkane to give a compound having the following general formula (IX) ##STR15## and then condensing the resulting compound with an amine derivative (V) in a usual manner.
The compound having the general formula (I) and pharmacologically acceptable salts thereof (such as hydrochlorides, sulfates, nitrates, hydrobromides, phosphates, methanesulfonates, p-toluenesulfonates, acetates, oxalates, malonates, succinates, tartrates, maleates, fumarates, lactates, citrates and malates) according to the present invention can be administered alone, or if necessary and desirable, in combination with other commonly pharmacologically acceptable additives such as carriers, excipients and diluents in desired shapes such as tablets, capsules, powder, liquids, injectable liquids, and suppositories through oral or parenteral routes. Examples of such carriers or diluents are polyvinylpyrrolidone, gum arabic, gelatin, sorbit, cyclodextrin, tragacanth, magnesium stearate, talc, polyethylene glycol, polyvinyl alcohol, silica, lactose, crystalline cellulose, sugar, starches, potassium phosphate, vegetable oils, calcium carboxymethyl cellulose, sodium laurylsulfate, water, ethanol, glycerin, mannitol, and syrup.
The concentration of the compound of the formula (I) in the pharmaceutical composition is not restricted, but is generally from 1 to 100% by weight, preferably 10 to 90% by weight. Moreover, the dose thereof is not critical, but is generally from 0.01 to 1,000 mg/day/man, preferably 0.1 to 500 mg/day/man. The frequency of the administration is usually 1 to 3 times per day.
EXAMPLES
The present invention will now be further illustrated by, but is by no means limited to, the following Reference Examples, Examples and Test Examples.
REFERENCE EXAMPLE 1 Preparation of 4-(5-bromopentyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one ##STR16##
In 20 ml of dimethylformamide (DMF) was dissolved 100 mg of 2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one, and the solution then ice-cooled. Then, to the resulting solution were added 0.251 ml (3 equivalents) of 1,5-dibromopentane and 29.4 mg (1.2 equivalent) of a 60% sodium hydride oil dispersion, and the mixture was stirred for one hour with ice-cooling. The reaction solution was poured into a citric acid aqueous solution and extracted with ethyl acetate, and the ethyl acetate phase was washed with an aqueous saturated sodium chloride solution, dried over anhydrous magnesium sulfate, and then filtered. The filtrate was then concentrated and the resulting residue was purified by silica gel column chromatography (eluent: hexane/ethyl acetate (8:2)) to give 124 mg (yield: 65.0%) of the title compound.
REFERENCE EXAMPLE 2 Preparation of 4-(5-bromopentyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-3-one ##STR17##
In 20 ml of DMF was dissolved 100 mg of 2,3,4,5-tetrahydro-1,4-benzoxazepin-3-one and the solution then ice-cooled. Then, to the resulting solution were added 0.125 ml (1.5 equivalent) of 1,5-dibromopentane and 29.4 mg (1.2 equivalent) of a 60% sodium hydride oil dispersion and the mixture was stirred for 1.5 hour with ice-cooling. Thereafter, the reaction solution was reacted and/or treated and purified in the same manner as in Reference Example 1 to give 133 mg (yield: 69.5%) of the title compound.
REFERENCE EXAMPLE 3 Preparation of 4-(5-bromopentyl)-2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione ##STR18##
In 20 ml of DMF was dissolved 102 mg of 2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione and the solution then ice-cooled. Then, to the resulting solution were added 0.116 ml (1.5 equivalent) of 1,5-dibromopentane and 27.4 mg (1.2 equivalent) of a 60% sodium hydride oil dispersion and the mixture was stirred for 2 hours with ice-cooling. Thereafter, the reaction solution was reacted and/or treated and purified in the same manner as in Reference Example 1 to give 79.2 mg (yield: 42.4%) of the title compound.
REFERENCE EXAMPLE 4 Preparation of 4-(5-bromopentyl)-2,3,4,5-tetrahydro-1,4-benzodiazepine-3,5-dione ##STR19##
In 10 ml of dimethylformamide (DMF) was dissolved 100 mg of 2,3,4,5-tetrahydro-1,4-benzodiazepine-3,5-dione and the solution then ice-cooled. Then, to the resulting solution were added 0.116 ml (1.5 equivalent) of 1,5-dibromopentane and 27.3 mg (1.2 equivalent) of a 60% sodium hydride oil dispersion and the mixture was stirred for 2 hours with ice-cooling. The reaction solution was poured into ice-cooled water containing citric acid, made alkaline with sodium hydrogen carbonate, and extracted with ethyl acetate. The ethyl acetate phase was then washed with an aqueous saturated sodium chloride solution and dried over anhydrous magnesium sulfate. The product was purified in the same manner as in Reference Example 1 to give 97.5 mg (yield: 52.8%) of the title compound.
REFERENCE EXAMPLE 5 Preparation of 2-(5-bromopentyl)-1,3,4,5-tetrahydro-2-benzazepine-1,3-dione ##STR20##
In 20 ml of DMF was dissolved 100 mg of 1,3,4,5-tetrahydro-2-benzazepine-1,3-dione and the solution then ice-cooled. Then, to the resulting solution were added 0.117 ml (1.5 equivalent) of 1,5-dibromopentane and 27.4 mg (1.2 equivalent) of a 60% sodium hydride oil dispersion and the mixture was stirred for 1.5 hour with ice-cooling. Thereafter, the reaction solution was reacted and/or treated and purified in the same manner as in Reference Example 1 to give 109 mg (yield: 58.9%) of the title compound.
Physical data of the compounds prepared in Reference Examples 1 to 5 are summarized in Table 1.
TABLE I__________________________________________________________________________Ref. Ex. No. m.p. IR (cm.sup.-1) NMR (δ ppm) Mass__________________________________________________________________________1 Oily 2930 2870 1.48-1.96(m, 6H) HiMs product 1640 1600 3.43(t, 2H, J=6.6Hz), 3.50(t, 2H, J=5.3Hz) Calcd. 311.0520 1470 1420 3.60-3.65(m. 2H) Obsd. 311.0504 1360 1320 4.37(t, 2H, J=5.3Hz) 1285 1210 7.00(d. 1H, J=7.9Hz) 1110 1045 7.16(t, 1H, J=7.9Hz) 875 805 7.41(dt, 1H, J=2.0Hz & 7.9Hz) 790 760 7.80(dd, 1H, J=2.0Hz & 7.9Hz) 7052 Oily 2930 2870 1.38-1.92(m, 6H) HiMs product 1670 1640 3.37(t, 2H, J=6.6Hz) Calcd. 311.0520 1580 1495 3.55(t, 2H, J=7.3Hz) Obsd. 311.0536 1460 1435 4.47(s, 2H) 1350 1310 4.69(s, 2H) 1230 1220 7.03-7.33(m, 4H) 1195 1115 1055 1025 845 760 7003 Oily 2920 2850 1.43-1.95(m, 6H) HiMs product 1690 1640 3.40(t, 2H, J=6.6Hz) Calcd. 341.0084 1580 1455 3.68(s, 2H) Obsd. 341.0074 1430 1330 4.00(t, 2H, J=7.3Hz) 1290 1260 7.37-7.49(m, 3H) 1220 1105 8.16-8.20(m, 1H) 1080 950 910 780 740 6854 65-66° C. 3350 2940 1.39-1.92(m, 6H) HiMs 2860 1700 3.78(t, 2H, J=6.6Hz) Calcd. 324.0472 1620 1495 3.87-3.92(m, 2H) Obsd. 324.0424 1430 1395 3.90(d, 2H, J=4.6Hz)4.87(t, 1H, J=4.6Hz) 1360 1320 6.79(d. 1H, J=7.9Hz) 1240 1155 6.95(dd, 1H, J=7.3Hz & 7.9Hz) 1125 1105 7.35(ddd, 1H, J=1.3Hz & 7.3Hz & 7.9Hz) 1020 980 8.25(dd, 1H, J=1.3Hz & 7.9Hz) 860 785 755 7005 Oily 2950 2860 1.48-1.97(m, 6H) HiMs product 1700 1645 2.99(s, 4H) Calcd. 323.0520 1600 1455 3.40-3.45(m, 2H) Obsd. 323.0472 1340 1315 4.00(t, 2H, J=7.3Hz) 1265 1240 7.16(d, 1H, J=7.3Hz) 1210 1115 7.33-7.48(m, 2H) 1040 890 7.96(dd, 1H, J=1.3Hz & 7.9Hz) 795 755 710__________________________________________________________________________
REFERENCE EXAMPLE 6 Preparation of 4-(4-bromobutyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one ##STR21##
The same procedures as used in Reference Example 1 were repeated except that 1,4-dibromobutane was substituted for 1,5-dibromopentane to give the title compound.
REFERENCE EXAMPLE 7 Preparation of 4-(4-bromobutyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-3-one ##STR22##
The same procedures as used in Reference Example 2 were repeated except that 1,4-dibromobutane was substituted for 1,5-dibromopentane to give the title compound.
REFERENCE EXAMPLE 8 Preparation of 4-(4-bromobutyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-3,5-dione ##STR23##
The same procedures as used in Reference Example 1 were repeated except that 2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione was substituted for 2,3,4,5-tetrahydro-1,4-benzoxazepin-3-one to give the title compound.
REFERENCE EXAMPLE 9 Preparation of 4-(4-bromobutyl)-2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione ##STR24##
The same procedures as used in Reference Example 3 were repeated except that 1,4-dibromobutane was substituted for 1,5-dibromopentane to give the title compound.
REFERENCE EXAMPLE 10 Preparation of 4-(4-bromobutyl)-2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione ##STR25##
The same procedures as used in Reference Example 4 were repeated except that 1,4-dibromobutane was substituted for 1,5-dibromopentane to give the title compound.
REFERENCE EXAMPLE 11 Preparation of 1-methyl-4-(4-bromobutyl)-2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione ##STR26##
The same procedures as used in Reference Example 10 were repeated except that 1-methyl-2,3,4,5-tetrahydro-1,4-benzodiazepine-3,5-dione was substituted for 2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione to give the title compound.
REFERENCE EXAMPLE 12 Preparation of 2-(4-bromobutyl)-1,3,4,5-tetrahydro-2-benzazepine-1,3-dione ##STR27##
The same procedures as used in Reference Example 5 were repeated except that 1,4-dibromobutane was substituted for 1,5-dibromopentane to give the title compound.
REFERENCE EXAMPLE 13 Preparation of 4-(5-bromopentyl)-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR28##
The same procedures as used in Reference Example 8 were repeated except that 1,5-dibromopentane was substituted for 1,4-dibromobutane to give the title compound.
EXAMPLE 1 Synthesis of 4-(4-(4-phenyl)-1-piperidinyl)butyl-2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one ##STR29##
In 10 ml of dioxane was dissolved 49.8 mg of the compound obtained in Reference Example 6, 80.8 mg (3 equivalents) of 4-phenylpiperidine was added to the resulting solution, and the mixture was stirred at 110° C. for 3 hours with heating. The dioxane was distilled off, an aqueous solution of sodium hydrogen carbonate was added thereto, and the resulting solution was extracted with methylene chloride. The methylene chloride phase was washed with water, dried over anhydrous magnesium sulfate, and then filtered. The resulting filtrate was concentrated and the residue obtained was subjected to silica gel column chromatography (developing solution : ethyl acetate) to give 56.3 mg (yield: 89.1%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 2 Synthesis of 4-(4-(4-(4-chlorophenyl)-1-piperidinyl)butyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one ##STR30##
In 110 ml of dioxane was dissolved 61.3 mg of the compound prepared in Reference Example 6, then 121 mg (3 equivalents) of 4-(4-chlorophenyl)piperidine was added thereto, and the resulting mixture was stirred at 110° C. for 3 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 76.9 mg (yield: 90.6%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 3 Synthesis of 4-(4-(4-hydroxy-4-phenyl)-1-piperidinyl)butyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one ##STR31##
In 10 ml of dioxane was dissolved 119 mg of the compound prepared in Reference Example 6, then 212 mg (3 equivalents) of 4-hydroxy-4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 100° C. for 2 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 153 mg (yield: 97.2%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 4 Synthesis of 4-(4-(4-phenyl)-1-piperidinyl)butyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one ##STR32##
In 10 m l of dioxane was dissolved 20 mg of the compound prepared in Reference Example 7, then 32.5 mg (3 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 100° C. for 5 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 17.9 mg (yield: 70.5%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 5 Synthesis of 4-(4-(4-chlorophenyl)-1-piperidinyl)butyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-3-one ##STR33##
In 7 ml of dioxane 30.5 mg of the compound prepared in Reference Example 7, then 60 mg (3 equivalents) of 4-(4-chlorophenyl)piperidine was added thereto, and the resulting mixture was stirred at 110° C. for 4 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 21.7 mg (yield: 51.4%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 6 Synthesis of 4-(4-(4-hydroxy-4-phenyl)-1-piperidinyl)butyl-2,3,4,5-tetrahydro-1,4-benzoxazepin-3-one ##STR34##
In 10 ml of dioxane was dissolved 45.0 mg of the compound prepared in Reference Example 7, then 80.3 mg (3 equivalents) of 4-hydroxy-4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 110° C. for 4 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 58.3 mg (yield: 98.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 7 Synthesis of 4-(4-(4-(4-chlorophenyl)-4-hydroxy)-1-piperidinyl)-butyl-2,3,4,5-tetrahydro-1,4-benzoxazepin-3-one ##STR35##
In 8 ml of dioxane was dissolved 47.0 mg of the compound prepared in Reference Example 7, then 100 mg (3 equivalents) of 4-(4-chlorophenyl)-4-hydroxypiperidine was added thereto, and the resulting mixture was stirred at 120° C. for 3 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 61.2 mg (yield: 90.5%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 8 Synthesis of 4-(4-(4-phenyl)-1-piperidinyl)butyl-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR36##
In 40 ml of dioxane was dissolved 1.30 g of the compound prepared in the Reference Example 8, 966 mg (1.5 equivalent) of 4-phenylpiperidine and 1.10 g (2 equivalents) of anhydrous potassium carbonate were added to the resulting solution, and the mixture was refluxed for 16 hours. The dioxane was distilled off under a reduced pressure, water and ethyl acetate were added to the resulting residue to perform a liquid-liquid separation, the ethyl acetate phase was dried over anhydrous magnesium sulfate, and then the solvent was distilled off under a reduced pressure. The residue was developed with ethyl acetate-hexane (9:1) using silica gel column chromatography to give 1.52 g (yield: 96.8%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 9 Synthesis of 4-(4-(4-(4-chlorophenyl)-1-piperidinyl)butyl)-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR37##
In 8 ml of dioxane was dissolved 20 mg of the compound prepared in Reference Example 8, then 37.6 mg (3 equivalents) of 4-(4-chlorophenyl)piperidine was added thereto, and the resulting mixture was stirred at 110° C. for 6 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 19.1 mg (yield: 69.7%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 10 Synthesis of 4-(4-(4-hydroxy-4-phenyl)-1-piperidinyl)butyl)-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR38##
In 10 ml of dioxane was dissolved 114 mg of the compound prepared in Reference Example 8, then 194 mg (3 equivalents) of 4-hydroxy-4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 120° C. for 3 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 148 mg (yield: 99.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 11 Synthesis of 4-(4-(4-(4-chlorophenyl)-4-hydroxy-l-piperidinyl)butyl-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR39##
In 10 ml of dioxane was dissolved 48.7 mg of the compound prepared in Reference Example 8, then 99.0 mg (3 equivalents) of 4-(4-chlorophenyl)-4-hydroxypiperidine was added thereto, and the resulting mixture was stirred at 120° C. for 6 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 58.0 mg (yield: 83.9%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 12 Synthesis of 4-(4-(4-phenyl-1,2,3,6-tetrahydro)-1-pyridyl)butyl-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR40##
In 10 ml of dioxane was dissolved 218 mg of the compound prepared in Reference Example 8, then 318 mg (2.9 equivalents) of 4-phenyl-1,2,3,6-tetrahydropyridine was added thereto, and the resulting mixture was refluxed for 20 hours. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 50 mg (yield: 18.2%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 13 Synthesis of 4-(4-(4-(4-chlorophenyl)-1,2,3,6-tetrahydro-1-pyridyl)butyl-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR41##
In 10 ml of dioxane was dissolved 50 mg of the compound prepared in Reference Example 8, then 93.0 mg (3 equivalents) of 4-(4-chlorophenyl)-1,2,3,6-tetrahydropyridine was added thereto, and the resulting mixture was stirred at 110° C. for 7 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 23.0 mg (yield: 33.7%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 14 Synthesis of 4-(4-(4-(2-pyridyl)-1-piperidinyl)butyl)-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR42##
In 20 ml of dioxane was dissolved 326 mg of the compound obtained in Reference Example 8, 552 mg (2 equivalents) of 4-(2-pyridyl)piperidine.trifluoroacetate and 2.76 g (20 equivalents) of anhydrous potassium carbonate were added thereto, and the resulting mixture was refluxed for 8 hours. The dioxane was distilled off under a reduced pressure, a 0.5 N aqueous solution of sodium hydroxide was added to the resulting residue, the product was extracted with ethyl acetate, the ethyl acetate phase was dried over anhydrous magnesium sulfate, and then the solvent was distilled off under a reduced pressure. The residue obtained was subjected to silica gel column chromatography (developing solution: methylene chloride-methanol (9:1) to give 270 mg (yield: 68.5%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from ethanol-ether.
EXAMPLE 15 Synthesis of 4-(4-(4-hydroxy-4-(2-pyridyl)-1-piperidinyl)butyl)-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR43##
In 20 ml of dioxane was dissolved 326 mg of the compound obtained in Reference Example 8, 873 mg (3 equivalents) of 4-hydroxy-4-(2-pyridyl)piperidine.trifluoroacetate and 2.76 g (20 equivalents) of anhydrous potassium carbonate were added thereto, and the resulting mixture was refluxed for 3 days. The same procedures for reaction and treatment as used in Example 8 were repeated and the resulting residue was subjected to silica gel column chromatography (developing solution: methylene chloride-methanol (10:1)) to give 270 mg (yield: 66.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from ethanol-ether.
EXAMPLE 16 Synthesis of 4-(4-(4-(2-pyridyl)-1,2,3,6-tetrahydro-1-pyridyl)butyl)-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR44##
In 20 ml of dioxane was dissolved 260 mg of the compound obtained in Reference Example 8, 411 mg (1.9 equivalent) of 4-(2-pyridyl)-1,2,3,6-tetrahydropyridine.trifluoroacetate and 2.07 g (19 equivalents) of anhydrous potassium carbonate were added thereto, and the resulting mixture was refluxed for 23 hours. The dioxane was distilled off under a reduced pressure, ethyl acetate and conc. aqueous ammonia were added to the resulting residue to separate into solutions, the ethyl acetate phase was dried over anhydrous magnesium sulfate, and then the solvent was distilled off under a reduced pressure. The residue obtained was purified in the same manner as used in Example 8 to give 179 mg (yield: 57.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from ethanol-ether.
EXAMPLE 17 Synthesis of 4-(4-(4-phenyl)-1-piperidinyl)butyl-2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione ##STR45##
In 5 ml of dioxane was dissolved 27.0 mg of the compound prepared in Reference Example 9, then 41.5 mg (3 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 110° C. for 3.5 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 15.7 mg (yield: 46.3%) of the title compound. The maleate of this compound was obtained by converting the compound into maleate in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 18 Synthesis of 4-(4-(4-phenyl)-1-piperidinyl)butyl-2,3,4,5-tetrahydro- 1,4-benzodiazepine-3,5-dione ##STR46##
In 5ml of dioxane was dissolved 16.3 mg of the compound prepared in Reference Example 10, then 25.4 mg (3 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 110° C. for 4 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 16.9 mg (yield: 62.2%) of the title compound. The hydrochloride and fumarate of this compound were obtained by converting the compound into hydrochloride and fumarate in the usual manner, and then recrystallizing the salts from methylene chloride-ether.
EXAMPLE 19 Synthesis of 4-(4-(4-chlorophenyl)-1-piperidinyl)butyl-2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione ##STR47##
In 10 ml of dioxane was dissolved 33.0 mg of the compound prepared in Reference Example 10, then 31.1 mg (1.5 equivalent) of 4-(4-chlorophenyl)piperidine and 22.0 mg (1.5 equivalent) of potassium carbonate were added thereto, and the resulting mixture was stirred at 110° C. for 21 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 29.3 mg (yield: 65.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 20 Synthesis of 4-(4-(4-hydroxy-4-phenyl)-1-piperidinyl)butyl-2,3,4,5-tetrahydro-1,4-benzodiazepine-3,5-dione ##STR48##
In 10 ml of dioxane was dissolved 44.8 mg of the compound prepared in Reference Example 10, then 76.5 mg (3 equivalents) of 4-hydroxy-4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 100° C. for 4 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 51.7 mg (yield: 88.2%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 21 Synthesis of 1-methyl-4-(4-(4-phenyl) -1-piperidinyl)butyl-2,3,4,5-tetrahydro-1,4-benzodiazepine-3,5-dione ##STR49##
In 10 ml of dioxane was dissolved 56.9 mg of the compound prepared in Reference Example 11, then 62.0 mg (2.2 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 110° C. for 12 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 66.6 mg (yield: 93.9%) of the title compound. The fumarate of this compound was obtained by converting the compound into fumarate in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 22: Synthesis of 2-(4-(4-phenyl)-1-piperidinyl)butyl-1,3,4,5-tetrahydro-2-benzazepine-1,3-dione ##STR50##
In 5 ml of dioxane was dissolved 19.7 mg of the compound prepared in Reference Example 12, then 30.7 mg (3 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 110° C. for 4 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 21.9 mg (yield: 88.3%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 23 Synthesis of 2-(4-(4-(4-chlorophenyl)-1-piperidinyl)butyl)-1,3,4,5-tetrahydro-2-benzazepine-1,3-dione ##STR51##
In 10 ml of dioxane was dissolved 20.0 mg of the compound prepared in Reference Example 12, then 18.9 mg (1.5 equivalents) of 4-(4-chlorophenyl)piperidine and 13.3 mg (1.5 equivalent) of potassium carbonate were added thereto, and the resulting mixture was stirred at 110° C. for 21 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 19.9 mg (yield: 72.5%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 24 Synthesis of 2-(4-(4-phenyl)-1-piperidinyl)butyl-1,3,4,5-tetrahydro-2-benzazepine-1,3-dione ##STR52##
In 10ml of dioxane was dissolved 53.5 mg of the compound prepared in Reference Example 12, then 91.8 mg (3 equivalents) of 4-hydroxy-4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 110° C. for 4 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 68.6 mg (yield: 98.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 25 Synthesis of 2-(4-(4-(4-chlorophenyl)-4-hydroxy)-1-piperidinyl)butyl-1,3,4,5-tetrahydro-2-benzazepine-1,3-dione ##STR53##
In 10 ml of dioxane was dissolved 39.0 mg of the compound prepared in Reference Example 12, then 79.8 mg (3 equivalents) of 4-(4-chlorophenyl)-4-hydroxypiperidine was added thereto, and the resulting mixture was stirred at 120° C. for 5 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 52.0 mg (yield: 93.8%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 26 Synthesis of 4-(5-(4-phenyl)-1-piperidinyl)pentyl-2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one ##STR54##
In 10 ml of dioxane was dissolved 80.0 mg of the compound prepared in Reference Example 1, then 95 mg (2.2 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 100° C. for 6 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 94.8 mg (yield: 93.4%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 27 Synthesis of 4-(5-(4-(4-chlorochenyl)1-piperidinyl)pentyl)-2,3,4,5-tetrahydro-1,4-benzoxazepin-5-one ##STR55##
In 10 ml of dioxane was dissolved 64.5 mg of the compound prepared in Reference Example 1, then 116 mg (3 equivalents) of 4-(4-chlorophenyl)piperidine was added thereto, and the resulting mixture was stirred at 110° C. for 6 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 86.3 mg (yield: 99.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 28 Synthesis of 4-(5-(4-phenyl)-1-piperidinyl)pentyl-2,3,4,5-tetrahydro-1,4-benzoxazepin-3-one ##STR56##
In 10 ml of dioxane was dissolved 65.0 mg of the compound prepared in Reference Example 2, then 96.0 mg (3 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 110° C. for 8 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 49.0 mg (yield: 60.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 29 Synthesis of 4-(5-(4-(4-chlorophenyl)1-piperidinyl)pentyl-2,3,4,5-tetrahydro-1,4-benzoxazepin-3-one ##STR57##
In 10 ml of dioxane was dissolved 65.2 mg of the compound prepared in Reference Example 2, then 123 mg (3 equivalents) of 4-(4-chlorophenyl)piperidine was added thereto, and the resulting mixture was stirred at 110° C. for 6 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 46.7 mg (yield: 52.4%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 30 Synthesis of 4-(5-(4-phenyl)-1-piperidinyl)pentyl-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR58##
In 10 ml of dioxane was dissolved 40.0 mg of the compound prepared in Reference Example 13, then 62.0 mg (3 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 100° C. for 3 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 39.8 mg (yield: 79.2%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 31 Synthesis of 4-(5-(4-(4-chlorophenyl)-1-piperidinyl)pentyl-2,3,4,5-tetrahydro-1,4-benzoxazepine-3,5-dione ##STR59##
In 20 ml of dioxane was dissolved 100 mg of the compound prepared in Reference Example 13, then 173 mg (3 equivalents) of 4-(4-chlorophenyl)piperidine was added thereto, and the resulting mixture was stirred at 110° C. for 7 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 123 mg (yield: 92.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 32 Synthesis of 4-(5-(4-phenyl)-1-piperidinyl)pentyl-2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione ##STR60##
In 5 ml of dioxane was dissolved 30.5 mg of the compound prepared in Reference Example 3, then 29.0 mg (2.2 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 110° C. for 24 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 33.4 mg (yield: 88.0%) of the title compound. The maleate and fumarate of this compound was obtained by converting the compound into maleate and fumarate in the usual manner, and then fumarate was recrystallized from ether-hexane.
EXAMPLE 33 Synthesis of 4-(5-(4-(4-phenyl)-1-piperidinyl)pentyl)-2,3,4,5-tetrahydro-1,4-benzothiazepine-3,5-dione ##STR61##
In 10 ml of dioxane was dissolved 44.0 mg of the compound prepared in Reference Example 3, then 57.7 mg (2.2 equivalents) of 4-(4-chlorophenyl)piperidine was added thereto, and the resulting mixture was stirred at 110° C. for 30 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 37.5 mg (yield: 63.1%) of the title compound. The maleate of this compound was obtained by converting the compound into maleate in the usual manner.
EXAMPLE 34 Synthesis of 4-(5-(4-phenyl)-1-piperidinyl)pentyl-2,3,4,5-tetrahydro-1,4-benzodiazepine-3,5-dione ##STR62##
In 5 ml of dioxane was dissolved 57.8 mg of the compound prepared in Reference Example 4, then 86.0 mg (3 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 100° C. for 8 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 70.8 mg (yield: 98.3%) of the title compound. The fumarate of this compound was obtained by converting the compound into fumarate in the usual manner, and then recrystallizing the salt from acetone-ether.
EXAMPLE 35 Synthesis of 4-(5-(4-(4-chlorophenyl)-1-piperidinyl)pentyl)-2,3,4,5-tetrahydro-1,4-benzodiazepine-3,5-dione ##STR63##
In 5 ml of dioxane was dissolved 40.9 mg of the compound prepared in Reference Example 4, then 61.5 mg (2.5 equivalents) of 4-(4-chlorophenyl)piperidine was added thereto, and the resulting mixture was stirred at 100° C. for 12 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 49.9 mg (yield: 90.2%) of the title compound. The fumarate of this compound was obtained by converting the compound into fumarate in the usual manner, and then recrystallizing the salt from acetone-ether.
EXAMPLE 36 Synthesis of 2-(5-(4-phenyl)-1-piperidinyl)pentyl-1,3,4,5-tetrahydro-2-benzazepine-1,3-dione ##STR64##
In 8 ml of dioxane was dissolved 44.0 mg of the compound prepared in Reference Example 5, then 48.2 mg (2.2 equivalents) of 4-phenylpiperidine was added thereto, and the resulting mixture was stirred at 110° C for 6 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 46.6 mg (yield: 85.0%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
EXAMPLE 37 Synthesis of 2-(5-(4-(4-chlorophenyl)-1-piperidinyl)pentyl)-1,3,4,5-tetrahydro-2-benzazepine-1,3-dione ##STR65##
In 10 ml of dioxane was dissolved 61.2 mg of the compound prepared in Reference Example 5, then 111 mg (3 equivalents) of 4-(4-chlorophenyl)piperidine was added thereto, and the resulting mixture was stirred at 110° C. for 7 hours with heating. Thereafter, the same procedures for reaction, treatment and purification as used in Example 1 were repeated to give 66.7 mg (yield: 79.6%) of the title compound. The hydrochloride of this compound was obtained by converting the compound into hydrochloride in the usual manner, and then recrystallizing the salt from methylene chloride-ether.
The physical data of the compounds prepared in Examples 1 to 37 are summarized in Table II.
TABLE II__________________________________________________________________________Ex. No.m.p. IR (cm.sup.-1) NMR (δppm) Elemental Analysis__________________________________________________________________________ 1 202-205° C. 2920 2750 1.59-1.78(m, 6H), 1.82-1.86(m, 2H) HCl salt 1/4 H.sub.2 O(HCl salt) 1630 1600 2.02-2.09(m, 2H), 2.42-2.54(m, 3H) C H N 1465 1450 3.05-3.09(m, 2H), 3.51(t, 2H, J=5.3Hz) Calc. 68.72 7.57 6.68 1410 1360 3.62-3.67(m, 2H), 4.38(t, 2H, J=5.3Hz) Obsd. 68.98 7.53 6.74 1280 1205 7.00(d, 1H, J=7.9Hz) 1100 1040 7.16-7.32(m, 6H) 800 755 7.40(ddd, 1H, J=1.3Hz&7.3Hz&7.9Hz) 695 7.80(dd, 1H, J=1.3Hz&7.9Hz) 2 205-207° C. 2920 2740 1.57-1.81(m, 8H), 1.96-2.06(m, 2H) HCl salt 3/4 H.sub.2 O(HCl salt) 1635 1600 2.38-2.50(m, 3H), 3.00-3.04(m, 2H) C H N 1465 1410 3.46(t, 2H, J=5.3Hz) Calc. 62.26 6.86 6.05 1370 1310 3.58- 3.63(m, 2H) Obsd. 62.12 6.56 6.02 1280 1205 4.34(t, 2H, J=5.3Hz) 1105 1080 6.97(d, 1H, J=7.9Hz) 1040 1005 7.09-7.40(m, 6H) 820 800 7.77(dd, 1H, J=1.3Hz&7.9Hz) 755 695 3 192-194° C. 3350 2930 1.50-1.82(m, 6H), 2.23-2.38(m, 2H) HCl salt 1/4 H.sub.2 O(HCl salt) 2820 1625 2.55-2.68(m, 4H) C H N 1470 1420 3.51(t, 2H, J=5.3Hz) Calc. 66.19 7.29 6.43 1380 1305 3.66(t, 2H, J=6.6Hz) Obsd. 66.08 7.42 6.42 1280 1210 4.38(t, 2H, J=5.3Hz)7.00(d, 1H, J=8.6Hz) 1120 1040 7.16(dd, 1H, J=7.3Hz&7.9Hz) 980 800 7.30-7.44(m, 4H) 760 730 7.52(d, 2H, J=7.3Hz) 695 7.79(dd, 1H, J=1.3Hz&7.3Hz) 4 189-190° C. 2920 2750 1.44-1.59(m, 4H), 1.71-1.78(m, 4H) HCl salt 1/4 H.sub.2 O(HCl salt) 1660 1630 1.93-2.02(m, 2H), 2.31-2.45(m, 3H) C H N 1570 1485 2.93-2.97(m, 2H), 3.48-3.53(m, 2H) Calc. 68.72 7.57 6.68 1470 1430 4.43(s, 2H), 4.62(s, 2H) Obsd. 68.71 7.44 6.71 1340 1300 6.95-7.00(m, 2H) 1220 1185 7.09-7.25(m, 7H) 1115 1050 1015 750 690 5 167-169° C. 2920 2750 1.48-1.64(m, 4H), 1.72-1.80(m, 4H) HCl salt(HCl salt) 1660 1575 1.97-2.04(m, 2H), 2.36-2.49(m, 3H) C H N 1485 1450 2.97-3.02(m, 2H), 3.52-3.57(m, 2H) Calc. 64.14 6.73 6.23 1340 1300 4.47(s, 2H) Obsd. 64.00 7.02 6.15 1220 1190 4.67(s, 2H) 1120 1090 6.99-7.25(m, 8H) 1050 1010 820 755 690 6 176-179° C. 3350 2920 1.56-1.81(m, 6H), 2.32-2.34(m, 2H) HCl salt 1/2 H.sub.2 O(HCl salt) 2810 1650 2.57-2.65(m, 4H), 2.90-2.94(m, 2H) C H N 1570 1485 3.59(t, 2H), J= 6.6Hz) Calc. 65.51 7.33 6.37 1440 1345 4.51(s, 2H), 4.70(s, 2H) 65.80 7.38 6.43 1300 1220 7.02-7.07(m, 2H) 1185 1125 7.18-7.53(m, 7H) 1040 1020 755 695 7 182-184° C. 3350 2920 1.48-1.74(m, 6H) HCl salt(HCl salt) 2800 1640 2.09-2.20(m, 2H) C H N 1485 1460 2.39-2.50(m, 4H) Calc. 61.93 6.50 6.02 1430 1360 2.78-2.82(m, 2H) Obsd. 61.66 6.45 5.98 1300 1220 3.55-3.60(m, 2H) 1190 1125 4.50(s, 2H), 4.70(s, 2H) 1090 1040 7.02-7.46(m, 8H) 1010 910 820 755 730 695 8 174-176° C. 2940 2800 1.52-1.83(m, 8H), HCl salt 3/4 H.sub.2 O(HCl salt) 2770 1705 2.04(m, 2H) C H N 1650 1600 2.40(t, 2H, J=7.3Hz) Calc. 65.15 6.94 6.33 1490 1460 2.48(m, 1H), 3.04(d, 2H, J=11.2Hz) Obsd. 65.00 6.56 6.25 1290 1210 4.02(t, 2H, J=7.9Hz), 4.75(s, 2H) 1110 1060 7.08(dd, 1H, J=1.3Hz&7.9Hz) 1040 760 7.15-7.31(m, 6H) 700 7.51(m, 1H) 8.16(dd, 1H, J=1.3Hz&7.9Hz) 9 202-204° C. 2910 2750 1.55-1.83(m, 8H), 1.98-2.08(m, 2H) HCl salt(HCl salt) 1700 1645 2.38-2.51(m, 3H) C H N 1600 1480 3.02-3.07(m, 2H), 4.01(t, 2H, J=7.3Hz) Calc. 62.20 6.09 6.05 1440 1360 4.75(s, 2H), 7.08-7.30(m, 6H) Obsd. 62.51 6.36 5.96 1330 1290 7.51(ddd, 1H, J=1.3Hz&7.9Hz&8.6Hz) 1210 1120 8.17(dd, 1H, J=1.3Hz&7.9Hz) 1080 1005 815 780 760 69010 151-153° C. 3350 2930 1.47-1.79(m, 6H) HCl salt 1/4 H.sub.2 O(HCl salt) 2800 1700 2.14-2.25(m, 2H), 2.41-2.51(m, 4H) C H N 1640 1600 2.64-2.88(m, 2H) Calc. 64.13 6.62 6.23 1480 1445 3.99-4.05(m, 2H) Obsd. 64.32 6.77 6.26 1360 1335 4.76(s, 2H) 1290 1215 7.10(d, 1H, J=7.9Hz) 1040 955 7.21-7.55(m, 7H) 815 755 8.17(dd, 1H, J=1.7Hz&7.9Hz) 69511 186-188° C. 3300 2900 1.44-1.75(m, 6H), HCl salt(HCl salt) 2750 1695 2.05-2.20(m, 2H) C H N 1640 1600 2.35-2.55(m, 4H) Calc. 60.13 5.89 5.84 1475 1445 2.78-2.90(m, 2H), 3.98-4.03(m, 2H) Obsd. 59.98 5.82 5.79 1360 1330 4.76(s, 2H) 1285 1205 7.08(d, 1H, J=7.9Hz) 1115 1080 7.21-7.54(m, 6H) 1035 820 8.15(dd, 1H, J=1.3Hz&7.9Hz) 76012 141-145° C. 2550 1710 1.60-1.78(m, 4H) Mass(HCl salt) 1640 1480 2.50(t, 2H), J=7.9Hz), 2.57(m, 2H) HiMs (free base) 1450 1300 2.70(t, 2H, J=5.3Hz), 3.14(m, 2H) Calc. 390.1942 1220 1120 4.03(t, 2H, J=7.9Hz), 4.75(s, 2H) Obsd. 390.1943 6.05(m, 1H), 7.09(dd, 1H, J=1.3Hz&7.9Hz) 7.20-7.40(m, 6H) 7.51(m, 1H) 8.16(dd, 1H, J=1.3Hz&7.9Hz)13 155-158° C. 2880 2750 1.49-1.70(m, 4H) HCl salt 1/4 H.sub.2 O(HCl salt) 1700 1640 2.41-2.45(m, 4H), 2.61-2.65(m, 2H) C H N 1600 1480 3.06-3.08(m, 2H), 3.92-3.98(m, 2H) Calc. 60.30 5.89 5.84 1440 1335 4.68(s, 2H), 5.96-5.98(m, 2H) Obsd. 60.03 5.66 5.87 1290 1215 7.02(d, 1H, J=7.9Hz) 1120 1090 7.14-7.47(m, 6H) 1040 820 8.09(dd, 1H, J=1.3Hz&8.4Hz) 76014 167-170° C. 2940 1705 1.57-2.12(m, 10H), Mass(HCl salt) 1650 1600 2.42(t, 2H, J=7.3Hz), 2.71(m, 1H) HiMs (free base) 1480 1460 3.06(d, 2H, J=11.9Hz), 4.02(t, 2H, J=7.9Hz) Calc. 393.2051 1440 1300 4.76(s, 2H), 7.09(dd, 1H, J=1.3Hz, &7.9Hz) Obsd. 393.2057 1220 1130 7.12-7.23(m, 3H), 7.51(m, 1H) 1040 760 7.61(m, 1H), 8.16(dd, 1H, J=1.3Hz&7.9Hz) 8.51(dd, 1H, J=1.3Hz&4.0Hz)15 188-190° C. 3300 2950 1.56-1.77(m, 6H), 1.94(br, s, 1H) Mass(HCl salt) 2820 1705 2.11(dt, 2H, J=4.6Hz&12.5Hz) HiMs (free base) 1650 1600 2.47-2.57(m, 4H), 2.88(m, 2H) Calc. 409.2000 1490 1460 4.02(t, 2H, J=7.9Hz), 4.76(s, 2H) Obsd. 409.2004 1440 1300 7.09(dd, 1H, J=1.3Hz&7.9Hz) 1220 1130 7.18-7.24(m, 2H), 7.40(d, 1H, J=7.9Hz) 1050 790 7.51(m, 1H), 7.71(m, 1H) 8.16(dd, 1H, J=1.3Hz&7.9Hz) 8.51(d, 1H, J=4.6Hz)16 172-175° C. 2920 2800 1.55-1.75(m, 4H), 2.52(t, 2H, J=7.9Hz) Mass(HCl salt) 1700 1650 2.65-2.75(m, 4H), 3.22(m, 2H) HiMs (free base) 1600 1580 4.03(t, 2H, J=7.3Hz), 4.75(s, 2H) Calc. 391.1893 1480 1460 6.62(s, 1H), 7.07-7.14(m, 2H) Obsd. 391.1881 1450 1430 7.23(m, 1H), 7.36(d, 1H, J=8.6Hz) 1370 1290 7.51(m, 1H), 7.62(m, 1H) 1220 1120 8.16(dd, 1H, J=1.3Hz&7.9Hz) 1040 760 8.55(d, 1H, J=4.0Hz)17 103-105° C. 2920 2750 1.51-1.83(m, 8H) Maleate(Maleate) 1695 1635 1.98-2.07(m, 2H) C H N 1580 1440 2.37-2.50(m, 3H), 3.01-3.06(m, 2H) Calc. 64.10 6.15 5.34 1430 1350 3.68(s, 2H), 4.03(t, 2H, J=7.2Hz) Obsd. 63.76 6.35 5.22 1320 1265 7.16-7.49(m, 8H) 1110 1085 8.17-8.21(m, 1H) 780 740 69518 153-155° C. 3250 2920 1.40-1.63(m, 4H), 1.66-1.75(m, 4H) HCl salt H.sub.2 O(Fumarate) 2850 1685 1.89-1.98(m, 3H), 2.92-2.96(m, 2H) C H N 1630 1600 3.83(d, 2H, J=4.6Hz), 3.83-3.89(m, 2H) Calc. 64.63 7.23 9.42 1485 1425 4.77(t, 1H) Obsd. 64.92 7.09 9.36 1360 1315 6.70(d, 1H, J=7.9Hz) 1285 1150 6.87(dd, 1H, J=7.3Hz&7.9Hz) 1120 1010 7.08-7.30(m, 6H) 970 780 8.18(dd, 1H, J=1.3Hz&7.9Hz) 740 69019 Undeterminable 3300 2920 1.49-1.81(m, 8H), 1.95-2.04(m, 2H) HCl salt H.sub.2 Obecause of 2750 1690 2.31-2.49(m, 3H), 2.98-3.03(m, 2H) C H Nhygroscopicity 1635 1600 3.90(d, 2H, J=4.6Hz), 3.93(t, 2H, J=7.3Hz) Calc. 60.00 6.50 8.75(HCl salt) 1485 1425 4.91(t, 1H, J=4.6Hz) Obsd. 59.76 6.70 8.62 1360 1315 6.78(d, 1H, J=7.9Hz) 1290 1120 6.94(dd, 1H, J=7.2Hz&7.9Hz) 1085 1005 7.12-7.37(m, 5H) 970 820 8.25(dd, 1H, J=1.3Hz&7.9Hz) 780 745 69520 203-205° C. 3300 2930 1.41-1.76(m, 6H), 2.10-2.22(m, 2H) HCl salt 1/2 H.sub.2 O(HCl salt) 2800 1685 2.38-2.46(m, 4H), 2.78-2.82(m, 2H) C H N 1625 1600 3.91(d, 2H, J=4.6Hz), 3.49(t, 2H, J=6.6Hz) Calc. 63.63 6.90 9.28 1480 1420 4.75(t, 1H, J=4.6Hz) Obsd. 63.21 6.79 9.18 1360 1315 6.78(d, 1H, J=7.9Hz) 1290 1120 6.95(dd, 1H, J=7.3Hz&8.6Hz), 1035 970 7.23-7.38(m, 4H) 775 745 7.51(d, 2H, J=7.2Hz) 690 8.26(dd, 1H, J=1.3Hz&8.6Hz),21 153-155° C. 2910 2750 1.51-1.81(m, 6H) Fumarate 1/2 H.sub.2 O(Fumarate) 1690 1630 1.95-2.07(m, 2H), 2.37(t, 2H, J=7.2Hz) C H N 1595 1490 2.37-2.53(m, 1H), 2.98-3.02 (m, 2H) Calc. 65.64 6.84 7.92 1430 1360 3.22(s, 3H), 3.85(s, 2H) Obsd. 65.49 6.88 7.94 1325 1260 3.89-3.94(m, 2H) 1240 1190 6.91-6.98(m, 2H) 1100 1070 7.18-7.46(m, 6H) 995 775 8.32(d, 1H, J=7.9Hz) 745 69522 175-177° C. 2920 2730 1.47-1.78(m, 8H) HCl salt 1/2 H.sub.2 O(HCl salt) 1690 1635 1.92-2.02(m, 2H), 2.32-2.43(m, 3H) C H N 1595 1485 2.92(s, 4H), 2.92-3.01(m, 2H) Calc. 68.87 7.40 6.43 1440 1305 3.93-3.98(m, 2H) Obsd. 69.13 7.23 6.43 1265 1180 7.08-7.37(m, 8H) 1100 745 7.89(dd, 1H, J=1.3Hz&7.9Hz) 69023 180-182° C. 2920 2750 1.55-1.81(m, 8H) HCl salt(HCl salt) 1690 1640 1.99-2.08(m, 2H), 2.39-2.50(m, 3H) C H N 1595 1490 2.99-3.07(m, 6H) Calc. 65.07 6.55 6.07 1440 1370 3.99-4.05(m, 2H) Obsd. 65.01 6.62 6.14 1335 1310 7.13-7.47(m, 7H) 1270 1180 7.96(dd, 1H, J=1.3Hz&7.9Hz) 1100 1005 885 820 750 71024 201-202° C. 3350 2930 1.52-1.79(m, 6H) HCl salt 1/4 H.sub.2 O(HCl salt) 2800 1690 2.14-2.25(m, 2H), 2.41-2.51(m, 4H) C H N 1640 1600 2.83-2.88(m, 2H), 3.00(s, 4H) Calc. 67.10 7.10 6.26 1490 1440 4.00-4.05(m, 2H) Obsd. 67.22 7.07 6.27 1380 1300 7.17(d, 1H, J=7.3Hz) 1265 1180 7.25-7.54(m, 7H) 1105 1040 7.96(d, 1H, J=7.9Hz) 960 790 755 69525 186-188° C. 3400 2920 1.49-1.75(m, 6H) HCl salt(HCl salt) 2800 1690 2.09-2.20(m, 2H), 2.40-2.48(m, 4H) C H N 1640 1600 2.84-2.96(m, 2H), 2.99(s, 4H) Calc. 62.89 6.33 5.87 1480 1440 4.03(t, 2H, J=7.3Hz) Obsd. 62.39 6.25 5.82 1340 1315 7.16(d, 1H, J=7.3Hz) 1270 1185 7.29-7.46(m, 6H) 1110 1040 7.96(d, 1H, J=7.9Hz) 1010 960 820 790 75026 178-180° C. 3300 2920 1.39-1.72(m, 6H), 1.83-1.90(m, 4H) HCl salt 1/2 H.sub.2 O(HCl salt) 2860 2750 2.06-2.15(m, 2H), 2.39-2.55(m, 3H) C H N 1630 1600 3.07-3.15(m, 2H) Calc. 68.55 7.82 6.40 1460 1420 3.50(t, 2H, J=5.3Hz) Obsd. 69.00 7.65 6.41 1370 1315 3.60-3.65(m, 2H), 4.38(t, 2H, J=5.3Hz) 1280 1210 7.00(d, 1H, J=8.7Hz) 1105 1040 7.12-7.43(m, 7H), 980 800 7.80(dd, 1H ,J=2.0Hz&7.9Hz) 755 69527 180-181° C. 2900 2740 1.33-1.52(m, 2H), 1.53-1.88(m, 8H) HCl salt(HCl salt) 1635 1600 2.02-2.10(m, 2H), 2.36-2.54(m, 3H) C H N 1460 1410 3.06-3.10(m, 2H) Calc. 64.79 6.96 6.04 1360 1310 3.50(t, 2H, J=5.3Hz), 3.62(t, 2H, J=7.2Hz) Obsd. 64.64 6.93 6.03 1280 1205 4.38(t, 2H, J=5.3Hz), 7.00(d, 1H, J=7.9Hz) 1085 1040 7.13-7.27(m, 5H), 820 755 7.40(dt, 1H, J=1.3Hz&7.9Hz) 690 7.81(dd, 1H, J=1.3Hz&7.9Hz)28 161-163° C. 2920 2730 1.26-1.40(m, 2H), 1.49-1.70(m, 4H) HCl salt 1/4 H.sub.2 O(HCl salt) 1660 1630 1.78-1.89(m, 4H), 2.00-2.10(m, 2H) C H N 1485 1450 2.33-2.39(m, 2H) Calc. 69.27 7.79 6.46 1340 1300 2.47-2.53(m, 1H) Obsd. 69.30 7.61 6.49 1220 1185 3.02-3.10(m, 2H) 1105 1050 3.55(t, 2H, J=7.3Hz), 4.49(s, 2H) 1020 750 4.69(s, 2H), 7.03-7.32 (m, 9H) 69529 144-148° C. 2900 2850 1.25-1.36(m, 2H), 1.49-1.69(m, 4H) HCl salt 1/2 H.sub. 2 O(HCl salt) 2750 1660 1.70-1.82(m, 4H), 1.97-2.09(m, 2H) C H N 1575 1480 2.32-2.37(m, 2H) Calc. 63.56 7.04 5.93 1440 1340 2.41-2.51(m, 1H), 3.03-3.07(m, 2H) Obsd. 63.38 6.86 5.91 1300 1215 3.52-3.58(m, 2H) 1185 1080 4.49(s, 2H), 4.69(s, 2H) 1045 1020 7.03-7.32(m, 8H), 815 745 69030 176-178° C. 2920 2750 1.33-1.72(m, 6H) HCl salt 1/4 H.sub.2 O(HCl salt) 1700 1645 1.74-1.85(m, 4H), 1.98-2.06(m, 2H) C H N 1600 1480 2.35-2.40(m, 2H), 2.45-2.51(m, 1H) Calc. 67.10 7.10 6.26 1445 1370 3.03-3.07(m, 2H), 3.96-4.01(m, 2H) Obsd. 67.16 7.09 6.28 1335 1290 4.76(s, 2H) 1215 1115 7.09(d, 1H, J=7.9Hz) 1060 1040 7.16-7.33(m, 6H) 985 815 7.51(dt, 1H, J=1.3Hz&7.9Hz) 755 695 8.17(dd, 1H, J=1.3Hz&7.9Hz)31 166-168° C. 2910 2740 1.35-1.44(m, 2H) HCl salt(HCl salt) 1700 1645 1.48-1.83(m, 8H) C H N 1600 1475 1.96-2.05(m, 2H), 2.33-2.39(m, 2H) Calc. 62.89 6.33 5.87 1440 1360 2.42-2.52(m, 1H), 3.02-3.06(m, 2H) Obsd. 63.02 6.32 5.86 1325 1290 3.95-4.01(m, 2H), 4.76(s, 2H) 1210 1115 7.08-7.27(m, 6H), 1085 1035 7.51(dt, 1H, J=1.3Hz&7.9Hz) 815 760 8.16(dt, 1H, J=1.3Hz&7.9Hz) 69032 124-128° C. 2930 2750 1.31-1.50(m, 2H) Fumarate 1/2 H.sub.2 O(Fumarate) 1695 1640 1.51-1.84(m, 8H), 1.94-2.07(m, 2H) C H N 1580 1490 2.35(t, 2H), J=7.9Hz), 2.45-2.52(m, 1H) Calc. 63.60 6.44 5.12 1430 1350 3.02-3.06(m, 2H) Obsd. 63.73 6.41 5.11 1320 1255 3.68(s, 2H), 4.00(t, 2H, J=7.9Hz) 1230 1085 7.16-7.47(m, 8H) 985 780 8.17-8.21(m, 1H), 740 69533 Oily product 2920 2750 1.33-1.47(m, 2H) Maleate(Maleate) 1690 1630 1.50-1.85(m, 8H), 1.91-2.04(m, 2H) C H N 1580 1490 2.35(t, 2H, J=7.3Hz) Calc. 60.77 5.80 4.89 1460 1430 2.39-2.52(m, 1H), 3.01-3.05(m, 2H) Obsd. 60.26 5.88 4.78 1320 1255 3.68(s, 2H), 3.97-4.02(m, 2H) 1230 1085 7.13-7.49(m, 7H) 1010 985 8.19(dd, 1H, J=1.9Hz&7.9Hz) 820 780 740 68534 183-184° C. 3250 2900 1.33-1.39(m, 2H), 1.52-1.84(m, 8H) Fumarate 1/2 H.sub.2 O(Fumarate) 2750 1685 1.98-2.07(m, 2H), 2.33-2.38(m, 2H) C H N 1630 1600 2.45-2.48(m, 1H), 3.02-3.07(m, 2H) Calc. 65.64 6.84 7.92 1485 1425 3.91(d, 2H, J=4/6Hz), 3.90-3.93(m, 2H) Obsd. 65.24 6.63 7.72 1350 1310 4.71(t, 1H, J=4.6Hz), 6.77(d, 1H, J=7.9Hz) 1290 1230 6.95(t, 1H, J=7.9Hz), 1150 1110 7.19-7.37(m, 6H) 970 745 8.26(dd, 1H, J=1.3Hz&7.9Hz) 69035 171-173° C. 3250 2900 1.25-1.39(m, 2H), 1.49-1.84(m, 8H) Fumarate(Fumarate) 2750 1695 1.95-2.05(m, 2H), 2.31-2.37(m, 2H) C H N 1640 1605 2.37-2.51(m, 1H), 3.01-3.05(m, 2H) Calc. 62.64 6.16 7.56 1490 1430 3.87-3.92(m, 4H) Obsd. 62.29 6.17 7.56 1360 1320 4.70-4.73(m, 1H), 6.77(d, 1H, J=8.6Hz) 1240 1120 6.94(t, 1H, J=7.9Hz) 1090 980 7.13-7.37(m, 5H) 825 750 8.26(d, 1H, J=7.9Hz)36 151-152° C. 2920 2750 1.33-1.44(m, 2H), 1.50-1.84(m, 8H) HCl salt 1/4 H.sub.2 O(HCl salt) 1695 1640 1.98-2.07(m, 4H), 2.37(t, 2H, J=7.9Hz) C H N 1600 1445 2.43-2.53(m, 1H), 2.99(s, 4H) Calc. 70.10 7.58 6.29 1335 1310 3.03-3.07(m, 2H) Obsd. 70.26 7.49 6.29 1240 1180 4.00(t, 2H, J=7.3Hz) 1090 980 7.15-7.44(m, 8H) 885 750 7.97(dd, 1H, J=1.3Hz&7.3Hz) 695 37 175-178° C. 2920 2750 1.35-1.44(m, 2H) HCl salt(HCl salt) 1690 1640 1.53-1.84(m, 8H) C H N 1595 1485 1.97-2.05(m, 2H), 2.34-2.40(m, 2H) Calc. 65.68 6.78 5.89 1440 1335 2.43-2.51(m, 1H), 2.99(s, 4H) Obsd. 65.60 6.95 5.84 1310 1240 3.03-3.07(m, 2H) 1180 1085 3.97-4.02(m, 2H) 1005 980 7.13-7.45(m, 7H) 880 820 7.97(dd, 1H, J=1.3Hz&7.9Hz) 750 705__________________________________________________________________________
The pharmacological test results will now be explained.
(I) AFFINITY TO σ-receptor
The affinities of the present compounds to the δ-receptor were determined according to a method described in the "Molecular Pharmacology," Vol. 32, 772-784 (1987).
That is, 50 mM of a Tris-HCl (pH=7.7) buffer solution was added to all of the cerebra, other than the cerebellum, of Wistar male rats, followed by homogenizing for 30 minutes in a Polytson.sup.® and then centrifugally separating same at 35000 G for 10 minutes. To the resultant precipitate was added the same buffer solution as used above, and the homogenizing and the centrafugalization were repeated. This procedure was repeated once more, and to the final precipitate was added a 50 mM Tris -HCl (pH=8.0) buffer solution and the receptor having a binding capability. In the binding experiments, 3nM [ 3 H] propyl-3-(3-hydroxyphenyl) piperidine (i.e., [ 3 H]3PPP) was used, and as a non-specific ligand, 1 μM haloperidol was used. After incubation at 25° C. for 90 minutes, the bound ligand was recovered by filtration and the determination was carried out. The filter used was a Whatmen GF/B filter treated with 0.5% polyethylene imine.
All of the present compounds exhibit strong activities on the order of μM or less. The receptor binding capabilities of the typical compounds are shown in Table III.
TABLE III______________________________________Affinity to δ-ReceptorExample No. IC.sub.50 (nM)______________________________________ 1 14.2 2 11.7 4 9.22 5 18.7 8 6.61 9 4.7312 12.114 17.817 4.0018 14.119 16.121 13.722 3.7423 6.4026 10.927 10.628 8.0229 10.330 4.7331 7.8232 3.9533 17.636 3.6237 8.91______________________________________
(II) Inhibitory Activity Against Locomotor Hyperactivity Induced by Anfoneric Acid
The inhibitory activity against locomotor hyperactivity induced by amfoneric acid of the present compounds were determined according to a method described in the "Journal of Pharmacology & Experimental Therapeuties," Vol. 239, 124-131 (1986) by R. T. Matthews et al.
That is, to a ddy male mouse having a body weight of about 25g, were simultaneously administered amfoneric acid (2.5 mg/kg, subcutaneous administration) and the present compound (intraperitoneal administration), and the amount of movement was determined using an apparatus for determining the amount of movement of a mouse. The amount of movement was determined over 100 minutes, and the test of significance thereof was effected for the total count number for 100 minutes by a Manwhitnee test. The value was indicated as the inhibition rate based, as a control, upon the group to which 2.5 mg/kg of amfoneric acid was subcutaneously administered.
The results are shown in Table IV.
TABLE IV______________________________________Inhibitory activity against locomotorhyperativity induced by anfoneric acid Inhibition Rate (%)Example No. (mg/kg Intraperitoneal administration)______________________________________ 8 73%* (30)18 90%** (10), 65%* (1)19 53%* (10)22 52%* (10)26 65%** (10)29 60%** (10)30 70%* (30)37 74%* (10)Control BMY14802 51%* (30)______________________________________ *0.05 > P > 0.01 **0.01 > P > 0.001
(III) Catalepsy
To ddy male mice having a body weight of about 25 g was intraperitoneally administered the present compound and the catalepsy was determined after 30, 60, 90, and 120 minutes therefrom. The score of the catalepsy was as follows.
The forelegs of the mouse were placed on an aupper edge of a 5.5 cm height box and the time until the more fulled its forelegs down from the box or the mouse jumped up onto the top of the box was measured and the score was determined based upon the following standard.
______________________________________Score Condition______________________________________0 15 sec or less1 more than 15 sec but less than 30 sec2 more than 30 sec but less than 60 sec3 more than 60 sec______________________________________
The results are evaluated based upon the determined score as follows.
______________________________________Evaluation Score______________________________________- less than 1+ more than 1 but less than 2++ more than 2 but less than 3______________________________________
The results of the typical compounds are shown in Table V.
TABLE V______________________________________Catalepsy CatalepsyExample No. (mg/kg Intraperitoneal administration)______________________________________ 8 - (30)18 - (10)19 - (20)21 - (30)26 - (30)29 - (30)30 - (30)31 - (30)37 - (30)Control ++ (0.1)(Haloperidol)______________________________________ | A condensed heterocyclic compound having the formula (I): ##STR1## wherein A and B are both carbonyl groups of one thereof represents a methylene group and the other represents a carbonyl group; Z represents an oxygen atom, a sulfur atom, a substituted or unsubstituted nitrogen atom, or a methylene group; n is an integer of 2 to 6; and R represents a group having the following formula: ##STR2## wherein R 1 represents a hydrogen atom or a hydroxyl group; R 2 represents a substituted or unsubstituted phenyl or 2-pyridyl group or salts thereof.
The compounds according to the present invention exhibit a strong affinity to the σ-receptor and are useful as psychopharmaceuticals. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for compressing material, for example straw or other crop material.
2. Description of the Prior Art
In a known baling machine for example for compressing and baling straw, a pick up rotor on a tractor drawn machine collects straw from the ground and the straw is transferred sideways across the machine by, for example, an auger into the input opening of a longitudinal compression chamber positioned along the length of the machine. The straw is periodically compressed by a reciprocating compression piston driven along the compression chamber, straw being fed into the chamber transversely, at right angles to the direction of travel of the piston. There is no end door to the compression chamber for the compression piston to bear against, the compression of straw taking place instead by virture of the resistance to the movement of the straw along the compression chamber. The walls of the compression chamber are slightly converging in the direction of compression, or alternatively the side walls of the compression chamber may be parallel and there may be provided compression plates at the top and bottom of the chamber which are arranged to converge towards each other. Periodically, measured lengths of the column of compressed straw are tied with two or more strands of twine to form bales.
The form of compressor baler described above has a number of limitations. For example the density of compression which can be achieved is relatively low due to the fact that there is no end plate for the compression piston to bear against. Also it is difficult to obtain uniform compression due to variations in the moisture or other qualities of the straw and hence variations in the friction between the straw and the walls resulting in varying resistance offered to the compression piston.
Furthermore, it is not possible to have a truly continuous input of material for compression because the material is fed into the side of the compression chamber at right angles to the direction of compression of the piston. The input cannot be truly continuous because no input can pass into the chamber during a compression stroke.
According to the present invention there is provided a compression apparatus including a press framework defining a compression region for housing material to be compressed, one or more compression elements for compressing material by movement along the compression region, and a drive mechanism for moving the compression element or elements in a cycle of movement having one stage in which the or each element enters into the compression region, a further stage in which the or each compression element is moved along the compression region along a substantially rectilinear path to compress material in the compression region, and a yet further stage in which the or each compression element is returned to the position it occupied at the beginning of the first mentioned stage, the compression element or elements being at least partially removed from the compression region during the return movement in the last mentioned stage.
By the term press framework is meant a structure which houses the material during compression and restrains the material sufficiently to allow compression to take place during movement of the compression elements along the framework. Thus the framework may consist of a relatively open framework having floor members sufficient to support the material during compression, and side members sufficient to restrain the material during compression. In some examples an upper part of the framework may be open allowing some upward movement of the material during compression.
However it will be appreciated that in some arrangements the press framework may comprise a bale chamber or conduit having one or more continuous walls. Conveniently one or more such walls may have slots suitable to accommodate the entry of the compression element or elements.
The press framework may have an input opening for receiving material to be compressed and at the other end thereof an end stop member positioned for the compression element or elements to compress the material against, the end stop member being openable or removable after compression of the material to allow removal of the compressed material from the compression region.
The press framework may have at one end an input opening for receiving material to be compressed, and the input opening may be arranged to receive material into the compression region by movement of the material along the same general direction as the movement of the compression element or elements during compression of the material.
Preferably there are provided mechanism for shaping the material to be compressed into a preformed column of material and for feeding the preformed column of material into the compression region, and the compression element or elements may be arranged during the last mentioned stage to execute the return movement by moving past the preformed column of material during its movement into the compression region.
Furthermore there may be provided a mechanism for shaping the material to be compressed into a preformed column of material and for feeding continuously the preformed column of material into the compression region, the drive mechanism being arranged to move the compression element or elements into a position between a main body of the column of material entering into the compression region and a portion of the column of material within the compression region, the compression element or elements being arranged during the further stage to compress the portion of material in the compression region while the main body of material continues to enter the compression region.
In some preferred arrangements of the invention the compression element or elements are adapted to sever the portion of material to be compressed from the main body of material.
The drive mechanism may include a mounting member for moving the compression element or elements into and out of the compression region by a movement of the compression element or elements transverse to the direction of movement of the compression element or elements during the further stage when the material is being compressed in the compression region. The transverse movement may be in a direction substantially at right angles to the direction of movement of the compression element or elements during the further stage of the cycle when the material is being compressed.
Preferably, the drive mechanism includes a pivotal mounting assembly for moving the compression element or elements into and out of the compression region by a pivotal movement of the compression element or elements.
Conveniently the compression element or elements are mounted by a mounting assembly positioned externally of the compression region.
Conveniently the end stop member comprises an end door pivoted along a horizontal axis substantially at the level of the roof of the press framework and secured in place by a catch mechanism substantially at the level of the floor of the press framework. Alternatively the end stop member may comprise two half width doors pivoted horizontally top and bottom, or two vertical doors pivoted at the sides thereof.
In some arrangements it may be preferable for the drive mechanism to be coupled directly between the end stop member and the compression element or elements during compression of the material. In this way the compressive forces can be applied directly between the end stop member and the compression element or elements and if desired the end stop member may be allowed some degree of movement relative to the rest of the press framework. In some cases the end door or doors can conveniently be coupled directly to the drive machanism in such a manner that the doors are secured in a closed position during compression by the forces exerted on the compression elements to effect the compression.
There may be provided a pressure sensitive switch in the region of the end door of the press framework which is sensitive to contact by the material to be compressed, the movement of the compression elements being initiated in response to a signal from the pressure sensitive switch.
There may also be provided in the region of the end of the press framework remote from the input opening one or more roof members in the upper part of the compression region which is or are movable between a lower and an upper position, the or each roof member being arranged to be in the lower position when the door is shut, and to be movable to the upper position when the door is opened after complete compression of material so as to allow partial expansion of the compressed material to facilitate ejection of the compressed bale from the compression region.
The compression element or elements may be mounted on a subframe positioned externally of the compression region, the subframe being mounted for substantially rectilinear movement relative to the compression region to effect the said movement of the compression element or elements along the compression region during the further stage of the cycle. The subframe may comprise a yoke extending around the compression region.
Conveniently the subframe may be mounted on tracks running along opposed sides of the compression region on the outside thereof. The drive mechanism may include a pair of hydraulic rams positioned one on each side of the compression region and coupled between the subframe and an end door or other end stop mechanism against which the material is to be compressed. As has been mentioned before the drive mechanism may be coupled indirectly to the end door (or other stop member) by being coupled to the press framework to which in turn the end door (or other stop member) is coupled. Alternatively the drive mechanism may be coupled directly to the end door (or other stop member) in such a manner that the tension forces applied to compress the material act directly between the compression elements and the end door (or other stop member). The coupling may be arranged in such a manner that the forces applied to compress the material also act to secure the end door (or other end stop member) in a closed position.
There may be provided control mechanism along the press framework which engage the compression element or elements on advance of the subframe during the further stage of the cycle, the engagement of the compression element or elements with the control mechanism being such as to force the compression element or elements inwardly towards the compression region.
In embodiments of the invention it is preferred that the drive mechanism includes support member on each of two opposed sides of the compression region for applying force to the compression element or elements for driving the element or elements along the compression region during the compression of material. The support member on each side of the compression region may have the function of driving one or more compression elements which span the compression region between the two opposed sides, or may have the function of driving two oppositely facing arrays of cantilevered compression elements.
Thus in some preferred arrangements at least one compression element is positioned on each of two opposed sides of the compression region. Preferably a plurality of compression elements is provided, arranged in two oppositely facing arrays extending into the compression region during the further stage of the cycle.
It will be appreciated that the cycle of movement of the compression element or elements may include further stages in addition to the three stages set out above. For example the drive mechanism may move the compression element or elements in a preliminary stage so that the compression element or elements being to move along a general longitudinal direction of the press framework before the one stage in which the or each element enters into the compression region.
The compression element or elements may during the last mentioned stage of the cycle be totally withdrawn from the compression region by action of the drive mechanism, or the compression element or elements may be moved along the return movement by the drive means and may be removed from the compression region merely by the effect of further material to be compressed entering the compression region while the compression elements are on the return stroke so that the compression element or elements are forced outwardly from the compression region by the incoming material to be compressed. In such a case the compression element or elements may be only partially withdrawn from the compression region and may to some small extent extend into the incoming crop during the relative movement between the crop and the compression elements on their return stroke.
SUMMARY OF THE INVENTION
The apparatus of the present invention may be particularly adapted for compression of straw or other crop material and may be mounted on a framework adapted for mounting on the rear of the compression chamber of a conventional bale compressor.
Where there is provided a mechanism for shaping the material into a preformed column of material, there may be provided a pressure-responsive trigger mechanism positioned to be actuated by the advancing preformed column of material and coupled to the drive mechanism for actuating the drive mechanism to commence the cycle of movement when a required amount of the material has entered the compression region.
The pressure-responsive trigger mechanism may be adjustable to respond to different pressures exerted by the advancing column of material in such a manner as to allow variation of the density of the material after compression by the compression elements.
Where there are provided end stop members as set out hereinbefore, the pressure-responsive mechanism may be coupled to the end stop members.
As has been mentioned, there are preferably provided mechanism for shaping material into a preformed column of material before it is fed into the press framework of the main compression apparatus. This shaping mechanism may itself comprise a compression apparatus embodying the present invention, but of a generally lighter construction than the main compression apparatus. This preliminary compression apparatus may conveniently accept material (to be lightly compressed into the preformed column) as unformed material such as loose straw or hay picked up from the field.
According to the present invention in another aspect there is provided compression apparatus comprising a press framework defining a compression region for housing material to be compressed, one or more compression elements for compressing material by movement along the compression region, and a drive mechanism for moving the compression element or elements in a cycle of movement having one stage in which the or each element enters into the compression region, a further stage in which the or each compression element is moved along the compression region to compress material in the compression region, and a yet further stage in which the or each compression element is returned to the position it occupied at the beginning of the first mentioned stage, the compression element or elements being at least partially removed from the compression region during the return movement in the last mentioned stage, and the drive mechanism including support member on each of two opposed sides of the compression region for applying force to the compression element or elements for driving the element or elements along the compression region during the compression of the material.
According to the present invention in a further aspect there is provided compression apparatus comprising a press framework defining a compression region for housing material to be compressed, one or more compression elements for compressing material by movement along the compression region, a drive mechanism for moving the compression element or elements in a cycle of movement having one stage in which the or each element enters into the compression region, a further stage in which the or each compression element is moved along the compression region to compress material in the compression region, and a yet further stage in which the or each compression element is returned to the position it occupied at the beginning of the first mentioned stage, and a mechanism for shaping the material to be compressed into a preformed column of material and for feeding the preformed column of material into the compression region, the compression element or elements being arranged during the last mentioned stage to execute the return movement by moving past the said preformed column of material during its movement into the compressed region.
According to the present invention in a yet further aspect there is provided compression apparatus comprising a press framework defining a compression region for housing material to be compressed, one or more compression elements for compressing material by movement along the compression region, drive mechanism for moving the compression element or elements in a cycle of movement having one stage in which the or each element enters into the compression region, a further stage in which the or each compression element is moved along the compression region to compress material in the compression region, and a yet further stage in which the or each compression element is returned to the position it occupied at the beginning of the first mentioned stage, and a mechanism for shaping the material to be compressed into a preformed column of material and for feeding continuously the preformed column of material into the compression region, the drive mechanism being arranged to move the or each compression element into a position between a main body of the column of material entering into the compression region and a portion of the column of material within the compression region, the compression element or elements being arranged, during the further stage to compress the portion of material in the compression region while the main body of material continues to enter the compression region.
It is an advantage of the various preferred arrangements set out hereinbefore that the continuous column of precompressed straw may continue to be fed into the compression chamber while the compressing phase is taking place. In another known apparatus for compressing to a higher density precompressed straw coming from a conventional baler, it has been proposed to take the previously compressed and tied bale, optionally to cut or untie the bale, to place the bale in a compression chamber having an internal piston and then to recompress the bale to increase the density. This has a number of disadvantages. For example firstly the secondary compression is not a continuous process in that the machine cannot easily be directly coupled to a conventional baler. In the present invention however it is possible to arrange for the output from a conventional baler to be fed directly and continuously into the compression chamber. Secondly the bales formed by a secondary compression in known apparatueses have the disadvantage that they are smaller, usually half the length of conventional bales, so that they cannot conveniently be handled by existing bale handling equipment. The present invention allows high density bales to be produced having substantially the same dimensions as conventional bales (thus allowing conventional bale handling equipment to be used) or in any other dimensions which are found desirable. Finally an advantage of the present invention is that it is not necessary to go through the step of tying conventional bales and retying them again after further compression. In embodiments of the present invention it is possible to feed precompressed straw directly into the compression chamber without tying until the further compression has taken place.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description when considered in connection with the accompanying drawings, wherein like reference characters designate like or corresponding parts throughout the several views, and wherein:
FIG. 1 is a side view of a compression apparatus embodying the invention for use in compression of straw or other crop material;
FIG. 1A and 1B show details of the elements of the compression apparatus of FIG. 1;
FIG. 2 is a plan view of the compression apparatus shown in FIG. 1;
FIG. 3 shows a half-view along the longitudinal axis of the compression apparatus of FIG. 1;
FIG. 3A is an end view of the compression apparatus shown in FIGS. 1 and 2;
FIG. 4 is a perspective view showing compression elements present in the compression apparatus of FIGS. 1 to 3;
FIG. 5 is a side view partly in section of an end door of the compression apparatus shown in the preceding Figures;
FIG. 6 is an end view of the door shown in FIG. 5;
FIGS. 7 and 8 are plan and side views, respectively, of a device for introducing an extra loop of slack into the twine of a bale tying mechanism shown in FIGS. 1 and 2;
FIGS. 9 and 10 are plan and side views, respectively, of roof members of a press framework shown in FIGS. 1, 2, 3 and 4; and
FIG. 11 shows in diagrammatic form a modification of part of the apparatus shown in the preceding Figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring firstly in particular to FIGS. 1, 2 and 3, compression apparatus 11 comprises a press framework 9 defining a compression region 12 for housing straw or other crop to be compressed. The press framework 9 has an input opening 13 at one end for receiving precompressed straw from a conventional baler compressor 10. The end of the bale chamber of the conventional baler 10 is indicated at 14. The apparatus 11 is pivotally linked to the baler 10 by a drawbar 48 and pivotal mounting 15 so that angular movement between the baler 10 and the compression apparatus 11 is allowed temporarily up to 90° on either side of the centre line of the apparatus 11. The whole apparatus 11 is mounted on a main frame 27 which in turn is carried on land wheels 47. In the embodiment shown the main frame 27 is towed behind the conventional baler 10 by the drawbar 48. The precompressed straw from the baler 10 is guided into the compression chamber 12 by inclined vertical doors 16 and horizontal doors 17.
Mounted externally of the compression region 12 is a subframe 18 in the form of a yoke encompassing the compression region 12. The subframe 18 is mounted on two pairs of guide wheels 19 on each side of the press framework 9 the guide wheels 19 being arranged to run in guide tracks 20 allowing longitudinal motion of the subframe 18 along the press framework 9.
Mounted on the subframe 18 are a plurality of compression elements consisting of compression teeth 21. Four of the teeth 21 are positioned in a parallel array mounted on an upper cross member 22 of the subframe 18, and four of the teeth 21 are positioned in a parallel array mounted on a lower cross member 23 of the subframe 18. The teeth 21 of each array are fixed relative to each other and mounted for rotation about a horizontal shaft common to the array. Thus the upper cross member 22 comprises a sleeve rotatable on an upper cross shaft 82 and the lower cross member 23 comprises a sleeve rotatable on a lower cross shaft 83 (FIG. 4).
External of the press framework 9 there are provided two hydraulic rams 25 and 26 positioned one on each side of the press framework 9 and constituting part of drive mechanism for moving the subframe 18 along the press framework 9. The rams 25 and 26 are secured to the main frame 27 by means of pivotal ram mountings 28 and 29, and are coupled to the subframe 18 by pivotal ram mountings 30 and 31.
The detailed operation of the apparatus will be described hereinafter, but a brief outline of the operation will be described at this stage to facilitate understanding of descriptive details referred to below. The broad steps of operation are that a precompressed column of straw is fed into the compression region 12 through the opening 15 until the region 12 is full of straw. The subframe 18 is then propelled to the left in FIGS. 1 and 2 and the teeth 21 are urged inwardly into the straw column to tear off and compress a portion of the column of straw. The compressed bale is then tied, an end door 38 (FIG. 5) is opened and the tied bale is ejected through an end opening remote from the inlet opening 13. The subframe 18 is then returned to the right in FIG. 1 and the end door 38 is closed to allow a fresh cycle to begin.
Referring to FIG. 1, on each side of the press framework 9 there is upstanding from the guide tracks 20 a rail 65 on which is mounted a pawl 66 pivotally mounted on a bracket 67 which itself is fixedly mounted on the rail 65. The bracket 67 is mounted on the rail 65 by bolts or pins passing through apertures in the bracket 67 and the rail 65. There are provided along the rail 65 a plurality of apertures 68 allowing the position of the bracket 67 to be varied. The pawl 66 is spring loaded into an upstanding position (as shown in full lines) by a tension spring 69, but is pivotable to a lower position (shown in broken lines) by extension of the spring 69.
On each side of the carriage 18 there is mounted a trip claw 70 bolted to the cross member 22 which rotates about the shaft 82 with the upper teeth 21. The claw 70 is so positioned that on the rearward stroke of the carriage 18, the claw 70 meets the pawl 66 in its upstanding position. The pawl 66 is so positioned and so shaped that on the return stroke of the carriage 18, the claw 70 rides over the pawl 66 by rotation of the pawl 66 to the lower position against the spring 69. Tripping of the claw 70 on the pawl 66 during the rearward stroke of the carriage 18 rotates the upper teeth 21 in an counterclockwise direction in FIG. 1.
As shown in FIG. 1(a) the pawl and claw arrangement shown in FIG. 1(b) is duplicated on mountings for the lower compression teeth 21 so that both upper and lower teeth 21 are positively driven into the straw column. All the elements 65 to 70 for the upper teeth 21 are duplicated by corresponding elements 65' to 70' for the lower teeth 21.
On the return stroke of the subframe 18, the lower teeth 21 fall clear of the incoming straw column by gravity, and the upper teeth 21 ride over the incoming straw column by pivotting upwardly. Thus the upper teeth are removed from the compression region on the return stroke by the effect of the incoming straw itself.
In a modification, the teeth 21 may be spring loaded in such a sense that the teeth 21 are biassed outwardly from the compression region 12. The spring loading may be effected for example by a tension spring 84 coupled between a bracket 51 rotatable with the teeth 21 on the lower member 23, and a bracket 52 fixed relative to the press framework 9. The upper and lower teeth 21 may be coupled together by a wire rope 53 wound in opposite senses around the upper and lower rotary cross members 22 and 23. The rope then ensures that the upper and lower teeth 21 rotate in unison, although in opposite senses, and also biasses the upper teeth 21 outwardly by virtue of the effect on the lower teeth 21 of the said tension spring.
There is also provided on the main frame 27 a conventional bale tying mechanism comprising two twine tying needles 32 carried by a needle yoke 34, and a drive rod 54 coupled between the needle yoke 34 and a drive arm 33 for driving the needle 32. The drive arm 33 is driven conventionally by a continuously rotating shaft 55 to which it is coupled when triggered at the end of a compression stroke as will be described hereinafter. A conventional knotting mechanism is provided and is indicated generally at 35. The purpose of the bale tying mechanism is to tie the compressed material after it has been compressed (as will be described hereinafter) into an end portion of the compression region 12.
The bale tying mechanism differs from a conventional device only in that there is provided mechanism for catching an extra loop of slack in the loop passed around the compressed bale. The compression apparatus according to the invention in this embodiment is arranged to overcompress the straw so that upon release from the compression apparatus the bale expands slightly but thereafter constitutes a permanently formed shape. In order to allow for this slight expansion after overcompression, an extra loop of twine is caught during the tying and knotting sequence.
The device for catching the extra loop of twine is shown in plan and side view respectively in FIGS. 7 and 8. Beneath the subframe 18 and pivotally mounted on the main frame 27 are two hooks 56 and 57 which pivot about vertical axes and are biased apart by a compression spring 58. The hooks 56 and 57 are mounted on a subcarriage 59 which is movable along the length of the machine relative to the main frame 27. The hooks 56 and 57 bear outwardly against guide plates 60 and 61 and, by virtue of the compression spring 58, the hooks 56 and 57 urge the subcarriage 59 to the right in FIGS. 7 and 8 against a stop.
Upon movement of the carriage 18 of FIG. 1 to the left in FIG. 1, the carriage 18 strikes a plunger 62 which moves to the left in FIG. 7 relative to the main frame 27. As the subcarriage 59 is carried to the left by the plunger 62, the hooks 56 and 57 are moved inwardly and rearwardly and operate to catch the twines carried by the needles 32. Thus, movement of the main carriage 18 at the end of the compression stroke automatically provides a loop of slack in the twine carried by the needles 32.
Upon release of the main carriage 18 and the return stroke of the main carriage 18, the subcarriage 59 moves to the right in FIG. 7 and the hooks 56 and 57 move outwardly to release the slack loops in the twine. This is timed to occur just before or at the time when the compressed bale is being released from the end of the press framework 9 so that as the compressed bale expands the slack is taken up.
As shown in detail in FIGS. 5 and 6, the end of the press framework 9 remote from the input opening 13 has an output opening 37 which is closable by an end door 38. The end door 38 is pivoted at its upper end about a door pivot 39, and is held closed at its lower end by a latch 40. The latch 40 is releasable by a ram 41 operating a pivot plate 42 which in turn drives a connecting rod 43. The pivot plate 42 is pivotable about a primary pivot 45 linking the pivot plate 42 to the door 38 and also about a secondary pivot 46 linking the pivot plate 42 to the connecting rod 43. The pivot plate 42 is linked to a pivot rod 36 of the ram 41 by a piston pivot 50.
When it is required to release the door 38, the ram 41 is actuated to move the piston rod 36 to the right in FIG. 5. While the door is held shut by the latch 40, contraction of the ram 41 pivots the plate 42 about the primary pivot 45 and produces downward movement of the rod 43. Downward movement of the rod 43 rotates the latch 40 in an counterclockwise direction about the latch pivot 44 and allows the door 38 to open. After the latch 40 has been released, continued contraction of the ram 41 now rotates the plate 42 together with the door 38 about the door pivot 39 and completely opens the door.
There is coupled between the end door 38 and the main frame 27 a sensor 63 (shown diagrammatically in FIG. 5) which is arranged to detect pressure on the end door. Before the compression stroke of the apparatus begins, a central panel 64 of the door 38 is biased to the position indicated in FIG. 5 and is in contact with a plunger (not shown) of the sensor 63. The pressure detection of the sensor 63 may be set at a relatively low level such as to detect contact on the door 38 by the precompressed column of straw from the conventional baler 10 as soon as the column has filled the compression region 12. This initial contact closes the switch 63 and triggers the start of the compression stroke.
The sensor 63 also provides a means for varying the density of the bale formed by the compression apparatus. The door 38 is biased slightly forwardly in the position shown in FIG. 5 by an adjustable spring biassing member 64'. Adjustment of the biassing member 64' varies the amount of pressure required to be applied to the door 38 before it moves back to a vertical position and triggers the sensor 63. Thus by for example increasing the spring loading on the door, there can be brought about an increase in the amount of the preformed column of straw which is driven into the compression region before the main compression by the teeth 21 takes place. It will be appreciated that with a greater amount of straw in the compression region before the main compression starts, the final bale will have a greater density.
With regard to the structure of the press framework 9 which defines the compression region 12, it will be appreciated that the press framework may be a fully enclosed bale chamber or may be a relatively open framework such as is shown in the accompanying Figures. In particular, with reference to FIG. 3, the straw to be compressed is housed essentially by side members 71 and angle section lower members 72. With long straw it is not found necessary to provide a complete floor to the press framework 9 because the material to be compressed is entered into the compression chamber 12 in the form of a preformed column of material. However it is found, in the embodiment shown, to be advantageous to provide a further angle section member 73 on each side of the compression region 12 running along the length of the press framework 9. The angle section member 73 is arranged to have one limb of its angle section projecting horizontally into the compression region 12, and during compression the preformed column travels along the member 73 so that a groove in the bale is formed by this member. The presence of the ledge or fin 73 extending into the material during compression is found to be useful in preventing buckling of the bale during compression.
It is also not found necessary to provide a roof to the press framework 9 at least for most of the length of the press framework 9. In fact during compression of the material, some slight upward movement occurs as the column of material is compressed. However it is found advantageous to provide a partial roof to the press framework 9 in the end portion 49 of the compression region 12, which constitutes the portion of the compression region 12 in which the compressed bale exists after the compression elements 21 come to the end of their stroke.
Referring to FIGS. 9 and 10 the roof members which are provided in the end portion 49 of the compression region 12 are conveniently arranged to provide a false ceiling. The roof members consist of a pair of parallel beams 74 and 75 which hang from a central upper member 76 of the press framework 9 and are pivotable on four pivot links 77 to 80 of which links 77 and 78 are seen in FIG. 10.
The roof members 74 and 75 are pivotable between three main positions in which the pivot links 77 and 78 adopt different angles.
In the first, rest position, the beams 74 and 75 hang at their lowest positions and the links 77 to 80 assume a vertical position. When a column of straw begins to be compressed in the compression region 12, the roof beams 74 and 75 move upwardly and rearwardly until an adjustable end stop 75' comes into contact with the end door 38. The roof beams 74 and 75 stay in this second position for the remainder of the compression stroke. Upon opening of the door 38 after the compressed bale has been formed, the roof beams 74 and 75 are released to move upwardly and rearwardly until they are alongside the main roof member 76.
The purpose of this false ceiling provided by the roof members 74 and 75 is two-fold. Firstly during the initial compression of the straw the slight movement allowed in the roof beams allows a better positioning of the straw and a more uniform formation of the bale and avoids buckling. Secondly, upon release of the door 38 the relaxation of the roof beams 74 and 75 allows a slight expansion of the compressed bale from the original overcompressed state. As has been explained, a certain amount of slack is allowed in the twine tying the bale to allow for this expansion from overcompaction. As a result of this slight expansion, the bale can be ejected much more easily from the end of the press framework than would be the case if it were wedged into a fixed end portion 49 of the press framework 9.
Final ejection of the compressed bale from the press framework 9 is achieved in the embodiment shown in two stages. Firstly the oncoming column of straw which enters the compression region 12 during the return stroke of the carriage 18 eventually contacts the compressed bale of straw and nudges it towards the end opening 37. As soon as this movement has begun the compressed bale comes in contact with a pair of continuously rotating sets of star wheels 81 and 82 one on each side of the press framework 9. Once these rotating star wheels 81 have gripped the bale, the bale is swiftly ejected from the rear of the compression framework 12 and as it leaves the framework it trips a microswitch (not shown) at the rear of the frame which is arranged to close a hydraulic valve to actuate the door ram 41 and swiftly close the door 38. This is accomplished before the oncoming column of straw reaches the centre panel 64 of the door 38.
There will now be described in more detail the manner of operation of the apparatus shown in the drawings. At the initial stage of the cycle, the end door 38 is closed and held shut by the latch 40. The subframe 18 is positioned at the front most part of the bale chamber 12 and a precompressed column of straw from the conventional baler 10 is passed through the input opening 13 into the compression region 12 until the column of straw makes contact with the centre panel 64 of the end door 38. This closes the sensor switch 63 which opens hydraulic valves (not shown) to actuate the main rams 25 and 26 which move the subframe 18 away from the input opening 13 along the guide tracks 20.
At the start of the cycle the teeth 21 are positioned outwardly, having previously pivoted out from the compression region 12 to allow the straw column to pass between the teeth 21. Movement of the subframe 18 rearwardly, away from the input opening 13, brings the claws 70 and 70' against the pawls 67 and 67' which causes the teeth 21 to dig into the column of straw and to tear a length of the straw column equivalent to the swept length of the compression region 12 away from the continuous column of straw. The subframe 18 is arranged to move to the left more quickly than the input of the continuous column of straw from the baler 10, and the teeth 21 compress the freed length of straw column against the end door 38.
The subframe 18 is driven along the press framework 9 until the straw column is overcompressed beyond the required size and fits into an end portion 49 of the press framework 9. At this stage the conventional needles 32 and knotters 35 operate to tie the compressed bale, this operation being triggered by a further sensor (not shown) positioned to co-operate with the subframe 18 when it reaches the end portion 49 of the press frame 9. At the end of the tying cycle, part of the tying mechanism triggers a valve which actuates the rams 25 and 26 and the subframe 18 is returned to its position at the forward end of the bale chamber 12. On this return stroke, the teeth 21 are pivoted outwardly by the incoming straw column. Also at the end of the cycle of the tying mechanism, the ram 41 is triggered by part of the tying mechanism to operate and release the end door 38 as has been explained. As the door 38 opens, the roof members 74 and 75 are enabled to move upwardly and rearwardly to release the compressed bale which is then ejected by the star wheels 81. The ram 41 returns the door 38 to its closed position, and the apparatus is then in position for a further cycle of compression when the advancing straw column again reaches the end door 38 and triggers the associated sensor 63.
It will be appreciated that although the teeth 21 have been described as entering the straw in vertical directions from above and below, a simple modification of the apparatus can be made if required whereby the teeth enter the straw by horizontal movements, the teeth entering through the sides of the press framework instead of through the roof and floor regions of the framework.
It will also be appreciated that the press framework can have cross-sectional dimensions greater or smaller than those of a conventional piston baler so as to produce bales larger than conventional bales if required. Bale density and/or size may be varied by varying the traversing distance of the compression elements. Also more than two twine needles and knotters may be deployed to tie the compressed bale.
In FIG. 11 there is shown in strictly diagrammatic form a modification of the apparatus described with reference to the preceding Figures. The purpose of FIG. 11 is to indicate the principle of the modification and it will be appreciated that various changes will be required to the remainder of the compression apparatus in order to carry the modification into effect.
Referring to FIG. 11, a plurality of compression elements comprising teeth 121 are mounted on support means on each of two opposed sides of a compression region 112 defined by a press framework 109. The support members comprise an upper cross member 122 and a lower cross member 123 joined by vertical telescopic side members 122' to form a subframe 118 in the form of a yoke around the compression region 112.
One modification illustrated in FIG. 11 is that the teeth 121 are moved into and out of the compression region 112 by a linear movement at right angles to the main compression movement of the subframe 118 along the compression region 112. This is an alternative to the pivotal movement of the teeth 21 in the preceding Figures. The linear movement of the teeth 121 in FIG. 11 may conveniently be carried out by further hydraulic rams, not shown.
Another modification illustrated in FIG. 11 is that the teeth 121 are arranged to enter into the compression region 112 until they make contact with the lower cross-member 123. During the compression of material, force is applied to the teeth 121 by both the upper and lower cross-members 122 and 123 in contrast to the cantilevered teeth 21 and 22 in the preceding Figures. | Compression apparatus including a press framework defining a compression region for housing material such as straw to be compressed, one or more compression elements such as two opposed arrays of compression teeth for compressing material by movement along the compression region, and a drive mechanism for moving the compression teeth in a cycle of movement. The cycle includes the compression teeth entering into the compression region, moving along the compression region along a substantially rectilinear path to compress material in the compression region, and returning to the position occupied at the beginning of the cycle, the compression teeth being at least partially removed from the compression region during the return movement. Preferably the material to be compressed is preformed into a column of material fed continuously into the compression region, the compression teeth being arranged to sever a portion of the column, to compress the portion, and to execute the return movement by moving past the preformed column while it continues to move into the compression region. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation of prior filed copending PCT International application no. PCT/EP01/13218, filed Nov. 15, 2001, on which priority is claimed under 35 U.S.C. §120, the disclosure of which is hereby incorporated by reference.
This application claims the priority of German Patent Application, Serial No. 100 57 302.9, filed Nov. 17, 2000, pursuant to 35 U.S.C. 119(a)-(d), the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates, in general, to an injection molding machine of a type having a stationary platen and a movable platen connected to one another in a tension-proof manner by at least one tie bar, and more particularly to a traction transmitting securing mechanism for use in an injection molding machine and having a securing element connected form-fittingly with the tie bar in an engagement zone via interlocking projections and recesses.
Injection molding machine oftentimes encounter a problem relating to the fact that the force, generated as a result of a stretching of the tie bar(s) and compression of the securing element in the engagement zone, can be transmitted via only very few projections and recesses, typically only two to three, so that stress peaks occur in these components. Oftentimes, this causes the tie bar to break off at those spots. These stress peaks are encountered on the tie bar ends which project beyond the backside of the platen and are formed with recesses and annular grooves for engagement by the inwardly projecting semicircular ring-shaped ribs of the clamping clamps.
It is generally known, to compensate stress peaks in the area of the abutment through provision of specially designed nuts, e.g. tension nuts. While this approach results in a significant increase in structural complexity, the presence of stress peaks, and thus damage to the components, can still not reliably be eliminated.
It would therefore be desirable and advantageous to provide an improved injection molding machine, to obviate prior art shortcomings and to prevent the presence of stress peaks while still being simple in structure.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, an injection molding machine includes a stationary platen, a movable platen constructed for movement relative to the stationary platen, at least one tie bar for tension-proof connection of the fixed and movable platens, and a traction transmitting securing device including a securing element, disposed on a rear side of one of the platens, for interacting with the tie bar within an engagement zone, wherein one of the securing element and the tie bar has a number of projections in axial spaced-apart relationship, and the other one of the securing element and the tie bar has a number of recesses disposed in axial spaced-apart relationship and engageable by the projections to establish a form-fitting connection, wherein the projections and the recesses are pressed together when exposed to a tensile stress and interlock at an axial clearance which increases along the engagement zone in axial direction corresponding to the tensile stress of the tie bar.
According to another feature of the present invention, the tie bar may be configured as a screw bolt, and the securing element may be configured as a nut, wherein the projections and the recesses are configured as meshing threads, with the increase of the clearance in the engagement zone being realized by slight differences of the helix angle of the threads of the screw bolt and the nut.
According to another feature of the present invention, the tie bar may be configured as a spindle bolt formed with thread grooves, and the securing element may be a spindle nut, wherein the thread grooves of the spindle bolt and the thread grooves of the spindle nut are connected in a form-fitting manner via rolling elements, disposed in the thread grooves of the spindle bolt and the thread grooves of the spindle nut, wherein the increase in clearance in the engagement zone is realized by slight differences of the helix angle of the thread grooves of the spindle bolt and the thread grooves of the spindle nut. Suitably the spindle bolt, the rolling elements and the spindle nut form part of a ball screw mechanism.
According to another feature of the present invention, the tie bar may be configured as a threaded spindle, and the securing element may be configured as a threaded nut of a roller screw mechanism which further includes thread rollers disposed in the threaded nut in axis-parallel relationship, wherein the threaded spindle, the threaded rollers and the threaded nut have threads meshing in a form-fitting manner, and wherein the increase in flank clearance in the engagement zone is realized by slight differences of the helix angle of the threads of the threaded spindle bolt, on the one hand, and the threaded rollers and the threaded nut, on the other hand, or by slight differences of the helix angle of the threads of the threaded spindle bolt and the threaded rollers, on the one hand, and the threaded nut, on the other hand.
According to another feature of the present invention, the projections and the recesses are annular grooves interlocking in form-fitting manner, and the securing element is configured as a split locking element. Suitably, the split clamping element has inwardly projecting ribs of semicircular ring-shaped configuration for engagement in complementary annular grooves of the tie bar.
According to another feature of the present invention, the bolt element may include a toothed rack having a number of projections in the form of teeth in axial spaced-apart relationship, and the securing element may include detent pawls in axial spaced-apart relationship for form-fitting engagement between the teeth.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
FIG. 1 is a schematic fragmentary illustration of a screw and nut connection, incorporating the subject matter according to the present invention;
FIG. 2 is a schematic fragmentary perspective view of a ball screw mechanism, incorporating the subject matter according to the present invention;
FIG. 3 is a schematic fragmentary perspective view of a roller screw mechanism, incorporating the subject matter according to the present invention;
FIG. 3 a is an enlarged detailed view of the area delimited in FIG. 3 ; and
FIG. 4 is a top plan view of a basic configuration of a two-platen injection molding machine, incorporating the subject matter according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Throughout all the Figures, same or corresponding elements are generally indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way.
Turning now to the drawing, and in particular to FIG. 1 , there is shown a schematic fragmentary illustration of a screw and nut connection, including a screw bolt 1 which defines an axis A, a nut 2 , and an abutment 3 . The screw bolt 1 is formed with a buttress thread having load-carrying flanks 4 extending in vertical relationship to the axis A of the screw bolt 1 . The nut 2 has an internal thread which substantially complements the buttress thread of the screw bolt 1 . The screw bolt 1 is exposed to a tensile load Z so that the nut 2 is pressed by a force W against the abutment 3 . The internal thread of the nut 2 and the thread of the screw bolt 1 mesh along the length of an engagement zone E.
In accordance with the invention, the pitch of the buttress thread of the screw bolt 1 is slightly smaller than the pitch of the internal tread of the nut 2 . As a consequence of this configuration, the flank play or clearance ΔS at the flank 4 at the one end of the engagement zone E, which is distal to the attack point of the tensile load Z, here the “trailing” end on the right side of FIG. 1 , is at a minimum ΔS min which is preferably zero. The flank clearance ΔS uniformly increases in the direction of the tensile load Z to the other end of the engagement zone E until reaching a maximum flank clearance ΔS max . Thus, when the screw bolt 1 is subjected to the tensile load Z, the flanks 4 in the area of the trailing end of the engagement zone E enter first into a force-transmitting contact, and only as the tensile load Z rises will the flanks 4 in the leading area of the engagement zone E gradually enter into a force-transmitting contact until ultimately all flanks 4 are involved across the entire length of the engagement zone E for force transmission, when the tensile load Z is at a maximum. As a result, the expansion that the screw bolt 1 undergoes in response to the maximum tensile load Z is substantially spread evenly across the entire length of the engagement zone E so that the presence of stress peaks in the leading zone of the engagement zone E is prevented.
As the tensile load Z increases in a screw thread, the force-transmitting contact of the flanks 4 is effected continuously along a helical path in correspondence to the flank pattern.
The preceding description of FIG. 1 relates to a configuration of a screw and nut connection which incorporates a traction-transmitting securing mechanism according to the present invention. In a same manner, the configuration of FIG. 1 may also equally be applicable for a second embodiment in which reference numeral 1 designates a bolt element having recesses 11 or parallel grooves in axial spaced-apart relationship and exhibiting vertical flanks 4 . Reference numeral 2 designates here a split securing element having two parts 14 , 15 ( FIG. 1 shows only part 14 , part 15 is shown, e.g., in FIG. 4 ) which have each projections 13 of substantially complementary configuration to the grooves 11 for engagement therein. The flank clearance ΔS between the flanks 4 of the bolt element 1 and the complementary confronting flanks of the projections 13 of the securing element 2 is at a minimum at the “trailing” end of the engagement zone E, designated by ΔS min , preferably zero, and increases steadily in the direction of the tensile load Z to the other “leading” end of the engagement zone E until reaching the maximum flank clearance ΔS max .
Thus, as the bolt element 1 is subjected to a tensile load Z, first the flanks 4 in the “trailing” area of the engagement zone E enter in force-transmitting contact. As the tensile load Z rises, the flanks 4 in the “leading” area of the engagement zone E enter into force-transmitting contact, step-by-step, until the tensile load Z is at a maximum and all flanks 4 effectuate a force transmission evenly over the entire length of the engagement zone E. As a result, the expansion that the bolt element 1 undergoes in response to the maximum tensile load Z is substantially spread evenly across the entire length of the engagement zone E so that the presence of stress peaks in the leading zone of the engagement zone E is prevented.
The configuration of FIG. 1 may further equally be applicable for a third embodiment in which reference numeral 1 designates a bolt element in the form of a toothed rack having a number of projections in the form of teeth in axial spaced-apart relationship, and the securing element 2 may include detent pawls in axial spaced-apart relationship for form-fitting engagement between the teeth.
FIG. 2 shows a schematic fragmentary perspective view of a ball screw mechanism, having a bolt element in the form of a spindle bolt 20 which is provided with thread grooves 21 to receive a plurality of balls 22 as rolling elements. The balls 22 are also in engagement with thread grooves 23 of a spindle nut 24 which is in surrounding relationship to the spindle bolt 20 . In accordance with the invention, there is a clearance ΔS between the balls 22 in the thread grooves 21 of the spindle bolt 20 and the thread grooves 23 of the spindle nut 24 , whereby the clearance ΔS is at a minimum clearance ΔS min , preferably zero, at the trailing distal end with respect to the tensile load Z, and uniformly increases in the direction of the tensile load Z until reaching the maximum clearance ΔS max at the leading end of the spindle nut 24 . It will be appreciated by persons skilled in the art that the novel and inventive principle is shown in FIG. 2 only in a highly schematic manner, i.e. with reference to only three balls 22 , with the left ball positioned without clearance, i.e. ΔS min , in both thread grooves 21 and 23 in force-transmitting contact, while already the ball after the next ball, i.e. the right hand ball, is positioned at a maximum clearance ΔS max with respect to the thread groove 23 of the spindle nut 24 .
As the spindle bolt 20 is subjected to the tensile load Z, the balls 22 in the leading area first enter into a force-transmitting contact with the thread grooves 23 of the spindle nut 24 . As the tensile load Z increases, also the trailing balls 22 enter gradually into force-transmitting contact until ultimately, when the tensile load Z is at a maximum, all balls 22 , surrounded by the spindle nut 24 , are involved uniformly in the force transmission.
Turning now to FIG. 3 , there is shown a roller screw mechanism of a type described in a brochure published by INA Lineartechnik oHG, Homburg (Saar); 1999 Mar. 8 th revision and having a bolt element in the form of a threaded spindle 30 , and a securing element in the form of a threaded nut 31 . Disposed between the threaded spindle 30 and the threaded nut 31 are threaded rollers 32 arranged in axis-parallel relationship and serving as rolling elements. The threads of the threaded spindle 30 , threaded rollers 32 and threaded nut 31 mesh with one another in form-fitting manner, wherein the length of the threaded rollers 32 is essentially determinative for the engagement zone E of the roller screw mechanism.
In accordance with the invention, a flank clearance ΔS is adjusted between the flanks of the threads of the threaded rollers 32 and the flanks of the threads of the threaded nut 3 , whereby the flank clearance ΔS is at a minimum, preferably zero, at the end distal to the tensile load Z, and increases evenly in the direction of the tensile load Z until reaching a maximum ΔS max at the leading end of the threaded nut 31 , as shown in FIG. 3 a . As the threaded spindle 30 is subjected to the tensile load Z, the flanks of the threaded rollers 32 and the threaded nut 31 in the trailing area are first to enter into a force-transmitting contact. As the tensile load Z increases, also the flanks in the leading area enter gradually into force-transmitting contact until ultimately, when the tensile load Z is at a maximum, all flanks are involved uniformly in the force transmission.
The afore-described flank clearance ΔS is preferably provided in a same manner between the flanks of the thread of the threaded spindle 30 and the threaded rollers 32 to ensure that an even load distribution is realized in the three threaded components, namely threaded spindle 30 , threaded rollers 32 and threaded nut 31 , and thus to prevent stress peaks. Unlike the balls screw mechanism, shown in FIG. 2 , the roller screw mechanism exhibits a substantially higher load-carrying capability.
Turning now to FIG. 4 , there is shown a top plan view of a basic configuration of a two-platen injection molding machine including a machine bed 40 , a stationary platen 41 securely mounted to the machine bed 40 , and a movable platen 44 comprised of a pressure pad 42 and a plate 43 and supported on the machine bed 40 . Disposed between the pressure pad 42 and the plate 43 are pressure rams 46 . The movable platen 44 is connectable to the stationary platen 41 in a tension-proof manner via tie bars 46 which extend through the stationary platen 41 and are mechanically lockable on the backside of the stationary platen 41 . A molding tool 47 is located between the fixed and movable platens 41 , 44 .
Clamping is realized in a same manner as described in conjunction with the second option described with reference to FIG. 1 . Parts corresponding with those in FIG. 1 are therefore denoted by identical reference numerals. The ends of the tie bars 46 , extending beyond the stationary platen 41 correspond to the bolt elements 1 with the recesses 11 or parallel grooves in spaced-apart relationship. The recesses 11 have flanks 4 in vertical relationship to the axis A of the bolt elements 1 and are engaged by substantially complementary projections 13 of the split securing element 2 . The upper area of FIG. 4 shows the components 14 , 15 of the securing element 2 in a clamping position, whereas the lower area of FIG. 4 shows the components 14 , 15 of the securing elements, by way of a sectional illustration, in the release position. Since the traction transmitting securing mechanism is identical to the embodiment shown in FIG. 1 , a further detailed description thereof is omitted for the sake of simplicity.
While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. | An injection molding machine includes a stationary platen, a movable platen constructed for movement relative to the stationary platen, at least one tie bar for tension-proof connection of the fixed and movable platens, and a traction transmitting securing device including a securing element, disposed on a rear side of one of the platens, for interacting with the tie bar within an engagement zone. The securing element and the tie bar are provided with a number of projections and recesses in axial spaced-apart relationship to establish a form-fitting connection, whereby the projections and the recesses are pressed together when exposed to a tensile stress and interlock at an axial clearance which increases along the engagement zone in axial direction corresponding to the tensile stress of the tie bar. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. national stage application of PCT/EP2011/004575 filed on Sep. 12, 2011, and claims priority to, and incorporates by reference, German patent application No. 10 2010 045 702.7 filed on Sep. 16, 2010.
PRIOR ART
[0002] DE 10 2007 052 586 has already disclosed a converter cutting device for a converter which is provided for converting a continuous fiber into cut fibers, with a cutting unit which can be driven in rotation about an axis of rotation and which comprises a cutting means with a cutting edge.
SUMMARY
[0003] The invention proceeds from a converter cutting device for a converter which is provided for converting at least one continuous fiber into cut fibers, with at least one cutting unit which can be driven in rotation and which comprises at least one cutting means with at least one cutting edge.
[0004] It is proposed that the cutting means forms a cutting angle unequal to 0 degrees with a plane which is oriented perpendicularly to the axis of rotation. Wear of the cutting unit can thereby be reduced. Moreover, a cutting performance of the converter cutting device can consequently be maintained, as compared with known converter cutting devices, with the result that a converter can be provided which has an advantageously long service life and an advantageously high processing speed.
[0005] A “cutting unit” is to be understood in this context to mean, in particular, a group of components which are connected fixedly to one another and which, overall, can be driven in rotation. A “cutting means” is to be understood, in particular, to mean a component of the cutting unit which has the at least one cutting edge. A “cutting edge” of the cutting means is to be understood in this context to mean, in particular, a side edge of the cutting means, in which side edge two faces of the cutting means are contiguous to one another at an acute angle. The cutting edge can therefore be described ideally by a line which runs along the side edge forming the cutting edge. The cutting edge has a length of at least 5 millimeters, preferably a length of at least 10 millimeters and especially advantageously a length of approximately 20 millimeters to 30 millimeters, even greater lengths basically being conceivable. The cutting edge is in this case advantageously designed as a straight line. Basically, however, the cutting edge may also be curved. The word “provided” is to be understood, in particular to mean specially equipped and/or designed.
[0006] A “cutting angle” which the cutting means forms with the plane is to be understood in this context to mean, in particular, an angle which the cutting means forms, at least in the region of the cutting edge, with the plane perpendicular to the axis of rotation. The cutting angle is preferably designed as an angle which an underside of the cutting means forms with a direction of movement of the cutting means in the plane. A “direction of movement” is to be understood in this context to mean, in particular, a direction vector which defines a provided cutting movement direction of any point on the cutting edge at any point in time. In this case, in particular, it is advantageous if the cutting means has the cutting angle unequal to 0 degrees at at least one point on the cutting edge, but preferably over an entire length of the cutting edge. What can be achieved thereby is that the entire cutting edge forms an angle unequal to 0 degrees with the plane perpendicular to the axis of rotation. To determine the cutting angle, advantageously a point on the cutting edge is used which is at the shortest distance from the axis of rotation of the cutting unit. In principle, the cutting angle may have different angles along an extension of the cutting edge.
[0007] Further, it is proposed that the at least one cutting means has a cutting angle of approximately 1 degree. By means of a cutting angle of approximately 1 degree, especially low wear of the cutting edge can be achieved, with the result that an especially long service life can be achieved. The word “approximately” is to be understood in this context to mean, in particular, that the cutting angle lies in a range of between 0.5 degrees and 1.5 degrees and especially advantageously in a range of between 0.8 and 1.2 degrees.
[0008] Furthermore, it is proposed that the cutting unit comprises at least one cutting support element which defines the cutting angle unequal to zero for the cutting means. The cutting means can thereby have a simple configuration, and in this case, in particular, conventional cutting means can continue to be used. A “cutting support element” is to be understood in this context to mean, in particular, an element which has for the cutting means a defined bearing surface, the inclination of which defines the cutting angle.
[0009] Moreover, it is proposed that the cutting edge comprises an inner point and an outer point, between which it has an axial cutting edge offset. Especially advantageous bearing contact of the cutting element against a countercutting element can thereby be achieved, with the result that the continuous fiber can be cut reliably. An “axial cutting edge offset” is to be understood in this context to mean, in particular, that the inner point of the cutting edge is offset in the axial direction with respect to the outer point of the cutting edge. “Axial direction” is to be understood in this context to mean, in particular, a direction parallel to the axis of rotation of the cutting unit. An “inner point” of the cutting edge is to be understood to mean a point on the cutting edge which is at the shortest distance from the axis of rotation of the cutting unit. An “outer point” of the cutting edge is to be understood to mean a point on the cutting edge which is at the longest distance from the axis of rotation of the cutting unit.
[0010] In a development of the invention, it is proposed that the converter cutting device has at least one fixed countercutting unit with at least one countercutting means which forms a countercutting edge. An especially advantageous countercutting edge can thereby be provided. The word “fixed” is to be understood in this context to mean, in particular, that the countercutting unit is fixed at least during normal operation. In principle, at least the countercutting means may be adjustable.
[0011] In an advantageous refinement, the cutting edge and the at least one countercutting edge are provided for a shear cut. An especially advantageous cutting action can thereby be achieved. A “shear cut” is to be understood in this context to mean, in particular, that an intersection point of the cutting edge with the countercutting edge travels during a cutting movement, preferably the intersection point traveling from the inner point of the cutting edge successively in the direction of the outer point of the cutting edge. An “intersection point” is to be understood in this context to mean, in particular, a point at which the cutting edge and the countercutting edge intersect in a plane of projection perpendicular to the axis of rotation of the cutting unit.
[0012] Preferably, the at least one countercutting means forms a cutting angle of approximately 0 degrees with a plane which is oriented perpendicularly to the axis of rotation. An especially advantageous shear cut can thereby be achieved. A cutting angle of approximately 0 degrees is to be understood in this context to mean, in particular, that the countercutting edge of the countercutting means runs in a plane which is oriented perpendicularly to the axis of rotation of the cutting unit. In this context, “approximately” is to be understood to mean a deviation of at most 0.5 degrees and especially advantageously a deviation of at most 0.2 degrees.
[0013] Moreover, it is advantageous if the cutting edge and the countercutting edge are at a maximum cutting distance which is shorter than the cutting offset of the cutting edge. An especially advantageous cut can thereby be achieved. What can thereby be achieved, in particular, is that the cutting edge bears against the countercutting edge over at least one region of the cutting movement, with the result that an especially clean and reliable cut of the continuous fiber can be implemented. A “cutting distance” is to be understood in this context to mean, in particular, a distance between the inner point of the cutting edge and the countercutting edge. The cutting distance is advantageously greater than zero and lower than 0.1 millimeters, a cutting distance lower than 0.01 millimeters being especially advantageous.
[0014] In a further refinement, it is proposed that the converter cutting device comprises at least one continuous fiber feed which is assigned to the at least one countercutting edge and which is provided for introducing at least two continuous fibers simultaneously into a cutting space in the region of the countercutting edge. An especially high cutting capacity can thereby be achieved, since, by means of a single shear cut, the at least two continuous fibers can be cut simultaneously. In this context, “in the region of the countercutting edge” is to be understood to mean, in particular, that the continuous fibers are introduced into the cutting space directly in front of the countercutting edge, as a result of which, during a cutting movement, the two continuous fibers are located between the cutting edge and the countercutting edge.
[0015] Preferably, the continuous fiber feed has at least two fiber outlet orifices assigned to the one countercutting edge. An especially advantageous configuration can thereby be achieved. In this context, “assigned” is to be understood to mean, in particular, that a continuous fiber led through the fiber outlet orifice is cut by means of the countercutting edge.
[0016] Further, a converter which is provided for converting at least one continuous fiber into cut fibers, with a converter cutting device according to the invention, is proposed.
[0017] Preferably, in this case, the converter cutting device has at least three countercutting units distributed about an axis of rotation of the cutting unit. A converter can thereby be provided in which, during a single rotational movement of the cutting unit once about its axis of rotation, a plurality of continuous fibers, in particular continuous fibers of different thickness and/or different type, are cut simultaneously, with the result that an especially advantageous configuration of a converter, particularly with a high cutting capacity, can be implemented in a simple way. Preferably, the converter cutting device comprises a central cutting space, in which the rotatably arranged cutting unit and the at least three fixed countercutting units are arranged. Especially preferably, the at least three countercutting units are distributed uniformly about the axis of rotation of the cutting unit.
[0018] Furthermore, it is advantageous if the converter has a fiber-draw-forward device for feeding at least one continuous fiber, which device has at least one roller draw-forward unit and at least one compressed-air draw-forward unit. Advantageously simple conveyance of the at least one continuous fiber can thereby be achieved, with the result that the converter can have a reliably high cutting capacity. Preferably, in this case, the compressed-air conveying unit is provided for threading in the continuous fiber, with the result that a continuous fiber can be threaded into the fiber-draw-forward device in a simple way.
[0019] Further, it is proposed that the compressed-air draw-forward unit has at least one entry-side guide tube and one exit-side guide tube. An advantageous configuration of the fiber-draw-forward device can thereby be achieved, which makes it possible, in particular, to have reliable normal operation and to thread in the continuous fiber in a simple way.
[0020] Moreover, it is advantageous if the fiber-draw-forward roller unit has at least one draw-forward roller which is arranged between the guide tubes of the compressed-air draw-forward unit. The fiber-draw-forward unit can thereby be configured especially advantageously. In particular, reliable transport of the continuous fiber can be achieved as a result, while at the same time a draw-forward speed can advantageously be set.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Further advantages may be gathered from the following drawing description. The drawings illustrate an exemplary embodiment of the invention. The drawings, description and claims contain numerous features in combination. A person skilled in the art will expediently also consider the features individually and combine them into appropriate further combinations.
[0022] FIG. 1 is a cross sectional view through a cutting unit of a converter cutting device,
[0023] FIG. 2 is a view of the cutting unit in a perspective illustration,
[0024] FIG. 3 is a top view of the cutting unit,
[0025] FIG. 4 is an overall view of an underside of the converter cutting device, and
[0026] FIG. 5 is a view of a fiber-draw-forward device for feeding a continuous fiber.
DETAILED DESCRIPTION
[0027] FIGS. 1 to 4 show a converter which is provided for converting endless fibers into cut fibers. The converter comprises a converter cutting device 10 and a fiber-draw-forward device 37 . The fiber-draw-forward device 37 feeds the continuous fibers to the converter cutting device 10 at an adjustable draw-forward speed. The converter cutting device 10 cuts the continuous fibers into short cut fibers.
[0028] The converter cutting device 10 comprises a rotatably arranged cutting unit 12 and a fixed countercutting unit 19 . Further, the converter cutting device 10 comprises a drive 43 for the cutting unit 12 . The drive 43 comprises a driving machine, not illustrated in any more detail, with a drive shaft 44 , to which the cutting unit 12 is connected. The cutting unit 12 forms a cutting head which can be driven in rotation by means of the driving machine.
[0029] The cutting unit 12 is of multipart form. The cutting unit 12 comprises a basic body 45 which provides a receptacle for mounting the drive shaft 44 of the driving machine. Further, the cutting unit 12 comprises a cutting means 13 which is connected fixedly to the basic body 45 . To tie up the cutting means 13 to the basic body 45 , the cutting unit 12 comprises a cutting edge receptacle with a cutting edge support element 16 and with a clamp fastening 46 . Moreover, the cutting unit 12 comprises a cover 47 which covers the cutting edge receptacle.
[0030] The clamp fastening 46 comprises a clamping disk 48 and a screw 49 for providing a clamping force. The cutting means 13 of the cutting unit 12 is tension-mounted between the clamping disk 48 of the clamp fastening 46 and the cutting support element 16 . The screw 49 of the clamp fastening 46 is screwed into the basic body 45 . Starting from a head of the screw 49 , the screw 49 passes in succession through the clamping disk 48 , the cutting means 13 and the cutting edge support element 16 before it engages into a thread in the basic body 45 .
[0031] The basic body 45 and the cover 47 have an essentially round cross section in a cross-sectional plane running perpendicularly to an axis of rotation 36 of the cutting unit 12 . The cutting means 13 of the cutting unit 12 projects laterally beyond the cross section of the basic body 45 with respect to the axis of rotation 36 . The cutting means 13 is in this case fastened decentrally to the basic body 45 . In particular, the cutting edge receptacle with the clamp fastening 46 is arranged so as to be offset with respect to the axis of rotation 36 .
[0032] The cutting means 13 and the cutting receptacle form an unbalance. The cover 47 which covers the cutting receptacle forms a counterweight. The cutting unit 12 thus has a symmetrical weight distribution with respect to the axis of rotation 36 .
[0033] The screw 49 of the clamp fastening 46 is arranged approximately centrally between the axis of rotation 36 and a margin of the basic body 45 . The cutting receptacle extends over a region which occupies approximately half of the basic body 45 . The cutting means 13 of the cutting unit 12 is thus arranged asymmetrically with respect to the axis of rotation 36 .
[0034] The cutting means 13 has two blunt side edges 50 , 51 and at least one sharp side edge 52 . A fourth side edge, not illustrated in any more detail, may likewise be sharp. The two blunt side edges 50 , 51 are arranged opposite one another. They run virtually parallel to one another. The two sharp side edges, of which only the side edge 52 is illustrated, are likewise arranged opposite one another. The blunt side edges 50 , 51 and the sharp side edge 52 are respectively at an angle of approximately 45 degrees and of 135 degrees to one another. The cutting means 13 thus has a shape which corresponds approximately to a parallelogram.
[0035] The two blunt side edges 50 , 51 , between which the sharp side edge 52 is arranged, project out of the basic body 45 . The sharp side edge 52 is therefore arranged outside the basic body 45 and forms a cutting edge 14 , by means of which the continuous fiber is cut.
[0036] During cutting operation, the cutting unit 12 is driven in rotation. A cutting movement is consequently executed as a rotational movement about the axis of rotation 36 of the cutting unit 12 . A direction of movement 53 in which the cutting means 13 is moved is therefore directed in the circumferential direction with respect to the axis of rotation 36 . The provided direction of movement 53 which the cutting means 13 executes is therefore defined by a tangent of a circle which has the axis of rotation 36 as its center and which the axis of rotation 36 passes perpendicularly through.
[0037] The cutting means 13 forms an angle unequal to 0 degrees with the provided direction of movement 53 . The cutting means 13 therefore forms a cutting angle 15 unequal to 0 degrees with a plane which is oriented perpendicularly to the axis of rotation 36 . To set the cutting angle 15 , the entire cutting means 13 is tilted about a tilting axis 61 which runs in the plane parallel to the axis of rotation 36 . Basically, however, it is also conceivable that the cutting means 13 has the cutting angle 15 unequal to 0 degrees in subregions only, for example in the case of a cutting means of curved form. In particular, in this case, it is conceivable that the cutting means 13 has the cutting angle unequal to 0 degrees solely in the region of the cutting edge, for example as a result of corresponding grinding in the region of the cutting edge.
[0038] The cutting means 13 is of plate-like form, that is to say has an essentially constant thickness which is markedly lower than a length of the side edges 50 , 51 , 52 . The cutting means 13 therefore has two main faces which run parallel to one another and which form a top side 54 and an underside 55 of the cutting means 13 . The underside 55 of the cutting means 13 confronts the countercutting unit 19 .
[0039] The cutting angle 15 of the cutting means 13 is defined by the underside 55 . The cutting angle 15 can therefore be illustrated by an extension of the underside 55 in a cross-sectional plane in which lies a direction vector defining the direction of movement 53 . The main axis of rotation 36 , of which the projection in the cross-sectional plane can be illustrated, runs perpendicularly to the direction of movement 53 in this cross-sectional plane. The cross-sectional plane for determining the cutting angle 15 is therefore defined by the direction of movement 53 and the projection of the axis of rotation 36 .
[0040] The tilting axis 61 runs perpendicularly to the axis of rotation 36 . The side edge 50 runs parallel to the tilting axis 61 . The tilting axis 61 itself therefore has an extension which corresponds virtually to a radial extension with respect to the axis of rotation 36 . A minimum distance between the tilting axis 61 and the axis of rotation 36 is virtually zero.
[0041] The cutting edge 14 of the cutting means 13 is linear. The cutting edge 14 has a length of approximately 20 millimeters. The cutting means 13 therefore has the same cutting angle 15 over the entire length of the cutting edge 14 . The cutting angle 15 which the cutting means 13 has amounts to approximately 1 degree. With respect to the cutting edge 14 , the cutting angle 15 is negative, that is to say it has the effect that, during a cutting movement, a distance between the cutting edge 14 and a countercutting edge 25 becomes shorter at an intersection point.
[0042] The two blunt side edges 50 , 51 of the cutting means 13 form a front side and a rear side of the cutting means 13 . During a cutting movement, first, a point on the side edge 50 designed as the front side runs over a fixed point, for example, on the countercutting unit 19 before an equivalent point on the side edge 51 designed as the rear side runs over this point.
[0043] In a plane perpendicular to the axis of rotation 36 of the cutting unit, the cutting edge 14 has an extension which is oriented obliquely to the direction of movement. The cutting edge 14 therefore comprises an inner point 17 , which is at the shortest distance from the axis of rotation 36 , and an outer point 18 , which is at the longest distance from the axis of rotation 36 .
[0044] The cutting angle 15 , defined as the angle which the underside 55 of the cutting means 13 forms with the plane perpendicular to the axis of rotation 36 , specifically starting from the inner point 17 and parallel to the direction of movement 53 , has the effect that the cutting edge 14 likewise forms an angle unequal to 0 degrees with the plane perpendicular to the axis of rotation. Owing to the negative cutting angle 15 , the cutting edge 14 , starting from the inner point 17 , runs obliquely in the direction of the countercutting unit 19 . The inner point 17 of the cutting edge 14 is offset axially along the axis of rotation 36 with respect to the outer point 18 of the cutting edge 14 . The cutting edge 14 therefore has a cutting offset 28 which corresponds to an axial distance between the two points 17 , 18 of the cutting edge 14 .
[0045] The countercutting unit 19 comprises a countercutting means 22 which has a top side which confronts the cutting unit 12 and which runs perpendicularly to the axis of rotation 36 of the cutting unit 12 . The countercutting means 22 therefore forms a cutting angle of 0 degrees with a plane which is oriented perpendicularly to the axis of rotation 36 . The top side of the countercutting means 22 in this case runs parallel to the plane which is oriented perpendicularly to the axis of rotation 36 of the cutting unit 12 . The countercutting means 13 forms a countercutting edge 25 which runs in the radial direction with respect to the axis of rotation 36 of the cutting unit 12 .
[0046] A cutting distance between the cutting means 13 of the cutting unit 12 and the countercutting means 22 of the countercutting unit 19 is shorter than the cutting offset 28 of the cutting means 13 . The cutting distance is in this case defined as a distance by which the inner point 17 of the cutting edge 14 is spaced apart from the countercutting edge 25 . The cutting distance amounts to approximately 0.01 millimeters.
[0047] During a cutting movement, the inner point 17 runs at a distance over the countercutting edge 25 . As the cutting movement continues, all the points between the inner point 17 of the cutting edge 14 and the outer point 18 of the cutting edge 14 run over the countercutting edge 25 in succession. The cutting movement is consequently designed as a shear cut for which the cutting edge 14 and countercutting edge 25 are provided.
[0048] Owing to the negative cutting angle 15 , during the cutting movement one of the points which are arranged between the inner point 17 and the outer point 18 of the cutting edge 14 comes into contact with the countercutting edge 25 . In a continuation of the cutting movement, the negative cutting angle 15 causes the cutting edge 14 to exert pressure force upon the countercutting edge 25 . In the course of the cutting movement, in this case a distance between the cutting edge 14 and the countercutting edge 25 is equal to zero.
[0049] The converter cutting device 10 comprises a cutting space 32 in which the cutting unit 12 and countercutting unit 19 are arranged. Further, the converter cutting device 10 comprises a continuous fiber feed 29 which is provided for introducing two or more continuous fibers simultaneously into the cutting space 32 . The continuous fiber feed 29 is in this case assigned to only the one countercutting edge 25 of the countercutting unit 19 , that is to say the continuous fibers introduced simultaneously into the cutting space are cut by the countercutting edge 25 during a cutting movement of the cutting edge 14 .
[0050] The continuous fiber feed 29 comprises an outlet element 56 into which three fiber outlet orifices 33 , 34 , 35 are introduced. The three fiber outlet orifices 33 , 34 , 35 are arranged along the countercutting edge of the countercutting unit 19 . The fiber outlet orifices 33 , 34 , 35 are in this case arranged in the radial direction one behind the other in a region in front of the countercutting edge 25 , with the result that they are cut by means of a single shear cut during a cutting movement.
[0051] The outlet element 56 is exchangeable. The outlet element 56 used in the exemplary embodiment illustrated comprises the three fiber outlet orifices 33 , 34 , 35 which have a different size. In principle, instead of the outlet element 56 , an outlet element may also be used which has only two or only one fiber outlet orifice. In this case, in principle, fiber outlet orifices with different diameters may also be used. Both a number of continuous fibers and a diameter of the continuous fibers can be adapted to different requirements by means of the exchangeable outlet element 56 .
[0052] The converter cutting device 10 comprises, in addition to the countercutting unit 19 described, two further countercutting units 20 , 21 which are of similar design. The converter cutting device 10 therefore comprises the three similarly designed fixed countercutting units 19 , 20 , 21 and the cutting unit 12 which can be driven in rotation.
[0053] The three countercutting units 19 , 20 , 21 are arranged symmetrically about the axis of rotation 36 . The countercutting units 19 , 20 , 21 in each case comprise a countercutting means 22 , 23 , 24 which form in each case a countercutting edge 25 , 26 , 27 of the corresponding countercutting unit 19 , 20 , 21 . The countercutting edges 25 , 26 , 27 are arranged here so as to be in each case offset at 120 degrees with respect to one another. The three countercutting means 22 , 23 , 24 are arranged in the central cutting space 32 of the converter cutting device 10 . A rotational movement of the cutting unit 12 over 360 degrees leads to a shear cut on each of the countercutting units 19 , 20 , 21 .
[0054] To draw the continuous fibers forward, the fiber-draw-forward device 37 of the converter comprises a roller draw-forward unit 38 and a compressed-air draw-forward unit 39 . The roller draw-forward unit 38 has a driven draw-forward roller 42 and a pressure roll 57 . The compressed-air draw-forward unit 39 comprises a compressed-air feed, by means of which an air stream is generated along a conveying direction 60 of the continuous fibers.
[0055] The roller draw-forward unit 37 comprises an adjusting mechanism 58 , by means of which the pressure roll 57 can be lifted off from the draw-forward roller 42 . The compressed-air draw-forward unit 39 comprises two guide tubes 40 , 41 which are arranged along the conveying direction 60 fore and aft of the roller draw-forward unit 38 . The exit-side guide tube 41 , which is followed by the converter cutting device 10 , is arranged fixedly. The entry-side fiber guide tube 40 is arranged displaceably.
[0056] To thread a continuous fiber 11 into the fiber-draw-forward device 37 , the draw-forward roller 42 and the pressure roll 57 are moved apart from one another. The two fiber guide tubes 40 , 41 of the compressed-air draw-forward unit 39 are subsequently pushed so near to one another that the continuous fiber, when introduced into the entry-side guide tube 40 , is automatically drawn into the exit-side guide tube 41 by the air stream. The guide tubes 40 , 41 are in this case led through between the draw-forward roller 42 and the pressure roll 57 .
[0057] An air stream is subsequently generated in the guide tubes 40 , 41 . By means of the air stream, the continuous fiber 11 , which has been introduced into the entry-side guide tube 40 , is automatically drawn through the fiber-draw-forward device 37 and, in particular, between the draw-forward roller 42 and the pressure roll 57 .
[0058] To fix the continuous fiber 11 , the fiber-draw-forward device comprises a fiber clamping unit 59 . The fiber clamping unit 59 is arranged in front of the entry-side fiber guide tube 40 with respect to the conveying direction 60 . As soon as the continuous fiber 11 passes completely through the fiber-draw-forward device 37 , the continuous fiber 11 is secured by means of the fiber clamping unit 59 .
[0059] The two guide tubes 40 , 41 are subsequently pushed apart from one another and the pressure roll 57 is brought into contact with the draw-forward roller 42 . The continuous fiber 11 is thereby clamped between the draw-forward roller 42 and the pressure roll 57 . The fiber clamping unit 59 can be opened again.
[0060] During normal cutting operation, in which the converter cutting device 10 comminutes the continuous fibers into cut fibers, a conveying speed for the continuous fiber 11 is set by means of the roller draw-forward unit 38 . The conveying speed is in this case set via a rotational speed of the draw-forward roller 42 . The compressed-air draw-forward unit 39 is provided, during normal operation, for transporting the continuous fiber 11 through the guide tubes 40 , 41 and further guide tubes, not illustrated in any more detail, which may be arranged fore or aft of the fiber-draw-forward device 37 . | The invention proceeds from a converter cutting device for a converter which is provided for converting at least one endless fibre into cut fibres, having at least one cutting unit which can be driven rotationally about a rotational axis and comprises at least one cutting means with at least one blade. It is proposed that the cutting means encloses a cutting angle which does not equal 0 degrees with a plane which is oriented perpendicularly with respect to the rotational axis. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method and apparatus for providing a bio prevention cycle for an automatic clothes washer, and more particularly to methods and systems for preventing the build-up of microorganisms or other materials in an automatic clothes washer or similar appliances.
[0002] Under normal usage of an automatic clothes washer, detergent residues build up with minerals and soils, which harden on the washer, often in areas that the consumer cannot see. This is particularly true when a consumer uses a higher sudsing detergent. These soils then form an excellent medium for supporting and growing bacteria, fungi, and other microorganisms. Consumers rarely see such microorganisms, but the washer will eventually release or have a foul odor due to these microorganisms.
[0003] It would therefore be an improvement in the art if there was provided a method or system for killing the microorganisms which are existing in an automatic clothes washer.
SUMMARY OF THE INVENTION
[0004] The present invention provides an improvement in the art by providing methods and systems for an automatic washer which will kill microorganisms that are present in the washer.
[0005] In an embodiment of the invention, an appliance having an enclosure arranged to receive articles to be treated also includes a water container and a steam chamber with a steam outlet. A water dispenser is arranged to dispense water from the water container to the steam chamber. A heating element is thermally associated with the steam chamber. A control is arranged to selectively operate the heating element. A steam path extends between the steam outlet and the enclosure. A chemical dispenser is positioned along the steam path. The heating element heats water in the steam chamber to create steam, and the chemical dispenser adds a chemical to the steam as the steam passes through the steam path.
BRIEF DESCRIPTION OF THE DRAWING
[0006] FIG. 1 is a perspective view of an automatic washer embodying the principles of the present invention.
[0007] FIG. 2 is a schematic partial view of the interior of one embodiment of the disinfecting unit of the automatic washer of FIG. 1 , consistent with methods and systems embodying the principles of the present invention.
[0008] FIG. 3 is a perspective view of one embodiment of the exterior of the disinfecting unit.
[0009] FIG. 4 is a flow diagram of the steps performed by the disinfecting unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] The present invention is useful in many different types of appliances having a washing or cleaning cycle, such as clothes washers, dish washers, clothes refreshers, dry cleaning appliances, etc., in which various types of articles are to be treated. For the purposes of disclosing an embodiment of the invention, the environment of a clothes washer is used, although the invention is not limited to such an appliance, or to the particular type of clothes washer illustrated.
[0011] In FIG. 1 there is illustrated an appliance in the form of an automatic washer generally at 10 embodying the principles of the present invention. The washer has an outer cabinet 12 with an openable lid 13 which encloses an imperforate wash tub 14 for receiving a supply of wash liquid. Concentrically mounted within the wash tub is a wash basket 16 for receiving a load of materials to be washed and a vertical axis agitator 18 . A motor 20 is provided which is drivingly connected to the agitator 18 to rotatingly drive it in an oscillatory or rotary manner, and is also selectively connectable to the basket 16 for simultaneous rotation with the agitator 18 . The assembly of the tub 14 , wash basket 16 , agitator 18 , and motor 20 is mounted on a suspension system 22 . A plurality of controls 26 are provided on a control console 28 for automatically operating the washer through a series of washing, rinsing, and liquid extracting steps.
[0012] The washer also includes a disinfecting unit 30 , which may be connected to an external water supply via a conduit 32 and to the wash tub 14 , or elsewhere in the enclosure formed by the outer cabinet 12 , via a conduit 34 . The location for the disinfecting unit 30 is only schematically illustrated, and it could actually be located in a variety of different locations in the cabinet 12 , where space permits, or even remote from the cabinet, such as in an adjacent cabinet or appliance. The invention can also be used with clothes washers that do not include a vertical agitator, such as those that agitate by other mechanisms, such as nutating plates, baffles on the basket, etc., as well as horizontal axis washers which provide agitation via tumbling. Other washing or cleaning appliances do not agitate the materials being washed or cleaned, but rather provide sprays or mists of water or other cleaning, washing, refreshing and rinsing fluids.
[0013] FIG. 2 provides the details of the disinfecting unit 30 . The disinfecting unit 30 includes a water container 36 , a heating element 38 , a steam chamber 40 , a chemical or biocide container 42 , and a mixing chamber 44 . The mixing chamber 44 includes a projection which may be in the form of a wire 46 attached to a chemical dispenser 48 . The chemical dispenser 48 may be electrically or mechanically controlled, although a control is not necessary in all embodiments. The water container 36 may be automatically filled via the conduit 32 from an external water supply, such as that used to supply water to other parts of the washer 10 .
[0014] In other embodiments, the water container 36 may include an openable cap 50 ( FIG. 3 ) and the user of the washer may refill the water container manually. The chemical container 42 may also include an openable cap 52 to permit refilling of the chemical. In some embodiments, the chemical container may contain a long term supply, such as a supply that should last for 10 years under normal usage. The chemical container 42 might be a cartridge that is removable and replaceable, with a fresh supply of chemical, separately from the remainder of the disinfecting unit 30 . In still other embodiments, the entire disinfecting unit 30 is removable and replaceable with a fresh unit, so that no refilling is necessary, or so that accessibility for refilling is improved.
[0015] The water container 36 includes a water dispenser 54 , which also may be electrically or mechanically controlled, to cause drops of water to be dispensed into the steam chamber 40 , preferably located below the water container. The heating element 38 is thermally associated with a portion of the steam chamber 40 to heat the water drops that have entered the steam chamber. Although depicted as being at the bottom of the steam chamber 40 , one skilled in the art will recognize that the heating element 38 could be associated with the steam chamber in a number of configurations. For example, the heating element 38 could surround the steam chamber 40 , or it could be located in the center of the chamber. When the heating element 38 is located at the bottom of the steam chamber 40 , the water drops from the water container 36 will fall on a surface 56 heated by the heating element, and will quickly be converted to steam.
[0016] A passageway 58 allows steam to flow along a path from the steam chamber 40 to the mixing chamber 44 . The chemical dispenser 48 allows chemical drops from within the chemical container 42 to flow along the wire 46 into the mixing chamber 44 . These drops will coat a large surface area of the wire 46 , allowing for quick and efficient absorption or adsorption of the chemical by the steam in the mixing chamber 44 . One skilled in the art will recognize that other configurations or arrangements to dispense the chemical into the mixing chamber 46 can be used. For example, the chemical could be a solid that dissolves upon contact with the steam, or the chemical could automatically travel down the wire without the dispenser, like a wick.
[0017] A wide variety of chemicals may be used with the invention, including various pesticides, for example, common EPA registered antimicrobials, such as the full list of “MICROBAN” products. Also, hydrogen peroxide and its variations, silver, copper or zinc ions, chlorine bleach, and in some instances, simply steam.
[0018] The steam chamber 40 may have a collection sump 60 for receiving any condensate from the steam that has not exited the steam chamber. The mixing chamber 44 may have a bottom wall or floor 62 which is sloped downwardly towards the passageway 58 , also to allow condensate, or excess chemical liquid, to flow into the collection sump 60 in the steam chamber 40 . If the disinfecting unit 30 is permanent or refillable, the sump may have an openable drain to allow removal of collected liquids from time to time. Alternatively, a liquid moving mechanism, such as a pump or piston, could be used to redirect the condensate back to the surface 58 heated by the heating element 38 to assure that all of the chemical and water is dispensed with the steam.
[0019] In operation, when a disinfecting cycle is initiated, the water dispenser 54 , operated by a control 61 , permits drops of water to leave the water container 36 and fall into the steam chamber 40 . The heating element 38 , also operated by the control 61 , heats the water in the steam chamber 40 until steam is formed (step 63 , FIG. 4 ). The steam exits through the passageway 58 to enter mixing chamber 44 . The chemical dispenser 48 controllably allows chemical drops to enter the mixing chamber 44 via the wire 46 . The chemical drops are absorbed or adsorbed (depending on the solubility of the chemical in water) by the steam in the mixing chamber 46 , so that the steam becomes impregnated with the chemical (step 64 ). The impregnated steam enters the wash tub 14 through the conduit 34 (step 65 ).
[0020] The heating element 38 continues to heat the water until the temperature in the wash tub 14 reaches a threshold temperature for a given duration (step 66 ). Temperature sensors 70 provided at appropriate locations within the appliance, which communicate with the control 61 , measure the temperature in the region of the wash tub. The threshold temperature may be 65° C., 70° C., 75° C. or higher for durations of 5 minutes, 10 minutes, 15 minutes, or longer to kill the microorganisms. Preferably, the temperature will be elevated to 67-70° C. for 10 minutes, as determined by a clock 74 in the control 61 . With increased temperatures, the duration may be shortened and with decreased temperatures, the duration may be increased. After the threshold temperature is reached for the given duration, the control 61 terminates operation of the heating element 38 to stop the heating of the water (step 76 ) and terminates the dispensing of water and chemical. For some chemicals, such as silver, copper or zinc ions, would allow for ambient temperatures to be used, rather than elevated temperatures for some given period of time.
[0021] The steam impregnated with the chemical is used to thermally and/or chemically kill any microorganisms that exist in the appliance, or to provide other chemical treatment in the appliance, such as scale removal. The steam is able to transport the chemical to areas that are not typically reachable by other means, e.g., by rinsing the washer tub or basket with chemically treated water. In a washer environment, the present invention allows for treatment of the inside and outside of the basket, the tub, the sump, and all of the hoses.
[0022] The bio prevention (or other chemical treatment) cycle can be performed as an automatic cycle by the control operating the washer 10 , such as at the end of each complete wash cycle. Alternatively, or in addition, the bio prevention cycle could be initiated by the user via a manual selection on a control panel of the washer.
[0023] The use of the present invention could also provide for reduced water usage in a wash cycle. The water usage savings could come from the utilization of steam as the vehicle to deliver heat to the wash load, rather than a deep water fill. Less energy would be required to heat a smaller volume of water into steam for the heating, in addition to using less water in the wash cycle.
[0024] As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art. | An appliance having an enclosure arranged to receive articles to be treated also includes a water container and a steam chamber with a steam outlet. A water dispenser is arranged to dispense water from the water container to the steam chamber. A heating element is thermally associated with the steam chamber. A control is arranged to selectively operate the heating element. A steam path extends between the steam outlet and the enclosure. A chemical dispenser is positioned along the steam path. The heating element heats water in the steam chamber to create steam, and the chemical dispenser adds a chemical to the steam as the steam passes through the steam path. | 3 |
This application is a continuation of application Ser. No. 08/302,271, filed Sep. 8, 1994, now abandoned.
FIELD OF THE INVENTION
This invention relates generally to devices which provide electrical surge protection. More particularly, the invention relates to a surge arrestor for an RF electrical device which provides improved performance for wide band RF applications.
BACKGROUND OF THE INVENTION
The proliferation of radio frequency (RF) systems and components have increased greatly in recent years. Cable television systems have introduced RF components into millions of homes, and the number continues to grow every year. RF components have also become much more complex as cable television companies offer an increasing array of services, and consumers continue to demand more features from cable television suppliers such as movies on demand, phone services and other interactive services.
The complexity of the RF devices, such as cable television channel selector units, video cassette recorders and cable-ready televisions, greatly increases the number of electronic components contained within each device. The electronics within RF devices include amplifiers, microprocessors and other semiconductor components. These components are easily damaged when exposed to electrical voltage or current surges from outside sources. RF transmission lines are subject to electrical transients and faults, which may be introduced to the RF devices, causing damage to sensitive electronic components.
Accordingly, protection is needed for the sensitive electronic components within an RF device from damage caused by electrical transients on RF transmission lines and sources.
There are several well known techniques for preventing undesirable electrical surges in RF transmission lines from causing damage to electronic components. One technique is to filter the input by inserting an inductor between the input transmission line and the RF device. The filter suppresses the transient by diverting energy from the RF device, and preventing most of the energy from the transient from reaching the RF device. The magnitude of the transient, although reduced, is still significant enough to cause considerable damage to sensitive electronic components within RF devices.
The use of an inductor as a filter is conventionally enhanced by coupling the inductor with a gas discharge tube. This has been the industry standard for over 30 years. The gas discharge tube greatly increases the ability of the inductor to suppress large electrical transients. However, gas discharge tubes are relatively expensive for this type of application and their service life is limited to only a small number of electrical transients.
Another common surge suppression technique utilized for electronic applications is to buffer the device from the input line with a transformer. Although this provides adequate surge protection, the performance of conventional transformers degrade as the frequency increases. For wide band RF devices, conventional transformer surge suppression is not acceptable since the ferrite core will not carry the RF signal energy from the primary side to the secondary side.
Applicant has recognized that there is a need to develop a more economical electrical surge protection device for wide band RF applications.
SUMMARY OF THE INVENTION
An improved surge arrestor for RF devices is disclosed. The arrestor includes a bifilar conductor pair wound around a ferrite core wherein one end of each conductor is grounded.
The energy of RF signals input to the surge arrestor from an RF transmission line is transferred from the primary windings to the secondary windings through the magnetic and capacitive coupling of the bifilar conductor pair. The signals are then output to the RF device. When an electrical transient or fault causes a surge on the input side of the surge arrestor and the primary windings, the core becomes saturated, thereby limiting the amount of energy transferred to the secondary windings and the RF device. This effectively isolates the secondary side of the surge arrestor from the damaging surge in voltage and prevents the secondary side from conducting the surge to electronic components within the RF device.
Accordingly, it is an object of the present invention to provide an economical means for electrical surge protection of an RF device which supports operation of the RF device over a wide band of RF frequencies.
Further objects and advantages of the invention will become apparent to those of ordinary skill in the art from the following specification and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an RF device coupled to a surge arrestor made in accordance with the teachings of the present invention.
FIG. 2 is a perspective view of the surge arrestor of the present invention.
FIG. 3 is an alternate embodiment of the surge arrestor of FIG. 2.
FIG. 4 is a second alternate embodiment of the surge arrestor of FIG. 2.
FIG. 5 is a third alternate embodiment of the surge arrestor of FIG. 2.
FIG. 6 is an electrical schematic diagram of an RF device including the arrestor of FIG. 2.
FIG. 7 is a prior art surge suppressor utilizing an inductor.
FIG. 8 is a prior art surge suppressor utilizing an inductor coupled with a gas discharge tube.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a surge arrestor 12 for RF devices of the present invention is shown. The surge arrestor 12 is located at the junction between an RF signal generator, or transmission line 14, and an RF device 16 or load. The RF transmission line 14 is the component of the RF system 10 that is typically subject to voltage surges caused by lightning, electrical faults or other electrical transients. The surge arrestor 12 includes an input coaxial interface 18 and an output coaxial interface 20. Preferably, each coaxial interface 18, 20 comprises a standard female RF coaxial connector. The input coaxial interface 18 is coupled to the coaxial interface 20 of the RF transmission line 14, shown as a coaxial cable with a standard male RF coaxial connector. The output coaxial interface 20 is coupled to the coaxial interface 24 of the RF device 16, such as a cable television channel selector unit. The power input 26 to the RF device is connected to a standard 120 VAC power supply. Other RF devices include video cassette recorders and cable-ready television sets. Alternatively, as shown in FIG. 1, the surge arrestor 12 can be combined with a conventional power surge suppressor 13 having a power input lead 25 and at least one outlet 27. The power input 26 of the RF device 16 would then be connected to the power output 27 of the surge suppressor 13.
Referring to FIG. 2, the surge arrestor 12 comprises a bifilar conductor pair 28 forming a coil 30 of primary and secondary windings 32, 34 which is wound around a ferrite core 36. The physical dimensions of the core 36 and the windings 32, 34 are selected to achieve the desired surge suppression and frequency response.
The primary end of the first bifilar conductor 38 is connected to a capacitor 40, preferably 0.001 μF, which is coupled to the inner conductor of the input coaxial interface 18. The capacitor limits the total amount of energy entering the surge arrestor 12. The primary end of the second bifilar conductor 42 is connected to a ground terminal 44. The ground terminal 44 is connected by conductors 46, 48 to the outer conductor, or shield, of both coaxial interfaces 18, 20 respectively.
The secondary end of the first bifilar conductor 50 is connected to the ground terminal 44. The secondary end of the second bifilar conductor 52 is connected the inner conductor of the output coaxial interface 20.
The low frequency performance of the surge arrestor 12 is dependent upon the amount of inductive reactance in the core 36. Energy transfer from the primary windings 32 to the secondary windings 34 is dependent upon the frequency of the input RF signals. For frequencies above 100 MHz, the core 32 appears as though it is electrically isolated. Therefore, energy transfer is accomplished primarily through the magnetic coupling of the primary windings 32 to the secondary windings 34. Below 10 MHz, most of the energy transfer occurs through the magnetic coupling of the windings 32, 34 through the core 36. Therefore, the low frequency energy from the RF signals in the primary windings 32 must pass through the core 36 before entering the secondary windings 34. From 10-100 MHz energy is transferred through both types of magnetic coupling, however, the transfer of energy from the core 36 steadily decreases as the frequency of the RF signals approaches 100 MHz.
In operation, RF signals transmitted over the RF transmission line 14 are input to the surge arrestor 12 through the coaxial coupling 18 and enter the primary end of the first bifilar conductor 38. Through magnetic and capacitive coupling, energy from the RF signals on the primary windings 32 is transferred to the secondary windings 34. Since the turns ratio is 1:1, the RF signals are unchanged. The RF signals on the secondary windings 34 flow via the secondary end of the second bifilar conductor 52 to the inner conductor of the output coaxial interface 48.
When a transient on the RF transmission line 14 causes a voltage surge, the surge travels to the primary windings 32. Since the frequency of most transients that occur on RF systems is below 10 MHz, energy transfer of the transients is primarily dependent upon the magnetic coupling of the core 36 to the windings 32, 34. The voltage transient will quickly saturate the core 36, thereby limiting the amount of energy transferred through the core 36 to the secondary windings 34. Accordingly, the secondary windings 34 will be isolated from most of the voltage surge, thereby protecting the electronic components in the RF device 16 from damage.
In a preferred embodiment, the core 36 is substantially cylindrical in shape with a 5 mm diameter, a 3 mm core void diameter and a 5 mm length. A bifilar conductor pair 36 with an impedance of 75Ω is used, and there are approximately seven turns of the conductor pair 36 comprising the windings 32, 34. This results in core saturation with a transient voltage of greater than 100 volts, which is sufficient to provide isolation of the sensitive electronic components within the RF device 16 from the electrical transient. Preferably, the surge arrestor 12 permits an operational bandwidth of 4-250 MHz. This supports the desired operational bandwidth of 5-200 MHz.
FIG. 3 is an alternate embodiment of the invention wherein the core 54 is shaped substantially similar to a toroid upon which the bifilar conductor pair 56 is wound. FIG. 4 is a second alternate embodiment of the invention wherein a twisted conductor pair 58 is utilized in place of the bifilar conductor pair. FIG. 5 is a third alternate embodiment wherein a bifilar conductor pair 60 is wound around the outer circumference of the core 62.
Although the surge arrestor 12 is shown as an auxiliary device for use with pre-existing RF devices, it can easily be built into the RF device when new RF devices are manufactured. Such a device is shown in FIG. 6 wherein the surge arrestor 12 is incorporated into an RF amplifier 64. In these cases, the input of the surge arrestor 12 would constitute the input of the RF device.
The amplifier electronics 68, are buffered from electrical transients occurring on the RF input 66 by the surge arrestor 12. This allows the amplifier 64 to provide an RF output 70 free from damaging electrical transients to an RF device 72.
Comparative tests were conducted between the inventive surge arrestor 12 and conventional surge suppressors schematically represented in FIGS. 7 and 8. The test results reflect a dramatic gain in surge protection of the inventive surge arrestor 12 over the prior art. As shown in FIG. 7, a conventional filter 74 comprises an inductor 76 inserted between the RF input line 78 and the load 80. The filter 74 was subjected in tests to a 3000 volt surge at the RF input 78. The surge was reduced to approximately 1112 volts across the load 80. A subsequent surge of 6000 volts vaporized the load 80. The magnitude of the voltage, although reduced, is significant enough to cause considerable damage to electronic components in RF devices.
As shown in FIG. 8, a conventional surge arrestor 82 which is in widespread industry use comprises a filter enhanced with a gas discharge tube 82. The suppressor 82 was subjected in tests to a 6000 volt surge at the RF input 81. The input voltage surge was reduced to 294 volts at the load 80.
By way of comparison, the preferred embodiment of the present invention was subjected in similar tests to a 6000 volt surge. The surge was reduced to a maximum voltage of 116 volts.
The preferred embodiment of the present invention costs approximately 1/10 of the cost of an equivalent conventional filter coupled with a gas discharge tube. This represents a significant improvement in performance over the prior art devices at a fraction of the cost.
The invention has been described in conjunction with a presently preferred embodiment and alternate embodiments. Other variations with respect to the embodiments described above will be apparent to those of ordinary skill in the art and are within the scope of the present invention. | An improved surge arrestor for RF devices includes a bifilar conductor pair wound around a ferrite core wherein one end of each conductor is grounded. The energy of RF signals input to the surge arrestor from an RF transmission line is transferred from the primary windings to the secondary windings through the magnetic coupling. When an electrical transient or fault causes a surge on the input or primary side of the surge arrestor, the core becomes saturated, thereby limiting the amount of energy transferred to the secondary windings and the RF device. This effectively isolates the secondary side of the surge arrestor from the damaging surge in voltage and prevents the secondary side from conducting the surge to electronic components within the RF device. | 7 |
[0001] This application claims the priority benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/399,458, filed Jul. 31, 2002, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention is in the field of medicinal chemistry. In particular, the invention relates to novel aryl substituted benzimidazoles, and the discovery that these compounds are blockers of sodium (Na + ) channels.
[0004] 2. Related Art
[0005] Several classes of therapeutically useful drugs, including local anesthetics such as lidocaine and bupivacaine, antiarrhythmics such as propafenone and amioclarone, and anticonvulsants such as lamotrigine, phenyloin and carbamazepine, have been shown to share a common mechanism of action by blocking or modulating Na + channel activity (Catterall, W. A., Trends Pharmacol. Sci. 8:57-65 (1987)). Each of these agents is believed to act by interfering with the rapid influx of Na + ions.
[0006] Recently, other Na + channel blockers such as BW619C89 and lifarizine have been shown to be neuroprotective in animal models of global and focal ischemia and are presently in clinical trials (Graham et al., J. Pharmacol. Exp. Ther. 269:854-859 (1994); Brown et al., British J. Pharmacol. 115:1425-1432 (1995)).
[0007] The neuroprotective activity of Na + channel blockers is due to their effectiveness in decreasing extracellular glutamate concentration during ischemia by inhibiting the release of this excitotoxic amino acid neurotransmitter. Studies have shown that unlike glutamate receptor antagonists, Na + channel blockers prevent hypoxic damage to mammalian white matter (Stys et al., J. Neurosci. 12:430-439 (1992)). Thus, they can offer advantages for treating certain types of strokes or neuronal trauma where damage to white matter tracts is prominent.
[0008] Another example of clinical use of a Na + channel blocker is riluzole. This drug has been shown to prolong survival in a subset of patients with ALS (Bensimm et al., New Engl. J. Med. 330:585-591 (1994)) and has subsequently been approved by the FDA for the treatment of ALS. In addition to the above-mentioned clinical uses, carbamazepine, lidocaine and phenyloin are occasionally used to treat neuropathic pain, such as from trigeminal neurologia, diabetic neuropathy and other forms of nerve damage (Taylor and Meldrum, Trends Pharmacol. Sci. 16:309-316 (1995)), and carbamazepine and lamotrigine have been used for the treatment of manic depression (Denicott et al., J. Clin. Psychiatry 55:70-76 (1994)). Furthermore, based on a number of similarities between chronic pain and tinnitus, (Moller, A. R. Am. J. 0 to 1. 18:577-585 (1997); Tonndorf, J. Hear. Res. 28:271-275 (1987)) it has been proposed that tinnitus should be viewed as a form of chronic pain sensation (Simpson, J. J. and Davies, E. W. Tips. 20:12-18 (1999)). Indeed, lignocaine and carbamazepine have been shown to be efficacious in treating tinnitus (Majumdar, B. et al. Clin. Otolaryngol. 8:175-180 (1983); Donaldson, I. Laryngol. Otol. 95:947-951 (1981)).
[0009] It has been established that there are at least five to six sites on the voltage-sensitive Na + channels which bind neurotoxins specifically (Catterall, W. A., Science 242:50-61 (1988)). Studies have further revealed that therapeutic antiarrhythmics, anticonvulsants and local anesthetics whose actions are mediated by Na + channels, exert their action by interacting with the intracellular side of the Na + channel and allosterically inhibiting interaction with neurotoxin receptor site 2 (Catterall, W. A., Ann. Rev. Pharmacol. Toxicol. 10:15-43 (1980)).
[0010] A need exists in the art for novel compounds that are potent blockers of sodium channels, and are therefore useful for treating a variety of central nervous system conditions, including pain.
SUMMARY OF THE INVENTION
[0011] One aspect of the present invention is directed to novel aryl substituted benzimidazoles of Formula I.
[0012] The present invention is also related to the discovery that aryl substituted benzimidazoles of Formula I act as blockers of sodium (Na + ) channels.
[0013] Another aspect of the present invention is directed to the use of novel compounds of Formula I as blockers of sodium channels.
[0014] The invention is also related with treating a disorder responsive to the blockade of sodium channels in a mammal suffering from excess activity of said channels by administering an effective amount of a compound of Formula I as described herein.
[0015] A further aspect of the present invention is to provide a method for treating, preventing or ameliorating neuronal loss following global and focal ischemia; treating, preventing or ameliorating pain including acute and chronic pain, and neuropathic pain; treating, preventing or ameliorating convulsion and neurodegenerative conditions; treating, preventing or ameliorating manic depression; using as local anesthetics and anti-arrhythmics, and treating tinnitus by administering a compound of Formula I to a mammal in need of such treatment or use.
[0016] Also, an aspect of the present invention is to provide a pharmaceutical composition useful for treating disorders responsive to the blockade of sodium ion channels, containing an effective amount of a compound of Formula I in a mixture with one or more pharmaceutically acceptable carriers or diluents.
[0017] Additional embodiments and advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or can be learned by practice of the invention. The embodiments and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
[0018] 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.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Novel compounds of the present invention are aryl substituted benzimidazoles of Formula I:
[0020] or a pharmaceutically acceptable salt, or solvate thereof, wherein:
[0021] R 1 is selected from the group consisting of:
[0022] where
[0023] Y is an optionally substituted C 2-6 alkylene, and
[0024] R 3 and R 4 are the same or different and are selected from hydrogen, alkyl, or aryl, or R 3 and R 4 together with the nitrogen to which they are attached form a ring having 4 or 5 carbon atoms, which ring optionally contains 1 or 2 additional heteroatoms independently selected from oxygen and NR 5 , where R 5 is hydrogen or alkyl, or said ring is optionally substituted with an alkyl or aryl moiety;
[0025] (ii) pyridylalkyl; and
[0026] (iii) piperidin-4-ylalkyl, optionally substituted by alkyl, aryl or aralkyl;
[0027] R 2 is selected from the group consisting of:
[0028] (i) optionally substituted phenoxyphenyl;
[0029] (ii) optionally substituted benzyloxyphenyl;
[0030] (iii) optionally substituted phenylthiophenyl;
[0031] (iv) optionally substituted benzylthiophenyl;
[0032] (v) optionally substituted phenylaminophenyl;
[0033] (vi) optionally substituted benzylaminophenyl;
[0034] wherein R 6 and R 7 are independently halogen, alkyl, alkoxy, or haloalkyl; and p and q are integers from 0 to 4;
[0035] wherein R 8 is hydrogen, halogen, alkyl or alkoxy;
[0036] wherein R 9 is hydrogen or alkyl; and
[0037] (x) naphthyl;
[0038] R 10 is selected from halogen, hydroxy, alkyl, alkoxy and alkoxyalkyl, wherein any alkyl moiety of R 10 can be optionally substituted by one or more of halogen or hydroxy; and
[0039] n is an integer from 0 to 4, where when n is 0, R 10 is absent and the benzene ring of the benzimidazole compound has four hydrogen atoms attached thereto, and when R 10 is present, R 10 replaces one or more of the available hydrogen atoms on the benzene ring of the benzimidazole compound.
[0040] Preferred compounds of Formula I are those wherein R 2 is phenoxyphenyl or benzyloxyphenyl, wherein the phenyl group of the phenoxy or benzyloxy moiety is optionally substituted with alkyl, alkoxy, halogen or haloalkyl. Preferred substituents include one to three, preferably one or two, substituents independently selected from the group consisting of C 1-4 alkyl, C 1-4 alkoxy, halogen, and C 1-4 haloalkyl. Suitable values of R 2 in this embodiment of the invention include (3-phenoxy)phenyl, (4-phenoxy)phenyl, (3-benzyloxy)phenyl, or (4-benzyloxy)phenyl, any of which is optionally substituted by one, two or three groups independently selected from the group consisting of fluoro, chloro, bromo, methyl, ethyl, propyl, isopropyl, methoxy, ethoxy, fluoromethyl, and trifluormethyl.
[0041] Preferred compounds of Formula I are those wherein R 2 is optionally substituted phenoxyphenyl or optionally substituted benzyloxyphenyl; R 3 and R 4 together with the nitrogen to which they are attached form a piperidinyl, morpholinyl or pyrrolidinyl group; and Y is an optionally substituted C 2-6 alkylene chain.
[0042] Preferred compounds of Formula I are also those wherein R 2 is optionally substituted phenoxyphenyl or optionally substituted benzyloxyphenyl; and R 3 and R 4 are independently hydrogen, alkyl or aryl; and Y is an optionally substituted C 2-6 alkylene chain.
[0043] Preferred compounds are those of Formula I wherein R 2 is
[0044] where R 6 and R 7 are independently alkyl, alkoxy, halogen, or haloalkyl, and p and q are independently 0-4, preferably 0, 1 or 2. When R 6 and/or R 7 is present, these groups substitute for hydrogen atoms at any available position on the phenyl to which they are attached. Preferably, R 6 and R 7 are independently C 1-4 alkyl, C 1-4 alkoxy, halogen, or C 1-4 haloalkyl. Useful values of R 6 and R 7 include fluoro, chloro, bromo, methyl, ethyl, propyl, isopropyl, methoxy, ethoxy, fluoromethyl, and trifluormethyl.
[0045] Additionally, preferred compounds are those of Formula I wherein R 2 is
[0046] where R 8 is as defined above, and is preferably hydrogen or C 1-4 alkyl, such as methyl, ethyl, propyl and isopropyl. R 8 replaces a hydrogen atom at any available position on the phenyl ring.
[0047] Additionally, preferred compounds are those of Formula I wherein R 2 is
[0048] where R 9 is as defined above, and is preferably hydrogen or C 1-4 alkyl, such as methyl, ethyl, propyl and isopropyl.
[0049] Preferred compounds also are those of Formula I wherein R 2 is naphthalyl.
[0050] Further, additionally preferred compounds of Formula I are those wherein when R 2 is phenoxyphenyl or the benzyloxyphenyl, R 2 is attached to the benzimidazole at the 3- or 4-position of the phenyl component of the phenoxyphenyl or the benzyloxyphenyl.
[0051] Preferred compounds also are those of Formula I wherein R 1 is
[0052] where R 3 and R 4 are defined above.
[0053] Still, additionally preferred compounds of Formula I are those wherein R 1 is —Y—NR 3 R 4 , where Y is an optionally substituted C 2-6 alkylene and R 3 and R 4 together with the nitrogen to which they are attached form a piperidinyl, morpholinyl or pyrrolidinyl group.
[0054] Other preferred compounds of Formula I are those wherein Y is an optionally substituted C 2-6 alkylene; and R 3 and R 4 are the same or different and are selected from hydrogen, C 1-6 alkyl, and C 6-10 aryl.
[0055] For purposes of the present invention, the term “alkylene” has the meaning —(CH 2 ) m —, where m is an integer of from 1-6, preferably 2-4. Suitable alkylene chains include but are not limited to methylene, ethylene, propylene, butylene, pentylene and hexylene. The alkylene chain can also be optionally substituted.
[0056] Additionally preferred compounds of Formula I are those wherein R 1 is pyridylalkyl.
[0057] Preferred compounds of Formula I are also those wherein R 1 is piperidin-4-ylalkyl, optionally substituted by C 1-6 alkyl, C 6-10 aryl or C 6-10 ar(C 1-6 )alkyl.
[0058] The term “alkyl,” when not further defined, means a linear or branched C 1-10 carbon chain, preferably a C 1-6 carbon chain. Suitable alkyl groups include, but are not limited to, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tert-butyl, 3-pentyl, hexyl and octyl groups.
[0059] The term “optionally substituted,” when not further defined, means replacement of one or more carbon-attached hydrogens with halogen, halo(C 1-6 )alkyl, aryl, heterocycle, cycloalkyl, C 1-6 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, aryl(C 1-6 )alkyl, aryl(C 2-6 )alkenyl, aryl(C 2-6 )alkynyl, cycloalkyl(C 1-6 )alkyl, heterocyclo(C 1-6 alkyl), hydroxy(C 1-6 )alkyl, amino(C 1-6 )alkyl, carboxy(C 1-6 ) alkyl, alkyloxy(C 1-6 )alkyl, nitro, amino, ureido, cyano, acylamino, hydroxy, thiol, acyloxy, azido, alkyloxy, carboxy, aminocarbonyl, and C 1-6 alkylthiol. Preferred “optionally substituted alkyl” include aryl and halogen.
[0060] The term “optionally substituted alkylene chain,” when not further defined, means replacement of an alkylene hydrogen with one or more alkyl groups, aryl groups and halogen atoms. Preferred “optionally substituted alkylene chain” include alkyl groups and halogen atoms, preferably alkyl groups.
[0061] The term “aryl,” when not further defined, means a C 6-14 mono- or polycyclic aromatic ring system. Suitable carbocyclic aryl groups include, but are not limited to, phenyl, naphthyl, phenanthryl, anthracyl, indenyl, azulenyl, biphenyl, biphenylenyl and fluorenyl groups. Particularly preferred carbocyclic aryl groups are phenyl and naphthyl.
[0062] Exemplary compounds that can be employed in this method of invention include, without limitation:
[0063] 3-(2-piperidinylethyl)-2-(4-phenoxyphenyl)benzimidazole;
[0064] 3-(2-piperidinylethyl)-2-(3-(4-tert-butylphenoxy)phenyl)benzimidazole;
[0065] 3-(2-piperidinylethyl)-2-(3-(3,4-dichlorophenoxy)phenyl)benzimidazole;
[0066] 3-(2-piperidinylethyl)-2-(2,2-diphenylethenyl)benzimidazole;
[0067] 3-(2-piperidinylethyl)-2-(3-phenoxyphenyl)benzimidazole;
[0068] 3-(2-piperidinylethyl)-2-(3-(3-trifluoromethylphenoxy)phenyl)benzimidazole;
[0069] 3-(2-piperidinylethyl)-2-(N-ethyl-3-carbazolyl)benzimidazole;
[0070] 3-(2-piperidinylethyl)-2-(3-benzyloxyphenyl)benzimidazole; and
[0071] 3-(2-piperidinylethyl)-2-(4-(4-fluorophenoxy)phenyl)benzimidazole;
[0072] as well as pharmaceutically acceptable salts thereof.
[0073] Particularly preferred compounds are selected from:
[0074] 3-(2-piperidinylethyl)-2-(4-phenoxyphenyl)benzimidazole;
[0075] 3-(2-piperidinylethyl)-2-(3-(4-tert-butylphenoxy)phenyl)benzimidazole;
[0076] 3-(2-piperidinylethyl)-2-(3-(3,4-dichlorophenoxy)phenyl)benzimidazole;
[0077] 3-(2-piperidinylethyl)-2-(2,2-diphenylethenyl)benzimidazole;
[0078] 3-(2-piperidinylethyl)-2-(3-phenoxyphenyl)benzimidazole;
[0079] 3-(2-piperidinylethyl)-2-(3-(3-trifluoromethylphenoxy)phenyl)benzimidazole;
[0080] 3-(2-piperidinylethyl)-2-(3-benzyloxyphenyl)benzimidazole; and
[0081] 3-(2-piperidinylethyl)-2-(4-(4-fluorophenoxy)phenyl)benzimidazole;
[0082] as well as pharmaceutically acceptable salts thereof.
[0083] The invention disclosed herein is meant to encompass all pharmaceutically acceptable salts thereof of the disclosed compounds. The pharmaceutically acceptable salts include, but are not limited to, metal salts such as sodium salt, potassium salt, cesium salt and the like; alkaline earth metals such as calcium salt, magnesium salt and the like; organic amine salts such as triethylamine salt, pyridine salt, picoline salt, ethanolamine salt, triethanolamine salt, dicyclohexylamine salt, N,N′-dibenzylethylenediamine salt and the like; inorganic acid salts such as hydrochloride, hydrobromide, sulfate, phosphate and the like; organic acid salts such as formate, acetate, trifluoroacetate, maleate, tartrate and the like; sulfonates such as methanesulfonate, benzenesulfonate, p-toluenesulfonate, and the like; amino acid salts such as arginate, asparginate, glutamate and the like.
[0084] The invention disclosed herein is also meant to encompass prodrugs of the disclosed compounds. Prodrugs are considered to be any covalently bonded carrier which releases the active parent drug in vivo.
[0085] The invention disclosed herein is also meant to encompass the in vivo metabolic products of the disclosed compounds. Such products can result for example from the oxidation, reduction, hydrolysis, amidation, esterification and the like of the administered compound, primarily due to enzymatic processes. Accordingly, the invention includes compounds produced by a process comprising contacting a compound of this invention with a mammal for a period of time sufficient to yield a metabolic product thereof. Such products typically are identified by preparing a radiolabelled compound of the invention, administering it parenterally in a detectable dose to an animal such as rat, mouse, guinea pig, monkey, or to man, allowing sufficient time for metabolism to occur and isolating its conversion products from the urine, blood or other biological samples.
[0086] The invention disclosed herein is also meant to encompass the disclosed compounds being isotopically-labelled by having one or more atoms replaced by an atom having a different atomic mass or mass number. Examples of isotopes that can be incorporated into the disclosed compounds include isotopes of hydrogen, carbon, nitrogen, oxygen, phosphorous, fluorine and chlorine, such as 2 H, 3 H, 13 C, 14 C, 15 N, 18 O, 17 O, 31 P, 32 P, 35 S, 18 F, and 36 Cl, respectively.
[0087] Some of the compounds disclosed herein can contain one or more asymmetric centers and can thus give rise to enantiomers, diastereomers, and other stereoisomeric forms. The present invention is also meant to encompass all such possible forms as well as their racemic and resolved forms and mixtures thereof. When the compounds described herein contain olefinic double bonds or other centers of geometric asymmetry, and unless specified otherwise, it is intended to include both E and Z geometric isomers. All tautomers are intended to be encompassed by the present invention as well.
[0088] As used herein, the term “stereoisomers” is a general term for all isomers of individual molecules that differ only in the orientation of their atoms in space. It includes enantiomers and isomers of compounds with more than one chiral center that are not mirror images of one another (diastereomers).
[0089] The term “chiral center” refers to a carbon atom to which four different groups are attached.
[0090] The term “enantiomer” or “enantiomeric” refers to a molecule that is nonsuperimposeable on its mirror image and hence optically active wherein the enantiomer rotates the plane of polarized light in one direction and its mirror image rotates the plane of polarized light in the opposite direction.
[0091] The term “racemic” refers to a mixture of equal parts of enantiomers and which is optically inactive.
[0092] The term “resolution” refers to the separation or concentration or depletion of one of the two enantiomeric forms of a molecule. The phrase “enantiomeric excess” refers to a mixture wherein one enantiomer is present is a greater concentration than its mirror image molecule.
[0093] The benzimidazoles of Formula I can be prepared using methods known to those skilled in the art. Specifically, the benzimidazoles of the present invention are generally obtained from a method comprising:
[0094] (a) reacting a primary amine with 2-fluoro-1-nitrobenzene to produce an amine substituted nitrobenzene;
[0095] (b) reducing said amine substituted nitrobenzene obtained in (a) in the presence of hydrogen and a catalyst to produce an amine substituted aniline; and
[0096] (c) reacting said amine substituted aniline obtained in step (b), with an aldehyde to produce a substituted benzimidazole of Formula
[0097] For this method, the primary amine in step (a) is selected from the groups consisting of:
[0098] wherein
[0099] Y is an optionally substituted C 2-6 alkylene; and
[0100] R 3 and R 4 are the same or different and are selected from hydrogen, alkyl, or aryl, or R 3 and R 4 together with the nitrogen to which they are attached form a ring having 4 or 5 carbon atoms, which ring optionally contains 1 or 2 additional heteroatoms independently selected from oxygen and NR 5 , where R 5 is hydrogen or alkyl, or said ring is optionally substituted with an alkyl or aryl moiety;
[0101] (ii) pyridylalkyl amine; and
[0102] (iii) an optionally substituted piperidin-4-ylalkyl amine, wherein optional substituents are selected from the group consisting of alkyl, aryl or aralkyl. Preferred values of Y, R 3 and R 4 are as described above.
[0103] Additionally, for this method, the aldehyde in (c) has the formula:
[0104] wherein R 2 is as defined above.
[0105] The reaction time for steps (a) and (b) above, is generally between about 14 to about 17 hours and results in yields of greater than 90%. The reaction time for step (c) is about 45 to about 50 hours and results in product yields of from about 60 to about 95%.
[0106] The reduction of step (b) is generally carried out at a pressure of about 2 to about 4 atms, preferably about 3 atms.
[0107] The general method of making benzimidazoles of the present invention is shown in the following reaction scheme.
[0108] Reagents/Reaction Times: (a) 5% DIEA/DMF, 14-17 hrs; (b) Pd/C, H 2 , 3 atm, MeOH, 16 hrs; (c) aldehyde, PhNO 2 , 100° C., 45-50 hrs.
[0109] The invention is also directed to a method for treating disorders responsive to the blockade of sodium channels in mammals suffering therefrom. The benzimidazole compounds of the invention can be used to treat humans or companion animals, such as dogs and cats. Particular preferred embodiments of the benzimidazoles of the invention for use in treating such disorders are represented as previously defined for Formula I.
[0110] The compounds of the present invention are assessed by electrophysiological assays in dissociated hippocampal neurons for sodium channel blocker activity. These compounds also can be assayed for binding to the neuronal voltage-dependent sodium channel using rat forebrain membranes and [ 3 H]BTX-B.
[0111] Sodium channels are large transmembrane proteins that are expressed in various tissues. They are voltage sensitive channels and are responsible for the rapid increase of Na + permeability in response to depolarization associated with the action potential in many excitable cells including muscle, nerve and cardiac cells.
[0112] One aspect of the present invention is the discovery of the mechanism of action of the compounds herein described as specific Na + channel blockers. Based upon the discovery of this mechanism, these compounds are contemplated to be useful in treating or preventing neuronal loss due to focal or global ischemia, and in treating or preventing neurodegenerative disorders including ALS, depression, and epilepsy. They are also expected to be effective in treating, preventing or ameliorating neuropathic pain, surgical pain, chronic pain and tinnitus. The compounds are also expected to be useful as antiarrhythmics, anesthetics and antimanic depressants.
[0113] The present invention is directed to compounds of Formula I that are blockers of voltage-sensitive sodium channels. According to the present invention, those compounds having preferred sodium channel blocking properties exhibit an IC 50 of about 100 μM or less in the electrophysiological assay described herein. Preferably, the compounds of the present invention exhibit an IC 50 of 10 μM or less. Most preferably, the compounds of the present invention exhibit an IC 50 of about 1.0 μM or less. Compounds of the present invention can be tested for their Na + channel blocking activity by the following binding and electrophysiological assays.
[0114] In Vitro Binding Assay:
[0115] The ability of compounds of the present invention to modulate either site 1 or site 2 of the Na + channel was determined following the procedures fully described in Yasushi, J. Biol. Chem. 261:6149-6152 (1986) and Creveling, Mol. Pharmacol. 23:350-358 (1983), respectively. Rat forebrain membranes are used as sources of Na + channel proteins. The binding assays are conducted in 130 μM choline chloride at 37° C. for 60-minute incubation with [ 3 H] saxitoxin and [ 3 H] batrachotoxin as radioligands for site 1 and site 2, respectively.
[0116] In Vivo Pharmacology:
[0117] The compounds of the present invention can be tested for in vivo anticonvulsant activity after i.v., p.o. or i.p. injection using a number of anticonvulsant tests in mice, including the maximum electroshock seizure test (MES). Maximum electroshock seizures are induced in male NSA mice weighing between 15-20 g and male Sprague-Dawley rats weighing between 200-225 g by application of current (50 mA, 60 pulses/sec, 0.8 msec pulse width, 1 sec duration, D.C., mice; 99 mA, 125 pulses/sec, 0.8 msec pulse width, 2 sec duration, D.C., rats) using a Ugo Basile ECT device (Model 7801). Mice are restrained by gripping the loose skin on their dorsal surface and saline-coated corneal electrodes were held lightly against the two corneae. Rats are allowed free movement on the bench top and ear-clip electrodes are used. Current is applied and animals are observed for a period of up to 30 seconds for the occurrence of a tonic hindlimb extensor response. A tonic seizure is defined as a hindlimb extension in excess of 90 degrees from the plane of the body. Results are treated in a quantal manner.
[0118] The compounds can be tested for their antinociceptive activity in the formalin model as described in Hunskaar, S., O. B. Fasmer, and K. Hole, J. Neurosci. Methods 14: 69-76 (1985). Male Swiss Webster NIH mice (20-30 g; Harlan, San Diego, Calif.) are used in all experiments. Food is withdrawn on the day of experiment. Mice are placed in Plexiglass jars for at least 1 hour to accommodate to the environment. Following the accommodation period mice are weighed and given either the compound of interest administered i.p. or p.o., or the appropriate volume of vehicle (10% Tween-80). Fifteen minutes after the i.p. dosing, and 30 minutes after the p.o. dosing mice are injected with formalin (20 μL of 5% formaldehyde solution in saline) into the dorsal surface of the right hind paw. Mice are transferred to the Plexiglass jars and monitored for the amount of time spent licking or biting the injected paw. Periods of licking and biting are recorded in 5 minute intervals for 1 hour after the formalin injection. All experiments are done in a blinded manner during the light cycle. The early phase of the formalin response is measured as licking/biting between 0-5 minutes, and the late phase is measured from 15-50 minutes. Differences between vehicle and drug treated groups are analyzed by one-way analysis of variance (ANOVA). A P value <0.05 is considered significant. Activity in blocking the acute and second phase of formalin-induced paw-licking activity is indicative that compounds are considered to be efficacious for acute and chronic pain.
[0119] The compounds can be tested for their potential for the treatment of chronic pain (antiallodynic and antihyperalgesic activities) in the Chung model of peripheral neuropathy. Male Sprague-Dawley rats weighing between 200-225 g are anesthetized with halothane (1-3% in a mixture of 70% air and 30% oxygen) and their body temperature is controlled during anesthesia through use of a homeothermic blanket. A 2-cm dorsal midline incision is then made at the L5 and L6 level and the para-vertibral muscle groups retracted bilaterally. L5 and L6 spinal nerves are then be exposed, isolated, and tightly ligated with 6-0 silk suture. A sham operation is performed exposing the contralateral L5 and L6 spinal nerves as a negative control.
[0120] Tactile Allodynia: Rats are transferred to an elevated testing cage with a wire mesh floor and allowed to acclimate for five to ten minutes. A series of Semmes-Weinstein monofilaments are applied to the plantar surface of the hindpaw to determine the animal's withdrawal threshold. The first filament used possesses a buckling weight of 9.1 g (0.96 log value) and is applied up to five times to see if it elicited a withdrawal response. If the animal has a withdrawal response then the next lightest filament in the series is applied up to five times to determine if it can elicit a response. This procedure is repeated with subsequent less filaments until there is no response and the lightest filament that elicits a response is recorded. If the animal does not have a withdrawal response from the initial 9.1 g filament then subsequent filaments of increased weight are applied until a filament elicits a response and this filament is then recorded. For each animal, three measurements are made at every time point to produce an average withdrawal threshold determination. Tests are performed prior to and at 1, 2, 4 and 24 hours post drug administration. Tactile allodynia and mechanical hyperalgesia tests were conducted concurrently.
[0121] Mechanical Hyperalgesia: Rats are transferred to an elevated testing cage with a wire mesh floor and allowed to acclimate for five to ten minutes. A slightly blunted needle is touched to the plantar surface of the hindpaw causing a dimpling of the skin without penetrating the skin. Administration of the needle to control paws typically produces a quick flinching reaction, too short to be timed with a stopwatch and arbitrarily gives a withdrawal time of 0.5 second. The operated side paw of neuropathic animals exhibits an exaggerated withdrawal response to the blunted needle. A maximum withdrawal time of ten seconds is used as a cutoff time. Withdrawal times for both paws of the animals are measured three times at each time point with a five-minute recovery period between applications. The three measures are used to generate an average withdrawal time for each time point. Tactile allodynia and mechanical hyperalgesia tests are conducted concurrently.
[0122] The compounds can be tested for their neuroprotective activity after focal and global ischemia produced in rats or gerbils according to the procedures described in Buchan et al. (Stroke, Suppl. 148-152 (1993)) and Sheardown et al. (Eur. J. Pharmacol. 236:347-353 (1993)) and Graham et al. (J. Pharmacol. Exp. Therap. 276:1-4 (1996)).
[0123] The compounds can be tested for their neuroprotective activity after traumatic spinal cord injury according to the procedures described in Wrathall et al. (Exp. Neurology 137:119-126 (1996)) and Iwasaki et al. (J. Neuro Sci. 134:21-25 (1995)).
[0124] Electrophysiological Assay:
[0125] An electrophysiological assay was used to measure potencies of compounds of the present invention rBIIa/beta 1 sodium channels expressed in Xenopus oocytes.
[0126] Preparation of cDNA encoding cloned rat brain type IIa (rBIIa) and beta 1 (β1): cDNA clones encoding the rat brain beta 1 subunit are cloned in house using standard methods, and mRNA are prepared by standard methods. mRNA encoding rBIIa is provided by Dr. A. Golden (UC Irvine). The mRNAs are diluted and stored at −80° C. in 1 μL aliquots until injection.
[0127] Preparation of oocytes: Mature female Xenopus laevis are anaesthetized (20-40 min) using 0.15% 3-aminobenzoic acid ethyl ester (MS-222) following established procedures (Woodward, R. M., et al., Mol. Pharmacol. 41:89-103 (1992)).
[0128] Two to six ovarian lobes are surgically removed. Oocytes at developmental stages V-VI are dissected from the ovary, wherein the oocytes are still surrounded by enveloping ovarian tissues. Oocytes are defolliculated on the day of surgery by treatment with collagenase (0.5 mg/mL Sigma Type I, or Boehringer Mannheim Type A, for 0.5-1 hr). Treated oocytes are vortexed to dislodge epithelia, washed repeatedly and stored in Barth's medium containing 88 mM NaCl, 1 mM KCl, 0.41 mM CaCl 2 , 0.33 mM Ca(NO 3 ) 2 , 0.82 mM MgSO 4 , 2.4 mM NaHCO 3 , 5 mM HEPES, pH 7.4 adjusted with 0.1 mg/mL gentamycin sulphate.
[0129] Micro-injection of oocytes: Defolliculated oocytes are micro-injected using a Nanoject injection system (Drummond Scientific Co., Broomall, Pa.). Injection pipettes are beveled to minimize clogging. Tip diameter of injection pipettes is 15-35 μm. Oocytes are microinjected with approximately 50 nL 1:10 ratio mixtures of cRNAs for rBIIa and beta 1 respectively.
[0130] Electrophysiology: Membrane current responses are recorded in frog Ringer solution containing 115 mM NaCl, 2 mM KCl, 1.8 mM CaCl 2 , 5 mM HEPES, pH 7.4. Electrical recordings are made using a conventional two-electrode voltage clamp (Dagan TEV-200) over periods ranging between 1-7 days following injection. The recording chamber is a simple gravity fed flow-through chamber (volume 100-500 mL depending on adjustment of aspirator). Oocytes are placed in the recording chamber, impaled with electrodes and continuously perfused (5-15 mL min −1 ) with frog Ringer's solution. The tested compounds are applied by bath perfusion.
[0131] Voltage protocols for evoking sodium channel currents: The standard holding potential for whole oocyte clamp is −120 mV. Standard current-voltage relationships are elicited by 40 ms depolarizing steps starting from −60 mV to +50 mV in 10 mV increments. Peak currents are measured as the maximum negative current after depolarizing voltage steps. The voltage from maximum current response is noted and used for the next voltage protocol.
[0132] The purpose is to find compounds that are state dependent modifiers of neuronal sodium channels. Preferably, the compounds have a low affinity for the rested/closed state of the channel, but a high affinity for the inactivated state. The following voltage protocol is used to measure a compounds affinity for the inactivated state. Oocytes are held at a holding potential of −120 mV. At this membrane voltage, nearly all of the channels are in the closed state. Then a 4 second depolarization is made to the voltage where the maximum current is elicited. At the end of this depolarization, nearly all the channels are in the inactivated state. A 10 ms hyperpolarizing step is then made in order to remove some channels from the inactivated state. A final depolarizing test pulse is used to assay the sodium current after this prolonged depolarization (see analysis below). Sodium currents are measured at this test pulse before and after the application of the tested compound. Data is acquired using PCLAMP 8.0 software and analyzed with CLAMPFIT software (Axon instruments).
[0133] Data analysis: Apparent inhibition constants (K i values) for antagonists are determined from single point inhibition data using the following equation (a generalized form of the Cheng-Prusoff equation) (Leff, P. and I. G. Dougall, TiPS 14:110-112 (1993)).
K i =( FR/ 1 −FR )*[drug] Eq.1
[0134] Where FR is the fractional response and is defined as sodium current elicited from the final depolarizing test pulse prior to application of the drug divided by the sodium current measured in the presence of the drug. [drug] is the concentration of the drug used.
[0135] Drugs: Drugs are initially made up at concentrations of 2-10 mM in DMSO. Dilutions are then made to generate a series of DMSO stocks over the range 0.3 μM to 10 mM—depending upon the potency of the compound. Working solutions are made by 1000-3000 fold dilution of stocks into Ringer. At these dilutions DMSO alone has little or no measurable effects on membrane current responses. DMSO stocks of drugs are stored in the dark at 4° C. Ringer solutions of drugs are made up fresh each day of use.
[0136] Compositions within the scope of this invention include all compositions wherein the compounds of the present invention are contained in an amount that is effective to achieve its intended purpose. While individual needs vary, determination of optimal ranges of effective amounts of each component is within the skill of the art. Typically, the compounds can be administered to mammals, e.g. humans, orally at a dose of 0.0025 to 50 mg/kg, or an equivalent amount of the pharmaceutically acceptable salt thereof, per day of the body weight of the mammal being treated for epilepsy, neurodegenerative diseases, anesthetic, arrhythmia, manic depression, and chronic pain. For intramuscular injection, the dose is generally about one-half of the oral dose.
[0137] In the method of treatment or prevention of neuronal loss in global and focal ischemia, brain and spinal cord trauma, hypoxia, hypoglycemia, status epilepsy and surgery, the compound can be administrated by intravenous injection at a dose of about 0.025 to about 10 mg/kg.
[0138] The unit oral dose can comprise from about 0.01 to about 50 mg, preferably about 0.1 to about 10 mg of the compound. The unit dose can be administered one or more times daily as one or more tablets each containing from about 0.1 to about 10, conveniently about 0.25 to 50 mg of the compound or its solvates.
[0139] In addition to administering the compound as a raw chemical, the compounds of the invention can be administered as part of a pharmaceutical preparation containing suitable pharmaceutically acceptable carriers comprising excipients and auxiliaries which facilitate processing of the compounds into preparations that can be used pharmaceutically. Preferably, the preparations, particularly those preparations which can be administered orally and which can be used for the preferred type of administration, such as tablets, dragees, and capsules, and also preparations which can be administered rectally, such as suppositories, as well as suitable solutions for administration by injection or orally, contain from about 0.01 to 99 percent, preferably from about 0.25 to 75 percent of active compound(s), together with the excipient.
[0140] Also included within the scope of the present invention are the non-toxic pharmaceutically acceptable salts of the compounds of the present invention. Acid addition salts are formed by mixing a solution of the particular benzimidazoles of the present invention, with a solution of a pharmaceutically acceptable non-toxic acid such as, but not limited to: acetic acid, benzoic acid, carbonic acid, citric acid, dichloroacetic acid, dodecylsulfonic acid, 2-ethylsuccinic acid, fumaric acid, glubionic acid, gluconic acid, hydrobromic acid, hydrochloric acid, 3-hydroxynaphthoic acid, isethionic acid, lactic acid, lactobionic acid, levulinic acid, maleic acid, malic acid, malonic acid, methanesulfic acid, methanesulfonic acid, nitric acid, oxalic acid, phosphoric acid, propionic acid, sulfuric acid, sulfamic acid, saccharic acid, succinic acid, tartaric acid, and the like. Basic amine salts are formed by mixing a solution of the benzimidazole compounds of the present invention with a solution of a pharmaceutically acceptable non-toxic acid such as those listed above, and preferably, hydrochloric acid or carbonic acid.
[0141] The pharmaceutical compositions of the invention can be administered to any animal that can experience the beneficial effects of the compounds of the invention. Foremost among such animals are mammals, e.g., humans and companion animals such as, dogs and cats, although the invention is not intended to be so limited.
[0142] The pharmaceutical compositions of the present invention can be administered by any means that achieve their intended purpose. For example, administration can be by parenteral, subcutaneous, intravenous, intramuscular, intraperitoneal, transdermal, or buccal routes. Alternatively, or concurrently, administration can be by the oral route. The dosage administered will be dependent upon the age, health, and weight of the recipient, kind of concurrent treatment, if any, frequency of treatment, and the nature of the effect desired.
[0143] The pharmaceutical preparations of the present invention are manufactured in a manner that is itself known, for example, by means of conventional mixing, granulating, dragee-making, dissolving, or lyophilizing processes. Thus, pharmaceutical preparations for oral use can be obtained by combining the active compounds with solid excipients, optionally grinding the resulting mixture and processing the mixture of granules, after adding suitable auxiliaries, if desired or necessary, to obtain tablets or dragee cores.
[0144] Suitable excipients are, in particular, fillers such as saccharides, for example lactose or sucrose, mannitol or sorbitol, cellulose preparations and/or calcium phosphates, for example tricalcium phosphate or calcium hydrogen phosphate, as well as binders such as starch paste, using, for example, maize starch, wheat starch, rice starch, potato starch, gelatin, tragacanth, methyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, and/or polyvinyl pyrrolidone. If desired, disintegrating agents can be added such as the above-mentioned starches and also carboxymethyl-starch, cross-linked polyvinyl pyrrolidone, agar, or alginic acid or a salt thereof, such as sodium alginate. Auxiliaries are, above all, flow-regulating agents and lubricants, for example, silica, talc, stearic acid or salts thereof, such as magnesium stearate or calcium stearate, and/or polyethylene glycol. Dragee cores are provided with suitable coatings that, if desired, are resistant to gastric juices. For this purpose, concentrated saccharide solutions can be used, which can optionally contain gum arabic, talc, polyvinyl pyrrolidone, polyethylene glycol and/or titanium dioxide, lacquer solutions and suitable organic solvents or solvent mixtures. In order to produce coatings resistant to gastric juices, solutions of suitable cellulose preparations such as acetylcellulose phthalate or hydroxypropymethyl-cellulose phthalate, are used. Dye stuffs or pigments can be added to the tablets or dragee coatings, for example, for identification or in order to characterize combinations of active compound doses.
[0145] Other pharmaceutical preparations which can be used orally include push-fit capsules made of gelatin, as well as soft, sealed capsules made of gelatin and a plasticizer such as glycerol or sorbitol. The push-fit capsules can contain the active compounds in the form of granules which can be mixed with fillers such as lactose, binders such as starches, and/or lubricants such as talc or magnesium stearate and, optionally, stabilizers. In soft capsules, the active compounds are preferably dissolved or suspended in suitable liquids, such as fatty oils, or liquid paraffin. In addition, stabilizers can be added.
[0146] Possible pharmaceutical preparations, which can be used rectally, include, for example, suppositories, which consist of a combination of one or more of the active compounds with a suppository base. Suitable suppository bases are, for example, natural or synthetic triglycerides, or paraffin hydrocarbons. In addition, it is also possible to use gelatin rectal capsules which consist of a combination of the active compounds with a base. Possible base materials include, for example, liquid triglycerides, polyethylene glycols, or paraffin hydrocarbons.
[0147] Suitable formulations for parenteral administration include aqueous solutions of the active compounds in water-soluble form, for example, water-soluble salts and alkaline solutions. In addition, suspensions of the active compounds as appropriate oily injection suspensions can be administered. Suitable lipophilic solvents or vehicles include fatty oils, for example, sesame oil, or synthetic fatty acid esters, for example, ethyl oleate or triglycerides or polyethylene glycol-400 (the compounds are soluble in PEG-400). Aqueous injection suspensions can contain substances which increase the viscosity of the suspension, and include, for example, sodium carboxymethyl cellulose, sorbitol, and/or dextran. Optionally, the suspension can also contain stabilizers.
[0148] The following examples are illustrative, but not limiting, of the method and compositions of the present invention. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in clinical therapy and which are obvious to those skilled in the art are within the spirit and scope of the invention.
EXAMPLE 1
[0149] 2-Nitrophenyl-aminoethyl Piperidine (1):
[0150] To a solution of 1-(2-aminoethyl)piperidine (10.0 g, 78.0 mmol) and 2-fluoro-1-nitrobenzene (22.0 g, 156.0 mmol) in DMF (250 mL) was added diisopropylethylamine (12.5 mL) and the mixture was stirred at room temperature for 15 hours. The reaction mixture was poured into a mixture of CHCl 3 and water. The water layer was extracted with CHCl 3 and the combined organic layers were washed with water and brine, dried (Na 2 SO 4 ), and evaporated, and the residue was purified by silica gel column chromatography to give 1 (17.6 g, 91%) as a yellowish solid.
[0151] N-(2-piperidin-1-yl-ethyl)-benzene-1,2-diamine (2):
[0152] To a solution of 1 (1.30 g, 5.21 mmol) in MeOH (75 mL) was added 10% Pd—C (0.130 g). The mixture was agitated under a hydrogen atmosphere at room temperature and a pressure of 3 atm, for 16 hours. The catalyst was filtered off and washed with MeOH. The eluent was concentrated in vacuo to give the crude product 2 (1.20 g) with >95% purity as a slight yellowish oil. The crude product 2 was used for the next step without further purification.
[0153] 2-Substitued-1-(2-piperidin-1-yl-ethyl)-1H-benzoimidazole (3):
[0154] To a solution of the above crude 2 (0.150 g, 0.685 mmol) in nitrobenzene (2.0 mL) was added an appropriate aldehyde (1.370 mmol) and the mixture was agitated at 100° C. for 48 hours. After cooling to room temperature, the mixture was directly poured onto a silica gel column and purified with a gradient elution (100% hexane, 90% hexane/ethyl acetate to 100% ethyl acetate) to give 3 in 60-85% yield as a yellowish solid. The recovered product was purified by column chromatography.
TABLE 1 STRUCTURES OF REPRESENTATIVE BENZIMIDAZOLE COMPOUNDS OF THE INVENTION Compound n R 1 R 2 3a 0 3b 0 3c 0 3d 0 3e 0 3f 0 3g 0 3h 0 3i 0
[0155] Physical data for each of compounds 1-3a-i appear in Table 2 below.
TABLE 2 PROTON NMR DATA AND MASS SPECTROSCOPY DATA FOR BENZIMIDAZOLE COMPOUNDS OF THE INVENTION Compound 1 H NMR(400 MHz, CDCl 3 ); MS(ESI) m/z 1 δ 8.45(br, 1H), 8.18(d, 1H, J=8.3Hz), 7.43(d 1H, J=7.0, 8.3Hz), 6.86(d, 1H, J=8.3Hz), 6.63(dd, 1H, J=7.0, 8.3Hz), 3.43(m, 2H), 2.71(m, 2H), 2.51(m, 4H), 1.66(m, 4H), 1.48(m, 2H); MS(ESI) m/z for C 13 H 19 N 3 O 2 ((MH + ): 250.2. 2 δ 6.76(m, 1H), 6.65(m, 3H), 6.59(d, 1H, J=7.5Hz), 6.51(m, 2H), 6.26(d, 1H, J=7.5Hz), 3.29(m, 2H), 2.88(m, 2H), 2.61(m, 4H), 1.69(m, 4H), 1.49(m, 2H); MS(ESI) m/z for C 13 H 21 N 3 (MH + ): 220.2. 3a δ 7.83(m, 1H), 7.80(d, 2H, J=8.7Hz), 7.46(m, 1H), 7.41(m, 2H), 7.32(m, 2H), 7.21 (m, 1H), 7.15(m, 2H), 7.10(m, 2H), 4.38(t, 2H, J=7.2Hz), 2.76(t, 2H, J=7.2Hz), 2.40(br, 4H), 1.55(m, 4H), 1.44(m, 2H); MS(ESI) m/z for C 26 H 27 N 3 O(MH + ): 398.2. 3b δ 7.83(m, 1H), 7.52(m, 2H), 7.46(m, 2H), 7.38(d, 2H, J=8.7Hz), 7.32(m, 2H), 7.18 (m, 1H), 7.01(d, 2H, J=8.7Hz), 4.35(t, 2H, J=7.2Hz), 2.69(t, 2H, J=7.2Hz), 2.35(br, 4H), 1.52(m, 4H), 1.41(m, 2H), 1.34(s, 9H); MS(ESI) m/z for C 30 H 35 N 3 O(MH + ): 454.3. 3c δ 7.82(m, 1H), 7.63(m, 1H), 7.53(m, 1H), 7.50(d, 1H, J=8.7Hz), 7.45(m, 1H), 7.40 (d, 1H, J=8.7Hz), 7.32(m, 2H), 7.17(m, 1H), 7.14(d, 1H, J=2.8Hz), 6.90(dd, 1H, J=2.8, 8.7Hz), 4.35(t, 2H, J=7.2Hz), 2.70(t, 2H, J=7.2Hz), 2.32(br, 4H), 1.49(m, 4H), 1.39(m, 2H); MS(ESI) m/z for C 26 H 25 Cl 2 N 3 O(MH + ): 466.1. 3d δ 7.64(m, 1H), 7.39(m, 5H), 7.25(m, 2H), 7.20(m, 6H), 6.89(s, 1H), 4.05(t, 2H, J=7.2Hz), 2.52(t, 2H, J=7.2Hz), 2.37(br, 4H), 1.53(m, 4H), 1.41(m, 2H); MS(ESI) m/z for C 28 H 29 N 3 (MH + ): 408.2. 3e δ 7.80(m, 1H), 7.53(m, 1H), 7.47(d, 1H, J=7.9Hz), 7.42(m, 2H), 7.36(m, 2H), 7.28 (m, 2H), 7.14(m, 2H), 7.05(m, 2H), 4.33(t, 2H, J=7.2Hz), 2.67(t, 2H, J=7.2Hz), 2.32(br, 4H), 1.49(m, 4H), 1.39(m, 2H); MS(ESI) m/z for C 26 H 27 N 3 O(MH + ): 398.2. 3f δ 7.81(m, 1H), 7.64(m, 1H), 7.54(m, 2H), 7.44(m, 2H), 7.37(d, 1H, J=7.6Hz), 7.31 (m, 3H), 7.18(m, 2H), 4.35(t, 2H, J=7.2Hz), 2.70(t, 2H, J=7.2Hz), 2.31(br, 4H), 1.48(m, 4H), 1.38(m, 2H); MS(ESI) m/z for C27H26F3N3O(MH+): 466.2 3g δ 8.54(d, 1H, J=1.6Hz), 8.14(d, 1H, J=8.0Hz), 7.91(dd, 1H, J=1.6, 8.4Hz), 7.85(m, 1H), 7.53(d, 1H, J=8.0Hz), 7.50(m, 3H), 7.31(m, 3H), 4.45(m, 4H), 2.82(t, 2H, J=7.2Hz), 2.42(br, 4H), 1.59(m, 4H), 1.54(m, 2H), 1.50(t, 3H, J=7.2Hz); MS(ESI) m/z C 28 H 30 N 4 (MH + ): 423.2. 3h δ 7.83(m, 1H), 7.4(m, 8H), 7.31(m, 3H), 7.12(m, 1H), 5.16(s, 2H), 4.34(t, 2H, J=7.2Hz), 2.69(t, 2H, J=7.2Hz), 2.34(br, 4H), 1.51(m, 4H), 1.40(m, 2H); MS(ESI) m/z for C 27 H 29 N 3 O(MH + ) 412.2. 3i δ 7.83(m, 1H), 7.79(d, 2H, J=8.7Hz), 7.44(m, 1H), 7.30(m, 2H), 7.08(m, 6H), 4.35 (t, 2H, J=7.2Hz), 2.73(t, 2H, J=7.2Hz), 2.38(br, 4H), 1.53(m, 4H), 1.42(m, 2H); MS (ESI) m/z for C 26 H 26 FN 3 O(MH + ): 416.2.
[0156] Compounds of the present invention were assayed in the electrophysiological assay discussed above. The K i values obtained from the electrophysiological assays compounds 3a-3i ranged from 180-1790 nM. The K i values for these compounds demonstrate that the compounds of the invention are potent blockers of the sodium channel.
EXAMPLE 2
Tablet Preparation
[0157] Tablets containing 25.0, 50.0, and 100.0 mg, respectively, of the compound of the invention (“active compound”) are prepared as illustrated below:
TABLET FOR DOSES CONTAINING FROM 25-100 MG OF THE ACTIVE COMPOUND Amount-mg Active compound 25.0 50.0 100.00 Microcrystalline cellulose 37.25 100.0 200.0 Modified food corn starch 37.25 4.25 8.5 Magnesium stearate 0.50 0.75 1.5
[0158] All of the active compound, cellulose, and a portion of the corn starch are mixed and granulated to 10% corn starch paste. The resulting granulation is sieved, dried and blended with the remainder of the corn starch and the magnesium stearate. The resulting granulation is then compressed into tablets containing 25.0, 50.0, and 100.0 mg, respectively, of active ingredient per tablet.
EXAMPLE 3
Intravenous Solution Preparation
[0159] An intravenous dosage form of the compound of the invention (“active compound”) is prepared as follows:
Active compound 0.5-10.0 mg Sodium citrate 5-50 mg Citric acid 1-15 mg Sodium chloride 1-8 mg Water for injection (USP) q.s. to 1 ml
[0160] Utilizing the above quantities, the active compound is dissolved at room temperature in a previously prepared solution of sodium chloride, citric acid, and sodium citrate in Water for Injection (USP, see page 1636 of United States Pharmacopeia/National Formulary for 1995, published by United States Pharmacopeial Convention, Inc., Rockville, Md. (1994).
[0161] Having now fully described this invention, it will be understood by those of ordinary skill in the art that the same can be performed within a wide and equivalent range of conditions, formulations and other parameters without affecting the scope of the invention or any embodiment thereof.
[0162] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
[0163] All patents and publications cited herein are fully incorporated by reference herein in their entirety. | This invention relates aryl substituted benzimidazoles of Formula I:
or a pharmaceutically acceptable salt, prodrug or solvate thereof, wherein R 1 , R 2 , R 10 and n are defined in the specification. The invention is also directed to the use of compounds of Formula I for the treatment of neuronal damage following global and focal ischemia, for the treatment or prevention of neurodegenerative conditions such as amyotrophic lateral sclerosis (ALS), and for the treatment, prevention or amelioration of both acute or chronic pain, as antitinnitus agents, as anticonvulsants, and as antimanic depressants, as local anesthetics, as antiarrhythmics and for the treatment or prevention of diabetic neuropathy. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 08/031,945, filed Mar. 16, 1993, now U.S. Pat No. 5,564,417; which in turn is a Continuation-in-Part of U.S. application Ser. No. 07/645,590, filed Jan. 24, 1991; which in turn is a Continuation-in-Part of U.S. Ser. No 07/578,063, filed Sep. 5, 1990, now U.S. Pat. No. 5,122,974; which in turn is a Continuation of U.S. application Ser. No. 07/307,066, filed Feb. 6, 1989, now U.S. Pat. No. 4,972,331.
This application is a continuation-in-part of application Ser. No. 07/611,400, filed Nov. 7, 1990, entitled "User-Wearable Hemoglobinometer for Measuring the Metabolic Condition of a Subject", which is a continuation of application Ser. No. 07/266,019, filed Nov. 2, 1988, of the same title.
This application is also a continuation-in-part of co-pending application Ser. No. 07/266,116, filed Nov. 2, 1988, in the name of Britton Chance, entitled, "Optical Coupling System for Use in Monitoring Oxygenation State Within Living Tissue," which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
In one aspect, the present invention relates to wearable apparatus for noninvasive determinations of the concentration of oxygen in a specific target region of tissue. More specifically, the present invention discloses a user-wearable system for monitoring the oxygen concentration, or oxygenation trend, in the tissue of a subject undergoing aerobic stress, such as an exercising person.
The increasing popularity of all forms of exercise over the last several decades has also lead to an increased interest in the measurement of individual athletic performance. However, at the present time, athletes are limited to obtaining heartbeat and blood pressure data while they are exercising. Although of some use, these data do not reflect peripheral circulatory capacity or the oxygenation state of specific muscle tissue.
In order to measure oxygen delivery to the capillary bed of the muscles, an athlete must be tethered to electrocardiogram apparatus and have blood samples drawn while running on a treadmill. These are essentially operating room apparatus and procedures, which do no simulate the actual conditions of exercise. The measurement of aerobic efficiency by analyzing the oxygenation state of a particular muscle while exercising is important due to a variety of persons. For example, as a casual jogger strives to become a marathon runner, the efficiency at which they use oxygen can severely impact performance; data reflecting the utilization of oxygen can provide information which allows an athlete to change pacing strategies or otherwise adjust their activity to produce better results. Other athletes, such as swimmers, cyclists and rowers would also find this information useful for evaluating performance. However, the use of blood oxygenation data is not limited to competitive athletes; even geriatrics who undergo mild aerobic exercise to maintain and improve their health can benefit from data concerning the changes in blood oxygenation brought about by exercise or other activity. Other animals, such as racehorses, can also benefit from this type of performance data. By measuring the oxygen delivery to the muscles, both the quality of training and the natural ability to exercise may be evaluated.
In addition to monitoring and maximizing athletic performance, information pertaining to the delivery of oxygen to the limbs and the brain is important in military and space applications where changes in gravity and other stresses may result in fatigue, and ultimately, blackouts.
Although apparatus are available which measure the oxygenation content of blood using data collected from a fingertip or ear lobe, these devices do not actually measure the oxygenation state of nearby muscle groups or the brain. To monitor athletic performance, or the condition of exerted muscles, data collection must be performed at the site of interest. For example, runners will wish to be provided with this information during a race, not in a laboratory. Therefore, for an apparatus measuring the metabolic condition of an athlete to be truly useful, a rugged, lightweight, user-wearable system must be provided.
One method by which the oxygen level in a muscle may be measured by tissue spectrometry. For example, red and near-red light, having wavelengths between about 600-800 nanometers (nm), will harmlessly penetrate body tissues. As the light penetrates the tissue, it migrates and is absorbed by deoxygenated hemoglobin in small blood vessels. Normally, tissue receives oxygen from hemoglobin contained in red blood cells, which circulate in the major blood vessels and eventually into the capillary bed, supplying muscle tissue with oxygen. Aerobic activity can cause the level of oxygen use to rise, causing a commensurate rise in the level of deoxyhemoglobin which is compensated for by increased blood flow in trained individuals. Near-red light is absorbed by tissue that is not receiving as much oxygen as the surrounding tissue due to increased levels of deoxyhemoglobin in less trained individuals. Thus, by determining the amount of incident radiation absorbed, the oxygenation state of a specific area of tissue, and the training level of an individual, can be determined.
SUMMARY OF THE INVENTION
The present invention provides a novel, wearable system for determining the metabolic condition of an aerobically stressed portion of the muscle tissue of an exercising person. The system comprises a lightweight rugged detector, worn against the skin surface of the subject, adjacent the muscle being monitored. The system of the present invention thus minimizes any performance impairment. The preferred system further comprises a wearable power pack and a wearable display means for displaying information indicative of the aerobic metabolic condition of the region being monitored. In a preferred embodiment intended for use while running or engaged in similar athletic activities, the display is worn on the wrist and displays information from a leg-mounted detector. In another embodiment, intended to provide information to coaches, a telemetry system is employed to transmit a signal carrying the data from the detector to a remote location, for processing and display.
The detector of the present invention preferably employs a continuous wave spectrophotometer having one or more sources of electromagnetic radiation with wavelengths between about 760 nanometers and about 800 nanometers directed into the tissue of the subject. The detector is efficiently coupled to the body tissue and utilizes the principle of photon migration to detect the portion of the transmitted radiation arriving at an adjacent skin region.
The present invention also discloses methods for displaying the aerobic metabolic condition of a subject. The percentage of deoxyhemoglobin in the blood of the subject is determined, and a signal representative of this percentage is converted into a graphic representation. The display may preferably be a digital display, a bar graph or a series of deoxyhemoglobin levels, placed on a time scale.
OBJECTS AND FEATURES OF THE INVENTION
It is an object of the present invention to provide methods and apparatus which allow a rapid determination of the oxygenation state of tissue, such as muscle tissue, located beneath the surface of the skin of a subject, such as an athlete, without requiring the subject to be tethered or physically connected to laboratory or operating room monitoring equipment.
It is also an object of the present invention to provide apparatus which may be attached to a user which would determine the oxygenation state of a portion of the user's body and provide that information in a readily understandable form.
It is a further object of certain embodiments of the present invention to provide information pertaining to the oxygenation state of tissue directly to a user wearing the apparatus of the present invention.
It is another object of certain embodiments of the present invention to transmit information pertaining to the oxygenation state of tissue to a remote observer.
According to one aspect of the invention, an oximeter is provided for determining the oxygenation state of localized body tissue per se, constructed to be worn over a period of activity by a user and comprising a flexible, body-conformable support member which supports, adjacent the skin of a user, over the localized tissue of interest, at least a pair of spaced apart light sources, and intermediate thereof, at least a pair of wavelength-specific photo detectors, each light source exposed to transmit wavelengths of both of the specific wavelengths toward the localized tissue of interest lying below the skin and below the associated subcutaneous fat layer of the user, and each detector exposed to receive photons of the respective specific wavelength that have originated from each light source, and scattered from the localized tissue and passed back to the detectors through the subcutaneous fat layer and skin of the user, the support member including conformable barrier means disposed between each light source and the detectors, the barrier means being of substance capable of conforming to the contour of the wearer and preventing light energy proceeding laterally in the region of the barrier means from reaching the detectors.
Somewhat more generally, according to another aspect of the invention, an oximeter is provided for determining the oxygenation state of localized body tissue per se, constructed to be worn over a period of activity by a user and comprising a flexible support member which supports, over the localized tissue of interest, at least a pair of spaced apart light sources, and intermediate thereof, at least a pair of wave length-specific light detectors (e.g., photo detectors), each light source exposed to transmit wavelengths of both of the specific wavelengths toward the localized tissue of interest, and each detector exposed to receive photons of the respective specific wavelength that have originated from each light source, and scattered from the localized tissue and passed back to the detectors.
Preferred embodiments of these aspects of the invention have one or more of the following features.
The light sources comprise broad spectrum CW light sources.
The light sources comprise tungsten filament lamps.
The oximeter includes control means for simultaneously flashing the light sources to enable each detector to pick up light energy at its specific wavelength simultaneously from each light source.
Means are provided to flash the light sources at selected intervals unrelated to the interval of heart beats of the user.
According to another aspect of the invention, an oximeter is provided comprising a flexible support member comprised of a molded-elastomeric backing member, the backing member mounting at least one light source means capable of producing one or more (e.g., two) selected wavelengths and oriented to direct the light to tissue of a user and the backing member also mounting detector means capable of separately detecting energy at each of the wavelengths scattered by tissue of the user, integral elastomeric portions of the backing member defining a barrier exposed for conformable contact with an exposed surface of the user, in position to prevent lateral movement of light in subcutaneous layers from the source means to the detector means.
According to another aspect of the invention, an oximeter is provided comprising a flexible support member, the support member mounting at least one light source means capable of producing two selected wavelengths and oriented to direct the light to tissue of a user and the support member mounting detector means capable of separately detecting energy at each of the wavelengths scattered by tissue of the user, the support member supporting a barrier member exposed for conformable contact with an exposed surface of the user in position to prevent lateral movement of light from the source means to the detector means, the barrier comprising a member having an edge sized and positioned to indent skin and the flesh of the user thereby to intercept light migrating laterally in the subcutaneous fat layer and prevent such light from reaching said detector means.
Preferred embodiments of these aspects of the invention have one or more of the following features.
The barrier member is elastomeric, adapted to conform to the contour of the skin of the wearer.
The flexible support member comprises a molded-elastomeric backing member and the barrier member is integral with the backing member.
The member defining the flesh-indenting edge is about 0.5 cm thick in the region that engages the skin.
The barrier member comprises a rib-form member.
There are in series at least one (e.g., two) barrier members, one closely adjacent to the light source means and one closely adjacent to the detector means.
The support member mounts at least one (e.g., two) spaced-apart light sources and at least one (e.g., a pair) of detectors are disposed parallel to each other, disposed laterally relative to the line between the light sources and equal distance from each of the light sources.
The light sources comprise broad spectrum CW light sources.
Electronic control circuitry for the light source and the detector means are provided in which the circuitry is disposed upon a miniature semiconductor chip carried by the support member.
Electronic control circuitry is provided comprised of entirely non-magnetic components enabling use of the device in conjunction with nuclear magnetic resonance imaging.
The oximeter is combined with a real-time readout device constructed to be worn by the user and having a display responsive to the oximeter disposed for viewing by the user.
The oximeter is associated with means securing it to an appendage of the user and the readout device is constructed to be worn by a user.
The oximeter is combined with radio frequency telemetry means for transmitting oximeter data on a real time basis to a station remote from the user or to a receiver in a readout device constructed to be worn by a user.
The oximeter includes electronic control circuitry for the light source and the detector means, the circuitry disposed upon a miniature semiconductor chip carried by the support member in combination with radio frequency telemetry means controlled by the circuitry for transmitting oximeter data on a real time basis to a station remote from the user.
Means are provided for battery-operation of the oximeter and to record oximetry data in internal digital memory for subsequent display or data analysis on a computer.
The oximeter includes electronic control circuitry for the light source and the detector means, the circuitry disposed upon a miniature semiconductor chip carried by the support member, and means for battery-operation of the oximeter and means to record oximetry data in internal digital memory for subsequent display or data analysis on a computer.
According to still another device aspect of the invention, an oximeter is provided comprising a support mounting a light source and detector means at fixed spacing, and electronic control circuitry for the light source and the detector means, the circuitry disposed upon a miniature semiconductor chip carried by the support member, the oximeter encapsulated in biocompatible, water impermeable material, the oximeter constructed and arranged for implantation under the skin of a user for monitoring internal tissue oxygen trends.
The invention also features a number of methods. The method is provided of monitoring the derivative or rate of change of the time based curve representing detected change of tissue oxygen levels and blood volume and employing these rates as a quantitative standard of measurement of tissue oximetry.
The method is provided of assisting an aviator or other person engaged in activity that can subject the person to high G-forces including providing to the person a comfortable oximeter sensor suitable to be worn about the head (e.g., either integrally in a helmet or helmet lining) and capable of responding to tissue oxygen level and blood volume of brain tissue on a real time basis, employing the oximeter sensor to monitor oxygen level of brain tissue of the wearer as the wearer engages in the activity, comparing the monitored value to a standard and generating a signal, such as a warning or control signal, in the event the monitored level(s) violate(s) a pre-established standard.
Preferably, the oximeter is constructed to monitor the trend of oxygen level in the brain, and means are provided to evaluate the rate of change being detected and using the rate of change as the control value and alarm reference.
The method is provided of monitoring a person suspect of sleep apnea or sudden infant death syndrome including providing to the person a comfortable oximeter sensor capable of automatically responding to oxygen level of the person while permitting the person to sleep, automatically monitoring the output of the oximeter by comparing it to a standard and generating a signal, such as a warning or control signal, in the event the monitored level violates a pre-established standard. Preferably the oximeter sensor is taped comfortably to the head for monitoring. Also, preferably the method is used in conjunction with impedance pneumography (breathing rate measurement using chest-wall impedance) and/or EKG to provide an effective in-home apnea monitor to alarm the patient or other individuals in the area so as to wake the patient and prevent hypoxic tissue damage during sleep.
The method is provided of monitoring the cerebral tissue oxygen rate of change as a means of triggering alarm to awaken a subject in danger of infarct due to hypoxia.
The method is provided of monitoring both tissue oxygen level and blood volume in skin flaps such as are produced either by wound or surgery, as the flaps heal, the separation between the source and the detector being established in relation to the thickness of the skin flap to ensure tissue of the flap per se is being monitored.
The method is provided of emergency monitoring of cerebral tissue oxygen level and blood volume in an emergency care situation with the implantable device, in this case, preferably a stand-alone oximeter carried on a backing member with micro-circuitry to monitor the brain or other tissues in peril of damage due to hypoxia.
The method is provided of employing the device of any of the configurations described above wherein the oxygen levels, blood volume and/or rate of charge are measured in cancerous tissue to indicate the activity and viability of the tissue. Also preferably the method includes monitoring of the viability of a tumor following treatment intended to wipe out the cancerous tissue.
Another aspect of the invention is a helmet into which is molded a tissue oximeter in position to engage the head of the wearer when the helmet is put on, the oximeter being of the NIR type, comprising light source means for transmitting near infrared light into the head, detector means held in spaced position relative to the light source means for receiving light scattered by brain tissue and a barrier disposed to engage the head between the light source means and the detector means to prevent light traveling laterally from the light source means from reaching the detector means. Preferably the oximeter has other features described above. In particular, preferably, the oximeter in the helmet includes control circuitry on a miniature chip and preferably means are provided for determining the rate of change of oximetry readings and for comparing the rate of change to a standard and, e.g. producing an appropriate alarm and/or control signal.
Another feature of the invention is a tissue oximeter comprising a support, a detector fixed to the support and a light source mounted in an adjustable manner to the support to enable selection of the spacing between light source and detector for adjusting the mean depth of tissue to which the oximeter responds.
Still another feature of the invention is a tissue oximeter in combination with means connected to receive tissue oxygen readings from the oximeter, and to determine the rate of change of the readings, the rate of change serving as a quantified indication of the state of the charging metabolic process of the tissue.
Another feature of the invention is an oximeter as described, disposed on an endoscope, catheter or guidewire or the like for insertion via a body passge to internal tissue, and including means such as an inflatable balloon to press the oximeter sensor against the localized tissue of interest. Another feature includes providing a water impermeable coating over the device for use in the presence of water.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a depiction of a preferred configuration of an embodiment of the present invention.
FIG. 2 is a partially diagrammatic, partially schematic representation of a preferred embodiment detector.
FIG. 3 illustrates another preferred configuration of an embodiment of the present invention.
FIG. 4 is a partially diagrammatic, partial schematic representation of an alternate preferred embodiment detector.
FIG. 5 is a plan view of another preferred embodiment.
FIG. 6a is a plan view of the oximeter sensor of FIG. 5.
FIG. 6b is a longitudinal sideview of the oximeter sensor of FIG. 6a.
FIG. 6c is a longitudinal cross-sectional view taken on lines 6c of FIG. 6a;
FIG. 7 is a transverse cross-sectional view of a oximeter sensor according to the invention in place upon the flesh of a wearer;
FIGS. 8a, 8b and 8c are plan views of other preferred embodiments of the oximeter sensor;
FIG. 9a is a plan view of an implantable oximeter sensor according to the invention,
FIG. 9b is a longitudinal sideview of the oximeter of FIG. 9a, while
FIG. 9c is a cross-sectional view taken on line 9c of FIG. 9a.
FIG. 10 is a block diagram of an analog version of the control system for the oximeter of the previous figures.
FIG. 11 is a block diagram of a digital version of the control circuit of the oximeter of the previous figures.
FIG. 12 is a software flow diagram of the software used with the circuitry of FIG. 11.
FIG. 13 is a front of a helmet according to the invention.
FIG. 14 shows an endoscopic oximeter according to the invention.
DETAILED DESCRIPTION
A preferred embodiment of the apparatus of the present invention is illustrated in FIG. 2. In this embodiment an electro-optical pickoff detector unit 10 is worn on the leg of the exercising subject 50. It is preferred that the weight of the detector be kept to a minimum so that hindrance to a competing athlete is negligible. In a preferred embodiment, the detector will be housed in a flexible array constructed from a suitable non-irritating, lightweight material.
Power is provided to the detector unit 10 from a replaceable battery pack 30. The replaceable power pack 30 is preferably designed to be of minimal dimensions and weight. Most preferably, the battery pack 30 would be designed to last only for the duration of the activity, e.g., several minutes of sprinting, several hours for a marathon runner, etc. In competitive sports applications, the life of the battery pack is preferably based upon the interval between substitutions or other interruptions between periods of competition.
The embodiment illustrated in FIG. 1 further comprises an arm indicator 40, which is preferably worn on the arm in the manner of a wristwatch. The arm indicator 40 displays the percentage of deoxyhemoglobin (% Hb) as a measure of the subject's metabolic state. As seen in FIG. 1A, such a display may comprise a simple readout of this information, such as a bar graph. Alternatively, the information displayed may be placed on a time scale, to graphically illustrate the change in % Hb concentration over the course of the activity, as illustrated by FIG. 1B. In a most preferred embodiment, the graphic displays illustrated by FIGS. 1A and 1B are comprised of liquid crystal displays (LCD's), although other electrical or electronic display means may also be used. The amplitude interval of this embodiment is preferably divided into 6-10 levels, each covering a portion of the designated % Hb scale.
It will be appreciated that the range of the % Hb scale may be adjusted depending upon the range expected to occur during the activity. Since the precision of the present invention is limited by that of the indicator, the range which is displayed is an important variable parameter. In the most accurate embodiment of the present invention, with the endpoints of the % Hb scale set at 20% and 40%, the apparatus would have an accuracy of about 6%, which is about the limit of precision which can be obtained from a moving limb. One of ordinary skill will realize that the gain of the apparatus is preset, depending upon the intensity of the activity expected. In a most preferred embodiment, a button placed on the arm indicator 40 allows the gain to be set.
Referring now to FIG. 2, there is illustrated a partially schematic, partially diagrammatic representation of a preferred embodiment of a circuit which comprises the optical pickoff component of a DC tissue spectrophotometer detector 10 contemplated for use in the system of the present invention. The detector 10 is shown for illustrative purposes mounted against a skin surface 25 of a subject. In a typical configuration, the detector is mounted against either large, homogeneous muscles, such as the gastrocnemius or the quadriceps or against the forehead of an adult. Two lamps 12,14 and two detectors 16,18 are contained in a flexible waterproof array. Also contained in the array is an opaque specular barrier, which is a concentric ring of material 11 between the lamps 12,14 and the detectors 16,18 which acts as a barrier zone to light of a specified wavelength. Most preferably, the material which comprises the barrier zone will not only be opaque to light within a specified region, but will further act as an absorber as well. The configuration of dual wavelength light sources combined with a barrier zone is disclosed in "Optical Coupling System for Use in Monitoring Oxygenation State Within Living Tissue," Application Ser. No. 266,116; filed Nov. 2, 1988, which is incorporated herein by reference, as noted above.
Thus, superficial light rays from the skin are, in effect, blocked by the opaque barrier 11 from entering the detectors 16,18. This blocking action by the barrier 11 of these superficial rays enables the system to determine the oxygenation state of hemoglobin within the muscle rather than at the skin surface. The rays that migrate deep within the tissue are received by the detectors 16,18. The light rays that migrate superficially "escape" through the skin surface and will be absorbed by the opaque barrier 11. When, for example, a 760 nm impulse is applied, the deoxygenated hemoglobin (Hb) within the muscle is detected and when an 800 nm signal is applied, the oxygenated and deoxygenated hemoglobin (HbO 2 and Hb) within the tissue region are detected. The system is able to ignore the oxygenation state at the skin surface and determine that within the tissue.
The lamps 12,14 may be, for example, 1/2 W flashlight bulbs that are periodically illuminated in the NR region. The lamps are provided with cutoff filters 13,15 so that only energy of a specified wavelength illuminates the tissue. The silicon diode detectors 16,18 are sensitive to 760±20 nm and 800±20 nm wavelengths respectively.
In a preferred embodiment, the lamps 12,14 are light emitting diode (LED) sources, which emit light having a wavelength of about 760 nanometers and about 800 nanometers respectively. In either embodiment, the lamps are flashed or pulsed at a predetermined repetition rate. The repetition rate of sampling, i.e., the rate at which the lamps are flashed determines the rate at which data may be collected. Thus, for a long distance runner, the lamps are flashed slowly; the output is commensurately changed for a sprinter, the lamps flashed rapidly to produce sufficient data to evaluate an exercise having a duration on the order of seconds. The selection of LEDs as sources of electromagnetic radiation provides a further advantage, since these sources produce a signal-to-noise ratio (S/N) approximately one order of magnitude greater than previously disclosed optical coupling systems using optical light fiber sources.
Referring now to FIG. 4, an alternate embodiment of a circuit for use with the present invention is illustrated. In this case a single detector 17 responding to separate light flashes collects and transmits signals to an amplifier 24, which has bipolar outputs that are connected intermittently to an integrator 27 by a switch 25. Another switch 26 adjusts the relative duration of the two light pulses to equalize the two signals. One of ordinary skill will understand that those portions of FIG. 2 and FIG. 4 having the same reference numerals perform substantially similar functions. Many details of the particular circuits comprising the present invention need not be set forth with particularity as they are well known or will be obvious to those of ordinary skill.
Referring to FIG. 2, it can be seen that the detectors 16,18 are also protected by a transmitting filter 19 to minimize the effect of background light. The filter 19 may be comprised of a separate member, a coating or integrated into the housing of the circuit. The DC output of each of the detectors 16,18 is timeshared into its respective differential amplifier 20,22. The amplifiers are connected in opposite polarity, one non-inverting, the other inverting. The dwell time of the switch 23 connecting the amplifiers 20,22 is adjusted to equalize the response of the two signals by appropriate circuitry 28. The signal from the integrator is coupled to a recorder (not illustrated). As shown in FIG. 4, the signal from the 800 nm lamp 12 may be simultaneously employed to vary the gain of the amplifier 24 so as to correct the signals for changes of blood volume and to produce the ratio of the two signals, and thus maintaining constant sensitivity for difference detection. One of ordinary skill will appreciate that a similar gain compensation circuit can be incorporated into the circuitry of the 800 nm detector amplifier 22, shown in FIG. 2. Whether incorporated into the circuits of FIG. 2 or FIG. 4, the 800 nm signal is also coupled to a second recorder channel to collect data reflecting total absorption or blood volume.
Another configuration of the present invention is illustrated in FIG. 3. In this embodiment, a radio-linked telemetry system comprised of a transmitter 60 attached to the subject and a receiver 62, allows the remote monitoring of the subject. A supervisor, coach, or clinician is thereby enabled to monitor the performance of the subject. The data display is remote, one of ordinary skill will appreciate that the displays utilized may be similar to those illustrated in FIGS. 1A and 1B, or may be more complex, displaying data using various scales, time overlays, colors, etc. In a most preferred embodiment the telemetry signal would be carried on the 220-400 MHz band, using a transmitter in the 100 MW range.
The configuration illustrated by FIG. 3 allows the present invention to monitor athletes in competition or workers and military/space personnel located in remote locations. For example, the apparatus of the present invention may be used in training to determine the duration of peak performance and the appropriate times for the substitution of fresh players or other adjustments. This configuration would also be preferred for monitoring the metabolic condition of an animal such as a racehorse, racing dog, or any animal whose metabolic condition is being studied for clinical or other purposes. A "postage stamp" oximeter may be provided for, e.g., emergency use, where the oximeter is held to the subject by an adhesive pad positioned peripherally around the device.
In any of the embodiments of the present invention, it is preferred that the data be integrated over at least about ten seconds to smooth out irregularities which normally occur in the concentration of deoxyhemoglobin during exercise. However, it will be understood that the period integration can be varied, depending upon the duration of the activity being monitored.
Although manual balancing of the apparatus of the present invention is required, in a preferred embodiment, the balancing is accomplished by depressing a button, which will normalize the output of the two wavelengths.
Another preferred embodiment of the oximeter is shown in FIGS. 5 and 6a-6c. A rubber-backing member 101, provides support for two lamps 100 spaced equi-distant from two detectors 102 also mounted on backing member 106. The backing member is formed of an opaque, e.g., black, silicone rubber of suitable durometer to enable it to conform to the curvature of the subject part of the human body to which it is applied. For this embodiment, which may be as long (L 1 ) as e.g., 12, especially 8 centimeters, flexure configurations 106 are provided. Light barrier members 103, 104 serve to depress the subcutaneous fat layer and thereby reduce light interference directly between the light sources 100 and the detectors 102, see description below regarding FIG. 7. Behind the detectors 102 of FIG. 6a, as shown in FIG. 6c, housing 107, defined by the rubber wall, contains the supporting circuitry for these lamps and detectors. As shown in FIG. 6c, narrow band optical filter 110 lies over photodetector 111, which lies over circuitry 108. Depth D is typically 2 cm. Wiring harness 115 carries power to the lamp.
On the rubber supporting member 101 there are a number of integral raised members 103, 104, 105 and 106. Raised rib 105, which extends about the perimeter, both prevents external light from interfering with the reading and serves to support comfortably the backing member 101 on the subject. Rib 104 extending laterally, adjacent the lamp, and disposed across the line projected between the lamp 100 and the detectors 102, serves as a second light barrier to prevent interfering light transmission between light source 101 and detectors 102. Rib 103 closely surrounds the detectors, and serves as a primary eliminator of environmental light interference, and also serves to absorb light migrating along subcutaneous fat and other subsurface interposed layers, etc. All of these ribs are on the order of 1/2 centimeter high and 1/2 centimeter thick. Their outside flesh-engaging edges are rounded for comfort to the wearer. The supporting member 101 and its associated ribs are manufactured in one piece of molded rubber. A suitable mold is provided and black silicone rubber is poured into the mold, cured and dried, leaving the subsequent rubber backing 101 with integral ribs and structures. Suitable mounting sites are provided in the backing into which the detectors 102 and the lamp 100 are mounted during final manufacturing. The backing member for the oximeter sensor of FIGS. 6a-6c has width, W, length, L1, and depth, D, which may be varied depending upon the application. L2 represents the spacing between light source 100 and the center of detectors 102. Sensors with dimension (L 2 ) from one centimeter to four or five centimeters with corresponding changes in L1 and W are appropriate. One centimeter separation L2 is useful for muscles of very shallow depth while L2 of four or five centimeters is useful for deeper tissue penetration, for example for the brain or other organs.
Small L2 spacings of as low as one centimeter are also appropriate for monitoring tissue flaps, though the best configuration of the sensor for flaps is that shown in FIG. 8c, described below, because flaps are of varying thickness and the adjustability of the device of FIG. 8c enables L 2 adjustment proportional to the thickness of the flap. It will also be realized that monitoring may be achieved through wound dressings, bandages, etc.
In the currently preferred embodiment, the light sources 100 are lamps having tungsten filaments, are broad band light sources which eliminating the problem of matching the light sources to the detector filters.
Each detector is comprised of interference filter 110 which blocks out all light except for that which is desired, each of two detectors having a separate wavelength of interest. At this time 760 nm and 850 nm are preferred, although one can envision that changing, depending upon the application. Beneath the filter is a photosensitive detector which picks up the light and transduces it to an electrical signal which is amplified in the circuit 108 and later transmitted to the control circuitry represented in either FIG. 10 or 11.
In the presently preferred embodiment, the interference filter is manufactured by Omega, Inc., and the photodiode beneath it is Part No. F1227-66BR, available from Hamamatsu, having a large sensitive area for favorable signal to noise ratio and an NIR wavelength sensitivity. The sensitive area is approximately 6 millimeters squared.
In the present embodiment the filter and detector are epoxied together around and an electronic shield 115 surrounds the diode/filter pair 110 and 111. This surrounding electronic shield eliminates or reduces extraneous electronic interference. It is presently preferred to form this shield of copper in the form of a windowed box which surrounds the detector filter pair.
Once the two separate filter diode pairs are constructed, they are soldered together and then mounted directly to the circuit board 108. Connected also to circuit board 108 is an ultra low noise operational amplifier with high gain, which converts the current signal from the diodes to a voltage applicable to the control circuitry of FIGS. 10 or 11. The circuit board 108 can be connected via either telemetry or cabling to the oximetry system 99 of FIG. 5, which contains the circuitry shown in FIGS. 10 or 11. Power supply for the amplifier of 108 is supplied by the oximetry system 99 where a cable connection is employed. In other embodiments, a battery is provided for operating the oximeter sensor along with the telemetry system, to be described below in connection with an implantable embodiment.
Referring now to FIG. 7, the preferred embodiment of FIGS. 6a-6c is shown diagrammatically as it is placed upon the skin of a subject. The edges of the upstanding rib-form barrier members serve to concentrate pressure upon the skin, depressing the skin layer and the underlying fat layer. The barriers 103 and 104 serve to prevent light from migrating directly between the source 100 and the detectors 102 and because the barriers are placed with pressure upon the surface of the skin, they serve to reduce the area of the fat through which light can pass directly. If one were to imagine the situation without a barrier, one would see light passing almost directly between the source and the photodiodes, the fat layer serving, effectively as a light guide. The absorbing ribs reduce this noise effect. Light which is emitted by the sources 100 enters the skin directly beneath the source, passes through the fat to the underlying tissue, migrates through the tissue, is absorbed, scattered. and eventually is received by the photodiode. The path has been described in prior art as a banana-shaped path which is due to the photon migration between the source and the detector. "Banana-shaped" is a mean representation of the photon path, whereas the actual path constitutes many scattering changes of direction of the photons as they course between the light source and the photodiode.
FIG. 8a-8c show alternate preferred embodiments of the oximetry sensor.
The embodiment of FIG. 8a is useful for muscle. It is shown here as a comparison to FIGS. 6a-6c, wherein the overall length L1 and the overall width W depends upon the application and L2 as in FIGS. 6a-6c can vary dependent upon the application from one centimeter or less to five centimeters or more.
The overall length L1 is determined chiefly as a result of the source 100 to detector 102 spacings L2. The spacing determines the depth of penetration of the light which is scattered and migrated through the tissue. The farther the source is from the detector, the deeper the mean penetration. So for shallow penetrations, one would envision a short L2 and thereby L1. The penetration desired depends upon the muscle of interest. For a large muscle, for example, in the thighs or the calf, which tend to be fairly large, one needs a substantial separation to both (a) penetrate the thicker fat layer and (b) to sense deeper into the larger muscle.
For such muscles, a common dimension for L2 would be 3 to 5 centimeters and L1 would thereby be 7 to 11 centimeters.
The width of the sensor is chiefly dependent upon the size of the detectors 102. In the configuration of the presently preferred embodiment wherein each detector has a photosensitive area of approximately 6 millimeters squared, the width is dependent almost entirely upon those two dimensions. As the photodetectors reduce in dimension width W decreases.
The larger photodetector units provide better signal to noise ratio and thereby enable more accurate representation of the oxygenation state of the tissue. As improvements in technology occur and better photodetectors and initial amplification circuitry are developed, the detector size will decrease, with consequent decrease in W.
As with FIG. 6a-6c, the supporting member 101 of FIG. 8acarries numerous rib-form barriers. In this case barriers 103, 104 and 105 serve both support and light reduction functions. Perimeter barrier 105 in this case completely surrounds the light source and detector grouping. Between the light source and barrier 103, is barrier 104 on opposite sides of the detectors. Barrier 104, as previously mentioned, serves to reduce light as it travels between source and detector in the subcutaneous layer.
The embodiment of FIG. 8b represents an alternate to that of FIG. 8a wherein the dimensions of FIG. 6a are significantly reduced to achieve a smaller probe. In addition to the backing member 101 being reduced in size, in FIG. 8b, barrier 104 has been eliminated and barrier 103 serves as the primary and only eliminator of both external light and interference between source 100 and detector 102.
The typical dimensions for L2 of FIG. 8b would be 3 centimeters or less, L1 being 6 centimeters maximum or less. In comparison, the minimum size for the embodiment of FIGS. 8aand 6a-6c of L2 would be 3 centimeters or greater.
The embodiment pictured in FIG. 8b is suitable to be used for example in neonate applications where the desired tissue volume is extremely small and one needs a small probe. It would also be used for very shallow depth muscle and for example, skin flap measurements where skin flaps are created either by surgery or by wound. The sensor is placed over the skin flap to determine the health of that flap as it heals.
The smaller sensor sizes improve the flexibility of the device to correspond to perhaps smaller target muscles and smaller regions of interest.
Referring to FIG. 8c, a similar embodiment to that of FIG. 6a-6c is shown, but having a light source track 109 to enable variable spacing between the light source 100 and detector. Barrier 103 has been omitted in favor of allowing for user settable variations of L2. L2 may be varied between for example 2 centimeters to say 5 centimeters depending upon the application. This may be used for skin flap work in determining the health of a skin flap as described above, with the distance L2 set in accordance with measurement of the thickness of the skin flap.
For this adjustability, a slide mechanism is employed in manner to keep L2 equal on both sides, in dependent motion such that as the spacing of one varies, the spacing of the other will also change.
The embodiments of FIGS. 5-8 share the desirable features of a parallel pair of detectors 102, side-by-side extending across the line between the light source. By simultaneous flashing of both lamps each detector receives photons at its wavelength from both lamps, simultaneously.
FIG. 9 shows another preferred embodiment of the tissue oximeter sensor, in the form of an implantable probe. To further reduce size, one of the light sources 100 is omitted. As in FIG. 8b, light barrier 104 is omitted. The lone barrier in this case 117 serves to reduce direct light interference.
As previously mentioned, backing member 101 holds in fixed relation the light source 100 and the detectors 102. The length L1 is solely dependent upon a single L2 between the single source and the dual detectors. The spacing depends chiefly upon the muscle location internally of the organ which is being studied. As previously mentioned, from 1/2 centimeter or 1 centimeter to 5 centimeters may be appropriate, depending upon the application. Applications envisioned are horse muscle studies.
For application, the physician makes an incision in the skin and slips the oximeter sensor underneath the skin and cutaneous fat layer. There are suture points 113, e.g., biocompatible webbing, surrounding the backing member 101. A coating over the entire sensor is comprised of a biocompatible base material 112, which protects the circuitry from the human system, and protects the human from the invasive nature of the circuitry.
The thickness of the device is of the order of 1 to 2 centimeters maximum. That depth dimension will, as technologically changes, diminish. In FIG. 9c the supporting circuitry is shown. As previously described, the filter/photodiode pair 110, 111 is disposed above the circuit 108. In addition to receiving and amplifying the signal, the circuit, shown here is responsible for telemetric communication of the signal to a receiver outside of the body. A battery 114 powers that circuitry.
By employing a radio signal to transmit the information from within the body to a receiver outside the body there is no need for wires and the like puncturing the skin.
Referring to FIG. 10, one embodiment of the circuitry for driving the device is shown. This is an analog circuit wherein the signal from photodetectors 118 and 119 is amplified by amplifiers 120 and sent to three manipulative circuits that take the difference, the sum and the derivative of the signal. The difference is simply as described in much earlier work, in which circuit 123 simply subtracts 760 nm minus 850 nm to obtain a signal representing deoxygenation.
The sum circuit 124 takes a weighted sum of the 760 nm and 850 nm signals, weighting being chosen appropriate to the fact that the signal variation due to oxygenation or deoxygenation is greater for 760 nm than it is for 850 nm. Because these contrabestic wavelengths tend to cancel the signal due to the difference in oxygenation, the sum shows independent of the difference and is taken as representative of the blood volume changes in the tissue.
The derivative circuit 125 takes the simple derivative to show the rate of change of both of the signals. This is useful as described above to trigger alarm circuitry based upon established standards, wherein the higher the rate of the change, and the more sustained that rate of change, the more potentially dangerous the rate of change. This is useful, as mentioned, for example in monitoring aviators for possible black-out conditions and for apnea, as discussed above.
The outputs of these units 123, 124 and 125 are applied to the control circuit which controls where the signals are directed and how they are displayed and/or sent to a computer. The control circuit may be simply embodied as a switch to switch the output to an LCD display, for example. The analog signal from control circuit can be digitized in the display unit 127 and displayed as a digital number. Additionally it can be digitized and sent to a computer or sent in analog form to a computer for digitization.
The oscillator 121 is an independent source for determining the frequency of lamp flashing. Lamps flash at frequency of 1/2 Hz or 2 flashes per second or greater. This frequency may be independent of heart rate or any other external factor and is set externally by the user, and may be dependent upon application as mentioned earlier. For example, during exercise, the frequency chosen for the lamp will depend upon the frequency of the exercise, such as the the revolutions per minute on a bicycle. If one is expected to encounter a slow change in oxygenation due to the nature of the exercise or the muscle of interest, one can employ a fairly low flashing rate. There is no need for high resolution measure of the rate of change as is required in pulse oximetry.
The lamp rate is tied to the control circuit. The oscillator establishes the timing for the sum and difference circuits because the sum, difference and derivative circuits need to be synchronous. In operation, the lamp flashes, the signal is picked up by the photodetectors and while the lamps are on, the difference, sum and derivative are calculated and are thereby stored in the appropriate memories, and via the control circuit can be directed to the display and to the computer.
The derivative system is the basis of the alarm system. Output from the derivative is compared to a standard within the alarm circuitry, which then determines if there is, for example, a normal rate of change, represented say by a green light, a cautionary rate of change, which may be represented by a yellow light, and a fairly rapid and/or sustained rate of change, which would be for example shown by a red light, an alarm or a buzzer or the like, which would alarm both the wearer or act remotely for example to warn the parents of a neonate in the case of SIDS (Sudden Infant Death Syndrome).
In the alternative, digital version of the circuity of FIG. 11, the same photodetectors 118 and 119 and similar amplifiers output signal to an analog to digital conversion system 128 and a derivative circuit 124. The derivative circuit outputs signal to the analog digital converter, in this case for evaluation by the central processing unit, CPU, or microprocessor 129. Software, shown in FIG. 12, controls the system of data collection and lamp frequency 122 as well as the storing of data, interfacing with external computers and displaying/telemetrically communicating this information. The heart of this circuit is the central processing unit driven by software which will collect data, store it, display it and sound alarm if necessary.
FIG. 12 shows the software. Initialization of the system 140 takes place whereby the analog and digital system is set up and configured properly. The digital memory, communication and telemetry are configured as in FIG. 11. Secondly the device calibration takes place such that the gain of the amplifiers is set electronically by software. The gain of the amplifiers is set to an acceptable range so that digitization can take place accurately, as well as other small internal routines to determine whether the derivative is working properly or not. In the case that the calibration cannot take place, the program will stop and alarm the user. The alarm 134 represents "not working properly, please reset" etc. After calibration is completed successfully, data collection is begun. Data collection is taken in a loop format starting with 142. It starts with turning the lamp on, and sampling the signal, 143. Approximately 500 points of data are taken in rapid succession over approximately 1/2 second sampling interval or less. That data is accumulated, then the lamp is turned off after a delay period, which is set by the user and by the software. The samples are collected and then averaged at 144. This average is then used at 145 to calculate the sum, difference and derivative. In this case the calculated derivative serves as a redundant comparison with the analog derivative calculated in 125 of FIG. 11. In addition to the averaging of 760 and 850 nm, the derivative signal is also averaged and sampled in the same way, for example with 500 points. By this means a calculated derivative as well as a sample derivative are obtained which are compared to provide a much more repeatable and reliable result for an alarm.
The data after it has been manipulated in 145 will be stored, appropriately transmitted and/or displayed. In addition the alarm is set off if necessary at this point. Then finally an independent timer or delay would be introduced. The processor is delayed for a set period to obtain desired lampflash/data collections frequency.
The sequence is thus: lamp on, collect sample, lamp off, average sample, calculate sum, difference and derivative, then transmit, display etc., wait if necessary, and then turn on the lamp again and repeat the whole procedure.
Referring now to FIG. 13, a helmet 170 is shown having a tissue oximeter 172 molded at a position to snugly engage the head of the wearer when the helmet is put on, typically at a position free of body hair, e.g., at the forehead above the eyebrow. The oximeter is of the type, e.g., as described in FIG. 8b, having a source for transmitting NIR light, a detector to receive the light scattered from tissue such as brain tissue and a barrier to engage the head between the light source and the detector to prevent light traveling laterally between source and detector through subcutaneous layers. Preferably, the oximeter in the helmet includes a control circuitry on a miniature chip and preferably circuitry and/or software are provided for determining the rate of change of oximetry readings and for comparing the rate of change to a standard.
Referring now to FIGS. 14a-14b, an oximeter 180 is disposed on a catheter 150 (e.g., an endoscopic catheter), having an inflatable balloon 160 and endoscope optics 190. The oximeter 180 is preferably of the design illustrated in FIG. 7, and is molded or otherwise attached to the outer surface of the balloon. Controlling and detected signals may be passed to and received from the oximeter by wires passing through the balloon and a lumen within the catheter or by transmission from the oximeter to a receiver outside the body by telemetry as discussed, e.g., with respect to FIG. 9. In operation, the catheter, with the balloon deflated, is passed through a body lumen to the position of interest, guided for example, by fluorimetry or by endoscopic viewing. The balloon is then inflated to press the oximeter against the tissue of interest and measurements taken as described above. The technique and apparatus may be applied, for example, to body lumens such as the GI tract (e.g., for measurements of GI track wall ischemia or hypoxia as determined to be a preliminary indicator of multiple organ failure) or to blood vessels, employing an angiographic catheter for analysis and treatment of occlusions, etc. Still other embodiments are possible. For example, a "postage stamp" oximeter may be provided, e.g., for emergency use (self-contained system with alarm as discussed), where the oximeter is held to the subject by an adhesive pad, positioned peripherally around the device. Another embodiment includes providing a water impermeable coating about the device for applications in the presence of water, e.g., for scuba divers, etc. In yet another embodiment a phase modulation spectrophotometer may be employed for calibration of the oximeters described above, especially for in-home or long-term portable monitoring applications, e.g., greater than 3 hours. Such calibration allows more quantitive measure of blood oxygen levels, etc. One example of such a spectrophotometer can be found in U.S. Pat. No. 4,972,331, the entire contents of which is hereby incorporated by reference. It will also be understood that implantable probes may be configured using direct wiring, with corresponding punctures in the skin as an alternative to telemetry.
One of ordinary skill in the art will appreciate that the present invention is not limited to the particular embodiments described in detail. Modifications to the circuitry disclosed, and other aspects of the spectrophotometer configurations disclosed, as well as other modifications to the physical arrangement of the present apparatus will be obvious to those of ordinary skill. Further, the present invention is not limited to any of the uses described herein. In order to fully appreciate the scope of the present invention, reference should be made to the following claims. | The present invention provides in various embodiments novel, wearable systems for determining the metabolic condition of an aerobically stressed portion of tissue such as the muscle tissue of an exercising person. Generally, the systems comprise lightweight rugged detectors, worn adjacent the tissue being monitored. The system of the present invention thus minimizes any performance impairment. In preferred systems a wearable power pack and a wearable display means are provided for displaying information indicative of the aerobic metabolic condition of the region being monitored. In a preferred embodiment intended for use while running or engaged in similar athletic activities, the display is worn on the wrist and displays information from a leg-mounted detector. In another embodiment, intended to provide information to coaches, a telemetry system is employed to transmit a signal carrying the data from the detector to a remote location, for processing and display. Various other embodiments and applications are also included. | 6 |
PRIORITY
The present application claims the benefit of U.S. Provisional Application Ser. No. 61/306,347, filed Feb. 19, 2010, which is herein incorporated by reference in its entirety.
THE FIELD OF THE INVENTION
The present invention relates to acid etching of polycrystalline diamond compacts inserts. More specifically, the present invention relates to a support fixture for the acid etching of polycrystalline diamond (PCD) inserts used in drill bits and industrial cutters.
BACKGROUND
PCD inserts are used to form the cutting tips on underground drill bits, such as those used to drill oil and gas wells. Such inserts are cylindrical in nature, having a substrate which is typically sintered carbide and a layer of sintered polycrystalline diamond on an end of the cylinder. Multiple of such inserts are attached to drill bits as the PCD forms a durable cutting edge.
One limitation in the use of PCD cutting tips is the solvent metal which occupies the interstitial spaces between the diamond crystals. The diamond accounts for about 85 to 95 percent of the PCD, and the remaining material is a metal which acts as a solvent for carbon and a catalyst for diamond formation while sintering the PCD. The fraction of solvent metal is sufficient to cause problems in using the resulting PCD cutting insert. One problem is that the solvent metal expands more with temperature than diamond, and can cause cracking of the PCD layer as the cutting insert is used. Another limitation is that the solvent metal, being a solvent for carbon during the formation of diamond crystals, also acts as a carbon solvent for the degradation of the diamond at elevated temperatures. As such, the solvent metal remaining in the PCD causes the diamond to convert into carbon dioxide, carbon monoxide, or graphite at temperatures near 700 degrees Celsius.
As such, it is desirable to remove the solvent metal from the PCD cutting inserts before use. The solvent metal may be etched from the PCD using a mixture of strong acids, such as hydrofluoric and nitric acids (HF and HNO 3 ). U.S. Patent Publication 2007/0284152 discusses the use of PCD cutting inserts, the problems associated with the solvent metal remaining in the PCD, and the etching of the PCD in acid to remove the solvent metal. In removing the solvent metal from the sintered diamond with acid, it is necessary to protect the substrate from the acid, as it is not desirable to etch or erode the substrate.
U.S. 2007/0284152 shows a fixture in FIG. 12 which is used to hold the PCD insert during etching and to protect the substrate from the acid. For discussion, the fixture is reproduced as Prior Art FIG. 2 . FIG. 1 shows a typical PCD cutter insert 10 . The insert 10 includes a substrate 14 and a PCD layer 18 . As discussed, the substrate 14 is typically sintered carbide, which is comprised of metal carbides sintered together by metals. The PCD layer 18 typically includes about 85 to 95 percent diamond crystals and the remainder an appropriate solvent catalyst metal. The insert 10 is typically about 0.5 inches in diameter and about 0.75 inches in length. To increase the useful life of the insert 10 , it is desirable to remove the solvent metal from between the diamond crystals.
FIG. 2 shows a cross-sectional view of a prior art fixture 22 used to hold the insert 10 in order to acid etch the PCD layer 18 to remove the solvent metal from between the diamond crystals. The fixture 22 has a center bore 26 which receives in insert 10 , a hole 42 connecting the center bore through the back side of the fixture, and a groove 34 formed adjacent the front of the center bore. In use, the insert 10 is placed into the center bore 26 of the fixture 22 . Afterwards, an elastomeric o-ring 30 is placed into the O-ring groove 34 formed in the front part of the bore 26 . The insert 10 is then slid out of the bore 26 into the position shown, causing the o-ring 30 to seat on the diamond layer 18 . A rubber stopper 38 is then placed into the hole 42 formed in the back of the fixture 22 . The insert 10 is thus sealed into the fixture 22 , having only a portion of the diamond table 18 exposed for etching. Etching is accomplished by placing the fixture 22 , with the diamond table 18 facing downwardly, into a shallow bath of concentrated acid. The acid bath is kept at a desired temperature for a desired time period. Typically, the inserts 10 are etched for a period of 5 to 10 days in order to remove the solvent metal to a sufficient depth.
There are several problems associated with the fixtures 22 of FIG. 2 . One significant problem is the expense of the fixture 22 . The o-ring groove 34 must be machined into the fixture 22 , making the cost of the fixture about $4.00 each. Since the fixtures typically may be used only a few times, the cost per insert etched is high. Another problem with the fixtures 22 is the time required to load the insert 10 into the fixture. Multiple steps are required to load the insert 10 , install the o-ring, and set the insert at the proper depth. This increases the time required for assembly prior to etching, raising the cost of etching the insert 10 .
Additionally, the O-ring 30 itself also presents a weakness in the design. Since the O-ring is elastomeric, it can be nicked or damaged while pushing the diamond table 18 through the o-ring during installation. Damage to the o-ring often results in a failed seal and thus an insert which is damaged during etching. Additionally, the O-ring 30 itself adds significant cost to the procedure, since the O-ring costs about $0.50, and is replaced after each use. Even using an O-ring 30 properly selected for the acids, such as a Viton® o-ring, the o-ring periodically fails while etching, resulting in a damaged part. Even if the o-ring 30 does not fail, it is typically softened by the acid and must be laboriously removed from the PCD insert 10 after etching.
A final limitation of the fixture 22 is the inability to precisely delineate the etched and non-etched portions of the diamond layer 18 . FIG. 3 illustrates an etched PCD insert 10 a . The o-ring 30 and fixture 22 produce an irregular border between the non-etched diamond layer 18 and the etched portion of the diamond layer 18 a . The irregular boundary between the etched and non-etched portions of the diamond layer 18 require conservative placement of the insert 10 in the fixture 22 so as to prevent etching of the substrate 14 . Additionally, an irregular boundary between etched and non-etched diamond layer 18 may result in damage to or failure of the insert 10 at the portions of the diamond layer 18 which still have solvent metal therein.
There is thus a need for an improved fixture for etching PCD drilling inserts. There is a need for an etching fixture which is easier to use, more reliable, and less expensive than prior art fixtures.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved fixture for etching PCD drilling inserts.
According to one aspect of the invention, a fixture is provided which does not require the use of an o-ring seal. The fixture thus eliminates the various modes of o-ring failure which may occur, and eliminates the expense of the O-rings. The fixture also provides a sharp delineation between etched and non-etched diamond, allowing the diamond to be etched more consistently and allowing the diamond layer to be etched to a level closer to the substrate.
According to another aspect of the invention, a fixture design is provided which may be injection molded rather than machined, significantly reducing the cost of the fixture. By reducing the cost of the fixture, the fixture may simply be discarded after use rather than cleaning the fixture for reuse.
According to another aspect of the invention, a fixture is provided which creates a positive pressure therein when loaded. The positive pressure helps keep the acid from leaking into the fixture and provides an additional measure of safety in etching the PCD inserts.
These and other aspects of the present invention are realized in a fixture for acid etching PCD drilling inserts as shown and described in the following figures and related description.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the present invention are shown and described in reference to the numbered drawings wherein:
FIG. 1 shows a perspective view of a known PCD drilling insert;
FIG. 2 shows a partial cross-sectional view of a prior art etching fixture;
FIG. 3 shows a side view of a PCD insert etched with the prior art fixture of FIG. 2 ;
FIG. 4 shows a perspective view of an etching fixture of the present invention;
FIG. 5 shows cross-sectional view of the fixture of FIG. 4 ;
FIG. 6A shows a detailed view of the indicated section of the fixture of FIG. 5 ;
FIG. 6B shows another detailed view of the indicated section of the fixture of FIG. 5 ;
FIG. 7 shows a side view of the fixture of FIG. 4 ;
FIG. 8 shows a bottom view of the fixture of FIG. 4 ; and
FIG. 9 shows a cross-sectional view of the fixture of FIG. 4 .
It will be appreciated that the drawings are illustrative and not limiting of the scope of the invention which is defined by the appended claims. The embodiments shown accomplish various aspects and objects of the invention. It is appreciated that it is not possible to clearly show each element and aspect of the invention in a single figure, and as such, multiple figures are presented to separately illustrate the various details of the invention in greater clarity. Similarly, not every embodiment need accomplish all advantages of the present invention.
DETAILED DESCRIPTION
The invention and accompanying drawings will now be discussed in reference to the numerals provided therein so as to enable one skilled in the art to practice the present invention. The drawings and descriptions are exemplary of various aspects of the invention and are not intended to narrow the scope of the appended claims.
Turning now to FIG. 4 , a perspective view of a fixture 46 of the present invention is shown. The fixture has a body 50 which is generally cylindrical, and has a bore 54 therethrough and a base 58 formed at the bottom thereof. The base 58 extends radially outwardly from the bottom of the body 50 . The bore 54 is sized to receive a PCD insert 10 . As there are different diameters of PCD inserts, different diameters of fixtures 46 are made. A plurality of feet 62 extend downwardly from the base 58 . The feet 62 elevate the base 58 and the face of the insert 10 which is being etched to raise these off of the bottom of the etching tank and allow for better circulation of the acid around the PCD insert. This improves the etching of the insert.
Currently, the PCD inserts 10 are commonly 13, 16 or 19 millimeters in diameter. This application primarily discusses the 13 mm diameter insert as an example. The larger sizes of inserts 10 would use a correspondingly larger fixture 46 , with similar clearance or interference in the fit. The 13 millimeter insert may be casually referred to herein as a one half inch insert, since 13 mm is 0.512 inches in diameter.
FIG. 5 shows a cross-sectional view of the fixture body 50 . As shown, the bore 54 may be made with two sections of different diameter. As shown, the top portion 54 a of the bore (approximately the top half) has a diameter of 0.533 inches. The lower portion 54 b of the bore (approximately the lower half) has a diameter of 0.525 inches. These diameters allow an insert 10 having a diameter of 0.512 inches to easily be placed within the fixture body 50 while keeping the insert aligned within the body. A small rib 66 is formed at the bottom of the bore 54 . The rib 66 seals against an insert 10 which is pressed through the top of the bore 54 , through the lower end of the bore 54 and past the rib 66 by a desired amount.
FIG. 6A and FIG. 6B show detailed views of the rib 66 . The rib 66 extends approximately 0.03 inches into the bore 54 , making the diameter of the bore 54 at the rib 66 approximately 0.47 inches. The rib thus forms an interference fit with a 0.512 inch diameter PCD drill insert. It is currently preferred to have a rib 66 which is between about 0.01 inches and 0.04 inches smaller in diameter than the insert. When an insert 10 is pressed into the body 50 , the rib 66 seals against the insert. As shown in FIG. 6A , the rib 66 may have a radiused upper portion 66 a which transitions into a lower sealing portion 66 b . The upper portion and lower portion may both be between about 0.01 and 0.03 inches in height, and have a protrusion into the bore 54 as discussed.
As shown in FIG. 6B , the rib 66 may have an upper portion 66 c which transitions from the bore 54 to a lower sealing portion 66 d . The sealing portion 66 d protrudes into the bore 54 as discussed above to create an interference fit between about 0.01 and 0.03 inches with the insert. The upper transition portion 66 c and the lower sealing portion 66 d are both between about 0.01 and 0.03 inches in height. The rib 66 may also have a smaller secondary rib 66 e extending outwardly from the lower portion 66 d and further into the bore 54 . The secondary rib 66 e is typically between about 0.001 and 0.01 inches in both height and width (protrusion into the bore 54 ), and preferably may be about 0.003 inches in height and protrusion into the bore.
The upper transition region 66 a , 66 c helps the insert move smoothly past the rib 66 without causing damage. The lower sealing region 66 b , 66 d presses against the insert to seal thereto. The secondary rib 66 e , if used, provides a more easily deformable section of material to the sealing rib 66 and can improve the effectiveness and reliability of the sealing rib 66 .
Different etching conditions such as time or temperature may affect the inner size of the rib 66 , requiring the rib to be larger or smaller in size. Thus, the interior diameter defined by the rib 66 may be a few hundredths of an inch larger or smaller. Typically, the same amount of interference is used between the rib 66 and a larger insert 10 , such as a 16 or 19 millimeter insert. That is to say that the difference in size between the inner diameter of the rib 66 and the outer diameter of the insert 10 would be approximately the same. Advantageously, the fixture 46 may be adapted to receive 16 or 19 millimeter diameter inserts by changing the diameter of the body 50 while leaving the diameter of the base 58 and location of the feet 62 the same. This allows the use of the same loading and processing equipment for different insert sizes.
FIG. 7 shows a side view of the fixture body 50 with an insert 10 loaded therein. The insert 10 is placed into the top of the bore 54 and pressed downwardly past the rib 66 . A simple pressing jig can be made which contacts the bottom of the base 58 and which allows the insert 10 to move downwardly past the base 58 a predetermined distance before stopping the insert. This allows the insert 10 to be easily and repeatably loaded into the fixture body 50 . The prior art fixture 22 requires more time to load, requiring the insert 10 to be placed into the fixture, then the o-ring 30 to be placed into the groove 34 , and finally requiring the insert to be pressed past the O-ring into position. Thus, the fixture 46 achieves a significant time savings in loading the insert 10 as well as providing a much more accurate and repeatable loading and etching process. The improved accuracy and repeatability of loading and etching allows the diamond layer 18 to be etched closer to the substrate 14 .
FIG. 8 shows a bottom view of the fixture body 50 , showing the placement of the feet 62 . FIGS. 7 and 8 illustrate how the fixture body 50 keeps the diamond layer 18 off of the bottom of the etching reservoir, and allows better circulation of acid around the etched face of the diamond layer 18 . This allows for more consistent etching of the diamond layer 18 .
FIG. 9 shows a cross-sectional view of the fixture 46 ready for etching. The fixture 46 has a PCD insert 10 loaded into the body 50 . After pressing the insert 10 into place, a cap 70 is pressed into the top of the bore 54 . The cap 70 extends downwardly into the bore approximately 0.2 inches. The cap 70 has a slight interference fit with the bore 54 , sealing against the bore 54 as it is pushed into place. As such, inserting the cap compresses the air in the bore 54 and causes a positive pressure to be formed inside of the bore 54 . This positive pressure helps to keep the etching acid out of the bore 54 while etching the insert 10 , further reducing the risk of leakage.
The cap 70 extends outwardly beyond the body 50 and forms a lifting flange which makes it easier to move the fixtures 46 into and out of the acid reservoir. The fixture body 50 and cap 70 are preferably made from a plastic such as polypropylene, polyethylene, polyvinylidene fluoride, polytetraflouroethylene, and mixtures thereof. Other plastics that may also work could be Liquid Crystal Polymer (LCP) or PolyEtherKetone (PEK). A currently preferred material is C3350 TR polypropylene co-polymer.
One significant advantage of the fixture 46 is that the boundary between etched and non-etched portions of the diamond layer 18 can be precisely controlled. The rib 66 forms a sharp delineation between etched and non-etched diamond compact. The precise control of the etching boundary allows the insert 10 to be mounted into the fixture 46 with a greater amount of the diamond layer 18 exposed, improving the temperature stability and useful life of the etched insert.
Another significant advantage of the fixture 46 is the reduction of leaks during etching. The prior art fixtures 22 had a failure rate of between 2 and 5 percent. The present fixture 46 has a failure rate of less than one percent. The reduction of the failure rate is significant because of the cost associated with producing the inserts 10 and the time and cost of etching the inserts.
Another significant advantage of the fixture 46 is the ease with which it is used. The fixture 46 may be loaded in much less time than the prior art fixture 22 . The fixture 46 may also be quickly unloaded and disposed of where the relatively expensive prior art fixture needed to be cleaned for reuse. Cleaning of the prior art fixture 22 and the produced insert 10 took significant time because the o-ring was damaged by the acid and became sticky and difficult to remove from the insert 10 and fixture 22 .
Another advantage of the fixture 46 is that the design of the cap 70 and body 50 allow the fixture to be more easily moved into and out of the acid reservoir for etching, and also allow a closer spacing between adjacent fixtures in the etching reservoir. This allows more inserts 10 to be etched in a batch. This is advantageous as the batch time is quite long (typically between 5 and 10 days) and the etching acid is not reused.
There is thus disclosed an improved etching fixture for PCD drill inserts. It will be appreciated that numerous changes may be made to the present invention without departing from the scope of the claims. | A fixture for etching PCD drill inserts is provided. The fixture design allows the fixture to be injection molded, significantly reducing costs and allowing the fixture to be disposed of after a single use. The fixture allows for faster use and more accurate etching of the PCD insert. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to measuring web tension, and in particular for the sonic measurement of web tension in paper machines.
2. Description of Prior Art
As is well known to those skilled in the paper making art, and to those skilled in the handling of moving webs of paper, excessive tension can tear the web and inadequate tension can cause edge flutter at high machine speeds, which will eventually cause a break if the amplitude of the flutter becomes excessive. In both cases, down time results. Conventionally, unsupported web tension is controlled by slight differences in machine speed, and machine speed differential is manually controlled and must be changed as the web shrinks as it passes through different sections of the machine. Therefore, the control of tension through the control of machine speed has heretofore been a critical operation and must be frequently monitored.
An open draw is necessary because as the web loses water, it shrinks. Shrinkage in the machine direction is restrained somewhat by the changes of machine speeds. Therefore, the paper quality, for example, ultimate strength, stretchability, etc., will be affected by the web tension.
As reported by K. W. Britt, Pulp and Paper Technology, 2nd, E. Van Nostrant, 1970, p.468 "There is no known instance of a successful attempt being made to automatize any of the critical draws on a paper machine. For example, on an open draw machine, the speed difference between the machine wire and the first press felt has an important effect on both machine runability and the product of mechanical and/or functional properties. A technique for sensing the tension in such a draw and adjusting it to maintain web tension at a specified level would be quite beneficial. At present, no practical method for sensing said tension is available, but optical scanning methods and knowledge of paper rheology (as a function of moisture content) may offer a route to do a successful solution."
Transverse waves are created when a string, under tension, is disturbed, and transverse waves are created when the surface of water is disturbed. Likewise, when a membrane under tension is disturbed transverse waves are also generated. If the bending stiffness of the membrane can be neglected, these transverse waves have a wave velocity in accordance with the relationship ##EQU1## where T=tension in membrane (lb force/ft),
w=weight of membrane/unit area (lb mass/ft 2 ),
a=wave velocity (ft/sec),
g c =conversion factor (37.17 lb mass/lb force ft sec 2 )
In U.S. Pat. No. 4,109,520, Leif Eriksson discloses a method for measuring web tension of a stationary web which applies a frequency near the resonance of a loudspeaker pressed against the web. The impedance of the loudspeaker at this frequency is a function of the web tension.
In U.S. Pat. No. 2,661,714, I. A. Greenwood, Jr. et al disclose a method of measuring web thickness of a traveling web with ultrasonic techniques in which the web must be pressed or held against an anvil-type support at the measuring location below an X-cut piezoelectric crystal which produces air compressional waves.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a sonic measurement of web tension for a running web which is not supported in the area of measurement, with the exception of the conventional support given by the rolls which define the path of web travel. According to the invention, the above object is achieved by energizing a sonic transducer at a first location adjacent an open draw to create a burst of transverse waves in the travelling web. At a second location, downstream from the sonic transducer, a microphone is provided to receive the burst of transverse waves and to convert the same into electrical signals. The machine speed is also measured and fed as representative electrical signals to an electronics unit which measures the time of travel of the transverse wave and the moving web and subtracts the web speed to provide the velocity of the transverse wave. The velocity of the transverse wave is directly related to a web tension and is calculated and displayed in units of tension.
The electronic control circuit generates an electronic window during an interval during which the burst of transverse waves should be received so that noise and echoes may be discriminated. In addition, a control circuit provides for a minimum reception duration time threshold in order to make the system more immune to noise. Thus, the burst of waves must be detected for a certain length of time before a decision is made by the control system that a wave train is truly detected.
Several advantages are obtained by practicing the present invention. First of all, ultrasonic sound is employed to avoid signal interference problems in that there is a much lower frequency sound around a paper machine, and a sharper, more accurate measurement can be made with ultrasonic measurements. Secondly, a train of pulses of high frequency sound is employed so that the signal from the microphone can be processed with a moderate width band pass filter so that only frequencies close to the nominal ultrasonic transducer frequency will pass through the circuit. Since high frequency is absorbed (damped) more than low frequencies, an optimum range of frequencies exists and the selection of a particular frequency is dependent on the application. The calculation of tension requires the mass per square foot of the web, which depends on the solids content as well as the moisture content and in my preliminary investigations with the same has been assumed to provide a mass of 32 lb/3000 ft 2 for an open draw of newsprint.
High frequency sound is very directional and can be provided as a narrow beam. Therefore, the ultrasonic transducer may be located at a greater distance from the web than the microphone, and it is submitted that the microphone would best be located near a roll where the extraneous web excursions would be smaller, and hence the signal-to-noise ratio would be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention, its organization, construction and operation will be best understood from the following detailed description, taken in conjunction with the accompanying drawings, on which:
FIG. 1 is a schematic illustration of an open draw, for example of newsprint, in which the rolls at each end of the draw are drawn at slightly different speeds to control web tension, and illustrating, in schematic form, a sonic web tension measurement of system;
FIG. 2 is a graphic illustration of the excursions of a web, in the form of transverse waves, due to an ultrasonic pulse train, for example, 20 kHz, and a wave form of the signals received by the microphone, including noise from the paper machine secondary waves, and echoes;
FIG. 3 is a schematic diagram of a web tension measurements system which may be employed in practicing the present invention;
FIG. 4 is a graphic illustration of signals at various points in the circuit of FIG. 3;
FIG. 5 is a partial computer flow chart of the main program for the system of FIG. 3;
FIG. 6 is a computer flow chart illustrating the electronic window generation routine; and
FIG. 7 is a computer flow chart illustrating the routine which is entered upon interrupt of the microprocessor by the roll speed transducer which provides machine speed signals.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, and open draw of a paper machine is illustrated, generally at 10 as comprising a pair of rolls 12 and 14 carrying a moving web 16 in the direction indicated. The mill operator must adjust the speed of each of the rolls 12 and 14 so that the web tension remains within an acceptable range. The web is oscillated in a vertical direction by a train of pulses from an ultrasonic horn 18 to create a transverse wave which travels along the moving web 16 toward a microphone 22. The time interval between emission of the ultrasonic signal and the receipt of the wave at the microphone 22 is a combination of web velocity and wave velocity relative to the web; therefore, the web speed (machine speed) must be subtracted in order to provide the wave velocity relative to the web. For this purpose, a machine speed transducer 24 is connected to the roll 14 and produces a signal representing machine speed. The machine speed signal and the signal received by the microphone 22 are fed to a web tension electronics circuit 20 which calculates wave velocity from these two inputs and converts web velocity into an output signal which indicates web tension. This output signal is fed to a display 26 for observation by the mill operator.
FIG. 2 illustrates the vertical displacement of the web at 28 which includes two successive sets of displacements 30,32, and due to successive blasts of ultrasonic horn 18 and minor excursions therebetween due to extraneous disturbances from the paper machine. In the lower portion of FIG. 2, the signals received by the microphone 22 are illustrated at 34 as comprising a signal 40 which resulted from the blast causing the excursions 30 and composite echoes 36 and 38 from previous blasts, secondary waves, as well as the minor noise generated by the paper machine. Secondary waves originate at the horn and move along the moving web in a direction opposite to that of web travel. However, if the web is traveling faster than the transverse wave velocity, these waves move, with respect to fixed coordinates, in the direction of the web and will reach the microphone at a time later than the primary waves 40, and can be discriminated against on a time of travel basis.
Referring to FIGS. 3 and 4, a circuit and corresponding wave forms are illustrated for a web tension measurement system constructed in accordance with the present invention. Inasmuch as a microprocessor may readily be programmed for the simple functions necessary for practicing the present invention, the same is used herein at 42 and may contain, for example, an Intel 8080 or a Zilog Z80 microprocessor, as well as a memory, a power supply and signal conditioning circuits. The microprocessor 42 receives the machine's speed signal 44 from a roll speed transducer 46 which may simply be a magnetic pulser driven by a roll, producing one pulse for each revolution of the roll.
The microprocessor 42 is programmed to provide wave velocity in accordance with the equation.
a=[Y/(τ.sub.M -d.sub.min)]-(K/τ.sub.s) (2)
where
K=π(D+t) (ft),
D=diameter of roll (ft),
t=thickness of web (ft),
a=wave speed (ft/sec),
Y=distance between horn and mike (ft),
τ m =time interval between beginning of wave transmitted and confirmed receipt, including d min (sec),
d min =minimum reception time (sec) for noise immunity, and
τ s =time interval for one revolution of the roll (sec).
The microprocessor is also programmed to provide web tension by a calculation made in accordance with the equation
T=a.sup.2 w/g.sub.c (3)
which is, using the nomenclature above, the same as equation (1).
In order to provide these functions, the microprocessor 42 generates a square wave ultrasonic frequency 48 to a power amplifier 50 which energizes an ultrasonic horn 52 to excite the web into transverse oscillations. As seen in FIG. 4, the ultrasonic frequencies are generated with a half period of d 1 and is repeated at an interval d 2 . The resulting transverse waves travel along the web, and with the web moving toward a microphone 54 where they are received, converted into electrical signals and amplified by an amplifier 56. The signals are fed to a band pass filter 60 to provide an output signal 62, as indicated in FIG. 4. The signal 62 is rectified and filtered. Signals of sufficient strength pass through the Schmitt trigger circuit 65, and are gated at 66 with a signal 68 provided by the microprocessor 42, to form a signal 70 which is fed back to the microprocessor 42.
The signal 68 is a gate signal which represents an electronic window which is open only slightly more than the expected duration of receipt of the transverse wave and is determined to open at a time d 3 from the beginning of emission and is to close at a time d 4 , also referenced to the initial time of emission. Signals received at the microphone outside of the time interval d 3 to d 4 are rejected as being noise, composite echoes and the like.
In order to further increase noise immunity, the signal 70 must also be received for a minimum duration d min .
The key board 72 is provided to input alarm set points and time intervals d 1 ,d 2 ,d 3 and d 4 as well as the parameter n which sets the length of time of the ultrasonic blast.
Referring to FIG. 5, a flow chart illustrates the above process which starts at 80 and in the next step interrupts are inhibited, a counter is set to zero and a FLAG is set=0. A real time clock signal, called clock, is saved and stored in memory at a location CLOCKSAVE. Thus the parameters are initialized. The next step is to operate the output line 48 (FIG. 5) which is the line for controlling the power amplifier for so many cycles to form a blast of, for example ten cycles, at a frequency of, for example, 20 or 22 kHz. At each toggle, "1" is added to the counter, as indicated at 86 and a software delay loop 88 is provided before it is determined at 90 whether the counter is less than n where n=the total number of toggles desired. If the counter has not reached n, the output line 48 is again toggled. After achieving n counts a window routine is entered, as indicated at 92, and the web tension as calculated by the window routine is displayed by a routine READOUT at 94. Subsequently, the time interval from the start of a blast is determined and is compared to the interval d 2 , and if the interval d 2 is less, the operation above is repeated. If the time d 2 has not been achieved, interrupts are allowed, as at 98, and the electronic window routine is again initiated.
Referring to FIG. 6, the routine for the electronic window generation is illustrated with a START at 100 which initiates a CLOCK-CLOCKSAVE determination at 102 and 108. If this time is less than or equal to d 3 and is greater than d 4 then GATEX is set "0" and a return to the main program is executed at 106. Otherwise, the GATEX line is set to "1".
As long as line 68 remains at a "1", the signal from the microphone 54 may pass through the AND gate 66. A determination is then made as to whether a FLAG is equal to "1". If not a return is provided at 114. This test of FLAG allows only one calculation of web tension per blast. If FLAG="0", however, at 116, it is determined as to whether the line 70 has been "1" for a time interval d min . If not, a return is provided at 118. If so, however, FLAG is set to "1", as in 120, and the wave velocity is calculated so that the tension may be calculated. At 122, it is also provided that an alarm setting is energized if the web tension falls outside of prescribed limits as set by the alarm set points. Afterward, there is a return to the main program where the web tension is displayed by a read out routine, as indicated at 94. At 96, if the time interval is greater than d 2 , the main program is restarted.
The roll speed transducer is connected to an interrupt line. Upon an interrupt caused by the roll speed transducer, the routine of FIG. 7, is entered, if interrupts are allowed. This starts at 126 and the next step determines the timed interval for a revolution of the roll which is equal to (CLOCK-CLOCKSAVES). CLOCKS is then set equal to the value of the real time clock set 130, whereupon a return is provided at 132.
The readout flow sheet has not been included herein for the sake of simplicity. It basically involves the transfer of web tension stored in memory to a display unit (FIG. 3), e.g. a series seven segment light emitting diode units. If three significant digits are to be read, there would be 7+3=10 output lines, assuming the use of multiplexing for signal transfer.
For the case where wave travel velocity is faster than the web travel speed, the velocity of the wave traveling upstream can be measured by positioning the microphone upstream of the ultrasonic horn. The velocity of the wave relative to the web can be calculated by adding the web velocity to the wave velocity with respect to fixed coordinates.
Although I have described my invention by reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art, without departing from the spirit and scope of the invention. I therefore intend to include within the patent warranted hereon all such changes and modifications as may be reasonable and properly be included within the scope of my contribution to the art. | Tension in a moving web is measured by subjecting the web to an ultrasonic pulse train and measuring the time interval for the resultant transverse waves in the web to proceed a known distance past a point upstream (or downstream). The composite web plus wave velocity is calculated and the web travel time is added (or subtracted) to obtain wave velocity which is related to tension in accordance with the equation T=a 2 w/g c , where T=web tension, a=wave velocity, w=mass per unit area and g c =lb mass ft/lb force sec 2 conversion factor. | 6 |
FIELD OF THE INVENTION
The present invention relates to a data compression utilization method and apparatus for a computer main storage or store.
DESCRIPTION OF THE PRIOR ART
Computers and computer systems include a main memory or store that advantageously store data in a compressed format. However, different data compression utilization solutions than used for direct access storage devices (DASDs) are required. DASD data compression is not real time and the available DASD storage space is not typically fully used.
When data compression is used, the physical size necessary to store the compressed representation of the data is unknown. It depends on the exact data and order of data that is being compressed. When compression is used for storing data in a computer's main store tradeoffs exist between maximizing memory utilization and minimizing system failures.
First, it is desirable for the main store to present a real address space as large as possible. This is done by estimating the compression ratio or uncompressed data size/compressed data size to be at least as large as can actually be achieved. This implies that all of the main store will be utilized and none will be wasted due to having a smaller than necessary real address space. A large real address space improves system performance, but it must be mapped to a physical address space.
The physical address space is limited by the amount of memory that is installed in the system. The physical address space is a fixed size; however, as the compression ratio will change dynamically, the true amount of real memory is variable also. Operating systems are designed to handle fixed sizes of real memory. When an access to memory cannot be handled, this can cause a system outage. As a result, it is highly undesirable for an access to a real address not be translatable to a physical address for any reason.
If the estimated compression ratio is set too high, there is a higher probability that there will not be a physical address for each real address. If the estimated compression ratio is set too low, there will be no significant gain made by using main store compression.
SUMMARY OF THE INVENTION
Important objects of the present invention are to provide an improved data compression utilization method and apparatus for a computer main storage or store; to provide such method and apparatus that maximizes the utilization of memory compression while keeping the chance of failure to acceptable levels; and to provide such method and apparatus that overcome many of the disadvantages of prior art arrangements.
In brief, a data compression utilization method and apparatus for a computer main store are provided. An amount of unused memory in the computer system main store is dynamically calculated and compared with a plurality of predefined threshold values. One interrupt of a plurality of predefined interrupts is selectively generated responsive to the compared values. Each of the predefined interrupts is handled in order to adjust memory usage. The usage of the computer system main store is adjusted responsive to the particular generated interrupt.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention together with the above and other objects and advantages may best be understood from the following detailed description of the preferred embodiments of the invention illustrated in the drawings, wherein:
FIG. 1A is a block diagram illustrating a computer system for implementing a data compression utilization method in accordance with the present invention;
FIG. 1B is a block diagram illustrating a data compression software structure for the system of FIG. 1A;
FIG. 2 is a logic diagram illustrating how the software structure of FIG. 1B handles interrupts from a compression engine of the computer system of FIG. 1A; and
FIG. 3 is a more detailed view of the compression engine of the computer system of FIG. 1A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, in FIG. 1A there is illustrated a block diagram representation of an exemplary system generally designated by 10 for performing a data compression utilization method of the invention. As illustrated, the exemplary system 10 includes at least one data processor unit 12 (1 to X) generally designated by 12. Processor unit 12 is coupled to a main store subsystem generally designated by 14. The main store subsystem 14 includes a memory controller 18 operatively coupled to a main memory store 16 for storing compressed data and a compression engine 20 operatively coupled to the memory controller 18. Processor 12 is also coupled to the compression engine 20 via the memory controller 18 to read and write certain control information. The main memory store 16 typically comprises dynamic random access memory (DRAM).
In FIG. 1B, there is shown a software structure generally designated by 22 for the system 10. The software structure 22 includes a memory management function 24, an operating system 26 and user tasks 28.
In accordance with the method of the invention, the utilization of memory compression is maximized while the chance of catastrophic failure is kept to acceptable levels. The invention uses a combination of hardware of system 10 and of software 22 as shown in FIGS. 2 and 3. An interface in the form of interrupts is provided from hardware 10 to software 22. The interrupts present information to the software 22 regarding the current utilization of the physical main store 16. Data processing unit 12 is directed by the predetermined interrupts to temporarily suspend its present process to run a predefined routine corresponding to a particular interrupt for adjusting the usage of the computer system main store 16. After the predefined routine for the particular interrupt is completed, the data processing unit 12 resumes its original work.
As shown in FIGS. 2 and 3, predefined interrupts are represented by a plurality of lines 314, 316, 317 that together define a predetermined interrupt value 315 in FIG. 3 and a case of a received external interrupt value is identified at a block 216 in FIG. 2. The interrupts 314, 316, 317 are implemented including a memory overflow interrupt 316 indicating that the main store 16 is over utilized, a memory underflow interrupt 314 indicating that the main store 16 is not fully utilized, and an urgent memory overflow interrupt 317 indicating that the main store 16 is over utilized and that the main store 16 is nearly full.
Referring now to FIG. 3, an expanded view of the compression engine 20 is provided. Compression engine (CE) 20 includes a compression/decompression unit 350, an unused memory counter 302, multiple external multi-byte registers including an urgent threshold 304, an overflow threshold 306 and an underflow threshold 308, a plurality of comparators 340, 342 and 344, an interrupt register 310 and a CE control register 320. Unused memory counter 302 indicates how much physical storage remains available; thus if the compression ratio is high, the unused memory counter value will be higher than for a lower compression ratio.
The multi-byte registers 304, 306, 308 are readable and writable from processor 12 as indicated at a line labeled REGISTER ACCESS. An input from the unused memory counter 302 and an input from a respective one of the multi-byte registers 304, 306, 308 are applied to the comparators 340, 342 and 344. The comparators 340, 342 and 344 are typical multi-byte comparators of a size as required by the registers 302, 304, 306, 308. An output line 311 of comparator 344 labeled GT is true when unused memory 302 is greater than the underflow register 308. An output line 312 of comparator 342 labeled LE is true when unused memory 302 is less than or equal to the overflow threshold register 306. An output line 313 of comparator 340 labeled LE is true when unused memory 302 is less than or equal to the urgent threshold register 304.
Interrupt register 310 returns values as indicated at interrupt value 315 of the interrupt requests at lines 311, 312 and 313 as modified by the interrupt enable lines 361, 362 and 363 from the CE register 320 using three AND gates 371, 372 and 373. Interrupt value 315 is collectively readable as an I/O register or other suitable memory access from processor(s) 12. Interrupt value 315 can be, by convention, the value of the outputs of AND gates 373, 372 and 371 such that their output lines 317, 316 and 314 represent the high order to low order bit of interrupt value 315. For example, if 317 is 1 and 316 and 314 are zeros, the hexidecimal value of Interrupt Value 315 is 04. The individual AND gate outputs at lines 317, 316 and 314 also are applied to an OR gate 323, which produces an interrupt to the processor 12 as indicated at the OR output line labeled INT SIGNALLED 324.
CE control register 320 includes programmable latches 322 having individual input lines labeled 368, 367 and 366 and output lines labeled 363, 362 and 361. The latches 322 are at least writable by processor(s) 12 as I/O registers or other suitable memory access. IntEnable 322, by convention, can be written as a register with its high order bit being 368, its middle bit 367 and its low order bit 366. Since the output lines 363, 362 and 361 of latches 322 feed the AND gates 373, 372 and 371, respectively, it follows that these lines enable or disable interrupts from 313 (urgent interrupt), 312 (overflow interrupt) and 311 (underflow interrupt), from high order bit to low order bit, since setting the line to 0 will ensure that 373, 372 or 371, respectively, is zero.
FIG. 2 shows how the software system 22 and compression engine 20 communicate and process interrupts in accordance with the present invention. When external interrupts are enabled, the software system 22 executes the sequential functions of FIG. 2. In FIG. 2, at a block 210, control is received for an arbitrary external interrupt and sufficient state is saved to begin interrupt processing. Since main storage compression would likely be an important interrupt for system performance of the computer system 10, this embodiment shows an immediate check of an interrupt value to determine if the interrupt value 315 is from the compression engine 20 as indicated at a decision block 212. If the interrupt value 315 is a 0, then the interrupt is not from compression engine 20, so existing prior art interrupt handling for processor 12 is invoked. If interrupt value 315 is not zero, then there is an interrupt signalled by compression engine 20. Since the detailed processing might be quite lengthy, possibly involving hard disk operations, software 22 can disable further interrupts by writing the value zero to IntEnable 322 before re-enabling external interrupts.
Several possibilities are represented by a block 214. If the hardware 10 is arranged to deliver the IntSignalled 324 line to one processor 12, no processing is needed at block 214. If the IntSignalled 324 is delivered to multiple processors 12 in a multiprocessor configuration for system 10, then any suitable means, for example, a test-and-set instruction, can be used to insure that one processor 12 discovers that it owns the interrupt and goes on to block 216, while the other processors 12 exit the interrupt without further processing. In the multiprocessor configuration, a type of semaphore is set by the owning processor 12 at block 214 and cleared at a block 224 with completion of the interrupt processing by the owning processor.
Interrupt value 315 identified at block 212 is remembered and at a block 216 appropriate software processing will be invoked based on that remembered value. Block 216 represents a software case statement where the next block executed is based on the remembered value of interrupt value 315. As shown in FIG. 2, a value 1 causes a block 218 to be invoked. A value of 2 or 3 causes a block 220 to be invoked. A value of 4, 5, 6, or 7 causes a block 222 to be invoked. This priority encoded checking individual bits of interrupt value 315 provides that urgent interrupts 313 (317) are serviced ahead of overflow interrupts 312 (316) and those, in turn, are serviced ahead of underflow interrupts 311 (314).
With the underflow interrupt 314 on and the other interrupts 316 and 317 off, block 218 is reached. This means that too much main storage 16 is being wasted so that storage utilization should be increased. Block 218 invokes suitable programs to increase main storage use. Conventional arrangements for adjusting page utilization are extensive and the software system 22 can arrange, among other things, to run more jobs to increase its workload, or reduce the rate at which the paging subsystem preemptively ejects pages from main storage 16 to an auxiliary storage (not shown). This should cause more main storage consumption and, eventually, may increase the use of physical main store 16.
With overflow interrupt 316 on and the urgent interrupt 317 off, block 220 is reached. This means that main store 16 is getting overcommitted. That is, while the system 10 still is thought to be healthy, the amount of main storage 16 being used is approaching a level that, if left untended, might eventually reach the urgent threshold 304. Software at block 220, again using conventional techniques can reduce the main store load by either suspending jobs temporarily or by changing parameters on the paging subsystem to have it eliminate more active pages and thus allow the eliminated pages to be zeroed out, while awaiting reassignment. The key is that explicit action is provided to take real pages away from executing programs, write them to hard file or other backing store if necessary, and then zero them out to improve compression in the system 10. Zeroing of pages in the main storage 16 is provided to make the memory space of the eliminated pages available for storing other compressed data pages.
With the urgent interrupt 317 on, block 222 is reached. This means storage 16 is near exhaustion. Too many jobs are creating a physical store whose size is much too close to exceeding the available physical store and an outage is reasonably imminent. Software at block 222 takes energetic action, such as terminating unessential jobs, suspending work, calling the machine operator for assistance and the like. As at block 220, the zeroing of storage will increase redundancy and improve compression in the system 10.
Note that this embodiment effectively multiplexes three interrupts 311, 312, 313 into a single external interrupt 315 and then successfully demultiplexes the three interrupts 311, 312, 313 in the interrupt handling.
At a block 224, interrupts 314, 316 and 317 from interrupt register 310 are reenabled by setting CE Register 320 to 7. Processor 12 will then return from interrupt, which might cause the particular interrupt to be immediately reinvoked in some particularly difficult cases.
This is a race condition, but race conditions are not new for paging subsystems. Thus, this issue is simply another form of the pacing questions that paging subsystems already commonly deal with in the art. The paging subsystem and compression engine 20 must cooperatively ensure that the various thresholds 304, 306, and 308 permit the paging subsystem to keep up with increases in physical storage consumption. Except for potential differences in consumption rate caused by compression, no novel problems occur over prior art and the thresholds are designed to keep the pacing correctly bounded.
It should also be pointed out that while ordinary zeroing of pages by programming could be employed, the prior art compression system may also provide special operations to eliminate this process and ensure ready realization of the relinquishing of the pages. However this is accomplished, the zeroing operation will affect unused memory counter of the prior art and so, if software succeeds, reducing at block 218 or increasing at blocks 220, 222, of the unused memory counter 302 value enough to alleviate the interrupt condition so interrupts can be reenabled.
Processor(s) 12 establishes the thresholds 304, 306, and 308. In a practical system, the values need not be updated frequently. It is presumed throughout that in a running system 10, the urgent threshold 304 is greater than or equal to overflow threshold 306 and that is in turn greater than or equal to underflow threshold 308.
The method of FIG. 2 shows a simple illustrative embodiment. Those skilled in the art could readily add other features, such as individually enabling or disabling the various interrupts, or allowing multiple processors to concurrently service blocks 218, 220, or 222 instead of having one processor perform the work and the like, using conventional techniques known in the art.
Since the results of FIGS. 2 and 3 are effectively a never-ending loop, the initial conditions bear disclosure.
Memory Controller 18 initially works with compression effectively off. This permits standard initial program load to occur as on machines with no compression. The initial value of the CE control register 320 is zero on machine reset, with the various registers 302, 304, 306, and 308 arbitrary. Software system 22 would not look at interrupt value 315 until the compression engine 20 was enabled.
Conventional techniques can be used for initialization for data compression that produce a real result, for example, compressed main storage 16 on the actual machine or system 10. The initialization results can be used, possibly with past information, to establish the initial values of the threshold registers 304, 306 and 308. Then, a conventional initialization process occurs where compression engine 20 utilizes compressed data encoding. Thereafter, the processor 12 sets CE control register 320 to either 00, or 07, as required (eventually to 07) and the continuous monitoring of usage of main store 16 begins.
It should be understood that the concept of the present invention to communicate the current utilization status of the physical main storage is not restricted to the use of three interrupt levels. For example, another implementation might have three levels of over-utilization status and two levels of under-utilization status thus allowing the software finer control. With another implementation including additional threshold levels, additional corresponding adjustment routines for the additional corresponding interrupts would be used for controlling the utilization of the main store 16.
While the present invention has been described with reference to the details of the embodiments of the invention shown in the drawing, these details are not intended to limit the scope of the invention as claimed in the appended claims. | A data compression utilization method and apparatus are provided for a computer main store. An amount of unused memory in the computer system main store is dynamically calculated and compared with a plurality of predefined threshold values. One interrupt of a plurality of predefined interrupts is selectively generated responsive to the compared values. Then the usage of the computer system main store is adjusted responsive to the generated interrupt. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to removal of pet hair, lint or the like from fabric articles such as clothing, blankets, bedding etc., and more particularly to the removal of such debris using adhesive sheets placed within the rotatable drum of a tumble dryer.
BACKGROUND
[0002] Accumulation of pet hair on fabric articles such as clothing, blankets, bedding, curtains, and others is a well-known problem.
[0003] A common method of removing pet hair is the use of a hand-held lint roller which features a long continuous roll of adhesive sheet material that has an adhesive coating on one side thereof. The roll is rotatably disposed around a cylindrical portion of a plastic dispenser that features a handle extending axially from one end thereof. The adhesive face of the sheet material faces radially outward from the dispenser, whereby rolling movement of the roll over a pet hair contaminated article will cause the pet hair to adhere to the outside of the roll, thus removing the hair from the article. The sheet material has cross-wise perforation lines at regular intervals therealong that divide the roll into separable sheets, whereby once the exposed adhesive surfaces at the exterior of the roll have a substantial accumulation of hair thereon, these outer sheets can be torn off at one of the perforation lines to reveal the fresh adhesive surface of the underlying remainder of the roll.
[0004] Such lint rollers work relatively well for removing small amounts of pet hair from individual pieces of clothing or the like, but require significant effort for larger pet hair accumulations, for example as may occur on larger articles such as bedding, blankets, curtains, etc. Some pet owners may opt to avoid the time-intensive manual removal of pet hair with a lint roller by machine washing the fabric article in a laundry washer, typically followed by drying of the article in a conventional tumble dryer. However, this is also not an ideal solution, as pet hair is not fully removed by conventional machine washing and drying processes, and remnant hair left behind in the washing machine can become attached to subsequent loads of laundry placed therein.
[0005] U.S. Pat. No. 7,441,345 of Taylor discloses a laundering aid intended to help remove pet hair or other debris from laundry during a conventional drying cycle in a tumble dryer. An elastomeric ball with an abrasive or brush-like material is placed in the rotatable drum of the tumble dryer along with the fabric articles, and a normal heated-air drying cycle is carried out, during which the aid freely tumbles around inside the drum along with the fabric articles, collecting pet hair therefrom as it comes into contact with the tumbling articles.
[0006] U.S. Pat. No. 4,920,662 of Seeburger discloses placement of a free-tumbling article with adhesive surfaces inside the rotatable drum of a tumble dryer to remove lint or hair from fabric articles, or placement of an adhesive sheet on interior surfaces of the rotatable drum for the same purpose.
[0007] Applicant has developed a new solution that improves on the adhesive-sheet dryer-based pet hair solution proposed by Seeburger.
SUMMARY OF THE INVENTION
[0008] According to a first aspect of the invention, there is provided an apparatus for removal of pet hair or other debris from an article placed in a rotatable drum, the apparatus comprising a plurality of adhesive sheets compiled atop one another in a stack, the stack of sheets being attachable to the rotatable drum within an interior thereof.
[0009] Preferably the adhesive sheets in the stack have respective adhesive faces that face in a same common direction, and except for a lowermost adhesive sheet in the stack, each adhesive sheet is connected to an underlying adhesive sheet in the stack only by the adhesive face of said underlying adhesive sheet.
[0010] Preferably there is provided a base arranged for attachment to the rotatable drum within the interior thereof, the plurality of adhesive sheets being stacked atop the base member with an adhesive face of each of said adhesive sheets facing away from said base member.
[0011] Preferably the base is planar.
[0012] Preferably the adhesive sheets are stacked flat atop the base.
[0013] Preferably the base is a flexible member having a greater strength than the adhesive sheets.
[0014] Preferably a lowermost adhesive sheet in the stack is adhesively attached to the base, and each other sheet in the stack is secured to an underlying adhesive sheet in the stack by the adhesive face of said underlying adhesive sheet.
[0015] Preferably the plurality of adhesive sheets are discrete adhesive sheets.
[0016] Preferably the discrete adhesive sheets in the stack have respective adhesive faces that face in a same common direction, and except for a lowermost adhesive sheet in the stack, each adhesive sheet is connected to an underlying adhesive sheet in the stack only by the adhesive face of said underlying adhesive sheet.
[0017] Preferably there is provided a release liner overlying the adhesive face of an uppermost adhesive sheet in the stack to maintain a clean state thereof until installation and use of the apparatus.
[0018] In one embodiment, there is provided a fastener for securing the stack of adhesive sheets to the rotatable drum. In such instance, preferably the fastener comprises a hook and loop fastener.
[0019] Preferably the hook and loop fastener comprises two matable components, one of which is attached to the base on a side thereof opposite the adhesive sheets, and the other of which is attachable to the rotatable drum.
[0020] In another embodiment, there is provided at least one magnet for securing the stack of adhesive sheets to the rotatable drum.
[0021] Preferably the at least one magnet is attached to the base for magnetic retention of the base on the rotatable drum.
[0022] There may be provided a re-fill pack of stacked adhesive sheets for replenishing said apparatus by mounting the stacked adhesive sheet of said re-fill pack atop the base after depletion of the original plurality of adhesive sheets.
[0023] Preferably each adhesive sheet in the stack comprises a peripheral tab projecting outward from a perimeter edge of said adhesive sheet for to define a manual grip for peeling of said sheet from the stack after use of said sheet to collect hair or other debris at a top end of the stack.
[0024] Preferably the peripheral tabs of adjacent sheets in the stack reside at distinct positions from one another.
[0025] Preferably the peripheral tabs of adjacent sheets in the stack are in non-overlapping relation to one another.
[0026] Preferably the peripheral tabs of the adhesive sheets are adhesive-free.
[0027] According to a second aspect of the invention, there is provided a method of preparing a rotatable drum for use in removal of pet hair or other debris from an article, the method comprising securing the foregoing apparatus of claim 1 to an interior surface of the rotatable drum with an innermost adhesive sheet in the stack situated nearest to a center of said rotatable drum is in an exposed position.
[0028] According to a third aspect of the invention, there is provided a method of replenishing the foregoing apparatus after depletion of the plurality of adhesive sheets from the stack, the method comprising mounting a re-fill pack of stacked adhesive sheets atop the base after depletion in place of the original plurality of adhesive sheets.
[0029] According to a fourth aspect of the invention, there is provided a method of preparing the foregoing apparatus for a subsequent use after a prior use thereof, the method comprising removing an innermost adhesive sheet of the stack that is closest to a center of the rotatable drum and to which pet or other debris adhered during said prior use, and thereby revealing an underlying adhesive sheet of said stack from beneath the innermost adhesive sheet for collection of additional pet hair or other debris on said underlying adhesive sheet during the subsequent use of the apparatus.
[0030] Preferably, removing the innermost adhesive sheet from the stack comprises peeling the innermost adhesive sheet from the stack using a peripheral tab of said innermost sheet that projects outward from a perimeter edge thereof.
[0031] According to a fifth aspect of the invention, there is provided a method of removing pet hair or other debris from an article, the method comprising, with the article in a dry state, placing the article in a rotatable drum of a laundry dryer that features one or more adhesively coated surfaces on an interior of the drum, and operating the laundry dryer to drive rotation of the drum, during which movement of the article within the rotating drum brings in the article into repeated contact with the one or more adhesively coated surfaces, to which the pet hair or other debris from the article becomes adhered.
[0032] To remove pet hair, operating said laundry dryer preferably comprises operating said laundry dryer in a non-heated operating mode.
[0033] According to a sixth aspect of the invention, there is provided a drum for rotational use in a pet hair removal or other debris removal process, the drum comprising a stack of adhesive sheets positioned with an innermost adhesive sheet in the stack situated nearest to a center of said drum in an exposed position within an interior of said drum, and each adhesive sheet having an adhesively coated surface facing toward said center of said drum.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Preferred embodiments of the invention will now be described in conjunction with the accompanying drawings in which:
[0035] FIG. 1 is a partially exploded perspective view of a first embodiment pet hair removal device of the present invention, featuring a collection of tabbed adhesive sheets stacked atop a flexible base with hook and loop fasteners for attachment to an internal surface of a tumble dryer's rotatable drum.
[0036] FIG. 2 is an exploded elevational view of the pet hair removal device of FIG. 1 .
[0037] FIG. 3 is an exploded elevational view similar to FIG. 2 , but showing a second embodiment pet hair removal device employing magnets for removable attachment of the flexible base to an internal surface a tumble dryer's rotatable drum.
[0038] FIG. 4 is a schematic elevational view of a rotatable drum of a tumble dryer, illustrating placement of three pet hair removal devices of the present invention on inwardly projecting baffles of the drum.
[0039] FIG. 5 is a schematic elevational view similar to FIG. 4 , but illustrating alternate placement of the pet hair removal devices on a circumferential wall of the drum at areas thereof between the baffles.
[0040] FIG. 6 is a partially exploded view of a re-fill pack for the device of FIG. 1 or 3 .
[0041] In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
[0042] FIG. 1 shows a pet hair removal device 10 of the present invention, which features a normally planar base member 12 in the form of a sheet of plastic or other flexible material, a plurality of tabbed adhesive sheets 14 stacked one over the other atop the base member 12 , and a thin release liner 16 placed atop the uppermost adhesive sheet 14 a in the stack. A sheet of double sided tape 18 is disposed between the base member 12 and the lowermost adhesive sheet 14 b in the stack, whereby an adhesively coated upper surface of the double sided tape 18 adheres to the underside of the lowermost adhesive sheet 14 b , and an adhesively coated lower surface of the double sided tape 18 adheres to the topside of the base member 12 , thereby securing the lowermost adhesive sheet 14 b to the the base member 12 at the topside thereof. Each adhesive sheet has a tacky adhesive coating on its upper face, and features an absence of adhesive on its opposing lower face. With the exception of the lowermost adhesive sheet 14 b , each adhesive sheet is secured to the underlying adhesive sheet in the stack by the adhesively coated upper face of the underlying adhesive sheet. Accordingly, the adhesive sheets self-retain themselves in a stacked configuration atop one another in the fully assembled pet hair removal product of the present invention.
[0043] Prototypes of the present invention have employed adhesive sheets of the type used in commercially available lint rollers of the type described in the forgoing background section of the present disclosure, but in the form of discrete sheets that are not interconnected together in a continuous roll. That is, the prototypes were produced by detaching the originally integral sheets of the continuous roll from one another along the perforation lies of the roll, and then stacking the sheets atop one another to create a layered stack having only a single sheet in each layer. As a result, the stack of adhesive sheets are connected to one another solely by the adherence provided between each pair of adjacent sheets by the adhesively coated upper face of the lower sheet in the pair. Accordingly, the illustrated embodiment, like the aforementioned prototypes, lacks any connection between the one-sided adhesive sheets other than this direct face-to-face adhesive attachment between the sheets, and the perimeter edges of each adhesive sheet are therefore free of any integral connection to the other sheets (unlike the continuous roll of the aforementioned lint rollers of the prior art).
[0044] Hook and loop fasteners 20 are used to secure the base 12 to an interior of a rotatable drum of a tumble dryer, for example that of an otherwise conventional laundry dryer. Each hook and loop fastener features a hook component 20 a in the form of a fabric piece having hook material projecting from one side thereof, and a mating loop component 20 b in the form of a fabric piece of equal or similar size having loop material projecting from one side thereof. One component 20 a of each fastener 20 is affixed to the underside of the base member 12 , for example adhered or sewn thereto, with its fastening material facing oppositely away from the base (i.e. facing downward in the illustrated orientation of the device in FIGS. 1 and 2 ). To install the device 10 on the drum of a tumble dryer, the other component 20 b of each fastener 20 is attached to an internal surface of the drum by adhesive or other suitable fastening means. Commercially available hook and loop fasteners having a double sided adhesive tape on the side of each component opposite its hook or loop fastening material may be used, in which case one fastener component 20 a is adhered to the base of the device 10 , and the other component 20 b is likewise adhered to the drum of the tumble dryer.
[0045] The release liner 16 is a piece of flexible plastic film laid over the adhesively coated upper face of the uppermost adhesive sheet 14 in the stack. The release liner 16 remains adhered to this uppermost adhesive sheet 14 in a position fully covering the adhesive upper face thereof until such time as the device is installed in a dryer drum for use. This protects the adhesive upper face of the uppermost sheet 14 from the accumulation of any debris thereon, thereby maintaining the same in a clean state until such time as the device is intended for use in a tumble dryer. Likewise, the adhesive upper face of each of the other adhesive sheets is covered and protected by the neighbouring sheet disposed above it.
[0046] The base 12 is preferably a sheet of plastic of greater thickness, or at least greater strength, than each of the individual adhesive sheets in order to provide greater resistance to tearing, puncture or other damage to the overall device, while still being flexible to allow conformation of the device to the shape of a surface to which the device is to be mounted for use, as described herein in more detail below. The base is preferably also of greater thickness and/or strength than the release liner. Prototypes of the invention employed the flexible plastic cover of a three-ring binder as the base material. Other flexible or pliable materials may alternatively be employed, for example including cardboard or cardstock, although use of a flexible plastic is likely to provide an improved wear life, and also provide better conformation to the underlying surface to which the device is mounted.
[0047] With reference to FIG. 1 , each adhesive sheet in the illustrated embodiment is generally rectangular in shape, departing from a true rectangle only the existence of a single peripheral tab 22 projecting outwardly away from what would otherwise be a purely linear perimeter side of a rectangular sheet. The peripheral tab 22 of each sheet is at a uniquely distinct position around the perimeter of the adhesive sheet relative to the tabs of the other adhesive sheets. In the illustrated embodiment, the tabs of the adhesive sheets all reside on a same common side of the stack, i.e. along a same common side of the shared and aligned rectangular shape of the equally sized adhesive sheets in the stack. Each tab resides at a discrete position along this side of the stack in non-overlapping relation to the tabs of the other sheets. The tab allows for easily manual gripping of a single individual sheet independently of the other sheets for the reasons set our herein further below.
[0048] Each tab is absent of any adhesive material thereon. That is, the adhesive upper face of each adhesive sheet does not occupy the entire area of the sheet's topside, specially terminating short of the outwardly projecting peripheral grip tab 22 of the sheet. The adhesive coating of the upper face may occupy the entire remainder of the sheet's topside (i.e. all areas other than the tab 22 ), and preferably spans at least a substantial majority of the sheet's topside, for example terminating a short distance inward from each perimeter edge of the sheet to prevent potential exposure of the adhesive of the sheets out from under the other sheets and release liner at the perimeter of the stack.
[0049] In the illustrated embodiment, the release liner 16 and the base member 12 are rectangular in shape, each having a surface area at least as large as the adhesive upper faces of the stacked adhesive sheets. On the other hand, the release liner and base member 12 of the illustrated embodiment do not overly the peripheral tabs 22 of the adhesive sheets, which remain exposed at the respective side of the stack in positions jutting outwardly beyond the respective perimeter edges of the release liner 16 and base 12 . This is perhaps best seen in FIG. 2 , where the tabs 22 can be seen to reach outwardly beyond the area occupied by the release liner 16 and base 12 , which as shown, may be of equal size to one another. While the illustrated embodiment has the tabs projecting outwardly beyond the release liner and the base, one or both of the base and the release liner may respectively overlie and underlie the tabs.
[0050] While the illustrated embodiment of FIGS. 1 and 2 features sixteen adhesive sheets 14 of generally rectangular shape tabbed on a singular common side of the stack, a rectangular base 12 , a rectangular release liner 16 , and four hook and loop fasteners positioned at the four corners of the rectangular base, it will be appreciated that the shape of the sheets, base and release linear may vary, as may the number of fasteners 30 , and the number of sides on which the adhesive sheets are tabbed. Each sheet may be tabbed on more than one side, or single-tabbed sheets having their tabs positioned on various sides of the stack may be employed. While the illustrated embodiment is described as having the hook component 20 a of each hook and loop fasteners 20 attached to the base, the loop component could alternatively be affixed to the base and the cooperating hook component installed on the dryer drum. While the illustrated embodiment features a singular sheet of double sided tape that is comparable in overall size to the adhesive sheets stacked above it and the base member lying beneath it, other embodiments may features one or more smaller pieces of double sided tape to adhere the lowermost adhesive sheet in the stack to the underlying base.
[0051] Having described the structure of the device, attention is now turned to its use. FIG. 4 illustrates installation of pet hair removal devices of the forgoing type on the baffles of a tumble dryer's rotatable drum 100 . The illustrated drum 100 features three baffles 102 , each equipped with a respective pet hair removal device 10 . Each baffle features two faces 102 a , 102 b facing in opposing directions around the central axis 104 of the drum 100 . The circumferential wall 106 is centered on this axis 104 and closes therearound, and the drum is rotated on this axis by the drive motor of the tumble dryer. To install each device 10 , one of the two components of each hook and loop fastener 20 is secured to the respective baffle 102 . For each fastener, this drum-mounted fastener component may be either the hook component 20 a or the loop component 20 b , depending on which component is affixed to the base 12 of the pet hair removal device 10 , and which component is therefore available for mounting to the dryer drum.
[0052] Half of the fasteners 20 have their drum-mounted component secured to one side 102 a of the baffle 102 , and the other half of the fasteners 20 have their drum-mounted component secured to the other side 102 b of the baffle 102 . The base 12 of the pet hair removal device 10 is then laid over the baffle 102 in a position folding or curving over the peak or edge of the baffle that defines its innermost free end that points inwardly toward the central axis 104 of the drum 100 . Accordingly, two halves of the folded or curved base reside on opposite sides of the fold or curved bend I the base, and the fastener components 20 a on the two halves of the base 12 mate with the respective fastener components on the respective side 102 a , 102 b of the baffle. The term ‘halves’ does not necessarily denote two equally sized portions each denoting 50% of the overall base, as the base need not be perfectly centered on the baffle. The stack of adhesive sheets attached to the flexible base 102 are likewise flexed into a folded or curved configuration spanning over the free of the baffle to place the two halves of each sheet on respective sides of the baffle. Accordingly, one half of each adhesive sheet faces one direction around the central axis 104 , and the other half faces the other way around the central axis.
[0053] FIG. 5 shows an alternate installation of three pet hair removal devices 10 on the same three-baffle dryer drum 100 . Here, the drum-mounted fastener components of each device 10 are secured to the circumferential wall 106 of the dryer drum 100 at an area between a respective pair of the baffles 102 . The flexibility of the base 12 likewise allows conformance of the device to the shape of the drum, with the base 12 taking on an arcuate shape when fastened to the drum wall by mating the base-carried fastener components 20 a with the drum-mounted fastener components 20 b . The adhesive sheets 14 in the stack likewise take on an arcuate form dictated by the mounting of the base 12 to the drum wall. In this circumferential wall installation of FIG. 5 , the adhesively coated upper surface of each adhesive sheet in the stack faces radially inward toward the central axis of the dryer drum 100 , instead of facing circumferentially therearound in the baffle installation of FIG. 4 . In either the baffle-mounted or wall-mounted installation, the stack of adhesive sheets resides on the side of the base 12 that faces inwardly into the hollow interior of the drum 100 from the interior baffle or wall surface of the drum to which the base is mounted. Prior or subsequent to the securing of the base 12 to the dryer drum, the release liner 16 is removed to expose the adhesively coated upper face of the uppermost adhesive sheet 14 a in the stack, which in the installed state of the device may be referred to as the innermost sheet, since it resides nearest to the central axis 104 of the dryer drum.
[0054] With one or more of the devices installed on the dryer drum and the adhesive face of the innermost adhesive sheet in an exposed position within the dryer drum, one or more fabric articles (clothing, bedding, blankets, drapes, etc.) having pet hair stuck thereto is placed within the dryer drum, and the dryer is operated in a tumbling laundry cycle driving the drum in a rotating fashion about it central axis, whereupon the rotational motion and the inwardly projecting baffles of the drum cause the fabric article(s) to tumble within the interior space of drum on an ongoing basis. During this process, the article(s) repeatedly come into contact with the exposed adhesive face of the innermost adhesive sheet 14 a in the stack, whereupon the pet hair previously clinging to the fabric article becomes adhered to this adhesive face of the innermost adhesive sheet, thereby removing the pet hair from the article. The ongoing tumbling motion ensures that different areas of the article will come into contact with the exposed adhesive face of the innermost adhesive during the laundry cycle, thereby providing an effective pet hair removal action.
[0055] Applicant tested prototypes of the present invention in various conditions, including heated and unheated dryer cycles and dry and wet states of the articles being cleaned. Applicant found the best pet hair removal results to occur when a fabric article is placed within a tumble-dry clothes dryer in a dry condition, and allowed to run through a laundry cycle. Testing found that when used on dry articles, the pet hair removal process did not seem to benefit from a heated drying cycle versus an air-fluff cycle, in which unheated room-temperature air is circulated through the dryer. Accordingly, it is preferred that the dry-processing of fabric articles for pet hair removal is performed with an unheated cycle in order to avoid wasting energy on the generation of an unnecessary supply of heated air. In testing performance of the device on wet articles, i.e. fabric articles run through a conventional clothes washing machine prior to placement thereof in the device, applicant found that while the device was effective at collecting lint from the fabric articles, the wet-article process was less effective at removing pet hair. Accordingly, the device can be employed for removal of debris other than pet hair, but is best employed in a dry-article process when particularly trying to address the removal of pet hair from fabric articles. Accordingly, a unique hair removal method of the present invention involves placement of fabric articles into a clothes dryer while in an already-dry state, and running the dryer in an unheated drum-rotating cycle in order to collect pet hair and other debris (e.g. lint) from the article without having performed a prior wet cleaning of the article.
[0056] The base 12 and the removable attachment thereof to the dryer drum allows the stack of adhesive sheets to be easily removed after use thereof in an unheated hair-removal process, for example in order to avoid expending any of the sheets in a subsequent conventional heated drying cycle used to dry wet laundry from a hand-washed or machine-washed operation. By attaching the base 12 to the dryer drum 100 , instead of attaching the lowermost sheet 14 b in the stack directly to the drum 100 , no damage to the device will occur upon attempting to remove the device from the drum 100 . For example, if the lowermost adhesive sheet were equipped with hook or loop fastening elements on the underside thereof in order to avoid the base 12 of the illustrated embodiment, the strength of an adhesive sheet of the commercially available type employed for lint rollers would be insufficient to withstand the pulling force required to separate a robust hook and loop fastener, and so attempts to the pull a baseless device free of its fastened condition to the drum wall would result in ripping, tearing, puncture or other damage to the lowermost sheet, rendering it unsuitable for reattachment to the dryer drum for subsequent use.
[0057] Accordingly, the combination of a stacked collection of adhesive sheets atop a materially distinct base provides an optimal solution for a re-usable pet-hair removal device that can be repeatedly attached and detached to the interior of a dryer drum. After each use of the device to remove pet hair from an article in a tumbling operation of the dryer, the uppermost adhesive sheet in the stack can be conveniently removed by pulling upward on its respective peripheral tab 22 in order to release the sheet's originally adhered state to the next underlying sheet. This removal of the uppermost sheet exposes the adhesively coated upper face of the next underlying sheet in order to act as a newly exposed adhesive surface in the dryer drum for collection of pet hair, lint or other debris thereon.
[0058] FIG. 3 shows a second embodiment device 10 ′ which is substantially similar to that of FIGS. 1 and 2 , differing only in the substitution of magnets 30 for the hook and loop fasteners 20 of the first embodiment. The magnets are attached to the base, for example adhered thereto or embedded therein (for example, molded in place during manufacture of a flexible plastic base), whereby the flexible base becomes self-securing to the metal drum of a clothes dryer. The magnetic embodiment avoids the need to install one half of each hook and loop fastener to the drum in a manner arranging the drum-mounted components of the fasteners in a layout on the drum that will properly align with the respective components affixed to the base of the pet hair removal device, as each magnet will self-attach to any magnetically-attractable area of the drum. Depending on relative costs of suitable magnets versus hook and loop fasteners, one option may be preferable to the other on a cost-efficiency basis. Alternatively, easier installation using hook and loop fasteners may result from the use of a single relatively large hook and loop fastener spanning a substantial majority or entirety of the base's underside, or from the use of a pair of relatively large fasteners each spanning a substantial majority or entirety of a respective half of the base's underside. These options avoid the need to worry about accurate alignment when mating the two halves of a plurality of smaller hook and loop fasteners, as required for the illustrated embodiment featuring four relatively small fasteners at the corners of the device.
[0059] Magnets and hook and loop fasteners are only two examples by which a device of the present invention may be installed on a dryer drum, but may be preferable over other options such as use of threaded fasteners to secure the base to the dryer drum, which would make for less convenient removal of the base from the drum and possibly introduce other undesirable complications. However, the uniqueness of a re-usable product with a collection of stacked adhesive sheets remains regardless of how the stack is held in place, and regardless of whether it uses a materially distinct base as part of its attachment to the drum. However, the base-equipped embodiments provide the potential sale of re-fill packs, where a consumer makes a one-time purchase of a base (preferably including a first stack of adhesive sheets supplied therewith in an attached or unattached relation to the base), and then can separately purchase re-fill packs, each featuring a stacked collection of adhesive sheets for replenishing of the device after multiple uses. The lowermost sheet in each re-fill pack may come with an adhesive on the underside thereof (whether as an integral part of the sheet, i.e. an adhesive coating applied thereto during manufacture of the sheet, or as a separate piece of double sided tape attached thereto). In such embodiments, the underside adhesive on the lowermost sheet in the re-fill pack is initially covered by a bottom release liner, which is removed when the re-fill pack is ready for attachment to the base in place of a previously depleted stack. FIG. 6 shows such a refill pack, which features the same stack of adhesive sheets as the devices of FIGS. 1 and 3 , but with a second release liner 16 ′ disposed beneath the double sided tape 18 instead of the flexible base.
[0060] While the illustrated embodiments present a pet hair removal device to be sold to consumers separately from a dryer drum for consumer installation on the drum of their existing clothes dryer to adapt the same for use in the described pet hair removal or other debris removal process, the present invention also extends to a dryer drum that comes equipped with one more stacks of adhesive sheets thereon for use in a pet hair removal or other debris removal process. In addition, while described primarily in the context of a clothes dryer, the stacked adhesive sheets may be employed on tumble dryers or other rotatable drums originally used for purposes other than drying of laundry, especially since it has been found that unheated tumbling cycles provide the best pet-hair removal results, and so a heated-air machine is not explicitly required for a pet hair removal process of the present invention.
[0061] Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the scope of the claims without departure from such scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | An apparatus is provided for removal of pet hair or other debris from an article placed in a rotatable drum of a tumble dryer. The apparatus features a plurality of adhesive sheets compiled atop one another in a stack, which is attachable to the rotatable drum within an interior thereof. The apparatus is secured to an interior surface of the rotatable drum with an innermost adhesive sheet in the stack situated nearest to a center of said rotatable drum. Rotation of the drum during operation of the dryer brings in the article into repeated contact with the innermost sheet, to which the pet hair or other debris from the article becomes adhered. After use, the innermost adhesive sheet of the stack is removed to reveal an underlying adhesive sheet for collection of additional pet hair or other debris on said underlying adhesive sheet during subsequent use of the apparatus. | 3 |
FIELD OF THE INVENTION
The present invention relates to a gate valve of a type commonly used to control fluid flow when servicing a hydrocarbon recovery well. More particularly, this invention relates to a thru-conduit gate valve with dual seal rings each supported on a seat ring.
BACKGROUND OF THE INVENTION
Gate valves are commonly used to control fluid flow, and are frequently the valves selected for use in gas injection wells to enhance the recovery of hydrocarbons. CO 2 is commonly injected into wells for improving hydrocarbon recovery, and gate valves are typically provided for controlling CO 2 injection. Thru-conduit gate valves have a thru-opening in the body corresponding to the diameter of the upstream and downstream conduit lines, and are frequently preferred over other types of gate valves. One type of thru-conduit gate valve is disclosed in U.S. Pat. No. 5,169,125.
In recent years, gate valves are being used in more corrosive and erosive environments. In critical service wells, for example, the demands on reliable operation of gate valves are increasing even though the valves are simultaneously being used on more highly corrosive and erosive fluids. One of the most common maintenance problems with gate valves is leakage between the gate and the seat ring seals positioned on opposing sides of the gate. Various techniques have been proposed to increase sealing reliability between the seat ring and the gate, including complex mechanisms which utilize biasing springs to force the seat rings into engagement with the gate, and seat rings with dual seal rings each carried by structurally separate seat ring supports.
One of the proposals for reducing maintenance on a thru-conduit gate valve utilizes a primary pressure seal carried on a seat ring, and a secondary seal ring carried on another ring movable independently of the primary seat ring and spaced radially inward thereof. The second seat ring is biased by a leaf spring for engagement with the gate. This design, while benefiting from dual seal rings, is operationally complex and is susceptible to failure in critical service applications. The metal bias ring may be subjected to corrosive and erosive fluids, thereby causing failure of the seat ring and thus leakage past the valve. This gate valve is described in U.S. Pat. No. 5,090,661.
Other gate valve designs utilize complex mechanisms for forcing the seat ring into sealing engagement with the gate. Some seat rings are fragile and cost several hundred dollars. Still other designs utilize seal rings which are installed on the seat ring and the face of the seat ring machined so that the seal ring is reliably retained within the seat ring. These designs increases manufacturing costs, and complicates replacement of the seal ring. Many gate valves require extremely high torque to slide the gate with respect to the seat rings during actuation of the valve. The need exists for reliable and cost efficient gate valve which may be used in various applications for reliably sealing between the seat rings and the gate, and which is operational under a relatively low operating torque.
The disadvantages of the prior art are overcome by the present invention, and an improved gate valve is hereinafter disclosed which utilizes dual seal rings mounted on a unitary seat ring. The gate valve of the present invention may be used in various applications, and is particularly well suited for gas injection wells in hydrocarbon recovery operations.
SUMMARY OF THE INVENTION
The gate valve according to this invention may be used for controlling the flow of fluids to a gas injection well of a hydrocarbon recovery operation. The gate valve may thus be subject to a pressure of up to 3700 psi and to fluid temperatures up to about 450° F. The gate valve comprises a thru-conduit valve body and a gate movable by a handle in a direction substantially perpendicular to the thru-axis of the valve body. The gate comprises opposing planar faces which each seal with a respective seat ring assembly when the gate valve is closed. Each seat ring assembly includes a metal seat ring, a radial seal for static sealing between the seat ring and the valve body, and a pair face seals each supported on the metal seat ring and concentric with the thru-axis of the valve body. The radial outer face seal is a low pressure seal preferably formed from a relatively soft material, such a polytetrafluroethylene. The radially inner seal is formed from a relatively hard plastic material, such a polyester ether ketone, and is tough, durable and corrosion resistant. Both seals have a low coefficient of friction with the respective planar gate face, thereby resulting in a low operating torque. The seat ring may also include a back side O-ring on the seat ring surface opposite the face seals for pressing the seat ring toward the gate for low pressure sealing.
Each face seal fits within a respective primary groove in the seat ring having a generally rectangular configuration, and a radial or pocket groove extending off the primary groove. The seal has a similar rectangular configuration with a radial shoulder that fits within the pocket groove to lock the seal in place on the seat ring. The face of the seal preferably extends beyond the face of the seat ring by a stand-off distance of from 0.02 to 0.07 inches. The seat ring is designed for easy removal from the valve body. A relief cut is formed in the radially outer surface of the seat ring for facilitating seat ring removal with a conventional screwdriver. Each seal may be easily replaced in the seat ring by snapping out the old seal and pressing in a new seal.
It is an object of the present invention to provide an improved gate valve with a seat ring assembly which reliably seals with the face of the gate. The seat ring assembly comprises a seat ring including a pair of face seals thereon, with each face seal being easily removed from and fitted into a respective groove within the seat ring so that the face seals may be selected for the particular application. By utilizing two face seals, the sealing area is increased, and the face seals cooperate to extend the useful life of the gate valve.
It is a feature of the present invention that the radially outer seal be formed from a relatively soft material for low pressure sealing, and that the radially inner seal be formed from a relatively hard and durable plastic material. Each face seal preferably extends from the face of the seat ring by a selected stand-off distance. A low coefficient of friction between the face seal and the planar surface of the gate results in a low operating torque for the gate valve. An elastomeric O-ring may be used to bias the seat ring toward engagement with the gate under low, fluid pressure conditions. As the fluid pressure to the valve increases, the higher pressure increases sealing effectiveness with the gate.
A significant advantage of this invention is the relatively low cost associated with customizing the gate valve by selecting each of the pair of face seals depending on anticipated application conditions. Gate valve maintenance costs are also reduced since each seat ring may be easily removed from the valve body, and the face seals on the seat ring easily replaced.
These and further objects, features and advantages of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, partially in cross-section, of a suitable thru-conduit gate valve according to the present invention.
FIG. 2 is a cross-sectional view through the gate valve seat ring assembly generally shown on FIG. 1.
FIG. 3 is an expanded view illustrating one of the face seals installed within a groove in the seat ring.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 discloses a thru-conduit gate valve 10 according to the present invention. The gate valve includes a valve body 12 having a thru-conduit central axis 14. Each end of the valve body includes threads 16 for mated connection with conventional tubulars. If desired, those skilled in the art will appreciate that the ends of the valve body may be designed for ranged interconnection, grooved end interconnection, butt weld, or other conventional interconnections with tubulars. The valve body 12 thus defines a generally cylindrical flow path 13 therein concentric with axis 14 and both sized and aligned with the flow path in both the upstream and downstream conduits connected to the valve body.
The valve body includes a lower valve body portion 18 forming a pocket 20 for receiving the gate 22 when the gate valve is in the closed position. An upper body portion 24 is configured for easy removal of the opposing seat assemblies 26 and 28, as described further below. A bonnet 30 is removably interconnected with the valve body by a plurality of circumferentially spaced securing members 32, which may comprise either bolts or stud and nut members. A static O-ring seal 34 seals between the bonnet and the valve body. The handle 36 is mounted on the bonnet 30, and is sealed therewith by an O-ring 38. If desired, a plurality of handles may be circumferentially arranged about the gate axis 52 to facilitate closing of the gate valve by an operator.
A T-nut 40 cooperates with lower stem portion 42 to raise and lower the gate 22 along the gate axis 52 in a conventional manner. The stem 44 is also provided with a role pin 46. A retaining nut 48 is threaded to the upper end of the bonnet 30, and presses downward on Chevron packing 50 to reliably seal between the stem and the upper portion of the bonnet 30. With the exception of the seat rings described below, the gate valve of the present invention may be similar to the Model BTC Gate Valve marketed by Baker SPD.
Each seat ring assembly 26, 28 may be identical in design and construction, and accordingly only seat ring 26 for sealing engagement with face 54 of the gate 22 is discussed in detail below. Seat ring 26 comprises a metal seat ring 56 having a radially inner shoulder 58 which defines a circumferential bore through the seat ring, and a radially outer surface 60 which is sealed with the body 12 by a conventional O-ring 62. The bore through the seat ring is substantially the same diameter as the cylindrical flow path 13 through the valve body. The seat ring 56 has a unitary construction, i.e., the metal seat ring itself has no moving parts. The seat ring 56 is also preferably monolithic since it is formed from a single piece of metal stock. The gate facing surface 64 of seat ring 26 is parallel to the gate surface 54, and the opposing end surface 66 of the seat ring engages the stop surface 68 and the valve body (see FIG. 1).
A radially inner seal ring 70 and a radially outer seal ring 72 are each supported on the seat ring 56. The radially outer shoulder 74 on the seat ring is sized so that the seat ring may support both seal rings, as shown. Relief cut 76 on the outer surface 78 of the shoulder 74 is provided for receiving the end of a screwdriver or other conventional tool to easily pry the seat assembly from its position on the valve body as shown in FIG. 2. Securing members 32 may thus be unthreaded to remove the bonnet 30 and the gate 22 from the valve body, then the seat assemblies 26 and 28 easily removed from the valve body.
FIG. 3 illustrates in greater detail the elastomeric material sealing ring 72 shown in FIG. 2. Each of the seal rings 70 and 72 may be identical in cross-sectional configuration, although the seal ring materials are preferably different. The outer seal ring 72 is formed for low pressure sealing of the seat ring with the gate, and is fabricated from a relatively soft elastomeric material, such as polytetrafluroethylene (TFE). The inner seal ring 70 is formed from a harder and more durable corrosion resistant plastic material, such as polyester ether ketone (PEEK™). Each seal ring is mounted on the same unitary seat ring 56, and has an axis concentric with axis 14.
The seal ring 72 has a generally rectangular configuration, and fits within a similarly configured groove 80 formed by sidewalls 82 and 84 within the seat ring each parallel to axis 14, and base 86 perpendicular to the sidewalls. The seal ring 70 has a face 88 parallel to the surface 54 of the gate 22, and extends from the surface 64 of the seat ring a selected distance of from 0.02" to 0.07", and preferably about 0.05". A rectangular-shaped shoulder 90 of the seal ring 72 extends radially outward from axis 14, and fits within a similarly configured groove 92 having walls 94 and 94 each perpendicular to axis 14, and having base 98 parallel to axis 14. The seal rings 70 and 72 are each configured for being reliably retained on the seat ring 56, which is a function primarily served by the annular shoulder 90. The seal rings are also designed for easy removal and installation on the seat ring, thereby allowing each seat ring assembly to be customized for a particular application by selecting a seal ring material for that application. Easy replacement of the seat ring also reduces maintenance costs for the gate valve.
Each seal ring may be removed from the seat ring by prying a screwdriver between the seat ring and the seal ring, and snapping each seal ring partially out of the groove, then pulling on the partially removed seal ring to pull the entire seal ring from its groove. A new seat ring may be easily installed by pressing a portion of the new seal ring against the side surface 82 and the base surface 86, then continuing to press the seal ring against the surfaces 82 and 86 until the shoulder 90 snaps within the groove 92. Once a portion of the seal ring is fitted within the groove, the entire seal ring may be pressed into the groove by applying pressure to the seal ring with a thumb, a piece of wood, or other available tool while slowly moving around the circumference of the seat ring as the seal ring is forced into its corresponding groove. In an alternative embodiment, the inner seal ring 70 and the groove in the seat ring for receiving the inner seal ring may have a reduced size holder, since a formation of this seal ring for insertion into the groove with a seal ring shoulder and corresponding side groove would be more difficult due to the harder material for the seal ring. Still a further embodiment, the inner seal ring and the inner groove may not have any shoulder, so that both the seal ring and the groove each have a rectangular cross-sectional configuration. Also, the radial thickness of the inner groove may be slightly less than the radial thickness of the more elastic outer seal ring.
Some applications, particularly when reliable sealing between the seal ring assembly and the gate is required when there is very low fluid pressure on the gate, elastomeric O-ring 63 may be provided on the surface 65 of the seat ring axially opposing the gate facing surface 64 of the seat ring. Since it is not required that the seal ring 63 seal between the seat ring and the valve body, the O-ring 63 may be split along its circumferential length. The purpose of the elastomeric O-ring 63 is to provide a small biasing force for pushing each seat ring axially in a direction toward engagement with the gate, thereby giving low pressure sealing between the seat ring assembly and the gate when fluid pressure in the valve is low. As fluid pressure in the valve increases, the increased fluid pressure will act on the rear surface 65 of the seat ring to hydraulically force each seat ring assembly toward engagement with the gate.
The valve operator for selectively raising and lowering the gate within the valve body to open and close the valve may be a manually operated handle as disclosed herein, which rotates a valve stem and, in cooperation with the T-nut 40, raises and lowers the gate. Those skilled in the art will appreciate that other valve operators may be used for raising and lowering the gate, including powered operators for large gate valves.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof, and it will be appreciated by those skilled in the art that various changes in the size, shape and materials as well as in the details of the illustrated construction or combinations of features of the various system elements and the method discussed herein may be made without departing from the spirit of the invention. | The gate valve 10 suitable for controlling fluid flow into a gas injection well of a hydrocarbon recovery operation includes a thru-conduit valve body 12, a bonnet 30, an operator handle 36 for raising and lowering a gate 22. A pair of seat assemblies 26, 28 are provided on opposing sides of the gate. Each seat assembly seals with a planar face of the gate, and includes a metal seat ring 56 and a pair of concentric face seals 70 and 72 supported on the seat ring. The seal rings are fabricated from a selected plastic material, and may be easily removed and reinstalled on the seat ring for customizing the gate valve for specific applications, and for reduced maintenance. The seat ring 56 is configured to facilitate its removal from the valve body. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application of Ser. No. 10/898,966, filed Jul. 27, 2004, which is now pending, and application Ser. No. 09/163,977, filed Sep. 30, 1998, which is now pending. This application claims the benefit of Korean Application No. 98-36628, filed Sep. 5, 1998, in the Korean Industrial Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method of acquiring program guide information in an image signal receiving apparatus, and to a method and apparatus for guiding a program using the same.
[0004] 2. Description of the Related Art
[0005] Generally, program information of a conventional analog TV broadcast is supplied to publications such-as newspapers, TVs, magazines, etc. However, in a digital multichannel broadcast, tens to hundreds of channels are provided, so that a total number of the selections available to viewers becomes larger and simultaneously program selection is significantly complicated.
[0006] In such a digital broadcast, an electronic program guide (EPG) providing a program list or information on the content of each program is introduced as a fundamental data service.
[0007] Current EPG information is transmitted per channel. That is, since the EPG information of a corresponding channel is transmitted per channel, it is difficult to obtain the EPG information of all channels capable-of being accessed.
[0008] To be more specific, the EPG information of a current received channel can be obtained by interpreting additional information included in a transport packet received. However, in order to acquire EPG information of all channels capable of being accessed, a user must tune all channels individually.
[0009] In the digital broadcast, many more channels are provided than in the analog broadcast, and each channel can include subchannels. Therefore, it is important to swiftly interface the EPG information of each channel to a user.
SUMMARY OF THE INVENTION
[0010] To solve the above problems, it is an object of the present invention to provide a method of acquiring useful EPG information.
[0011] It is another object of the present invention to provide a program guide method appropriate for the above method.
[0012] It is still another object of the present invention to provide a program guide apparatus appropriate for the above method.
[0013] Accordingly, to achieve the first object, there is provided a method of acquiring program guide information for channels wherein the program guide information for each channel is acquired by scanning accessible channels while a received program is not displayed.
[0014] To achieve the second object, there is provided a program guiding method in which a program list for channels is displayed in response to a program guide command. The program guiding method comprises the steps of acquiring program guide information of accessible channels, storing the acquired program guide information, writing a program list on the basis of the stored program guide information, and displaying the written program list to the user.
[0015] Also to achieve the second object, the step of acquiring the program guide information comprises the steps of writing and displaying a program list including program guide information of channels tuned before a program guide command is executed, from the stored program guide information, and acquiring program guide information for each channel by searching for accessible channels in a background operation while the program list is referred to.
[0016] To achieve the third object, there is provided an apparatus for acquiring the program guide information of accessible channels and guiding program guide information acquired in response to a program guide command in a multichannel receiver. The apparatus comprises a tuner tuning a channel, a program guide information detector, a memory, a key input, a microprocessor, and a character signal generator.
[0017] The program guide information detector detects program guide information introduced via the tuner. The memory stores the program guide information for each channel detected by the program guide information detector. The key input introduces a user manipulation command such as a program guide command or a channel search command. The microprocessor writes a program list based on program guide information stored in the memory in response to the manipulation command input via the key input and is programmed to search for accessible channels by controlling the tuner in a background operation while a user refers to the program list. The character signal generator generates a character signal corresponding to the program list written by the microprocessor and provides the character signal to a screen.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above objects and advantages of the present invention will become more apparent by describing in detail a preferred embodiment thereof with reference to the attached drawings in which:
[0019] FIG. 1 is a block diagram illustrating the configuration of a general DTV receiver;
[0020] FIG. 2 is a flowchart illustrating a method of acquiring program guide information, according to the present invention;
[0021] FIG. 3 is a flowchart illustrating a program guide method according to the present invention;
[0022] FIGS. 4A through 4C show a program list displayed on a screen in the method shown in FIG. 3 ;
[0023] FIG. 5 is a block diagram illustrating an embodiment of a program guide apparatus according to the present invention; and
[0024] FIG. 6 is a block diagram illustrating another embodiment of a program guide apparatus according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Channel numbers, channel names, program names schedules, etc., generally transmitted as data are displayed on a TV screen as a program list having a time axis and a channel axis by EPG software of a receiver. A user can perform operations such as tuning or programming in the program list by manipulating a cursor.
[0026] FIG. 1 is a block diagram showing the configuration of a conventional digital multichannel TV (hereinafter, called “DTV”) receiver (which is also used in the present invention, as explained with reference to FIG. 2 ). In FIG. 1 , a tuner 102 tunes a radio frequency (RF) channel from received broadcast signals via an antenna 100 under the control of a microprocessor 124 . The tuner 102 outputs an intermediate frequency (IF) signal of the tuned channel, and an IF module 104 outputs a baseband signal of the tuned channel to a channel decoder 106 .
[0027] The channel decoder 106 channel-decodes the baseband signal received from the IF module 104 and reproduces data bit lines. Each of the reproduced data bit lines is divided into audio data, video data, and additional data by a transport stream (TS) decoder 108 .
[0028] The audio data is transmitted to an audio decoder 110 and decoded according to an MPEG standard or dolby AC-3 standard by the audio decoder 110 . The audio data is processed by an audio processing and output unit 112 and output as sound through a speaker 114 .
[0029] The video data is transmitted to a video decoder 116 , decoded according to the MPEG standard, applied to an on-screen-display (OSD) mixer 118 , mixed with OSD data generated by the, microprocessor 124 , processed by a video processing and outputting unit 120 , and output on the screen of a picture tube 122 . Here the OSD data is used for the microprocessor 124 to display various information as graphics or text on a screen.
[0030] The additional data is transmitted to the microprocessor 124 . The microprocessor 124 extracts program guide information or other information and stores the extracted information in a memory unit 126 . Typical EPG information is stored in a nonvolatile memory such as an EEPROM or a flash ROM.
[0031] A key pad 130 and an infra red (IF) receiving unit 134 are connected to the microprocessor 124 , which is a control unit of a DTV receiver, via a user interface 128 . The microprocessor 124 performs operations depending on various operation commands received from an IR remote controller 132 via the keypad 130 and the IR receiving unit 134 , according to a program stored in the memory 126 . Here, the IR remote controller 132 can be a wireless mouse such as an air mouse, a remote controller, etc.
[0032] A command from the IR remote controller is received as an IR signal by the IR receiving unit 134 , and transmitted to the microprocessor 124 via the user interface 128 . Also, the additional data from the TS decoder 108 is transmitted to the microprocessor 124 . Here, the additional data includes program specific information (PSI) organized as a table with respect to program associated information prescribed in MPEG-2, and the aforementioned EPG information.
[0033] The memory unit 126 includes a ROM for storing the program of the microprocessor 124 , a RAM for temporarily storing data created during the program execution in the microprocessor 124 , and an electrically erasable and programmable ROM (EEPROM) for storing various reference data.
[0034] The microprocessor 124 is connected via a bus 136 to the tuner 102 , the IF module 104 , the channel decoder 106 , the TS decoder 108 , the audio decoder 110 , the audio processing and outputting unit 112 , the video decoder 116 , the OSD mixer 118 , the video process and output unit 120 , and the memory unit 126 .
[0035] In the apparatus shown in FIG. 1 , while a user selects and receives a channel, the microprocessor 124 detects, the EPG information from the additional data provided by the TS decoder 108 . The EPG information of a corresponding channel is stored in the memory unit 126 , and provided to a user in a program guide mode.
[0036] Since the EPG information is transmitted separately for each channel, the EPG information of a corresponding channel cannot be acquired if that channel is not tuned.
[0037] Thus, a program list for all channels cannot be provided in the program guide mode for guiding a program list for each channel to a user, in the conventional apparatus.
[0038] In the present invention, while a program of a channel tuned by the tuner 102 is not displayed, for example, while a user selects or programs a program with reference to EPG information displayed on a screen or views line input, an accessible channel is scanned in a background operation, to obtain the EPG information.
[0039] FIG. 2 is a flowchart showing a method of obtaining program guide information according to the present invention. FIG. 2 shows an example of obtaining EPG information in a program guide mode according to the present invention, using the conventional apparatus showing FIG. 1 .
[0040] When a program guide command is input from a user via the keypad 130 , the apparatus shown in FIG. 1 enters into a program guide mode. In the program guide mode, first, all channels capable of being accessed by the tuner 102 are scanned to obtain program guide information for each channel, in step S 200 . The microprocessor 124 controls the tuner 102 to scan as many channels as possible, and detects the program guide information for each channel from additional data introduced via the tuner 102 . Here, the accessible channels include not only the channels capable of being accessed by the tuner 102 but also line input.
[0041] Obtained EPG information is stored, in step S 202 .
[0042] The obtained EPG information is stored in the memory unit 126 . The EPG information is transmitted for each channel, so that the microprocessor 124 acquires EPG information of a corresponding channel whenever a channel is changed and stores the acquired EPG information to the memory unit 126 .
[0043] According to the method of FIG. 2 , when the program guide mode begins, program guide information with respect to all the accessible channels is acquired all at once in an initial stage. Thus, much time is required to display the program guide information.
[0044] An increase in the number of accessible channels requires a longer time to display the program guide information, and causes the user inconvenience. In particular, a digital broadcast provides tens or hundreds of channels, thus requiring a lot of time to acquire the EPG information of all channels.
[0045] To solve this problem, in the present invention, the EPG information of a prior channel among prioritized channels is first obtained, and the EPG information of a channel having the lowest priority is then obtained, thus accomplishing a smooth user interface.
[0046] The priority of the channel search is determined by the distance (interval) of the channels to the channel tuned before a program guide command is executed, or by a probability distribution of channels, i.e., the accumulation of the number of times which channels are selected.
[0047] A typical user searches using a channel up/down command, so it is natural for the user to search beginning with channels included in a currently-displayed program list and their closest channels.
[0048] Here, the closest channels include upper closest channels and lower closest channels, and it is preferable to determine by default which channel among the above closest channels is to be accessed first.
[0049] Also, it is necessary to change the direction of search according to the characteristics of a user, even if the search direction is determined by default. For example, even if the default search direction is set to be upward, once the user designates a channel down button, lower channels must be preferentially searched. It is preferable that in preparation for when a user changes the search direction in the middle of a search, a channel search direction is determined referring to a channel up/down command or page up/down command received just before determining a channel search.
[0050] FIG. 3 is a flowchart illustrating a program guide method according to a preferred embodiment of the present invention. Response must be preferentially considered in the interface with a user. It is considered that a good response is provided if a system quickly responds to a command input by a user. The response is not considered good if a user must wait until program guide information for all channels is obtained after inputting the program guide command.
[0051] However, the user immediately needs program guide information of a channel viewed before the program guide command is executed, and program guide information of several channels adjacent to the channel viewed, not the program guide information for all channels.
[0052] In the present invention, the channel viewed before the program guide command is executed, and the program guide information of several channels adjacent to the above channel are first acquired and displayed to the user, thus improving the response.
[0053] Also, channels adjacent to channels displayed in preparation for the channel search by a user are first searched, and farther channels are then gradually searched, thus obtaining the program guide information of accessible channels.
[0054] Referring to FIG. 3 , first, it is detected whether program guide information of a channel tuned before a program guide command is executed is effective, in step S 300 . Generally, a user executes a program guide command while receiving the program of a channel. The EPG information of a channel is automatically obtained while that channel is tuned, so that at least the program guide information of the channel tuned before the program guide command is executed can be considered effective.
[0055] In a display step S 310 , at least a program list of channels tuned before the program guide command is executed among stored EPG information is displayed. The microprocessor 124 writes a program list including channels tuned before the program guide command is executed among EPG information stored in the memory unit 126 , and provides the program list to the OSG mixer 118 . The OSG mixer 118 converts the program list provided by the microprocessor 124 into a character signal, and displays the character signal on a screen.
[0056] FIG. 4A shows the contents displayed on a screen as the result of the step S 310 . In FIG. 4A , reference numeral 400 is a screen, reference numeral 410 is a program list, reference numeral 420 is a cursor, reference numeral 430 is an up/down button, reference numeral 450 is a page up/down button, and reference numeral 440 is a left/right scan button.
[0057] The program list 410 lists a program for each channel on channel and time axes. Channels listed in the program list 410 are controlled by the up/down button 430 , and time is controlled by the left/right scan button 440 .
[0058] A user can search for a channel and time of a desired program, using the up/down button 430 and the left/right scan button 440 .
[0059] Whenever the up/down button 430 is pressed, a selection bar 460 moves between the listed channels. When the selection bar 460 departs from a screen boundary, the content of the program list 410 is renewed so that the next adjacent channel can be displayed.
[0060] If program guide information of channels tuned before the program guide command is executed is not effective or not stored, a screen display message like “please wait” or “ obtaining program guide information” is displayed to the user, in step S 360 . If it takes a short time to obtain the program guide information of the tuned channel, this message display step may be omitted.
[0061] Then, program guide information of channels tuned before a program guide command is executed is obtained, in step S 370 . A program list including this program guide information is displayed, in step 310 .
[0062] In a program guide information acquiring step S 320 , program guide information for each channel is obtained by scanning accessible channels via the tuner 102 while a user views displayed EPG information.
[0063] To be more specific, in the program list shown in FIG. 4 , an inverted channel number in a program list 410 of a channel No. 53 indicates that channel No. 53 was viewed before a program guide mode.
[0064] In the circumstances where the program list as shown in FIG. 4B is displayed, channels are searched to obtain EPG information, in the following sequence.
[0065] If a channel No. 52 is in an upper adjacent screen boundary 480 and a channel No. 54 are channels listed closest to a channel No. 53 , i.e., channels most adjacent, they have the highest preference.
[0066] If a channel No. 51 is in an upper adjacent screen boundary 480 and a channel No. 56 is in a lower adjacent screen boundary 470 are channels listed next closest to the channel No. 53 , they have the next highest preferences after the channels No. 52 and No. 54 .
[0067] If an upward search direction is determined by default, channels are searched for in the sequence of No. 53 , to No. 52 , to No. 54 , No. 51 , and No. 56 . In this instance, an upward search is conducted prior to a search in the downward direction. That is, a search is alternatingly executed in an upward direction and a downward direction with the upward search being executed first.
[0068] EPG information for each channel is stored in the memory unit 126 as soon as it is obtained, and the microprocessor 124 writes a new program list referring to this information and provides the new program to the OSG mixer 118 , in steps S 330 and S 340 . As a result, new program lists as shown in FIGS. 4B and 4C are sequentially displayed.
[0069] The sequence in which the EPG information is listed in the memory unit 126 is determined by a typical channel number. Also, when a channel has subchannels, the subchannels are listed after the main channel.
[0070] Accordingly, the microprocessor 124 already knows the listing sequence of the EPG information stored in the memory unit 126 , and also knows the channel viewed before the program guide mode, to determine one search sequence.
[0071] The sequence for searching for channels may not be determined according to adjacency (or proximity). For example, channels may be searched for upward or downward based on the channel viewed before the program guide mode. However, considering the response to the user, it is more proper that the channel search sequence be determined according to the adjacency between channels instead of just to those closest to the channels shown in adjacent screen boundaries 470 and 480 .
[0072] The channel search sequence may be changed by the search preference of a user. For example, if a user manipulates the channel up/down button 430 referring to a screen shown in FIG. 4C , a continuous search in a direction to be indicated later can be expected. Thus, when a channel up operation is indicated, the channel search operation may be limited to upper channels instead of just to those closest to the channel shown in adjacent screen boundaries 470 and 480 .
[0073] The channel search sequence can be determined referring to past viewing tendencies of users. This determines the probability that a channel is to be tuned based on the accumulated frequency of channels tuned by a user. A channel having a higher probability is searched for earlier.
[0074] In a storing step S 330 of FIG. 3 , the obtained EPG information is stored in the memory unit 126 . Here, the obtained program guide information can be renewed only when there is a difference between the obtained program guide information and program guide information stored in the memory unit 126 .
[0075] The obtained EPG information is stored in the memory unit 126 . Since the EPG information is transmitted by channels, the microprocessor 124 acquires EPG information of a corresponding channel whenever a channel is changed, and stores the acquired EPG information in the memory unit 126 .
[0076] A program list is displayed, in step S 340 .
[0077] The microprocessor 124 accesses the program guide information stored in the memory unit 126 to generate the program list as shown in FIGS. 4A through 4C . The program list generated by the microprocessor 124 is displayed on a screen via the OSG mixer 118 .
[0078] The program list is controlled according to a channel up/down command or page up/down command from a user, and when a channel selection command is applied by the user, the program of a selected channel is displayed, in step S 350 .
[0079] According to the program guiding method of the present invention, the longer it takes for a user to refer to the program list, the program guide information of more channels can be obtained. However, the program guide information of channels immediately required by a user can be sufficiently acquired even in a short searching time.
[0080] According to the method shown in FIG. 3 , while a program is selected referring to the EPG information displayed by a user, accessible channels are scanned in a background operation unnoticeable to a user, thus obtaining the EPG information. Also, the EPG information is obtained referring to the search direction of a user, thus accomplishing a smooth interface with the user.
[0081] Furthermore, in order to obtain the program guide information, the program guide information of a preferential channel is obtained first and provided to a user. Therefore, a user does not need to wait until the program guide information of all the channels is obtained, increasing convenience.
[0082] In the program guide method shown in FIG. 3 , the program list as shown in FIG. 4C may be displayed in the display step S 310 . This is the case when a program list including a channel viewed before and channels adjacent to the channel is displayed in the initial stage of a program guiding operation.
[0083] According to an advanced television standard committee (ATSC) standard, the EPG information is recommended to be transmitted in a quantity of at least 3 hours to a maximum of 584 hours, at time intervals of 3 hours. Thus, erroneous program guide information is less likely to be displayed if a program guide command is performed within 384 hours at maximum.
[0084] Accordingly, it is acceptable to display the program list including a channel viewed before the program guide mode and several channels adjacent to the channel.
[0085] However, a program may be changed by the circumstances of a broadcasting station, or unstored program guide information may be requested. Thus, it is preferable that channels are searched for by the above-described searching method even after the program list including the channel viewed before the program guide mode and several channels adjacent to the channel is displayed, to again obtain a program guide.
[0086] Meanwhile, when the program list including the channel viewed before the program guide mode and several channels adjacent to that channel is displayed in the initial stage of the program guide operation, possible erroneous information of some channels can be replaced with correct information by searching for channels using the aforementioned search method.
[0087] FIG. 5 is a block diagram illustrating the configuration of a program guide apparatus according to the present invention. As shown in FIG. 5 , the apparatus includes a tuner 50 , a ROM 52 , a program guide information detector 54 , a memory 56 , a key input unit 58 , a microprocessor 60 , and an OSD generator 62 .
[0088] The tuner 50 is tuned to a broadcast signal of a tuned channel. The program guide information detector 54 detects EPG information from the broadcast signal of a channel tuned by the tuner 50 . The detected EPG information is stored in the memory 56 .
[0089] The microprocessor 60 writes a program list from the EPG information stored in the memory 56 according to a program stored in the ROM 52 , and provides the program list. to the OSD generator 62 . The OSD generator 62 converts the program list written from the EPG information stored in the memory 56 into a character signal to display the program list to a CRT 64 .
[0090] The microprocessor 60 controls tuning of the tuner 50 in the background operation while the program list is displayed on the CRT 64 , i.e., while the viewer does not watch any broadcast program via the tuner, to obtain EPG information of the accessible channels.
[0091] The microprocessor 60 searches for channels in a programmed channel searching sequence. This channel searching sequence depends on the sequence of channels which are displayed in the program guide mode.
[0092] When the channel up/down command is input via the key input unit 58 during channel search, the microprocessor 60 changes the channel searching sequence referring to the, input channel up/down command.
[0093] When the EPG information is not stored in the memory 56 , the microprocessor 60 generates a message of “please wait” or “acquiring guide information”. When at least a current channel and current program guide information are obtained, the microprocessor 60 generates a program list corresponding, to the stored program guide information.
[0094] FIG. 6 is a block diagram illustrating another embodiment of a program guide apparatus according to the present invention. Units shown in FIG. 6 performing the same operations as those in FIG. 5 are referred to by the same reference numerals, and will not be described again. The apparatus of FIG. 6 further comprises a probability estimator 64 in addition to the components of the apparatus of FIG. 5 .
[0095] The probability estimator 64 accumulates the number of times channels are tuned (or selected) by a user, and calculates the probability that each channel will be selected, according to the accumulated value. It can be estimated that the probability of selecting a channel is high as a channel is selected more often.
[0096] The microprocessor 124 determines the order of priority of channel search according to the probability calculated by the probability estimator 64 .
[0097] In the program guide information acquiring method according to the present invention as described above, while a viewer does not watch the program of any channel tuned in a tuner, program guide information of accessible channels is obtained in a background operation. Therefore, the program guide information of the accessible channels can be obtained by only a single tuner.
[0098] Furthermore, in the program guide method and apparatus according to the present invention, information immediately required by a user is obtained first, and information of less preferential channels is obtained next, thus smoothing the interface with the user. | A digital television signal receiver, which includes an audio processor to process the audio data to be output as sound; a video processor to process a video data to be output on a screen; a storage to store the extracted program information; a processor to access the storage to generate a channel list based on the stored program information; wherein the channel list comprises at least one main channel number and the at least one main channel number has at least one corresponding sub-channel number in the received transport stream; a user interface to allow a user to navigate the channel list to search a channel number. | 7 |
[0001] The present invention relates to the field of aviation gas turbine engines and is aimed more particularly at a method for treating bearing lubrication oil waste.
BACKGROUND OF THE INVENTION
[0002] A gas turbine engine consists basically of an air compression assembly that supplies a combustion chamber in which the air is mixed with a fuel to produce hot gases whose energy is recovered in a turbine assembly driving the compression means. The shafts connecting the various rotor bodies are supported in the statoric portions by bearings mounted in a pressurized enclosure. The enclosures make it possible to contain the oil that is injected onto the rolling bearings to ensure their lubrication and comprise sealing members, most frequently of the labyrinth type, that the containment air passes through. This air is laden with oil particles and in order to keep the oil consumption to as low a level as possible, it is a known practice to use deoiling equipment that separates the oil from the air that has flowed into the rolling bearing enclosures. In current engines, this equipment is incorporated either into the engine near the bearings themselves, or in the accessory gearbox, also called the AGB. The deoilers however are not 100% efficient. The exhausted air after it has passed through the deoilers still contains oil residues in the form of droplets that are ejected into the atmosphere. They are therefore the source of pollution and harm the environment.
[0003] The applicant has set itself the objective of reducing the polluting effect of the oil waste in the atmosphere.
[0004] According to the invention, the applicant has perfected a method for treating an airflow, laden with oil particles, flowing in a tube in communication with a rolling bearing enclosure of a gas turbine engine, wherein said airflow is made to travel into a coking box associated with a heating means, in which the air is heated to a sufficient temperature to coke the oil particles that it contains. Preferably, the solid residues produced by the coking are collected in the coking box.
[0005] Therefore the transformation by coking of the oil into gaseous and solid residues makes it possible to reduce the toxicity of the gases ejected into the atmosphere. On the one hand the coking makes it possible to reduce the volume of the oil waste, on the other hand, the residues are less toxic in themselves.
DESCRIPTION OF THE PRIOR ART
[0006] Document GB 2 374 026 is known, according to which the flow is made to travel into a box in which the air is heated to a sufficient temperature to vaporize the oil particles contained in the airflow. However, the oil particles are heated for the purpose of making the emissions in the atmosphere invisible and not to reduce their toxicity. There is no chemical transformation of the coking.
SUMMARY OF THE INVENTION
[0007] According to one embodiment of the method, the box is attached to said tube so that the air travels from the tube into the box. More particularly, in a gas turbine engine comprising an exhaust cone downstream of the turbine, the box is placed in said cone so that it is heated by the gases in the exhaust cone.
[0008] According to a preferred embodiment, the air is heated to a sufficient temperature to pyrolize the oil particles particularly by taking hot gases immediately downstream of the turbine.
[0009] A coking box for the treatment of an airflow containing oil particles flowing in a tube communicating with a rolling bearing enclosure of a gas turbine engine comprises a cylindrical casing with an opening on one side to receive the airflow from the tube and means forming chicanes. Preferably the box comprises a means for collecting the coked oil and more particularly the casing comprises an attachment means at the end of the central ventilation tube of the engine and an internal grid through which the oil particles are sprayed onto the internal wall of the casing and forming a means for collecting the coked oil.
[0010] The invention also relates to a gas turbine engine comprising a central ventilation tube and a gas exhaust cone, said tube opening into the exhaust channel, wherein the coking box is mounted on the central tube so as to be heated by the engine gases from the exhaust channel.
[0011] Preferably, said coking box is heated by gases taken downstream of the turbine at a sufficient temperature to pyrolize the oil particles. For example, the coking box is placed on the central ventilation tube close to a gas offtake connection immediately downstream of the turbine where the temperature is of the order of 500° C. This solution is of value because it leads to the elimination of any solid residue. In this case, it is therefore no longer necessary to intervene repeatedly on the coking box.
[0012] According to another embodiment for a gas turbine engine comprising an AGB with gears driving accessories, said box is mounted on said AGB.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] An embodiment of the invention will now be described in greater detail with reference to the drawings in which
[0014] FIG. 1 represents a gas turbine engine to which the invention applies,
[0015] FIG. 2 shows the rear portion of an engine with a central ventilation tube fitted with a coking box of the invention,
[0016] FIG. 3 shows in greater detail a coking box according to the invention,
[0017] FIG. 4 shows a means for heating the coking box according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The gas turbine engine of FIG. 1 is a turbojet with a turbofan. Such an engine comprises, in this example, a high-pressure body with an HP compressor 2 driven by an HP turbine 4 both mounted on one and the same shaft 6 . A shaft 5 concentric with the shaft 6 connects an upstream fan 3 , associated with a low-pressure LP compressor 3 ′, to a low-pressure LP turbine 7 downstream of the HP turbine 4 . The air compressed by the compressors 3 ′ then 2 travels into an annular combustion chamber 8 where it is mixed with the fuel to produce combustion gases. The latter are guided toward the HP turbine 4 then the LP turbine 7 and finally exhausted via the downstream nozzle comprising an exhaust cone. The propulsion force is supplied mostly for this type of engine by the airflow bypassing the combustion chamber and exhausted either directly into the atmosphere via an annular nozzle or mixed with the gases originating from the turbine and forming the main exhaust flow. The shafts are supported by intershaft bearings for the concentric rotating portions and by bearings mounted on the fixed, statoric, structures for the shaft 5 .
[0019] Because of the temperatures, the bearings are lubricated and cooled permanently by oil that is contained in an enclosure called the rolling bearing enclosure. Pressurized air is injected at the seals to form a barrier and prevent oil from traveling toward the hot portions of the engine and causing a fire. After it has traveled into the deoiler for oil collection, the containment air is usually exhausted to the atmosphere via the central ventilation tube 9 . This is the case when the deoilers are placed near the bearing enclosures. In the rest of the description, the invention applies to this case, but it is also valid for the case where the deoilers are placed on the AGB.
[0020] The air channeled via the tube 9 is exhausted downstream via a central duct placed in the frustoconical or substantially frustoconical part 10 , defining the internal surface of the stream of gases originating from the turbine stages. This is called the exhaust cone. In the solutions of the prior art, the residual oil, even in a small quantity, is sent into the atmosphere through the exhaust cone.
[0021] According to the invention, all the residual oil in the air is removed, before the latter is exhausted into the atmosphere, by trapping it and oxidizing it to transform it into gaseous species and into coke with a lower toxicity than oil.
[0022] One way of achieving this is illustrated in FIG. 2 which shows in greater detail the rear portion of an engine like that of FIG. 1 . The rear bearing 12 supporting the trunnion 14 of the LP turbine can be seen. The rolling bearings 12 a of the bearing 12 are mounted in a cage placed between the fixed bearing support 13 and the trunnion 14 . The assembly is contained in an enclosure 15 . Labyrinth seals 15 a , 15 b are arranged between the fixed structure of the enclosure and the LP rotor disk. Labyrinth seals 15 c and 15 d are also arranged between the fixed structure and the central ventilation tube that is fixedly attached to the LP shaft. The air of the enclosure is taken by the deoiler 16 and then is discharged centrally via the tube 9 . The elements that have just been described do not form part of the invention and are known per se.
[0023] The air of the tube 9 is driven downstream inside the exhaust cone and is then mixed with the engine gases.
[0024] According to the invention, a box, which will hereafter be called the coking box 20 , has been placed on the downstream end of the central ventilation tube 9 . This box is shown in detail in FIG. 3 .
[0025] It comprises a cylindrical casing 21 of slightly greater diameter than that of the tube 9 . The casing is attached at the end of the tube by any appropriate removable means. It is mounted so as to be open onto the tube. Inside the casing a cylindrical grid 22 makes an annular space 22 a with the casing. Over the length of the casing 21 , regularly spaced transverse plates 24 are attached in the volume delimited by the grid 22 , in an alternating manner in the form of chicanes. The casing is closed downstream by a grid with axial holes and defining a flame-arrester 26 . The casing 21 is therefore mounted downstream of the tube 9 so as to collect therefrom the air that passes through it. This air is forced into the casing by the plates 24 in a path alternately radially outward and radially inward. It follows that the oil particles that it contains are centrifuged through the grid 22 . They are collected in the annular space 22 a . By being placed at the end of the tube 9 , the casing is heated by the ambient gases inside the exhaust cone which thereby, when the engine is operating, keep the wall of the casing 21 at a temperature of approximately 300° C. At this temperature, the oil in the space 22 a sustains a thermal oxidation transformation. It is transformed partly into coked oil in the vapor phase CV and partly into coke CS, solid residue.
[0026] A means of eliminating the solid residue is to remove the box and change it. It is an operation that is carried out easily on the ground during the maintenance operations of the engine beneath the aircraft wing. According to an embodiment that is more economically advantageous, the box may be made in the form of a removable and replaceable cartridge. However, it must be recognized that, in certain turbojet operating conditions or in the case of a fault (excessive oil consumption), the quantity of coke formed may not be negligible. This means either relatively frequent or unscheduled interventions, harming profitability, or an increase in the volume of the box resulting in a space requirement and a weight that is just as harmful.
[0027] An advantageous means of eliminating the solid residue more rapidly is to pyrolize it as it forms by taking it to high temperature. Specifically, above 500° C., the coke is burnt without leaving any residue. Therefore, according to a particular embodiment, the device comprises a means of heating the box to 500° C. FIG. 4 shows an installation of the box inside the exhaust cone as in the previous case but adding a tube 18 to bring a determined quantity of gas from the stream of the main flow to the walls of the box. | The present invention relates to a method for treating an airflow, laden with oil particles, flowing in a tube ( 9 ) communicating with a rolling bearing enclosure of a gas turbine engine, wherein said airflow is made to travel into a coking box ( 20 ) associated with a heating means, in which the air is heated to a sufficient temperature to coke the oil particles contained in the airflow. Preferably, the solid residues produced by the coking are collected in the coking box ( 20 ). | 5 |
[0001] The present invention relates to novel compounds selected from 2-(3-substitutedaryl)amino-4-aryl-thiazoles that selectively modulate, regulate, and/or inhibit signal transduction mediated by certain native and/or mutant tyrosine kinases implicated in a variety of human and animal diseases such as cell proliferative, metabolic, allergic, and degenerative disorders. More particularly, these compounds are potent and selective c-kit inhibitors.
[0002] Tyrosine kinases are receptor type or non-receptor type proteins, which transfer the terminal phosphate of ATP to tyrosine residues of proteins thereby activating or inactivating signal transduction pathways. These proteins are known to be involved in many cellular mechanisms, which in case of disruption, lead to disorders such as abnormal cell proliferation and migration as well as inflammation.
[0003] As of today, there are about 58 known receptor tyrosine kinases. Other tyrosine kinases are the well-known VEGF receptors (Kim et al., Nature 362, pp. 841-844, 1993), PDGF receptors, c-kit and the FLK family. These receptors can transmit signals to other tyrosine kinases including Src, Raf, Frk, Btk, Csk, Abl, Fes/Fps, Fak, Jak, Ack. etc.
[0004] Among tyrosine kinase receptors, c-kit is of special interest. Indeed, c-kit is a key receptor activating mast cells, which have proved to be directly or indirectly implicated in numerous pathologies for which the Applicant filed WO 03/004007, WO 03/004006, WO 03/003006, WO 03/003004, WO 03/002114, WO 03/002109, WO 03/002108, WO 03/002107, WO 03/002106, WO 03/002105, WO 03/039550, WO 03/035050, WO 03/035049, U.S. 60/359,652 and U.S. 60/359,651.
[0005] It was found that mast cells present in tissues of patients are implicated in or contribute to the genesis of diseases such as autoimmune diseases (rheumatoid arthritis, inflammatory bowel diseases (IBD)) allergic diseases, tumor angiogenesis, inflammatory diseases, and interstitial cystitis. In these diseases, it has been shown that mast cells participate in the destruction of tissues by releasing a cocktail of different proteases and mediators such as histamine, neutral proteases, lipid-derived mediators (Prostaglandins, thromboxanes and leucotrienes), and various cytokines (IL-1, IL-2, IL-3, IL-4, IL-5, IL-6, IL-8, TNF-α, GM-CSF, MIP-1a, MIP-1b, MIP-2 and IFN-γ).
[0006] The c-kit receptor also can be constitutively activated by mutations leading to abnormal cell proliferation and development of diseases such as mastocytosis and various cancers.
[0007] For this reason, it has been proposed to target c-kit to deplete the mast cells responsible for these disorders.
[0008] The main objective underlying the present invention is therefore to find potent and selective compounds capable of inhibiting wild type and/or mutated c-kit.
[0009] Many different compounds have been described as tyrosine kinase inhibitors, for example, bis monocyclic, bicyclic or heterocyclic aryl compounds (WO 92/20642), vinylene-azaindole derivatives (WO 94/14808) and 1-cycloproppyl-4-pyridyl-quinolones (U.S. Pat. No. 5,330,992), styryl compounds (U.S. Pat. No. 5,217,999), styryl-substituted pyridyl compounds (U.S. Pat. No. 5,302,606), selenoindoles and selenides (WO 94/03427), tricyclic polyhydroxylic compounds (WO 92/21660) and benzylphosphonic acid compounds (WO 91/15495), pyrimidine derivatives (U.S. Pat. No. 5,521,184 and WO 99/03854), indolinone derivatives and pyrrole-substituted indolinones (U.S. Pat. No. 5,792,783, EP 934 931, U.S. Pat. No. 5,834,504, U.S. Pat. No. 5,883,116, U.S. Pat. No. 5,883,113, U.S. Pat. No. 5,886,020, WO 96/40116 and WO 00/38519), as well as bis monocyclic, bicyclic aryl and heteroaryl compounds (EP 584 222, U.S. Pat. No. 5,656,643 and WO 92/20642), quinazoline derivatives (EP 602 851, EP 520 722, U.S. Pat. No. 3,772,295 and U.S. Pat. No. 4,343,940) and aryl and heteroaryl quinazoline (U.S. Pat. No. 5,721,237, U.S. Pat. No. 5,714,493, U.S. Pat. No. 5,710,158 and WO 95/15758).
[0010] However, none of these compounds have been described as potent and selective inhibitors of c-kit or of the c-kit pathway.
[0011] In connection with our previous invention which is described in WO2004014903, we found that compounds corresponding to the 2-(3-aminoaryl)amino-4-aryl-thiazoles are potent and selective inhibitors of c-kit or c-kit pathway. These compounds are good candidates for treating diseases such as autoimmunes diseases, inflammatory diseases, cancer and mastocytosis.
[0012] We now have determined that other 2-(3-substitutedaryl)amino-4-aryl-thiazole derivatives display very strong inhibitory activity on several forms of c-kit.
DESCRIPTION
[0013] Therefore, the present invention relates to compounds belonging to the 2-(3-ketoarylamino-4-aryl-thiazoles. These compounds are capable of selectively inhibiting signal transduction involving the tyrosine phosphokinase c-kit and mutant forms thereof. In a first embodiment, the invention is aimed at compounds of formula I, which may represent either free base forms of the substances or pharmaceutically acceptable salts thereof:
and wherein
[0014] R 6 and R 7 are independently from each other chosen from one of the following:
[0000] i) hydrogen, a halogen (selected from F, Cl, Br or I),
[0015] ii) an alkyl 1 group defined as a linear, branched or cycloalkyl group containing from 1 to 10 carbon atoms, or from 2 or 3 to 10 carbon atoms, (for example methyl, ethyl, propyl, butyl, pentyl, hexyl . . . ) and optionally substituted with one or more hetereoatoms such as halogen (selected from F, Cl, Br or I), oxygen, and nitrogen (the latter optionally in the form of a pendant basic nitrogen functionality); as well as trifluoromethyl, carboxyl, cyano, nitro, formyl;
[0000] (iii) an aryl 1 group defined as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as
[0000]
halogen (selected from I, F, Cl or Br);
an alkyl 1 group;
a cycloalkyl, aryl or heteroaryl group optionally substituted by a pendant basic nitrogen functionality;
trifluoromethyl, O-alkyl 1 , carboxyl, cyano, nitro, formyl, hydroxy, NH-alkyl 1 , N(alkyl 1 )(alkyl 1 ), and amino, the latter nitrogen substituents optionally in the form of a basic nitrogen functionality;
(iv) a heteroaryl 1 group defined as a pyridyl, pyrimidinyl, pyrazinyl, pyridazinyl, thienyl, thiazolyl, imidazolyl, pyrazolyl, pyrrolyl, furanyl, oxazolyl, isoxazolyl, triazolyl, tetrazolyl, indolyl, benzimidazole, quinolinyl group, which may additionally bear any combination, at any one ring position, of one or more substituents such as
halogen (selected from F, Cl, Br or I);
an alkyl 1 group;
a cycloalkyl, aryl or heteroaryl group optionally substituted by a pendant basic nitrogen functionality,
trifluoromethyl, O-alkyl 1 , carboxyl, cyano, nitro, formyl, hydroxy, NH-alkyl 1 , N(alkyl 1 )(alkyl 1 ), and amino, the latter nitrogen substituents optionally in the form of a basic nitrogen functionality;
(v) trifluoromethyl, carboxyl, cyano, nitro, formyl, hydroxy, N(alkyl 1 )(alkyl 1 ), and amino, the latter nitrogen substituents optionally in the form of a basic nitrogen functionality.
[0024] R 8 is one of the following:
[0000] (i) hydrogen, or
[0025] (ii) a linear or branched alkyl group containing from 1 to 10 carbon atoms and optionally substituted with one or more hetereoatoms such as halogen (selected from F, Cl, Br or I), oxygen, and nitrogen, the latter optionally in the form of a pendant basic nitrogen functionality, or
[0000] (iii) CO—R 8 or COOR 8 or CONHR8 or SO2R8 wherein R8 may be
[0000]
a linear or branched alkyl group containing from 1 to 10 carbon atoms and optionally substituted with one or more hetereoatoms such as halogen (selected from F, Cl, Br or I), oxygen, and nitrogen, the latter optionally in the form of a pendant basic nitrogen functionality, or
an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen (selected from F, Cl, Br or I), alkyl groups containing from 1 to 10 carbon atoms and optionally substituted with one or more hetereoatoms such as halogen (selected from F, Cl, Br or I), oxygen, and nitrogen, the latter optionally in the form of a pendant basic nitrogen functionality; as well as trifluoromethyl, C 1-6 alkyloxy, carboxyl, cyano, nitro, formyl, hydroxy, C 1-6 alkylamino, di(C 1-6 alkyl)amino, and amino, the latter nitrogen substituents optionally in the form of a pendant basic nitrogen functionality; as well as CO—R, COO—R, CONH—R, SO2-R, and SO2NH—R wherein R is a linear or branched alkyl group containing from 1 to 10 carbon atoms and optionally substituted with at least one heteroatom, notably a halogen (selected from F, Cl, Br or I), oxygen, and nitrogen, the latter optionally in the form of a pendant basic nitrogen functionality, or
a heteroaryl group such as a pyridyl, pyrimidinyl, pyrazinyl, pyridazinyl, thienyl, thiazolyl, imidazolyl, pyrazolyl, pyrrolyl, furanyl, oxazolyl, isoxazolyl, triazolyl, tetrazolyl, indolyl, benzimidazole, quinolinyl group, which may additionally bear any combination, at any one ring position, of one or more substituents such as halogen (selected from F, Cl, Br or I), alkyl groups containing from 1 to 10 carbon atoms and optionally substituted with one or more hetereoatoms such as halogen (selected from F, Cl, Br or I), oxygen, and nitrogen, the latter optionally in the form of a pendant basic nitrogen functionality; as well as trifluoromethyl, C 1-6 alkyloxy, carboxyl, cyano, nitro, formyl, hydroxy, C 1-6 alkylamino, di(C 1-6 alkyl)amino, and amino, the latter nitrogen substituents optionally in the form of a basic nitrogen functionality; as well as CO—R, COO—R, CONH—R, SO2-R, and SO2NH—R wherein R is a linear or branched alkyl group containing from 1 to 10 carbon atoms and optionally substituted with at least one heteroatom, notably a halogen (selected from F, Cl, Br or I), oxygen, and nitrogen, the latter optionally in the form of a pendant basic nitrogen functionality.
[0029] R2, R3, R4 and R5 each independently are selected from hydrogen, halogen (selected from F, Cl, Br or I), a linear or branched alkyl group containing from 1 to 10 carbon atoms and optionally substituted with one or more hetereoatoms such as halogen (selected from F, Cl, Br or I), oxygen, and nitrogen, the latter optionally in the form of a pendant basic nitrogen functionality; as well as trifluoromethyl, C 1-6 alkyloxy, amino, C 1-6 alkylamino, di(C 1-6 alkyl)amino, carboxyl, cyano, nitro, formyl, hydroxy, and CO—R, COO—R, CONH—R, SO2-R, and SO2NH—R wherein R is a linear or branched alkyl group containing from 1 to 10 carbon atoms and optionally substituted with at least one heteroatom, notably a halogen (selected from F, Cl, Br or I), oxygen, and nitrogen, the latter optionally in the form of a pendant basic nitrogen functionality.
[0000] A is: CH 2 , 0, S, SO2, CO, or COO,
[0000] B is a bond or NH, NCH3, NR*, (CH2)n (n is 0, 1 or 2), O, S, SO2, CO, or COO,
[0000] B′ is a bond or NH, NCH3, NR*, (CH2)n (n is 0, 1 or 2), O, S, SO2, CO or COO;
[0000] R* being an alkyl 1 , aryl 1 or heteroaryl 1
[0000] W is a bond or a linker selected from NH, NHCO, NHCOO, NHCONH, NHSO2, NHSO2NH, CO, CONH, COO, COCH2, (CH2)n (n is 0, 1 or 2), CH2-CO, CH2COO, CH2-NH, O, OCH2, S, SO2, and SO2NH
[0030] R 1 is:
[0000] a) a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0000] b) an aryl or heteroaryl group optionally substituted by an alkyl or aryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality
[0000] c) an alkyl 1 , aryl 1 or heteroaryl 1 .
[0031] It will be understood that a C1-C10 alkyl encompasses a methyl, ethyl, propyl, and a C2 to C4 alkyl or a C2 to C10 alkyl.
[0032] For example, a subset of compounds may correspond to
Wherein R1, R4 and R6 have the meaning as defined above.
[0033] It will be understood that A-B-B′ includes but is not limited to:
[0000] CH2, CH2-CO, CH2-CO—CH2, CH2COO, CH2-CH2-CO, CH2-CH2-COO, CH2-NH, CH2-CH2-NH, CH2-NH—CH2 or CH2-NH—CO or CH2-CO—NH
[0034] It will be understood that A-B-B′ also includes but is not limited to:
[0000] CO—CH2, COO—CH2, CO—CH2-CH2, CO—NH, or CO—NH—CH2 as well as O—CH2
[0035] It will also be understood that NH in B or B′ can also be NCH3
[0036] In the above formula I, when W is other than a single bond, it will be understood that A can be also be NH or NCH3.
[0037] In the above formula, the following combinations are contemplated:
R6 is (iv), R4 is H or CH3, A-B-B′ is CO—NH and R1 is as defined above. R6 is (iv), R4 is H or CH3, A-B-B′ is CH2-CO—NH and R1 is as defined above. R6 is (iv), R4 is H or CH3, A-B-B′ is CH2-CO and R1 is as defined above. R6 is (iv), R4 is H or CH3, A-B-B′ is CH2-NH—CO and R1 is as defined above. R6 is (iv), R4 is H or CH3, A-B-B′ is CH2-NH and R1 is as defined above. R6 is (iv), R4 is H or CH3, A-B-B′ is CH2 and R1 is as defined above. R6 is W-(iv), R4 is a C 1 -C 2 alkyl, A-B-B′ is CO—NH and R1 is as defined above. R6 is (iv), R4 is a C 1 -C 2 alkyl, A-B-B′ is CH2-CO—NH and R1 is as defined above. R6 is (iv), R4 is a C 1 -C 2 alkyl, A-B-B′ is CH2-CO and R1 is as defined above. R6 is a pyridyl according to (iv), R4 is a C 1 -C 2 alkyl, A-B-B′ is CO—NH, CH2-CO—NH, CH2-CO, CH2-NH, CH2-NH—CO and R1 is as defined above.
[0048] In the above combination, R1 can be an alkyl 1 .
[0049] In the above combination, R1 can be an aryl 1 .
[0050] In the above combination, R1 can be an heteroaryl 1 .
[0051] In one preferred embodiment, when ABB′ is CONH, the invention is directed to compounds of the following formula I-1:
[0052] wherein R is H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality.
[0053] In one other preferred embodiment, the invention is directed to amide-aniline compounds of the following formula I-2:
[0054] wherein R is H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; or a a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with:
a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; a SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; a CO—R or a CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0058] Among the particular compounds in which R1 has the meaning as depicted above, the invention is directed to amide-benzylamine compounds of the following formula I-3:
[0059] wherein R is H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or an alkyl, cycloalkyl, aryl or heteroaryl group substituted by a alkyl, cycloalkyl, aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
[0060] a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H or an aryl heteroaryl, alkyl and cycloalkyl group optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality.
[0061] Among the particular compounds in which R1 has the meaning as depicted above, the invention is directed to amide-phenol compounds of the following formula I-4:
[0062] wherein R is H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0063] a cycloalkyl, aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; or an alkyl, cycloalkyl, aryl or heteroaryl group substituted by a alkyl, cycloalkyl, aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality;
[0064] a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H or an aryl, heteroaryl, alkyl and cycloalkyl group optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality.
[0065] Among compounds of formula I, the invention is particularly directed to 3-(thiazol-2-ylamino)-benzamide compounds of the following formula I-5:
[0066] wherein Y is a single bond, a linear or branched alkyl group containing from 1 to 10 carbon atoms, especially CH2 or CH2-CH2; or NH
[0067] wherein Z represents an aryl or heteroaryl group, optionally substituted at one or more ring position with any permutation of the following groups:
a halogen such as F, Cl, Br, I; a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an O—R, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NRaRb, where Ra and Rb represents a hydrogen, or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality or a cycle; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0072] R 2 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, cyano or alkoxy;
[0073] R 3 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, cyano or alkoxy;
[0074] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, cyano or alkoxy;
[0075] R 5 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, cyano or alkoxy;
[0076] R 6 is one of the following:
[0000] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0000] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0077] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0078] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl group containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; and R 7 is one of the following:
[0000] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0000] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0079] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0080] iv) H, an halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl group containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0081] An example of preferred compounds of the above formula is depicted below:
001: 4-[4-Methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzoylamino]-benzoic acid 2-diethylamino-ethyl ester
[0082]
[0083] Among the compounds of formula I, the invention is particularly embodied by the compounds of the following formula II:
Formula II
[0084] wherein X is R or NRR′ and wherein R and R′ are independently chosen from H, an aryl, a heteroaryl, an allyl, or a cycloalkyl group optionally substituted with at least one heteroatom, such as for example a halogen chosen from F, I, Cl and Br and optionally bearing a pendant basic nitrogen functionality; or an aryl, a heteroaryl, an alkyl or a cycloalkyl group substituted with an aryl, a heteroaryl, an alkyl or a cycloalkyl group optionally substituted with at least one heteroatom, such as for example a halogen chosen from F, I, Cl and Br and optionally bearing a pendant basic nitrogen functionality,
[0085] R 2 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0086] R 3 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0087] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0088] R 5 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0089] R 6 is one of the following:
[0000] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0000] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0090] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0091] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl group containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0092] In another alternative, substituent R 6 , which in the formula II is connected to position 4 of the thiazole ring, may instead occupy position 5 of the thiazole ring.
[0093] Among the preferred compounds corresponding formulas I and II, the invention is directed to compounds in which R1 and X, respectively, is a substituted alkyl, aryl or heteroaryl group bearing a pendant basic nitrogen functionality represented for example by the structures a to m shown below, wherein the wavy line and the arrow line correspond to the point of attachment to core structure of formula I or II.
[0094] Among group a to f and g to m R1 of formula I and X of formula II is preferentially group d. Also, for g to m, the arrow includes a point of attachment to the core structure via a phenyl group.
[0095] Furthermore, among the preferred compounds of formula I or II, the invention concerns the compounds in which R 2 and R 3 are hydrogen. Preferentially, R 4 is a methyl group and R 5 is H. In addition, R 6 is preferentially a 3-pyridyl group (cf. structure g below), or a 4-pyridyl group (cf. structure h below). The wavy line in structure g and h correspond to the point of attachment to the core structure of formula I or II.
[0096] Thus, the invention contemplates:
1—A compound of formula II as depicted above, wherein X is group d and R 6 is a 3-pyridyl group. 2—A compound of formula II as depicted above, wherein X is group d and R 4 is a methyl group. 3—A compound of formula I or II as depicted above, wherein R 1 is group d and R 2 is H. 4—A compound of formula I or II as depicted above, wherein R 1 is group d and R 3 is H. 5—A compound of formula I or II as depicted above, wherein R 1 is group d and R 2 and/or R 3 and/or R 5 is H. 6—A compound of formula I or II as depicted above, wherein R 6 is a 3-pyridyl group and R 3 is a methyl group. 7—A compound of formula I or II as depicted above, wherein R 6 is a 3-pyridyl group and R 2 is H. 8—A compound of formula I or II as depicted above, wherein R 2 and/or R 3 and/or R 5 is H and R 4 is a methyl group. 9—A compound of formula I or II as depicted above wherein R 2 and/or R 3 and/or R 5 is H, R 4 is a methyl group and R 6 is a 3-pyridyl group.
[0106] Among the compounds of formula II, the invention is particularly embodied by the compounds wherein R 2 , R 3 , R 5 are hydrogen, corresponding to the following formula II-1:
[0107] wherein X is R or NRR′ and wherein R and R′ are independently chosen from H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
[0108] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0109] R 6 is one of the following:
[0000] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0000] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0110] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0111] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl group containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0112] In another alternative, substituent R6, which in the formula II is connected to position 4 of the thiazole ring, may instead occupy position 5 of the thiazole ring.
EXAMPLES
002: N-(3,5-Bis-trifluoromethyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0113]
[0114] 1 H NMR (DMSO-d 6 ) δ=2.36 (s, 3H, ArCH 3 ); 7.43 (d, 1H, J=7.5 Hz, Ar—H); 7.68 (dd, 1H, J=7.5, 1.5 Hz, Ar—H); 7.73 (s, 1H, thiazol-H); 7.82 (m, 3H, pyridyl-H+ Ar—H); 8.54 (m, 4H, pyridyl-H+2×Ar—H); 8.85 (br s, 1H, Ar—H); 9.67 (s, 1H, NH), 10.84 (s, 1H, NH).
003: N-(3,5-Bis-trifluoromethyl-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0115]
092: N-Cyclohexyl-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0116]
[0117] 1 H NMR (DMSO-d 6 ) δ=1.00-1.40 (m, 5H, cyclo-H); 1.50-1.85 (m, 5H, cyclo-H); 2.34 (s, 3H, ArCH 3 ); 7.28 (d, 1H, J=7.9 Hz, Ar—H); 7.48 (dd, 1H, J=7.9, 1.5 Hz, Ar—H); 7.67 (s, 1H, thiazol-H); 7.82 (d, 2H, J=6.0 Hz, pyridyl-H); 8.57 (d, 2H, J=6.0 Hz, pyridyl-H); 8.63 (d, 1H, J=1.5 Hz, Ar—H); 9.55 (s, 1H, NH).
093: 4-Methyl-N-(1-methyl-1-indol-6-yl)-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0118]
094: N-(2-Methoxy-ethyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0119]
096: N-(2-Cyano-ethyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0120]
[0121] Among the compounds of formula II, the invention is particularly embodied by the compounds wherein X is a -substituted Aryl group, corresponding to the N-[3-(Thiazol-2-ylamino)-phenyl]-amide family and the following formula II-3:
[0122] wherein Ra, Rb, Rc, Rd, Re are independently chosen from H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
[0123] a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, and or bearing a pendant basic nitrogen functionality;
[0124] Ra, Rb, Rc, Rd, Re may also be
a halogen such as I, Cl, Br and F a NRR′ group where R and R′ are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; an OR group where R is H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a —SO2-R′ group wherein R′ is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a NRaCORb group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a NRaCONRbRc group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a COOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; a CONRaRb, where Ra and Rb are a hydrogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NHCOOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an OSO 2 R, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NRaOSO 2 Rb, where Ra and Rb are a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; Ra can also be a hydrogen; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; a CN group a trifluoromethyl group
[0137] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0138] R 6 is one of the following:
[0000] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0000] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0139] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0140] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl group containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
EXAMPLES
028: N-(2-Fluoro-3-trifluoromethyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0141]
029: N-(3-Fluoro-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0142]
030: 4-Methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-N-(3-trifluoromethyl-phenyl)-benzamide
[0143]
031: 4-Methyl-N-(4-methyl-3-trifluoromethyl-phenyl)-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0144]
032: N-(2-Fluoro-5-trifluoromethyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0145]
[0146] 1 H NMR (DMSO-d 6 ) δ=2.39 (s, 3H, ArCH 3 ); 7.41 (d, 1H, J=7.9 Hz, Ar—H); 7.54-7.70 (m, 3H, Ar—H); 7.72 (s, 1H, thiazol-H); 7.82 (d, 2H, J=6.0 Hz, pyridyl-H); 8.10 (dd, 1H, J=6.8, 2.2 Hz, Ar—H); 8.55 (d, 2H, J=6.0 Hz, pyridyl-H); 8.84 (d, 1H, J=1.8 Hz, Ar—H); 9.65 (s, 1H, NH); 10.31 (s, 1H, NH).
033: N-(4-Cyano-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0147]
034: N-(4-Fluoro-phenyl-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0148]
035: N-(3-Fluoro-4-methyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0149]
036: N-(4-tert-Butyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0150]
038: N-(3-Cyano-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0151]
039: N-(3-Cyano-4-methyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0152]
[0153] 1 H NMR (DMSO-d 6 ) δ=2.37 (s, 3H, ArCH 3 ); 2.46 (s, 3H, ArCH 3 ); 7.43 (m, 2H, Ar—H); 7.63 (dd, 1H, J=7.9, 1.8 Hz, Ar—H); 7.72 (s, 1H, thiazol-H); 7.83 (d, 2H, J=6.0 Hz, pyridyl-H); 7.96 (dd, 1H, J=8.3, 1.8 Hz, Ar—H); 8.19 (d, 1H, J=2.3 Hz, Ar—H); 8.55 (d, 2H, J=6.0 Hz, pyridyl-H); 8.81 (d, 1H, J=1.5 Hz, Ar—H); 9.65 (s, 1H, NH); 10.46 (s, 1H, NH).
040: N-(3-Bromo-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0154]
041: N-(3-Bromo-4-methyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0155]
042: N-(3,5-Dibromo-4-methyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0156]
043: N-(3-Chloro-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0157]
044: N-(3-Chloro-4-methyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0158]
045: N-(3-Methoxy-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0159]
046: 4-Methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-N-m-tolyl-benzamide
[0160]
047: N-(4-Fluoro-3-methyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0161]
048: N-(3-Iodo-4-methyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0162]
049: 4-Methyl-N-(3-nitro-phenyl)-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0163]
050: 4-Methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-N-p-tolyl-benzamide
[0164]
051: 4-Methyl-N-phenyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0165]
052: N-(3,4-Dimethyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0166]
053: 4-Methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-N-(3-trifluoromethoxy-phenyl)-benzamide
[0167]
054: N-(3,4-Dicyano-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0168]
055: N-(2-Fluoro-5-methyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0169]
056: N-(2,4-Difluoro-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide benzamide
[0170]
057: N-(4-Cyano-2-fluoro-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0171]
058: N-(2-Fluoro-4-methyl-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0172]
059: N-(2,4-Difluoro-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0173]
060: N-(4-Cyano-2-fluoro-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0174]
061: N-(2-Fluoro-4-methyl-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0175]
062: N-(4-Cyano-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0176]
065: N-(4-Fluoro-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0177]
099: 4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-N-m-tolyl-benzamide
[0178]
100: 4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-N-(3-trifluoromethyl-phenyl)-benzamide
[0179]
101: 4-Methyl-N-(4-methyl-3-trifluoromethyl-phenyl)-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0180]
102: N-(2-Fluoro-3-trifluoromethyl-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0181]
105: N-(4-Cyano-3-trifluoromethyl-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0182]
106: N-(4-Cyano-3-methyl-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0183]
[0184] Among compounds of formula II, the invention is particularly embodied by the compounds wherein X is a -substituted-aryl group, corresponding to the 4-(4-substituted-1-ylmethyl)-N-[3-(thiazol-2-ylamino)-phenyl]-benzamide family and the following formula II-4:
wherein X is a heteroatom, such as O or N
[0185] wherein Ra, Rb, Rd, Re, Rf, Rg, Rh are independently chosen from H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
or a NRR′ group where R and R′ are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or an OR group where R is H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a —SO2-R′ group wherein R′ is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a NRaCORb group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a NRaCONRbRc group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a COOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a CONRaRb, where Ra and Rb are a hydrogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or an NHCOOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an OSO 2 R, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or an NRaOSO 2 Rb, where Ra and Rb are a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; Ra can also be a hydrogen; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0196] Ra, Rb, Rd, Re can also be halogen such as Cl, F, Br, I or trifluoromethyl;
[0197] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0198] R 6 is one of the following:
[0000] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0000] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0199] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0200] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl group containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
EXAMPLES
004: 4-Methyl-N-[4-(4-methyl-piperazin-1-ylmethyl)-3-trifluoromethyl-phenyl]-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0201]
[0202] 1 H NMR (MeOH-d 4 ) δ=2.41 (s, 6H, NCH 3 +ArCH 3 ); 2.50-2.70 (m, 4H, pyperazine-H); 2.90 (m, 4H, pyperazine-H); 3.68 (br s, 2H, CH2-piperazine); 7.38 (d, 1H, J=7.9 Hz, Ar—H); 7.50 (m, 1H, thiazol-H); 7.60 (m, 1H, Ar—H); 7.76 (d, 1H, J=8.3 Hz, Ar—H); 7.90 (m, 2H, pyridyl-H); 8.00 (m, 1H, Ar—H); 8.12 (m, 1H, Ar—H); 8.46 (m, 2H, pyridyl-H); 8.90 (m, 1H, Ar—H).
005: 4-Methyl-N-{4-[1-(4-methyl-piperazin-1-yl)-ethyl]-phenyl}-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0203]
[0204] Among compounds of formula II, the invention is particularly embodied by the compounds wherein X is a -aryl-substituted group, corresponding to the 3-Disubstituted-amino-N-[3-(thiazol-2-ylamino)-phenyl]-benzamide family and the following formula II-5:
[0205] wherein Ra, Rb, Rc, Re, Rf, Rg are independently chosen from H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
or a NRR′ group where R and R′ are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or an OR group where R is H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a —SO2-R′ group wherein R′ is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a NRaCORb group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a NRaCONRbRc group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a COOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a CONRaRb, where Ra and Rb are a hydrogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or an NHCOOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an OSO 2 R, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or an NRaOSO 2 Rb, where Ra and Rb are a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; Ra can also be a hydrogen; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0216] Ra, Rb, Rc, Re can also be halogen such as Cl, F, Br, I or trifluoromethyl;
[0217] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0218] R 6 is one of the following:
[0000] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0000] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0219] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0220] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl group containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
EXAMPLES
089: N-(3-Dimethylamino-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0221]
[0222] 1 H NMR (DMSO-d 6 ) δ=2.36 (s, 3H, ArCH 3 ); 2.88 (s, 6H, 2×CH 3 ); 6.50 (d, 1H, J=7.9 Hz, Ar—H); 7.10-7.30 (m, 3H, Ar—H); 7.38 (d, 1H, J=7.9 Hz, Ar—H); 7.62 (dd, 1H, J=7.9, 1.5 Hz, Ar—H); 7.70 (s, 1H, thiazol-H); 7.85 (d, 2H, J=6.4 Hz, pyridyl-H); 8.54 (d, 1H, J=6.4 Hz, pyridyl-H); 8.78 (br s, 1H, Ar—H); 9.63 (s, 1H, NH), 10.04 (s, 1H, NH).
090: N-(3-Dimethylamino-phenyl)-4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-benzamide
[0223]
[0224] In a second embodiment, the invention is directed to a process for manufacturing a compound of formula I depicted above. This entails the condensation of a substrate of general formula 10 with a thiourea of the type 11.
[0225] Substituent “L” in formula 10 is a nucleofugal leaving group in nucleophilic substitution reactions (for example, L can be selected from chloro, bromo, iodo, toluenesulfonyloxy, methanesulfonyloxy, trifluoromethanesulfonyloxy, etc., with L being preferentially a bromo group).
[0226] Group R1 in formula 11a corresponds to an alkoxy group.
[0227] The reaction of 10 with 1a-d leads to a thiozole-type product of formula 12a-d.
[0228] Formula 12a is the same as formula I. Therefore, R1 in 12a corresponds to R1 in formula I.
[0000] Examples of Compound Synthesis
[0229] General: All chemicals used were commercial reagent grade products. Dimethylformamide (DMF), methanol (MeOH) were of anhydrous commercial grade and were used without further purification. Dichloromethane and tetrahydrofuran (THF) were freshly distilled under a stream of argon before use. The progress of the reactions was monitored by thin layer chromatography using precoated silica gel 60F 254, Fluka TLC plates, which were visualized under UV light. Multiplicities in 1 H NMR spectra are indicated as singlet (s), broad singlet (br s), doublet (d), triplet (t), quadruplet (q), and multiplet (m) and the NMR spectrum were realized on a 300 MHz Bruker spectrometer.
[0230] Dibromine (17.2 g, 108 mmol) was added dropwise to a cold (0° C.) solution of 4-acetyl-pyridine (12 g, 99 mmol) in acetic acid containing 33% of HBr (165 mL) under vigourous stirring. The vigorously stirred mixture was warmed to 40° C. for 2 h and then to 75° C. After 2 h at 75° C., the mixture was cooled and diluted with ether (400 mL) to precipitate the product. which was recovered by filtration and washed with ether and acetone to give white crystals (100%). This material may be recrystallised from methanol and ether.
[0231] 1 H NMR (DMSO-d 6 ) δ=5.09 (s, 2H, CH 2 Br); 8.62 (m, 2H, pyridyl-H); 9.07 (m, 2H, pyridyl-H).
[0232] Benzoyl chloride (5.64 g, 80 mmol) was added dropwise to a well-stirred solution of ammonium thiocyanate (3.54 g, 88 mmol) in acetone (50 mL). The mixture was refluxed for 15 min, then, the 3-amino-4-methyl-benzoic acid methyl ester (13.2 g, 80 mmol) was added slowly portionswise. After 1 h, the reaction mixture was poured into water (350 mL) and the bright yellow precipitate was isolated by filtration. This crude solid was stirred at room temperature with an excess anhydrous potassium carbonate in 200 mL of methanol for 2 hours. Then, the solvent was removed under reduced pressure and the crude product wax extracted with ethyl acetate and washed with water. The organic layer was dried over Na 2 SO 4 and concentrated to give a white solid. The solid was stirred in ether for 15 min and filtered to give the final product as a white solid.
[0233] 1 H NMR (DMSO-d 6 ) δ=2.22 (s, 3H, ArCH 3 ); 3.81 (s, 3H, CO 2 CH 3 ); 7.38 (d, 1H, J=7.9 Hz, Ar—H); 7.70 (dd, 1H, J=7.9, 1.5 Hz, Ar—H); 7.82 (d, 1H, J=1.8 Hz, Ar—H).
4-Methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzoic acid methyl ester
[0234]
[0235] A mixture of 4-bromoacetyl-pyridine, HBr salt (0.40 g, 1.43 mmol), 4-methyl-3-thioureido-benzoic acid methyl ester (0.32 g, 1.43 mmol) and KHCO 3 (˜0.4 g) in ethanol (10 mL) was heated at 75° C. for 20 h. The mixture was cooled, filtered (removal of KHCO 3 ) and evaporated under reduced pressure. The residue was dissolved in CHCl 3 (40 mL) and washed with saturated aqueous sodium hydrogen carbonate solution and with water. The organic layer was dried over Na 2 SO 4 and concentrated. The crude product was triturated in small amount of ethyl acetate and filtered to give the final product as an orange solid.
[0236] 1 H NMR (DMSO-d 6 ) δ=2.38 (s, 3H, ArCH 3 ); 3.88 (s, 3H, CO 2 CH 3 ); 7.58 (dd, 1H, J=7.9, 1.8 Hz, Ar—H); 7.75 (s, 1H, thiazol-H); 7.85 (d, 2H, J=6.0 Hz, pyridyl-H); 8.62 (d, 1H, J=6.0 Hz, pyridyl-H); 9.12 (d, 1H, J=1.8 Hz, Ar—H); 9.63 (s, 1H, NH).
N-(4-Cyano-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide
[0237]
4-Methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzoic acid methyl ester
[0238] A 2M solution of trimethyl aluminium in hexane (1.9 mL) was added dropwise to a cold (0° C.) solution of 4-amino-benzonitrile (0.29 g, 2.46 mmol) in anhydrous dichloromethane (30 mL) under argon atmosphere. The mixture was warmed to room temperature and stirred at room temperature for 30 min. A solution of 4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzoic acid methyl ester (0.80 g, 2.46 mmol) in anhydrous dichloromethane (30 mL) and added slowly, and the resulting mixture was heated at reflux for 5 h. The mixture was cooled to 0° C. and quenched by dropwise addition of a 4N aqueous sodium hydroxide solution (3 mL). The mixture was extracted with dichloromethane (3×20 mL). The combined organic layers were washed with brine (3×20 mL) and dried over anhydrous MgSO 4 . N-(4-Cyano-phenyl)-4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-benzamide is obtained in 98% after trituration of the crude product in methanol.
[0239] 1 H NMR (CDCl 3 ) δ=2.40 (s, 3H, ArCH 3 ); 7.40 (d, 1H, J=7.9 Hz, Ar—H); 7.63 (dd, 1H, J=7.9, 1.5 Hz, Ar—H); 7.72 (s, 1H, thiazole-H); 7.80-7.88 (m, 4H, Ar—H); 8.10 (d, 2H, J=8.6 Hz, Ar—H); 8.56 (m, 2H, Ar—H); 8.86 (d, 1H, J=1.8 Hz, Ar—H); 9.66 (br s, 1H, NH).
EXAMPLES
[0240]
[0241] In a third embodiment, the invention relates to a pharmaceutical composition comprising a compound as depicted above.
[0242] Such medicament can take the form of a pharmaceutical composition adapted for oral administration, which can be formulated using pharmaceutically acceptable carriers well known in the art in suitable dosages. Such carriers enable the pharmaceutical compositions to be formulated as tablets, pills, dragees, capsules, liquids, gels, syrups, slurries, suspensions, and the like, for ingestion by the patient. In addition to the active ingredients, these pharmaceutical compositions may contain suitable pharmaceutically-acceptable carriers comprising excipients and auxiliaries which facilitate processing of the active compounds into preparations which can be used pharmaceutically. Further details on techniques for formulation and administration may be found in the latest edition of Remington's Pharmaceutical Sciences (Maack Publishing Co., Easton, Pa.).
[0243] The composition of the invention can also take the form of a pharmaceutical or cosmetic composition for topical administration.
[0244] Such compositions may be presented in the form of a gel, paste, ointment, cream, lotion, liquid suspension aqueous, aqueous-alcoholic or, oily solutions, or dispersions of the lotion or serum type, or anhydrous or lipophilic gels, or emulsions of liquid or semi-solid consistency of the milk type, obtained by dispersing a fatty phase in an aqueous phase or vice versa, or of suspensions or emulsions of soft, semi-solid consistency of the cream or gel type, or alternatively of microemulsions, of microcapsules, of microparticles or of vesicular dispersions to the ionic and/or nonionic type. These compositions are prepared according to standard methods.
[0245] The composition according to the invention comprises any ingredient commonly used in dermatology and cosmetic. It may comprise at least one ingredient selected from hydrophilic or lipophilic gelling agents, hydrophilic or lipophilic active agents, preservatives, emollients, viscosity enhancing polymers, humectants, surfactants, preservatives, antioxidants, solvents, and fillers, antioxidants, solvents, perfumes, fillers, screening agents, bactericides, odor absorbers and coloring matter.
[0246] As oils which can be used in the invention, mineral oils (liquid paraffin), vegetable oils (liquid fraction of shea butter, sunflower oil), animal oils, synthetic oils, silicone oils (cyclomethicone) and fluorinated oils may be mentioned. Fatty alcohols, fatty acids (stearic acid) and waxes (paraffin, carnauba, beeswax) may also be used as fatty substances.
[0247] As emulsifiers which can be used in the invention, glycerol stearate, polysorbate 60 and the PEG-6/PEG-32/glycol stearate mixture are contemplated.
[0248] As hydrophilic gelling agents, carboxyvinyl polymers (carbomer), acrylic copolymers such as acrylate/alkylacrylate copolymers, polyacrylamides, polysaccharides such as hydroxypropylcellulose, clays and natural gums may be mentioned, and as lipophilic gelling agents, modified clays such as bentones, metal salts of fatty acids such as aluminum stearates and hydrophobic silica, or alternatively ethylcellulose and polyethylene may be mentioned.
[0249] As hydrophilic active agents, proteins or protein hydrolysates, amino acids, polyols, urea, allantoin, sugars and sugar derivatives, vitamins, starch and plant extracts, in particular those of Aloe vera may be used.
[0250] As lipophilic active, agents, retinol (vitamin A) and its derivatives, tocopherol (vitamin E) and its derivatives, essential fatty acids, ceramides and essential oils may be used. These agents add extra moisturizing or skin softening features when utilized.
[0251] In addition, a surfactant can be included in the composition so as to provide deeper penetration of the compound capable of depleting mast cells, such as a tyrosine kinase inhibitor, preferably a c-kit inhibitor.
[0252] Among the contemplated ingredients, the invention embraces penetration enhancing agents selected for example from the group consisting of mineral oil, water, ethanol, triacetin, glycerin and propylene glycol; cohesion agents selected for example from the group consisting of polyisobutylene, polyvinyl acetate and polyvinyl alcohol, and thickening agents.
[0253] Chemical methods of enhancing topical absorption of drugs are well known in the art. For example, compounds with penetration enhancing properties include sodium lauryl sulfate (Dugard, P. H. and Sheuplein, R. J., “Effects of Ionic Surfactants on the Permeability of Human Epidermis: An Electrometric Study,” J. Ivest. Dermatol., V.60, pp. 263-69, 1973), lauryl amine oxide (Johnson et. al., U.S. Pat. No. 4,411,893), azone (Rajadhyaksha, U.S. Pat. Nos. 4,405,616 and 3,989,816) and decylmethyl sulfoxide (Sekura, D. L. and Scala, J., “The Percutaneous Absorption of Alkylmethyl Sulfides,” Pharmacology of the Skin, Advances In Biology of Skin, (Appleton-Century Craft) V. 12, pp. 257-69, 1972). It has been observed that increasing the polarity of the head group in amphoteric molecules increases their penetration-enhancing properties but at the expense of increasing their skin irritating properties (Cooper, E. R. and Berner, B., “Interaction of Surfactants with Epidermal Tissues: Physiochemical Aspects,” Surfactant Science Series, V. 16, Reiger, M. M. ed. (Marcel Dekker, Inc.) pp. 195-210, 1987).
[0254] A second class of chemical enhancers are generally referred to as co-solvents. These materials are absorbed topically relatively easily, and, by a variety of mechanisms, achieve permeation enhancement for some drugs. Ethanol (Gale et. al., U.S. Pat. No. 4,615,699 and Campbell et. al., U.S. Pat. Nos. 4,460,372 and 4,379,454), dimethyl sulfoxide (U.S. Pat. Nos. 3,740,420 and 3,743,727, and U.S. Pat. No. 4,575,515), and glycerine derivatives (U.S. Pat. No. 4,322,433) are a few examples of compounds which have shown an ability to enhance the absorption of various compounds.
[0255] The pharmaceutical compositions of the invention can also be intended for administration with aerosolized formulation to target areas of a patient's respiratory tract.
[0256] Devices and methodologies for delivering aerosolized bursts of a formulation of a drug is disclosed in U.S. Pat. No. 5,906,202. Formulations are preferably solutions, e.g. aqueous solutions, ethanoic solutions, aqueous/ethanoic solutions, saline solutions, colloidal suspensions and microcrystalline suspensions. For example aerosolized particles comprise the active ingredient mentioned above and a carrier, (e.g., a pharmaceutically active respiratory drug and carrier) which are formed upon forcing the formulation through a nozzle which nozzle is preferably in the form of a flexible porous membrane. The particles have a size which is sufficiently small such that when the particles are formed they remain suspended in the air for a sufficient amount of time such that the patient can inhale the particles into the patient's lungs.
[0257] The invention encompasses the systems described in U.S. Pat. No. 5,556,611:
liquid gas systems (a liquefied gas is used as propellent gas (e.g. low-boiling FCHC or propane, butane) in a pressure container, suspension aerosol (the active substance particles are suspended in solid form in the liquid propellent phase), pressurized gas system (a compressed gas such as nitrogen, carbon dioxide, dinitrogen monoxide, air is used.
[0261] Thus, according to the invention the pharmaceutical preparation is made in that the active substance is dissolved or dispersed in a suitable nontoxic medium and said solution or dispersion atomized to an aerosol, i.e. distributed extremely finely in a carrier gas. This is technically possible for example in the form of aerosol propellent gas packs, pump aerosols or other devices known per se for liquid misting and solid atomizing which in particular permit an exact individual dosage.
[0262] Therefore, the invention is also directed to aerosol devices comprising the compound as defined above and such a formulation, preferably with metered dose valves.
[0263] The pharmaceutical compositions of the invention can also be intended for intranasal administration.
[0264] In this regard, pharmaceutically acceptable carriers for administering the compound to the nasal mucosal surfaces will be readily appreciated by the ordinary artisan. These carriers are described in the Remington's Pharmaceutical Sciences” 16th edition, 1980, Ed. By Arthur Osol, the disclosure of which is incorporated herein by reference.
[0265] The selection of appropriate carriers depends upon the particular type of administration that is contemplated. For administration via the upper respiratory tract, the composition can be formulated into a solution, e.g., water or isotonic saline, buffered or unbuffered, or as a suspension, for intranasal administration as drops or as a spray. Preferably, such solutions or suspensions are isotonic relative to nasal secretions and of about the same pH, ranging e.g., from about pH 4.0 to about pH 7.4 or, from pH 6.0 to pH 7.0. Buffers should be physiologically compatible and include, simply by way of example, phosphate buffers. For example, a representative nasal decongestant is described as being buffered to a pH of about 6.2 (Remington's, Id. at page 1445). Of course, the ordinary artisan can readily determine a suitable saline content and pH for an innocuous aqueous carrier for nasal and/or upper respiratory administration.
[0266] Common intranasal carriers include nasal gels, creams, pastes or ointments with a viscosity of, e.g., from about 10 to about 3000 cps, or from about 2500 to 6500 cps, or greater, may also be used to provide a more sustained contact with the nasal mucosal surfaces. Such carrier viscous formulations may be based upon, simply by way of example, alkylcelluloses and/or other biocompatible carriers of high viscosity well known to the art (see e.g., Remington's, cited supra. A preferred alkylcellulose is, e.g., methylcellulose in a concentration ranging from about 5 to about 1000 or more mg per 100 ml of carrier. A more preferred concentration of methyl cellulose is, simply by way of example, from about 25 to about mg per 100 ml of carrier.
[0267] Other ingredients, such as art known preservatives, colorants, lubricating or viscous mineral or vegetable oils, perfumes, natural or synthetic plant extracts such as aromatic oils, and humectants and viscosity enhancers such as, e.g., glycerol, can also be included to provide additional viscosity, moisture retention and a pleasant texture and odor for the formulation. For nasal administration of solutions or suspensions according to the invention, various devices are available in the art for the generation of drops, droplets and sprays.
[0268] A premeasured unit dosage dispenser including a dropper or spray device containing a solution or suspension for delivery as drops or as a spray is prepared containing one or more doses of the drug to be administered and is another object of the invention. The invention also includes a kit containing one or more unit dehydrated doses of the compound, together with any required salts and/or buffer agents, preservatives, colorants and the like, ready for preparation of a solution or suspension by the addition of a suitable amount of water.
[0269] Another aspect of the invention is directed to the use of said compound to manufacture a medicament. In other words, the invention embraces a method for treating a disease related to unregulated c-kit transduction comprising administering an effective amount of a compound as defined above to a mammal in need of such treatment.
[0270] More particularly, the invention is aimed at a method for treating a disease selected from autoimmune diseases, allergic diseases, bone loss, cancers such as leukemia and GIST, tumor angiogenesis, inflammatory diseases, inflammatory bowel diseases (IBD), interstitial cystitis, mastocytosis, infections diseases, metabolic disorders, fibrosis, diabetes and CNS disorders comprising administering an effective amount a compound depicted above to a mammal in need of such treatment.
[0271] The above described compounds are useful for manufacturing a medicament for the treatment of diseases related to unregulated c-kit transduction, including, but not limited to:
neoplastic diseases such as mastocytosis, canine mastocytoma, human gastrointestinal stromal tumor (“GIST”), small cell lung cancer, non-small cell lung cancer, acute myelocytic leukemia, acute lymphocytic leukemia, myelodysplastic syndrome, chronic myelogenous leukemia, colorectal carcinomas, gastric carcinomas, gastrointestinal stromal tumors, testicular cancers, glioblastomas, solid tumors and astrocytomas. tumor angiogenesis. metabolic diseases such as diabetes mellitus and its chronic complications; obesity; diabete type II; hyperlipidemias and dyslipidemias; atherosclerosis; hypertension; and cardiovascular disease. allergic diseases such as asthma, allergic rhinitis, allergic sinusitis, anaphylactic syndrome, urticaria, angioedema, atopic dermatitis, allergic contact dermatitis, erythema nodosum, erythema multiforme, cutaneous necrotizing venulitis and insect bite skin inflammation and blood sucking parasitic infestation. interstitial cystitis. bone loss (osteoporosis). inflammatory diseases such as rheumatoid arthritis, conjunctivitis, rheumatoid spondylitis, osteoarthritis, gouty arthritis and other arthritic conditions. autoimmune diseases such as multiple sclerosis, psoriasis, intestine inflammatory disease, ulcerative colitis, Crohn's disease, rheumatoid arthritis and polyarthritis, local and systemic scleroderma, systemic lupus erythematosus, discoid lupus erythematosus, cutaneous lupus, dermatomyositis, polymyositis, Sjogren's syndrome, nodular panarteritis, autoimmune enteropathy, as well as proliferative glomerulonephritis. graft-versus-host disease or graft rejection in any organ transplantation including kidney, pancreas, liver, heart, lung, and bone marrow. Other autoimmune diseases embraced by the invention active chronic hepatitis and chronic fatigue syndrome. subepidermal blistering disorders such as pemphigus. Vasculitis. melanocyte dysfunction associated diseases such as hypermelanosis resulting from melanocyte dysfunction and including lentigines, solar and senile lentigo, Dubreuilh melanosis, moles as well as malignant melanomas. In this regard, the invention embraces the use of the compounds defined above to manufacture a medicament or a cosmetic composition for whitening human skin. CNS disorders such as psychiatric disorders, migraine, pain, memory loss and nerve cells degeneracy. More particularly, the method according to the invention is useful for the treatment of the following disorders: Depression including dysthymic disorder, cyclothymic disorder, bipolar depression, severe or “melancholic” depression, atypical depression, refractory depression, seasonal depression, anorexia, bulimia, premenstrual syndrome, post-menopause syndrome, other syndromes such as mental slowing and loss of concentration, pessimistic worry, agitation, self-deprecation, decreased libido, pain including, acute pain, postoperative pain, chronic pain, nociceptive pain, cancer pain, neuropathic pain, psychogenic pain syndromes, anxiety disorders including anxiety associated with hyperventilation and cardiac arrhythmias, phobic disorders, obsessive-compulsive disorder, posttraumatic stress disorder, acute stress disorder, generalized anxiety disorder, psychiatric emergencies such as panic attacks, including psychosis, delusional disorders, conversion disorders, phobias, mania, delirium, dissociative episodes including dissociative amnesia, dissociative fugue and dissociative identity disorder, depersonalization, catatonia, seizures, severe psychiatric emergencies including suicidal behaviour, self-neglect, violent or aggressive behaviour, trauma, borderline personality, and acute psychosis, schizophrenia including paranoid schizophrenia, disorganized schizophrenia, catatonic schizophrenia, and undifferentiated schizophrenia, neurodegenerative diseases including Alzheimer's disease, Parkinson's disease, Huntington's disease, the prion diseases, Motor Neurone Disease (MND), and Amyotrophic Lateral Sclerosis (ALS). substance use disorders as referred herein include but are not limited to drug addiction, drug abuse, drug habituation, drug dependence, withdrawal syndrome and overdose. Cerebral ischemia Fibrosis Duchenne muscular dystrophy
[0291] Regarding mastocytosis, the invention contemplates the use of the compounds as defined above for treating the different categories which can be classified as follows:
[0292] The category I is composed by two sub-categories (IA and 13). Category IA is made by diseases in which mast cell infiltration is strictly localized to the skin. This category represents the most frequent form of the disease and includes: i) urticaria pigmentosa, the most common form of cutaneous mastocytosis, particularly encountered in children, ii) diffuse cutaneous mastocytosis, iii) solitary mastocytoma and iv) some rare subtypes like bullous, erythrodermic and teleangiectatic mastocytosis. These forms are characterized by their excellent prognosis with spontaneous remissions in children and a very indolent course in adults. Long term survival of this form of disease is generally comparable to that of the normal population and the translation into another form of mastocytosis is rare. Category IB is represented by indolent systemic disease (SM) with or without cutaneous involvement. These forms are much more usual in adults than in children. The course of the disease is often indolent, but sometimes signs of aggressive or malignant mastocytosis can occur, leading to progressive impaired organ function.
[0293] The category II includes mastocytosis with an associated hematological disorder, such as a myeloproliferative or myelodysplastic syndrome, or acute leukemia. These malignant mastocytosis does not usually involve the skin. The progression of the disease depends generally on the type of associated hematological disorder that conditiones the prognosis.
[0294] The category III is represented by aggressive systemic mastocytosis in which massive infiltration of multiple organs by abnormal mast cells is common. In patients who pursue this kind of aggressive clinical course, peripheral blood features suggestive of a myeloproliferative disorder are more prominent. The progression of the disease can be very rapid, similar to acute leukemia, or some patients can show a longer survival time.
[0295] Finally, the category IV of mastocytosis includes the mast cell leukemia, characterized by the presence of circulating mast cells and mast cell progenitors representing more than 10% of the white blood cells. This entity represents probably the rarest type of leukemia in humans, and has a very poor prognosis, similar to the rapidly progressing variant of malignant mastocytosis. Mast cell leukemia can occur either de novo or as the terminal phase of urticaria pigmentosa or systemic mastocytosis.
[0296] The invention also contemplates the method as depicted for the treatment of recurrent bacterial infections, resurging infections after asymptomatic periods such as bacterial cystitis. More particularly, the invention can be practiced for treating FimH expressing bacteria infections such as Gram-negative enterobacteria including E. coli, Klebsiella pneumoniae, Serratia marcescens, Citrobactor freudii and Salmonella typhimurium.
[0297] In this method for treating bacterial infection, separate, sequential or concomitant administration of at least one antibiotic selected bacitracin, the cephalosporins, the penicillins, the aminoglycosides, the tetracyclines, the streptomycins and the macrolide antibiotics such as erytliromycin; the fluoroquinolones, actinomycin, the sulfonamides and trimethoprim, is of interest.
[0298] In one preferred embodiment, the invention is directed to a method for treating neoplastic diseases such as mastocytosis, canine mastocytoma, human gastrointestinal stromal tumor (“GIST”), small cell lung cancer, non-small cell lung cancer, acute myelocytic leukemia, acute lymphocytic leukemia, myelodysplastic syndrome, chronic myelogenous leukemia, colorectal carcinomas, gastric carcinomas, gastrointestinal stromal tumors, testicular cancers, glioblastomas, and astrocytomas comprising administering a compound as defined herein to a human or mammal, especially dogs and cats, in need of such treatment.
[0299] In one other preferred embodiment, the invention is directed to a method for treating allergic diseases such as asthma, allergic rhinitis, allergic sinusitis, anaphylactic syndrome, urticaria, angioedema, atopic dermatitis, allergic contact dermatitis, erythema nodosum, erythema multiforme, cutaneous necrotizing venulitis and insect bite skin inflammation and blood sucking parasitic infestation comprising administering a compound as defined herein to a human or mammal, especially dogs and cats, in need of such treatment.
[0300] In still another preferred embodiment, the invention is directed to a method for treating inflammatory diseases such as rheumatoid arthritis, conjunctivitis, rheumatoid spondylitis, osteoarthritis, gouty arthritis and other arthritic conditions comprising administering a compound as defined herein to a human in need of such treatment.
[0301] In still another preferred embodiment, the invention is directed to a method for treating autoimmune diseases such as multiple sclerosis, psoriasis, intestine inflammatory disease, ulcerative colitis, Crohn's disease, rheumatoid arthritis and polyarthritis, local and systemic scleroderma, systemic lupus erythematosus, discoid lupus erythematosus, cutaneous lupus, dermatomyositis, polymyositis, Sjogren's syndrome, nodular panarteritis, autoimmune enteropathy, as well as proliferative glomerulonephritis comprising administering a compound as defined herein to a human in need of such treatment.
[0302] In still another preferred embodiment, the invention is directed to a method for treating graft-versus-host disease or graft rejection in any organ transplantation including kidney, pancreas, liver, heart, lung, and bone marrow comprising administering a compound as defined herein to a human in need of such treatment.
Example 1
In vitro TK Inhibition Assays
[0303] Procedure
[0304] Experiments were performed using purified intracellular domain of c-kit expressed in baculovirus. Estimation of the kinase activity was assessed by the phosphorylation of tyrosine containing target peptide estimated by established ELISA assay.
[0305] Experimental Results on Tested Compounds
[0306] Result in Table 1 shows the potent inhibitory action of the catalytic activity of c-kit with an IC50<10 μM. Further experiments (not shown) indicates that at least one compound acts as perfect competitive inhibitors of ATP.
Example 2
Ex Vivo TK Inhibition Assays
[0307] Procedures
[0308] C-Kit WT and Mutated C-Kit (JM) Assay
[0000] Proliferation Assays
[0309] Cells were washed two times in PBS before plating at 5×104 cells per well of 96-well plates in triplicate and stimulated either with hematopoietic growth factors (HGF) or without. After 2 days of culture, 37 Bq (1.78 Tbq/mmol) of [3H] thymidine (Amersham Life Science, UK) was added for 6 hours. Cells were harvested and filtered through glass fiber filters and [3H] thymidine incorporation was measured in a scintillation counter. For proliferation assay, all drugs were prepared as 20 mM stock solutions in DMSO and conserved at −80° C. Fresh dilutions in PBS were made before each experiment. DMSO dissolved drugs were added at the beginning of the culture. Control cultures were done with corresponding DMSO dilutions. Results are represented in percentage by talking the proliferation without inhibitor as 100%.
[0000] Cells
[0310] Ba/F3 murine kit and human kit, Ba/F3 mkitD27 (juxtamembrane deletion) are derived from the murine IL-3 dependent Ba/F3 proB lymphoid cells. The FMA3 and P815 cell lines are mastocytoma cells expressing endogenous mutated forms of Kit, i.e., frame deletion in the murine juxtamembrane coding region of the receptor-codons 573 to 579. The human leukaemic MC line HMC-1 expresses mutations JM-V560G;
[0311] Immunoprecipitation Assays and Western Blotting Analysis
[0312] For each assay, 5.106 Ba/F3 cells and Ba/F3-derived cells with various c-kit mutations were lysed and immunoprecipitated as described (Beslu et al., 1996), excepted that cells were stimulated with 250 ng/ml of rmKL. Cell lysates were immunoprecipitated with a rabbit immunserum anti murine KIT, directed against the KIT cytoplasmic domain (Rottapel et al., 1991). Western blot was hybridized either with the 4G10 anti-phosphotyrosine antibody (UBI) or with the rabbit immunserum anti-murine KIT or with different antibodies (described in antibodies paragraph). The membrane was then incubated either with HRP-conjugated goat anti mouse IgG antibody or with HRP-conjugated goat anti rabbit IgG antibody (Immunotech), Proteins of interest were then visualized by incubation with ECL reagent (Amersham).
[0313] Experimental Results
[0314] The experimental results for various compounds according to the invention using above-described protocols are set forth at Table 2:
TABLE 2 Target IC50 (mM) Compounds c-Kit WT IC50 < 10 mM 001; 002; 003; 004; 005; 028; 029; 030; 031; 032; 033; 034; 35; 036; 038; 039; 040; 041; 042; 043; 044; 045; 046; 047; 048; 049; 050; 051; 052; 053; 054; 055; 056; 057; 058; 059; 060; 061; 062; 0.65; 089; 090; 092; 093; 094; 096; 099; 100; 101; 102; 105; 106 c-Kit JM IC50 < 1 mM D27 | The present invention relates to novel compounds selected from 2-(3substitutedaryl)amino-4-aryl-thiazoles that selectively modulate, regulate, and/or inhibit signal transduction mediated by certain native and/or mutant tyrosine kinases implicated in a variety of human and animal diseases such as cell proliferative, metabolic, allergic, and degenerative disorders. More particularly, these compounds are potent and selective c-kit inhibitors. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This Application is a Division of application Ser. No. 09/826,036 filed on Apr. 4, 2001 now U.S. Pat. No. 6,762,121, the entire contents of which are incorporated herein by reference.
BACKGROUND
This invention relates to a method of forming a refractory metal contact over a silicon substrate in a solid state structure, and to related structures. More particularly, the invention relates to a method employing a sacrificial silicon layer that serves as a nucleation layer for subsequent deposition of a refractory material to form a contact.
Conductive metal contacts are frequently found in semi-conductor devices, and typically are formed by deposition of a refractory material, such as tungsten or the like, confined by a silicon oxide layer previously deposited over a conducting substrate containing, for example, a silicide. Steps in the conventional method of forming such contacts, and the nature of a problem that sometimes arises, are best understood with reference to FIGS. 1 , 2 , 3 and 4 (A)-(B) hereof.
FIG. 1 is a cross-sectional view of a relevant portion of the underlying structure, wherein an underlying silicide layer 100 serves as a substrate 4 with an oxide layer 102 formed thereon. The location, shape and size of the desired conductor is determined by a through opening 104 formed in the oxide layer 102 , with exposed surface 106 of the silicide serving as a bottom 106 of the opening 104 . As best seen in FIG. 2 , a thin metallic layer 200 is then deposited at the bottom of aperture 104 to serve as a contact liner. Then, per FIG. 3 , a thin nucleation layer 300 of a refractory material such as tungsten is formed in the presence of silane gas to cover oxide layer 102 , the sides 108 of aperture 104 , per liner 200 . This is followed, per FIG. 4 (A), by the deposition of a layer 400 containing the desired refractory material in an amount sufficient to totally cover and fill up the inside of aperture 104 and to extend over the upper surface of oxide layer 102 . Note that the nucleation layer 300 becomes, in effect, absorbed within the refractory layer 400 .
Unfortunately, when a refractory material such as tungsten is deposited from decomposition of WF 6 through the use of either physical vapor deposition (PVD) or chemical vapor deposition (CVD), particularly during a chemical vapor deposition step, some of the fluorine released from decomposition of WF 6 combines with silicon in the silicide layer 100 and a propensity to form an undesirable region 402 , as is probably best seen in the enlarged view in FIG. 4 (B).
An example of a prior patent which appears to address a similar problem is U.S. Pat. No. 5,804,499, to Dehm et al., titled “Prevention of Abnormal WSi x Oxidation by In-Situ Amorphous Silicon Deposition”, which suggests a process in which amorphous silicon is deposited in a thin layer on top of tungsten silicide to prevent abnormal WSi x oxidation during subsequent process steps. The layer of amorphous silicon as mentioned in this patent is bounded by a spacer also made of amorphous silicon. The reference does not teach the provision of a continuous layer of silicon to address the problem at issue.
The present invention seeks to address this particular problem in a simple and efficient manner.
BRIEF SUMMARY
This invention provides a method by which a refractory material may be deposited in and over an opening in a non-conducting layer over a conducting layer, employing a known PVD or CVD step, without damage to the underlying conducting layer.
The present invention also provides a structure which includes a refractory material contact formed over an opening in a non-conductive layer deposited over a conductive metal silicide layer.
Accordingly, in a first aspect of this invention, there is provided a method of filling an opening in an oxide layer, over a liner layer formed on a silicide layer underlying both the oxide layer and the liner layer, which includes the step of forming a continuous first layer of silicon on the oxide layer, a wall of the opening and the liner layer and, thereafter, forming a second layer of a refractory material on the first layer so as to cover the same and to also substantially fill the opening.
In another aspect of this invention, there is provided a multi-layer structure which includes a silicide layer having a first surface; an oxide layer formed on the first surface and having a second surface with a through opening defined in the oxide layer from the second surface to the first surface; a liner layer formed on the first surface at a bottom of the opening, a continuous silicon layer formed to extend over the second surface, the opening surface and the liner layer; and a refractory material layer formed on the silicon layer so as to substantially fill the opening.
These and other aspects, objectives and advantages of the present invention will become clearer from an understanding of the following detailed description with reference to the appended figures.
DESCRIPTION OF THE DRAWINGS
FIGS. 1 , 2 , 3 and 4 (A)-(B) all relate to the prior art.
FIG. 1 is a cross-sectional view showing a metal silicide layer over which is formed a non-conducting oxide layer with a through aperture defined therein.
FIG. 2 is a cross-sectional view showing the structure per FIG. 1 , with a metallic liner layer formed at a bottom surface of the aperture.
FIG. 3 is a cross-sectional view at a stage following FIG. 2 , showing the deposition of a nucleation layer 300 of tungsten over the oxide layer, the sides of the opening formed therein, and the liner at the bottom of the opening.
FIG. 4 (A) is a cross-sectional view at a later stage in the known process, wherein a deposit of a refractory material covers the oxide layer and fills the opening above the liner, and also indicates the presence of an undesirable region that may sometimes be formed during deposition of the refractory material due to interaction with the underlying silicide.
FIG. 4 (B) is an enlarged view of a relevant portion of FIG. 4 (A), to show more clearly the undesired contamination of the underlying silicide layer at the bottom of the opening that is otherwise filled with refractory material.
FIG. 5 , per the method according to the present invention, is a cross-sectional view of the structure per FIG. 2 with the deposit of a continuous silicon layer over the oxide layer, the sides of the opening formed therein, and the underlying liner at the bottom of the opening.
FIG. 6 is a cross-sectional view after deposition of a refractory material over the continuous silicon layer shown in FIG. 5 .
DETAILED DESCRIPTION
As indicated above, the present invention is aimed at providing a method that ensures against contamination of an underlying suicide substrate by any constituent of a refractory conducting layer during its deposition into the desired structure.
Referring to the structure illustrated in cross-sectional view in FIG. 2 , note that a silicide layer 100 , of the order of 300-800 Å in thickness and deposited on a silicon substrate 150 , typically serves as a substrate for an oxide layer 102 deposited thereon with a through opening 104 defined therein, with a liner layer 200 deposited at the bottom 106 of opening 104 in known manner. Liner layer 200 may comprise at least one of titanium, titanium nitride, tungsten, and an alloy of titanium and tungsten, and may incidentally be deposited on the oxide layer 102 . The preferred method according to this invention includes these steps of the prior art.
In the prior art, as best understood with reference to FIG. 3 , a layer 300 of tungsten (W) deposited from WF 6 decomposition in the presence of silane was then formed as a nucleation layer.
According to the present invention, a continuous layer 500 of amorphous or polycrystalline silicon is deposited to a controlled thickness preferably by either physical vapor depositions (PVD) or by chemical vapor deposition (CVD), to extend over the oxide layer 102 and the upper surface of liner layer 200 . This is best understood with reference to FIG. 5 .
The continuous silicon layer 500 is intended to be a sacrificial layer, i.e., it is anticipated that it may chemically interact and combine with any fluorine (F) that becomes available when, for example, WF 6 is decomposed to generate a tungsten contact layer 400 . In other words, it is intended in the present invention that some of this silicon be consumed in preference to any silicon from the underlying silicide layer 100 . The deposited silicon layer 500 must be in the form of a continuous amorphous or polycrystalline silicon layer. The deposited polysilicon may be obtained by decomposition of a silane such as silane, disilane or trisilane. However, silanes containing ions such as dichlorosilane may advantageously be used and are preferred for this purpose.
The resulting structure is best understood with reference to FIG. 6 , in which the silicide substrate 100 supports oxide layer 102 and liner 200 , and the continuous sacrificial amorphous or polycrystalline silicon layer 500 formed thereon serves as a base for the refractory layer 600 which extends over oxide layer 102 and substantially fills the opening 104 . Note that a small imperfectly filled region 502 may exist in the refractory material 600 within the volume of the substantially filled opening 104 without any deleterious effects on the resulting contact structure and its functionality.
The structure as illustrated in FIG. 6 can then be subjected to conventional subsequent processing such as planarization of 600 , 500 and 200 .
As previously indicated, the present invention is intended to provide a satisfactory refractory layer while avoiding the known problems associated with the related prior art. It is intended, further, that the “refractory material” may be a refractory metal, e.g., tungsten, titanium, tantalum or molybdenum employed directly as a “metal”; a refractory metal employed as a constituent of a “compound” thereof, e.g., titanium nitride, tantalum nitride, etc.; or even as a constituent of an “alloy” with another metal, e.g., titanium-tungsten. With any of these available options, the provision of a continuous silicon layer as discussed above ensures against the known problem.
It is intended that the desired refractory material layer 600 be formed in known manner by either a PVD or CVD process step.
It is preferred that the continuous sacrificial silicon layer 500 be provided as an amorphous or polysilicon film of a thickness not greater than about 50 Å.
The application of the continuous sacrificial silicon layer 500 by either the PVD or the CVD process is preferably accomplished at a temperature in the range 500°-650° C., with 600° C. being particularly preferred. It should be noted that when a PVD process is employed there may be little or no deposition of the silicon on sides 108 , 108 of opening 104 .
It should also be noted that the traditional way of providing a silicon deposition is to flow the silane gas in one process chamber over the underlying structure and, subsequent to depositing the desired silicon layer, to move the wafer supporting the desired structure into another process chamber where a WF 6 environment, for example, could be provided for the subsequent step of depositing tungsten thereon. An obvious problem in doing this is that the timing and conditions required to form the proper layer of silicon to protect the wafer from the chemically active WF 6 gas has a narrow process window and is subject to control problems.
The present invention, by utilizing the silicon layer as it does, i.e., as both a sacrificial layer and a nucleation layer, advantageously eliminates the need to do this. In other words, the wafer may be maintained in a single chamber and first be exposed to the silane or dichlorosilane to obtain the desired silicon layer under controlled conditions of time, temperature and flow rate, and this may be followed by passage of WF 6 gas over the same wafer in the same chamber under appropriate process conditions of controlled temperature, pressure and flow rate. The process is readily adaptable to either physical vapor deposition or chemical vapor deposition conducted in known manner. Any adaptation to employ any refractory metal, compound or alloy, may be made in known manner. It is considered that under all circumstances such as these, the sacrificial use of the continuous polysilicon film as taught in this invention ensures against deterioration of the underlying silicide layer.
It is considered that persons of ordinary skill in the art will consider obvious modifications of the present invention, both of the method and of the structure, and all such modifications are considered to be comprehended within the present invention which is limited solely by the claims appended below. | A structure which ensures against deterioration of an underlying silicide layer over which a refractory material layer is deposited by physical vapor deposition (PVD) or chemical vapor deposition (CVD) is realized by first providing a continuous polysilicon layer prior to the refractory material deposition. The continuous polysilicon layer, preferably no thicker than 50 Å, serves a sacrificial purpose and prevents damage to an underlying silicide layer by blocking interaction between any fluorine and the underlying silicide that is released when the refractory material is formed. | 2 |
FIELD OF THE INVENTION
This invention relates generally to devices used with vascular catheters, and more particularly to manifolds for delivering liquids to the patient through the catheter.
BACKGROUND OF THE INVENTION
Manifolds for delivering liquids, such as contrast media, saline and drugs, through a catheter are known in the art. The manifold has a number of ports through which different liquids are supplied and an outlet port through which liquid is delivered. A device, such as a power injector or syringe, connected to another port, draws liquid from a selected supply port and then forces the liquid into the catheter via the delivery port. The manifold thus acts as a traffic-keeping device of sorts which is manipulated by the operator to deliver different liquids to the patient as needed.
One of the problems associated with the manifolds in use today is that the valves employed to direct liquids are fully manual. For example, the MORSE® MANIFOLD most commonly used employs manual stopcock valves to control flow from the various liquid supply ports, to and from the injector, and to the liquid delivery port. Each time it is desired to deliver a particular liquid to a patient, one or more of these stopcocks first must be manually moved to draw liquid into the injector, and then again must be manually moved to inject the liquid into the catheter. This wastes time, which is particularly valuable when performing diagnostic, therapeutic or interventional vascular procedures, is a distraction during such procedures, and requires the use of an extra hand. There is also the possibility that the stopcocks could accidentally be moved to the wrong positions such that the wrong fluid is delivered, an air bubble is created, or some other risk to the patient occurs. These risks are of particular concern as nonphysicians become more involved with procedures.
What has been needed is a manifold for a catheter assembly which automatically controls flow between the liquid supply ports and the liquid delivery port when injecting liquid into the patient.
SUMMARY OF THE INVENTION
According to the present invention, an automatic manifold for a catheter assembly is provided. The automatic manifold could be employed in a variety of venous medical device assemblies, including cardiac, neurological and arterial applications.
In one aspect of the invention, the automatic manifold comprises a housing having a liquid delivery port for communication with the catheter assembly, and a liquid supply port for connection to an injector. A chamber defined in the housing is in fluid communication with the liquid delivery and supply ports. A one-way valve controls flow between the supply and delivery ports and through the chamber. The valve is biased toward a closed position and is constructed and arranged to move to an open position when liquid is forced into the supply port under pressure.
In another aspect of the invention, the automatic manifold comprises a liquid delivery port for communication with a catheter assembly, and a liquid supply port for connection to an injector. A valve mechanism automatically opens flow between the supply and delivery ports when liquid is forced into the supply port under pressure, and automatically closes flow between the supply and delivery ports when liquid no longer is forced into the supply port.
These and other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto. However, for a better understanding of the invention and its advantages, reference should be made to the drawing which forms a further part hereof, and to the accompanying descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an automatic manifold according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, an embodiment of the automatic manifold of the present invention is shown in FIG. 1 .
Manifold 10 comprises housing 11 including liquid supply 20 and delivery 12 ports connected by first 14 and second 16 chambers. Check valve 18 between chambers 14 , 16 controls flow between supply 20 and delivery 12 ports. Valve 18 is a one-way valve known (see U.S. Pat. No. 4,535,820) and available (from Burron Medical Inc. of Bethlehem, Pennsylvania) for medical applications. Valve 18 is made of elastomeric material supported by conical member 17 against seating surface 19 to a closed position (shown). When liquid is forced under pressure into supply port 20 by syringe 22 , valve 18 automatically opens (by lifting from surface 19 ) to allow the liquid to pass into chamber 14 , out delivery port 12 and into the catheter (not shown). After liquid is no longer being forced through valve 18 by syringe 22 , valve 18 automatically closes (against surface 19 ) so as to isolate supply port 20 (and second chamber) from first chamber 14 .
First liquid supply port 30 communicates with second chamber 16 via passage 35 , flow being controlled by another one-way valve 32 including a conical member 34 and seating surface 33 . When syringe 22 draws liquid from second chamber 16 , valve 18 automatically stays closed and valve 32 automatically opens so that liquid is drawn into first supply port 30 , through second chamber, and into syringe 22 . When syringe 22 is depressed, valve 32 automatically stays closed and valve 18 automatically opens as discussed above.
Employing one or more automatic one-way valves in this way permits supplying liquids to the patient without having to manually manipulate various valves. The necessary opening and closing between ports, chambers and/or passages is automatically done simply by operating an injector to draw in and then force out liquid.
It will be understood that the makeup of, and arrangement of, the various components could be varied to achieve similar results. For example, first supply port 30 (or additional supply ports) need not necessarily have a one-way valve, but could use a manual or another valve control means. A power injector, or other pressure-generating device, could be employed instead of a syringe. Various automatic one-way valve designs could be employed.
In the preferred embodiment, there are four liquid supply ports 20 , 30 , 40 , 50 (not including the syringe port 20 ), only one ( 30 ) of which has a one-way valve 32 . The latter three ( 30 , 40 , 50 ) act as inlets for different liquids, specifically contrast media, saline, and drugs, respectively, in the preferred embodiment. It will be understood that these ports could be rearranged, some taken away, or others added, within the principles of the invention. Further one-way valves associated with particular ports, in various arrangements, could also be employed.
Second supply port 40 communicates with first chamber 14 via passage 42 . This port is intended for saline flushing liquid, such as a slow continuous flush, a fast periodic flush, or both.
Third supply port 50 is intended for drug delivery and includes a novel coupling mechanism 52 . When a standard threaded male Luer (such as 12 , threads not shown) is threaded onto female Luer 51 , the central protrusion of the male Luer (see 12 again) abutts against head 55 and compresses spring 57 on stem 54 of plunger 53 , thereby moving O-ring 56 away from seat 59 . Liquid then flows into and around head 55 and around the rest of plunger 53 , through chamber 70 and passage 58 , and into first chamber 14 . When the male Luer is unthreaded, spring 57 automatically returns coupling mechanism 52 to a closed position (shown). In this way, a reliable and simple seal is created where, as when introducing drugs, it is desired to have the capability to quickly connect different liquid sources to, and disconnect them from, the manifold. It will be understood that the components of coupling 52 , and their arrangement, could be varied within the principles of the invention.
When liquid is injected into either second 40 or third 50 supply ports, valve 18 automatically stays closed.
Manifolds known today are connected to a pressure sensor/monitor via another port and a line communicating liquid from the manifold to the sensor/monitor. This is undesirable because readings can sometimes be inaccurate (due to the liquid in the line limiting frequency response, or due to a bubble in the line) and the additional line can be cumbersome. The novel design herein accordingly incorporates a pressure sensor 60 directly into the manifold. Sensor 60 employs a pressure transducer (such as the Motorola MPX2300D) which senses pressure directly from chamber 14 and transmits an electronic signal to a monitor (not shown) via electrical leads 61 .
It will be understood that the last three components discussed ( 40 , 50 , 60 ) could be arranged in different locations. For example, 40 or 50 could be located on an upstream side of valve 18 in communication with second chamber 16 . Various other arrangements could also be imagined.
It should be understood that the present invention is not limited to the preferred embodiment discussed above, which is illustrative only. Changes may be made in detail, especially in matters of the type, arrangement, shape and size of components within the principles of the invention, to the full extent indicated by the broad general meanings of the terms in which the appended claims are expressed. | An automatic manifold for a catheter assembly. Valve means automatically open and close flow between a liquid supply port for connection to injection means and a liquid delivery port for communication with the catheter assembly. A pressure sensor is integrated into the manifold. The manifold also includes a quick-disconnect coupling mechanism for a liquid supply port. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a pharmaceutical preparation (pharmaceutical composition) comprising 7-[4-(4-benzo[b]thiophen-4-yl-piperazin-1-yl)butoxy]-1H-quinolin-2-one or a salt thereof and substituted β-cyclodextrin.
BACKGROUND ART
[0002] It is known that 7-[4-(4-benzo[b]thiophen-4-yl-piperazin-1-yl)butoxy]-1H-quinolin-2-one (hereinafter to be referred to as compound (I)) or a salt thereof has dopamine D 2 receptor partial agonist action, serotonin 5-HT 2A receptor antagonist action and adrenaline α 1 receptor antagonist action, and further has a serotonin uptake inhibitory action (or serotonin reuptake inhibitory action) in addition to those actions (patent document 1), and has a wide treatment spectrum for central neurological diseases (particularly schizophrenia). However, since compound (I) and a salt thereof are poorly soluble in water, an aqueous pharmaceutical preparation thereof is difficult to produce.
[0003] Cyclodextrin has a function to form an inclusion complex with a hydrophobic molecule, and is known to provide an effect to increase the solubility of a particular drug. However, there are many drugs that are not capable of forming a complex with cyclodextrin, or fail to provide a clear advantage. For example, such drugs are disclosed in J. Szejtli,
[0004] Cyclodextrinsin Drug Formulations: Part II, Pharmaceutical Technology, 24-38, August, 1991 (non-patent document 1).
[0005] U.S. Pat. Nos. 5,134,127 (patent document 2) and 5,376,645 (patent document 3) disclose a sulfoalkyl ether cyclodextrin derivative and use of said derivative as a solubilizer of water-insoluble drugs for oral, intranasal or parenteral administration including intravenous and intramuscular administrations. In addition, they disclose an inclusion complex of water-insoluble drug and a sulfoalkyl ether cyclodextrin derivative and pharmaceutical compositions containing the complex. Examples of the disclosed sulfoalkyl ether cyclodextrin derivative include monosulfobutyl ether of β-cyclodextrin and monosulfopropyl ether of β-cyclodextrin. Examples of the water-insoluble drug include benzodiazepine, chlorpromazine, diazepam, mephobarbital, metharbital, nitrazepam and phenobarbital.
[0006] U.S. Pat. No. 6,232,304 (patent document 4) discloses an inclusion complex of a salt of an arylheterocyclo compound, which includes, for example, ziprasidone tartrate in cyclodextrin such as sulfobutyl ether (3-cyclodextrin (SBECD) and hydroxypropyl β-cyclodextrin (HPBCD), and also discloses use of such inclusion complexes for oral agents and parenteral agents.
[0007] U.S. Pat. No. 5,904,929 (patent document 5) discloses a pharmaceutical composition for transmucosal or transdermal administration, which contains a drug, and peracylated cyclodextrin as a solubilizer. Examples of the drug include antidepressants such as amitriptyline HCl, amoxapine, butriptyline HCl, clomipramine HCl, desipramine HCl, dothiepin HCl, doxepin HCl, fluoxetine, gepirone, imipramine, lithium carbonate, mianserin HCl, milnacipran, nortriptyline HCl and paroxetine HCl; anti-muscarinic agents such as atropine sulphate and hyoscine; sedating agents such as alprazolam, buspirone HCl, chlordiazepoxide HCl, chlorpromazine, clozapine, diazepam, flupenthixol HCl, fluphenazine, flurazepam, lorazepam, mazapertine, olanzapine, oxazepam, pimozide, pipamperone, piracetam, promazine, risperidone, selfotel, seroquel, sulpiride, temazepam, thiothixene, triazolam, trifluperidol and ziprasidone; anti-migraine drugs such as alniditan and sumatriptan; beta-adrenoreptor blocking agents such as atenolol, carvedilol, metoprolol, nebivolol and propranolol; anti-Parkinsonian drugs such as bromocryptine mesylate, levodopa and selegiline HCl; opioid analgesics such as buprenorphine HCl, codeine, dextromoramide and dihydrocodeine; parasympathomimetics such as galanthamine, neostigmine, physostymine, tacrine, donepezil, ENA 713 (exelon) and xanomeline; and vasodilators such as amlodipine, buflomedil, amyl nitrite, diltiazem, dipyridamole, glyceryl trinitrate, isosorbide dinitrate, lidoflazine, molsidomine, nicardipine, nifedipine, oxpentifylline and pentaerythritol tetranitrate.
[0008] JP-A-2006-501240 (patent document 6) discloses a preparation containing an inclusion complex of aripiprazole in sulfobutyl ether β-cyclodextrin (SBECD).
DOCUMENT LIST
[Patent Documents]
[0000]
patent document 1: JP-A-2006-316052
patent document 2: U.S. Pat. No. 5,134,127
patent document 3: U.S. Pat. No. 5,376,645
patent document 4: U.S. Pat. No. 6,232,304
patent document 5: U.S. Pat. No. 5,904,929
patent document 6: JP-A-2006-501240
[Non-Patent Document]
[0000]
non-patent document 1: J. Szejtli, Cyclodextrinsin Drug Formulations: Part II, Pharmaceutical Technology, 24-38, August, 1991
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0016] The present invention aims to provide an aqueous pharmaceutical preparation comprising compound (I) or a salt thereof, by improving the water solubility of compound (I) or a salt thereof.
Means of Solving the Problems
[0017] The present inventors have conducted various studies in an attempt to solve the above-mentioned problem, and found that the water solubility of compound (I) or a salt thereof is sufficiently improved by adding substituted β-cyclodextrin, and an aqueous pharmaceutical preparation (particularly, an aqueous preparation for injection) thereof can be produced.
[0018] In addition, the present inventors have found that compound (I) or a salt thereof forms an inclusion complex with substituted β-cyclodextrin, and the inclusion complex shows good water-solubility.
[0019] The present invention has been completed as a result of further studies based on the above-mentioned findings, and provides the following.
[0020] Accordingly, the present invention relates to the following [1]-[19].
[1] A pharmaceutical preparation comprising compound (I) or a salt thereof, and substituted β-cyclodextrin. [2] The preparation of the above-mentioned [1], wherein the substituted β-cyclodextrin is sulfobutyl ether β-cyclodextrin or hydroxypropyl β-cyclodextrin. [3] The preparation of the above-mentioned [1], wherein the substituted β-cyclodextrin is sulfobutyl ether β-cyclodextrin. [4] The preparation of any of the above-mentioned [1]-[3], which is a preparation for injection. [5] The preparation of any of the above-mentioned [1]-[4], is an aqueous preparation for injection. [6] The preparation of the above-mentioned [5], which has a pH of 3.5-5. [7] The preparation of the above-mentioned [6], further comprising an acid buffering agent. [8] The preparation of the above-mentioned [7], wherein the acid buffering agent is phosphoric acid, hydrochloric acid, succinic acid, acetic acid, tartaric acid, lactic acid, citric acid, malic acid or glycolic acid. [9] The preparation of the above-mentioned [8], wherein the acid buffering agent is tartaric acid.
[0030] [10] The preparation of any of the above-mentioned [1]-[9], wherein the weight ratio of the substituted β-cyclodextrin, and compound (I) or a salt thereof is 5:1-2000:1.
[11] The preparation of any of the above-mentioned [5]-[10], wherein the content of compound (I) or a salt thereof is 0.1-10 mg/mL. [12] The preparation of any of the above-mentioned [1]-[11], wherein the substituted β-cyclodextrin is sulfobutyl ether β-cyclodextrin, and the weight ratio of sulfobutyl ether β-cyclodextrin, and compound (I) or a salt thereof is 10:1-1000:1. [13] The preparation of any of the above-mentioned [1]-[12], wherein the compound (I) or a salt thereof and substituted β-cyclodextrin exist in the form of an inclusion complex. [14] The preparation of the above-mentioned [13], wherein the amount of compound (I) or a salt thereof provided in the form of an inclusion complex, which is measured in an aqueous solution having a substituted β-cyclodextrin concentration of 150 mg/mL, is at least 0.2 mg/mL.
[0035] [15] An aqueous preparation for injection comprising compound (I) or a salt thereof, sulfobutyl ether β-cyclodextrin, tartaric acid, sodium hydroxide and water, and having pH within the range of about 4-4.6.
[16] The preparation of any of the above-mentioned [1]-[15], which is a preparation for muscle injection. [17] An inclusion complex of substituted β-cyclodextrin and compound (I) or a salt thereof. [18] The inclusion complex of the above-mentioned [17], wherein the substituted β-cyclodextrin is sulfobutyl ether β-cyclodextrin or hydroxypropyl β-cyclodextrin. [19] The inclusion complex of the above-mentioned [18], wherein the substituted β-cyclodextrin is sulfobutyl ether β-cyclodextrin.
Effect of the Invention
[0040] According to the present invention, the water solubility of compound (I) or a salt thereof can be sufficiently improved by adding substituted β-cyclodextrin, and an aqueous pharmaceutical preparation comprising compound (I) or a salt thereof can be provided.
DESCRIPTION OF EMBODIMENTS
[0041] In the present invention, compound (I) or a salt thereof is contained as an active ingredient.
[0042] Compound (I) or a salt thereof can be produced according to the method described in the above-mentioned patent document 1, or a method analogous thereto.
[0043] While the salt of compound (I) usable in the present invention is not particularly limited as long as it is a pharmacologically acceptable salt, for example, inorganic acid salts such as sulfate, nitrate, hydrochloride, phosphate, hydrobromide and the like; organic acid salts such as acetate, sulfonates such as p-toluenesulfonate, methanesulfonate, ethanesulfonate and the like, oxalate, maleate, fumarate, malate, tartrate, citrate, succinate, benzoate and the like can be used.
[0044] The “substituted β-cyclodextrin” in the present invention includes, for example, a compound obtainable by modification of one or more hydroxyl groups of β-cyclodextrin, such as hydroxyalkylation (e.g., hydroxypropylation), sulfoalkyl etherification (e.g., sulfobutyl etherification), methylation, carboxymethylation, benzylation, polyethylene glycolation, aminoethylation and the like. Specifically, the “substituted β-cyclodextrin” in the present invention includes, for example, a compound wherein one or more hydroxyl groups of β-cyclodextrin are substituted by —O—CH 2 —CH(OH)—CH 3 , —O—(CH 2 ) 4 —SO 3 − and the like.
[0045] For the purpose of the present invention, an average number of substituents to be introduced into substituted β-cyclodextrin is preferably 2-10, more preferably 4-9, per molecule.
[0046] The substituted β-cyclodextrin can be produced by a method known per se, and a commercially available product sold with a trade name of, for example, “2-hydroxypropyl-β-cyclodextrin” (manufactured by Wako Pure Chemical Industries, Ltd.), “Captisol” (manufactured by Cydex) and the like can also be used. In the present invention, one or more kinds selected from the aforementioned substituted β-cyclodextrins can be used.
[0047] As the substituted β-cyclodextrin to be used in the present invention, sulfoalkyl ether β-cyclodextrin and hydroxyalkyl β-cyclodextrin are preferable, sulfobutyl ether β-cyclodextrin (SBECD) and hydroxypropyl β-cyclodextrin (HPBCD) are more preferable, and SBECD is particularly preferable.
[0048] The pharmaceutical preparation of the present invention is provided in a preferable form of an aqueous parenteral preparation or a preparation for injection (particularly preparation for muscle injection). The pharmaceutical preparation of the present invention may also be in a dosage form of, for example, freeze-dry injection, oral preparation (e.g., tablet, capsule, elixir etc.), transdermal agent, transmucosal agent or inhalant and the like.
[0049] The preparation for injection in the present invention includes an aqueous preparation for injection and freeze-dry injection.
[0050] In the pharmaceutical preparation of the present invention (particularly aqueous preparation for injection), the weight ratio of the substituted β-cyclodextrin, and compound (I) or a salt thereof (substituted β-cyclodextrin: compound (I) or a salt thereof) is generally 5:1-2000:1, preferably 10:1-1000:1, more preferably 20:1-500:1.
[0051] The amount of the substituted β-cyclodextrin necessary for inhibiting or preventing precipitation of compound (I) or a salt thereof at an administration site varies depending on the kind of substituted β-cyclodextrin to be used.
[0052] For example, in the pharmaceutical preparation of the present invention (particularly aqueous preparation for injection), when the substituted β-cyclodextrin is SBECD, the weight ratio of SBECD, and compound (I) or a salt thereof (SBECD:compound (I) or a salt thereof) is preferably 10:1-1000:1, more preferably 20:1-500:1.
[0053] Since excess substituted β-cyclodextrin aids dissolution of compound (I) or a salt thereof, substituted β-cyclodextrin may be present in an amount more than necessary for forming an inclusion complex with compound (I) or a salt thereof in the pharmaceutical preparation of the present invention.
[0054] In the pharmaceutical preparation of the present invention, the content of compound (I) or a salt thereof varies depending on the dosage form and the like. For example, when it is an aqueous preparation for injection, the content is generally about 0.1- about 10 mg/mL, more preferably about 0.2- about 4 mg/mL.
[0055] The amount of the aqueous preparation for injection of the present invention to be filled in a container such as vial and the like is preferably 0.5-2 mL.
[0056] In the pharmaceutical preparation of the present invention, the content of the substituted β-cyclodextrin varies depending on the dosage form and the like. For example, when it is an aqueous preparation for injection, the content is generally about 25- about 250 mg/mL, preferably about 50-200 mg/mL, more preferably about 100- about 200 mg/mL.
[0057] When the pharmaceutical preparation of the present invention is an aqueous preparation for injection, the pH of said preparation is preferably about 3.5- about 5, more preferably about 4- about 4.6, further preferably about 4.3, from the aspect of solubility.
[0058] In the aqueous preparation for injection of the present invention, pH is preferably buffered within the above-mentioned range.
[0059] The method for adjusting or buffering the pH of an aqueous preparation for injection to fall within the above-mentioned range is not particularly limited, and a method known in the field of pharmaceutical preparation may be used. For example, a buffering agent containing an acid or a salt thereof is used.
[0060] Examples of the acid include phosphoric acid, hydrochloric acid, succinic acid, acetic acid, tartaric acid, lactic acid, citric acid, malic acid or glycolic acid and the like. Of these, tartaric acid, citric acid, lactic acid, phosphoric acid and hydrochloric acid are preferable, and tartaric acid is most preferable.
[0061] Where necessary, pH may be adjusted to fall within the above-mentioned range by adding a base such as hydroxide of alkali metal (e.g., sodium hydroxide, potassium hydroxide or lithium hydroxide, preferably sodium hydroxide); or hydroxide of alkaline earth metal (e.g., magnesium hydroxide or calcium hydroxide) and the like.
[0062] As the aqueous preparation for injection of the present invention, an aqueous preparation for injection comprising compound (I) or a salt thereof, SBECD, tartaric acid, sodium hydroxide and water, and having pH within the range of about 4-4.6 is preferable.
[0063] Moreover, as the aqueous preparation for injection of the present invention, a preparation comprising the following components is preferable.
(1) about 0.2- about 4 mg/mL of compound (I) or a salt thereof (2) about 100- about 200 mg/mL of SBECD (3) about 7-9 mg/mL of an acid (preferably tartaric acid) or a salt thereof for adjusting pH to the range of about 3.5- about 5 (4) a base (preferably alkali metal hydroxide, preferably sodium hydroxide) for further adjusting pH to the range of about 4- about 4.6 and (5) water to make the total volume 1 mL.
[0069] The pharmaceutical preparation of the present invention can comprise a general additive used for general formulation as long as the characteristics of the present invention are not impaired. Examples of such additive include excipient, emulsifier, suspending agent, preservative, corrigent, film coating agent, colorant, flavoring agent and the like. Particularly, for an aqueous preparation for injection, other solubilizing agents such as sorbitol, propylene glycol, polyoxyethylene sorbitan monolaurate and the like; isotonicity agents such as potassium chloride, sodium chloride, glycerol and the like; stabilizers such as sodium edetate and the like; antioxidants such as ascorbic acid and the like; soothing agents such as meprylcaine hydrochloride, lidocaine hydrochloride, etc. and the like can be recited as examples.
[0070] The pharmaceutical preparation of the present invention can be produced by a conventional method, for example, the method described in preparation General Rules of the Japanese Pharmacopoeia, US Pharmacopeia, etc. and the like.
[0071] The dosage form of an aqueous preparation for injection can be produced by, though not particularly limited to, a method including, for example, dissolving by adding compound (I) or a salt thereof, and substituted β-cyclodextrin together with a buffering agent such as an acid or a salt thereof and the like, and other additives to water for injection that meets the standards of, for example, the Japanese Pharmacopoeia, US Pharmacopeia and the like, filling the homogenized solution in a container, tightly sealing and sterilizing the same; or by dissolving by adding the aforementioned components to water for injection, and aseptically filtering the homogenized solution or aseptically preparing to give a homogenized solution, and filling the solution in a container and tightly sealing the same.
[0072] The aqueous preparation for injection of the present invention can be specifically prepared, for example, as follows.
[0073] An acid such as tartaric acid and the like or a salt thereof is dissolved in water for injection. Substituted β-cyclodextrin (preferably SBECD) is dissolved in the obtained aqueous solution, and then compound (I) or a salt thereof is dissolved. Then, a base such as sodium hydroxide, other alkali metal hydroxide or alkaline earth metal hydroxide and the like is added, and pH of said solution is adjusted to about 3.5-35 about 5, preferably about 4- about 4.6, more preferably about 4.3, and water is added to give a desired volume.
[0074] The obtained solution is aseptically filtered through, for example, a 0.22 μm-membrane filter, and filled in a vial. The vial is tightly sealed and finally sterilized.
[0075] In the aqueous preparation for injection of the present invention, generally, compound (I) or a salt thereof and substituted β-cyclodextrin form an inclusion complex wherein compound (I) or a salt thereof is a guest molecule and substituted β-cyclodextrin is a host molecule.
[0076] Not only a pharmaceutical preparation comprising compound (I) or a salt thereof, and substituted β-cyclodextrin as an inclusion complex, but also a pharmaceutical preparation comprising a physical mixture thereof are similarly encompassed in the present invention.
[0077] Such inclusion complex or physical mixture thereof is added to various pharmaceutically acceptable carriers such as liquid, emulsion, gel, powder and the like to give a pharmaceutical preparation, which can be provided in various dosage forms such as liquid, emulsion, gel, powder, granule, pill, tablet, capsule, aerosol and the like.
[0078] In the present invention, the inclusion complex of compound (I) or a salt thereof and substituted β-cyclodextrin may be formed in advance and added to the above-mentioned carrier, or each of compound (I) or a salt thereof, and substituted β-cyclodextrin may be separately added to the above-mentioned carrier and mixed or administered to allow them to form a complex in a solution, or may be formed in vivo (in gastrointestinal tract or oral cavity).
[0079] The pharmaceutical preparation of the present invention may be formulated as a physically dried mixture of compound (I) or a salt thereof and substituted β-cyclodextrin, or a dried inclusion complex thereof, and may be reconstituted as a preparation for injection by adding water. As a different method, an aqueous preparation for injection may be freeze-dried and thereafter reconstituted as a preparation for injection by adding water.
[0080] When compound (I) or a salt thereof and substituted β-cyclodextrin contained in the pharmaceutical preparation of the present invention are contained in the form of an inclusion complex and the concentration of substituted β-cyclodextrin is 150 mg/mL, the amount of compound (I) or a salt thereof in said complex is preferably at least 0.2 mg/mL, more preferably 4 mg/mL or less.
[0081] The pharmaceutical preparation of the present invention preferably in the form of an aqueous preparation for injection can be used for the treatment of schizophrenia and associated disorders (e.g., bipolar disorder and dementia) and the like in human patients. In the aqueous preparation for injection of the present invention, a preferable dose of compound (I) or a salt thereof is 0.05-6 mg per day for an adult. The aqueous preparation for injection of the present invention is preferably administered intramuscularly, but is also effective by subcutaneous injection or intravenous injection.
[0082] Thus, the present invention also provides a method of treating schizophrenia and associated disorders, comprising administering the above-mentioned aqueous preparation for injection preferably intramuscularly to patients in need of the treatment.
[0083] In the aqueous preparation for injection of the present invention, water solubility of compound (I) or a salt thereof is improved, and precipitation upon administration is suppressed. Therefore, the preparation is preferably administered intramuscularly for a good treatment of schizophrenia and associated disorders.
[0084] The present invention also provides an inclusion complex of substituted β-cyclodextrin and compound (I) or a salt thereof. The “substituted β-cyclodextrin” and “compound (I) or a salt thereof” are as explained for the above-mentioned pharmaceutical preparation of the present invention.
EXAMPLES
[0085] The present invention is explained in more detail in the following by referring to Examples, which are not to be construed as limitative.
[0086] In the Examples, 7-[4-(4-benzo[b]thiophen-4-yl-piperazin-1-yl)butoxy]-1H-quinolin-2-one is compound (I).
[0087] A colorless transparent aqueous preparation for injection essentially having no problem by visual inspection (compound (I) 4 mg/mL, 8 mg/vial) was prepared as follows;
[0088] An adequate amount of water for injection was filled in a stainless reaction vessel, and tartaric acid granules (8.58 g) and sulfobutyl ether β-cyclodextrin (SBECD, 165 g) were added to the reaction vessel and dissolved in the stirring water.
[0089] Compound (I) (4.4 g) was added to the reaction vessel, and dissolved by stirring.
[0090] A 1N aqueous sodium hydroxide solution was added to the above-mentioned solution to adjust the pH to about 4.3.
[0091] Water for injection was added to the above-mentioned solution to the final volume of 1.1 L with stirring.
[0092] The above-mentioned solution was aseptically filtered through a 0.22 μm-membrane filter and filled in an aseptic container. The above-mentioned solution (8 mg as compound (I)) was filled in an aseptic vial and the vial was tightly sealed aseptically.
INDUSTRIAL APPLICABILITY
[0093] According to the present invention, water solubility of compound (I) or a salt thereof is sufficiently improved by adding substituted β-cyclodextrin, and an aqueous pharmaceutical preparation comprising compound (I) or a salt thereof can be provided.
[0094] The present application is based on U.S. provisional application No. 61/580,708, the contents of which are encompassed in full herein. | Provided is an aqueous pharmaceutical preparation comprising 7-[4-(4-benzo[b]thiophen-4-yl-piperazin-1-yl)butoxy]-1H-quinolin-2-one (compound (I)) or a salt thereof, which shows improved water solubility of compound (I) or a salt thereof achieved by addition of substituted β-cyclodextrin. The present invention provides a pharmaceutical preparation comprising compound (I) or a salt thereof, and substituted β-cyclodextrin. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of prior application Ser. No. 10/858,813, filed Feb. 9, 2005, now abandoned, and such specifically enumerated prior application is hereby incorporated by reference.
FIELD OF INVENTION
The present invention relates to a ceiling fan assembly for dispensing scent and, more particularly, to an improved ceiling fan assembly having a fan blade provided with a recess for receiving an air freshener insert.
BACKGROUND OF THE INVENTION
Rooms of a home can often take on strong odors. If a meal with strong-smelling food has recently been prepared in a kitchen, the cooking odors can often spread to different rooms of the home. Other odors from trash cans or toilets may also linger in bathrooms, bedrooms or kitchens.
In order to eliminate these odors, there are various steps that can be taken. Air freshener sprays can be sprayed around a room or a window can be opened to allow fresh air to enter a room. Other methods of eliminating odors include thoroughly cleaning a room or using a solid or plug-in air freshener.
A prior art ceiling fan blade assembly comprises a housing, an electric motor mounted in the housing, a plurality of fan blades secured to the shaft of the motor, and in a majority of fan blade assemblies on the market, a light bulb depends from the housing. Electric wires connect the motor and the light bulb to the home's electrical system. According to applicant's invention, the fan blade is provided with a recess and an air freshener insert is designed to snap into the recess and contains a scented oil, gel, or the like.
DESCRIPTION OF BACKGROUND ART
Boubin U.S. Pat. Appl. Pub. No. US2004/0247440, Keyes U.S. Pat. No. 5,947,686, and other prior art patents, attach an external air freshener dispenser to the outside or outer surface of a fan blade. Kuryliw U.S. Pat. No. 5,341,565, and other prior art patents, form a cavity or perforation through both surfaces of a fan blade for receiving a filter element that filters the air when the fan blade and filter are in rotary motion. However, the prior art does not suggest or teach that the filters receive, disperse, or dispense a solid, liquid or gaseous fragrance and the filters are not so designed. The blades and filters are incapable of dispersing or dispensing the fragrance as no reservoir is shown in the prior art patents. It would therefore be desirable to provide a fan blade with a built-in air freshener instead of attaching an external air freshener to the outside of the fan blade.
In view of the foregoing, it is an object of the present invention to provide an improved ceiling fan blade assembly with a built-in air freshener insert in the blade.
Another object of the present invention is to provide a ceiling fan blade assembly with an air freshener insert that is replaceable in a simple and facile manner.
A further object of the present invention is to provide a ceiling fan blade assembly capable of storing and dispensing a fragrance, e.g., a liquid or gel, from the air freshener insert.
Additional objects and advantages will become apparent to one skilled in the art and still other advantages will become apparent hereinafter.
BRIEF SUMMARY OF INVENTION
In summary, to accomplish the foregoing and other objects of the present invention, there is provided a ceiling fan blade assembly comprising a fan blade provided with a recess in the ceiling fan blade adapted to receive an air freshener insert. The insert, when fixedly attached to the ceiling fan blade, is located in the blade. The air freshener insert contains a fragrance bearing gel which disperses fragrance in the surrounding air when the ceiling fan blade is in rotary motion.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the objects of the present invention, reference should be had to the detailed description given hereinbelow with the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a bottom perspective view of a preferred embodiment of a blade of a ceiling fan blade assembly (not shown) having a recess in the bottom surface of the blade and an air freshener insert adapted to be inserted into the recess;
FIG. 2 is a cross-sectional view along a line 2 — 2 of FIG. 1 further illustrating the recess located in the bottom surface of the blade; and
FIG. 3 is a top view of another preferred embodiment of a blade of a ceiling fan blade assembly (not shown), the blade being provided with a recess, and an air freshener insert is mounted in the recess provided in the blade.
DETAILED DESCRIPTION OF THE INVENTION
In accord with the present invention, FIG. 1 illustrates a blade 10 of a ceiling fan assembly (not shown) having a top surface 11 and a bottom surface 12 defining a thickness 13 . Bolts (not shown) are inserted into holes 14 provided in the inner portion of the blade 10 to secure the blade 10 to a hub (not shown) of the ceiling fan blade assembly preferably rotated by an electric pancake motor (not shown). The blade 10 according to the present invention is provided with a recess 15 in the bottom surface 12 of the blade 10 . The recess 15 has a depth 16 . An air freshener 20 being insertable into the recess 15 , also hereinafter referred to an air freshener insert 20 , is defined by a container 21 having a bottom wall 22 and side walls 23 for receiving a fragrance 24 containing a scent that is dispensed or dispersed into the air upon rotation of the blade 10 of a ceiling fan blade assembly.
It is to be understood that the fragrance 24 as used in the present invention refers to a solid, liquid, or gaseous carrier vehicle containing the scent. It is also to be understood that the thickness of the sidewalls 23 of the air freshener insert 20 can be greater or less than the thickness 13 of the blade 10 or the depth 16 of the recess 15 in the blade 10 . Suitable means such as detents, resilient walls, and the like for fixedly securing the air freshener insert into the recess are well known in the art and will not be described in further detail herein.
In accord with the present invention, another preferred embodiment illustrates a blade 30 shown in FIG. 3 of the drawings having a top surface 31 and a bottom surface 32 defining a thickness 33 . The blade 30 is provided with a recess 34 communicating with the top surface 31 for receiving an air freshener insert 35 . The configuration of the recess 34 is not critical, the only requirement being that the air freshener insert 35 be provided with a mating configuration and with suitable means well known in the art for fixedly and detachably securing the insert 35 in the recess 34 to prevent accidental release of the insert 35 during operation of the ceiling fan assembly (not shown) and rotation of the blade 30 . The air freshener insert 35 can be a plug of a solid fragrance dispensing material 36 that emits a scent or the fragrance material 36 can be deposited in a container 37 that is insertable into the recess 34 . Preferably, and in accord with the present invention, the insert 35 provided with an outer surface 38 is flushably mounted with one of the surfaces 31 or 32 of the blade 30 and the same surface of the blade 30 is substantially flush with the surface 39 of the fragrance material 36 . The insert 35 is provided with a periphery configured to the periphery of the recess 34 . The air freshener insert 35 preferably is of the same density as the blade 30 to prevent the ceiling fan blade assembly (not shown) from vibrating unless the inserts 35 are inserted into opposing fan blades 30 secured to a hub (not shown).
To use the ceiling fan blade assembly, an owner installs the air freshener insert into the fan blade. When the fan blade assembly is in use, it creates a cool breeze, the light provides illumination and the breeze conveys the scent of the air freshener insert into a room or throughout the house. When the fan blade assembly is not in use, the air freshener insert continues to provide a pleasant scent in the room.
While two preferred embodiments have been described above, the present invention is not limited thereto, and it is to be understood that various changes in design can be made without departing from the scope of the claims.
The present invention being thus described, it will be obvious that the same can 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 are to be included within the scope of the claims. | A fan blade is provided with a recess for mounting an air freshener insert therein. The air freshener insert, after being mounted in the recess provided in the blade, releases a fragrance which is dispersed in the air when the fan blade is in rotary motion due to airflow over the air freshener insert. | 5 |
TECHNICAL FIELD
The present invention relates generally to a non-volatile memory architecture. More specifically, the present invention is an EEPROM non-volatile memory architecture providing multiple byte select lines to alternating word line rows.
BACKGROUND ART
EEPROM arrays include floating-gate memory cells arranged in rows and columns. When a floating gate of a programmed memory cell is charged with electrons, a source-drain path under the charged floating gate is nonconductive when a wordline select voltage is applied to a control gate of the cell. A nonconductive state is read as a “1” bit. If the floating gate of a non-programmed cell is either positively charged, neutrally charged, or slightly negatively charged, the source-drain path under the non-programmed floating gate is conductive when the wordline select voltage is applied to the control gate. The conductive state is read as a “0” bit.
In memories based on a Fowler-Nordheim tunneling mechanism, an oxide between a floating gate of a transistor and a drain of the transistor must be fabricated to be very thin, typically only a few nanometers thick. When a voltage is applied across the control gate (to which the floating gate is strongly capacitively coupled) and the drain, a strong electrical field is produced. Electrons can then tunnel from the drain region via the thin oxide to the floating gate. A tunneling current in the opposite direction can be obtained by reversing the field. Thus, it is possible to write and erase a cell.
Each column and row of an EEPROM array may contain thousands of cells. Control gates of each cell in a row are connected to a wordline. Prior to first programming, the source-drain paths of the cells begin to conduct at a relatively uniform control-gate threshold voltage, V t , since the floating gates are neutrally charged (having neither an excess nor a deficiency of electrons). An initial uniform threshold voltage may be, for example, +2.5 volts between the control gate and the source terminal. The initial uniform threshold voltage may be adjusted by appropriately doping the channel regions of the cells during fabrication.
After programming, source-drain paths of the programmed cells have control-gate threshold voltages distributed over a voltage range, typically between −3.5 volts to −0.5 volts. After electrical erasure of the cells, the threshold voltages of the erased cells may be distributed over a range from perhaps +0.5 to 3.5 volts with a majority of the cells having erased threshold voltages near 2.5 volts. The actual range of erased threshold voltages is dependent on factors such as localized variations in the tunnel oxide thickness, geometrical areas of tunneling regions, capacitive coupling ratios between wordlines and floating gates, and relative strengths of erasing pulses. Using a lower-strength erasing pulse, the erased threshold voltage range may be from perhaps +1.5 to +3.5 volts with a majority of the cells having erased threshold voltages near 2.5 volts. With a higher-strength erasing pulse applied, the distribution may range from perhaps +3.0 to +6 volts with a majority of cells having erased threshold voltages near +4.5 volt. An excess of positive charges on the floating gates causes channel regions under the gates of floating gate transistors to be enhanced with electrons.
In general, an extent of channel doping, programming pulse strength, erasing pulse strength, and other factors are chosen such that the source-drain path of a cell will either be conductive or non-conductive when applying a wordline select voltage to the control gate.
With reference to FIG. 1 , a portion 100 of a prior art memory array includes a first byte select transistor 101 connected to a gate of a first floating gate transistor 103 . A first wordline, WL(n), is connected to gates of both the first byte select transistor 101 and a first bit select transistor 105 . An asserted high value (e.g., a logical “1”) on the wordline, WL(n) allows both the first byte select transistor 101 and the first bit select transistor 105 to conduct, thereby allowing the first floating gate transistor 103 to be selected for read, write, or programming operations through a bitline, BL(m). The asserted high value on the wordline, WL(n), allows a source-drain current to flow from a byte select (i) line to a control gate of the first floating gate transistor 103 . The byte select (i) line is also arranged with seven additional floating gate transistors (not shown) in parallel with the first floating gate transistor 103 to store a byte of data. The portion 100 of the prior art memory array also includes a second byte select transistor 107 , a second floating gate transistor 109 , and a second bit select transistor 111 . A gate of the second bit select transistor 111 is connected to a second wordline, WL(n+1), and seven other floating gate transistors (not shown) in parallel with the second floating gate transistor 109 . The second floating gate transistor 109 is connected to the bitline, BL(m). Note that the first 101 and the second 107 byte select transistors are both connected to the same byte select (i) line.
In operation, when the first floating gate transistor 103 is erased, a voltage (e.g., a high voltage above V cc is preferred) is applied to the gate of the first byte select transistor 101 and a high voltage (e.g., 12-14 volts) is applied to the byte select (i) line, allowing electrons to transfer from a floating gate of the first floating gate transistor 103 through the mechanism of Fowler-Nordheim tunneling. However, due to the close proximity between adjacent byte select transistors 101 , 107 , a source-drain current on the first byte select transistor 101 may induce a source-drain current on the second byte select transistor 107 thereby causing the second floating gate transistor 109 to be inadvertently erased. Even though the length of the line from the source of, for example, the second byte select transistor 107 is very short, due to an extremely high packing density of transistors in integrated circuits, the lines are close enough that parasitic effects, such as capacitive coupling, may readily occur.
A block diagram of FIG. 2 typifies an addressable portion of a prior art memory array and exemplifies how the capacitive coupling occurs between adjacent rows of memory cells contained within the same column. For example, the first byte select transistor 101 and the first floating gate transistor 103 of FIG. 1 can be conceptualized as being located at a point b 0 (“bit 0 ”) of row x=1 and column y=1 of FIG. 2 . Assuming wordlines for each of the rows (x=1 through x=4 is at logic high,) byte select ( 1 ) would, when asserted, activate the first byte select transistor 101 and select each of a plurality of data bytes (e.g., bits b 0 - b 7 ) within column y=1. Thus, rows x=1, x=2, and so on are all selected by byte select ( 1 ). Each column is thus controlled by a single byte select line (e.g., column y=0 is controlled by byte select line ( 0 ), column y=2 is controlled by byte select line ( 2 ) and so on.)
Further, adjacent byte select lines, when activated, tend to parasitically couple to a mirrored prior column. In FIG. 2 , column y=0 mirrors column y=1, column y=2 mirrors column y=3, and so on. Thus, when byte select ( 1 ) in column y=1 is activated, byte select ( 0 ) may also have a voltage coupled as well.
Therefore, for robust and proper memory operation, it is desirable to eliminate or minimize any potential for parasitic cross coupling between memory cells in adjacent rows.
SUMMARY
A byte select circuit of a memory cell array wherein each column of the memory cell array has two byte select lines. A first byte select line is coupled to the even numbered rows in the column and a second byte select line is coupled to the odd numbered rows in the column. The second byte select line is configured to be driven to a low voltage level when the first byte select line is driven to a high voltage level, thereby minimizing or eliminating any parasitic voltage coupling between adjacent rows of memory cells.
In an exemplary embodiment, the present invention is a byte select circuit of an EEPROM memory cell array; the byte select circuit is arranged such that each column within the EEPROM array has two byte select lines. A first byte select line is coupled to a first plurality of memory cells in a first column of the memory cell array, the first plurality of memory cells being considered to be in an even row and selectable by a first wordline. A second byte select line is coupled to a second plurality of memory cells in the first column of the memory cell array. The second plurality of memory cells being considered to be in an odd row and selectable by a second wordline.
Any parasitic coupling is minimized or completely eliminated by this arrangement of dual byte select lines coupled with voltages placed on the wordlines. For example, the second byte select line is configured to be driven to a low voltage level when the first byte select line is driven to a high voltage level. Concurrently, any wordlines in the array that are not immediately adjacent to the first wordline are allowed to float when a voltage is asserted on the first wordline. Any wordlines immediately adjacent to the first wordline are driven to approximately zero volts when a voltage is asserted on the first wordline.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of a localized area of a prior art memory cell.
FIG. 2 is a block layout of a section of a prior art memory cell.
FIG. 3 is a circuit diagram of a localized area of an exemplary embodiment of a memory cell of the present invention.
FIG. 4 is a portion of an exemplary embodiment of an arrangement of wordline and byte select lines of the present invention.
FIG. 5 is a block layout of a section of an exemplary embodiment of a memory cell incorporating the present invention.
DETAILED DESCRIPTION
With reference to FIG. 3 , a portion 300 of an exemplary embodiment of a memory array of the present invention includes a first byte select transistor 301 coupled to a gate of a first floating gate transistor 303 . A first wordline, WL(n) is coupled to gates of both the first byte select transistor 301 and a bit select transistor 305 . As with the prior art, an asserted high value (e.g., a logical “1”) on the wordline, WL(n) allows both the first byte select transistor 301 and the bit select transistor 305 to conduct, thereby allowing the first floating gate transistor 303 to be selected for read, write, or programming operations through a bitline, BL(m). The asserted high value on the wordline, WL(n), allows a source-drain current to flow from a byte select (i o ) line to a control gate of the first floating gate transistor 303 . The byte select (i o ) line is also arranged with seven additional floating gate transistors (not shown) in parallel with the first floating gate transistor 303 to store a byte of data. The drain of the first byte select transistor 301 is coupled to an odd byte select line.
The portion 300 of the exemplary embodiment of the present invention also includes a second byte select transistor 307 , a second floating gate transistor 309 , and a second bit select transistor 311 . A gate of the second bit select transistor 311 is coupled to a second wordline, WL(n+1). The second floating gate transistor 309 is connected to the bitline, BL(m). The drain of the second byte select transistor 307 is coupled to an even byte select line (“Byte Select (i e )”). Seven other floating gate transistors (not shown) are in parallel with the second floating gate transistor 309 .
Maintaining two byte select lines for each column of memory (i.e., an odd byte select line (“Byte Select (i o )”) and an even byte select line (“Byte Select (i e )”) prevents effects of capacitive coupling of the prior art.
For example, with reference to FIG. 4 , adjacent rows of byte select transistors are coupled alternately to either an odd byte select line (i o ) or an even byte select line (i e ). Byte select transistors in odd rows, i.e., a first, second, and third odd byte select transistor, 401 n - 401 n+4 , are coupled to the odd byte select line (i o ). Byte select transistors in even rows, i.e., a first, second, and third even byte select transistor, 402 n+1 - 402 n+5 , are coupled to the even byte select line (i e ). Also shown are sense lines, S(n)-S(n+5). If a high voltage is placed on, for example, odd byte select line (i o ) and wordline WL (n+2), only the second odd byte select transistor 401 n+2 will conduct. If any parasitic voltage is induced on wordlines or sense lines immediately proximate to wordline WL (n+2) and sense lines S(n+2), namely wordlines WL(n+1) and WL (n+3) and sense lines S(n+1) and S(n+3), no high voltage can be conducted on those wordlines since a voltage on the even byte select line (i e ) is driven low (e.g., to ground) while WL(n+2) is high. Sense lines located distally to sense line S(n+2) (e.g., sense lines S(n), S(n+4), S(n+5), etc.) can be allowed to float. Control circuitry or software to maintain appropriate voltage levels (i.e., high, low, or float) can be readily conceived by one of skill in the art.
With reference to FIG. 5 , an addressable portion of an exemplary embodiment of a memory array of the present invention is illustrative of how parasitic effects are minimized or eliminated. For example, the first byte select transistor 301 and the first floating gate transistor 303 of FIG. 3 can be conceptualized as being located at a point b 0 (not shown explicitly) of row x=1 and column y=1 of FIG. 5 . Assuming wordline x=1 is at logic high, byte select ( 1 o ) would, when asserted, activate the first byte select transistor 301 and select only a single data byte within column y=1. Thus, rows x=1 and x=3 in column y=1 are selected by byte select ( 1 o ), rows x=1 and x=3 in column y=2 are selected by byte select ( 2 o ) and so on. In contrast, rows x=2 and x=4 in column y=1 are selected by byte select ( 1 e ); rows x=2 and x=4 in column y=2 are selected by byte select ( 2 e ). Each column is thus controlled by two byte select lines depending on whether an even or odd row is chosen. Further, a skilled artisan will readily recognize that parasitic coupling between sense lines or wordlines on mirrored columns is effectively minimized or eliminated as well as parasitic coupling between adjacent rows. Thus, data may be reliably erased, programmed, and read without an effect on or from adjacent rows in an array of memory cells.
In the foregoing specification, the present invention has been described with reference to specific embodiments thereof. It will, however, be evident to a skilled artisan that various modifications and changes can be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. For example, skilled artisans will appreciate that additional byte select lines may be added to each column with, of course, a concomitant increase in complexity of control signals. Further, byte select lines may be laid out in various geometries (e.g., at a single side of each column as opposed to a mirrored arrangement) to minimize parasitic coupling between adjacent select lines as well. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | A byte select circuit of a memory cell array wherein each column of the memory cell array has two byte select lines. A first byte select line is coupled to the even numbered rows in the column and a second byte select line is coupled to the odd numbered rows in the column. The second byte select line is configured to be driven to a low voltage level when the first byte select line is driven to a high voltage level, thereby minimizing or eliminating any parasitic voltage coupling between adjacent rows of memory cells. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/EP2012/002563, filed Jun. 18, 2012, which designated the United States and has been published as International Publication No. WO 2013/004342 and which claims the priority of German Patent Application, Serial No. 10 2011 106 247.9, filed Jul. 1, 2011, pursuant to 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The present invention relates to a method for controlling a reversible belt tensioner of a safety belt in a motor vehicle. In addition, the present invention relates to a driver assistance system for a motor vehicle. Finally, the present invention relates to such a vehicle.
Today's vehicles are equipped with a conventional belt system without a reversible belt tensioner or with a belt system with a reversible belt tensioner. For motor vehicles that are equipped with reversible belt tensioners, the safety belt is tightened at the beginning of a trip when the belt is inserted and the so-called belt slack is removed. However, slack can be introduced again into the respective safety belt system during the trip by movement of the driver or of the passenger or as a result of a driving maneuver. The safety belt is then no longer sufficiently tightened and the safety of the driver or of the other vehicle occupants is no longer fully guaranteed.
DE 10 2005 035 850 A1 relates to a method for controlling a reversible belt tensioner in a motor vehicle, wherein the time profile of a measured value characterizing the vehicle dynamics is determined and a gradient of this measured value is calculated. The belt tensioner is activated when the gradient of the measured value exceeds a predetermined threshold value.
DE 10 2005 035 863 A1 describes a method for controlling a reversible belt tensioner in a motor vehicle. In this case, the belt tensioner is activated, so that a safety belt is brought from a normal position to a second position wherein the belt is tightened more than in the normal position. The belt tensioner is here activated independent of any dangerous situation.
DE 10 2008 050 316 A1 discloses a method for dynamically securing a vehicle occupant strapped in a seat of the vehicle with a safety belt. Here, a transverse dynamics of the vehicle is determined by at least one sensor. A slack of the safety belt is then at least partially rolled up by a safety belt retractor, when an upper threshold value of the transverse dynamics is exceeded, and a radius of curvature of a road course ahead remains constant or decreases.
DE 10 2008 007 149 A1 describes a method for generating, controlling and triggering a warning signal in a motor vehicle. Here, an attentiveness measure of the driver is determined by analyzing the driver's eye blink. A corresponding warning signal is outputted, for example by activation of the belt tensioner, in response to the attentiveness.
Lastly, systems are used in modern motor vehicles, wherein the field of vision of the driver is monitored by a camera. For example, when the driver turns his eyes away from the road and the driver assistance system recognizes a corresponding obstacle on the road, the driver is warned visually or audibly. However, the installation of such systems results in additional costs.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a method for controlling a reversible belt tensioner of the aforementioned type which allows a safer and more effective control of a belt tensioner of a safety belt in a motor vehicle. In addition, a corresponding driver assistance system is to be provided.
This object is attained according to the invention by a method for controlling a reversible belt tensioner of a safety belt in a motor vehicle by
detecting a time profile of at least one state variable and/or at least one environment variable of a motor vehicle,
detecting a predetermined driving maneuver and/or a value characterizing the attentiveness of a driver based on the time profile of the at least one detected state variable and/or environment variable, and
controlling the reversible belt tensioner in response to the detected driving maneuver or in response to the detected value that characterizes the driver's attentiveness.
A previously determined driving maneuver performed by the driver is detected based on the time profile of a state variable and/or an environment variable. “State variable” is to be understood in the following as the speed, the acceleration, the transverse acceleration, the yaw rate, the direction of travel and the like. “Environment variable” refers preferably to those variables that are captured with forward-looking environment sensors. Examples include the course of the road, the distance from an obstacle or from other vehicles or the detection of the corresponding road markings or traffic signs. A previously determined driving maneuver is detected based on the time profile of these variables and the reversible belt tensioner is controlled in response to the detected maneuver. The reversible belt tensioner can thus be controlled based on the respective driving maneuver so as to guarantee the maximum safety for the driver or the other passengers. The point in time may also be determined based on the respective driving maneuver when the reversible belt tensioner is controlled and consequently the safety belt is tightened.
Based on the time profile of the at least one state variable and/or environment variable of the motor vehicle, a value characterizing the driver's attentiveness can also be determined. This value can also be used to make a statement about the driver's fatigue. It can be determined, for example, from the state variables of the motor vehicle at which time intervals driving commands are given by the driver. It can also be determined from the state variables and/or from the environment variables, how quickly the driver reacts to an environment of the automobile. The attentiveness of the driver can be deduced from these quantities, whereby the driver per se does not have to be monitored, for example by using suitable optical systems; moreover, existing sensors installed inside the vehicle can be used. A plurality of attentiveness levels of the driver may be set based on the detected state variables and/or environment variables. The belt tensioner can be controlled accordingly as a function of the attentiveness of the driver.
In one embodiment, the predetermined driving maneuver is an evasive maneuver and the belt tensioner is controlled during the evasive maneuver and/or after the evasive maneuver to tighten the safety belt. “Evasive action” is to be understood as a driving maneuver, wherein the driver deviates from the previously determined lane or direction of travel, for example, to avoid an obstacle. Such evasive maneuver is performed, for example, to test the driving dynamics of a motor vehicle and is known under the name of Lane Change Test or “Elk Test”. In such an evasive maneuver, the driver performs suitable steering movements, whereby slack is introduced in the safety belt by the typically hectic movements from the driver. Such an evasive maneuver represents a critical situation for the driver where he needs special protection. There is also a non-negligible risk immediately after the evasive maneuver that the driver loses control of the vehicle. This loss of control can cause an accident. By detecting the evasive maneuver, the belt tensioner can be activated already during and/or preferably after the evasive maneuver and the safety belt can be tensioned. The safety belt is thus in perfect contact with the body of the driver after the evasive maneuver. The driver is hence optimally prepared in the event of an impending accident and the protective potential of the belt is fully exploited.
According to another embodiment, the predetermined driving maneuver is a transition from reverse travel to forward travel and the belt tensioner is controlled at a start of the forward travel for tightening the safety belt. While travelling in reverse, the driver does not only rely on the existing side-view and rear-view mirrors and on existing audio or visual warning systems, but usually turns his upper body toward the passenger seat to get a better view through the rear window. If the driver wears a safety belt, this movement by the driver produces slack in the safety belt. After reverse travel is completed and when forward travel is resumed, the safety belt may then not be sufficiently tightened. The reversible belt tensioner is therefore controlled accordingly when starting the forward travel so that the safety belt is tightened. The conditioning of the driver in the driver's seat is thereby improved and passive safety systems can become more effective in a dangerous situation.
In another embodiment, the predetermined driving maneuver is cornering, wherein at least one predefined threshold value for the state variable and/or the environment variable is exceeded while cornering, and the belt tensioner is controlled before and/or while driving through curves to tighten the safety belt. There is an increased risk of accidents with dynamic cornering, because for example an excessive speed can lead to oversteering or understeering of the vehicle depending on the vehicle design. To be able to take advantage of the full protective potential of the belt system, slack is gently removed from the belt system by the reversible belt tensioner before negotiating a curve. Optionally, the set tightness of the safety belt is thereafter maintained until the curve has been negotiated or the speed of the motor vehicle has been adjusted back to the road conditions. The safety belt is in ideal contact with the body of the driver or the other passengers during cornering. In this way, all vehicle occupants are ideally protected by the belt system in the event of a possible accident. For example, a predicative route of the road may be detected with appropriate look-ahead environment sensors and compared with the state variables of the motor vehicle. It can then be determined before negotiating a curve, whether the speed of the motor vehicle is too high for driving through the curve. It can also be detected whether the motor vehicle leaves the assigned lane. In this case, the safety belt can be tightened by the reversible belt tensioner by applying a large force.
In another embodiment, the predetermined driving maneuver is an approach to an intersection wherein a predetermined threshold value for the state variable and/or the environment variable is exceeded for such an approach to an intersection, and the belt tensioner is controlled so as to tighten the safety belt before and/or during the intersection is crossed. Likewise, there is an increased risk of an accident when the motor vehicle is moving into an intersection at an excessive speed. In such a case, there is a risk of a collision with an obstacle or with another vehicle. Likewise, such an approach to an intersection may cause a sudden evasive maneuver by the driver. Here, the course of the road or the presence of an intersection may be detected with look-ahead environment sensors, and it may be determined based on the detected state variables, whether these state variables exceed a predetermined threshold value for the present intersection. Thus, the reversible belt tensioners of the motor vehicle can already be controlled before entering the intersection, and the safety belt can be tightened accordingly. The tightness of the safety belt is preferably maintained until the intersection is safely crossed or the speed of the vehicle has been reduced.
Preferably, the driver is warned as soon the value characterizing the driver's attentiveness exceeds or falls below a predetermined threshold value by tightening the safety belt through control of the belt tensioner. A value characterizing the driver's attentiveness can be determined from the time profile of the state variables and/or the environment variables of the motor vehicle. This value can also be used to determine the driver's fatigue. When this value exceeds or falls below a predetermined threshold value, the reversible belt tensioner can be activated accordingly so as to tighten the safety belt. The driver can then be warned by the activation of the reversible belt tensioner, thereby increasing the driver's attentiveness.
This warning operates directly on the body of the driver and can therefore be perceived by the driver more immediately and more quickly than corresponding alerts generated, for example, by an audible or visual signal. In particular, the driver can be particularly effectively warned by the tightening of the belt when the driver is at risk of falling asleep, has already fallen asleep or is at risk of falling asleep again. Different escalating levels of attentiveness or fatigue of the driver may also be determined based on the detected state and/or environment variables, which can then be used to control a selectable alarm profile. For example, different jerk profiles may be generated by tightening the safety belt. This reduces the period of inattentiveness by the driver, thus allowing the driver to more quickly resume control of the motor vehicle. This therefore also reduces the danger for the surrounding traffic and the driver himself. If the driver's attentiveness can not be sufficiently restored by the warning function, then all reversible belt tensioners may be permanently controlled so as to safely prepare all vehicle occupants for a possible accident. Suitable sensors which are normally present in the vehicle can be used with this warning function. For example, additional cameras are then not required to monitor the eye blink or the driver's viewing direction. Accordingly, there are no additional costs.
Preferably, the at least one state variable is determined based on at least a wheel rotation speed, a position of a brake pedal, a position of an accelerator pedal, a position of a clutch pedal, a steering wheel angle and/or an engaged gear. The respective sensors for determining these parameters of the motor vehicle are usually already present in the motor vehicle. Likewise, the state variables may be determined, for example, from the engine controller and/or the brake controller. The existing systems can therefore be used and there are no additional costs.
Preferably, the at least one environment variable is determined based on a course of the road detected by a camera and/or based on data of the course of the road obtained from a navigation system. Look-ahead environment sensors are usually already present in motor vehicles and therefore need not be additionally upgraded. Alternatively or in addition to a camera, other environment sensors, such as optical sensors, radar sensors and/or lidar sensors, may be used.
Furthermore, according to the invention, a driver assistance system for a motor vehicle is provided, with
a sensor for detecting a time profile of at least one state variable and/or an environment variable of the motor vehicle,
a reversible belt tensioner for a safety belt, and
a controller which is configured to detect based on the time profile of the at least one detected state variable and/or environment variable a predetermined driving maneuver and/or a value characterizing the attentiveness of a driver, and to activate the reversible belt tensioner in response to the detected driving maneuver or the detected value characterizing the attentiveness of the driver.
Lastly, according to the invention, a motor vehicle with a driver assistance system described above is provided. The embodiments described with reference to the method of the invention can be applied commensurately to the driver assistance system according to the invention and to the motor vehicle according to the invention.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will now be explained in more detail with reference to the appended drawings. These show in:
FIG. 1 a motor vehicle having suitable sensors for detecting state variables of the vehicle and a controller,
FIG. 2 a motor vehicle having suitable sensors for detecting environment variables of the motor vehicle and a controller, and
FIG. 3 a motor vehicle having state and environment sensors, which can be used to determine the future position of the motor vehicle.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The embodiments illustrated in greater detail below represent preferred embodiments of the present invention.
FIG. 1 shows a motor vehicle 10 having a controller 12 . The controller 12 is connected via corresponding data lines to the wheel rotation speed sensors 14 a to 14 d of the wheels of the motor vehicle. Furthermore, the controller 12 is connected with a steering angle sensor 16 , which is operatively connected with the steering system of the motor vehicle. The controller 12 is configured to determine at least one state variable of the vehicle 10 based on the data of the wheel rotation speed sensors 14 a to 14 d and based on the data of the steering angle sensor 16 . Such state variable may be, for example, the speed, the acceleration, the direction of travel and the like. The motor vehicle may have additional (unillustrated) sensors configured to determine other state variables of the motor vehicle 10 .
In addition, the controller 12 is configured to identify a predetermined driving maneuver based on the time profile of the state variables. A belt tensioner 18 can be activated accordingly in response to this driving maneuver so as to tighten a safety belt. Such predetermined driving maneuver may be an evasive maneuver, wherein the belt tensioner 18 is controlled during the evasive maneuver and/or after the evasive maneuver to tighten the safety belt. Another driving maneuver may be the transition from reverse travel to forward travel, wherein the belt tensioner 18 is controlled at a start of forward travel, so that the safety belt is tightened accordingly. During the aforementioned driving maneuvers, slack is introduced into the belt system by movement of the driver. Usually, the belt tensioners 18 are controlled for all occupants in the motor vehicle.
FIG. 2 shows another embodiment of a motor vehicle 10 , which likewise has a controller 12 . In addition, the motor vehicle 10 includes a camera 20 and a navigation system 22 . The controller 12 is in this example coupled with two belt tensioners 18 . Corresponding environment data of the motor vehicle 10 can be detected with the camera 20 and/or the navigation system 22 . Other types of optical sensors or other forward-looking environment sensors, such as radar sensors and/or lidar sensors can be used instead of the camera 20 . The controller 12 is configured to determine the time profile of at least one environment variable of the motor vehicle 10 from the data of the camera 20 and of the navigation system 22 . Based on the time profile of the environment variable, a predetermined driving maneuver performed by the driver of the motor vehicle 10 can be determined. Such a driving maneuver may, for example, involve cornering, wherein at least one predetermined threshold value for the environment variable for cornering is exceeded. Such driving maneuver may also be an approach of an intersection, wherein at least one predetermined threshold value for the environment variable for such an approach of an intersection is exceeded.
A corresponding environment sensor or the camera 20 of the motor vehicle 10 continuously detects the travel lane. Corresponding curves, intersections and/or distances to other vehicles or to obstacles are reported to the controller 12 . The controller 12 then already controls the belt tensioners 18 before the corresponding driving maneuver, for example dynamic cornering or when an intersection is approached at excessive speed. The belt tensioner 18 is hereby controlled before and preferably during the respective driving maneuver. The safety belt preferably remains tensioned until the driving maneuver has been performed or until the speed of the motor vehicle has been adjusted accordingly.
The navigation system 22 can also continuously send a predicative course of the route to the controller. An artificial horizon is hereby produced in the controller 12 , from which the controller 12 can determine corresponding curves, intersections, or distances to other vehicles or obstacles. Here too, the belt tensioner(s) 18 can already be controlled in advance by the controller 12 so as to tighten the safety belt.
FIG. 3 shows a motor vehicle 10 which likewise has a corresponding controller 12 . The controller 12 can be used to determine corresponding state variables and/or environment variables of the motor vehicle 10 . For this purpose, the motor vehicle includes suitable sensors 10 , as previously described for example in conjunction with FIG. 1 and FIG. 2 . Alternatively or in addition to the sensors described in FIGS. 1 and 2 , the position of an accelerator pedal, the position and change in the position of a brake pedal and/or a possible operation of a clutch pedal can be detected. For example, the accelerator pedal position can be detected by an engine controller 24 which is connected to the controller 12 . Likewise, the position or change in the position of a brake pedal may be detected by a brake controller 26 which is also connected to the controller 12 . In addition, as previously described in conjunction with FIG. 1 , the operation of the steering system or the change of the steering angle is detected. Furthermore, the operation of corresponding man-machine interfaces operated by the driver may be taken into consideration.
A value characterizing the driver's attentiveness can be determined from the detected variables, in particular from the time profile of the measured state and/or environment variables. Other features indicative of an increased inattentiveness of the driver can be derived, for example, from an open side window, from a blower running at high speed and/or from a low temperature and a high sound level in the passenger compartment of the motor vehicle. A continuous driver model providing information about the driver activity is calculated from the above data. In this way, a single-stage driver model estimator can be determined. It is also feasible to expand this driver model estimator to a multi-stage estimator by using the data from a potentially available lane departure warning and an object recognition system 28 . For this purpose, the data from the lane departure warning are compared with the position of the vehicle within lane markers 30 , and a predictive travel direction is calculated by taking into account the turn signal lever and compared with the current and future direction of travel. When data from an object-based environment sensor system are also considered, the driver's reaction time in relation to vehicles driving in front as a function of the selected operating mode (e.g., car, dynamic or comfort) also enter the attentiveness model.
If the continuously calculated driver model leads to the conclusion that the driver is increasingly inattentive or fatigued, then the controller 12 activates the reversible belt tensioner 18 and thus noticeably tightens the safety belt. Different warning levels can be provided to warn the driver by a corresponding jerk on the safety belt. Because the safety belt is in direct contact with the body of the driver, the driver can immediately notice the warning, thereby enhancing his attentiveness. Additional controllable actuators may also be provided in the vehicle which can be used to generate an audible and/or visual warning or a haptic warning, such as a vibration of the steering wheel. Also, for example, a suitable intervention in the braking system can be performed, which causes a corresponding jerk.
A predetermined driving maneuver and/or a value characterizing the attentiveness of a driver can also be determined with a combination of the sensors shown in FIGS. 1 to 3 for detecting state variables and/or environment variables of the motor vehicle. | A method for controlling a reversible belt tensioner of a safety belt in a motor vehicle includes detecting a time profile of at least one state variable and/or at least one variable relating to the surroundings of the motor vehicle, identifying a predetermined driving maneuver and/or a value characterizing the attentiveness of a driver from the time profile of the at least one detected state variable and/or variable relating to the surroundings, and controlling the reversible belt tensioner based on the identified driving maneuver or on the basis of the value characterizing the attentiveness of the driver. | 1 |
FIELD OF THE INVENTION
[0001] The field of the invention is drainage management systems, more particularly, flow limiting inlet structures designed to collect water or other fluids in a pool above grade and to regulate water discharge, enabling the system to capture sediments and surface pollutants such as oil and grease in the pool before allowing the collected water to discharge into an outlet pipe.
BACKGROUND OF THE INVENTION
[0002] Contaminated sediments, greases, and oils, and other pollutants collect on the ground during dry periods when little or no rainfall occurs. When a storm occurs after such a dry period, the accumulated pollutants are mobilized by storm water and get flushed into surface water drainage systems. The flushing of pollutants into such drainage systems is generally undesirable, particularly if the water or other fluids flowing through such drainage systems remain untreated before being discharged into a river, lake, or ocean. The occurrence of a storm after a dry period and the corresponding flushing of pollutants into drainage systems is often referred to as a “first flush” event. First flush events are particularly troublesome in industrial areas due to the types and amounts of pollutants that accumulate.
[0003] Because the effects of first flush events are undesirable, efforts have been made to limit such effects. A common way to do so is to allow storm waters to initially flow into a detention basin and to use a flow limiting structure to control flow out of the detention basin. Such flow limiting structures include, among others, risers, trash racks, filters, and weirs. Such structures typically try to allow sediments to settle out, prevent the outflow of surface contaminants, or prevent the outflow of larger sized pollutants.
[0004] A concern in designing such flow limiting structures is that they should not allow flooding to occur, even if preventing flooding allows pollutants to escape. As a result, flow-limiting structures are typically designed to provide for “overflow” situations during which quantities of water in excess of the design first-flush storm are allowed to flow through the structure untreated if the incoming water volume exceeds the capacity of the system. In an attempt to help prevent overflow from occurring, some structures such as perforated risers are designed to permit a higher flow rate through an outlet as water levels rise.
[0005] Unfortunately, previously known flow-limiting structures do not always provide a solution that adequately balances the design goals of preventing flooding, allowing sediments to settle, preventing flushing of surface pollutants, and limiting peak discharge flow rates. As such, there is a need for new flow limiting structures such as are disclosed herein.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a flow limiting inlet structure designed to collect water or other fluids in a pool above grade, and to provide improved capture of sediments and surface pollutants such as oils and greases in the pool, while regulating the flow of water or other fluids during discharge into an outlet pipe. More particularly, the present invention is directed to the use of a conventional storm water detention basin, and the use of a vertical cylindrical discharge structure to regulate the basin water depth and discharge flow rate of storm water out of the detention basin, in conjunction with a specially designed baffle system that prevents the release of any greases or oils floating on the water surface while capturing any floating trash or debris.
[0007] If a perforated discharge structure is used, the location and diameter of holes in the discharge structure can be varied to produce a wide variety of discharge flow rates so as to control the approach velocity of incoming storm water and promote complete settlement of suspended sediments. This system attenuates the peak storm water inflow rate and reduces the peak discharge flow rate as needed. Flow in excess of “first flush” volumes pass through the system untreated by entering the top of the discharge structure while concurrently flowing over a basin perimeter weir set at the same elevation. These larger storm volumes are not completely attenuated nor treated by the detention basin.
[0008] After a storm has passed, site staff can shovel out the collected sediment from the detention basin, washout all of the accumulated grease and oil, and in so doing make the system ready for the next storm event.
[0009] It is contemplated that the methods and systems disclosed herein are particularly well adapted for use in managing the quality of storm waters draining from industrial sites. However, it is also contemplated that the methods and systems disclosed herein will prove advantageous in other drainage and/or fluid control applications.
[0010] In one embodiment, the present invention comprises a storm water detention basin comprising a basin sized and positioned to accumulate storm water, an outlet, and a flow limiting structure impeding flow of water out of the basin through the outlet, the flow limiting inlet structure comprising: a set of one or more baffles adapted to hinder the flow of surface contaminants into the outlet; and a discharge riser adapted to control the discharge flow rate out of the basin to effectively capture sediment in the basin. In some such embodiments the set of one or more baffles are a tiered set of nested baffles wherein each baffle that is nested within another baffle is positioned at a lower height than the baffle it is nested within, and the baffles of the set of baffles overlap each other. This nested set of baffles is design to prevent the release of a water surface containing floating oils and greases, and has adequate nested baffle overlap to prevent the release of such oil and grease when the water surface is depressed passing through the baffle system.
[0011] In another embodiment the present invention comprises a flow limiting inlet structure comprising a set of one or more baffles adapted to inhibit the flow of surface materials through the baffle set, wherein the inlet area of the baffle set increases as fluid depth increases.
[0012] In another embodiment, the present invention comprises a flow limiting inlet structure comprising a discharge riser surrounded by a tiered set of nested baffles. In some such embodiments, each baffle that is nested within another baffle may be positioned at a lower height than the baffle it is nested within, and the baffles of the set of baffles may overlap each other. Such a flow limiting inlet structure comprising a discharge riser surrounded by a tiered set of nested baffles may also have a lower inlet area of a baffle of the set of baffles that is less than the non-overflow inlet area of the discharge riser. In some instances the difference may be great enough that the lower inlet area of a baffle of the set of baffles is less than half or even less than one third of the non-overflow inlet area of the discharge riser.
[0013] Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1A is an illustration of a flow limiting input structure in a detention basin.
[0015] FIG. 1B is a side view of the flow limiting input structure of FIG. 1A .
[0016] FIG. 1C is a cutaway side view of the flow limiting input structure of FIG. 1A .
[0017] FIG. 1D is a bottom view of the baffles and riser of the flow limiting input structure of FIG. 1 a.
[0018] FIG. 2A is a partial cutaway side view of the flow limiting input structure of FIG. 1A illustrating operation of the structure at a first fluid depth.
[0019] FIG. 2B is a partial cutaway side view of the flow limiting input structure of FIG. 1A illustrating operation of the structure at a second fluid depth.
[0020] FIG. 2C is a partial cutaway side view of the flow limiting input structure of FIG. 1A illustrating operation of the structure at a third fluid depth.
[0021] FIG. 2D is a partial cutaway side view of the flow limiting input structure of FIG. 1A illustrating operation of the structure at a fourth fluid depth.
[0022] FIG. 3A is a cutaway side view of a second flow limiting input structure.
[0023] FIG. 3B is a bottom view of the flow limiting structure of FIG. 4A .
[0024] FIG. 4 is a bottom view of the baffles and riser of an alternative embodiment of the flow limiting input structure of FIG. 1 a.
[0025] FIG. 5 is a partial cutaway view of an alternative baffle set.
[0026] FIG. 6A is a cutaway view of an alternative baffle.
[0027] FIG. 6B is a cutaway view of an alternative baffle.
[0028] FIG. 7 is a cutaway side view of the input structure of FIG. 1 providing reference numbers for various measurements.
DETAILED DESCRIPTION
[0029] In FIG. 1A , a flow limiting structure 100 is positioned in a detention basin 20 where basin 20 is partially bounded by basin bottom 21 and by basin perimeter weir 22 , and basin 20 includes an outlet 160 . Basin 20 contains sediment and surface pollutant containing water 10 , and structure 100 controls the flow of water 10 (or any other fluid in basin 20 ) out of basin 20 through outlet 160 . In preferred embodiments, weir 22 is adapted to spill water out of basin 20 when water 10 reaches a height sufficient to overflow structure 100 .
[0030] As can be seen in FIGS. 1A-1D , flow limiting structure 100 comprises a perforated riser 110 having holes 111 and opening 112 covered by hinged grate 113 , and a set of two nested and tiered baffles 120 and 130 , each baffle ( 120 , 130 ) comprising lower edges ( 121 , 131 ) forming lower openings ( 122 , 132 ), upper edges ( 123 , 133 ) forming upper openings ( 124 , 134 ), and a set of support legs ( 125 , 135 ), separating lower edges ( 121 , 131 ), from a foundation 150 . Baffles 120 and 130 are tiered in the sense that the distance of separation between lower edges 121 and 131 differs between each of the baffles as do the heights of upper edges 123 and 133 . Baffle 120 is nested within baffles 130 in that baffle 130 at least partially surrounds baffle 120 and baffle 120 is positioned between baffle 130 and riser 110 . Baffle 120 , in turn, surrounds riser 110 . Baffles 120 and 130 overlap in that upper edge 123 of baffle 120 is higher than lower edge 131 of baffle 130 , while lower edge 121 of baffle 120 is lower than lower edge 131 of baffle 130 . Structure 100 controls fluid flow into outlet 160 and outlet pipe 170 .
[0031] FIGS. 2A-2D illustrate the flow input structure 100 of FIGS. 1A-1D as the structure operates to control flow of fluid 10 out of the basin through outlet 160 . In FIG. 2A , fluid 10 has a depth D 1 at which the surface of fluid 10 is below lower edge 121 of baffle 120 and the lowest set of openings 111 in riser 110 . As such, at depth D 1 fluid 10 is prevented from flowing through outlet 160 by riser 110 . In FIG. 2B , fluid 10 has risen to a level D 2 above edge 121 and the lowermost set of openings 111 . As such, fluid 10 is able to flow through flow paths F 1 under baffle 120 , into riser 110 , and out outlet 160 . In FIG. 2C , fluid 10 has risen to a level D 3 above lower edge 130 and above upper edge 123 . As such, fluid 10 is able to flow under baffles 120 and 130 and into riser 110 through the four lowermost sets of holes 111 in riser 110 via flow paths F 1 -F 4 . In FIG. 2D , fluid 10 has risen to a level D 4 above upper edge 131 , but just below the upper edge of riser 110 that defines opening 112 . As such, fluid 10 is able to flow both over and under baffles 120 and 130 into riser 110 through all the sets of holes 111 in riser 110 via flow paths F 1 -F 5 .
[0032] It should be noted that flow paths F 1 -F 5 are provided for illustrative purposes only. The actual flow paths through the baffles and riser will likely vary based on a number of factors such as the size, relative spacing, and positions of the holes, risers, and baffles as well as the number and shape of the baffles.
[0033] Many of the features of structure 110 are equally applicable to side-discharge structures as illustrated in FIGS. 3A and 3B as they are to bottom discharge structures as shown in FIGS. 1A-1D . In FIGS. 3A-3B , a flow limiting input structure 300 is used to control flow of fluids through side outlet 310 where the structure comprises tiered and nested baffles 320 , 330 , 340 , 350 , 360 , and 370 . As shown in FIGS. 3A and 3B , flow limiting input structures as disclosed herein (whether for side or bottom discharge outlets) need not comprise any riser or other flow control device other than the set of nested and tiered baffles. However, although the sizes, positions, and relative spacing of the baffles in a baffle set could be used to control flow rate of fluid into an outlet, it is preferred that a riser or other flow control apparatus be used in conjunction with the baffle set to provide simpler flow rate control, and to provide more options in regard to baffle design. In preferred embodiments, the baffles of a baffle set will be spaced sufficiently far from each other, from the discharge riser, and from the foundation that flow rate through the outlet 160 is substantially, if not totally, determined by any discharge riser or other flow rate control apparatus used in conjunction with the baffle set.
[0034] If one compares structure 300 of FIGS. 3A-3B with structure 100 of FIGS. 1A-1D , it is apparent that the number of baffles in the baffle set of structure 300 is greater than the number of baffles in the baffle set of structure 100 . The number of baffles will vary between different embodiments, but preferred embodiments will comprise at least two baffles, while more preferred embodiments will comprise three or more baffles. It is contemplated that increasing the number of baffles allows for reduced spacing between baffles and between the innermost baffle and any riser, with a corresponding decrease in surface contaminants that may make it into structures 100 and 300 as being on a surface of fluid 10 inside the perimeter of a baffle as the fluid level rises from below to above the lower edge of the baffle. As such, a design comprising a single baffle sized large enough to allow for maximum flow through the outlet may allow larger amounts of initial leakage of surface contaminants at low fluid levels and is the less preferred than designs that utilize a larger number of baffles.
[0035] Such a comparison between structure 300 and structure 100 also makes it apparent that the shape of baffles differs between structure 100 and structure 300 . When viewed from the top or bottom, the shape of the baffles of a particular embodiment may be square (see FIG. 1D ), circular (see FIG. 4 ), semi-circular (see FIG. 3B ), elliptical, or any other shape. Although the embodiments shown have baffle sets wherein every baffle of the set has substantially the same shape as every other baffle, less preferred embodiments may have any combination of similarly or differently shaped baffles within a baffle set. FIGS. 3A and 5 illustrate that baffle shapes may vary in other ways as well. In FIG. 3A , one baffle of the set forms a hood over the other baffles, while in FIG. 5 each baffle forms a partial hood that can help direct flow from higher baffles or from overflow into the structure. Moreover, baffles need not be elongated such that their height exceeds their width as shown in the pictured embodiments. As such, baffles may comprise any shape so long as they function to minimize the amount of surface contaminants that flow through the flow limiting input structure they are a part of.
[0036] Although the baffles shown in FIGS. 1A-1D comprise support legs ( 125 , 135 ), other embodiments may utilize different mechanisms for providing baffle support. Any mechanism that supports the baffles while still allowing them to function to prevent flow of a majority of surface contaminants through the inlet structure may be used. As an example, baffles may hang from a bracket or other structure that couples them to a discharge riser, or may all be coupled to one or more baffles that provide support to any other baffles. Another example can be seen in FIG. 3A where the baffles 320 - 370 may be coupled directly to the side wall that outlet 310 pass through. Yet another option similar to the use of support legs is to use outer baffles that are self supporting but have slots, perforations, or some other feature that permits water to flow through the lower portions of the baffles such as the baffles of FIGS. 6A and 6B .
[0037] It is also contemplated that instead of using “short” baffles (i.e. baffles that don't extend to the top of the structure), one or more of the baffles, particularly the innermost baffle ( 120 , 320 ) may be extended upwards but have the extended portion comprise perforations or slots, or otherwise be adapted to allow fluid to flow through such extended portions. It is contemplated that the use of a partially perforated inner baffles would minimize or eliminate the need for any central discharge riser as the functionality of such a riser would be provided by the upper portions of the interior baffles.
[0038] Gaps between baffles and any gap between the innermost baffle and a riser, may include strainers, filter, vanes, or other fluid control mechanisms. It is contemplated that the use of filters in the gaps between baffles may prove advantageous as at least some materials captured in such filters may fall free once fluid levels drop below the height of the filter. It also is contemplated that the use of vanes or other fluid control mechanisms may be advantageously used to improve flow through the flow limiting input structure. Some input structures may be designed to include such screens or filters and also to facilitate the flushing of such screens of filter, possibly without requiring fluid levels to drop below filter heights.
[0039] As illustrated by FIGS. 2A-2D , the number of flow paths through the set of baffles ( 120 , 130 ) increases as the depth of fluid 10 increases. The term “flow path” is used herein to denote any path through which fluid can flow for the current level of fluid. As such, there are no “flow paths” through structure 100 in FIG. 2A as the riser prevents flow of fluid 10 through the structure at a depth/head D 1 (measured between the surface and the top of base 150 which defines the top of outlet 160 ). At a depth D 2 , structure 100 comprises flow paths F 1 under baffle 120 and into the lowermost set of holes 111 . At depth D 3 , structure 100 comprises additional flow paths F 2 -F 4 , and at depth D 4 also includes flow path F 5 . The flow paths through the baffle set ( 120 , 130 ) do not necessarily increase at the same rate as the flow paths through riser 110 , or structure 100 , as the flow paths through the baffle set depend on the number, size, and relative positions of the baffles in the set. In contrast, the number of flow paths through structure 100 depends on both the number of flow paths through the baffle set and the number of flow paths through riser 110 .
[0040] In conjunction with the increase in the number of flow paths, the total inlet area of the baffle set ( 120 , 130 ) and structure 100 increases as the depth of fluid 10 increases. The term “total inlet area” is used herein to denote the sum of the areas of the various openings between the exterior and interior of structure 100 through which fluid can flow for the current level of fluid. In the embodiment shown, this equates to the sum of the areas of the various openings between the interior and exterior of the baffle set ( 120 , 130 ) for non-overflow levels. At level D 1 , the total inlet area is zero. At level D 2 , the total inlet area is equal to the area of opening 122 , which is approximately equal to the area defined by lower edge 121 minus the cross sectional area of riser 110 . At level D 3 , the total inlet area is equal to the area of opening 122 plus the area of opening 123 . At level D 4 , the total inlet area is equal to the area of openings 122 , plus the area of opening 123 , plus the area of opening 134 .
[0041] The actual sizes and positions of the baffles will vary between embodiments. However, referring to FIG. 7 , in preferred embodiments baffles should overlap (i.e. B 22 <BH 1 ) and should be nested (BR 1 <BR 2 ) such that the higher baffles ( 130 , 430 - 470 ) are outermost in order to prevent flow of surface contaminants out of the detention basin. Although many embodiments may have baffles of similar dimensions (such as having B 11 be approximately equal to B 21 ), it is contemplated that the relative heights of the upper and lower edges of adjacent baffles is much more relevant to proper operation that the sizes of the baffles used. In addition to being higher than the lower edges of outer baffles (BH 1 >B 22 ), the top edges of inner baffles ( 120 , 420 - 460 ) in preferred embodiments will be lower (BH 1 <BH 2 ) than the top edges of outer baffles ( 130 , 440 - 470 ) to provide additional access to the upper portions of any riser. In preferred embodiments, the lower edges of outer baffles will be higher than the lower edges of inner baffles (B 22 >B 12 ) in order to spread flow paths across the length/height of the inlet structure rather than concentrating them at the bottom. Spreading the flow paths decreases that amount of fluid flowing into the structure near its base and minimizes the amount of sediment pulled into the structure by such bottom flows. Spreading flow paths along the structure also help to prevent the spacing between the bottoms of the baffles and the foundation from becoming a limiting factor on the flow rate of the structure. As sizes and positions may vary, different embodiments may have different values for B 11 , B 12 , B 21 , B 22 , BH 1 , BH 2 , BB, BR 1 , BR 2 , and R 1 -R 6 .
[0042] Riser 110 is preferred to be an elongated, perforated cylinder with a vertical central axis, and may be tall enough to extend higher than the highest baffle surrounding it. However, if it has an overflow inlet that is positioned below the top edge of the outermost baffles, the baffles can still act to prevent flow of surface contaminants into riser 110 and orifice 160 even when fluid levels are sufficiently great as to cause overflow of riser 110 .
[0043] In less preferred embodiments, riser 110 may not be perforated, may be substantially shorter than the baffles surrounding it, or may be eliminated altogether. In less preferred embodiments, the orifices of riser 110 may be positioned above the highest surrounding baffle if surface filtering of contaminants is less desired at higher fluid levels. Similarly, riser 110 may permit fluid that flows under all the baffles of the baffle set to flow into outlet 160 if surface filtering of contaminants is less desired at lower fluid levels. Although a cylindrical shape is preferred, any riser used may be elliptical, polygonal, irregular or have some other shape. Although holes providing passage from the exterior to the interior of riser 110 are preferred, other embodiments may use slits, rectangular orifices, filtered openings, or some other mechanism to control the flow of fluid from the exterior of riser 110 to its interior. Riser 110 may, in some embodiments, be replaced with some other type of flow control apparatus.
[0044] In preferred embodiments the size and positions of the holes (or other inlets) into riser 110 will be sufficient to allow as much fluid to flow into riser 110 as can flow through outlet 160 such that overflow flows through the top of the riser don't increase the throughput of the riser unless fluid is prevented from flowing into one or more of the holes in the riser. Similarly, the baffles of the baffle set at least partially surrounding the riser and/or outlet will be sized and positioned such that the maximum amount of fluid that can be handled by the riser and/or outlet flows through the baffle set without having to overflow the baffle set.
[0045] In preferred embodiments the baffles and riser will comprise an open top to handle overflow conditions that may arise from large quantities of fluid accumulating in the detention basin whether from a large storm, clogged inlets in the input structure, or some other reason. However, less preferred embodiments may have riser and/or one or more baffles that are closed on top.
[0046] In the embodiment shown, riser 110 comprises a hinged grate 113 that helps prevent objects from flowing into riser 110 during overflow conditions. However, other embodiments may not have any similar type of mechanism, or may use a mechanism other than a hinged grate. In some embodiments, a grate or similar mechanism may be used to filter baffle overflows as well with such grates being used in conjunction with or in place of grate 113 .
[0047] It is contemplated that the various components of flow limiting inlet structures as disclosed herein may comprise different materials or combinations of materials. The actual choice of materials will likely be determined based on the conditions a structure is expected to have to endure, and the desired life of the structure. In preferred embodiments, flow limiting inlet structures will be constructed of durable and UV resistant materials.
[0048] Thus, specific embodiments and applications of storm water control basins and flow limiting inlet structures have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. As an example, although particularly well adapted for storm water control, the apparatus disclosed herein can be applied equally well to other fluid control applications where settling of sediment and/or filter of surface materials is desired. As an example, fluid accumulating in a detention basin may be the result of a container being drained or a surface being washed rather than a storm. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. | A flow limiting inlet structure is designed to collect water or other fluids in a pool above grade, and to provide improved capture of sediments and surface pollutants such as oils and greases in the pool, while regulating the flow of water or other fluids during discharge into an outlet pipe. In a conventional storm water detention basin a vertical cylindrical discharge structure can be used to regulate the basin water depth and discharge flow rate of storm water out of the detention basin, in conjunction with the use of a specially designed baffle system that prevents the release of any greases or oils floating on the water surface while capturing any floating trash or debris. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of United Kingdom Patent Application No. 0428001.2, filed on Dec. 22, 2004, which hereby is incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a hydraulic control system and a well installation incorporating the control system.
BACKGROUND OF THE INVENTION
In fluid extraction well installations there is a frequent requirement to control a small number of subsea hydraulic devices, typically valves for example, on a manifold or other structure from a well head tree, located typically 100 m distant from the manifold/structure. The traditional method of implementing this requirement is to install a hydraulic jumper between the tree and the manifold/structure hydraulic devices and use a tree ‘subsea control module’ (SCM) to control these devices.
FIG. 1 illustrates a traditional arrangement for control of hydraulic devices, in this example valves on a remote manifold. A tree 1 houses an SCM 2 , which is connected to the manifold 3 . Each valve 4 on the manifold 3 is fed via a hydraulic control line 5 such that a directional control valve (DCV) in the SCM 2 controls the operation of one valve 4 . Each tree around the manifold would be connected similarly to a respective set of three valves. Historically, hose-type jumpers 5 have been employed to link the hydraulic control from the SCM to the manifold valves. However, with the current trend for subsea wells to be at greater depths, fluid well installation companies are specifying steel tube jumpers, which are extremely expensive, both to buy and to install.
The requirement to operate hydraulic devices remote from the well head means that additional DCVs have to be integrated into the SCM. In general, SCMs are designed and manufactured as ‘common’ in that they contain sufficient DCVs to meet the requirement of a typical well. However, when further remote devices have to be operated, the ‘common’ SCM has to be modified which incurs substantial design costs. If, on the other hand, the ‘common’ SCM is designed to accommodate additional remote devices, then in many ‘straightforward’ applications the surplus capacity makes the SCM more expensive.
Intelligent downhole systems are becoming more common and generally require three hydraulic functions, operating at high pressure (typically 10 k to 15 k psi), inside the SCM. Not all wells need an intelligent completion. It is usual to have a ‘common’ design of SCM, so in many cases these three functions are unused. Typically, an intelligent well system will also need an additional high pressure (HP) accumulator to ensure that operating the intelligent well does not adversely affect the ‘surface controlled sub-surface safety valve’ (SCSSV) which is also on the HP supply and vice versa.
FIG. 2 illustrates a traditional arrangement for the control of downhole hydraulic devices, in this example valves 6 . The tree 1 carries an SCM 2 , which is connected to the downhole valves 6 via hydraulic feeds 7 .
It should be noted that such systems are not the only systems available, for example British Patent Application No. GB 0319622.7 describes a decentralized control system which does not use an SCM. Likewise the system as described in British Patent No. GB 2264737 describes a further system in which the SCM is replaced by a multiplicity of integrated electronic and hydraulic functions in modules, such as smaller and dedicated electronic units and hydraulic units. In contrast to these two described systems, while this invention also employs modules that contain electrically operated hydraulic functions and perhaps electronic functions in some embodiments, in the present invention they are under the control of an SCM.
SUMMARY OF THE INVENTION
It is an aim of the present invention to obviate the need for steel tube jumpers and to allow standard minimum SCMs to be employed when there is a requirement to operate additional remote hydraulic devices.
This aim is achieved by the removal of the hydraulic controls for remote hydraulic devices, e.g. DCVs, from the tree mounted SCM and housing them instead in a separate ‘pod’ which is then located external to the SCM and in some applications close to the remote devices.
In accordance with a first aspect of the present invention, there is provided a hydraulic control system for controlling an external device at a well installation, comprising a control module for generating electrical and/or optical control signals, a control pod for receiving said control signals, the control pod comprising control means for controlling the external device, and a hydraulic line for linking the control means to said external device for the control thereof.
The control signals may be transmitted from the module to the pod via an electrically conductive coupling, e.g. via a serial data link, or via optical fiber.
A plurality of control means may be provided, linked to respective external devices by respective hydraulic lines.
The or each control means may be a valve, for example a directional control valve.
Preferably, the control pod is adapted to receive hydraulic fluid from a supply.
According to a second aspect of the present invention, there is provided a well installation for location underwater, comprising a well tree, a well, an external device and the hydraulic control means according to the first aspect of the present invention, wherein the control module is located at the tree.
The control pod may be located at a structure remote from the tree, for example a manifold. The external device may also be located at the structure. The pod may further receive low pressure hydraulic fluid from a supply located at the structure.
Alternatively, the control pod may be located at the tree. The pod may receive hydraulic fluid from a high pressure supply via the control module.
As a third alternative, the control pod may be mounted at or within the well.
The external device may be located within the well.
The external device may be a valve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a prior art arrangement for control of valves on a subsea manifold.
FIG. 2 is a schematic of a prior art arrangement for control of downhole valves of a subsea well.
FIG. 3 is a schematic of an arrangement in accordance with this invention for control of valves on a subsea manifold.
FIG. 4 is a schematic of an arrangement in accordance with this invention for control of downhole valves of a subsea well.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 illustrates a first embodiment of the invention relating to the control of valves on a remote manifold/structure. In this embodiment, replacement of the hydraulic control lines from the tree with an electric or a fiber optic cable is achieved so that the need to modify or expand a minimal ‘common’ SCM is removed. An SCM 2 is housed on tree 1 and is connected either electrically or optically via a cable 9 to a pod 8 , which is mounted on the remote manifold/structure 3 . Each valve 4 on the manifold/structure 3 is fed via a hydraulic control line 10 from the pod 8 . Electrical or optical signals from the SCM 2 operate DCVs in the pod 8 which in turn control the hydraulic power from a local source, designated ‘LP (low pressure) supply’ in FIG. 3 , to each valve 4 via hydraulic feeds 10 internal to the manifold/structure 3 . Thus the cost of steel hydraulic tubing from the SCM to the manifold/structure is obviated as is the need to add additional DCVs to the SCM.
FIG. 4 illustrates a second embodiment of the invention relating to the control of downhole valves. In this embodiment, a pod can be located on the tree but external to the SCM thus avoiding the need to modify or expand a minimal standard SCM. An SCM 2 is housed on tree 1 and is connected either electrically or optically via cable 9 to the pod 8 . In this embodiment, the pod 8 is also mounted on the tree 1 . The pod 8 feeds downhole valves 4 via respective hydraulic control lines 7 . Electrical or optical signals from the SCM 2 operate DCVs in the pod 8 , which in turn control the hydraulic power from the SCM, designated ‘HP (high pressure) supply’ in FIG. 4 , to each valve 4 , via the hydraulic control lines 7 . Thus the need to add additional DCVs to the SCM is obviated.
As an alternative form of this embodiment, a pod may be located downhole and the hydraulic feeds, which could be several kilometers long, replaced by a much cheaper electric or fiber optic cable, similar to the arrangement used in the first embodiment of FIG. 3 .
In all these embodiments, the pod contains, as a minimum, electrically operated DCVs to provide hydraulic operation of the hydraulic devices at the location, powered from a local hydraulic source. When more than one device is to be operated it may be cost effective to replace the individual wires that provide electric control of each DCV with a serial data link, transmitting on its own separate pair of wires, or superimposed on the electric power, with decoding electronics incorporated in the pod. Alternatively the digital message could be transmitted to the pod via an optical fiber with a single pair of wires to provide electric power.
It will be apparent that the described systems provide the following advantages over the prior art systems:
1) Removal of both the need for long expensive steel hydraulic tubing, when used between a tree and a remote manifold/structure and the cost of installation which is expensive because of the need for special remotely operated vehicle (ROV) tools and facilities to install it.
2) Removal of the need to modify a ‘common’ SCM when used to control hydraulic devices remote from the tree. Normally the pod would only be fitted to trees that need it. Although the consequence of this is that all trees would still need a mounting plate for it to be plugged into, these are relatively cheap.
3) Enables replacement of the remote hydraulic device control i.e. a pod (e.g. by an ROV), without disrupting the operation of the SCM.
4) Provides the opportunity, when applied to intelligent wells, of having just one pod and deploying it when needed and then recovering it afterwards, since an intelligent well operation is often only needed only a few times in the system's approximate 25 year life.
5) For control of downhole hydraulic devices, the pod offers the opportunity to mount a small additional hydraulic accumulator inside the pod, although this may well have to sit on an auxiliary stab plate. Such an application may provide isolation of the SCM hydraulic fluid from the downhole hydraulic control system which, in terms of prevention of fluid contamination of the SCM hydraulics from the downhole hydraulics, is attractive to well installers. | A hydraulic control system for controlling an external device ( 4 ) at a well installation includes a control module ( 2 ) for generating electrical and/or optical control signals. A control pod ( 8 ) receives the control signals, the control pod controlling the external device. A hydraulic line ( 10 ) links the control pod to the external device ( 4 ) for controlling it. | 4 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to therapeutic devices and more particularly to such devices which are designed to facilitate inversion and suspension of a human from the lower legs so as to provide a natural gravitational traction on the upper body portions.
Various types of apparatus have long been utilized by individuals to suspend themselves in an inverted position. Such apparatus has taken a wide variety of forms such as for example ranging from a trapeze commonly provided on children's swing sets to specialized footwear which is designed to be hooked over an elevated bar or rod. Other types of apparatus have been designed to be secured within a doorway or the like and provide means for suspending an individual from the lower portions of the legs such as for example the apparatus illustrated in U.S. Pat. Nos. 4,458,894; 4,461,287 or 3,593,708. While such apparatus may be well suited for supporting an individual in an inverted position, it is relatively difficult for an individual to position himself within the apparatus as well as to extracate himself therefrom. The principal reason for this difficulty lies in the fact that this prior art apparatus is designed to be secured in the position from which the individual will be suspended thus requiring the user thereof to elevate himself sufficiently so as to be able to position his lower extremities in appropriate relationship with the apparatus. While this may not be a problem for a strong, healthy individual, such apparatus is difficult if not impossible for use by less able bodied individuals. Another problem associated with the apparatus lies in the fact that to the extent such apparatus may incorporate leg engaging supports, they are positioned in a fixed relationship which may not correspond to the ideal location for a given size individual and thus render the apparatus uncomfortable for use by such individual.
The present invention, however, provides inversion apparatus which overcomes these problems and disadvantages of prior art apparatus in that it incorporates means for easily and readily adjusting the relative distances between body engaging portions thereof as well as providing adjustment for the relative angulation thereof. The inversion apparatus of the present invention is of the type which employs a pair of spaced support members which are designed to be engaged by the back of the knee of an individual and the individual's instep in such a manner as to thereby provide support for suspending the upper portions of the body in an inverted position. The apparatus incorporates means whereby the relative positioning of these support members may be easily modified so as to readily accommodate different size individuals as well as to insure that the support members engage the user of the apparatus in the most comfortable position possible. Additionally, the apparatus incorporates means whereby the angulation between the upper and lower portions of the leg may be set to any desired degree thus further contributing to the comfortable usage of the apparatus.
One embodiment of the present invention is designed to be fixedly positioned in a vertical orientation and thus require a user thereof to physically elevate and position himself within the apparatus. Other embodiments of the apparatus of the present invention are designed to enable the individual to position himself therein while the apparatus is in a horizontal position after which the individual may easily elevate the apparatus into a vertical position with the user thereof moving into suspended relationship with respect thereto. This arrangement greatly facilitates use of the apparatus not only by strong, healthy individuals but also enables those less able bodied individuals to obtain the benefits offered thereby without requiring a great amount of assistance from third parties. Thus, as will become more apparent from the following description, the present invention is well suited for use by a wide variety of individuals having a great range of strength and agility.
Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an inversion apparatus in accordance with the present invention with an individual illustrated in suspended relationship thereto;
FIG. 2 is a front elevational view of the apparatus illustrated in FIG. 1;
FIG. 3 is a side elevational view of another embodiment of the inversion apparatus in accordance with the present invention;
FIG. 4 is a front elevational view of the apparatus illustrated in FIG. 3;
FIG. 5 is a side elevational view similar to that of FIG. 3 but illustrating a modified embodiment of the inversion apparatus illustrated therein, all in accordance with the present invention;
FIG. 6 is a view similar to that of FIG. 3 but illustrating an alternative drive arrangement therefor;
FIG. 7 is a plan view of the drive arrangement illustrated and incorporated in the embodiment of FIG. 6;
FIG. 8 is a side elevational view of yet another embodiment of the present invention;
FIG. 9 is a plan view of the embodiment illustrated in FIG. 8;
FIG. 10 is also another view similar to that of FIGS. 3 and 6 but illustrating yet another embodiment of the inversion apparatus of the present invention;
FIG. 11 is a front elevational view of the apparatus illustrated in FIG. 10 illustrating the adjustment arrangement for positioning of the instep support members;
FIG. 12 is an enlarged fragmentary detail view of the instep adjustment arrangement illustrated in FIG. 11;
FIG. 13 is an enlarged fragmentary view of the angulation adjustment forming a part of the inversion apparatus illustrated in FIGS. 10 and 11;
FIG. 14 is a side elevational view of apparatus similar to that illustrated in FIG. 10 but incorporating a further modification to facilitate use by a person desiring to lie in a face down position and requiring additional support along the thigh portion of the leg;
FIG. 15 is an enlarged fragmentary view of the thigh support positioning means incorporated in the embodiment of FIG. 14;
FIGS. 16 and 17 illustrate adjustable means for positioning of the knee and instep support members provided on the embodiment illustrated in FIG. 14;
FIGS. 18 and 19 illustrates an alternate releasable clamping arrangement for adjusting and securing various of the support members in a desired position with respect to the main frame members of the inversion apparatus illustrated and disclosed herein, all in accordance with the present invention;
FIG. 20 illustrates yet another embodiment of the inversion apparatus in accordance with the present invention which is particularly well suited for use by children;
FIG. 21 is a back elevational view of the embodiment illustrated in FIG. 20; and
FIG. 22 is an enlarged fragmentary section view of an alternative quick release locking assembly for use in adjustably positioning various support members.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and in particular to FIGS. 1 and 2, there is illustrated a relatively simple, straightforward embodiment of the inversion apparatus in accordance with the present invention indicated generally at reference number 10. Inversion apparatus 10 comprises a generally vertically ladder assembly 12 having secured to the upper end thereof an inversion support assembly 14.
The vertically extending ladder assembly 12 comprises a pair of generally parallel extending spaced frame members 16, 18 having a plurality of generally horizontally extending step members 20 extending therebetween and secured at their opposite ends to the respective frame members 16, 18. Any suitable means may be provided for securely supporting the ladder assembly in this vertically oriented position.
The inversion support assembly 14 comprises an instep support member 22 extending between and projecting laterally outwardly from opposite sides of respective ladder frame members 16, 18. A pair of elongated bar members 24, 26 are pivotably supported by the outer ends of the instep support member 22 intermediate the ends thereof. A knee support bar 28 is provided extending between the elongated bar members 24, 26 and adjustably supported thereby in spaced relationship to the instep support member 22. Suitably threaded set screw type clamp means 30, 32 are provided at opposite ends of knee support member 28 so as to enable it to be fixed along bar members 24, 26 in any desired relative spaced relationship to instep support 22.
In order to adjust the relative angulation between instep and knee support members 22, 28, a pair of elongated bracket members 34, 36 are provided each having one end pivotably connected to one of the respective elongated bar members 24, 26 and the other end adapted to be secured to suitable means provided on respective of the vertically extending ladder support members 16, 18. As shown therein, bracket members 34, 36 may be suitably positioned at any one of a plurality of locations thereby enabling the elongated bar member 24, 26 and hence the knee support member 28 to be positioned at any desired relative angulation with respect to the vertically extending ladder members 16, 18.
It should be noted that the elongated bar members 24, 26 pivotably supported to the top of the ladder support members 16, 18 will preferably be of a length substantially greater than the length needed to allow adjustment of the knee support member 28 so as to thus provide a pair of laterally spaced hand grips which may be utilized by the user of the apparatus to facilitate his positioning on the apparatus. Also, both instep and knee support members 22, 28 will preferably be provided with suitably cushioned pads.
In order for an individual to utilize inversion apparatus 10, it is first necessary for him to suitably position the knee support member 28 in the approximate desired location with respect to the instep support member 22. Thereafter, the relative estimated angulation will be selected and the elongated bracket members 34, 36 secured so as to position the knee support member 28 in a suitable location. Next, the individual will ascend the ladder structure via the horizontally extending step members 20 provided thereon and position himself with his insteps engaging the bottom surface of the instep support member 22 and the back of his knees engaging the upper surface of the knee support member 28 generally as illustrated in phantom in FIG. 1. Grasping the outwardly projecting ends of the elongated bar members 24, 26, the individual may then lower himself into an inverted suspended position with respect to the apparatus. The procedure may easily be reversed in order for the user thereof to extracate himself from the apparatus upon completion of his desired time in suspension.
While the above described inversion apparatus of the present invention is extremely well suited for use by healthy, strong able bodied individuals having the agility and dexterity to position and extracate themselves from the apparatus, there are many applications wherein an individual not possessing such sufficient agility may desire to obtain the benefits afforded by such inversion apparatus. Accordingly, the present invention contemplates an embodiment of the apparatus wherein a user may easily position himself within the apparatus in a reclining position after which the apparatus may be elevated either by the user or by an assistant into a position in which the individual is supported in a suspended inverted relationship. One such embodiment is illustrated and will be described in greater detail with reference to FIGS. 3 and 4.
Inversion apparatus 36 comprises a generally planar support platform 40 having a suitable supporting base 42 pivotably secured to one end thereof so as to support it in spaced relationship to the floor or the like. A suitable knee support bar 44 extends transversely across the platform 40 at the opposite end thereof and may be provided with a suitable pad or cushion 46. A pair of downwardly extending leg members 48, 50 are also pivotably secured at this end of the platform and operate to aid in supporting the platform when the platform is in a horizontal position as shown. An instep support member 52 is also provided extending laterally between the leg members 48, 50 and is adjustably secured thereto whereby the distance between the instep support member 52 and the knee support bar 44 may be suitably adjusted so as to accommodate a desired individual. In order to adjust the relative angulation or degree of leg bend required of an individual using this apparatus, each of the leg member 48, 50 is provided with a diagonally extending strut 54 having one end pivotably secured to the platform and the other end pivtably secured to the lower end of the respective leg structure. The struts 54 each comprises a pair of telescopically interfitted members 56, 58 which may be locked in any suitable position by means of hand wheel 60 thereby enabling the legs 48, 50 to be positioned in any desired angulation with respect to the platform itself. Additionally, these struts 54 serve to maintain the legs 48, 50 in the locked position once it has been adjusted so as to thereby enable the instep support member 52 to provide the necessary cantilevered support engagement to a user's legs.
One or preferably two suitable hydraulic or pneumatic actuated cylinders 62, 64 are also provided having one end pivotably secured to a base portion 66 and the other end suitably pivotably secured to the platform 40. Inlets/outlets 68, 70 are provided to which suitable supply lines may be connected so as to conduct a suitable pressurized fluid to opposite ends of each of the actuating cylinders 62. As best seen with reference to FIG. 3, pressure actuated cylinders 62, 64 operate to elevate the platform from a generally horizontal position to a generally vertical position such as that shown in phantom therein whereby an individual having initially positioned himself in a reclining position on the upper surface of the platform 40 is moved into a suspended relationship being held there securely by engagement of the knee and instep supporting members 44 and 52 with the respective portions of his legs. Preferably, suitable control means will also be provided on the platform 40 whereby the individual may easily control operation of cylinders 62, 64 and hence operate the platform 40 into the elevated position without assistance from third parties.
Referring now to FIG. 5, there is illustrated a modification of the embodiment illustrated and described with reference to FIGS. 3 and 4 which is designed to enable an individual to initially recline in a face down position. As shown therein, inversion apparatus 72 is substantially identical to inversion apparatus 38 except as noted below and hence corresponding portions thereof are illustrated by like numbers primed. In this embodiment, leg members 48' and 50' may be pivoted into a generally upwardly projecting position with respect to platform 40'. Also, in order to enable an individual to initially position himself in a face down position, it is necessary to fit an additional knee support member 74 to legs 48', 50' between instep support member 52' and knee support member 44' Additionally, in order to elevate platform 40', inversion apparatus 72 employs a single pressure actuated cylinder 76 positioned below platform 40' and extending between base 66' and a depending bracket member 78 secured to the undersurface of platform 40'. Usage of inversion apparatus 72 is substantially the same as described above with respect to apparatus 38 with the exception that the individual initially positions himself in a face down reclining position.
While the embodiments of FIGS. 3 through 5 have all been described with reference to the use of a pneumatic or hydraulically actuated piston in order to move the platform thereof into a vertically oriented position, other drive arrangements may be easily substituted therefor. As best seen with reference to FIGS. 6 and 7, it may be desirable in certain applications to provide the platform 40" with a pair of converging angularly extending support members 80, 82 extending generally outwardly and downwardly from the pivotably supported end portion thereof. A suitably threaded rod member 84 may then be utilized with one end 86 attached to the outer end of this extension and cooperating with a suitable electric motor brake drive assembly 88 positioned below platform 40". In this arrangement, the motor brake drive assembly 88 may operate to rotatably drive a threaded member so as to draw the threaded rod member to the left as illustrated therein via suitable gear reducing means so as to thus move the platform into or out of the generally vertical position. Preferably the electric motor brake drive assembly 88 will be fitted with a suitable brake mechanism whereby upon de-energization of the motor, the brake will automatically engage and operate to prevent further movement of the drive assembly thereby maintaining the platform in any desired elevated position. Alternatively, however, it may be possible, assuming a sufficient degree of gear reduction that the brake mechanism may be omitted therefrom or substantially reduced in size or capacity.
Another drive arrangement is illustrated and will be described with reference to FIGS. 8 and 9. In this embodiment, indicated generally by reference number 222, platform 224 is pivotably supported entirely and in cantilevered relationship to base 226 by use of either a single or multiple spaced coaxial pivot points. Base 226 will also preferably serve to house a suitable drive arrangement whereby platform 224 may be elevated about the single or multiple pivot points from an initial horizontal position to any desired degree of elevation. Any suitable drive arrangement may be employed therein such as for example an electric motor and/or brake assembly operating through suitable gear reduction means driving a gear segment secured to the pivotably supported end of the platform 224. Alternatively, chain or belt drives could be employed. In any event this embodiment offers the advantage of being extremely compact and occupies only a very limited area.
Alternatively, as shown in FIG. 10 in lieu of the screw drive arrangement illustrated and described with reference to FIGS. 6 and 7, it may also be possible or desirable to employ a hydraulic or pneumaticallly actuated cylinder 90 operable between a fixed pivot point 92 and support members 80', 82' provided on the platform.
Inversion apparatus 94 illustrated in FIG. 10 also incorporates an alternative arrangement for both adjusting the relative distance between the knee and instep support members 96 and 98 as well as the relative angulation between platform 100 and the instep support member 98 as is best seen and will be described with reference to FIGS. 11 through 13.
Referring now to FIG. 11, a knee support member 96 is provided positioned between and supported at one end of platform 100 and outwardly from a pair of vertically extending leg members 102, 104. The knee support member 96 includes a pair of laterally spaced pad members 106, 108 and an instep support end adjustment assembly 110 positioned therebetween. Instep support 98 is positioned below knee support 96 in depending relationship from adjustment assembly 110 and includes a pair of outwardly oppositely projecting rod members 112, 114 to which are fitted suitable pads 116, 118 which are to be engaged by the insteps of a user of apparatus 94.
In order to support instep support 98, adjustment assembly 110 includes a housing 120 from which a pair of elongated guide rod members 122, 124 project in generally spaced parallel relationship. A guide member 126 extends between and is integrally formed with rod members 122, 124 and includes suitably bushinged bores 128, 130 through which guide rods 122, 124 slidably extend.
A threaded shaft 132 also is rotatably supported in an axially fixed position by housing 120 and extends between guide rods 122, 124 in generally parallel spaced relationship thereto and entends through an elongated internally threaded member fixedly secured to guide member 126. The upper end of shaft 132 extends above housing 120 and has a suitable hand wheel 134 secured thereto whereby shaft 132 may be easily manually rotated so as to thereby effect movement of guide member 126 along guide rods 122, 124 so as to thus position instep support 98.
In order to angularly position instep support 98 with respect to knee support 96, support rods 136 of knee support 96 has secured thereto a ring gear 138 disposed within housing 120. A worm gear 140 is also provided being rotatably supported in engaging relationship with ring gear 138 by housing 120. In order to facilitate rotation of worm gear 140, a suitable hand wheel 142 is secured to an outwardly projecting end portion thereof. Thus, as worm gear 140 is rotated, housing 120 and associated guide rods 122, 124 and threaded shaft 132 which support instep support 98 will be moved circumferentially about support rod 136 thereby altering the relative angular relationship between instep support 98 and knee support 97. It should be noted that if desired suitable relatively small electric motors may be employed to rotatably drive either or both shaft 132 and/or worm gear 140.
Referring now to FIGS. 14 and 15, there is shown a further modification, generally designated 142, of the inversion apparatus illustrated in FIG. 10 which is particularly designed to enable an individual to be raised into a generally inverted position while being supported both by the knee and instep members as well as by a portion of the platform engaging the thigh portion of the legs. In this embodiment the main platform 144 is provided with a pivotable section 146 at one end thereof which is designed to be moved into a generally horizontal position as shown in phantom when the remaining portion of the platform 144 has been elevated to a generally vertical position. In order to effect the adjustment of this portion of the platform, a suitable arcuate gear segment 148 is secured to the platform section 146 and suitable arcuate guide means 150 are provided being secured to platform section 144. A housing 152 containing a worm gear 154 having a crank handle 156 provided thereon is also provided whereby upon rotation of worm gear 154 the angulation of the pivoting section 146 of the platform 144 may be easily altered. It is anticipated that a user of this apparatus may require assistance in setup and use thereof. Alternatively, it should also be noted that if desired, the worm gear 154 may also be driven by a suitable small electric motor operated by switches conveniently located and accessible to the individual lying in a face down position on the platform thereby enabling him to initially raise the platform 144 a few degrees after which the pivoting section 146 of the platform 144 can be lowered to a desired angulation and thereafter the platform 144 raised to its full generally vertical position or to any desired position therebetween.
It should also be noted that inversion apparatus 142 has provided thereon suitable elongated hand grips 158 extending along on opposite sides of and below platform 144 which may provide the user thereof with a greater feeling of security should this be found desirable.
Referring now to FIGS. 16 and 17, there is shown one form by which the adjustable knee and instep support members provided on the various embodiments may be adjustably fitted to the frame members. As illustrated therein, a pair of upstanding frame members 156, 158 are positioned in generally parallel relationship to each other having both instep and knee support members 160, 162 extending therebetween. The knee and instep support members 160, 162 each have a generally cylindrically shaped hollow tube member 164 secured to opposite ends thereof which is designed to slide up and down the respective frame members 156, 158. In order to secure the hollow tube members 164 in any desired location, a generally cylindrically shaped projection 166 is provided having an internally threaded bore provided therein through which a suitable set screw 168 is designed to move into clamping engagement with the sidewall of the respective frame members 156, 158. In order to facilitate rotational movement of the set screws 168, suitable hand wheels 170 are provided on the outer ends thereof. Thus, in order to adjust the relative positioning of either the knee or instep support members, the individual need merely loosen each of the set screw members on opposite ends of the support member, slide the support member to the desired position and thereafter retighten the set screws. It should also be noted that while as illustrated in FIGS. 16 and 17, frame members 156, 158 are rigid and hence do not allow for relative angular adjustment of the instep support member 160 relative to knee support member 162, it may be desirable to provide such a feature. One way of accomplishing this objective would be to support instep support member 160 on a pair of separate spaced parallel frame members having their lower ends pivotably secured to respective tube members 164 with tube members 164 being slidably and adjustably supported on frame members 156, 158. This would thus preserve the adjustability of knee support member 162 as well as provide for the desired angular adjustment of instep support member 160.
An alternative means for securing either of the knee or instep support members in a desired position along the upstanding frame members is illustated and will be described with reference to FIGS. 18 and 19. As shown therein, the clamping arrangement comprises first and second arcuate cylindrical segments 170, 172 which are designed to surround a substantial portion of the cylindrical sidewalls of an associated frame member 174. One of these segments is secured to the terminal end portion of the knee or instep support member 176 and also has a generally radially outwardly extending flange portion 178 provided thereon to which is pivotably secured an actuating handle 180. Similarly, the other arcuate segment 172 also has a pair of spaced generally radially outwardly extending flange portions 182, 184 having a connecting link 186 pivotably secured therebetween. The opposite end of the connecting link 186 is secured to the actuating handle 180 adjacent to but spaced from the pivotable connection of the actuating handle 180 to the first flange portion 178. In this manner, a quick and easy release of the clamping mechanism may be provided by merely swinging the actuating handle 180 so as to thereby move the connecting link 186 into the position illustrated in phantom in FIG. 18 which operates to pull the arcuate clamping segment 172 out of engagement with the frame member thereby releasing the knee or instep support member for repositioning and/or removal. Once the knee or instep support member has been positioned in a desired location, the operator need merely move the actuating handle 180 in a circumferential direction so as to thereby move the arcuate flange member 172 into clamping engagement with the frame member 174 thus securing the knee or instep support in a desired location. As noted in FIG. 18, the locking position illustrated in full lines therein provides an overcenter type latching mechanism wherein the connecting link 186 bears against the arcuate flange member 170. This arrangement is particularly advantageous in that it allows for quick and easy adjustment as well as removal of the associated apparatus.
While the above described embodiments are well suited for use by individuals of a wide variety of sizes and agility, there may very well be situations where a younger individual may wish to avail themselves of the therapeutic attributes of the inversion apparatus of the present invention. Accordingly, there is illustrated in FIGS. 20 and 21 an embodiment of the present invention generally designated by number 188 which is particularly well suited for younger individuals such as for example children. As illustrated therein, the inversion apparatus 188 comprises a frame assembly comprising three sections all of which are interconnected to form a generally U or V-shaped apparatus as viewed from the side thereof. The frame assembly comprises an upper section consisting of two relatively straight elongated leg sections 190, 192 positioned in generally parallel spaced relationship and an interconnecting integrally formed portion 194 at the upper end thereof. The opposite end of the frame assembly comprises a pair of generally straight elongated members 196, 198 having a platform 200 extending therebetween, the platform 200 extending substantially over the entire length thereof. Respective ends of these relatively straight sections 190, 192, 196, 198 are connected to respective of a pair of arcuately shaped intermediate sections 202, 204. Extending between the frame members 196, 198 at one end of the platform is a knee support bar member 206 having a suitable pad fitted thereto. Also secured to opposite ends of the knee support bar are a pair of leg members 208, 210 extending generally downwardly therefrom which are designed to support the apparatus with the platform in a slightly elevated inclined position generally as shown. An instep support bar 212 also having a suitable pad member secured thereto is adjustably fitted between the leg members and may be moved to varying positions with respect to the knee support member 206 and locked in position via locking means 207 so as to accommodate different length lower leg sections of the users thereof. This version of the apparatus also incorporates means whereby the relative angulation of the instep support member 212 with respect to the knee support member 206 may be suitably adjusted. In order to accomplish this, brace members 214 are provided each having one end pivotably secured to the lower end of each of the leg members 208, 210 and an opposite end secured to the relatively straight frame section 196, 198. The brace members 214 comprises two sections 216, 218 which are designed to be telescopically interfitted with each other and includes locking means 220 for clamping the telescoping members in any desired position with respect to each other. Thus, as is readily apparent, the relative angulation of the instep support member 212 with respect to the knee support member 206 may be easily altered by merely telescoping the brace members inwardly or outwardly so as to change the overall length thereof and thus reposition legs 208, 210.
Locking means 220 are substantially identical in construction and operation to locking means 207 which, as best seen with reference to FIG. 22, comprises a generally inverted cup-shaped member 228 having a generally radially outwardly projecting annular flange portion 230 provided thereon so as to enable it to be welded or otherwise secured to hollow cylindrical member 232 which is slidably supported on leg member 208. A plunger member 234 is movably positioned within cup-shaped member having a first end 236 adapted to project axially outwardly therefrom and through an opening 238 in hollow cylinder and be received within a respective one of a plurality of longitudinally aligned spaced openings 240 provided on leg member 208. The opposite end 242 of plunger member projects outwardly through a central bore 244 provided in cup-shaped member 228 and has a diametrically extending handle member 246 secured thereto.
In order to bias plunger member 234 into a locking position such as that shown in FIG. 22, a helical coil spring 248 is provided which acts between inner surface 250 of cup-shaped member 228 and a suitable annular flange member or washer 252 suitably secured to plunger member 234 adjacent end 236.
In order to maintain locking means 207 in a released position so as to facilitate positioning of instep support bar 212, a roll pin 254 is provided secured within a diametrically extending bore 256 provided in plunger member 234 intermediate its ends. Also a diametric slot 258 is provided in the outer surface of cup-shaped member. Thus, in order to reposition instep support bar 212, it is first necessary to grasp handle 246 and pull plunger 228 outwardly out of engagement with openings 240 while simultaneously moving pin 254 out of slot 258. By turning handle member 246 slightly, pin 254 will move out of alignment with slot 258 and bear against the outer surface of cup-shaped member 228 thus maintaining the locking means in a released position. Once instep support bar 212 has been moved to its desired position, handle member 246 may be easily rotated slightly so as to move pin 254 into alignment with slot 258 whereupon spring 248 will operate to move plunger 234 into engagement with a suitably positioned opening 240 in leg member 208 and thereafter maintain locking means 207 in a locked position.
As may now be appreciated, the above described locking means 207 provides a very quick and easy means whereby the instep support bar may be very easily and conveniently repositioned yet also assure a positive secure locking arrangement which effectively and reliably locks the associated support member in the desired position. It should be noted that while locking means 207 has been described for use in conjunction with child's inversion apparatus 188 it is also well suited for use with any of the other embodiments of the present invention. Similarly, the set screw securing arrangement or clamping arrangement illustrated and described above with respect to FIGS. 16 and 17 or 18 and 19 respectively may be used in lieu of locking means 207 in any of the embodiments although locking means 207 represents the presently preferred arrangement.
In order to utilize the child version 188 of the inversion apparatus of the present invention, the individual need merely position himself in a reclining position on the platform 200 and place his legs over the knee supporting section 206 and into position with respect to the instep support member 212. Thereafter, a supervising individual may easily grasp the interconnecting upper bar portion 194 and pull backward thereby rocking the apparatus along the arcuate sections 202, 204 and moving the individual on the platform into an elevated inverted suspended position. A cross bar may be provided if desired extending between arcuate sections 202, 204 at a position to provide a suitable foot rest to aid in moving platform 200 into an elevated position.
While it will be apparent that the preferred embodiments of the invention disclosed are well calculated to provide the advantages and features above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims. | Apparatus for enabling an individual to suspend themselves in an inverted position from suitably positioned spaced parallel supports engaging the individual's legs at the back of the knee and instep so as to subject the body to a natural gravitational traction thereby relieving the spinal column from compressive forces exerted thereon is disclosed. The apparatus includes arrangements for adjusting both the distance between the instep and back of the knee supports as well as the degree of knee bend required when the user is in an inverted position. In one embodiment, the apparatus is supported in an upright position and grab bars are provided for aiding the user in positioning himself therein. In another embodiment, the apparatus is movable between a horizontal position wherein the user may easily position himself on the apparatus and a vertical position wherein the user is positioned in the desired inverted position. Another embodiment is also illustrated which is particularly well suited for use by children. | 0 |
The present invention relates to a novel lithium, boron, oxygen compound especially useful as a source of oxygen and as a carbon dioxide absorber in life support systems and to a novel method of making the compound.
BACKGROUND OF THE INVENTION
Compounds and compositions capable of evolving oxygen and absorbing carbon dioxide are presently in demand for use in closed-circuit emergency breathing devices. Such compounds are a desirable alternative to heavy, bulky air or oxygen cylinders with canisters containing caustic alkali or soda lime for carbon dioxide removal. Compounds presently employed for this use include compounds of boron, oxygen and alkaline earth metals or alkali metals, especially sodium, potassium and lithium. For example, U.S. Pat. No. 4,238,464 discloses several air revitalization compounds or compositions, containing alkali metal or alkaline earth hydroxides, peroxides, superoxides and mixtures thereof. Lithium compounds disclosed in that patent include (LiOH) 2 .LiBO 5 ; (LiOH.Li 2 O 2 ) 2 .Li 3 B 3 O 13 , and (Li 2 O 2 ) 2 .Li 2 B 2 O 8 . The compounds of that patent contain 10 to 22%, by weight, effervescent oxygen, with the lithium compounds containing 16 to 20% effervescent oxygen. The compounds also contain between 6 to 15%, by weight, of peroxide oxygen. The '464 patent also teaches that the preparation of the oxygen-generating compounds requires slow dehydration in very high vacuum at low temperatures. The major portion of the dehydration takes place at temperatures of 8° C. or lower and under an extremely high vacuum of only 3-5 microns Hg over a period of 8 to 10 days. Only after the reactions and dehydration are essentially complete is the temperature allowed to rise to 23°-25° C.
From the standpoint of commercial production the use of such high vacuums, and especially over many days, is undesirable. Furthermore, the maintenance of very low temperatures, especially in view of the exothermicity involved, over many days adds significant expense to commercial production.
There is thus a need in the art for compositions which are inexpensive, readily obtainable and stable, and have a high rate of carbon dioxide absorption and of oxygen evolution.
SUMMARY OF THE INVENTION
As one aspect of the present invention, a novel lithium, boron, oxygen compound is provided which is characterized by greater stability and greater effervescent oxygen capacity than presently available air revitalization materials. This compound is charcterized by the empirical formula: LiOH.0.5Li 2 O 2 .LiBO 5
Another aspect of the invention provides a method for making the novel compound of the invention at elevated temperatures relying on the exothermicity of the preparative reaction. Briefly described, the compound is prepared by dehydrating, at a temperature maintained at above about 30° C. to about 90° C. and at a vacuum below about 1000 microns Hg, an aqueous solution of boric acid, lithium hydroxide and hydrogen peroxide, in stoichiometric proportions to provide the above empirical formula. Dehydration continues until there remains a dry solid having a water of decomposition content of less than about 10%. This method obviates the need for an extremely high vacuum, extremely low temperatures and extended reaction times used in presently available methods for making air revitalization compounds.
These aspects and other advantages of the composition and method of the invention will become apparent from a consideration of the following detailed description and claims.
DETAILED DESCRIPTION OF THE INVENTION
The novel active oxygen-rich lithium, boron, oxygen compound of the presentinvention is characterized by the empirical formula LiOH.0.5Li 2 O 2 .LiBO 5
The compound of the present invention generates oxygen gas upon exposure towater vapor and carbon dioxide, as found in exhaled breath, and, therefore,is useful as an oxygen source and carbon dioxide absorber in self-containedrebreather devices. The compound contains 27-30%, by weight, effervescent oxygen, and is capable of generating 27 to 30% of its weight as oxygen, when it is exposed to water. Effervescent oxygen is most important for application in self-contained rebreather devices. The novel compound also contains about 10% peroxide oxygen, and will generate 35 to 40% of its weight as oxygen when exposed to water in the presence of a catalyst, suchas MnO 2 .
The compound has two oxygens having a valance greater than -2, that is -1, which provide the effervescent oxygen. These are two of the oxygens (O 2- 1 ) in the LiBO 5 , which is an extremely unstable compound and cannot be made as such. In the present product, the LiBO 5 portion of the complex is stabilized by the LiOH.0.5Li 2 O 2 .
According to the method of the invention, an aqueous solution of lithium hydroxide, boric acid and hydrogen peroxide is prepared by dissolving the lithium hydroxide, boric acid and hydrogen peroxide in water. The concentration of reactants in terms of the empirical formula for the compound may range between about 10% and about 18%, by weight. The amount of water is that necessary to dissolve the materials. Since it is ultimately removed, excessive water is not desirable. Hydrogen peroxide may be present in excess in the reaction. The mixture is maintained at a constant temperature of about 0° C., that is, from about -5 to about 5° C., to avoid decomposition of the hydrogen peroxide. If the solution is left standing for an excess of 24 hours at 0° C., Li BO 3 .H 2 O will precipitate. This compound contains 19% available oxygen as peroxide oxygen.
According to the present method the solution is then dyhydrated. The temperature of the solution is substantially instantaneously raised to a selected temperature range under a selected vacuum for a fairly short period of time. Significantly, the method employs a moderately elevated dehydration temperature which prevents the formation of an unstable hydroperoxide complex, 2LiOOH.LiOH.B(OOH) 3 from occurring during dehydration. Strenuous cooling to maintain a temperature at 8° C. or lower is not used. The temperature is controlled to a range of from above 30° C. to about 90° C., preferably from at least about50° C. to about 90° C. The temperature is maintained within that range until the stated end point is reached. This is most conveniently accomplished by spreading the solution as a layer on a warm surface adapted to control the temperature within the stated range. A warmed metal surface, preferably continuously moving, having a high thermal conductivity is preferred. The solution may be sprayed onto it or run as a sheet onto it or deployed in shallow trays on traylike indentations in the surface.
In addition, an extremely high vacuum of 3-5 microns Hg, although operable,is not required in this method. From the standpoint of commercial operation, vacuums of from about 100 to about 1000 microns Hg are suitable, with a vacuum between about 200 and about 500 microns being preferred. These are well within the capabilities of a commercial apparatus.
As the temperature of the solution rises from its cold initial stable condition to a temperature within the stated range according to this method, water is removed and the desired reaction takes place. A dry solidproduct is formed. When samples show a water of decomposition content of less than about 10%, the product is removed from the surface and cooled.
Another important aspect of the method is the relatively short length of time of preparation. The process of dehydration under the conditions of the method of the invention with formation of the desired compound as a dry solid having a water of decomposition content of less than about 10%, by weight lasts from about 1 to about 48 hours, depending upon the temperature and vacuum. In general, the higher the temperature and vacuum within the stated ranges, the shorter the time required.
The present invention will be more readily understood from a consideration of the following specific examples which are given for illustration only and are not intended to limit the scope of the invention in any way.
In these examples effervescent oxygen is measured by decomposing a sample in water alone at ambient temperature, and collecting and measuring by conventional means the volume of the evolved oxygen. The volume of oxygen measured is converted to standard temperature and pressure (STP) conditions from which the weight of oxygen evolved is calculated. Total active oxygen is measured by decomposing a dry sample in water containing MnO 2 at ambient temperature and collecting and measuring the volume of the evolved oxygen. Water of decomposition is measured by heating a sample at 550°-660° C. for approximately one-half to one hour to constant weight and collecting and weighing the evolved water by absorbing it in a trap containing magnesium perchlorate.
EXAMPLE I
A solution was prepared at 0° C. containing 15.5 g. of H 3 BO 3 , 31.5 g. LiOH.H 2 O, 90.2 g. 49% H 2 O 2 and 137.6 g.H 2 O. The solution was sprayed onto a surface maintained initially at 60° C. and a vacuum applied. The surface was maintained at 60° C. for 22 minutes, then heated to 80° C. in 6 minutes and maintained at 80° C. for 32 minutes for a total dehydration time of 1 hour. The final vacuum was 19 microns Hg. The product contained 26.9 wt. % effervescent oxygen, 31.1 wt. % of total active oxygen and 9.1 wt. % of H 2 O of decomposition.
EXAMPLE II
A solution was prepared as in Example I and placed in a tray on a heated surface which was temperature programmed as follows: The temperature was increased from 25° C. to 90° C. over 24 hours and maintainedconstant at 90° C. for 24 hours. The vacuum was controlled to maintain a minimum pressure of 200 microns Hg. The dry product was analyzed as shown in Table I below.
Example III
A solution was prepared as in Example I and vacuum dried as in Example II except that the vacuum was controlled to maintain a minimum pressure of 500 microns Hg. The dry product was analyzed as shown in Table I below.
TABLE I______________________________________ Found Example ExampleProduct Composition II III Calculated______________________________________Wt. % effervescent oxygen 27.0 27.9 22-33.6Wt. % total active oxygen 37.2 36.2 38.7Wt. % Li as Li.sub.2 O 30.35 30.31 31.0Wt. % B as B.sub.2 O.sub.3 24.28 24.34 24.1Wt. % H.sub.2 O 5.2 6.9 6.2______________________________________
The calculation of 22% of Wt. % effervescent oxygen is based upon the reaction:
20.sub.2 -1→O.sub.2 -2+O.sub.2
The calculation of 33.6% of Wt. % effervescent oxygen is based upon the reaction:
20.sub.2 -1→O.sup.-2 +1.50.sub.2
The calculations of 38.7 Wt. % total active oxygen and 6.2 Wt. % H 2 O were based upon the thermal decomposition reaction:
2[LiOH.0.5 li.sub.2 O.sub.2.LiBO.sub.5 ]+heat→2Li.sub.3 BO.sub.3 +3.50.sub.2 +H.sub.2 O
EXAMPLE IV
A carbon dioxide test was run to determine the efficacy of a tablet of the novel compound for CO 2 absorbance. Tablets were 1/4 inches in diameter and 1/8 inch in height, having a sample weight of 21.3 grams. Thetest was conducted with a gas velocity of 345 cm/min. The absorption bed had a length of 10 cm and a volume of 78 cm 3 . The input gas had a relative humidity of 100%. The nitrogen gas contained 4% by volume CO 2 . At breakthrough, CO 2 was present at 1% volume.
The results of the test are revealed in Table II.
TABLE II______________________________________CO.sub.2 Test Results (At Breakthrough)______________________________________Grams O.sub.2 generated/g. sample 0.18Grams CO.sub.2 absorbed/g. sample 0.14Vol. Ratio O.sub.2 /CO.sub.2 evolved/absorbed 1.77(Metabolic volume ratio required: 1 ± 0.03)Pressure differential across absorbentduring test, mm Hg 0Average effluent volume % O.sub.2 in nitrogen 6.2Average effluent volume % CO.sub.2 in nitrogen 0.3______________________________________
Numerous modifications and variations in practice of this invention are expected to occur to those skilled in the art upon consideration of the foregoing descriptions of preferred embodiments thereof. Such modifications are believed to be encompassed by the appended claims. | There is provided a novel active-oxygen rich lithium, boron, oxygen compound having the empirical formula
LiOH·0.5Li.sub.2 O.sub.2 ·LiBO.sub.5
and a method for making the same. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a 371 national phase application of PCT Application No. PCT/CN2014/086034, filed Sep. 5, 2014.
FIELD OF THE INVENTION
[0002] The present invention discloses a new use of a compound in the preparation of a wound healing composition. Particularly, the present invention involves a new use of a flavonoid compound in the preparation of a wound healing composition.
BACKGROUND OF THE INVENTION
[0003] Flavonoids are refer generally to a series of compounds having two benzene rings containing phenolic hydroxyl groups, mutually connected with the central three-carbon atoms, having the structure shown as the general formula:
[0000]
[0004] They are generally found in fruits, vegetables, tea, grape wine, seeds, or plant roots etc. Although they are not belonged as vitamins, they are demonstrated to have anti-oxidation functions and anti-inflammatory reaction effects, and also confirmed to have the effects of resisting or relieving the formation of tumors, relieving pain and relieving cardiovascular diseases or malaemia.
[0005] Flavonoids include flavones and flavonols. Flavones also include glycosylated flavones and non-glycosylated flavones.
[0006] U.S. Pat. No. 7,471,973 B2 issued on Oct. 29, 2002 disclose that flavonoids can be used in cosmetics but does not mention other effects. In addition, U.S. Pat. No. 6,451,837B1 issued on Sep. 17, 2002 discloses the neuroprotective effects of flavonoids.
SUMMARY OF THE INVENTION
[0007] The purpose of the present invention is to provide a new use of flavonoids in the preparation of a wound healing composition.
[0008] In one aspect, the present invention provides a method for wound healing comprising administering to a patient in need thereof a therapeutically effective amount of a compound of the structure as shown in the general formula I or an isomer thereof:
[0000]
[0000] wherein A is a hydrogen atom, R or —OH;
n 1 and n 2 are the same or different, being an integer of 0 to 4, wherein the sum of n1 and n2 is equal to or less than 4; n 3 and n 4 are the same or different, being an integer of 0 to 5, wherein the sum of n3 and n4 is at most equal to 5; wherein R, R 1 , R 2 , R 3 or R 4 is a hydrogen atom, an alkyl group having 1 to 30 carbon atoms, an acyl group having an alkyl group having 1 to 30 carbon atoms, or a hydrocarbon chain having 1 to 30 carbon atoms; or a pharmaceutically acceptable ester or salt thereof.
[0013] According to the present invention, the method is used for treating and/or healing wounds, including skin symptoms of trauma, burns and scalds and chronic wounds, and particularly diabetic wounds.
[0014] According to one example of the present invention, the compound is a flavone, particularly a non-glycosylated flavone.
[0015] According to the preferred embodiment of the present invention, the non-glycosylated flavone compound is cirsimaritin, and has the following structure:
[0000]
[0016] Those and other aspects of the present invention may be further clarified by the following descriptions and drawings of preferred embodiments. Although there may be changes or modifications therein, they would not betray the spirit and scope of the novel ideas disclosed in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which this invention belongs.
[0018] Unless clearly specified herein, meanings of the articles “a,” “an,” and “said” all include the plural form of “more than one.” Therefore, for example, when the term “a component” is used, it includes multiple said components and equivalents known to those of common knowledge in said field.
[0019] The present invention provides a method for wound healing comprising administering to a patient in need thereof a therapeutically effective amount of a compound of the structure as shown in the general formula I or an isomer thereof:
[0000]
[0000] wherein A is a hydrogen atom, R or —OH;
n 1 and n 2 are the same or different, being an integer of 0 to 4, wherein the sum of n 1 and n 2 is equal to or less than 4; n 3 and n 4 are the same or different, being an integer of 0 to 5, wherein the sum of n3 and n4 is at most equal to 5; wherein R, R 1 , R 2 , R 3 or R 4 is a hydrogen atom, an alkyl group having 1 to 30 carbon atoms, an acyl group having an alkyl group having 1 to 30 carbon atoms, or a hydrocarbon chain having 1 to 30 carbon atoms; or a pharmaceutically acceptable ester or salt thereof.
[0024] According to the present invention, the compound is a flavone, particularly a non-glycosylated flavone. The non-glycosylated flavone is cirsimaritin, and has the following structure:
[0000]
[0025] According to the invention, the composition of the present invention comprises a pharmaceutically acceptable carrier.
[0026] According to the invention, the pharmaceutically acceptable carrier comprises an appropriate excipient and is prepared as an external medicament form, a cosmetic form or pharmaceutical form.
[0027] According to the invention, the composition further comprises a therapeutic agent, for example, other anti-inflammatory agents, antibacterial agents or other therapeutic agents.
[0028] As used herein, the term “skin symptoms” includes wounds or sores, including skin injuries such as incised injuries, lacerated injuries, stabbing injuries, wear injuries, etc. in skin. According to the present invention, the compounds show the effects in healing wounds for skin symptoms of trauma, burns and scalds and chronic wounds. In particular, the method of the invention in effective in treating diabetic wounds, for example, chronic wounds of diabetic present patients.
[0029] As used herein, the term “treatment” includes the meaning of “treating” or “promoting” which means improving symptoms.
[0030] As used herein, the term “patient” encompasses humans, and animals, particularly mammals.
[0031] As used herein, the term “pharmaceutically acceptable carrier” refers to a diluent, excipient or the like as used in a commonly used technique for the preparation of a pharmaceutical composition. According to the present invention, a medicament form, a cosmetic form, or a pharmaceutical material form can be made. According to the present invention, a form for local application can be made for example, in the form of a spray. Spray forms include a spray agent and a liquid agent; or in a semi-solid form or a solid form, preferably a solid form with dynamic viscosity greater than that of water. Appropriate formulations include, but are not limited to, suspension, emulsion, cream, ointment, liniment, etc. Preferably, it is in the form of an ointment. The pharmaceutical composition of the present invention, no matter what form it is, can further include emollient, fragrances or pigments to improve their acceptability for various uses.
[0032] As used herein, the term “therapeutically effective amount” refers to a dosage that can effectively treat injuries for treatment of symptoms. The appropriate dosage can be used based on the needs of patients or wounds and according to technologies and clinical knowledge commonly used in pharmaceutics, and adjusted according to the manners and treatment conditions of the application, including age, body weight, symptoms, treatment effects, application modes and treatment time.
[0033] The present invention is illustrated in the above description of the invention and the following examples, which are not intended for limiting the scope of the present invention.
EXAMPLE 1
Establishment of Animal Testing Mode
[0034] After rats' body weight reach 300 g, the induction of hyperglycemia was carried out with streptozotocin (STZ) (65 mg/kg, ip administration). Choosing animals with successfully induced hyperglycemia (300 mg/DL), the hyperglycemic animals were subjected to diabetic wound healing tests two months after the onset of hyperglycemic symptoms. Hyperglycemic animals with a body weight less than 300 g were excluded, and random grouping was performed. Animals were anesthetized with pentobarbital and then their backs were shaved and disinfected. Three pieces of animal skin (full thickness) were harvested from the back of the animals at points 4, 6 and 8 cm from the midpoint of the two scapula with an 1- cm-diameter drilling round knife.
[0035] Wounds of each animal were applied with testing agents. New skins were harvested for examination after the end of experiment.
[0036] Analyzing the areas of the three wounds on the back of each rat by image pro with the area on day zero as the original wound area. The original wound area is subtracted by the wound area at each time point and then divided by the original wound area to serve as the percentage of wound healing. The average value of the three percentages of wound healing of each rat is considered as the respective would healing extent of each rat. The number of rats was 6 for each group of each test. Data is expressed as mean±SEM. P value is calculated for the test results by t-test against control group, where P<0.05 indicates significant differences, denoted *.
[0037] A 0.5% cirsimaritin composition was prepared in an ointment form, and was applied to the rats as treated above. The results are as follows. The comparison between the percentages of wound healing at 9, 11, 13, and 15 days after administration, and the untreated control group is shown below. There were significant differences for each group. The wound half-closure time (CT50 value) was further calculated and also shows significant differences.
[0000]
Days after administration (%)
9
11
13
15
CT50
Control group
20.4 ± 4.1
35.0 ± 2.8
56.1 ± 2.8
67.7 ± 3.1
13.3 ± 0.4
cirsimaritin
37.2 ± 3.9*
51.5 ± 3.1*
70.6 ± 3.5*
83.3 ± 3.2*
10.7 ± 0.4*
(0.5%)
%: percentage of wound healing
CT50: wound half-closure time
*p < 0.05
Number of animals: n = 6
[0038] It is can be concluded from the results that the compounds of the present invention (taking cirsimaritin as an example) have the effects in healing of chronic wounds of diabetic patients. | Disclosed is a method for wound healing comprising administering a subject in need thereof a therapeutically effective amount of a flavonoid compound, wherein the compound is preferably nonglycosylated flavone. Specifically, the present invention can be used for treating skin symptoms of a trauma, a burn, a scald and a chronic wound, and can be particularly used for healing a wound of a diabetes patient. | 0 |
This application is a divisional application of U.S. application Ser. No. 11/893,264, filed Aug. 15, 2007 (of which the entire disclosure of prior application is hereby incorporated by reference), now abandoned, which in turn, is a continuation application of application Ser. No. 10/286,107, filed Oct. 31, 2002, now U.S. Pat. No. 7,318,842.
FIELD OF THE INVENTION
Background of the Invention
Synthetic fibers fabricated primarily from polyamide, polyester, vinylon, polyolefin, etc. are now used as industrial synthetic fibers for fishery, agricultural, and construction uses, because improved tenacity and weatherproof are demanded in such applications. For lack of self-degradability, however, such synthetic fibers, if left undisposed at hills and fields and in the sea after use, offer problems that not only are they detrimental to landscapes, but also they cling to birds, oceanic life, divers or the like, killing them or to marine engines, leading to shipwrecks. These problems may be solved if used-up synthetic fibers are disposed by incineration, landfilling or regeneration; however, they are still left undisposed at hills and fields or in the sea because much labor and cost are taken for such disposals. To provide a solution to those problems, the use of synthetic fibers fabricated from biodegradable polymers is now taken up for consideration, and so a variety of biodegradable synthetic fibers are under development. In particular, efforts are focused on making fibriform lactic acid polymers because they are biodegradable polymers from which articles having practical mechanical properties and heat resistance can be formed at relatively low costs. The present invention relates to improvements in an agent and method for treating biodegradable synthetic yarns fabricated from lactic acid polymers.
For agents for treating biodegradable synthetic yarns fabricated from lactic acid polymers, there have so far been proposed (1) an agent comprising water, ethylene glycol, polyethylene glycol, silicone oil, etc. (JP-A's 10-110332 and 2000-154425), (2) an agent in which mineral oil lubricants are used as a lubricant (JP-A 2000-192370), and (3) an agent comprising an anionic surfactant such as potassium laurylphosphate, an cationic surfactant such as a quaternary ammonium salt, a nonionic surfactant such as an aliphatic higher alcohol and a higher fatty acid ethylene oxide adduct, a polyalkylene glycol such as polyethylene glycol, block copolymer of polyethylene glycol and polypropylene glycol, and a silicone oil such as dimethylsiloxane, polyether-modified silicone oil and higher alcohol-modified silicone (JP-A's 7-118922 and 7-126970). However, problems with those prior art agents are that they cannot impart any sufficient lubricity, cohesion or the like to biodegradable synthetic yarns fabricated from lactic acid polymers, and so fuzzing and yarn breakage are often found at every step from spinning to down-stream step, especially at a false twisting step. These factors, combined with poor bulkiness, then interact one another, resulting in a failure in producing yarns having satisfactory mechanical properties in a stable fashion.
An object of the present invention is to provide an agent and method for treating biodegradable synthetic yarns fabricated from a polymer comprising lactic acid as a main component (hereinafter called the lactic acid polymer), which enable improved lubricity, cohesion, etc. to be so imparted to the biodegradable synthetic yarns that the yarns can be prevented from fuzzing and breaking at every step from spinning to down-stream step, especially at a false twisting step and improved in terms of bulkiness, providing yarns having improved mechanical properties in a stable manner.
The inventors have now found that for treating biodegradable synthetic yarns fabricated from the lactic acid polymer it is reasonably preferable to use an agent comprising a specific functional agent at a given proportion and having a friction coefficient in a predetermined range.
SUMMARY OF THE INVENTION
Thus, the present invention provides an agent for treating biodegradable synthetic yarns produced from the lactic acid polymer, characterized by comprising 0.1 to 30% by weight of the following functional agent and a lubricant and a surfactant in a total amount of 70 weight % or greater and having the following friction coefficient in the range of 0.04 to 0.35. The present invention also provides a method for treating biodegradable synthetic yarns produced from the lactic acid polymer, characterized in that such an agent for treating biodegradable synthetic yarns is provided in an aqueous solution form, and the yarns are then applied with that aqueous solution in an amount of 0.1 to 3 weight % as calculated on the basis of said agent.
The functional agent comprises one or more compounds selected from the following polyether compound having an average molecular weight of 3,000 to 20,000, the following polyether polyester compound having an average molecular weight of 3,000 to 50,000 and a polyolefin wax having an average molecular weight of 1,000 to 10,000, wherein:
said polyether compound is represented by formula 1
(A−B) n T (formula 1)
where A is a hydrogen atom, a monovalent hydrocarbon group or an acyl group, B is residual group obtained by removing hydrogen atoms in all hydroxyl groups from polyoxyalkylene glycol containing a polyoxyalkylene group of which the oxyalkylene unit have 2 to 4 carbon atoms, T is a monovalent to tetravalent hydrocarbon group or a hydrogen atom, and n is an integer of 1 to 4 when T is a monovalent to tetravalent hydrocarbon group and 1 when T is a hydrogen atom, and
said polyether polyester compound comprises one or more compounds selected from a polyether polyester compound obtained by the polycondensation of the following component D and the following component E and a polyether polyester compounds obtained by the polycondensation of the following component D, the following component E and the following component F, wherein:
said component D comprises one or more compounds selected from an aliphatic dicarboxylic acid having 4 to 22 carbon atoms, an ester-forming derivative of said aliphatic dicarboxylic acid, an aromatic dicarboxylic acid and an ester-forming derivative of said aromatic dicarboxylic acid,
said component E comprises one or more compounds selected from a polyoxyalkylene monol, a polyoxyalkylene diol and a polyoxyalkylene triol, each containing a polyoxyalkylene group having as a constitutional unit an oxyalkylene unit having 2 to 4 carbon atoms, and
said component F comprises an alkylene diol having 2 to 6 carbon atoms.
The friction coefficient of the agent is defined by a value as found in a 25° C. atmosphere having a relative humidity of 65% under a counter weight condition of 40 g/80 g, using a pendulum type oiliness friction tester.
ADVANTAGES OF THE INVENTION
As can already by understood from the foregoing and the specification and claims which follow, the advantages of the present invention are that improved lubricity, cohesion, etc. are so imparted to the biodegradable synthetic yarns fabricated from the lactic acid polymer that the yarns can be prevented from fuzzing and breaking at every step from spinning to down-stream step, especially at a false twisting step and improved in terms of bulkiness, providing yarns having improved mechanical properties in a stable matter.
It is therefore an object of the invention is to provide an agent and method for treating biodegradable synthetic yarns fabricated from a polymer comprising lactic acid as a main component.
It is an additional object of the invention to provide such an agent and method which enable improved lubricity, cohesion, etc. to be so imparted to the biodegradable synthetic yarns and that the yarns can be prevented from fuzzing and breaking at every step from spinning to down-stream step, especially at a false twisting step.
It is a further object of this invention to provide improved yarns so treated in terms of bulkiness, providing yarns having improved mechanical properties in a stable manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention, and together with the description serve to explain the principles of this invention.
FIG. 1 depicts Table 1. showing the compositions, etc. of the agents for treating biodegradable synthetic yarns according to the specification.
FIG. 2 depicts Table 2 which shows the results of various testing of the embodiments of the device and method herein disclosed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The functional agent used with the agent for treating biodegradable synthetic yarns according to the present invention comprises (1) a polyether compound having an average molecular weight of 3,000 to 20,000 and represented by formula 1, (2) a polyether polyester compound having an average molecular weight of 3,000 to 50,000, which is obtained by the polycondensation of the components D and E, (3) a polyether polyester compound having an average molecular weight of 3,000 to 50,000, which is obtained by the polycondensation of the components D, E and F, and (4) a polyolefin wax having an average molecular weight of 1,000 to 10,000.
The polyether compound used as the functional agent and represented by formula 1 includes (1) a polyether compound wherein all A's in formula 1 are hydrogen atoms (hereinafter called the polyether compound (a)), (2) a polyether compound wherein some of A's in formula 1 are hydrogen atoms with the rest being monovalent hydrocarbon groups (hereinafter called the polyether compound (b)), (3) a polyether compound wherein all A's in formula 1 are monovalent hydrocarbon groups (hereinafter called the polyether compound (c)), (4) a polyether compound wherein some of A's in formula 1 are hydrogen atom with the rest being acyl groups (hereinafter called the polyether compound (d)), (5) a polyether compound wherein all A's in formula 1 are acyl groups (hereinafter called the polyether compound (e)), (6) a polyether compound wherein some of A's in formula 1 are hydrogen atoms with the rest being monovalent hydrocarbon and acyl groups (hereinafter called the polyether compound (f)), and (7) a polyether compound wherein some of A's in formula 1 are monovalent hydrocarbon groups with the rest being acyl groups (hereinafter called the polyether compound (g)).
The polyether compounds (a) through (g) may all be synthesized by methods known in the art. For instance, the polyether compound (a) may be synthesized by the successive addition of an alkylene oxide having 2 to 4 carbon atoms to the monovalent to tetravalent hydroxy compound having a hydrocarbon group, which corresponds to T in formula 1. The polyether compounds (b) and (c) may each be synthesized by hindering the whole or a part of terminal hydroxyl groups in the polyether compound (a) with the hydrocarbon groups corresponding to A in formula 1 by means of etherification. The polyether compounds (d) and (e) may each be synthesized by hindering the whole or a part of terminal hydroxyl groups in the polyether compound (a) with the acyl groups corresponding to A in formula 1 by means of acylation. The polyether compounds (f) and (g) may each be synthesized by hindering the whole or a part of terminal hydroxyl groups in the polyether compound (a) with the hydrocarbon groups corresponding to A in formula 1 by means of etherification and with the acyl groups corresponding to A in formula 1 by means of acylation.
The monovalent to tetravalent hydroxy compounds used for the synthesis of polyether compound (a) include (1) monovalent, aliphatic hydroxy compounds having 1 to 40 carbon atoms such as methyl alcohol, butyl alcohol, octyl alcohol, lauryl alcohol, stearyl alcohol, ceryl alcohol, isobutyl alcohol, 2-ethylhexyl alcohol, isododecyl alcohol, isohexadecyl alcohol, isostearyl alcohol, isotetracosanyl alcohol, 2-propanol, 2-hexanol, 12-eicosanol, vinyl alcohol, butenyl alcohol, hexadecenyl alcohol, oleyl alcohol, eicosenyl alcohol, 2-methyl-2-propylene-1-ol, 6-ethyl-2-undecen-1-ol, 2-octen-5-ol and 15-hexadecen-2-ol; (2) monovalent hydroxy compounds having an aromatic ring such as phenol, propylphenol, octylphenol and tridecylphenol; and (3) divalent to tetravalent, aliphatic hydroxy compounds such as ethylene glycol, propylene glycol, butanediol, hexanediol, neopentyl glycol, glycerin, trimethylolpropane and pentaerythritol. Among these, monovalent, aliphatic hydroxy compounds having 1 to 6 carbon atoms and divalent, aliphatic hydroxy compounds having 2 to 4 carbon atoms are preferred, although particular preference is given to propyl alcohol, butyl alcohol, ethylene glycol, propylene glycol and trimethylolpropane.
The alkylene oxides having 2 to 4 carbon atoms used for the synthesis of polyether compound (a), for instance, include ethylene oxide, propylene oxide, 1,2-butylene oxide and 1,4-butylene oxide, which may be used alone or in admixture. When the alkylene oxides are used in admixture, they may be added to the hydroxy compound in random addition, block addition, and block•random addition forms.
In the polyether compounds (b) and (c), the monovalent hydrocarbon group corresponding to A in formula 1, for instance, includes (1) monovalent, aliphatic hydrocarbon groups having 1 to 8 carbon atoms such as methyl, ethyl, propyl, butyl, octyl, vinyl, butenyl and hexadecenyl groups and (2) monovalent hydrocarbon groups having an aromatic ring such as phenoxy, propylphenoxy, octylphenoxy and benzyl groups; however, preference is given to methyl groups. Known processes may be applied to the synthesis of such polyether compounds (b) and (c). For instance, use may be made of a process wherein an alkyl halide reacts with a metal complex salt of the polyether compound (a).
In the polyether compounds (d) and (e), the acyl group corresponding to A in formula 1, for instance, includes (1) aliphatic acyl groups having 2 to 22 carbon atoms such as acetyl, propanoyl, butanoyl, hexnoyl, heptanoyl, oxtanoyl, nonanoyl, decanoyl, hexadecanoyl, octadecanoyl, hexadecenoyl, eicosenoyl and octadecenoyl groups and (2) acyl groups having an aromatic ring such as benzoyl, toluoyl and naphthoyl groups, among which decanoyl and octadecenoyl groups are preferred. Known processes may be applied to the synthesis of such polyether compounds (d) and (e). For instance, use may be made of a process wherein an acyl halide reacts with a metal complex salt of the polyether compound (a).
For the hydrocarbon group corresponding to A in formula 1 in the polyether compounds (f) and (g), the same as referred to in conjunction with the polyether compounds (b) and (c) may hold true, and for the acyl group corresponding to A in formula 1, the same as referred to in conjunction with the polyether compounds (d) and (e) may go true. Known processes may be applied to the synthesis of such poylyether compounds (f) and (g). For instance, use may be made of processes wherein an alkyl halide reacts with a metal complex salt of the polyether compound (a) and an acyl halide reacts with the resulting reaction product.
All the polyether compounds as mentioned above and represented by formula 1 have an average molecular weight of 3,000 to 20,000, and preferably 3,500 to 18,000.
The polyether polyester compound used as the functional agent includes (1) a polyether polyester compound obtained by the polycondensation of component (D) and component (E), and (2) a polyether polyester compound obtained by the polycondensation of component (D), component (F) and component (F).
The component (D) used for the synthesis of the polyether polyester compound, for instance, includes (1) aliphatic dicarboxylic acids having 4 to 22 carbon atoms such as succinic acid, adipic acid, azelaic acid, sebacic acid, α,ω-dodecane dicarboxylic acid, dodecenylsuccinic acid, octadecenyl dicarboxylic acid and cyclohexane dicarboxylic acid, (2) aromatic dicarboxylic acids such as phthalic acid, isophthalic acid, terephthalic acid, 5-sulfoisophthalic acid, 2,6-naphthalene dicarboxylic acid, 2,3-naphthalene dicarboxylic acid and 1,4-naphthalene dicarboxylic acid, (3) ester-forming derivatives of said (1) such as dimethyl succinate, dimethyl adipate, dimethyl azelate and dimethyl sebacate, and (4) ester-forming derivatives of said (2) such as dimethyl phthalate, dimethyl isophthalate, dimethyl terephthalate, 5-sulfoisophthalic acid dimethyl ester salt, 2,6-bis(methoxycarbonyl)-naphtalene,2,6-bis(ethoxycarbonyl)-naphthalene and 1,4-bis(methoxycarbonyl)-naphthalene. Among these, preference is given to the aliphatic dicarboxylic acids having 6 to 12 carbon atoms, e.g., adipic acid, azelaic acid and sebacic acid, the aromatic dicarboxylic acid, e.g., phthalic acid, terephthalic acid and 5-sulfoisophthalic acid dimethyl ester salt, and the ester-forming derivatives thereof. Such organic dicarboxylic acids and ester-forming derivaties thereof, when used for polycondensation, may be used alone or in combination of two or more.
The component (E) used for polyether polyester synthesis contains polyoxyalkylene monols, polyoxyalkylene diols and polyoxyalkylene trials or any desired mixtures thereof, wherein an oxyalkylene unit having 2 to 4 carbon atoms is used as the constitutional unit.
The polyoxyalkylene monols, for instance, include those wherein one terminals of such polyoxyalkylene diols as mentioned below are hindered by monovalent hydrocarbon groups. Such monovalent hydrocarbon groups, for instance, include (1) aliphatic hydrocarbon groups having 1 to 22 carbon atoms, e.g., methyl, ethyl, butyl, n-octyl, lauryl, stearyl, isopropyl and 2-ethylhexyl groups and (2) hydrocarbon groups having an aromatic ring, e.g., phenyl, monobutylphenyl, octylphenyl and nonylphenyl groups, among which the phenyl group is preferred.
The polyoxyalkylene diols, for instance, include reaction products obtained by the addition of an alkylene oxide having 2 to 4 carbon atoms to alkylene diols having 2 to 6 carbon atoms, e.g., ethylene glycol, 1,2-propane-diol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol and neopentyl glycol. Preference is given to polyoxyalkylene diols having an average molecular weight of 500 to 5,000, and particular preference is given to polyoxyalkylene dials having such an average molecular weight, wherein the oxyalkylene unit comprises an oxyethylene unit or an oxyethylene unit and an oxypropylene unit and the oxyethylene unit/oxypropylene unit proportion is in the range of 100/0 to 50/50 (mold %).
The polyoxylalkylene triols include reaction products obtained by the addition of an alkylene oxide having 2 to 4 carbon atoms to an alkylene dial having 2 to 6 carbon atoms, e.g., glycerol and trimethylolpropane. Preference is given to polyoxyalkylene triols having an average molecular weight of 500 to 5,000, and particular preference is given to polyoxyalkylene dials having such an average molecular weight, wherein the oxyalkylene unit comprises an oxyethylene unit or an oxyethylene unit and an oxypropylene unit and the oxyethylene unit/oxypropylene unit proportion is in the range of 100/0 to 50/50 (mol %).
The component (F) used for polyether polyester synthesis includes an alkylene diol having 2 to 6 carbon atoms, e.g., ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol and neopenthyl glycol, among which ethylene glycol, 1,2-propanediol and 1,3-propanediol are preferred.
When the polyether polyester compound used as the functional agent is a reaction product obtained by the polycondensation of component (D) and component (E), it should preferably contain a constitutional unit formed from component (D) at a proportion of 40 to 60 mol %, preferably 48 to 52 mol %, and a constitutional unit formed from component (E) at a proportion of 40 to 60 mol %, preferably 48 to 52 mol %. When that polyether polyester compound is a reaction product obtained by the polycondensation of component (D), component (E) and component (F), it should preferably contain a constitutional unit formed from component (D) at a proportion of 20 to 40 mol %, preferably 20 to 25 mol %, a constitutional unit formed from component (E) at a proportion of 5 to 30 mol %, preferably 15 to 20 mol %, and a constitutional unit formed from component (F) at a proportion of 40 to 70 mol %, preferably 50 to 60 mol %.
Known processes may be applied to the synthesis of the polyether polyester compound used as the functional agent. For instance, reliance is on a direct poly-condensation process wherein an organic dicarboxylic acid that is component (D), a polyoxylalkylene diol that is component (E) and an alkylene diol that is component (F) are subjected to polycondensation in the presence of an anionic polymerization catalyst, a cationic polymerization catalyst, a coordination anionic polymerization catalyst or the like known in the art and under high-temperature, high-vacuum conditions while low-molecular-weight compounds are distilled off, thereby obtaining a polyether polyester compound.
Referring to the polyether polyester compounds as explained above, both the polyether polyester compound obtained from component (D) and component (E) and the polyether polyester compound obtained from component (D), component (E) and component (F) should have an average molecular weight of 3,000 to 50,000, and preferably 3,500 to 40,000.
The polyolefin wax used as the functional agent, for instance, includes oxidized polyethylene wax and copolymers of α-olefin and unsaturated fatty acids. The α-olefin used for the synthesis of such copolymers, for instance, includes ethylene, 1 propylene, 1 butene, 1 decene, 1 dodecene and 1 octadodecene. The unsaturated fatty acids, for instance, include acrylic acid, methacrylic acid, 4-pentenoic acid and 5-hexenoic acid. Preferable polyolefin waxes are oxidized polyethylene wax, and copolymers of ethylene and/or 1 propylene and acrylic acid and/or methacrylic acid. The waxes used should all have an average molecular weight of 1,000 to 10,000.
In the agent for treating biodegradable synthetic yarns according to the present invention, one or two or more compounds selected from such polyether compounds, polyether polyester compounds and polyolefin waxes as explained above is or are used as the functional agent or agents. However, it is preferable to use one or two or more compounds selected from the polyether compounds having an average molecular weight of 3,500 to 18,000 and the polyether polyester compounds having an average molecular weight of 3,500 to 40,000.
The agent for treating biodegradable synthetic yarns according to the present invention contains, in addition to the functional agent as explained above, a lubricant and a surfactant. For such a lubricant, lubricants that are known per se, for instance, aliphatic esters, polyether compounds and mineral oils or any desired mixtures thereof may be used.
The aliphatic ester used as the lubricant is obtained by the esterification of an aliphatic alcohol and a fatty acid, wherein carbon atoms of a hydrocarbon group in the aliphatic alcohol moiety and carbon atoms of a hydrocarbon group in the fatty acid moiety preferably adds up to 17 to 60, and more preferably 22 to 36. The aliphatic alcohols used for the synthesis of such aliphatic esters, for instance, include (1) aliphatic monohydric alcohols such as methyl alcohol, ethyl alcohol, butyl alcohol, 2-ethylhexyl alcohol, lauryl alcohol, palmityl alcohol, palmitoleyl alcohol, stearyl alcohol, isostearyl alcohol, oleyl alcohol and behenyl alcohol and (2) aliphatic polyhydric alcohols such as ethylene glycol, propylene glycol, butanediol, hexanediol, glycerol, trimethylolpropane, sorbitol and pentaerythritol. The fatty acids, for instance, include (1) saturated aliphatic monocarboxylic acids such as acetic acid, butyric acid, caproic acid, caprylic acid, capric acid, undecanoic acid, lauric acid, tridecanoic acid, myristic acid, pentadecanoic acid, palmitic acid, stearic acid, nonadecanoic acid, arachic acid, behenic acid, cerotic acid, montanic acid and mellisic acid, (2) aliphatic monoenoic monocarboxylic acids such as linderic acid, palmitoleic acid, oleic acid, elaidic acid and vaccenic acid, (3) aliphatic nonconjugated polyenoic monocarboxylic acids such as linolic acid, linoleic acid and arachidonic acid, and (4) aliphatic dicarboxylic acids such as succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid and sebacic acid. More specifically, fatty acid esters obtained from aliphatic monohydric alcohols and aliphatic monocarboxylic acids, for instance, include lauryl oleate, stearyl oleate, oleyl oleate, octyl oleate, tridecyl oleate, methyl oleate, butyl oleate, 2-ethylhexyl oleate, octyl stearate, oleyl stearate, oleyl palmitate, oleyl laurate, oleyl isostearate and oleyl octanate, with lauryl oleate and octyl stearate being preferred. Exemplary fatty acid esters obtained from aliphatic polyhydric alcohols and aliphatic monocarboxylic acids are ethylene glycol dilaurate, propylene glycol distearate, butanediol palmitate, hexanediol dilaurate, glycerol tri(12-hydroxystearate), glycerol trioleate, glycerol palmitate distearate, trimethylolpropane tripalmitate, sorbitan tetraoleate and pentaerythritol tetralaurate, with glycerol tri(12-hydroxystearate) and soribtan tetraoleate being preferred. Exemplary fatty acid esters obtained from aliphatic monohydric alcohols and aliphatic dicarboxylic acids are distearyl succinate, distearyl glutarate, dicetyl adipate, dibehenyl pimelate, dibehenyl suberate, disteary azelate and distearyl sebacate, with dicetyl adipate being preferred.
Preferable for the polyether compound used as the lubricant are those represented by the aforesaid formula 1 and having an average molecular weight in the range of 700 to 2,900.
The mineral oil used as the lubricant should have a viscosity at 30° C. of preferably 2×10 −6 to 2×10 −4 m 2 /s, and more preferably 2×10 −6 to 2×10 −5 m 2 /s. The more preferable mineral oil is a liquid paraffin oil.
The surfactant used may be those that are known per se, e.g., nonionic surfactants, anionic surfactants, cationic surfactants and amphoteric surfactants or any desired mixtures thereof.
The nonionic surfactants used, for instance, include (1) oxyalkylene adducts of aliphatic monohydric alcohols having 6 to 22 carbon atoms, (2) fatty acid esters of oxyalkylene adducts of aliphatic monohydric alcohols having 6 to 22 carbon atoms, (3) fatty acid esters of aliphatic polyhdric alcohols having 2 to 6 carbon atoms, (4) fatty acid esters of oxyalkylene adducts of aliphatic polyhydric alcohols having 2 to 6 carbon atoms, (5) oxyalkylene adducts of aliphatic amines having 6 to 22 carbon atoms, and (6) oxyalkylene adducts of aliphatic amides having 6 to 22 carbon atoms.
Referring to the oxyalkylene adducts of the aliphatic monohydric alcohols having 6 to 22 carbon atoms, used as the nonionic surfactant, the aliphatic monohydric alcohols having 6 to 22 carbon atoms, used as the synthesis material for the same, include hexyl alcohol, octyl alcohol, nonyl alcohol, decyl alcohol, undecyl alcohol, dodecyl alcohol, tridecyl alcohol, tetradecyl alcohol, pentadecyl alcohol, hexadecyl alcohol, hexadecenyl alcohol, heptadecyl alcohol, octadecyl alcohol, octadecenyl alcohol, nonadecyl alcohol, eicosyl alcohol, eicosenyl alcohol, docosayl alcohol, 2-ethylhexyl alcohol, 3,5,5-trimethylhexyl alcohol, etc. Among these, aliphatic monohydric alcohols having 8 to 18 carbon atoms are preferred, although 2-ethylhexyl alcohol and dodecyl alcohol are particularly preferred. Oxyalkylene adducts of such aliphatic monohydric alcohols having 6 to 22 carbon atoms, for instance, include oxyethylene adducts, oxypropylene adducts and oxyethylene-oxypropylene adducts as well as any desired mixtures thereof; however, preference is given to oxyalkylene adducts wherein oxylalkylenes are added at a proportion of 3 to 30 moles per mole of the aliphatic monohydric alcohol having 6 to 22 carbon atoms.
Referring to the fatty acid esters of oxyalkylene adducts of the aliphatic monohydric alcohols having 6 to 22 carbon atoms, used as the nonionic surfactant, the same as explained previously holds for the oxyalkylene adducts of aliphatic monohydric alcohols having 6 to 22 carbon atoms, used as the synthesis material for one of the same. In this case, however, it is preferable to add the oxyalkylene at a proportion of 1 to 10 moles per mole of the aliphatic monohydric alcohol having 6 to 22 carbon atoms. The fatty acid used as another synthesis material, for instance, includes (1) saturated aliphatic monocarboxylic acids having 2 to 22 carbon atoms such as acetic acid, butyric acid, caproic acid, caprylic acid, capric acid, undecanoic acid, lauric acid, tridecanoic acid, myristic acid, pentadecanoic acid, palmitic acid, stearic acid, nonadecanoic acid, arachic acid, behenic acid, cerotic acid, montanic acid and mellisic acid, (2) aliphatic monoenemonocarboxylic acids such as linderic acid, palmitoleic acid, oleic acid, elaidic acid and vaccenic acid, (3) aliphatic nonconjugated polyenoic acids having 18 to 22 carbon atoms such as linolic acid, linoleic acid and arachidonic acid, and (4) aliphatic dicarboxylic acids such as succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid and sebacic acid.
Referring to fatty acid esters of aliphatic polyhydric alcohols having 2 to 6 carbon atoms, used as the nonionic surfactant, the aliphatic polyhydric alcohols having 2 to 6 carbon atoms, used as the synthesis material for one of the same, for instance, include ethylene glycol, propylene glycol, butanediol, hexanediol, glycerol, trimethylolpropane, sorbitol and pentaerythritol. The same as explained previously goes true for the fatty acids used as another synthesis material. Exemplary fatty acid partial esters of such polyhydric alcohols are ethylene glycol monolaurate, propylene glycol monostearate, butanediol monopalmitate, hexanediol monolaurate, glycerol di(12-hydroxystearate), glycerol dioleate, glycerol monopalmitate monostearate, trimethylolpropane dipalmitate, sorbitan monooleate and pentaerythritol dilaurate, with glycerol di(12-hydroxystearate) and sorbitan monooleate being preferred.
Referring to the fatty acid esters of oxyalkylene adducts of the aliphatic polyhydric alcohols having 2 to 6 carbon atoms, used as the nonionic surfactant, the same as set forth previously holds true for the aliphatic polyhydric alcohols having 2 to 6 carbon atoms, used as the synthesis material for one of the same. Such oxyalkylene adducts of the aliphatic polyhydric alcohols having 2 to 6 carbon atoms, for instance, include oxyethylene adducts, oxypropylene adducts and oxyethylene-oxypropylene adducts or any desired mixtures thereof. However, it is preferable to use adducts wherein the oxyalkylene is added at a proportion of 3 to 40 moles per mole of the aliphatic polyhydric alcohol having 2 to 6 carbon atoms. The same as mentioned previously goes true for the fatty acids used as another synthesis material. Examples of such fatty acid esters of oxyalkylene adducts of the aliphatic polyhydric alcohols having 2 to 6 carbon atoms are polyoxyethylene glycol dilaurate, polyoxypropylene glycol distearate, 1,4-di(polyoxyethylene)butanediol palmitate, 1,6-di(polyoxyethylene-polyoxypropylene)hexanediol dilaurate, and 1,2,3-tri(polyoxyethylene)glycerol tri(12-hydroxystearate), although polyoxyethylene glycol dilaurate and 1,2,3-tri(polyoxyethylene)glycerol tri(12-hydroxystearate) are preferred.
Referring to the oxyalkylene adducts of aliphatic amines having 6 to 22 carbon atoms, used as the nonionic surfactant, the aliphatic amines having 6 to 22 carbon atoms, used as the synthesis material for the same, include (1) saturated aliphatic amines such as hexylamine, octylamine, nonylamine, laurylamine, myristylamine, cetylamine, stearylamine and arachinylamine, (2) unsaturated aliphatic amines scuh as 2-tetradecenylamine, 2-pentadecenylamine, 2-octadecenylamine, 15-hexadecenylamine, oleylamine, linolenylamine and eleostearylamine, and so on, among which laurylamine, palmitylamine and stearylamine are preferred. Such oxyalkylene adducts of the aliphatic amines having 6 to 22 carbon atoms, for instance, include oxyethylene adducts, oxypropylene adducts and oxyethylene-oxypropylene adducts or any desired mixtures thereof. However, it is preferable to use adducts wherein the oxyalkylene is added at a proportion of 2 to 20 moles per mole of the aliphatic amines having 6 to 22 carbon atoms.
Referring to the oxyalkylene adducts of aliphatic amide compounds having 6 to 22 carbon atoms, used as nonionic surfactant, the aliphatic amide compounds having 6 to 22 carbon atoms, used as the synthesis material for the same, includes those obtained by the amidation of polyalkylene polyamines and fatty acids. In such amidation, the proportion of fatty acids to the polyalkylene polyamines should be such that at least one of terminal amino groups of polyalkylene polyamine has to be amidated; however, that proportion should preferably be such that amino groups at both terminals of polyalkylene polyamine be amidated. The polyalkylene polyamines that form such fatty acid amides, for instance, include diethylenetriamine, triethylenetetramine, di(trimethylene)triamine and tri(trimethylene)tetramine, among which diethylenetriamine is preferred. The fatty acids used, for instance, include caproic acid, caprylic acid, capric acid, undecanoic acid, lauric acid, tridecanoic acid, myristic acid, pentadecanoic acid, palmitic acid, stearic acid, nonadecanoic acid, arachidic acid, behenic acid, cerotic acid, montanic acid, mellisic acid, linderic acid, palmitoleic acid, oleic acid, elaidic acid and vaccenic acid, among which laruic acid and oleic acid are preferred. Such oxyalkylene adducts of the aliphatic amide compounds having 6 to 22 carbon atoms, for instance, include oxyethylene adducts, oxypropylene adducts and oxyethylene-oxypropylene adducts or any desired mixtures thereof. However, it is preferable to use adducts wherein the oxyalkylene is added at a proportion of 1 to 15 moles per mole of the aliphatic amide compound having 6 to 22 carbon atoms.
The anionic surfactant used herein, for instance, include fatty acid salts, organic sulfonic acid salts, organic sulfuric acid salts and organic phosphoric acid ester salts. The fatty acid salts used as the anionic surfactant include (1) alkaline metal salts of fatty acids having 6 to 22 carbon atoms, and (2) amine salts of fatty acids having 6 to 22 carbon atoms. Such fatty acids having 6 to 22 carbon atoms, for instance, include capric acid, caprylic acid, lauric acid, myristic acid, palmitic acid, stearic acid, behenic acid, oleic acid, erucic acid, linolic acid and dodecenylsuccinic acid. The alkaline metals that form such alkaline metal salts of fatty acids having 6 to 22 carbon atoms, for instance, are sodium, potassium and lithium, and the amines that form the amine salts, for instance, are (1) aliphatic amines such as methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine, triethylamine, butylamine, dibutylamine, tributylamine and octylamines, (2) aromatic or heterocyclic amines such as aniline, pyridine, morphorine and piperazine or derivatives thereof, (3) alkanolamines such as monoethanolamine, diethanolamine, triethanolamine, isopropanolamine, diisopropanolamine, triisopropanolamine, butyldiethanolamine, octyldiethanolamine and lauryldiethanolamine, and (4) ammonia. Among these, potassium dodecenylsuccinate is preferred.
The organic sulfonic acid salts used as the anionic surfactant used herein, for instance, include (1) alkaline metal alkylsulfonates such as sodium decylsulfonate, sodium dodecylsuflonate, lithium tetradecylsulfonate and potassium hexadecylsulfonate, (2) alkaline metal alkylarylsulfonates such as sodium butylbenzenesulfonate, sodium dodecylbenzenesulfonate, potassium octadecyl-benzenesulfonate and sodium dibutylnaphthalenesulonate, and (3) alkaline metal ester sulfonates such as sodium 1,2-bis(dioctyloxycarbonyl)-ethanesulfonate, lithium 1,2-bis(dibutyloxycarbonyl)-ethanesulfonate, sodium 2-(dodecyloxy)-2-oxoethane-1-sulfonate and potassium 2-(nonylphenoxy)-2-oxoethane-1-sulfonate. Among these, alkaline metal alkylsulfonates and alkaline metal alkylarylsufonates, especially with 12 to 18 carbon atoms, are preferred.
The organic sulfates used as the anionic surfactant, for instance, include (1) alkaline metal alkylsuflates such as sodium decylsulfate, sodium dodecylsulfate, lithium tetradecylsulfate and potassium hexadecylsulfate, and (2) alkaline metal salts of sulfides of natural fats and oils such as sulfated tallow oil and sulfated castor oil. In particular, sodium dodecylsulfate is preferred.
The organic phosphoric acid ester salts used as the anionic surfactant include (1) alkyl phosphoric ester salts containing an alkyl group having 4 to 22 carbon atoms, and (2) (poly)oxyalkylene alkyl ether phosphoric ester salts in which an alkyl group has 4 to 22 carbon atoms and the number of an oxyalkylene unit that forms a (poly)oxy-alkylene group is 1 to 5.
The alkyl phosphoric ester salts containing an alkyl group having 4 to 22 carbon atoms, for instance, include butyl phosphoric ester salt, pentyl phosphoric ester salt, hexyl phosphoric ester salt, octyl phosphoric ester salt, isooctyl phosphoric ester salt, 2-ethylhexyl phosphoric ester salt, decyl phosphoric ester alkali metal salt, lauryl phosphoric ester alkali metal salt, tridecyl phosphoric ester salt, myristyl phosphoric ester salt, cetyl phosphoric ester salt, stearyl phosphoric ester salt, eicosyl phosphoric ester salt and behenyl phosphoric ester salt. These alkyl phosphoric ester salts also include a pure form of monoester and a pure form of diester or mixtures thereof. The diester includes a diester having identical alkyl groups (symmetric diester) and a diester having different alkyl groups (asymmetric diester). The alkyl phosophoric ester salt as explained above is formed from an acidic alkyl phosphoric ester, and a base compound for which an alkali metal hydroxide, an organic amine compound, an ammonium compound or the like are mentioned.
The (poly)oxyalkylene alkyl phosphoric ester salt, in which the alkyl group has 4 to 22 carbon atoms and the number of an oxyalkylene unit that forms a (poly)oxyalkylene group, includes polyoxyalkylene butyl ether phosphoric ester salt, polyoxylalkylene hexyl ether phosphoric ester salt, polyoxylalkylene octyl ether phosphoric ester salt, polyoxyalkylene isooctyl ether phosphoric ester salt, polyoxyalkylene decyl ether phosphoric ester salt, polyoxyalkylene lauryl ether phosphoric ester salt, polyoxyalkylene tridecyl ether phosphoric ester alkali metal salt, polyoxyalkylene myristyl ether phosphoric ester alkali metal salt, polyoxyalkylene cetyl ether phosphoric ester salt, polyoxyalkylene stearyl ether phosphoric ester salt, polyoxyalkylene behenyl ether phosphoric ester salt, etc. The (poly)oxyalkylene group in such (poly)oxyalkylene alkyl ether phosphoric ester salts, for instance, includes (poly)oxyethylene group, (poly)oxypropylene group and (poly)oxyethylene-oxypropylene group. These polyoxyalkylene alkyl ether phosphoric ester salts also include a pure form of monoester and a pure form of diester or mixtures thereof. The diester includes a diester having identical alkyl groups (symmetric diester) and a diester having different alkyl groups (asymmetric diester). The (poly)oxyalkylene alkyl ether phosphoric ester salt as explained above is formed from an acidic (poly)oxyalkylene alkyl ether phosphoric ester, and a base compound for which an alkali metal hydroxide, an organic amine compound, an ammonium compound or the like are mentioned.
The cationic surfactant used includes a quaternary ammonium salt and an organic amine oxide. The quaternary ammonium salts used as the cationic surfactant, for instance, includes tetramethylammonium salt, triethylmethylammonium salt, tripropylethylammonium salt, tributylmethylammonium salt, tetrabutylammonium salt, triisooctylethylammonium salt, trimethyloctylammonium salt, dilauryldimethylammonium salt, trimethylstearylammonium salt, dibutenyldiethylammonium salt, dimethyldioleyl-ammonium salt, trimethyloleylammonium salt, tributylhydroxyethylammonium salt, dipropyl bis(2-hydroxyethyl)ammonium salt, octyl tris(2-hydroxyethyl)ammonium salt, and methyl tris(3-hydroxpropyl)ammonium salt.
The organic amine oxide used as the cationic surfactant, for instance, includes hexylamine oxide, octylamine oxide, nonylamine oxide, laurylamine oxide, myristylamine oxide, cetylamine oxide, stearylamine oxide, arachinylamine oxide, dihexylamine oxide, dioctylamine oxide, dinonylamine oxide, dilaurylamine oxide, dimyristylamine oxide, dicetylamine oxide and distearylamine oxide.
Various amphoteric surfactants may be used; however, it is preferable to use betaine type amphoretic surfactants such as octyl dimethyl ammonioacetate, decyl dimethyl ammonioacetate, dodecyl dimethyl ammonioacetate, hexadecyl dimethyl ammonioacetate, octadecyl dimethyl ammonioacetate, nonadecyl dimethyl ammonioacetate and octadecenyl dimethyl ammonioacetate.
As the surfactant used with the agent for treating biodegradable synthetic yarns according to the present invention, the nonionic, anionic, cationic and amphoteric surfactants may be used alone or in admixture of two or more; however, it is preferable to use the nonionic and anionic surfactants in admixture. More preferably in this case, a fatty acid salt and/or an organic sulfonic acid salt is used as the anionic surfactant.
The agent for treating biodegradable synthetic yarns according to the present invention comprises a functional agent in an amount of 0.1 to 30 weight %, preferably 0.5 to 20 weight %, and a lubricant and a surfactant in a total amount of 70 weight % or greater, preferably 80 weight % or greater. In one preferable embodiment of the invention, the agent comprises 20 to 80 weight % of lubricant and 10 to 70 weight % of surfactant, and in one more specific embodiment, that agent should more preferably comprise 1 to 18 weight % of functional agent, 34 to 75 weight % of lubricant and 15 to 65 weight % of surfactant.
Besides the functional agent, lubricant and surfactant as explained above, the agent for treating biodegradable synthetic yarns according to the present invention may contain other components such as antioxidants, antiseptic agent and rust preventives with the proviso that their contents are reduced as much as possible.
The agent for treating biodegradable synthetic yarns according to the present invention should have a friction coefficient in the range of 0.04 to 0.35, and preferably 0.05 to 0.16. The “friction coefficient” used herein is understood to be indicative of a value as measured in an atmosphere of 25° C. and a relative humidity of 65% under a counter weight condition of 40 g/80 g, using a pendulum type oiliness friction tester.
Referring to how to treat biodegradable synthetic yarns according to the present invention, the aforesaid agent for treating biodegradable synthetic yarns according to the present invention is first prepared in an aqueous solution form. Then, biodegradable synthetic yarns fabricated from the lactic acid polymer are oiled with that aqueous solution in an amount of 0.1 to 3% by weight, and preferably 0.5 to 1.5% by weight as calculated on the basis of said agent for treating biodegradable synthetic yarns. Known oiling methods such as a roller oiling method, a guide oiling method using a measuring pump, a dip oiling method and a spray oiling method may be used. Oiling may be carried out at the step of spinning biodegradable synthetic yarns fabricated from the lactic acid polymer or at the step of carrying out spinning and drawing simultaneously. It is here noted that the present invention can most efficiently be applied to biodegradable synthetic yarns that are subjected to false twisting.
The agent and method for the treatment of biodegradable synthetic yarns according to the present invention may be applied to biodegradable synthetic yarns that are fabricated from (1) polylactic acid that is a homopolymer of lactic acid, (2) a lactic acid copolymer obtained from lactic acid and a cyclic lactone such as ε-caprolactone, γ-butyrolactone and γ-valerolactone, (3) a lactic acid copolymer obtained from lactic acid and a hydroxy acid such as hydroxybutyric acid, hydroxy-isobutyric acid and hydroxyvaleric acid, (4) a lactic acid copolymer obtained from lactic acid and a glycol such as ethylene glycol, propylene glycol and 1,4-butanediol, (5) lactic acid and a dicarboxylic acid such as succinic acid, sebacic acid and adipic acid, and (6) mixtures of two or more of (1) to (5) above.
PREFERRED EMBODIMENTS OF THE INVENTION
Set out below are nine embodiments (1) to (9) of the agent for treating biodegradable synthetic yarns according to the present invention.
First Embodiment
An agent for treating biodegradable synthetic yarns fabricated from the lactic acid polymer, which comprises 10 weight % of the following functional agent (K-1), 75 weight % of the following lubricant (L-1) and 15 weight % of the following surfactant (S-1), and has a friction coefficient of 0.09:
Functional Agent (K-1)
A polyether compound having an average molecular weight of 10,000, which is obtained by the random addition of ethylene oxide and propylene oxide to ethylene glycol at an ethylene oxide-to-propylene oxide proportion of 50/50 by mole.
Lubricant (L-1)
A 1/1 by-weight mixture of a polyether monol having an average molecular weight of 1,100, which is obtained by the random addition of ethylene oxide and propylene oxide to butyl alochol at an ethylene oxide-to-propylene oxide proportion of 60/40 by mole and a polyether monol having a number-average molecular weight of 2,400, which is obtained by the random addition of ethylene oxide and propylene oxide to butyl alcohol at an ethylene oxide-to-propylene oxide proportion of 75/25 by mole.
Surfactant (S-1)
A 67/27/6 by-weight mixture of polyoxyethylene (with the number of repetition of oxyethylene unit being 5, hereinafter mentioned n=5) lauryl ether/sorbitan monooleate/sodium dodecylsulfonate.
Second Embodiment
An agent for treating biodegradable synthetic yarns fabricated from the lactic acid polymer, which comprises 16 weight % of the following functional agent (K-2), 62 weight % of the following lubricant (L-2), 21 weight % of the aforesaid surfactant (S-1) and 1 weight % of the following subordinate component (E-1), and has a friction coefficient of 0.07.
Functional Agent (K-2)
A polyether compound having an average molecular weight of 6,000, which is obtained by the random addition of ethylene oxide and propylene oxide to trimethylolpropane at an ethylene oxide-to-propylene oxide proportion of 70/30 by mole and in which hydrogen atoms in all hydroxyl groups of resulting polyether triol are substituted by methyl groups.
Lubricant (L-2)
A 1/2 by-weight mixture of polyether monol having an average molecular weight of 2,500, which is obtained by the random addition of ethylene oxide and propylene oxide to dodecyl alcohol at an ethylene oxide-to-propylene oxide proportion of 40/60 by mole and polyether diol having a number-average molecular weight of 1,000, which is obtained by the random addition of ethylene oxide and propylene oxide to ethylene glycol at an ethylene oxide-to-propylene oxide proportion of 80/20 by mole.
Subordinate Component (E-1)
A polyether-modified silicone.
Third Embodiment
An agent for treating biodegradable synthetic yarns fabricated from the lactic acid polymer, which comprises 11 weight % of the following functional agent (K-3), 74 weight % of the aforesaid lubricant (L-1) and 15 weight % of the aforesaid surfactant (S-1), and has a friction coefficient of 0.10.
Functional Agent (K-3)
A polyether compound having an average molecular weight of 3,500, which is obtained by the random addition of ethylene oxide and butylene oxide to ethylene glycol at an ethylene oxide-to-butylene oxide proportion of 70/30 by mole and in which hydrogen atoms in all hydroxyl groups of resulting polyether diol are substituted by decanoyl groups.
Fourth Embodiment
An agent for treating biodegradable synthetic yarns fabricated from the lactic acid polymer, which comprises 5 weight % of the aforesaid functional agent (K-3), 40 weight % of the aforesaid lubricant (L-1) and 55 weight % of the following surfactant (S-2), and has a friction coefficient of 0.11.
Surfactant (S-2)
A 14/85/2 by-weight mixture of polyoxyethylene (n=5) lauryl ether/decanoic ester of polyoxyethylene (n=4) lauryl ester/dipotassium dodecenylsuccinate.
Fifth Embodiment
An agent for treating biodegradable synthetic yarns fabricated from the lactic acid polymer, which comprises 1 weight % of the following functional agent (K-6), 42 weight % of the aforesaid lubricant (L-1) and 57 weight % of the aforesaid surfactant (S-2), and has a friction coefficient of 0.08.
Functional Agent (K-6)
A polyether polyester compound having an average molecular weight of 20,000, which is obtained from a 1/1 by-mole mixture of dimethyl terephthalate and polyethylene glycol having an average molecular weight of 1,000.
Sixth Embodiment
An agent for treating biodegradable synthetic yarns fabricated from the lactic acid polymer, which comprises 3 weight % of the aforesaid functional agent (K-6), 66 weight % of the aforesaid lubricant (L-2), 30 weight % of the aforesaid surfactant (S-1) and 1 weight % of the aforesaid subordinate component (E-1), and has a friction coefficient of 0.06.
Seventh Embodiment
An agent for treating biodegradable synthetic yarns fabricated from the lactic acid polymer, which comprises 5 weight % of the following functional agent (K-7), 74 weight % of the aforesaid lubricant (L-1), 19 weight % of the aforesaid surfactant (S-1) and 2 weight % of the following subordinate component (E-2), and has a friction coefficient of 0.08.
Functional Agent (K-7)
A polyether polyester compound having an average molecular weight of 8,000, which is obtained from dimethyl terephthalate/dimethyl 5-sulfoisophthalate/polyethylene glycol having an average molecular weight of 600/ethyelene glycol at a proportion of 0.95/0.05/0.9/0.1 by mole.
Subordinate Component (E-2)
Ethylene glycol.
Eighth Embodiment
An agent for treating biodegradable synthetic yarns fabricated from the lactic acid polymer, which comprises 5 weight % of the aforesaid functional agent (K-7), 40 weight % of the following lubricant (L-3) and 55 weight % of the aforesaid surfactant (S-2), and has a friction coefficient of 0.10.
Lubricant (L-3)
Octyl stearate.
Ninth Embodiment
The ninth embodiment of the present invention is directed to a method for the treatment of biodegradable synthetic yarns.
According to this method the agent for treating biodegradable synthetic yarns according to any one of the 1st to 8th embodiments of the present invention is first provided in a 10 weight % aqueous solution form. Then, the biodegradable synthetic yarns spun from the lactic acid polymer are applied with that aqueous solution in an amount of 0.8 weight % as calculated on the basis of said agent.
By way of example but not by way of limitation, the present invention will now be explained with reference to working examples, etc., in which “part” means “part by weight” and “%” is given % by weight.
EXAMPLE
Experimentation 1
Preparation of the Agent for Treating Biodegradable Synthetic Yarns
Example 1
10 parts of the following functional agent (K-1), 75 parts of the following lubricant (L-1) and 15 parts of the following surfactant (S-1) were uniformly mixed together to prepare the following agent (P-1) for treating biodegradable synthetic yarns, with a friction coefficient of 0.09.
Functional Agent (K-1)
A polyether compound having an average molecular weight of 10,000, which was obtained by the random addition of ethylene oxide and propylene oxide to ethylene glycol at an ethylene oxide-to-propylene oxide proportion of 50/50 by mole.
Lubricant (L-1)
A 1/1 by-weight mixture of a polyether monol having an average molecular weight of 1,100, which was obtained by the random addition of ethylene oxide and propylene oxide to butyl alcohol at an ethylene oxide-to-propylene oxide proportion of 60/40 by mole and a polyether monol having a number-average molecular weight of 2,400, which was obtained by the random addition of ethylene oxide and propylene oxide to butyl alcohol at an ethylene oxide-to-propylene oxide proportion of 75/25 by mole.
Surfactant (S-1)
A 10/4/1 by-weight mixture of polyoxyethylene (with the number of repetition of oxyethylene unit being 5 and having an alkyl group having 12 carbon atoms) alkyl ether/sorbitan monooleate/sodium laurylsulfonate.
The friction coefficient of that agent was found in a 25° C. atmosphere having a relative humidity of 65% under a counter weight condition of 40 g/80 g, using a pendulum type oiliness friction tester manufactured by Shinko Zoki Co., Ltd.
Examples 2-19 & Comparative Examples 1-3
As in Example 1, the agents for treating biodegradable synthetic yarns according to Examples 2 to 19 and Comparative Examples 1 to 3 (P-2 to P-19 and R-1 to R-3) were prepared. Tabulated in Table 1 are the compositions, etc. of the agents for treating biodegradable synthetic yarns according to the examples inclusive of Example 1.
TABLE 1
Agent for treating biogradable synthetic yarn
Composition
Functional
agent
Lubricant
Surfactant
Other
Oiliness
Use
Use
Use
Use
Friction
Item
Kind
Kind
amount
Kind
amount
Kind
amount
Kind
amount
coefficient
Example
1
P-1
K-1
10
L-1
75
S-1
15
3.09
2
P-2
K-2
16
L-2
62
S-1
21
E-1
1
4.07
3
P-3
K-3
11
L-1
74
S-1
15
5.10
4
P-4
K-3
5
L-1
40
S-2
55
6.11
5
P-5
K-6
1
L-1
42
S-2
57
7.08
6
P-6
K-6
3
L-2
66
S-1
30
E-1
1
8.06
7
P-7
K-7
5
L-1
74
S-1
19
E-2
2
9.08
8
P-8
K-7
5
L-3
40
S-2
55
10.10
9
P-9
K-10
20
L-4
30
S-2
50
11.13
10
P-10
K-1
10
L-1
75
S-3
15
12.09
11
P-11
K-3
0.5
L-3
79
S-1
20.5
13.18
12
P-12
K-2
10
L-3
60
S-4
30
14.10
13
P-13
K-2
5
L-1
74
S-5
20
E-2
1
15.10
14
P-14
K-6
2
L-2
65
S-4
30
E-1
3
16.06
15
P-15
K-6
2
L-1
71
S-5
24
E-2
3
17.07
16
P-16
K-4
22
L-1
59
S-1
19
18.13
17
P-17
K-5
8
L-2
66
S-2
26
19.10
18
P-18
K-8
1.5
L-3
60
S-1
39.5
20.16
19
P-19
K-9
2.2
L-4
69
S-2
29
0.07
Comparative
1
R-1
L-1
80
S-1
15
E-2
5
21.22
Example
2
R-2
K-1
35
L-1
50
S-1
15
22.07
3
R-3
L-3
65
S-5
30
E-2
5
0.25
In Table 1, the amounts of the agent components used are given by part.
K-1 is a polyether compund having an average molecular weight of 10,000, which was obtained by the random addition of ethylene oxide and propylene oxide to ethylene glycol at an ethylene oxide-to-propylene oxide proportion of 50/50 by mole.
K-2 is a polyether compound having an average molecular weight of 6,000, which was obtained by the random addition of ethylene oxide and propylene oxide to trimethylolpropane at an ethylene oxide-to-propylene oxide proportion of 70/30 by mole and in which hydrogen atoms in all hydroxyl groups of resulting polyether triol were substituted by methyl groups.
K-3 is a polyether compound having an average molecular weight of 3,500, which was obtained by the random addition of ethylene oxide and butylene oxide to ethylene glycol at an ethylene oxide-to-butylene oxide proportion of 70/30 by mole and in which hydrogen atoms in all hydroxyl groups of resulting polyether diol were replaced by decanoyl groups.
K-4 is a polyether compond having an average molecular weight of 3,300, which was obtained by the random addition of ethylene oxide and butylene oxide to butyl alcohol at an ethylene oxide-to-butylene oxide proportion of 70/30 by mole.
K-5 is a polyether compound having an average molecular weight of 19,000, which was obtained by the random addition of ethylene oxide and propylene oxide to trimethylolpropane at an ethylene oxide-to-propylene oxide proportion of 75/25 by mole and in which hydrogen atoms in all hydroxyl groups of resulting polyether triol were substituted by octadecanoyl groups.
K-6 is a polyether polyester compound having an average molecular weight of 20,000, which was obtained from a 1/1 by-mole mixture of dimethyl terephthalic acid and polyethylene glycol having an average molecular weight of 1,000.
K-7 is a polyether polyester compound having an average molecular weight of 8,000, which was obtained from a 0.95/0.05/0.9/0.1 by-mole mixture of dimethyl terephthalate, dimethyl 5-sulfoisophthalate, polyethylene glycol having an average molecular weight of 600 and ethylene glycol.
K-8 is a polyether polyester compound having an average molecular weight of 15,000, which was obtained from a 1/1/2/1 by-mole mixture of terephthalic acid, adipic acid, polyethylene glycol having an average molecular weight of 1,000 and polyethylene glycol monophenyl ether having an average molecular weight of 1,000.
K-9 is a polyether polyester compound having an average molecular weight of 45,000, which was obtained from a 3/3/1 by-mole mixture of dimethyl terephthalate, polyethylene glycol monophenyl ether having an average molecular weight of 600 and polyoxyethylene glycol triol having an average molecular weight of 500 obtained by adding ethyleneoxide to glycerin.
K-10 is an oxidized polyethylene wax having an average molecular weight of 2,400.
L-1 is a 1/1 by-weight mixture of polyether monol having an average molecular weight of 1,100, which was obtained by the random addition of ethylene oxide and propylene oxide to butyl alcohol at an ethylene oxide-to-propylene oxide proportion of 60/40 by mole and polyether monol having a number-average molecular weight of 2,400, which was obtained by the random addition of ethylene oxide and propylene oxide to butyl alcohol at an ethylene oxide-to-propylene oxide proportion of 75/25 by mole.
L-2 is a 1/2 by-weight mixture of polyether monol having an average molecular weight of 2,500, which is obtained by the random addition of ethylene oxide and propylene oxide to dodecyl alcohol at an ethylene oxide-to-propylene oxide proportion of 40/60 by mole and polyether diol having a number-average molecular weight of 1,000, which is obtained by the random addition of ethylene oxide and propylene oxide to ethylene glycol at an ethylene oxide-to-propylene oxide proportion of 80/20 by mole.
L-3 is octyal stearate.
L-4 is a 60/40 by-weight mixture of glycerol tri(12-hydroxystearate) and a mineral oil of 5×10 −6 m 2 /s.
S-1 is a 67/27/6 by-weight mixture of polyoxyethylene (n=5) lauryl ether, sorbintan monooleate and sodium dodecysulfonate.
S-2 is a 14/85/2 by-weight mixture of polyoxyalkylene (n=5) lauryl ether, decanoic ester of polyoxyethylene (n=4) lauryl ether, and dipotassium dodecenylsuccinic acid.
S-3 is a 70/10/20 by-weight mixture of polyoxyethylene (n=4) lauryl aminoether, lauryl dimethyl ammonioacetate and lauryl phosphate•octyltrimethyl-ammonium.
S-4 is a 27/67/6 by-weight mixture of polyoxyethylene (n=5) lauryl ether, polyoxyalkylene (n=20) hardened castor oil and polyoxyethylene (n=3) lauryl ether phosphoric ester potassium.
S-5 is a 40/40/20 by-weight mixture of polyoxyethylene (n=5) lauryl ether, polyoxyalkylene (n=4) diethylenetriamineisostearylamide and lauryl dimethylamine oxide.
E-1 is polyether-modified silicone.
E-2 is ethylene glycol.
Experimentation II
Oiling and Evalulation of Each Agent with Respect to Biodegradable Synthetic Yarns
Oiling of Each Agent with Respect to Biodegradable Synthetic Yarns:
Lactic acid polymer chips having an average molecular weight 100,000, a melt flow rate of 25 g/10 min. at 210° C., a glass transition temperature of 64° C. and a specific gravity of 1.26 were fed into an extruder type melt spinning machine where they were melted at 210° C. After the hot melt was extruded from a spinneret and hardened by cooling, the resultant traveling yarns were oiled with a 10% aqueous solution obtained by diluting the agent for treating biodegradable synthetic yarns obtained in Experimentation 1 with water at an oiling amount as indicated in Table 2 on the basis of the agent for treating biodegradable synthetic yarns by means of a guide oiling method using a measuring pump. Thereafter, the yarns were bundled together on a guide, and wound at a speed of 2,800 m/min. without any mechanical drawing, thereby obtaining a plurality of 10 kg cakes comprising partially drawn yarns of 154-dtex 36-filaments. The obtained partially drawn yarns were found to have a tenacity of 2.8 g/dtx and an elongation of 78%.
Measurement of the Coverage of the Agent for Biodegradable Synthetic Yarns:
According to JIS-L1073 (for synthetic yarn testing), the coverage of the agent for treating biodegradable synthetic yarns with respect to biodegradable synthetic yarns was measured using a mixed solvent of n-hexane/ethanol (50/50 by volume) as an extraction solvent. The results are enumerated in Table 2.
Evaluation of Bulkiness:
Using a twisting system (employing a hard polyurethane rubber disk), the obtained partially drawn yarns were subjected to drawing and false twisting at a yarn traveling speed of 400 m/min. and a drawn ratio of 1.5 with a 2 m long heater on a twist side (at surface temperatures of 100° C. and 140° C. but without a heater on an untwisting side. The intended number of twisting was set at 2,800 T/m. Prior to winding, the obtained false-twisted yarns of 100 dtx 36 filaments were measured in terms of the number of twisting, using a twist monitor (Model TM-501 manufactured by Toray Industries, Inc.), and evaluated in terms of bulkiness on the following criteria. The results are set out in Table 2.
AA: the intended number of twisting, say 2,800 T/m, was achieved.
A: greater than 2,700 T/m but less than 2,800 T/m.
B: greater than 2,500 T/m but less than 2,700 T/m.
C: less than 2,500 T/m.
Evaluation of Fuzzes:
Prior to winding, the obtained false-twisted yarns of 100 dtx 36-filaments were measured in terms of the number of fuzzes per hour using a fray counter (DT-105 manufactured by Toray Engineering Co., Ltd.), and evaluated on the following criteria. The results are set out in Table 2.
AA: no fuzz was found.
A: Five or less fuzzes were found.
B: greater than five but less than 10 fuzzes were found.
C: Ten or more fuzzes were found.
Evaluation of Breaks:
After subjected to drawing and false twisting continuously over 10 days under the aforesaid conditions, the number of breaks per hour was evaluated on the following criteria. The results are shown in Table 2.
AA: no break was found.
A: one break was found per hour.
B: three breaks were found per hour.
C: five or more breaks were found per hour.
Measurement of Tenacity of False-Twisted Yarns:
According to JIS-L1013, the tenacity of the obtained false-twisted yarns was evaluated as tensile tenacity-elongation property. The results are shown in Table 2.
AA: tenacity of 5.4 g/dtx or greater.
A: tenacity of greater than 5.0 g/dtx but less than 5.4 g/dtx.
B: tenacity of greater than 4.0 g/dtx but less than 5.0 g/dtx.
C: tenacity of less than 4.0 g/dtx.
TABLE 2
Evaluation
Bulkiness
Fuzzes
Breaks
Tenacity
Oiling
Cond.
Cond.
Cond.
Cond.
Cond.
Cond.
Cond.
Cond.
Item
amount
1
2
1
2
1
2
1
2
Example
1
1.8
AA
AA
AA
AA
AA
AA
AA
AA
2
2.8
AA
AA
AA
AA
AA
AA
AA
AA
3
3.8
AA
AA
AA
AA
AA
AA
AA
AA
4
4.8
AA
AA
AA
AA
AA
AA
AA
AA
5
5.8
AA
AA
AA
AA
AA
AA
AA
AA
6
6.8
AA
AA
AA
AA
AA
AA
AA
AA
7
7.8
AA
AA
AA
AA
AA
AA
AA
AA
8
8.8
AA
AA
AA
AA
AA
AA
AA
AA
9
9.8
A
AA
AA
A
AA
A
AA
AA
10
10.8
A
AA
AA
A
AA
AA
AA
AA
11
11.8
A
AA
AA
A
AA
AA
AA
AA
12
12.8
A
AA
AA
A
AA
AA
AA
AA
13
13.8
A
AA
AA
A
AA
AA
AA
AA
14
14.8
A
AA
AA
A
AA
AA
AA
AA
15
15.8
A
AA
AA
A
AA
AA
AA
AA
16
16.8
A
AA
AA
A
AA
A
AA
AA
17
17.8
A
AA
AA
A
AA
A
AA
AA
18
18.8
A
AA
AA
A
AA
A
AA
AA
19
0.8
A
AA
AA
A
AA
A
AA
AA
Comparative
1
19.8
B
B
B
C
A
C
A
C
Example
2
20.8
A
A
C
C
C
C
A
A
3
0.8
C
B
C
C
B
C
A
C
In Table 2, the coverage of the agent, given in %, is defined with respect to biodegradable synthetic yarns.
Condition 1: heater temperature of 100° C.
Condition 2: heater temperature of 140° C.
While all of the fundamental characteristics and features and method of the present invention have been described herein, with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure and it will be apparent that in some instance, some features of the invention will be employed without a corresponding use of other features without departing from the scope of the invention as set forth. It should be understood that such substitutions, modifications, and variations may be made by those skilled in the art without departing from the spirit or scope of the invention. Consequently, all such modifications and variations are included within the scope of the invention as defined by the following claims. | An agent and method for treating biodegradable synthetic yarns fabricated from a polymer comprising lactic acid as a main component, which enable improved lubricity, cohesion, etc. to be so imparted to the biodegradable synthetic yarns that the yarns can be prevented from fuzzing and breaking at every step from spinning to down-stream step, especially at a false twisting step and improved in terms of bulkiness, providing yarns having improved mechanical properties in a stable manner. The agent of the invention comprises 0.1 to 30 weight % of a specific functional agent, and a lubricant and a surfactant in the total amount of 70 weight % or greater, and has a friction coefficient in the range of 0.04 to 0.35. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present invention is related to application (Attorney Docket TOL 0102 PUS) entitled “OPERABLE CLIMBING TREE STAND” filed simultaneously herewith and incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates to climbing tree stands and more particularly to a portable climbing tree stand.
BACKGROUND
[0003] Tree stands, in particular climbing tree stands, are well known in the art. Such stands may be placed on a tree or pole and used to elevate the hunter or other user to a desired height for observing nature, working or hunting game animals such as deer.
[0004] Climbing tree stands generally have a lower climbing member upon which the hunter stands and an upper climbing member upon which the hunter sits. Each of the upper and lower climbing members have a toothed or jaw member for biting the front side of the tree and a cable or blade device attached to the climbing member which encircles the backside of the tree, thereby supporting the climbing member in a cantilevered position. The jaws or blades bite into the tree, by pivotal action of the climbing member, to hold each climbing member in place after the tree stand is located in the desired position on the tree. Each climbing member may be released or repositioned by simultaneously raising or lifting the climbing member while releasing the cable or blade device encircled about the tree to pivotally disengage the climbing member. The lower climbing member includes foot straps or foot receiving members that are required to be engaged by a hunter for manipulating the position of the lower climbing member. The hunter typically manipulates and positions the upper climbing member with his hands.
[0005] When the lower climbing member is within the reach of the hunter, the hunter can use his feet to engage the lower climbing member and together with the upper climbing member may climb the tree as is well understood in the prior art. However, a problem encountered with climbing tree stands occurs when the user steps too close to the tree on the lower climbing member, causing the lower climbing member to lose its bite or connection to the tree and slides down the tree. To overcome this problem, the upper and lower climbing members are tied together with a retrieving rope so that there is little possibility of losing the lower climbing member. In this way, the rope is used to retrieve the lower climbing member should it get beyond the hunter's reach. However, the rope does not prevent the climbing members from becoming operatively disassociated from one another. In this regard, a shorter rope may interfere with the climbing ability of the climbing tree stand and would resultantly also be undesirable for keeping the climbing members operatively associated with one another.
[0006] Foot straps or foot receiving members found on climbing tree stands secure the user's feet to the lower climbing member in an attempt to allow the hunter to control the position of the lower climbing member. However, foot straps or foot receiving members are very awkward for the hunter due to body position and the size of hunting boots. The straps or receiving members provide an encumbrance to the hunter's motion. It would be desirable to eliminate the need for foot straps or foot receiving members, while still providing for the functionality of the climbing tree stand without inhibiting the hunter's motion.
[0007] Because the climbing members are bulky and difficult to pack or carry, the above-mentioned retrieving rope may be used to tie the lower and upper climbing member together. However, even with the climbing members tied together, the climbing tree stand remains bulky and difficult to carry, especially in dense forest or foliage. Also, the support arms that are rigidly fixed to the climbing member and extend upward therefrom also lend to the bulkiness of the climbing tree stand and may also become entangled with tree limbs and other foliage while hauling. The support arms provide attachment support to the climbing member for the cable or blade device, thereby allowing for pivotal deployment of the climbing members into its cantilevered position upon a tree. U.S. Pat. No. 4,553,634 entitled “Tree Stand” discloses a tree stand in which the support arms are pivotally connected and may swing into an inoperative position. However, the support arms extend undesirably beyond the contained platform member such that the support arms are likely to be caught up in trees or shrubs while walking through foliage. Moreover, the supports arms are likely to make undesirably loud noise while being transported.
[0008] Therefore, there is a need for an improved climbing tree stand that keeps the upper and lower climbing members operatively associated with one another. It would also be advantageous to provide a climbing tree stand that eliminates the need for foot straps or attachment members on the lower climbing member. Of further advantage would be to provide a climbing tree stand that is compactable into a user packable profile, especially advantageous for pack-in/pack-out hunting trips.
SUMMARY
[0009] Accordingly, a climbing tree stand is provided that advantageously keeps the upper and lower climbing platforms operatively associated with one another. The climbing tree stand advantageously eliminates the need for foot straps or attachment members on the lower climbing platform. Also, the climbing tree stand is compactable into a user packable profile, especially advantageous for pack-in/pack-out hunting trips.
[0010] A foldable climbing tree stand platform includes a first section having a first arm rotatably coupled to the first section and a second section having a second arm rotatably coupled to the second section. A hinge rotatably couples the first section to the second section, wherein a platform position is obtained when the first section and the second section are substantially coplanar, and a packed position is obtained when the first section and the second section are rotationally folded onto each other and the first arm and the second arm are contained therein. A securing member is connected between the arms, wherein the sections may selectively engage an upright support and the securing member selectively surrounds the upright support for providing cantilevered support when folded into the platform position.
[0011] A foldable climbing tree stand system is also provided.
[0012] Other advantages and features of the present invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention.
[0014] FIG. 1 shows a perspective view of a climbing tree stand system being used to advantage in accordance with the invention.
[0015] FIG. 2 shows a perspective view of an upper platform in accordance with the embodiment shown in FIG. 1 .
[0016] FIG. 2A shows a slidelock in accordance with the invention.
[0017] FIG. 3 shows a perspective view of a lower platform in accordance with the embodiment shown in FIG. 1 .
[0018] FIG. 4 shows a top view of the upper platform 30 in accordance with the embodiment shown in FIG. 2 .
[0019] FIG. 5 shows a top view of the upper platform in accordance with the embodiment shown in FIG. 3 .
[0020] FIG. 5A shows a partial cross-sectional view of the slidelock rigidly securing the first section and the second section in accordance with the embodiment shown in FIG. 5 .
[0021] FIG. 6 shows an isomeric view of the climbing tree stand system compactly folded for packing in accordance with the invention.
[0022] FIG. 7 shows the securing member in accordance with the invention.
[0023] FIG. 7A shows a partial assembly view of the securing member as shown in FIG. 7 .
[0024] FIG. 8 shows a plan view of the elasticized rope member according to FIG. 1 .
[0025] FIG. 9 shows a plan view of a second embodiment of an elasticized member assembly usable to advantage with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] In the following description, various operating parameters and components are described for one or more constructed embodiments. These specific parameters and components are included as examples and are not meant to be limiting.
[0027] FIG. 1 shows a perspective view of a climbing tree stand system 20 being used to advantage in accordance with the invention. The climbing tree stand system 20 , shown attached to a tree 21 , includes an upper member or platform 30 operatively connected to a lower member or platform 50 by elasticized rope members 22 , 24 . The elasticized rope members 22 , 24 provide a restoring force when stretched beyond their free length by either platform 30 , 50 , thereby providing self return of the lower platform 30 . The elasticized rope members 22 , 24 eliminate the need for foot straps or foot members typically required to raise or lower the platform.
[0028] The elasticized rope members 22 , 24 each have an upper end 25 and a lower end 26 . The upper end 25 of each elasticized rope member 22 , 24 is connected to opposite sides of the upper platform 30 , while the lower end 26 of each member 22 , 24 is connected to respective opposite sides of the lower platform 50 . The elasticized rope members 22 , 24 may have different lengths and or spring constants, but have the same length and spring constant for the embodiment here shown. The free length of the elasticized rope members 22 , 24 is selected or adjusted by the user so that the lower platform 50 provides for comfortable seating while still providing for the operative action required for climbing, e.g., the free length of the elasticized rope member being just shorter than a lower leg of an adult male.
[0029] The upper end 25 of each elasticized rope member 22 , 24 may be connected forward or backward of the cantilevered center of gravity of the upper platform 30 , but is shown here being connected approximately at the platform's cantilevered center of gravity. The elasticized rope members 22 , 24 connected to the lower platform 50 will enhance the upper platform's 30 securement to the tree 21 by providing additional downward loading and engagement loading thereon. A user may detach the upper platform 30 for adjustment up or down the tree 21 while standing on the lower platform 50 .
[0030] The lower end 26 of each elasticized rope member 22 , 24 may be connected forward or backward of the cantilevered center of gravity of the lower platform 50 , but is shown here being connected approximately at the platform's cantilevered center of gravity. If the lower end 26 of each elasticized rope member 22 , 24 is connected too far forward of the cantilevered center of gravity, then the lower member 50 may become inoperable or will not properly engage the tree 21 . If the lower end 26 of each elasticized rope member 22 , 24 is connected to far behind the cantilevered center of gravity, a user may have difficulties in releasing or disengaging the lower platform 50 from the tree 21 . In this regard, a user may raise the lower platform 50 by first raising the upper platform 30 and increasing the spring force in the elasticized rope members 22 , 24 and then lifting his feet, thereby allowing the restoring force in the rope members 22 , 24 to raise the platform 50 . However, the lowering of the lower platform 50 requires strategic or approximate placement of the user's feet upon the lower platform 50 between the elasticized rope members 22 , 24 and the tree 21 while exerting a downward force upon the lower platform 50 thereby increasing the spring force in the elasticized rope members 22 , 24 . The lowering of the lower platform 50 is completed when the upper platform 30 is carefully lowered thereby restoring the elasticized rope members 22 , 24 to their free length and decreasing the spring force within the elasticized rope members, else the lower platform 50 will have a tendency to climb back up until the spring force is minimized.
[0031] FIG. 8 shows a plan view of the elasticized rope member 22 according to FIG. 1 . Elasticized rope member 22 includes stretchable element 27 , shown here as a bungee cord, but may include any other type of elasticized strap, belt or rope. The stretchable element 27 is connected between the upper and lower ends 25 , 26 , which are selectively connectable to each platform as described. The upper and lower ends 25 , 26 are each securable to the platforms by tightening bracket bolt 28 and nut 29 . While a particular attachment is shown in FIGS. 1 and 8 , it is recognized that various alternatives for attaching the elasticized rope member 22 to the platforms 30 , 50 are available. Optionally, the stretchable element 27 may be directly attached to each platform. Also, the stretchable element 27 may optionally include a quick release connector 23 to facilitate assembly and removal of the climbing tree stand system 20 .
[0032] FIG. 9 shows a plan view of a second embodiment of an elasticized member assembly 92 usable to advantage with the invention. Elasticized member assembly 92 includes elasticized or stretchable straps 93 , each shown here as a bungee strap, but may include any other type of elasticized strap, belt or rope. The stretchable straps 93 are connected between the upper and lower end connectors 95 , 96 , which are selectively connectable to each platform 30 and 50 , as described herein. The upper and lower end connectors 95 , 96 adjustably secure the straps 93 to the platforms by spring retention clips 97 , 98 . The elasticized member assembly 92 includes a quick release connector assembly 94 for connecting the stretchable straps 93 , thereby facilitating assembly of the climbing tree stand system.
[0033] FIG. 2 shows a perspective view of an upper platform 30 in accordance with the embodiment shown in FIG. 1 . FIG. 4 shows a top view of the upper platform 30 in accordance with the embodiment shown in FIG. 2 . The upper platform 30 includes a first section 32 and a second section 33 separated by hinges 31 wherein the sections 32 , 33 can compactly fold onto each other. The first section 32 and the second section 33 are generally symmetric about hinges 31 , therefore similar parts are representatively discussed generally for the first section. It is recognized that while the sections 32 and 33 are generally symmetric, they may have different sizes or proportions consistent with the invention here presented. The first section 32 includes a front frame member 34 and a back frame member 35 separated by a side frame member 36 . The frame members 34 , 35 and 36 substantially define a compact plane in which the first section 32 conforms and is generally C-shaped for providing an opening in which a person will fit through. The front frame member 34 receives one hinge 31 and the back frame member 35 receives another hinge 31 thereby allowing the planar first section 32 to be rotated and received by the substantially similar planer second section 33 . The first section 32 is rectilinear in shape, however it is recognized that other shapes may be utilized to advantage to form the first section. The members 34 , 35 and 36 are each made from steel square tubing welded together, however they may also be from other structural shapes and materials, including rounds, L's, bars, pipe, and made from plastics, aluminum or other materials, respectively, for example. Also, the members 34 , 35 and 36 may be made from a continuous piece of stock material or may be made from separate pieces of material that are appropriately joined as is understood by a person of skill in the art. The first section 32 may include additional support members in order to structurally strengthen the platform. A triangular shaped member 37 provides support for and completes the connection between the side frame member 36 and the back frame member 35 , such that when the second section 33 and the first section 32 are folded into the same plane, each of the triangular shaped members 37 of each section 33 , 32 form a V-shaped contacting member 38 for engaging a tree. The triangular shaped member 37 may optionally include a friction or tooth element 46 for providing additional securement when engaging a tree or pole.
[0034] The first section 32 and the second section 33 further include pivot arm support members 39 , 40 that pivotally rotate from the plane of each section into a near perpendicular position, respectively. The pivot arm support member 39 includes an arm or triangular member 41 and a base 42 . The base 42 of the pivot arm support member 39 is rotationally connected to the members of the first section 32 by a retaining rod 75 , thereby allowing pivotal rotation of the pivot arm support member 39 in and out of the plane of the section 32 . The retaining rod 75 may be a pin or hinge-like structure that allows for the structural attachment of the pivot arm support members 39 , 40 while providing the pivotal functionality as provided herein. In this regard, the pivot arm support members 39 , 40 may pivot toward or away from a tree or pole thereby facilitating adjustment or positioning of the climbing tree stand system 20 . The triangular member 41 , although not necessarily triangular, includes upward angled receiving channel 43 that positionably and releasably receives an adjusting member 44 of a securing member 78 that is securable by a locking pin 45 thereto. As shown in FIG. 7 , the adjusting member 44 includes user selectable pin outs 47 for receiving the locking pin 45 for securing to the triangular member 41 or cable pin 48 for selectively securing a securing member or cable 49 . FIG. 7A shows a partial assembly view of the securing member 78 as shown in FIG. 7 . The pin outs 47 allow the adjusting member 44 to be adjusted to advantageously conform to various sizes of trees or poles. While the cable 49 is shown connected to the adjusting member 44 releasably attachable to the triangular member 41 by pins 48 and 45 , respectively, other fasteners or attachment methods may be used to accomplish the same purpose. Also, the pivot arm support members 39 , 40 may optionally include a backstop 69 that prevents the pivot arm support members from rotating beyond the plane when stored into a compact position.
[0035] FIG. 2A shows a slidelock 80 in accordance with the invention. The upper platform 30 includes a slidelock or bar 80 positionably engaging a first channel slot 81 in the front frame member 34 of the first section 32 . When the first section 32 and the second section 33 of the upper platform 30 lie in the same plane, the bar 80 can be positionably slid into a second channel slot 82 of the second section 33 to rigidly secure the sections 32 , 33 for use. The bar 80 may also include a retainment knob 83 that engages a keyway 84 in the front frame member 34 of the first section 32 . The retainment knob 83 is a threaded or compressive fastener that is capable of sandwiching the front frame member 34 to secure the bar 80 . The retainment knob may also be used to position the bar 80 . While the slidelock or bar 80 is shown engaging a first channel slot 81 in the front frame member 34 of the first section 32 for engagement with a second channel slot 82 of the second section 33 , the bar 80 may be utilized to advantage in another frame member or may be any securing system that may rigidly hold the first section 32 and the second section 33 in substantially the same plane.
[0036] FIG. 3 shows a perspective view of a lower platform 50 in accordance with the embodiment shown in FIG. 1 . FIG. 5 shows a top view of the upper platform 50 in accordance with the embodiment shown in FIG. 3 . The lower platform 50 includes a first section 52 and a second section 53 separated by hinges 51 wherein the sections 52 , 53 can compactly fold onto each other. It is recognized that while two hinges 31 are shown, one or more hinges may be utilized to advantage. The first section 52 and the second section 53 are generally symmetric about hinges 51 , therefore similar parts are representatively discussed generally for the first section. The first section 52 includes a front frame member 54 and a back frame member 55 separated by a side frame member 56 . The frame members 54 , 55 , and 56 substantially define a compact plane in which the first section 52 provides a first surface 70 which a person may stand upon. The front frame member 54 receives one hinge 51 and the back frame member 55 receives another hinge 51 thereby allowing the planer first section 52 to be rotated onto a substantially similar planer second section 53 . The first section 52 is rectilinear in shape, however it is recognized that other shapes may be utilized to advantage to form the first section. The members 54 , 55 and 56 are each made from steel square tubing welded together, however they may also be from other structural shapes and materials, including rounds, L's, bars, pipe, and made from plastics, aluminum or other materials, respectively, for example. Also, the members may be made from a continuous piece of stock material or may be made from separate pieces of material that are appropriately joined as is understood in the prior art. The first section 52 may include additional support members in order to structurally strengthen the platform. A triangular shaped member 57 provides support for and completes the connection between the side frame members 56 and the back frame member 55 , such that when the second section 53 and first section 52 are folded into the same plane, each of the triangular shaped members 57 of each section 53 , 52 form a V-shaped contacting member 58 for engaging a tree. The triangular shaped member 57 may optionally include a friction or tooth element 66 for providing additional securement when engaging a tree or pole.
[0037] The first section 52 and the second section 53 further include pivot arm support members 59 , 60 that pivotally rotate from the plane of each section into a near perpendicular position, respectively. The pivot arm support member 59 includes an arm or triangular member 61 and a base 62 . The base 62 of the pivot arm support member 59 is rotationally connected to the members of the first section 52 by a retaining rod 75 , thereby allowing pivotal rotation of the pivot arm support member 59 in and out of the plane of the section 52 . The retaining rod 75 may be a pin or hinge-like structure that allows for the structural attachment of the pivot arm support members 59 , 60 while providing the pivotal functionality as provided herein. In this regard, the pivot arm support members 59 , 60 may pivot toward or away from a tree or pole thereby also facilitating adjustment or positioning of the climbing tree stand system 20 . The triangular member 61 , although not necessarily triangular, includes upward angled receiving channel 63 that positionably and releasably receives an adjusting member 44 of a securing member 78 that is securable by a locking pin 45 , thereto. As shown in FIG. 7 , the adjusting member 44 includes user selectable pin outs 47 for receiving the locking pin 45 for securing to the triangular member 61 or cable pin 48 for selectively securing a securing member or cable 49 . FIG. 7A shows a partial assembly view of the securing member 78 as shown in FIG. 7 . The pin outs 47 allow the adjusting member 44 to be adjusted to advantageously conform to various sizes of trees or poles. While the cable 49 is shown connected to the adjusting member 44 and releasably attachable to the triangular member 61 by pins 48 and 45 , respectively, other fasteners or attachment methods may be used to accomplish the same purpose. Also, the pivot arm support members 59 , 60 can compactly fold into the plane created by the frame members 54 , 55 , 56 and against a second surface 71 that prevents the pivot arm support members from rotating beyond the plane when stored into a compact position. The second surface 71 on the lower platform 50 also provides additional standing area for a user. The second surface 71 may also help the user to pivotally release the lower platform 50 from a tree or pole by providing a place to exert a gravitational offset force.
[0038] FIG. 5A shows a partial cross-sectional view of the slidelock 80 rigidly securing the first section 62 and the second section 63 in accordance with the embodiment shown in FIG. 5 . The lower platform 50 also includes a slidelock or bar 80 for securing the first section 62 and the second section 63 in the same plane, as described herein for the upper platform 30 .
[0039] FIG. 6 shows an isomeric view of the climbing tree stand system 20 compactly folded for packing in accordance with the invention. Sections 32 and 33 of the upper platform 30 are folded into a packed position. Likewise, the sections 52 and 53 of the lower platform 50 are folded, thereby allowing the upper and lower platforms to be conveniently packed together. Also, the arms 39 and 40 , and the arms 59 and 60 of the platforms 30 , 50 , respectively, are stored conveniently therein.
[0040] The climbing tree stand system 20 may include other features that are typically associated with climbing tree stands such as accessory supports, a ladder, gun or binocular racks, or a positionable or hanging seat. Furthermore, the climbing tree stand system 20 may optionally include a rope or tether 90 tied between the lower platform 50 and the upper platform 30 for retrieving the lower platform 50 should it inadvertently fall beyond the reach of the user and the elasticized members 22 , 24 fail.
[0041] While particular embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Accordingly, it is intended that the invention be limited only in terms of the appended claims. | A foldable climbing tree stand platform includes a first section having a first arm rotatably coupled to the first section and a second section having a second arm rotatably coupled to the second section. A hinge rotatably couples the first section to the second section, wherein a platform position is obtained when the first section and the second section are substantially coplanar, and a packed position is obtained when the first section and the second section are rotationally folded onto each other and the first arm and the second arm are contained therein. A securing member is connected between the arms, wherein the sections may selectively engage an upright support and the securing member selectively surrounds the upright support for providing cantilevered support when folded into the platform position. A foldable climbing tree stand system is also provided. | 0 |
FIELD OF THE INVENTION
The present invention relates generally to graphical user interfaces for computer systems. More particularly, the present invention relates to control elements which, among other things, combine features of a menu element and a list element within a graphical user interface.
BACKGROUND
The evolution of the computer industry is unparalleled in its rate of growth and complexity. Personal computers, for example, which began as little more than feeble calculators with limited memory, tape-driven input and monochrome displays are now able to tackle almost any data processing task. While this meteoric increase in power was almost sufficient to satisfy the demand of application designers and end users alike, the corresponding increase in complexity created an ease-of-use problem which the industry was somewhat slower in solving. Thus, designers were faced with a new challenge: to harness this computing power in a form usable by even those with relatively little computer training to smooth the transition of other industries into a computer-based information paradigm.
As a result, in the early to mid-1980's many new I/O philosophies, such as “user friendly”, “WYSIWYG” and “menu driven” came to the forefront of the industry. These concepts are particularly applicable to microcomputers, also known as personal computers, which are intended to appeal to a broad audience of computer users, including those who previously feared and mistrusted computers. An important aspect of computers which employ these concepts was, and continues to be, the interface which allows the user to input commands and data and receive results, which is commonly referred to as a graphical user interface (GUI).
The success of this type of interface is evident from the number of companies which have emulated the desktop environment. Even successful concepts, however, must continually be improved in order to keep pace with the rapid growth in this industry. The advent of multimedia, especially CD-ROM devices, has provided vast quantities of secondary storage which have been used to provide video capabilities, e.g., live animation and video clips, as regular components of application displays. With these and other new resources at their disposal, application designers and users alike, demand additional functionality and greater ease of use from the desktop environment.
Today it is hard to imagine an operating system or application which does not provide a GUI. A system's or application's GUI along with the other man machine interface (MMI) elements is often referred to as its “look and feel.” Accordingly, developers of today's applications typically use the control elements of the operating system or platform GUI, adding their own GUI elements and ideas, to differentiate their application from other, competing applications being developed. Elements of a GUI include such things as windows, menus, lists, buttons, scroll bars, icons, pointers, etc. Two well known GUI control elements are the “pop-up menu” and “list box”, both of which have advantages and disadvantages which are discussed below.
An exemplary GUI control element commonly referred to as a list box is shown in FIG. 1 . The list box control element generally requires the specification of the number of visible rows in a viewing area 100 . The number of visible rows specified does not limit the number of possible entries which can be displayed within the list box, rather it affects the height of the displayed list box. If more entries are entered (i.e., more data is to be presented to the user) than can be displayed in the viewing area 100 of the list box, then a scroll bar 101 is automatically created. The scroll bar 101 permits the user to traverse all the entries in the list box by moving the slider element 102 . The list box control element has the advantage of permitting presentation of multiple entries simultaneously and the immediate interaction with those displayed entries. However, the list box control element has the drawback that the display of multiple entries using the conventional list box can require a lot of space on the GUI.
An example of another GUI control element, commonly referred to as a pop-up menu, is shown in FIG. 2 . The pop-up menu, unlike the list box, does not require a specification as to the number of visible rows. In the pop-up menu control element, the amount of data to be presented determines the number of visible rows. However, as shown on the left-had side of FIG. 2 , the pop-up menu, unlike the list box, typically operates in a default state to show a single selection 203 with an indicator 202 that informs the GUI user that other entries can be displayed when the user interacts with the menu. For example, the user can “pop-up” the list of entries 204 by clicking the triangle icon 202 on the menu 200 with the cursor via a mouse. Pop-up menus require minimal amount of display space in their default state. However, they require additional operations by the user in order to display and interact with the data to be presented and they are not convenient for large amounts of data.
Accordingly, as part of the continued evolution of GUIs generally, there exists a need for a new GUI control elements which optimally use the available space for displaying items to the user.
SUMMARY OF THE INVENTION
It is an objective of the present invention to provide a method and GUI control element which optimally present a list of items for both large and small amounts of available display space.
The above-identified and other objectives are achieved by combining the features of the menu and list control elements into a GUI control element which is capable of displaying data in multiple states, dependent on the amount of data to be displayed and/or the display space available. More specifically, according to exemplary embodiments of the present invention the control element is configured to display data in a first display state or a second display state, based on the amount of display space provided for the control element, wherein the control element, in the first display state, presents the data as a list, and the control element in the second display state, presents a menu which can be accessed to present the data.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:
FIG. 1 shows an exemplary display of a conventional list box GUI control element;
FIG. 2 shows an exemplary display of a conventional pop-up menu GUI control element;
FIGS. 3( a ) and ( b ) show a general computer system with which the present invention may be implemented;
FIG. 4 illustrates the display of an exemplary embodiment of the invention in its menu state;
FIG. 5 illustrates the display of an exemplary embodiment of the invention in its list state;
FIG. 6 shows a flow chart describing determination of the control element display state according to an exemplary embodiment of the invention;
FIG. 7 illustrates the display of another exemplary embodiment of the invention in its menu state;
FIG. 8 illustrates the display of another exemplary embodiment of the invention in its list state; and
FIG. 9 shows a flow chart describing a method for determining a control element display state according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION
In the following description, for the purpose of explanation and not limitation, certain details are set forth, such as particular techniques, steps, and system components, in order to provide a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced in other embodiments that depart from these details. In other instances, detailed descriptions of well-known concepts and methods have been omitted so as not to obscure the description of the present invention.
It will be readily appreciated by those skilled in the art that the techniques described herein may be implemented on any of a number of computing systems. In general, such computing systems, as illustrated in FIG. 3( a ), comprise a bus 300 for communicating information, a processor 301 coupled with the bus for processing information and instructions, a random access memory 302 coupled with the bus 300 for storing information and instructions for the processor 301 , a read only memory 303 coupled with the bus 300 for storing static information and instructions for the processor 301 , a data storage device 304 such as a magnetic disk and disk drive or CD ROM drive coupled with the bus 300 for storing information and instructions, a display device 305 coupled to the bus 300 for displaying information to the computer user, an alpha-numeric input device 306 including alpha-numeric and function keys coupled to the bus 300 for communication information and command selections to the processor 301 , a cursor control device 307 (e.g., a mouse) coupled to the bus for communicating information and command selections to the processor 301 , and a signal generation device 308 coupled to the bus 300 for communicating command selection to the processor 301 .
The display device 305 utilized with the computer system and the present invention may be a liquid crystal device, cathode ray tube, or other display device suitable for creating images and/or alphanumeric characters (and/or ideographic character sets) recognizable to the user. The cursor control device 307 allows the computer user to dynamically signal the two dimensional movement of a visible symbol (cursor) on a display screen of the display device 305 . Many implementations of the cursor control device are known in the art including a trackball, mouse, joystick or special keys on the alphanumeric input device 306 capable of signaling movement of a given direction or manner of displacement. It is to be appreciated that the cursor also may be directed and/or activated via input from the keyboard using special keys and key sequence commands. Alternatively, the cursor may be directed and/or activated via input from a number of specially adapted cursor directing devices, including those uniquely developed for the disabled. In the discussions regarding cursor movement and/or activation within the preferred embodiment, it is to be assumed that the input cursor directing device or push button may consist any of those described above and specifically is not limited to the mouse cursor device.
FIG. 3( b ) illustrates an exemplary computer system in which the present invention can be implemented. It will be appreciated that this computer system is one of many computer systems that can include the present invention. Therein, a keyboard 309 with keys 310 and keypad 312 is attached to the computer 314 along with a mouse device 316 and mouse push button(s) 318 for controlling the cursor. The mouse device 316 and push button 310 make up an exemplary cursor control device 307 . It will be appreciated that many other devices may be used as the cursor control device 307 , for instance the keyboard 309 may be substituted for the mouse device 316 and button(s) 318 as just discussed above or, alternatively, a touch-sensitive screen or speech recognition device (not shown) may be used. The computer 314 also typically contains a one or more media drives 320 (e.g., floppy disk, hard disk or CD ROM) and a display screen 322 .
Having described exemplary computer systems in which user interfaces and control elements according to the present invention can be implemented, the discussion now turns to a description of such user interfaces. According to exemplary embodiments of the present invention, the display features of both the list box and the pop-up menu are combined to form a new GUI control element capable of optimizing the available display space by presenting data to the user in one of two possible display states. This new GUI control element is referred to herein as a menu-list. The first display state of the menu-list control element 400 , referred to herein as the menu state, is illustrated in FIG. 4 .
Therein, the menu state presents the user with a single selection 404 which can be accessed to further display data on the GUI to the user. In common with conventional menu control elements, the menu state of the menu-list control element includes a triangular control icon 406 . The functionality and manipulation of pull-down or pop-up menus per se has been described above and, therefore, is not discussed in detail here again.
As shown in FIG. 5 , the list state of the menu-list control element 400 presents the data to the user as a list 501 . Data presented to the user in the menu-list control element 400 (in either its menu or list state) can be any kind of information, such as text, icons, symbols or any combination thereof. If there are more entries than visible rows, then a scroll bar 503 is automatically created to allow the user to traverse all the entries within the visible rows 501 .
FIG. 7 illustrates another exemplary embodiment of the menu-list control element in its menu state. In this embodiment, the menu-list control element presents multiple menu selections 701 , 705 , 709 which may be accessed to further display data to the user via the associated control icons 703 , 707 , 711 as discussed above with respect to the single menu-list control element.
The multiple menu-list control element in its list state is shown in FIG. 8 . As shown in the multiple visible display areas 800 , 802 , 804 , data presented to a user using the multiple menu-list control element (in either its menu or list state) can be any kind of information, such as text, icons, symbols or any combination thereof. The list state of the multiple menu-list element 700 presents data to the user as multiple lists 800 , 802 , 804 . Again, as with the single menu-list control element, if there are more entries than visible rows, then scroll bars 806 , 808 , 810 are automatically created.
According to an embodiment of the invention, the menu-list control is configured display data in either the menu or list state, dependent on the amount of data to be displayed and/or the display space available for use by the menu-list. The amount of space allocated to the menu-list control element may be a static value supplied, for example, by the application developer, or alternatively it may be a dynamic value calculated at runtime. For example, the amount of space allocated to the menu-list control could be derived from the amount of space remaining after space requirements have been determined for the other user interface elements on the display device. Alternatively, the desired size of the menu-list control element can be based on input data, for example, data received over a network.
The amount of space determined to be available can, in and of itself, determine the display state of the menu-list, e.g., if there is only sufficient space to display one selection, then the menu-list control element would display the data in the menu state. However, if the space determined to be allocated to the menu-list control element is greater than a predefined value, for example, two rows, then the data to be displayed is also taken into account in determining the display state of the menu-list control element. For example, assume that the space allocated to the control element is sufficient to display four rows of data and the data to be displayed consists of 5 selections. As a result the menu-list control element can be configured to display the data in the menu state. However, if the data to be displayed consists of 30 selections, the menu-list control element can be configured to display the data in the list state.
According to another embodiment of the invention, the menu-list control element is configured to dynamically transition between display states based on user manipulation with the menu-list control element. For example, as shown in FIG. 4 , the menu-list control element 400 further provides a resize gadget 408 which allows the user to manipulate the amount of space allocated to the menu-list control element. This can be accomplished by, for example, moving the cursor 410 over the resize gadget 408 , depressing a mouse button 318 and dragging the resize gadget 408 downwardly. The GUI can effect a visible change in the cursor 410 , e.g., from an arrow representation to a hand representation which appears to grab the resize gadget, in order to inform the user that the cursor 410 is in position to operate on the menu-list control element 400 . If the user resizes the control element such that an adequate amount space is available to display a predetermined amount of data, for example, two or more rows, the menu-list control element will transition into a second display state, referred to as the list state. As seen in FIG. 5 , the menu-list control element 400 retains the resize gadget 408 in its list state. If the user drags the resize gadget upwardly using cursor 410 such that the list space is reduced to less than the predetermined amount, e.g., two rows, then the menu-list control element will revert to its menu state.
Alternatively, the menu-list can be configured to dynamically transition between the menu and list states in response to user manipulation of other elements within the GUI. For example, the amount of space allocated to the menu-list control element can be derived from the amount of space remaining after the sizes have been determined for the other user interface elements on the display device. Accordingly, the user can indirectly control the space allocated to the menu-list control element by resizing other user interface elements.
FIG. 6 illustrates a method for displaying data to a user on a GUI according to an exemplary embodiment of the invention. As shown in FIG. 6 , which begins with step 600 , upon initiation of the menu-list control element, data is displayed to the user in a first state. The initial display state is either the menu state or the list state, the determination of which can be predefined or designated at run-time based on the amount of data be displayed. For example, if there are more than three but less than fifteen items to be presented to the user using the menu-list control element then the initial display state may be the menu state. However, if there are more than fifteen items to be presented, the initial state of the menu-list control element may be set to the list state. In either case, once the data has been initially displayed, the user can control which state the data is displayed in, as indicated in step 602 . The user can manipulate the resize gadget, for example, by selecting and dragging the gadget to a new location, thereby increasing or decreasing the amount of space allocated to the control element. In step 604 , if the allocated space is greater than a predefined amount, for example, two or more rows, then control flows to step 608 , wherein the data is displayed in the list state. However, if the allocated space is not greater than the predefined amount, the data is displayed in the menu state in step 606 . Those skilled in the art will appreciate that the range (or threshold) of the number of items which is used to determine the initial display state can vary and may be set by the user or the application which generates the menu-list control element.
Alternatively, the menu-list control element in its menu state can provide a transition gadget 713 to allow the user to transition the display of the menu-list from its menu state to its list state and vice versa. Accordingly, if the user activates the transition gadget 713 , for example, by selecting it with the mouse or other pointing device, the menu-list control element will transition from the menu state to the list state. As seen in FIG. 8 , the menu-list control element 700 retains the transition icon 713 in its list state. This permits the user to transition the multiple menu-list control element to its menu state. Unlike the resize gadget 408 , discussed above, the transition icon or disclosure triangle does not require that the user resize or drag the menu-list control element. To activate the transition icon or disclosure triangle 713 the user need only select the icon, e.g., click it with the mouse or other pointing device.
FIG. 9 shows a flow chart describing a method for reconfiguring the menu-list control element from its menu state to its list state and vise versa according to another exemplary embodiment of the invention. As shown in FIG. 9 , which begins with step 901 , data is displayed to the user in a first state upon initiation of the control element. As discussed previously with regard to FIG. 6 , the initial display state of the menu-list control element is either the menu state or the list state. Again, in either case, once the data has been initially displayed, the user can control which state the data is displayed in, as indicated in step 903 . At step 903 , the user can manipulate the transition gadget, for example, by selecting it with the mouse or other pointing device. Then, in step 907 , the control element with transition from it current display state to it alternate display state. For example, if the control element is currently in the menu state and the transition gadget is activated, then the control element will transition to the list state and vise versa.
The invention has been described with reference to particular embodiments. However, it will be readily apparent to those skilled in the art that it is possible to embody the invention in specific forms other than those of the preferred embodiments described above. This may be done without departing form the spirit of the invention. Thus, the preferred embodiment is merely illustrative and should not be considered restrictive in any way. The scope of the invention is given by the appended claims, rather than the preceding description, and all variations and equivalents which fall within the range of the claims are intended to be embraced therein. | A control element for use in a graphical user interface, which combines the display features of the list box element and the pop-up menu element into a single GUI control element. The combined menu list control element is capable of displaying data in multiple states thereby allowing to it to optimally use the available display space for presenting data to the user. By allowing menu list control element to display data as either a list or a menu, it combines the advantages of lists and menus while avoiding their disadvantages. | 6 |
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to a ceramic plate valve of a cold water and a hot water mixing bibcock of sanitary use, and an improvement in its operating method.
BACKGROUND OF THE INVENTION
A conventional valve mechanism having a pair of ceramic plate valves which are installed in a valve chamber of a mixing bibcock is shown in FIGS. 1 and 6 of Japanese Patent Publication No. 37179/1981, and in FIGS. 7 and 8 of the present application.
The valve mechanism shown in FIGS. 7 and 8 will now be briefly described.
A movable plate valve 40 has a mixing chamber 41 shaped as a downward-facing blind hole. The movable plate valve 40 is placed on top of a fixed plate valve 42. A hot water inlet port 43 and a cold water inlet port 44 in plate valve 42 are adapted to be freely opened and closed, and are adapted to be connected to an outlet 45 through the mixing chamber 41. The plate valve 40 is positioned in its forwardmost position and hot water inlet port 43 and the cold water inlet port 44 are closed when a lever 46 is positioned as shown by the solid lines. Hot water and cold water are discharged in equal quantities when the plate valve 40 is moved rearwardly when the lever 46 is pushed down to the horizontal position shown by the alternate long and two short dashed lines. More hot water is discharged when the lever 46 is turned horizontally to the right. The water is stopped when the lever 46 is restored to the central position and is tilted up. The movable plate valve 40, which is connected to the lever 46 by the valve shaft 47, moves backward and forward along a guide portion 49 connected to a guide groove 48 that is provided in the fixed plate valve 42 for the purpose of discharging or stopping the hot and cold water.
However, this structure has a problem in that the valve mechanism is not easy for children or people with handicapped hands to operate, and errors in operation tend to occur because the discharge and stopping of the hot and cold water is carried out by moving the lever vertically, and the discharge of hot and cold water, either separately or together, is carried out by moving the lever horizontally.
Furthermore, when the hot water inlet port is fully open, the water flow rate rapidly decreases. As a result, the temperature of the hot water must be adjusted whenever the hot water inlet port is fully open.
The mechanism of the connection between the fixed plate valve and the valve shaft is excessively complicated, because the movable plate valve is adapted to both turn and reciprocate. As a result, the number of parts is increased, and assembly and disassembly when a problem occurs is complicated, which adversely affects maintenance and productivity.
OBJECT AND BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a mechanism in which the individual supply of hot and cold water, and the mixture, temperature adjustment, supply and stoppage of water, can be conducted simply by turning the lever horizontally so as to move the movable plate valve which opens and closes the valve mechanism. To this end, the mechanism of the connection between the lever and the movable plate valve is simplified according to the present invention, to ensure easy operation, prevent operating errors, and simplifying maintenance.
The valve mechanism of the present invention comprises a fixed plate valve and a movable plate valve in the form of similar discs and which are made of ceramic. The movable plate valve has a recessed guide groove which is formed as a blind groove in the surface abutting the fixed plate valve (bottom surface in this embodiment). The recessed guide groove comprises a cold water guide port at one end thereof which is adapted to be connected to a cold water inlet port of the fixed plate valve by the movement of a lever. The recessed guide groove further comprises a hot water guide port at another edge part thereof which is adapted to be connected to the hot inlet port of the fixed plate valve by the movement of the lever. The recessed guide groove is always connected to an outlet of the fixed plate valve. A plurality of recessed pawl holes used for securing pawls which are provided on the fixed plate valve is provided in the edge of the upper surface of the movable plate valve. All of the hot water inlet port, cold water inlet port, and outlet, which are provided in the fixed plate valve, penetrate the fixed plate valve to connect the top surface thereof to the bottom surface. The surfaces of this fixed plate valve and the movable plate valve are fitted against each other to form a plate valve unit.
The interior of a main body of the mixing bibcock supports the fixed plate valve with a seating plate therebetween. A boss is rotatably secured by means of a securing pawl and a pawl hole to the valve chamber of an inner cylinder. The movable plate valve, which is movably secured by the boss, is inserted in the valve chamber of the inner cylinder. The movable plate valve and the fixed plate valve face each other at abutting surfaces thereof. A handle grill having a lever is secured by a screw to a handle shaft which is provided on the boss. As a result of this structure, the supply of appropriate quantities of hot and cold water, or a mixture thereof of any desired temperature, and temperature adjustment can be conducted by only horizontal operation of the lever.
The supply and stoppage of hot and cold water can be selectively conducted by the simple horizontal operation of a lever to meet various needs, such as the supply of appropriate quantities of hot or cold water, or a mixture thereof of a suitable temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a vertical sectional view of a mixing bibcock according to the present invention;
FIG. 2(A) is a plan view of a fixed plate valve thereof;
FIG. 2(B) is a plan view of a movable plate valve thereof;
FIG. 3(A) is a vertical cross sectional view of the operating mechanism thereof;
FIG. 3(B) is a cross sectional view taken along the line 3A--3A of FIG. 3(A);
FIG. 4(A) is a view of the plate valves illustrating the relationship between a lever and a position at which water flow is stopped;
FIG. 4(B) is a view similar to FIG. 4(A) illustrating the relationship between the lever position and the mixing ratio of hot and cold water and temperature adjustment;
FIG. 5(A) is a view similar to FIG. 4(A) illustrating the relationship between the lever position and the full flow of hot water and small flow of cold water;
FIG. 5(B) is a view similar to FIG. 4(A) illustrating the relationship between the lever position and full flow of cold water only;
FIG. 6 is a plan view, partly in section, of the mixing bibcock, illustrating the relationship between the bibcock and the levers; and
FIGS. 7 and 8 are views illustrating a conventional bibcock in which the procedure of operating the lever vertically and horizontally is illustrated.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1-3(B), a fixed plate valve 1 and a movable plate valve 2, which are formed from ceramic in a disc shape, are shown. The fixed plate valve 1 comprises at one edge part of the abutting surface 3 (surface against which the movable plate valve abuts) thereof a cold water inlet port 4 which is adapted to be connected to a cold water guide port 6 which is formed as a blind hole in movable plate valve 2, by the moving of a lever 5, to be described hereinafter. The fixed plate valve 1 further comprises at another edge part of the abutting surface 3 thereof a hot water inlet port 7 which is also adapted to be connected to a hot water guide port 8 of the movable plate valve 2 by the movement of the same lever 5. A recessed water guide groove 10 is provided in movable valve plate 2 which connects the hot water guide port 8 to the cold water guide port 6 by an intermediate portion thereof, and which is always open to an outlet 9 in the fixed plate valve 1. A plurality of pawl holes 13 which are adapted to be secured to a plurality of securing pawls 12 to be described later, is provided in the opposite surface of the movable plate valve 2 from the surface with the recessed guide groove 10 (namely, in the top of the movable plate valve 2). Each of the cold water inlet port 4, hot water inlet port 7, and outlet 9 extends through the fixed plate valve 1, connecting the top surface and bottom surface of the fixed plate valve 1. A plate valve unit A is formed by combining the fixed plate valve 1 and the movable plate valve 2 in such a manner that the abutting surface 3a of the movable plate valve 2 and the abutting surface 3 of the fixed plate valve 1 face and abut each other. A casing 15 is secured to a threaded mounting recess 14 in the upper portion of a main body B of the mixing bibcock. An inner cylinder 18 having a seating plate 16 and a valve chamber 17 is secured to the casing 15. The fixed plate valve 1 and the movable plate valve 2 are inserted in the valve chamber 17 in such a manner that the fixed plate valve 1 is below, and the movable plate valve 2 is positioned above, and the abutting surfaces 3 and 3a thereof face and abut each other. A handle shaft 19 is integrally provided on a boss 20 by insert forming. The boss 20 and the inner cylinder 18, which is inserted into the casing 15, are freely movable with respect to each other in the rotational direction through symmetrically formed step surfaces 21 and 21a. A spring 23 and a ball 24 which are arranged to stop the boss 20 at a cold water stop position, to be described hereinafter, are arranged in a lateral hole 22 that is bored in the boss 20 and a handle shaft 19. A stopper 25 which projects from the circumference of the boss 20 engaged with a lateral guide groove 26 which horizontally faces the inner circumference of the inner cylinder 18, and which is formed in a semicircular arc. The position at which the stopper 25 hits and stops at a left step part 27 is defined as a position for supplying hot water, to be described hereinafter, and the position at which the stopper 25 hits and stops at a right step part 27a is defined as a position for supplying cold water, to be described hereinafter. A plurality of securing pawls 12 projects from the bottom surface of the boss 20. These securing pawls 12 are fitted into the pawl holes 13 which are provided in the top surface of the movable plate valve 2, so as to enable the movable plate valve 2 to be turned by the boss 20. A handle grill 28 is connected to the handle shaft 19 by a screw 29. The lever 5 projects in the circumferential direction from the upper portion of the handle grill 28. Both hot water and cold water are stopped when the lever 5 is positioned in the same vertical plane with a water discharge pipe 30. When the lever 5 is positioned at the hot water supply position shown in FIG. 5(A), after being turned horizontally to the left from the water stop position, the hot water supply pipe 31 shown in FIG. 6 supplies a full flow of hot water. Simultaneously with this full flow of hot water, a part of the recessed guide groove 10 and a small corner portion 4a of the cold water inlet port 4 are connected to each other by guide groove 10. Due to this connection of the guide groove 10 and the cold water inlet port 4, cold water in a cold water supply chamber 32 is gradually heated by conduction of heat when hot water is fully supplied for a long time. As a result, the surfaces of the main body B of the mixing bibcock are protected from overheating. By moving the lever 5 to intermediate positions between the water stop position and the hot water supply position, a mixture of hot and cold water, and temperature adjustment of the water, can be freely conducted. By moving the lever 5 to intermediate positions between the water stop position and the cold water supply position, the cold water flow rate can be freely adjusted. The cold water in the cold water supply chamber 32 is supplied to the water delivery pipe 30 through the cold water inlet port 4, recessed guide groove 10, and outlet 9, and a delivery chamber 11 shown in FIG. 1. Hot water in the hot water supply chamber 33 is supplied to the water delivery pipe 30 through the hot water inlet port 7, recessed guide groove 10, outlet 9, and the delivery chamber 11.
When the lever 5 positioned at the stop position is gradually moved from the position shown in FIG. 4(A) to the left, the boss 20 which is connected to the handle grill 28, which is integrally formed with the lever 5 through the handle shaft 19, is turned in the same direction as that of the lever 5. The movable plate valve 2, which is connected to the boss 20 by the securing pawls 12 and the pawl holes 13, is turned in the same direction as the lever 5 and the boss 20. As a result, the hot water guide port 8 which is provided in the recessed guide groove 10 of the movable plate valve 2 is connected to the hot water inlet port 7 of the fixed plate valve 1, and, at the same time, the cold water guide port 6 of the recessed guide groove 10 is connected to the cold water inlet port 4 of the fixed plate valve 1. Consequently, hot and cold water are supplied in equal quantities. As the lever 5 is moved to the left with these positional relationships kept as they are, the quantity of hot water increases, while the quantity of cold water decreases toward zero. During this process, the stopper 25 of the boss 20 approaches the step part 27 in the lateral guide groove 26. The lever 5 stops at the position at which the stopper 25 hits the step part 27. A full flow of hot water is supplied at this stop position. When hot water is supplied in this way, the relationships between the recessed guide groove 10 and the hot water inlet port 7 and the cold water inlet port 4 are as shown in FIG. 5(A), in which the hot water guide port 8 and the hot water inlet port 7 are fully connected, and the cold water guide port 6 is cut off from the cold water inlet port 4. However, part of the recessed guide groove 10 and the corner portion 4a of the cold water inlet port 4 are slightly connected, so that some of the cold water in the cold water supply chamber 32 is delivered with the hot water. As a result, the cold water in the cold water supply chamber 32 is prevented from expansion by heating, even when hot water is continuously supplied. Since the quantity of cold water supplied increases linearly with the movement of the lever 5 to the right after the hot water supply has been ended by the movement of the lever 5 to the water stop position, a desired quantity of cold water can be supplied. As the lever 5 is gradually moved to the right, the stopper 25 of the boss 20 similarly approaches the step part 27a in the lateral guide groove 26. The lever 5 is stopped at the cold water supply position when the stopper 25 hits the step part 27a, and only cold water is supplied at this position. During the movement of the lever 5 to the right, the relationships between the recessed guide groove 10 and the cold water guide port 6 contribute to an increase in the quantity of cold water. Therefore, a desired quantity of cold water can be supplied.
As described above, the device according to the present invention displays the following advantages:
(1) Because a guide groove formed as a blind hole having a cold water guide port and a hot water guide port at each end thereof is recessed into an abutting surface of a movable plate valve, the flow rate of a mixture of hot and cold water and the temperature of the water can be adjusted, and a full flow of hot water can be supplied by turning a lever horizontally to the left from a stop position, and the full flow rate of cold water can be adjusted, and a full flow of cold water can be supplied by turning the lever horizontally to the right from the stop position.
(2) Because the movable plate valve and a boss are secured to each other by securing pawls and pawl holes, and a handle shaft integrally provided on the boss and a handle grill are integrally connected, operability is improved by enabling a simple turning of the lever horizontally to either side of a stop position, and dangerous splashing of hot water can be completely prevented, even if the lever is rapidly turned to either the right or the left.
(3) Because the boss and an inner cylinder which accommodates the boss are arranged to slide smoothly by means of the symmetrical step surfaces, the structure can be made to strongly correspond to the fluid pressure applied to the movable plate valve, and the mixing bibcock can be operated very smoothly without any restrictions applied to the turning of the boss and the movable plate valve.
(4) In comparison with the conventional vertical or horizontal movement of a lever, the operability is improved because a simple handling of the lever in only the horizontal direction to either the right or the left produces a supply of the desired hot water, cold water, or a mixture thereof, and even with hands that cannot move freely, the mixing bibcock can be operated securely and errors in operation can be prevented, and since the operating mechanism is so simple, the cost can be reduced in the manufacturing and in the product distribution process. | The invention relates the mixing valve for controlling the mixture of hot and cold water. The valve takes the form of a fixed and movable plate. A recessed guide groove in the movable plate is formed as a blind groove cooperating with hot and cold water ports and an outlet in the fixed plate. The guide groove has several branches arranged to variably connect to the hot and cold water ports in different relative positions of the movable and fixed plates. | 5 |
FIELD OF THE INVENTION
[0001] The present invention concerns casings for electric or electronic circuits, which are used for the circuits from electromagnetic interference. This type of casing is often also referred to as shield casing.
BACKGROUND OF THE INVENTION
[0002] Electric and electronic circuits are often subject to electromagnetic interference caused by other circuits in the vicinity, nearby conductors carrying high frequency signals or large currents, or other sources. Electromagnetic interference is commonly known under its acronym EMI and comprises electromagnetic radiation as well as static discharges and other phenomena, which may influence electric and electronic circuits. Electromagnetic interference of any kind is generally referred to hereinafter as EMI. EMI differently affects and influences different types of circuits or components. Especially, circuits for receiving high frequency signals having low signal levels are subject to EMI. To avoid problems due to this interference, the circuitry most susceptible to EMI is often mounted inside of casings made from electromagnetic shielding material. For proper operation the casing must not, e.g., have openings larger than the smallest expected wavelength of an interfering electromagnetic wave. The operating principle of shield casings of this type is to convert the energy of the electromagnetic wave into eddy currents flowing in the casing and finally convert the eddy currents into heat. The material of the shield casing preferably has a high electric conductivity and a low magnetic permeability. To improve the shield effect of the casing and to reduce detrimental effects due to capacitive coupling, the shield casing is generally connected to a low impedance circuit ground. For this purpose, the shield casing has projecting elements, which snugly fit into corresponding openings in a circuit carrier, e.g., a printed circuit board. The casing is then soldered to the circuit carrier, connecting the casing electrically conducting to the circuit ground.
[0003] Common shield casings generally consist of a frame, determining the space to be shielded, and a lid, or cover, which is fastened electrically conducting to the frame. A shield casing as mentioned above is shown exemplarily in FIG. 1 of the drawing.
[0004] FIG. 1 a ) shows, on its left side, a top view of a frame 1 and, on its right side, a lid 2 of a common shield casing according to the prior art. The frame 1 carries depressed parts 3 along its circumference, only few of which are referenced by a reference symbol for the sake of clarity. FIG. 1 b ) shows a side view of the shield casing's components according to the prior art. Again, the frame 1 is shown on the left side of the figure. The depressed parts 3 of the frame 1 serve as an engaging element for corresponding engaging elements of the lid 2 . The frame 1 further has projecting elements 4 , which serve for mounting the frame electrically conducting to a circuit carrier (not shown). The lid 2 shown on the right side of FIG. 1 b ) has resilient clamps 6 along its outer boundary, which are formed so as to engage with the corresponding depressed parts 3 of the frame 1 . When the lid 2 is correctly mounted to the frame 1 , the depressed parts 3 of the frame 1 and the resilient clamps 6 of the lid 2 ensure proper electrical and mechanical contact. In another embodiment, which is not shown in FIG. 1 , the depressed parts 3 of the frame 1 are projecting out of the frame 1 , similarly engaging with corresponding resilient clamps 6 of a lid 2 . Both of these methods along with other methods of fixing a lid 2 to a frame 1 of a shield casing are in the following considered equivalent and no distinction is made between them.
[0005] A correctly assembled shield casing as described above with reference to FIG. 1 has no large openings, thus preventing electromagnetic waves or other EMI phenomena from influencing the circuitry contained in the shielded space inside the casing. However, the circuitry inside the shield casing, especially active semiconductor components, may generate considerable heat, which has to be dissipated in order not to exceed the maximum allowable operating temperature of the respective components. As mostly the shield casings are rather small, surrounding only few components of a complex system, convection does not contribute much to heat transfer and dissipation. Generally, the components inside of the shield casings do not have defined and reliable thermal contact with any part of the casing. This is largely reducing the effect of direct heat transportation in solid matters, which is one of the most efficient ways to remove heat from a heat source via a heat sink. Dissipation of heat via radiation is generally far less effective than the other methods of heat transport mentioned above. As a result, the temperature of components inside properly closed shield casings may reach unwanted or even detrimental levels.
[0006] In order to overcome the problems of excessive heat inside of shield casings, attempts were made to establish a solid contact between a heat source inside of the casing and the casing itself, thus using the casing as a heat sink. FIG. 2 shows an exemplary shield casing with improved heat removal via a thermal conductor, which is brought into contact with heat generating components inside of the casing. FIG. 2 a ) shows on its left side a frame 1 and on its right side a lid 2 . In the frame 1 a heat source 7 is placed, represented by a schematic view of an integrated circuit. A part of the lid 2 shown on the right side of FIG. 2 a ) is used as a thermal conductor 11 , contacting the heat source 7 inside the shield casing once the casing is assembled properly. In order to do so, the thermal conductor 11 is partly cut free from the lid 2 and bent inwards. FIG. 2 b ) shows a side view of the frame 1 on its left side and the lid 2 on its right side, cut along the sectional line A-A′. The frame 1 is substantially the same as in FIG. 1 . The frame 1 is mounted to a circuit carrier 8 by means of the projecting elements 4 , and the circuit carrier 8 carries the heat source 7 . The lid 2 is similar to the lid 2 in FIG. 1 b ) but additionally carries the cut-and-bent thermal conductor 11 . Once assembled, the contact area 12 of the thermal conductor 11 comes into contact with the corresponding area of the heat source 7 inside the shield casing. In order to improve the thermal conducting contact between the contact area 12 and the heat-generating component, heat-conducting agents may be used. By cutting and bending the heat-conducting element 11 , an opening 13 in the shield casing is created, allowing electromagnetic waves or other EMI phenomena to influence components contained within the shielded space and reducing the shielding effect.
[0007] It is an object of the invention to solve the problem of excessive temperature of components in substantially closed casings, especially shield casings.
SUMMARY OF THE INVENTION
[0008] To achieve this object a shield casing is suggested having no unwanted openings, thus providing good shielding against EMI phenomena, and having means for thermally contacting heat generating components inside the casing, using the casing as a heat sink to dissipate heat. The suggested shield casing consists of at least a frame, a cover and an inwardly projecting element for thermally contacting a heat source within the casing, according to claim 1 . The inwardly projecting element is designed so as not to cause any unwanted openings in the casing. Advantageous embodiments of the invention are disclosed in the sub claims.
[0009] According to the invention, the shield casing has an element projecting inwards into the space confined by a frame and a lid, the element contacting a heat source inside the casing and serving as a thermal conductor. In a preferred embodiment the inwardly projecting element is attached to the frame near the top rim of the frame. It is, however, possible that the inwardly projecting element is attached to the lower rim of the frame. Depending on the number of heat-generating components inside the shield casing one or more inwardly projecting elements may be used. In a preferred embodiment the frame is a cut-and-bent part, which is produced by cutting a planar material, e.g., sheet metal, and bending the cut piece into its desired three-dimensional form. In this way the frame can be produced from one single piece. It is, however, possible to produce the frame using other techniques, such as die casting, or to assemble the frame from multiple parts using soldering or welding techniques, riveting or interlocking parts, a method also known to the public as snap-together. The inwardly projecting element is bent in a way, that a plane surface of the element resiliently contacts a corresponding surface of a heat source inside the casing. The heat transfer may be improved by using heat-conducting agents. A completely closed lid is fastened removable to the frame, closing the shield casing. The lid and the frame may have interlocking structures to improve the electrical and mechanical contact between the frame and the lid. The interlocking elements of the frame and the lid are known from the prior art and are not described in detail. It is, however, also possible to fasten the lid to the frame using screws, bolts, or similar means, or to solder or weld the parts together. In one embodiment, in order to improve the contact between the inwardly projecting element and the heat source, a free end of the element is resiliently bent towards the lid, such that the correctly placed lid applies an additional force on the element, advantageously improving the heat transfer by pressing the contact area of the element against the corresponding contact area of the heat source. In another embodiment the inwardly projecting element has two or more contact areas for contacting two or more heat sources inside the casing. In this case the inwardly projecting element is bent towards the lid between the individual contact areas, thereby improving the thermal contact of each individual contact area by applying a force pressing the contact areas onto the corresponding surfaces of the heat sources. The invention is not limited to inwardly projecting elements being attached to the frame. In another embodiment, the element serving as a thermal conductor is attached to the lid. In this case, the thermal conductor is first bent so as to form a resilient clamp fastening the lid from the inside rather than from the outside. The free end of the clamp is then used to form the heat conductor, which is brought into contact with the heat source.
BRIEF DESCRIPTION OF THE DRAWING
[0010] For a better understanding the invention is described in the following with reference to the drawing. In the drawing
[0011] FIG. 1 shows a shield casing according to the prior art,
[0012] FIG. 2 shows another shield casing according to the prior art,
[0013] FIG. 3 shows a first embodiment of a shield casing according to the invention,
[0014] FIG. 4 shows a second embodiment of a shield casing according to the invention, and
[0015] FIG. 5 shows a third embodiment of a shield casing according to the invention.
[0016] In the drawing, identical or similar elements are referenced with identical reference symbols.
[0017] FIGS. 1 and 2 have already been described in detail in the prior art section and will therefore not be described again.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] FIG. 3 shows a first embodiment of a shield casing according to the invention. The left side of FIG. 3 a ) shows a top view of a frame 1 with a thermal conductor 11 . A heat source 7 is represented by a schematic view of an integrated circuit. An area of contact 12 of the thermal conductor 11 thermally contacts a corresponding surface of the heat source 7 . Depressed parts 3 are arranged along the circumference of the frame, serving as engaging elements for corresponding parts of a lid. The right side of FIG. 3 a ) shows a top view of a lid 2 , which obviously has no openings caused by a thermal conductor, thus ensuring proper shielding when mounted to the frame 1 . FIG. 3 b ) shows in its left side a side view of the frame 1 cut along a section line B-B′ shown in FIG. 3 a ). The frame 1 is mounted to a circuit carrier 8 , which carries the heat source 7 , by means of projecting elements 4 . The thermal conductor 11 is bent inwards from the top right rim of the frame 1 . The thermal conductor 11 is bent in a way, such that its contact area 12 contacts a corresponding surface of the heat source 7 . The right side of FIG. 3 b ) shows a side view of the lid 2 and the resilient clamps 6 , which engage with the depressed parts 3 of the frame when the lid 2 is mounted. From FIGS. 3 a ) and 3 b ) it is easy to be seen that no unwanted openings in the frame 1 or the lid 2 are present caused by the forming of the thermal conductor 11 . During manufacturing, the heat source 7 is placed and soldered first, before the frame 1 is mounted. When mounting the frame 1 , the thermal contact 11 may be bent towards the heat source 7 more than necessary, thus forming a kind of spring loaded part, improving the contact between the heat source 7 and the thermal conductor 11 .
[0019] FIG. 4 shows a second embodiment of a shield frame according to the invention. On the left side of FIG. 4 a ) a top view of a frame 1 is shown. As previously described in FIG. 3 , the frame bears a thermal conductor 11 , attached to the upper right rim of the frame 1 . The thermal conductor 11 has an area of contact 12 for contacting a corresponding surface of a heat source 7 . The heat source 7 is represented by a schematic view of an integrated circuit. The free end or support section 14 of the thermal conductor 11 is bent towards a lid 2 , which is shown on the right side of FIG. 4 a ), and the correctly placed lid 2 applies a force on the support section 14 , increasing the pressure between the area of contact 12 and the corresponding surface of the heat source 7 . Like before, depressed parts 3 serve as an interlocking element for securing the lid 2 . The lid 2 is essentially of the same kind as the one described in FIG. 3 . The function of the support section 14 of thermal conductor 11 is easier understood when looking at the side view of the frame, which is presented in FIG. 4 b ). On the left side of FIG. 4 b ) a side view of the frame 1 is shown, cut along a section line C-C′. The frame 1 is mounted to a circuit carrier 8 by means of projecting elements 4 . The circuit carrier 8 carries the heat source 7 . The thermal conductor 11 bends inwards from the upper right rim of the frame 1 and downwards towards the heat source 7 . The area of contact 12 of the thermal conductor 11 contacts a corresponding surface of the heat source 7 and the thermal conductor 11 then bends upward again towards the upper side of the frame 1 , forming the support section 14 . The lid 2 , which is shown on the right side of FIG. 4 b ), when correctly placed on the frame 1 , applies a pressure on the support section 14 , increasing the pressure between the area of contact 12 and the corresponding surface of the heat source 7 . Depressed parts 3 on the frame 1 and resilient clamps 6 on the lid 2 ensure proper mechanical and electrical contact of the parts of the shield casing. This embodiment may advantageously be used when the heat source 7 is not placed close to the frame 1 , since a rather long thermal conductor 11 may not ensure good contact between the thermal conductor 11 and the heat source 7 due to a certain flexibility of the material.
[0020] FIG. 5 shows a third embodiment of a shield casing according to the invention. FIG. 5 a ) shows on its left side a top view of a frame 1 with depressed parts 3 along its circumference. Like in the embodiments described before, the depressed parts 3 serve as interlocking elements for corresponding elements of a lid 2 , which is shown on the right side of FIG. 5 a ). The lid 2 has a thermal conductor 11 attached to it on its right side. The thermal conductor 11 is bent downward underneath the lid 2 and has an area of contact 12 for contacting a corresponding surface of a heat sink. The thermal conductor further has a support section 14 , which is bent upward against the lid 2 and applies an additional force on the area of contact. The function is easier to be understood taking a look at FIG. 5 b ). FIG. 5 b ) shows on its left side a side view of the frame 1 with depressed parts 3 for electrically and mechanically contacting the lid 2 and projecting elements 4 for mounting the frame to a circuit carrier 8 . On its right side, FIG. 5 b ) shows a side view of a completely assembled shield casing cut along a section line D-D′. The frame 1 is mounted to the circuit carrier 8 with the projecting elements 4 . The circuit carrier 7 carries a heat source 7 . The lid 2 is fastened to the frame 1 and locked by the resilient clamps 6 engaging with the depressed parts 3 . The thermal conductor 11 bends inwards into the casing from the top right edge of the lid 2 . A part of the thermal conductor 11 is formed so as to form a resilient clamp pressing against the frame from the inside rather than from the outside, as do the resilient clamps 6 . This ensures good electrical and mechanical contact between the lid 2 and the frame 1 in the area of the inwardly bending thermal conductor 11 , too, thereby maintaining an almost entirely closed shield casing and thus good shielding properties. The thermal conductor further has an area of contact 12 for contacting a corresponding surface of the heat source 7 . A further section of the thermal conductor 11 is bent upward against the lid 2 , forming a support section 14 . This ensures application of an evenly distributed pressure between the area of contact 12 and the heat source 7 .
[0021] In all the embodiments described above it is of course possible to employ heat conducting agents to improve the thermal contact between the thermal conductor 11 and the heat source. It is also possible to form multiple areas of contact within one thermal conductor 11 . This may be accompanied by corresponding support sections between these multiple areas of contact 12 . It is also possible to omit the support section 14 of a thermal conductor 11 , if the requirements as to pressure force are less stringent. The frame 1 or the lid 2 may have more than one thermal conductor 11 , and different forms of thermal conductors, being part of either the frame 1 or the lid 2 , may be used in parallel in one single shield casing. Any combination of the embodiments described above is therefore considered to be encompassed by the invention. The invention is also not limited to shield casings shielding against EMI phenomena, it may also be used in closed casings designed for conserving vacua or preventing gases or liquids to enter the space inside the casing. | A casing for electric circuits is proposed, which shields the circuits from EMI phenomena. The circuit has means for making thermal contact with heat generating components inside the casing, allowing using the casing as a heat sink to dissipate the heat. The casing comprises a frame, a cover and an inwardly projecting element for thermally contacting a heat source within the casing. The inwardly projecting element is designed so as not to cause any openings in the casing. The inwardly projecting element may be an integral part of the frame or the cover and all parts of the casing may advantageously be produced using cut-and-bend procedures. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to quick disconnect, lockable mounting couplers for antennas.
2. Prior Art
In the prior art various devices have been advanced which show relatively lockable disconnectable members. U.S. Pat. No. 3,812,279 shows a cable television housing with the cover and base, and a key lock member for securing the cover and base when they are mounted together. When the key lock member is locked, the parts are prevented against relative rotation, but in a much different environment and with different specific construction.
U.S. Pat. Nos. 3,545,148; 3,492,769; and 3,369,247 deal specifically with automotive antenna mounting brackets, but none of which show a quick disconnect with a locking device. U.S. Pat. No. 3,492,769 does show a threaded nut that can be used for a connector, and U.S. Pat. No. 3,545,148 shows contactor connections that appear to be threaded together rather than quick disconnect devices, with a key lock for preventing tampering.
A tool lock is shown in U.S. Pat. No. 1,417,411 with a locking pin operated by a rotating member, and U.S. Pat. No. 2,147,026 shows a coupling that has a locking pin operated by a lever.
Australian Pat. No. 23,114 shows a twist lock base for an electric lamp, but not one which includes a key lock feature, and U.S. Pat. No. 3,521,218 shows a type of a lock for a heavy duty connector.
SUMMARY OF THE INVENTION
The present invention relates to a construction for mounting antennas or the like onto a surface such as a panel of an automobile, and which will permit removal of a cap and antenna portion from a base portion of the coupler when the device is unlocked, but which prevents removal of the antenna when the cap is locked, without damaging or breaking the antenna or the mounting base itself.
The present device involves a connector which is made of two parts, a base which can be attached to a surface in the normal manner, and a cap which houses the base or lower portion of an antenna. The cap is attachable and removable relative to the base portion of the connector, and at the same time the cap is installed the antenna itself is electrically connected to a receptacle in the base portion. A key lock unit can be rotated to position so that the cover cannot be removed. In one form of the device a twist lock cap is used, and in another form disclosed a straight line motion is used for mounting the cap.
Because the unit is made so that it can be easily molded, the device is economical, and yet secure, and as strong and rigid as other existing devices which do not have the quick removal feature.
The importance of the quick removal feature is that when a party leaves an automobile having an antenna on it parked for any length of time the antenna can be removed and stored inside, out of sight, or can be carried with the party for security. The removal of the antenna not only eliminates the likelihood of damage to the antenna itself, but removes an obvious signal to thieves that would like to steal the radio equipment with which the antenna is used. The base which remains is relatively unobtrusive, and not easily noticed. This tends to reduce attracting of attention to the antenna system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an antenna coupling made according to a first form of the present invention;
FIG. 2 is a fragmentary sectional view taken as on line 2--2 in FIG. 1;
FIG. 3 is a sectional view taken as on line 3--3 in FIG. 2;
FIG. 4 is a sectional view taken as on line 4--4 in FIG. 3;
FIG. 4A is a sectional view taken as on line 4A--4A in FIG. 4;
FIG. 5 is a vertical sectional view of a modified form of the present invention; and
FIG. 6 is a sectional view taken as on line 6--6 in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a first form of the invention a quick disconnect antenna coupling illustrated generally at 10 as shown includes a base member 11, and a cap member 12. The base member is mounted onto a vehicle trunk lid 13, or other suitable metal panel of a vehicle, in the usual manner. A clamping bracket 14 is used for holding the base and it extends through a provided opening 15 in the panel. A threaded screw clamps against the panel 15 to securely hold bracket 14 and the base 11 to the panel 15. A gasket 16 is used under the base.
The cap 12 has an antenna 20 mounted thereto, through a suitable ferrule 21, and the lower end of the antenna 20, as illustrated at 20A, is electrically connected to a male connector member 23 that is mounted in a suitable housing 24 that in turn is fixed to the interior portions of the cap 12. The male antenna connector is on the central axis of the cover and located within the housing. An adapter 24A has an external thread over which the lower portion 21A of the antenna is threadably secured to the adapter to secure the assembly. After assembly a rivet 28B may be used to secure the antenna components from unscrewing from the cap.
The cap includes an outer locking ring 25 that is at the base of the ferrule 21, and which is secured to the lower portion of the antenna as described. Other adapters may be used for different style antennas so the cap locking member can be easily adapted to a wide selection of antennas.
The locking ring 25 of the cap includes an annular flange 26 with outer serrations or irregularities that make it easy to grip, and this flange 26 extends downwardly at the outer periphery of the cap and has four inwardly extending dogs or lugs 27 positioned at 90° apart (see FIGS. 2 and 4). These lugs 27 are spaced from each other to form a twist lock arrangement, and it can be seen that when the locking ring 25 is properly positioned, it will fit over and slip down onto an upper lock top 30 of the base 11.
Additionally, the locking ring 25 has an integral or fixedly attached depending locking finger or prong 28 which protrudes downwardly farther than the lugs 27. When the cap 25 is placed onto the base 12, the locking finger will pass through a provided aperture 31 in the base.
The aperture 31 is provided in the top wall 32 of the housing 11, and four lugs 34, as can be seen, extend radially out from the top wall 32. The lugs 27 can be positioned between the lugs 34 when the cover is installed so that the flange 26 can be slipped down over the top portion 30 of the base 11 when the locking lugs 27 are positioned as shown in dotted lines in FIG. 4. At the same time, by proper orientation, the finger 28 can be inserted through the opening 31.
It should be noted that the skirt or side wall of the base 11 also has a key lock unit 35 thereon which is mounted in a housing 36 formed in the side wall of the base 11. This key lock unit has a locking tang or cam that can be rotated 90° from an unlocked position to a locked position, which is shown in solid lines in FIGS. 2, 3 and 4. The unlocked position is shown in dotted lines in FIG. 3. With the tang 36 in its unlocked position the finger 28 can pass downwardly through the opening 31 as the cap is placed over the upper portion 30 of base 14. The flange 26 of locking ring 25 moves to position so that the locking lugs 27 are below the plane of the lower surfaces of the lugs 34. Then the cap 12 can be rotated in direction opposite from that indicated by the arrow 37 and the cap lugs 27 will move underneath the base lugs 34 so that the locking ring 25 and its carried components, including the ferrule 21 and the antenna 20, cannot be removed from the base.
The locking finger 28 will then be moved to position as shown in solid lines in FIGS. 2, 3 and 4, with the edge of the locking finger 28 engaging an edge 40 of the opening 31. The finger 28 will be stopped from clockwise movement in this position (as seen in FIG. 4). This will prevent the locking ring 25 from being twisted too far to a position where the lugs 27 would clear the lugs 34.
Once the locking finger 28 is against the edge 40 as shown in FIG. 4, the key lock unit 35 can be rotated so that the tang 36 is upright as shown in FIG. 3, and also in FIG. 4. The tang 36 is locked in this position and cannot be turned to unlocked position unless a key is used. The tang 36 will prevent rotation of the locking ring 25 in the direction as indicated by the arrow 37. The locking ring 25 is then trapped and held securely so that the cover 12 cannot be removed from the base 11 until the key lock 35 is rotated to move the tang 36 to position where it clears the locking finger 28.
The center portion of the top wall 32 on base 11 has a depending socket 43 integrally molded therewith, and a female antenna connector 44 is mounted in this socket. The antenna connector 44 as shown is positioned so that it will receive the male connector 23 when the cover is axially moved into place, as shown in FIG. 2 and will provide an electrical connection between the connector 44 and the connector 23. An antenna wire 45 can be connected to the connector 44 for the lead antenna connection of a radio.
The male connector 23 will rotate inside the female connector 44 as the cap is twist locked to the base, and will provide a good electrical connection for the antenna.
The key lock unit can be of any desired type, such as for example, one made by the Corbin Lock Company, their disc tumbler cam lock type. The key lock would have a removable key for operation (not shown) which is operated in a normal manner for locking and unlocking the unit by movement of the tang 36 substantially 90° .
In FIG. 4A a ground connection arrangement is shown in detail. The upper wall 32 of the housing has a molded in receptacle 45 which receives a ground screw housing 46 having a spring tang 47 that extends annularly over the top wall 32 and within a formed receptacle 47A. The receptacle has a small rubber or resilient bumper 48 mounted therein and supported in the receptacle. The tang 47 overlies the bumper and is urged upwardly by the bumper. The bumper is compressible to resiliently urge the tang toward the overlying cover 12.
The adapter 24A as shown comprises a nut to which the antenna is attached, and the nut has an annular flange 24B that extends on the inside of the cap around the central axis of the antenna. The flange 24B will engage the tang or contactor as the cap 12 is put into place. The bumper 48 will be compressed and a ground connection made to the flange 24B. The housing 46 will be connected to a ground wire.
The ground connection between the cap and base is therefore easy to manufacture and provides a good electrical connection because of the backing of the rubber bumper 48 on the contactor or tang 47. Rotational locking or unlocking movement of the cap, as is described is permitted by the ground contactor assembly.
Further, the lugs 27 or 34 (or both) may have a ramp surface to tighten the cap 12 and base together as the cap is put into place. This will tighten the flange 24B against the tang and bumper. The bumper thus positively exerts a pressure for good electrical contact.
When the antenna cap 12 is to be removed from the base 11 for any reason, such as security, the key lock is moved to lower the tang 36 to its dotted line position, and then the cap locking ring 25 is rotated in direction as shown by the arrow 37, until the lugs 27 will pass between the lugs 34 generally as shown in dotted lines in FIG. 4. Then the entire cap 12 can be lifted up; the male connector 23 will be removed from the female connector 44, and the finger 28 will lift out of the opening 31. Replacement is the reverse procedure, namely placing the cap in position so that the finger 28 will pass into the opening 31 above the tang 36 (with the tang in its unlocked position); pushing the flange 26 down over the top portion 30 of the base; and then twist locking the cap an eighth of a turn to bring the finger 28, which is integrally molded or fixedly attached to the locking ring 25 against the edge 40, stopping it in its position with the locking lugs 27 underneath the lugs 34. Then the lock member 35 is moved so that the tang 36 is upright, the key can be removed, and the unit will be held in its locked condition.
Referring to FIGS. 5 and 6, a modified form of the present invention is disclosed. In this form, a quick disconnect antenna coupler is indicated generally at 50 and includes a base member 51 and a cap member at 52. The base member is mounted onto a suitable vehicle panel using a clip member 53A in the manner previously described, and a gasket 54 can be used between the mounting surface and the base member 51. The device shown in FIGS. 5 and 6 does not have a twist lock cap, but has a cap which is installed on the base member 51 with a linear or longitudinally axial movement.
As can be seen, the base member 51 has a top wall 54 that is joined to a lower portion 55 at a shoulder 56. The shoulder 56 is an annular shoulder that extends around the base member. The base member top wall 54 has three apertures which are defined by collars 57. The apertures are positioned to receive pegs or prongs 58 that are formed integrally with the cover member 52.
The cover member 52 includes a skirt 53 that fits around the upper portion of the base and against the shoulder 56 when the prongs 58 are inserted through the apertures 57. Additionally, the cover member supports a base 62 of the antenna which can be of a different design from the antenna shown in FIGS. 1 through 4. The antenna end indicated at 63 is connected to a male connector 65 carried by the cover member 52, and as shown, the top wall 54 has a collar 66 that receives a female antenna connector 67, which can in turn be connected to an antenna lead as previously described. The male connector 65 will connect to the connector 67 when the cap member 52 is installed on the base 51 with a linear motion by inserting the prongs 58 through the apertures defined by the collars 57. The male connector is held in place by an adapter 64 onto which the base 62 of the antenna can be threaded and locked in place.
Additionally, the top wall 54 of the base has an aperture 68 that is positioned adjacent one side thereof, and this aperture 68 is of size to permit a cam member 72 carried by a key lock assembly 73 to pass through the aperture when the cam member is in its unlocked position (180° from the position shown in FIGS. 5 and 6). The cam 72 is a disc that is eccentrically mounted onto the key lock shank 74 and is held in place with a nut 75. The cam disc 72 is thereby rotationally driven when the lock 73 is operated. The lock 73 has an external key entry plate 75, which is accessible from the top of the cap 52, and the lock itself is securely held in place in the cap in a suitable manner such as with a snap ring or similar holding device.
The aperture 68 is surrounded by a heavy collar 80, and a portion of the collar includes a cam surface 81 on the locking side of the collar. A stop lug 82 can also be used to prevent the cam disc 72 from being rotated clockwise beyond its locked position as shown in FIG. 6. The cam disc itself can have a step or offset that fits underneath the ramp 81, so that when the key lock is rotated, and the cam is moved to locked position by movement in clockwise direction as shown in FIG. 6, the cap 52 will be tightened down securely onto the base by this locking action.
When the key is removed, after the unit is locked, the cover is securely held in place. It should be noted that the prongs 58 will prevent rotation of the cap relative to the base, and the only way that the cap can be removed is by an upwardly movement. This upward movement in longitudinal axial direction is prevented by the cam disc 72 engaging the ramp 81.
Unlocking is achieved by using a key to operate the lock 73 in a counterclockwise direction as viewed in FIG. 6 and moving the cam to a position where it will clear ramp 81 and pass through the aperture 68, after it has been rotated 180° from its solid line position in FIG. 6. Then the cap itself can be lifted upwardly off the base for removal of the cap and the attached antenna for security purposes. The axial direction of movement of the cap as the prongs 58 pass through the apertures defined by the collars 57 serves to connect the male and female antenna connectors in a positive manner.
When the coupler is locked by turning the key and the cam disc 72 it is assured that the cap is securely seated on the base.
It should be noted that the caps in both forms of the invention can be designed to take different manufacturers' antenna connectors merely by modifying the adapters in the central portions of the cap, and attaching the parts to the cap itself. In this way, the locking portions, namely the cap and the base, can be adapted to a wide variety of different manufacturers' antennas with very little difference in operation, and with only a few parts being necessary for the adaptation.
The locking finger 28 in the first form of the invention and the prongs or pins 58 in the second form and their cooperating apertures also serve to index the cover and base to proper position for latching before the caps are slipped onto the respective bases. With finger 28 in aperture 31 and against the opposite end of the aperture from end 40 the twist lock lugs are in position for assembly. The prongs 57 index cam 72 so it will pass through opening 68 for assembly. | A quick disconnect, lockable mounting for a C.B. (citizens band) antenna, or other type of antenna, which permits removing the antenna whenever desired simply by unlocking a key lock device, and taking off a cap carrying the antenna. Yet, when the cap is in position, it cannot be removed because the lock member securely holds it in position.
The problem associated with breaking and stealing C.B. antennas (and radios, which are indicated as being present in a vehicle by the full antennas) has increased substantially, and the present device permits not only the quick disconnect and removal of the antenna, but the locking of the antenna to discourage thieves from attempting such removal. | 7 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates generally to methods of diagnosing cancer and more specifically to diagnosing and determining the prognosis of cancer patients using a biomarker based on fibroblast growth factor receptors.
BACKGROUND ART
[0002] Without limiting the scope of the invention, its background is described in connection with diagnosing, treating and determining the prognosis of cancer. Cancer is a generic name for a wide range of cellular malignancies characterized by unregulated proliferation, lack of differentiation, and the ability to invade local tissues and metastasize. These neoplastic malignancies affect, with various degrees of prevalence, every tissue and organ in the body. Fibroblast growth factors (FGFs) and their receptors (FGFR) are expressed at increased levels in several tissues and cell lines and overexpression is believed to contribute to the malignant phenotype. FGFs and FGFRs are a highly conserved group of proteins with instrumental roles in angiogenesis, vasculogenesis, and wound healing, as well as tissue patterning and limb formation in embryonic development. FGFs and FGFRs affect cell migration, proliferation, and survival, providing wide-ranging impacts on health and disease.
[0003] The FGFR family comprises four major types of receptors, FGFR1, FGFR2, FGFR3, and FGFR4. These receptors are transmembrane proteins having an extracellular domain, a transmembrane domain, and an intracytoplasmic domain. Each of the extracellular domains contains either two or three immunoglobulin (Ig) domains. Transmembrane FGFRs are monomeric tyrosine kinase receptors, activated by dimerization, which occurs at the cell surface in a complex of FGFR dimers, FGF ligands, and heparin glycans or proteoglycans. Extracellular FGFR activation by FGF ligand binding to an FGFR initiates a cascade of signaling events inside the cell, beginning with the receptor tyrosine kinase activity.
[0004] For example, U.S. Pat. No. 8,377,636, entitled, “Biological markers predictive of anti-cancer response to kinase inhibitors,” discloses diagnostic and prognostic methods for predicting the effectiveness of treatment of a cancer patient with inhibitors of EGFR kinase, PDGFR kinase, or FGFR kinase. Based on tumors cells having undergone an EMT, while being mesenchymal-like, still express characteristics of both epithelial and mesenchymal cells, and that such cells have altered sensitivity to inhibition by receptor protein-tyrosine kinase inhibitors, in that they have become relatively insensitive to EGFR kinase inhibitors, but have frequently acquired sensitivity to inhibitors of other receptor protein-tyrosine kinases such as PDGFR or FGFR, methods have been devised for determining levels of specific epithelial and mesenchymal biomarkers that identify such “hybrid” tumor cells (e.g. determination of co-expression of vimentin and epithelial keratins), and thus predict the tumor's likely sensitivity to inhibitors of EGFR kinase, PDGFR kinase, or FGFR kinase.
[0005] U.S. Pat. No. 7,982,014, entitled, “FGFR3-IIIc fusion proteins,” discloses FGFR fusion proteins, methods of making them, and methods of using them to treat proliferative disorders, including cancers and disorders of angiogenesis. The FGFR fusion molecules can be made in CHO cells and may comprise deletion mutations in the extracellular domains of the FGFRs which improve their stability. These fusion proteins inhibit the growth and viability of cancer cells in vitro and in vivo. The combination of the relatively high affinity of these receptors for their ligand FGFs and the demonstrated ability of these decoy receptors to inhibit tumor growth is an indication of the clinical value of the compositions and methods provided herein.
[0006] U.S. Patent Application Publication No. 2013/0345234, entitled, “FGFR and ligands thereof as biomarkers for breast cancer in HR positive subjects,” discloses methods for diagnosing, treating and determining the prognosis of breast cancer HR+ patient, the methods including detecting the amplification of one or more biomarkers comprising a FGFR ligand such as FGF3, FGF4, FGF19, and/or a FGFR, such as for example FGFR1 in a subject; determining an FGFR1 inhibitor for treating the subject based on the amplification of the one or more biomarkers in the subject; administering to the subject in need thereof the FGFR1 inhibitor and using the one or more biomarkers to indicate prognosis of the subject treated with the FGFR1 inhibitor.
DISCLOSURE OF THE INVENTION
[0007] The present invention provides a method of characterizing a cancer by obtaining a sample from a subject suspected of having cancer; and determining whether a fibroblast growth factor receptor (FGFR) fusion is present in the sample, wherein the FGFR fusion comprises a FGFR locus, thereby characterizing the cancer based on the presence or absence of the FGFR fusion.
[0008] The present invention provides a method for detecting a fibroblast growth factor receptor (FGFR) translocation event in one or more cancer cells by contacting a sample suspected of comprising one or more cancer cells with a plurality of distinguishably labeled probes capable of hybridizing to a portion of a fibroblast growth factor receptor (FGFR) fusion in the one or more cancer cells; hybridizing a first probe to a first region to form a first hybridization complex; hybridizing a second probe to a second region to form a second hybridization complex; and analyzing the first hybridization complex and the second hybridization complex to identify the presence of a FGFR fusion.
[0009] The present invention provides a method for identifying the response of a proliferative disorder responsive to treatment by detecting one or more FGFR biomarkers selected for a FGFR-fusion that is indicative of the prognosis of a subject.
DESCRIPTION OF THE DRAWINGS
[0010] For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures and in which:
[0011] FIG. 1A is an image of a tumor that shows intraductal growth and multiple foci with a nested architecture characterized by peripheral cells with scant cytoplasm surrounding cells with more open chromatin and more cytoplasm.
[0012] FIG. 1B is an image of the neoplastic cells showed only focal cytokeratin 19 expression.
[0013] FIG. 1C is an image of representative photomicrograph of prominent intraductal growth which characterized several cases.
[0014] FIG. 1D is an image showing both of these cases revealed FGFR2 translocations using a break-apart FISH probe.
[0015] FIG. 2A is an image of a low grade biliary intraductal papillary neoplasm of bile duct forming papillae with complex back to back glands.
[0016] FIG. 2B is an image of numerous goblet cells were admixed with the other columnar neoplastic cells.
[0017] FIG. 2C is an image of Cytokeratin 19 expression that was diffuse and strong.
[0018] FIG. 2D is an image of FGFR2 FISH confirmed translocation of FGFR2.
[0019] FIG. 3A is an image of an example of the anastomosing tubular architecture seen in a subset of tumors with FGFR2 translocations.
[0020] FIG. 3B is an image as seen in several cases, CK19 expression was patchy and weak.
[0021] FIG. 3C is an image of focally, the glands coalesced to form more solid areas.
[0022] FIG. 3D is an image of FGFR2 was translocated as confirmed by FISH.
[0023] FIG. 4A is an image of FISH showing HER2 amplification.
[0024] FIG. 4B is an image of FISH showing ROS1 translocation using break-apart FISH probe.
[0025] FIGS. 5A-5G are graphs showing the sequence variation effects.
[0026] FIGS. 6A and 6B are representative fluorescent in situ hybridization (FISH) demonstrating the presence of FGFR2 fusion. FIG. 6A shows cholangiocarcinoma with FGFR2 rearrangement.
[0027] FIG. 6B shows cholangiocarcinoma negative for FGFR2 rearrangement.
[0028] FIG. 7 is an image showing the copy number changes and structural rearrangements.
[0029] FIGS. 8A-8B are images of immunohistochemistry demonstrating FGFR2 and FGFR3 expression.
[0030] FIGS. 9A-9B are images showing immunohistochemistry demonstrating pFRS2 Y436, and pERK expression in Patients 1, 4, 5, and 6.
[0031] FIGS. 10A-10D are images showing transcripts and hypothetical protein products modeled to illustrate the potential functional impact of fusion events involving FGFR2.
DESCRIPTION OF EMBODIMENTS
[0032] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
[0033] To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a”, “an” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
[0034] The present invention provides methods of diagnosing, treating and determining the prognosis of a disease or condition comprising abnormal cell growth, the disease or condition comprising abnormal cell growth in one embodiment is a cancer. The present invention is directed to methods for diagnosing, selecting for treatment and determining the prognosis cancer patients using a biomarker based on fibroblast growth factor receptors and determining which patients will most benefit from treatment with inhibitors of receptor protein-tyrosine kinases.
[0035] The terms “receptor tyrosine kinase” and “RTK” are used interchangeably herein to refer to the family of membrane receptors that phosphorylate tyrosine residues. Many play significant roles in development or cell division. Receptor tyrosine kinases possess an extracellular ligand binding domain, a transmembrane domain and an intracellular catalytic domain. The extracellular domains bind cytokines, growth factors or other ligands and are generally comprised of one or more identifiable structural motifs, including cysteine-rich regions, fibronectin III-like domains, immunoglobulin-like domains, EGF-like domains, cadherin-like domains, kringle-like domains, Factor VIII-like domains, glycine-rich regions, leucine-rich regions, acidic regions and discoidin-like domains. Activation of the intracellular kinase domain is achieved by ligand binding to the extracellular domain, which induces dimerization of the receptors. A receptor activated in this way is able to autophosphorylate tyrosine residues outside the catalytic domain, facilitating stabilization of the active receptor conformation. The phosphorylated residues also serve as binding sites for proteins which will then transduce signals within the cell. Examples of RTKs include, but are not limited to, Kit receptor (also known as Stem Cell Factor receptor or SCF receptor), fibroblast growth factor (FGF) receptors, hepatocyte growth factor (HGF) receptors, insulin receptor, insulin-like growth factor-1 (IGF-1) receptor, nerve growth factor (NGF) receptor, vascular endothelial growth factor (VEGF) receptors, PDGF-receptor-.alpha., PDGF-receptor-.beta., CSF-1-receptor (also known as M-CSF-receptor or Fms), and the F1t3-receptor (also known as F1k2).
[0036] As used herein, the term “subject” is intended to include human and non-human animals. Non-human animals include all vertebrates, e.g. mammals and non-mammals, such as non-human primates, sheep, dogs, cats, cows, horses, chickens, amphibians, and reptiles.
[0037] An “FGFR fusion protein” is a protein typically comprising a sequence of amino acids corresponding to the extracellular domain of an FGFR polypeptide or a biologically active fragment thereof, and a fusion partner. The fusion partner may be joined to either the N-terminus or the C-terminus of the FGFR polypeptide and the FGFR may be joined to either the N-terminus or the C-terminus of the fusion partner. An FGFR fusion protein can be a product resulting from splicing strands of recombinant DNA and expressing the hybrid gene. An FGFR fusion protein may comprise a fusion partner comprising amino acid residues that represent some or all of, one or more fragments of, one or more genes. The FGFR fusion molecules of the invention comprise a first polypeptide that comprises an extracellular domain (ECD) of an FGFR polypeptide and a fusion partner. The FGFR polypeptide can be any of FGFR1, FGFR2, FGFR3, and FGFR4, including all their variants and isoforms. Hence, the family of FGFR polypeptides suitable for use in the invention includes FGFR1, FGFR1-IIIb, FGFR1-IIIc, FGFR2, FGFR2-IIIb, FGFR2-IIIc, FGFR3, FGFR3-IIIb, FGFR3-IIIc, FGFR4 and FGFR5, for example. The extracellular domain of the FGFR can be the entire ECD or a portion thereof.
[0038] A “fusion partner” is any component of a fusion molecule in addition to the extracellular domain of an FGFR or fragment thereof. A fusion partner may comprise a polypeptide, such as a fragment of an immunoglobulin molecule, or a non-polypeptide moiety, for example, polyethylene glycol. The fusion partner may comprise an oligomerization domain such as an Fc domain of a heavy chain immunoglobulin.
[0039] Patients with cholangiocarcinoma often present with locally advanced or metastatic disease. At present, there is a need for more effective traditional chemotherapeutic or targeted therapy strategies to treat patients with cholangiocarcinoma. 152 cholangiocarcinomas and 4 intraductal papillary biliary neoplasms of the bile duct were evaluated for presence of FGFR2 translocations by fluorescence in situ hybridization (FISH) and characterized the clinical, pathologic and immunohistochemical features of cases with FGFR2 translocations. In addition, 100 cholangiocarcinomas were assessed for ERBB2 amplification and ROS1 translocations, of which 3 (3%) and 1 (1%) where positive, respectively. Eight percent (13 of 156) of biliary tumors harbored FGFR2 translocations, including 12 intrahepatic cholangiocarcinomas and 1 intraductal papillary neoplasm of the bile duct. Thirteen percent (12/96) of intrahepatic cholangiocarcinomas harbored a FGFR2 translocation. FGFR2 translocations were also associated with a female predominance, longer disease-free and overall survival, and lack of underlying fibrotic liver disease. Lesions with FGFR2 translocations were frequently associated with weak and patchy expression of CK19. Markers of stem cell phenotype in cholangiocarcinoma, HepPar1 and CK20, were negative in all cases. This is the largest known study of cholangiocarcinomas assessing for FGFR2 translocations and confirms that FGFR2, ERRB2, and ROS1 alterations are potential therapeutic targets in cases of intrahepatic cholangiocarcinoma, with FGFR2 present at the highest frequency.
[0040] The present invention provides a fluorescent in situ hybridization (FISH) break-apart assay to detect fusions involving fibroblast growth factor receptor 2 (FGFR2) in patients with cholangiocarcinoma. The assay is able to discern true positive (in 3 of 3 RNA-Seq/Sanger-polymerase chain reaction validated cases) and true negative cases (in 3 of 3 RNA-Seq/Sanger-polymerase chain reaction validated cases). The present invention allows for rapid and reliable detection of cholangiocarcinoma patients with FGFR2 fusions for treatment with fibroblast growth factor receptor inhibitors.
[0041] The present invention provides molecular techniques which have led to the identification of therapeutic targets for various tumors, e.g., identified fibroblast growth factor receptor gene (FGFR2) translocations in cholangiocarcinoma which benefited from FGFR targeted therapy. FGFR2 and ROS1 Fluorescence In Situ Hybridization (FISH). Using the hematoxylin and cosin-stained slides as a guide, unstained 5 micron thick glass slides from a selected paraffin block were etched to indicate the areas of tumor for subsequent molecular testing. Slides were placed in an oven at 90° C. for 10 minutes and then pretreated with xylene at room temperature for two consecutive 15 minute intervals. Slides were then immersed in 100% ethanol for 5 minutes and allowed to air dry at 30° C. for 3 minutes. Acid treatment was then performed for 45 minutes using 10mM of citric acid at 80° C. This was followed by SSC pretreatment for 5 minutes at 37° C. and pepsin digestion (0.2%) for 48 minutes. The slides were then dehydrated in serial ethanol baths of increasing concentration and air dried for 5 minutes. FGFR2 break-apart FISH probe (Abbott Molecular Diagnostics, Des Plaines, Ill.) containing Spectrum Orange and Spectrum Green probes were used.
[0042] Three to 10 uL of FGFR2 break-apart FISH probe (Abbott Molecular Diagnostics, Des Plaines, Ill.) containing Spectrum Orange and Spectrum Green probes flanking the region of interest was then applied to the etched area of the slide and cover slipped. Hybridization was performed on a HYBRITE™ (Abbott Molecular Inc.) by denaturing at 80° C. for 3 minutes and hybridizing for 12 hours at 37° C. The slides were then removed from the HYBRITE™ and placed in 0.1% NP40/2×SSC at 74° C. for 2 minutes and transferred to a room temperature solution of 0.1% NP40/2×SSC for an additional 2 minutes. DAPI-I counterstain was applied to the sections and the slides were cover slipped.
[0043] FISH analyses were then performed in blinded fashion. In order to be considered positive, separate Spectrum Orange and/or Spectrum Green signals were present in greater than 20% of nuclei throughout the tumor. Cases not meeting these criteria were considered negative. All cases with FGFR2 translocation and a subset of cases without translocation were reviewed blindly by a second reviewer. For the ROS-1 break-apart probe, the same method was used. Cholangiocarcinomas (N=3) with FGFR2 translocations and FGFR2 overexpression from global transcriptome sequencing along with cholangiocarcinomas without FGFR2 translocations (N=5) were also evaluated as control specimens in a blinded fashion with this FISH strategy to verify accuracy of the FISH probes.
[0044] HER2 Immunohistochemistry and FISH. Five micron unstained sections from the chosen paraffin block were used for HER2 immunohistochemistry using the HercepTest kit (Dako, Carpinteria, Calif.) and following the manufacturer-provided protocol. The slides were reviewed by two pathologists and classified as negative, 1+, 2+ or 3+ based on previously published guidelines by the College of American Pathologists (CAP) and American Society for Clinical Oncologists (ASCO). In all 2+ or 3+ positive cases, the invasive tumor with immunoreactivity was circled and the sections were selected for HER2 FISH.
[0045] Immunohistochemistry using commercially available antibodies directed to cytokeratin 7 (clone OV-TL 12/30; 1:200, Dako, Calif.), cytokeratin 19 (clone RCK 108; 1:20,Dako, Calif.), cytokeratin 20 (clone K s 20.8, 1:200, Dako, Calif.), CD56 (clone 123C3; 1:100; Dako, Calif.), KIT (rabbit polyclonal; 1:500; Dako, Calif.) and HepPar 1 (clone OCH1E5; predilute; Ventana, Ariz.) was performed using 30-32 minute pretreatment and standard methods on each of the cases of cholangiocarcinoma with an FGFR2 translocation.
[0046] Statistical Analysis. The associations between the occurrence of FGFR2 rearrangements and clinicopathologic results were assessed using JMP 9.0 software and Wilcoxon test and Fisher Exact tests, as appropriate. Kaplan-Meier curves were plotted, and survival was compared using the log-rank value. All reported p values were 2 sided and p values <0.05 were considered significant.
[0047] One hundred and fifty-six specimens were evaluated including 152 cholangiocarcinomas and 4 IPNB. Patients ranged from 28 to 83 years of age with a median age of 62 years. The study included 80 males and 76 females. The 152 cholangiocarcinomas in this surgical series were predominantly intrahepatic (n=96; 63%), but also included hilar (n=25; 16%) and extrahepatic (n=31; 20%) tumors. The 4 IPNB specimens included 2 intrahepatic and 2 extrahepatic neoplasms. Two of the IPBN featured low grade dysplasia and the other 2 displayed features of high grade dysplasia. The median maximum dimension of the cholangiocarcinomas was 4.75 cm (range 0.5-14.0 cm) and the median maximum tumor size for the IPNB was 3.15 cm (range 1.8-7.5 cm).
[0048] Using FISH, FGFR2 translocations were identified in 12 cholangiocarcinomas and 1 IPNB for an overall frequency of 8% (13/156; FIGS. 1 and 2 ). All translocated specimens were intrahepatic, with a frequency of 13% (12/96) for intrahepatic cholangiocarcinomas. One of the 13 specimens with an FGFR2 translocation was previously reported as having IDII1mutation. There were significantly (p=0.043) more FGFR2 translocations identified in women (10/76, 13%) than in men (3/80, 4%). The patients with FGFR2-rearranged tumors had a median age of 52 years (range 36-83 years), which was 11 years younger than the median age for the biliary tumors without FGFR2 rearrangement, but this was not significant (p=0.121). The median tumor size for FGFR2 translocated cases was 6.0 cm (range 1.4-13.4 cm) which was similar to the median tumor size for tumors without FGFR2 rearrangement (p=0.201).
[0049] Morphologically, cases harboring FGFR2 translocations could be divided into 2 architectural groups; cases (8/13, 62%) which were characterized by prominent intraluminal growth in bile ducts (bile duct invasion/extension) and cases which did not (5/13, 38%). Of the former group, 3 cases were composed predominantly of solid nodules, 4 showed a predominantly trabecular pattern and the other was the case of an intestinal type IPNB. The cases with solid nodules were characterized either by syncytial neoplastic cells with indistinct cell membranes or alternatively by cells with distinct cell membranes. The cases with a trabecular pattern typically featured 2 cell populations including a) a peripheral rim of smaller cells with scant cytoplasm and nuclear hyperchromasia and b) central cells with more cytoplasm, round nuclei and open chromatin. In 2 cases, there were overlapping features including areas with a trabecular growth pattern and a two cell population, and solid areas without the two cell population.
[0050] FIG. 1A is an image of a tumor that shows intraductal growth and multiple foci with a nested architecture characterized by peripheral cells with scant cytoplasm surrounding cells with more open chromatin and more cytoplasm (original magnification 200×). FIG. 1B is an image of the neoplastic cells showed only focal cytokeratin 19 expression (original magnification 200×). FIG. 1C is an image of representative photomicrograph of prominent intraductal growth which characterized several cases (original magnification 400×). In this example, there is a solid proliferation of neoplastic cells. FIG. 1D is an image showing both of these cases revealed FGFR2 translocations using a break-apart probe as illustrated by this representative FISH image from the case in FIG. 1A . The tumor cells are aneuploid (>2 copies in each nucleus) but orange and green signals are separated confirming rearrangement of FGFR2.
[0051] While the IPNB with FGFR2 translocation showed intraluminal growth by definition, it did not harbor solid nodules or trabeculae but instead was composed of back to back anastomosing tubular glands with abundant goblet cells as shown in FIG. 2A-D .
[0052] FIG. 2A is an image of a low grade biliary intraductal papillary neoplasm of bile duct forming papillae with complex back to back glands (original magnification 100×). FIG. 2B is an image of numerous goblet cells were admixed with the other columnar neoplastic cells (original magnification 200×) FIG. 2C is an image of Cytokeratin 19 expression that was diffuse and strong (original magnification 200×). FIG. 2D is an image of FGFR2 FISH confirmed translocation of FGFR2.
[0053] The second group of FGFR2 translocated tumors (5 of 13) included cases which were all composed of anastomosing tubular structures accompanied by desmoplasia. In 2 of the 5 cases, multiple foci of intratubular growth (i.e. glands within a gland) were seen and in the remaining 3 cases the anastomosing tubules coalesced to form solid or syncytial areas in places. FIG. 3A is an image of an example of the anastomosing tubular architecture seen in a subset of tumors with FGFR2 translocations. This was accompanied by an intratumoral neutrophilic infiltrate (original magnification 100×). FIG. 3B is an image as seen in several cases, CK19 expression was patchy and weak (original magnification 200×). FIG. 3C is an image of focally, the glands coalesced to form more solid areas (original magnification 400×). FIG. 3D is an image of FGFR2 was translocated as confirmed by FISH. Separated spectrum orange and green signals are seen confirming translocation of the gene. In these latter 3 cases, there was a prominent intratumoral neutrophilic infiltrate.
[0054] By immunohistochemistry, all of the FGFR2-translocated cases were strongly positive for CK7. In 3 cases (23%), CK7 expression was patchy (approximately 10%-50% neoplastic cells positive) while in the remaining 10 cases (77%), CK7 expression was diffuse. Only 3 cases (23%) were diffusely positive for CK19. Six cases (46%) showed weak patchy reactivity for CK19, 3 (23%) revealed focal CK19 expression (<10% neoplastic cells) which was very weak. In a single case, a strong luminal pattern of CK19 expression was seen. Examples of CK19 immunoreactivity are shown in FIGS. 1A-3D . None of the cases expressed CK20, CD56, KIT or HepPar1.
[0055] For cholangiocarcinoma cases, clinical follow up was available for 99% (151/152) of patients up to 169 months after surgical resection. For the 139 cases without FGFR2 translocations, 77 patients (55%) developed metastases or local recurrence and 99 patients (71%) died during clinical follow up. Of the 99 patients who died, 69 died of disease (70%), 7 died of other causes (7%) and the cause of death was unknown for 23 patients (23%). The median cancer-specific survival interval for the group without FGFR2 translocations was estimated at 37 months (95% CI: lower limit=24 months, upper limit=49 months) and the median disease free interval was estimated at 26 months (95% CI: lower limit=19 months, upper limit=42 months). Six of the 12 (50%) patients whose tumors harbored FGFR2 translocations died during clinical follow up and 6 patients were alive without evidence of disease. Only 3 patients (25%) developed metastases or local recurrence. The median cancer-specific survival interval for patients with FGFR2 translocations was estimated at 123 months (95% CI: lower limit=51 months, upper limit=123 months) and was significantly longer (p=0.039) than patients without FGFR2 translocations. The disease free intervals for the 3 cases were 26 months, 63 months, and 125 months. Relative to the cases without FGFR2 translocations, this was also significant (p=0.007).
[0056] FIG. 4A is an image of FISH showing HER2 amplification (LSI HER-2/neu orange signals)/total CEP 17 green signals>2.2). FIG. 4B is an image of FISH showing ROS1 translocation using break-apart FISH probe. One hundred cases were tested by HER2 immunohistochemistry and 97 were negative. A single 2+ case (intrahepatic) and two 3+ cases (extrahepatic) were identified. FISH confirmed HER2 amplification (HER2/CEP17 ratio >2.2) in each of the 3 cases. None of the HER2 positive cases were positive for FGFR2 translocations. The 3 HER2 positive cases affected 2 men (extrahepatic; ages 69 and 71) and a 46 year old woman (intrahepatic) without PSC or underlying liver disease. The men developed metastatic or recurrent disease and died within 15 months of diagnosis. The woman with the intrahepatic tumor is alive without evidence of recurrence after more than 154 months of follow up.
[0057] FISH ROS1 testing was also performed on a group of 100 overlapping cases and was successful in 98 cases. Only a single case revealed a ROS1 translocation, resulting in a rearrangement frequency of 1%. This case was previously reported as harboring an IDH1 mutation. FGFR2 was not translocated in this case. The patient was a 63-year-old woman without underlying liver disease who presented with a localized intrahepatic tumor and is alive with no evidence of disease 66 months after surgery.
[0058] Cholangiocarcinoma is a malignancy of the biliary tree and arises within the liver (intrahepatic), at the hilum (central) or within the extrahepatic biliary tree. This anatomic classification is supported in embryology with the extrahepatic bile ducts arising in continuity with the intrahepatic bile ducts but from different cell populations. This classification separates biliary tree malignancies into groups with different mutational spectra and also informs surgical approach. Most cholangiocarcinomas are not amenable to surgical resection at diagnosis and the prognosis is poor. There are currently no FDA-approved targeted therapies for cholangiocarcinoma, a clear unmet clinical need. The present invention provides FISH testing of FGFR2, ERRB2, and ROS1 for the identification of patients whose tumors are candidates for targeted therapies. This is consistent with recent studies suggesting that cholangiocarcinomas harbor mutations that may benefit from tyrosine kinase targeted therapies.
[0059] FGFR2, located at chromosome 10q26, is a member of the fibroblast growth factor family of receptors including FGFR1, FGFR3 and FGFR4 and the encoded proteins share highly conserved amino acid sequences. Full length FGFR2, like the other members of the family, is composed of 3 extracellular immunoglobulin domains, an intramembranous segment and a cytoplasmic tyrosine kinase. It interacts with a variety of ligands and the activity of FGFR2 influences proliferation and cellular differentiation. Physiologically, FGFR2 is distributed in ectodermal, endodermal and mesenchymal structures. Point mutations in FGFR2 are associated with congenital craniosynostosis due to abnormal bone development. FGFR2 translocations were identified in a prospective clinical sequencing program in cholangiocarcinoma, breast and prostatic carcinoma. This novel oncogenic mechanism for FGFR2 was validated functionally 30 and was subsequently noted by others. As would be expected from their sequence homology, alterations in FGFR1, FGFR3 and FGFR4 have also been demonstrated as oncogenic drivers in various malignancies. Interestingly, prior to the discovery of FGFR2 translocations in cholangiocarcinoma, it was noted that FGFR2 was expressed in 2 cholangiocarcinoma cell lines and that FGFR2 activity not only stimulated neoplastic cell migration but confirmed that inhibition of FGFR2 impaired neoplastic cell migration in the presence of the ligand for FGFR2. Recently, a group identified FGFR2 translocations as a targetable alteration in approximately 15% intrahepatic cholangiocarcinomas which were wild type for KRAS and BRAF and did not harbor ROS1 translocations. FGFR2 is strongly implicated in the development of a subset of cholangiocarcinomas. In this large series of cholangiocarcinomas in patients from the United States, we confirmed the finding of FGFR2 translocations in 13% of intrahepatic tumors. This evidence supports that FGFR2 is a potential therapeutic target in intrahepatic cholangiocarcinoma.
[0060] Cholangiocarcinomas with FGFR2 translocations can be grouped morphologically into 2 clusters. The first of which was a group of tumors characterized by intraluminal growth (large duct invasion) by neoplastic cells. Within this group of tumors, 4 tumors formed predominantly solid compact nodules including two cases in which the neoplastic cells were characterized by indistinct cell borders, appeared syncytial in growth pattern and were accompanied by a neutrophilic infiltrate; 3 formed a nested architecture also including a case with a syncytial appearance to the neoplastic cells and were composed of a dual population of cells including a peripheral rim of cells with hyperchromasia and there was a single case of an intraductal papillary biliary neoplasm. The second group of cases (5 of 13) did not reveal large duct invasion and were characterized by anastomosing tubular structures with variable architectural complexity accompanied by a desmoplastic stroma and in 3 of these cases, a prominent neutrophilic infiltrate. It is not clear whether there are biological differences between tumors from these 2 morphologic groups. None of the described features could be used to distinguish cases harboring FGFR2 translocations from cases without FGFR2 translocations.
[0061] For some tumor types, morphologic characteristics may be suggestive of underlying molecular alterations. This is illustrated by the presence of abundant tumor infiltrating lymphocytes, signet ring cells and mucinous histology in microsatellite unstable colorectal carcinoma. High grade, triple negative, basal-like breast carcinomas are frequently poorly differentiated with a syncytial pattern of growth and abundant necrosis. Predominantly solid histology has been shown in KRAS mutated lung adenocarcinomas and others have recognized a distinctive recurrent morphologic constellation of features including chromophobe cytoplasm, abrupt anaplasia and pseudocysts in hepatocellular carcinomas with an unusual molecular cytogenetic phenotype. However, none of these morphologic features is sufficiently specific to act as a sole marker for the molecular alterations in routine practice.
[0062] Interestingly, a subset of the FGFR2-rearranged cases display stem-cell like features. Together with the physiologic role of FGFR2 in stem cell differentiation in organogenesis, this raised the possibility that tumors with FGFR2 translocations may display a stem cell phenotype. However, the markers of stem cell phenotype in cholangiocarcinomas, CD56 and KIT, were negative. While this argues against a stem cell phenotype, it is worth pointing out that the search for novel markers of stem cells in liver tumors is ongoing and additional robust markers are still needed. Importantly though, 69% (9 of 13) of cholangiocarcinomas harboring FGFR2 translocations showed significantly diminished expression of CK19 suggesting that they were primitive. CK19 is expressed in hepatic progenitor cells in early embryogenesis. At 10 weeks gestation, the expression of CK19 is downregulated in hepatocytes but continues in intrahepatic and extrahepatic bile ducts. This forms the biological basis for CK19 as a marker of pancreatobiliary tumors. Several large studies have reported that CK19 is diffusely positive in 80-100% of cholangiocarcinomas. Therefore, only focal and weak CK19 expression in most of the cases with FGFR2 translocations suggests that this subset of cholangiocarcinomas is enriched for tumors with primitive characteristics. This is also supported by the fact that most tumors revealed solid, syncytial or trabecular growth. Taken together, our data suggests that FGFR2 translocations are associated with intrahepatic neoplasms which display a duct invasive or weakly duct-forming phenotype with predominantly primitive morphologic features.
[0063] Both cholangiocarcinomas and hepatocellular carcinomas may arise in the setting of underlying disease or in apparently normal livers. 102 cholangiocarcinomas, 149 colorectal carcinomas, 212 gastric carcinomas and almost 100 hepatocellular carcinomas have been studied for FGFR2 translocations by RT-PCR. They found 5 of 11 total cases (including 1 colorectal carcinoma and 1 hepatocellular carcinoma) with FGFR2 translocations occurred in patients with viral hepatitis B or C. They do not comment on the features of the background liver in the 9 cholangiocarcinoma cases but they compare the rate of viral hepatitis in cases with FGFR2 translocations to control cases and found a statistically significant increase in the rate of viral hepatitis carriage. Two of 16 tested patients were positive for viral hepatitis C and only one of these was associated with fibrosis of the background liver. There were no cases with cirrhosis or primary sclerosing cholangitis. From these data, it is not clear if underlying liver disease or viral hepatitis are important contributors to the pathogenesis of FGFR2 translocation-associated cholangiocarcinomas.
[0064] The median disease free and cancer-specific survivals of cases without FGFR2 translocation were 26 and 37 months, respectively, compared to 125 and 123 months respectively for the patients whose tumors harbored FGFR2 translocations. In retrospective studies of patients treated with various combinations of therapy and not matched for performance status and other characteristics, it is difficult to determine the generalizability of survival data. The younger patients, feasibility of resection, unique tumor biology and lack of underlying liver disease may have contributed to the improved survival of patients whose tumors harbored FGFR2 translocations.
[0065] Clinically, detecting FGFR2 translocations is relevant because this appears to represent a targetable alteration. Wu et al. identified FGFR2 fusions in 2 cholangiocarcinoma specimens. Arai et al. showed the functional significance of FGFR2 translocations in cholangiocarcinoma including activation of the MAPK pathway and also provided data that FGFR2 inhibition led to diminished MAPK pathway activity. They also performed studies in murine avatars confirming the tractability of FGFR2 translocations in cholangiocarcinomas. If the studies are summed, 27 of 287 biliary neoplasms have been found to harbor FGFR2 translocations which comprise approximately 10% of cases studied and include exclusively intrahepatic tumors. In addition, rare cases with HER2 amplification and ROS1 translocation were identified. These targetable alterations were mutually exclusive of FGFR2 translocation and their molecular biology has already been characterized. FGFR2 translocations in intrahepatic cholangiocarcinoma are associated with a primitive phenotype, apparent female predominance, apparent tendency to longer disease free and overall survival and lack of underlying fibrotic liver disease. As such, FISH testing may be a useful clinical test for the detection of tyrosine kinase receptor rearrangements in patients with cholangiocarcinoma. Lastly, increasing data suggests that targeted therapy for FGFR2, ERBB2 and ROS1 chromosomal alterations are exciting potential treatments for this group of patients who currently have an overall unfavorable prognosis.
[0066] For example, advanced cholangiocarcinoma continues to harbor a difficult prognosis and limited therapeutic options. For example, biliary tract cancers (BTC) comprise malignant tumors of the intrahepatic and extrahepatic bile ducts. Known risk factors for BTC are the liver flukes O. viverrini and C. sinensis in high prevalence endemic regions in southeast Asia [1-3], as well as primary sclerosing cholangitis [4-7], Caroli's disease [8], hepatitis B and hepatitis C [9-14], obesity [13], hepatolithiasis [15,16] and thorotrast contrast exposure [17,18]. Surgical approaches such as resection and liver transplantation represent the only curative treatment approaches for BTC [19]. Unfortunately, most patients present with surgically unresectable and/or metastatic disease at diagnosis. Systemic therapy with gemcitabine and cisplatin has been established as the standard of care for patients with advanced disease, but is only palliative, [20] emphasizing the imminent need for novel therapies.
[0067] Mutations/allelic loss of known cancer genes in BTC [21-39] have been reported and recently, a prevalence set of 46 patients was used to validate 15 of these genes including: TP53, KRAS, CDKN2A and SMAD4 as well as MLL3, ROBO2, RNF43, GNAS, PEG3, XIRP2, PTEN, RADIL, NCD80, LAMA2 and PCDHA13. Recurrent mutations in IDH1 (codon 132) and IDH2 (codons 140 and 172) have been reported with a prevalence of 22-23% associated with clear cell/poorly differentiated histology and intrahepatic primary [40,41]. Fusions with oncogenic potential involving the kinase gene ROS1 have been identified in patients with BTC with a prevalence of 8.7% [42]. Less frequently, mutations in sporadic BTC have been reported in EGFR [43,44], BRAF [45], NRAS [40,46], PIK3CA [40,46,47], APC [40], CTNNB1 [40], AKT1 [40], PTEN [40], ABCB4 [48], ABCB11 [49,50], and CDH1 [51] as well as amplifications in ERRB2 [52]. FGFR fusions have also been seen in cholangiocarcinoma, e.g. a single case with FGFR2-AHCYL1 [53] as well as several cases identifying FGFR2-BICC1 fusions [53,54]. For example, FGFR2 fusions in a cohort of 102 cholangiocarcinoma patients showed that the fusions occurred exclusively in the intrahepatic cases with a prevalence of 13.6% [53]. Overexpression of the FGFR2-BICC1 and other selected fusions resulted in altered cell morphology and increased cell proliferation [54]. These data led to the conclusion that the fusion partners are facilitating oligomerization, resulting in FGFR kinase activation in tumors possessing FGFR fusions. In addition, in vitro and in vivo assessment of the sensitivity of cell lines containing an FGFR2 fusion to a FGFR inhibitor demonstrated sensitivity to treatment only in the fusion containing cells [53,54], suggesting the presence of FGFR fusions may be a useful predictor of tumor response to FGFR inhibitors.
[0068] To comprehensively evaluate the genetic basis of sporadic intrahepatic cholangiocarcinoma (SIC), with emphasis on elucidation of therapeutically relevant targets, integrated whole genome and whole transcriptome analyses was performed on tumors from 6 patients with advanced, sporadic intrahepatic cholangiocarcinoma (SIC). Notably, recurrent fusions involving the oncogene FGFR2 (n=3) were identified.
[0069] FIGS. 5A-5G are graphs showing the sequence variation effects. Functional effects of high confidence sequence variations for all of the patients were identified. The abundance of variations in each functional category is provided as percentages relative to the total number of high confidence variations and raw counts are provided in Table 1.
[0000]
TABLE 1
Summary of mutation type by patient
Patient 1
Patient 2
Patient 3
Patient 4
Patient 5
Patient 6
Nonsynonymous coding
20
30
31
44
101
34
Synonymous coding
13
12
0
0
0
0
Insertions/deletions
1
4
0
6
0
2
Stop gained
0
3
3
2
6
2
Start gained
0
1
0
0
0
0
Codon insertion
0
1
0
0
0
1
Codon deletion
0
0
0
0
0
1
Splice site donor
0
0
1
0
1
2
Splice site acceptor
0
0
0
0
4
0
Total
34
51
35
52
112
42
For categories where the percentage was less than 5%, values are not shown.
[0070] FIG. 5A shows a summary of the mutation type. Summaries by individual patients are shown in FIG. 5B for Patient 1, FIG. 5C for Patient 2, FIG. 5D for Patient 3, FIG. 5E for Patient 4, FIG. 5F for Patient 5, and FIG. 5G for Patient 6. Nonsynonymous single nucleotide variations were the predominant class in all of the patients. Two patients, Patients 1 and 2 also accumulated a high number of synonymous mutations in comparison to the other patients; Patient 5 carries the most stops gained likely contributing to a higher number of pseudogenes in comparison to the others; Patient 5 was also the only patient to carry several predicted high impact mutations that affect the splice site acceptor regions (light green, percentage <5%). In addition to the major functional classes summarized, Patient 6 also carried a codon change plus insertion variation. A total of 327 somatic coding mutations were identified with an average of 55 mutations/tumor (range 34-112), within our cohort. Nonsynonymous single nucleotide variations were the predominant class in all of the patients. Patients 1 and 2 accumulated a high number of synonymous mutations in comparison to the other patients. Patient 5 carried the most stops gained likely contributing to a higher number of pseudogenes in comparison to the others and was also the only patient to carry several predicted high impact mutations affecting splice site acceptor regions ( FIGS. 5A-5G , light green, percentage <5%). In addition, patient 6 also carried a codon change plus insertion variation. Sequencing statistics are provided in Table 2.
[0000]
TABLE 2
Sequencing metrics of 6 advanced, sporadic biliary tract cancer patients
Exome
Whole Genome
RNA Seq
Aligned
Mean
Aligned
Aligned
Aligned
Aligned
Reads
Target
% Target
# of Functional
Reads
Bases
Physical
Reads
Bases
Patient
Tissue
(Millions)
Coverage
Bases 10×
Coding Variants
(Millions)
(Billions)
Coverage
(Millions)
(Billions)
1
N
161
100
94%
—
266
22
37
—
—
T
156
112
94%
21
228
18
35
100
8.1
2
N
176
74
94%
—
179
14
5
—
—
T
202
81
94%
34
370
30
10
341
26
3
N
226
110
58%
—
296
24
50
163
13
T
195
92
58%
52
321
26
50
101
8.1
4
N
167
80
95%
—
317
26
42
—
—
T
202
93
96%
52
163
13
12
264
20
5
N
257
146
96%
—
335
27
51
—
—
T
133
78
93%
250
349
28
39
401
31
6
N
350
243
92%
—
—
—
—
—
—
T
340
245
92%
43
—
—
—
713
31
Liver
—
—
—
—
—
—
—
—
118
9.6
Control
N = Normal,
T = Tumor
[0071] Table 3 (submitted on CD and incorporated herein) is a table of the somatic point mutations, insertions and deletions identified in all samples. Genes with mutations in more than one case included CSPG4 (n=2), GRIN3A (n=2) and PLXBN3 (n=2); with half of these predicted to be potentially damaging by SIFT [55], Polyphen [56], Mutation Assessor [57] and Mutation Taster [58]. While there was overlap in the somatic landscape of SIC with liver-fluke associated cholangiocarcinoma, hepatocellular cancer and pancreatic cancer, most of the aberrations detected in our study were distinct. Table 4 is a comparison of mutation frequency in cholangiocarcinoma, pancreatic and liver caners.
[0000]
TABLE 4
Liver fluke
Non-liver
associated
fluke CCA
CCA [111]
CCA [40]
PDAC [112]
HCC [113]
Gene
(n = 6)
(n = 54)
(n = 62)
(n = 142)
(n = 149)
AKT1
0%
0%
1.6%
0%
0%
APC
0%
0%
0%
0%
1.3%
ARID2
0%
0%
NA
2.1%
6.0%
BAP1
16.7%
0%
NA
0%
0%
BRAF
0%
0%
1.6%
0.7%
0%
CDKN2A
0%
5.6%
NA
2.4%
7.4%
CSPG4
33.3%
0%
NA
0%
0.7%
CTNNB1
0%
0%
NA
0%
34.9%
DMXL1
0%
0%
NA
0%
0%
EGFR
0%
0%
0%
0%
0%
ERRFI1
16.7%
0%
NA
0%
0.7%
FLT3
0%
0%
0%
0%
0%
GNAS
0%
9.3%
NA
0.7%
0%
GRIN3A
33.3%
0%
NA
0%
0%
IDH1
0%
0%
13%
0%
0%
IDH2
16.7%
0%
2%
0%
0%
JAK2
0%
0%
0%
0%
0%
KIT
0%
0%
0%
0%
0%
KRAS
0%
16.7%
NA
66.2%
1.3%
LAMA2
16.7%
3.7%
NA
0%
0%
MLL3
16.7%
14.8%
NA
4.9%
0%
NDC80
0%
3.7%
NA
0%
0%
NLRP1
16.7%
0%
NA
0%
0%
NOTCH1
16.7%
0%
0%
0%
0%
NRAS
16.7%
0%
3.2%
0%
0%
PCDHA13
16.7%
3.7%
NA
0.7%
0%
PAK1
16.7%
0%
NA
0%
0%
PEG3
0%
5.6%
NA
1.4%
0%
PIK3CA
0%
0%
0%
0%
1.3%
PLXNB3
33.3%
0%
NA
0%
0%
PTEN
0%
3.7%
2%
0%
0%
PTK2
16.7%
0%
NA
0%
0%
RADIL
0%
3.7%
NA
0%
0%
RNF43
0%
9.3%
NA
0%
0%
ROBO2
0%
9.3%
NA
1.4%
0%
SMAD4
0%
16.7%
NA
11.3%
0%
TP53
33.3%
44.4%
8%
23.2%
19.5%
XIRP2
0%
5.6%
NA
3.5%
0%
CCA, cholangiocarcinoma;
PDAC, pancreatic ductal adenocarcinoma;
HCC, hepatocellular carcinoma;
NA, not assessed
[0072] FIGS. 6A-6B are images of representative fluorescent in situ hybridization (FISH) demonstrating the presence of FGFR2 fusion. The present invention provides molecular fusions involving FGFR2 that were therapeutically relevant in 3 patients and were identified with a break apart Fluorescent In situ Hybridization (FISH) assay as seen in FIGS. 6A and 6B . FIG. 6A shows cholangiocarcinoma with FGFR2 rearrangement (distinct orange and green signals are present in most of the cells). FIG. 6B shows Cholangiocarcinoma negative for FGFR2 rearrangement (orange and green signals remain fused). Notably, the patients who did not harbor the FGFR2 fusions were negative using the same assay.
[0073] BAP1 (R60*) presented with a truncating mutation that has been previously reported in skin, but have not been reported in biliary cancers. Somatic BAP1 mutations have been identified in a number of tumor types including: Breast, endometrium, eye, kidney, large intestine, lung, ovary, pleura, prostate, skin, and urinary tract. A deubiquitinating enzyme and possible tumor suppressor, BAP1, plays a critical role in the regulation of chromatin modulation and transcription. Furthermore, the loss of BAP1 has been associated with tamoxifen resistance in breast cancer, aggressive and metastatic disease in uveal melanomas.
[0074] A nonsynonymous mutation observed in PTK2 (P926S) occurs in a region of the gene whose protein product interacts with TGFB1I1 and ARHGEF28. PTK2, also known as focal adhesion kinase (FAK), is a tyrosine kinase involved in the regulation of cell migration, proliferation, adhesion, microtubule stabilization and actin cytoskeleton. Furthermore, FAK interacts with multiple signaling molecules and in multiple pathways suggesting the possible use of therapeutic treatments directly targeting these interactions or targeting downstream targets of PTK2 such as PI3K or mTOR.
[0075] A serine/threonine p21 protein-activated kinase 1 (PAK1) gene contains a nonsynonymous (R371C) mutation located in the protein kinase domain. The location of this mutation could potentially lead to loss of the critical protein kinase domain. While PAK1 is expressed in many normal tissues, it is highly-expressed in ovarian, breast, and bladder cancers. PAK1 plays a role in cell motility, proliferation, survival, and death although, the ability to therapeutically target PAK1 will require further study by tumor type as breast cancer subpopulations have shown response to PAK1 inhibition while non-small cell lung cancer has proven resistant. K5-rTA::tet-KRASG12D mice wildtype for Pak1, responded to treatment with PAK or MEK inhibitors, but did not respond to AKT inhibitors.
[0076] Tables 5 (submitted on CD and incorporated herein) 6 and 7 attached hereto are tables showing genes carrying single nucleotide or frameshift variations, or aberrant in copy number were annotated and clustered by GO term functional classes, some of which are known to play a role in Cancer. Proteins predicted to be integral to the membrane and involved in transport, as well as transcriptional regulators were among the most abundant class in all of the patients affected by small scale sequence variations and copy number variations. Variations specifically affecting the EGFR or FGFR gene families were prevalent in Patients 4, 5, and 6 and are highlighted in the figure with the gene name provided in parenthesis next to the pathway name. Comparative pathway analysis of genes carrying small scale nucleotide variations (SsNVs) has implicated several major pathways, possibly interacting as a network, that are predicted to underlie disease in biliary carcinoma patients. These shared pathways include EGFR, EPHB, PDGFR-beta, Netrin-mediated and Beta 1 integrin mediated signaling pathways. Interestingly, most of these pathways have known roles in mediating epithelial-to-mesenchymal cell transitions, which occur frequently during development as well as tumorigenesis. Cell growth and motility is inherent to the successful progression of both biological processes. Studies of the nervous system and lung development have shown that Netrins act to inhibit FGF7 and FGF10 mediated growth or cell guidance [60]. In addition, Netrin-1 has a known role in mediating cell migration during pancreatic organogenesis [60]. Furthermore, Netrin-1 acts as a ligand for α3β1 and α6β4 integrins, both of which are involved in supporting adhesion of developing pancreatic epithelial cells with Netrin-1 although it is thought that α6β4 plays the principle role during this process [60]. Interestingly, α3β1 has been hypothesized to play a role during the process of angiogenesis, when chemoattractants and chemorepellents act to guide filopodia during migration [60]. The α3β1 integrin receptor may act together with additional pathways proposed to play a role during angiogenesis such as VEGF, PDGFR-beta [61], and EphrinB [62] as well as tumorigenesis [60]. Patients 3 and 4 also shared several genes acting in cadherin signaling pathways (see Tables 6-7 submitted on CD and incorporated herein), which are important for maintaining cell-cell adhesion and are known to be intimately integrated with EGFR and FGFR signaling pathways [63].
[0077] FIG. 7 is an image showing the copy number changes and structural rearrangements. Whole genome data was utilized to determine copy number alterations and structural rearrangements in the genome for Patients 1-5. WGS was not conducted for patient 6. Red indicates copy number gain, green copy number loss and blue lines indicate structural rearrangements. Significant variability between samples was observed for both copy number changes and structural rearrangements. Patient 5 presented with numerous copy number changes and structural rearrangements contrasting with patient 4 who had minimal structural rearrangements and much smaller regions of copy number changes. Patient 3 is characterized by a large number of structural rearrangements with almost no copy number alterations; in contrast, Patient 1 has a moderate number of structural variations, but has large regions of copy number gain and loss. Patient 2 has a moderate number of structural rearrangements with multiple focal amplifications across the genome.
[0078] In addition to the variations identified in genes acting in EGFR, and/or FGFR signaling pathways, multiple sSNVs, and copy number variations (CNVs) ( FIG. 7 ) in genes such as IIDAC1, TP53, MDM2 and AKT1, acting in interaction networks or regulatory pathways involving the fusion partner genes in Patients 5 (BICC1), and 6 (TACC3) (Table 8) (submitted on CD and incorporated herein) are seen. Known mutations in BICC1 have been shown to disrupt canonical Wnt signaling [64] and genes, such as BCL9, involved in this pathway are known to regulate a range of biological processes such as transcription and cell proliferation and carry variations in Patient 5 (Table 8). CSPG4, a target that is being investigated for antibody-based immunotherapy in preclinical studies of triple negative breast cancer [65], is involved in the Wnt signaling pathway, and carries variations in both Patients 1 and 2, however, it is not mutated in Patient 5. TACC3 is known to mediate central spindle assembly and multiple genes including CDCA8, BUB1, and TACC1, belonging to the TACC3 interaction network exhibit aberrant copy number in Patient 6 (Table 8). A recent study has also implicated TACC3 in EGF-mediated EMT when overexpressed [64], and we find that the PLCG1, MAP2K1, and MAPK8 genes, which act in both FGFR and EGFR regulatory pathways, exhibit CNV in Patient 6. The DNAH5 gene encoding a dynein protein is part of the microtubule-associated motor protein complex carries two G→C missense mutations in Patient 6 (Table 4). Several genes carrying more than one variation in either the same patient or different patients also included genes with known roles similar to genes in FGFR/EGFR pathways including axon guidance, invasive growth, or cell differentiation (NAV3, LAMC3, PLXNB3, and PTPRK) (Table 4). In the case of Patient 4, our studies suggest that the primary effect of the FGFR2-MGEA5 fusion is on FGFR2 related signaling, since changes in expression were observed in FGF8 (p<0.05) and the genome of this patient also carries a 4-bp insertion ({circumflex over ( 0 )}GTGT) in the FGFR4 gene (Table 4).
[0079] FIGS. 8A-8B are images of immunohistochemistry demonstrating FGFR2 and FGFR3 expression. FIG. 8A is an image of a tumor stained with FGFR2 antibody. Patient 1 demonstrates moderate cytoplasmic positivity (solid arrows); background fibro-inflammatory tissue is negative (empty arrows). Patient 2 demonstrates moderate cytoplasmic expression for FGFR2; tumor nuclei are negative. Patient 3 demonstrates tumor cells with negative nuclear and weak cytoplasmic expression of FGFR2 (solid arrows) with cells demonstrating moderate basolateral or complete membranous staining as well. Patient 4 demonstrates weak/moderate cytoplasmic positivity with multi-focal weak/moderate membranous expression (solid arrows); background fibro-inflammatory tissue demonstrates negative/weak staining (empty arrows). Patient 5 demonstrates weak/moderate cytoplasmic positivity with multi-focal moderate/strong membranous expression (solid arrows); background fibro-inflammatory tissue is negative (empty arrows). Patient 6 demonstrates moderate/strong cytoplasmic positivity (solid arrows); background lymphocytes are negative (empty arrows). FIG. 8B is an image of a tumor stained with FGFR3 antibody. Patient 1 demonstrates strong cytoplasmic positivity, variable nuclear expression and occasional moderate/strong membranous expression (solid arrows); background fibrous tissue is negative (empty arrows). Patient 2 demonstrates negatively staining background neutrophils (focally intraepithelial-far right) (empty arrows) and tumor cells with strong nuclear expression and moderate cytoplasmic positivity (solid arrows). Patient 3 demonstrates negatively staining background inflammation (empty arrows) and tumor cells with weak nuclear expression and moderate cytoplasmic positivity (solid arrows). Patient 4 demonstrates weak/moderate cytoplasmic positivity and variable nuclear expression; background fibro-inflammatory tissue demonstrates negative/weak positivity (empty arrows). Patient 5 demonstrates moderate cytoplasmic positivity, variable nuclear expression and strong multi-focal membranous expression (solid arrows); background fibrous tissue is negative. Patient 6 demonstrates diffuse/moderate/strong cytoplasmic and membranous positivity and variable nuclear expression (solid arrows); background lymphocytes are negative (empty arrows).
[0080] Patient 4 is a 62 year-old white female found to have a left-sided intrahepatic mass with satellite lesions, with metastasis to regional lymph nodes. Table 9 shows the clinical characteristics of 6 advanced, sporadic biliary tract cancer patients
[0000]
TABLE 9
Patient 1
Patient 2
Patient 3
Patient 4
Patient 5
Patient 6
Age (years)
64
66
50
62
50
43
Gender
F
M
M
F
F
F
Location of
Intrahepatic
Intrahepatic/
Intrahepatic
Intrahepatic
Intrahepatic
Intrahepatic
Primary Tumor
Gallbladder
Stage
III
IV
IV
IV
IV
IV
CA19-9
WNL
1008
WNL
WNL*
N/A
56
(Units/ml)
Sites of
N/A
Abdominal
Cervical,
Abdominal,
Liver,
Lungs
Metastasis
Lymph
Thoracic,
Pelvic
Lungs,
Nodes
Abdominal,
Lymph
Peritoneum
Pelvic
Nodes,
Lymph Nodes
Liver
Underlying
Unknown
Unknown
Unknown
Unknown
Unknown
Unknown
Etiology
Liver fluke
No
No
No
No
No
No
Hepatitis B
Unknown
Unknown
Negative
Unknown
Unknown
Unknown
Hepatitis C
Unknown
Unknown
Negative
Unknown
Unknown
Unknown
Prior Surgical
No
Yes
Yes
No
Yes
No
Resection
Prior Radiation
No
No
No
No
No
No
Therapy
Systemic
Gem/Cis
Gem/Cis
Gem/Cis
Gem/Cis
Gem/Cis
Gem/Cis
Chemotherapy
Capecitabine
Gem/Cape
5-FU/
FOLFOX
PEGPH20
Carbo
Pazopanib
Survival Status
Alive
Dead
Dead
Alive
Dead
Alive
Survival
14.5+
8.8
9.0
9.3+
4.1
5.5+
Duration from
biopsy
(months)
F = female;
M = male;
WNL = Within Normal Limits;
Gem/Cis = Gemcitabine and Cisplatin;
Gem/Cape = Gemcitabine and Capecitabine;
PEGPH20 = pegylated hyaluronidase;
5-FU/Carbo = 5-Fluorouracil and Carboplatin;
FOLFOX - 5-FU, Leucovorin and Oxaliplatin,
*= WNL at baseline but 1408 U/ml prior to therapy and
N/A = Not Available
[0081] A biopsy of the liver mass revealed the presence of a poorly differentiated adenocarcinoma that was consistent with intrahepatic cholangiocarcinoma (CK7 + , CEA + , CK20 + , Hep-par 1 − , TTF-1 − ). Table 10 shows the pathological characteristics of 6 advanced, sporadic biliary tract cancer patients.
[0000]
TABLE 10
Patient 1
Patient 2
Patient 3
Patient 4
Patient 5
Patient 6
Grade/differentiation
Moderate
Moderate
Undifferentiated
Poor
Moderate
Poor
Biopsy Procedure
U/S
U/S
Excisional
U/S
U/S
Excisional
Guided
Guided
Biopsy Lymph
Guided
Guided
Lung
Liver
Liver
Node
Liver
Liver
Biopsy
Biopsy
Biopsy
Biopsy
Biopsy
% Necrosis
5 (1)
0 (2)
0-35 (7)
0 (3)
0-5 (3)
0
(aliquots)
% Tumor
50
10-20
25-75
0-20
40-50
30
% Stroma and
50
80-90
25-75
80-100
50-60
70
normal elements
Histological Type
NST**
NST
NST
NST
NST
NST
Clear Cell
No
No
No
No
No
No
Histology (Yes/No)
U/S = Ultrasound
*NST: No special type.
**Rare gland formation with expression of cytokeratin, polyclonal CEA, and MOC-31. All were adenocarcinomas of no special types and high grades as defined by the World Health Organization Classification of Tumors of the Digestive System (Lyon 2000). Degree of differentiation is based on the percentage of glands (defined as having visible lumens by visual estimate) as follow: 95% or more glands-well differentiated, 40-94% glands-moderately differentiated, 5-39% glands-poorly differentiated, <5% glands-undifferentiated.
[0082] She received gemcitabine and cisplatin and obtained clinical benefit in the form of stable disease for 6 months, followed by disease progression. She was re-treated with gemcitabine and capecitabine systemic therapy and attained stable disease for 6 months, followed by disease progression. A clinical trial of pegylated hyaluronidase (PEGPH20) produced only stable disease for 4 months, followed again by disease progression. At this juncture, she underwent a liver biopsy to obtain tissue for whole genome characterization of her tumor.
[0000]
TABLE 11
Fusion events
Predicted
Gene1 break
Gene2 break
Reciprocal
Gene1
Gene2
location
location
Translocation
Patient
Fusions
FGFR2
MGEA5
chr10:123243211
chr10:103552699
No
4
FGFR2
BICC1
chr10:123237843
chr10:60380614
Yes
5
BICC1
FGFR2
chr10:60272900
chr10:123237848
Yes
5
FGFR2
TACC3
chr10:123243211
chr4:1741428
No
6
[0083] Evaluation of pre-treatment immunohistochemistry demonstrated increased expression of FGFR2 and FGFR3 ( FIG. 7 ) and Clinical Laboratory Improvement Amendments (CLIA) validation by quantitative PCR revealed increased expression of FGFR3. In order to further validate the activation of the receptor, we conducted immunohistochemistry (IHC) of pFRS2 Y436 and pERK(MAPK) that revealed strong expression of pFRS2 Y436 and pERK, thus confirming activation of the receptor.
[0084] FIGS. 9A-9B are images showing immunohistochemistry demonstrating pFRS2 Y436, and pERK expression in Patients 1, 4, 5 and 6. FIG. 9A is an image showing a tumor stained with pFRS2 Y436 antibody. Patient 1 tumor cells demonstrating both strong cytoplasmic and nuclear expression of pFRS2 (solid arrows); background fibrous stroma is negative (empty arrows). Patient 4 tumor cells show strong nuclear expression and moderate to strong cytoplasmic positivity (solid arrows); occasional background fibrous stromal cells are negative for pFRS2 (empty arrows) and scattered tumor cells show basolateral/membranous staining as well (white arrows). Patient 5 tumor cells show intensely strong expression in both nuclei and cytoplasm (solid arrows); scattered background fibrous stromal cells are negative (empty arrows). Patient 6 tumor cells show negative nuclear expression of pFRS2, moderate cytoplasmic expression and basolateral or membranous expression of varying intensity (solid arrows); background fibrous stromal cells are negative (empty arrows). FIG. 9B is an image showing a tumor stained with pERK(MAPK) antibody. Patient 1 demonstrates negative/weak fibrous stroma (empty arrows) and tumor cells with negative nuclei and moderate to strong cytoplasmic expression (solid arrows). Patient 4 demonstrates negative inflammatory background (empty arrows) tumor cells with variable negative to strong nuclear expression and moderate to strong cytoplasmic positivity (solid arrows). Patient 5 demonstrates negative/weak fibrous stroma (empty arrows) and tumor cells with strong nuclear and cytoplasmic expression (solid arrows). Patient 6 demonstrates negative background lymphocytes/mononuclear inflammatory cells (empty arrows) and tumor cells with strong nuclear and cytoplasmic expression (solid arrows).
[0085] The FGFR2 fusion partner observed in this patient, MGEA5, is an enzyme responsible for the removal of O-GlcNAc from proteins [66]. Interestingly, soft tissue tumors myxoinflammatory fibroblastic sarcoma (MIFS) and hemosiderotic fibrolipomatous tumor (HFLT) both share a translocation event resulting in rearrangements in TGFBR3 and MGEA5 [67,68]. Associated with this translocation event is the upregulation of NPM3 and FGF8 [68], of which both genes are upregulated in this patient (fold change: NPM3=6.17865, FGF8=1.79769e+308). In breast cancer, grade III tumors had significantly lower MGEA5 expression than grade I tumors with a trend of decreasing expression observed with increasing tumor grade [66]. MGEA5 may play an important role in carcinogenesis as an FGFR fusion partner.
[0086] Patient 6 is a 43 year-old white female who underwent a right salpingo-oophorectomy and endometrial ablation in the context of a ruptured ovarian cyst (Table 9). Postoperatively she developed dyspnea and was found to have pulmonary nodules as well as a 5 cm left sided liver mass. Pathological evaluation of the liver mass was consistent with a moderately differentiated intrahepatic cholangiocarcinoma (CK7+, CK20−, TTF-1−) in the absence of any known risk factors (Table 10). She was treated systemically with gemcitabine and cisplatin and had stable disease for approximately 6 months, but was subsequently found to have disease progression. She was treated with FOLFOX for 7 months and again attained stable disease as best response to therapy but eventually experienced disease progression. Transcriptome analysis revealed the presence of an FGFR2-TACC3 fusion (Table 11). Further evaluation of phosphorylation of downstream targets FRS2 Y436, and ERK(MAPK) revealed strong expression of pERK and moderate expression of pFRS2 Y436 ( FIG. 5 ), confirming activation of the receptor.
[0087] The FGFR2 fusion partner observed in this patient's tumor, TACC3, is overexpressed in many tumor types with enhanced cell proliferation, migration, and transformation observed in cells overexpressing TACC3 [70]. Furthermore regulation of ERK and PI3K/AKT by TACC3 may contribute in part to epithelial-mesenchymal transition (EMT) in cancer [70], a significant contributor to carcinogenesis.
[0088] Interestingly, TACC3 has been identified as a fusion partner to FGFR3 in bladder cancer, squamous cell lung cancer, oral cancer, head and neck cancer and glioblastoma multiforme [54].
[0000]
TABLE 12
Gene
Location
Mutation
CLIA report
Patient
ERRFI1
chr1:8073509
C/A
G/T - small
3
percentage of T
IDH2
chr15:90631839
T/A
A/T
1
NRAS
chr1:115258745
C/G
C/G
1
PAK1
chr11:77051696
G/A
G/A
2
FGFR3
Overexpressed
Fold change
qPCR fold
4
3.32975
difference = 2.13
FGFR3
Overexpressed
Fold change
qPCR fold
5
3.58524
difference = 10.88
[0089] Integrated analysis of sporadic intrahepatic cholangiocarcinoma (SIC) genomic and transcriptomic data led to the discovery of FGFR2 fusion products in three of six assessed patients. Members of the FGFR family (FGFR-1-4) have been associated with mutations, amplifications and translocation events with oncogenic potential [71]. FGFR fusions with oncogenic activity have been previously identified in bladder cancer (FGFR3) [72], lymphoma (FGFR1 and FGFR3) [73,74], acute myeloid leukemia (FGFR1) [75], multiple myeloma [76], myeloproliferative neoplasms [77], and most recently glioblastoma multiforme (FGFR1 and FGFR3) [78]. FGFR2, FGFR3 and FGFR4 have been found to be overexpressed in IDH1/IDH2 mutant biliary cancers [79], a context seen within Patient 1 in our study; although, no fusion events were depicted in these studies or in Patient 1. Table 13 shows differential gene expression of fibroblast growth factor receptor pathway family members in 5 patients with advanced sporadic biliary tract cancer.
[0000]
TABLE 13
Up/Down Regulated
(TumorVs.Normal),
Patients
FGF Family Member
Ordered by patient
5
FGFR1
+
1, 5
FGFR2
+/−
1, 4, 5
FGFR3
+/+/+
1, 3, 4, 5
FGFR4
+/+/+/+
1, 4, 5
FGF17
+/+/+
1, 4*
FGFBP1
+/+
1, 4*
FGF8
+/+
1, 4, 5*
FGFR1OP
−/−/−
1, 4, 5
FGFBP3
−/−/−
1, 5
FGF2
−/−/−
1, 4, 5
FGF5
−/−/−
1, 4, 5
FGF7
−/−/−
1, 4, 5
FGF9
−/−/−
1, 4
FGF10
−/−
3, 5
FGF12
+/−
1, 4, 5
FGF21
−/−/−
Transcripts that undergo changes
Up/Down Regulated
in splicing during the E-M
(TumorVs.Normal),
Patients
Transition
Ordered by patient
1, 4
CTNND1
−/−
1, 4, 5
CD44
−/−/−
mRNA splicing factor that
Up/Down Regulated
regulates the formation of
(TumorVs.Normal),
Patients
epithelial cell-specific isoforms
Ordered by patient
1, 4, 5
ESRP1
+/+/+
*Not significant (10 −3 is threshold of significance)
[0090] FIG. 10A-10D are images showing transcripts and hypothetical protein products modeled to illustrate the potential functional impact of fusion events involving FGFR2. FIG. 10A shows the FGFR2 fusion event involving MGEA5 (Patient 4) and FIG. 10C shows the FGFR2 fusion event involving BICC1 (Patient 5, reciprocal event). FIG. 10D shows interchromosomal fusion events. In addition, Patient 6 carried an interchromosomal fusion event involving FGFR2 and TACC3 FIG. 10B . The FGFR2 gene encodes for several isoforms with eleven representative transcripts and Patients 4, 5, and 6 carry fusions involving the epithelial cell specific transcript isoform (FGFR2 -IIIb). All identified fusion breakpoints are close in proximity and are predicted to occur within the last intron of the transcript and terminal to a known protein tyrosine kinase domain ( FIGS. 10A-10C , gold domain). Predicted “Other” sites for all of the fusion protein models are the same and include the following: Casein kinase II phosphorylation sites, N-glycosylation sites, Protein kinase C phosphorylation sites, N-myristoylation sites, Tyrosine kinase phosphorylation sites, and cAMP-/cGMP-dependent protein kinase phosphorylation sites ( FIGS. 10A-10C , grey triangle annotations). In all cases, fusions result in a predicted expansion of Casein kinase II phosphorylation and Protein kinase C phosphorylation sites. A protein product model is shown only for one of the reciprocal events involving the FGFR2 and BICC1 genes (FGFR2→BICC1, FIG. 10C ). The fusion breakpoints of the reciprocal events effect Exons 1 and 2 of the BICC1 gene, which translates to a difference of a predicted phosphoserine site within the Casein kinase II phosphorylation region ( FIG. 10C , purple triangle within red circle). The FGFR2 gene is located within a fragile site region (FRA10F) and is flanked by two ribosomal protein pseudogenes, RPS15AP5 and RPL19P16 (see D inset (*)), whose repetitive sequence content may also contribute to genomic instability at the FGFR2 initiation site.
[0091] Although the gene partner fused to FGFR2 was different for each Patient (MGEA5, BICC1 and TACC3), the breakpoints in FGFR2 all occurred within the last intron distal to the last coding exon and terminal protein tyrosine kinase domain. All three fusions were validated at the DNA and/or RNA level of FGFR2 (Table 13) fusions in 3 Patients with advanced sporadic biliary tract cancer.
[0000]
TABLE 14
Annealing
PCR
SEQ
Fusion
site
input
Dir
ID NO
Primer sequence
FGFR2-MGEA5
FGFR2
gDNA
F
1
5′-CTGACTATAACCACGTACCC-3′
MGEA5
gDNA
R
2
5′-AGGGAGAAATTAAAGAACTTGG-3′
FGFR2
cDNA
F
3
5′-TGATGATGAGGGACTGTTG-3′
MGEA5
cDNA
R
4
5′-GAGTTCCTTGTCACCATTTG-3′
FGFF2-BICC1
FGFR2
gDNA
F
5
5′-GGCAGAAGAAGAAAGTTGG-3′
BICC1
gDNA
R
6
5′-ACTACTGCAGTTTGTTCAAT-3′
FGFR2
cDNA
F
7
5′-TGATGATGAGGGACTGTTG-3′
BICC1
cDNA
R
8
5′-TGTGTGCTCACAGGAATAG-3′
BICC1-FGFR2
BICC1
cDNA
F
9
5′-CGTGGACAGGAAGAAACT-3′
FGFR2
cDNA
R
10
5′-GTGTGGATACTGAGGAAG-3′
FGFR2-TACC3
FGFR2
gDNA
F
11
5′-TGACCCCCTAATCTAGTTGC-3′
TACC3
gDNA
R
12
5′-AACCTGTCCATGATCTTCCT-3′
[0092] Amongst these fusions, the FGFR2-BICC1 fusion has recently been independently identified in SIC [53,54]. For this particular fusion product we observed, and validated, the presence of two fusion isoforms (FGFR2-BICC1 and BICC1-FGFR2). Interestingly, BICC1 is a negative regulator of Wnt signaling [80] and when comparing expression of tumor and normal tissue we observed differentially expressed Wnt signaling genes, APC (fold change −4.75027), GSK3B (fold change −3.35309), and CTNNB1 (fold change −1.73148), yet when the expression was compared to other cholangiocarincomas, no difference was observed.
[0093] The FGFR genes encode multiple structural variants through alternative splicing. Notably, RNASeq data revealed that the FGFR2-IIIb isoform was present in all fusions detected in our study and has been shown to have selectivity for epithelial cells as opposed to the FGFR2-IIIc isoform, which is found selectively in mesenchymal cells [81]. Paradoxically, wildtype FGFR2-IIIb has been described as a tumor suppressor in pre-clinical systems of bladder cancer and prostate cancer [82,83]. As such, FGFR signaling appears context-dependent and exhibits variability in disparate tumor types.
[0094] Comparative pathway analysis of genes carrying mutations/aberrant in copy number identified additional potential therapeutic targets belonging to, or intimately integrated with, the EGFR and FGFR signaling pathways ( FIG. 6 , Tables 5-7). Interestingly, most of these pathways also have known roles in mediating epithelial-to-mesenchymal cell transitions, which occur frequently during development as well as during tumorigenesis [60]. Patients 3 and 4 harbored aberrations in several genes acting in cadherin signaling pathways (Tables 6-7), which are important for maintaining cell-cell adhesion [63].
[0095] Whole genome sequencing for Patients 1, 3, 4, and 5. 1.1 μg genomic DNA was used to generate separate long insert whole genome libraries for each sample using Illumina's (San Diego, Calif.) TruSeq DNA Sample Prep Kit (catalog #FC-121-2001). In summary, genomic DNAs are fragmented to a target size of 900-1000 bp on the Covaris E210. 100 ng of the sample was run on a 1% TAE gel to verify fragmentation. Samples were end repaired and purified with Ampure XP beads using a 1:1 bead volume to sample volume ratio, and ligated with indexed adapters. Samples are size selected at approximately 1000 bp by running samples on a 1.5% TAE gel and purified using Bio-Rad Freeze 'n Squeeze columns and Ampure XP beads. Size selected products are then amplified using PCR and products were cleaned using Ampure XP beads. Whole genome sequencing for Patient 2. 300 ng genomic tumor and normal DNA was used to create whole genome libraries. Samples were fragmented on the Covaris E210 to a target size of 200-300 bp and 50 ng of the fragmented product was run on a 2% TAE gel to verify fragmentation. Whole genome libraries were prepared using Illumina's TruSeq DNA Sample Prep Kit.
[0096] Exome sequencing for Patients 1 and 3. 1.1μg genomic DNA for each sample was fragmented to a target size of 150-200 bp on the Covaris E210. 100 ng of fragmented product was run on TAE gel to verify fragmentation. The remaining 1 μg of fragmented DNA was prepared using Agilent's SureSelect XT and SureSelect XT Human All Exon 50 Mb kit (catalog #G7544C). Exome sequencing for Patient 2. 50ng genomic tumor and normal DNA was used to create exome libraries using Illumina's Nextera Exome Enrichment kit (catalog #FC-121-1204) following the manufacturer's protocol. Exome sequencing for Patients 4 and 5. 1 μg of each tumor and germline DNA sample was used to generate separate exome libraries. Libraries were prepared using Illumina's TruSeq DNA Sample Prep Kit and Exome Enrichment Kit (catalog #FC-121-1008) following the manufacturer's protocols. Exome sequencing for Patient 6. 3 μg of genomic tumor and normal DNA was fragmented on the Covaris E210 to a target size of 150-200 bp. Exome libraries were prepared with Agilent's (Santa Clara, Calif.) SureSelectXT Human All Exon V4 library preparation kit (catalog #5190-4632) and SureSelectXT Human All Exon V4+UTRs (catalog #5190-4637) following the manufacturer's protocols.
[0097] RNA sequencing for Patients 1, 2 and 3. 50 ng total RNA was used to generate whole transcriptome libraries for RNA sequencing. Using the Nugen Ovation RNA-Seq System v2 (catalog #7102), total RNA was used to generate double stranded cDNA, which was subsequently amplified using Nugen's SPIA linear amplification process. Amplified products were cleaned using Qiagen's QIAquick PCR Purification Kit and quantitated using Invitrogen's Quant-iT Picogreen. 1 μg of amplified cDNA was fragmented on the Covaris E210 to a target size of 300 bp. Illumina's TruSeq DNA Sample Preparation Kit was used to prepare libraries from 1 μg amplified cDNA.
[0098] RNA sequencing for Patients 4, 5 and 6. 1μg of total RNA for each sample was used to generate RNA sequencing libraries using Illumina's TruSeq RNA Sample Prep Kit V2 (catalog #RS-122-2001) following the manufacturer's protocol.
[0099] Paired End Sequencing. Libraries with a 1% phiX spike-in were used to generate clusters on HiSeq Paired End v3 flowcells on the Illumina cBot using Illumina's TruSeq PE Cluster Kit v3 (catalog #PE-401-3001). Clustered flowcells were sequenced by synthesis on the Illumina HiSeq 2000 using paired-end technology and Illumina's TruSeq SBS Kit.
[0100] Alignment and variant calling for whole genome and whole exome. For whole genome and exome sequencing fastq files were aligned with BWA 0.6.2 to GRCh37.62 and the SAM output were converted to a sorted BAM file using SAMtools 0.1.18. BAM files were then processed through indel realignment, mark duplicates, and recalibration steps in this order with GATK 1.5 where dpsnp135 was used for known SNPs and 1000 Genomes' ALL.wgs.low_coverage_vqsr.20101123 was used for known indels. Lane level sample BAMs were then merged with Picard 1.65 if they were sequenced across multiple lanes. Comparative variant calling for exome data was conducted with Seurat [105].
[0101] Previously described copy number and translocation detection were applied to the whole genome long insert sequencing data [59]. Copy number detection was based on a log 2 comparison of normalized physical coverage (or clonal coverage) across tumor and normal whole genome long-insert sequencing data, where physical coverage was calculated by considering the entire region a paired-end fragment spans on the genome, then the coverage at 100 bp intervals was kept. Normal and tumor physical coverage was then normalized, smoothed and filtered for highly repetitive regions prior to calculating the log 2 comparison. Translocation detection was based on discordant read evidence in the tumor whole genome sequencing data compared to its corresponding normal data. In order for the structural variant to be called there needs to be greater than 7 read pairs mapping to both sides of the breakpoint. The unique feature of the long-insert whole-genome sequencing was the long overall fragment size (˜1 kb), where by two 100 bp reads flank a region of ˜800 bp. The separation of forward and reverse reads increases the overall probability that the read pairs do not cross the breakpoint and confound mapping.
[0102] For RNA sequencing, lane level fastq files were appended together if they were across multiple lanes. These fastq files were then aligned with TopHat 2.0.6 to GRCh37.62 using ensemb1.63.genes.gtf as GTF file. Changes in transcript expression were calculated with Cuffdiff 2.0.2. For novel fusion discovery reads were aligned with TopHat-Fusion 2.0.6 [106] (Patients 2, 3, 4 and 6). In addition, Chimerascan 0.4.5 [107] was used to detect fusions in Patient 1, deFuse 5.0 [108] used in Patients 2, 3 and 5 and SnowShoes [109] for Patients 2 and 5.
[0103] Briefly, slides were dewaxed, rehydrated and antigen retrieved on-line on the BONDMAX™ autostainer (Leica Microsystems, INC Bannockburn, Ill.). Slides were then subjected to heat-induced epitope retrieval using a proprietary EDTA-based retrieval solution. Endogenous peroxidase was then blocked and slides were incubated with the following antibodies: FGFR2 (BEK, Santa Cruz, catalog #sc-20735), FGFR3 (C-15, Santa Cruz, catalog #sc-123), panAKT (Cell Signaling Technology, catalog #4685, pAKT (Cell Signaling Technology, catalog #4060), EGFR (Cell Signaling Technology, catalog #4267, pEGFR (Cell Signaling Technology, catalog #2234), MAPK/ERK1/2 (Cell Signaling Technology, catalog #4695), pMAPK/pERK (Cell Signaling Technology, catalog #4376) and pFRS2 Y436 (Abcam, catalog #ab78195). Sections were visualized using the Polymer Refine Detection kit (Leica) using diaminobenzidine chromogen as substrate.
[0104] Fluorescent in-situ hybridization (FISH) was performed on formalin-fixed paraffin-embedded (FFPE) specimens using standard protocols and dual-color break-apart rearrangement probes specific to the FGFR2 gene (Abbott Molecular, Inc. Des Plaines, Ill.) located at 10 q26. The 5′ FGFR2 signal was labeled with Spectrum Orange (orange) and the 3′ FGFR2 signal was labeled with Spectrum Green (green).
[0105] In some embodiments, homology, sequence identity or complementarity, is between the antisense compound and target is from about 40% to about 60%. In some embodiments, homology, sequence identity or complementarity, is from about 60% to about 70%. In some embodiments, homology, sequence identity or complementarity, is from about 70% to about 80%. In some embodiments, homology, sequence identity or complementarity, is from about 80% to about 90%. In some embodiments, homology, sequence identity or complementarity, is about 90%, about 92%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99% or about 100%.
[0106] Examples of cancers (including solid tumors) which may be treated (or inhibited) include, but are not limited to, a carcinoma, for example a carcinoma of the bladder, breast, colon (e.g. colorectal carcinomas such as colon adenocarcinoma and colon adenoma), kidney, epidermis, liver, lung, for example adenocarcinoma, small cell lung cancer and non-small cell lung carcinomas, oesophagus, gall bladder, ovary, pancreas e.g. exocrine pancreatic carcinoma, stomach, cervix, endometrium, thyroid, prostate, or skin, for example squamous cell carcinoma; a hematopoietic tumour of lymphoid lineage, for example leukemia, acute lymphocytic leukemia, chronic lymphocytic leukemia, B-cell lymphoma, T-cell lymphoma, Hodgkin's lymphoma, non-Hodgkin's lymphoma, hairy cell lymphoma, or Burkett's lymphoma; a hematopoietic tumour of myeloid lineage, for example leukemias, acute and chronic myelogenous leukemias, myeloproliferative syndrome, myelodysplastic syndrome, or promyelocytic leukemia; multiple myeloma; thyroid follicular cancer; a tumour of mesenchymal origin, for example fibrosarcoma or rhabdomyosarcoma; a tumour of the central or peripheral nervous system, for example astrocytoma, neuroblastoma, glioma or schwannoma; melanoma; seminoma; teratocarcinoma; osteosarcoma; xeroderma pigmentosum; keratoctanthoma; thyroid follicular cancer; or Kaposi's sarcoma.
[0107] It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
[0108] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.
[0109] As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps. | The present invention provides a method of characterizing a cancer by obtaining a sample from a subject suspected of having cancer; and determining whether a fibroblast growth factor receptor (FGFR) fusion is present in the sample, wherein the FGFR fusion comprises a FGFR locus, thereby characterizing the cancer based on the presence or absence of the FGFR fusion. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a national phase of the International Application PCT/EP2014/061360 filed Jun. 2, 2014, claiming priority of the German Patent Application DE 10 2013 108 399.4 filed Aug. 5, 2013. The content of this aforementioned document is herewith incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a paper machine screen.
[0003] A paper machine screen may, e.g. be used in/applied to the wet end of a paper machine for draining/filtration of paper fibrous material, thus for forming of the paper sheet (so-called sheet forming screen or forming screen).
[0004] A paper machine screen may e.g. be configured as a so-called long floating screen, i.e. as a screen with lower transverse threads having/forming long floats on the running side. Such screens are mainly used for papers with higher grammage. Screens of this kind may generally be used at all speeds with Fourdrinier machines as well as with hybrid-formers or GAP-formers. Screens of this kind are highly regarded due to their long operating time.
[0005] In paper machine screens/forming screens, e.g. two different materials, for example polyester and polyamide, may be used on the running side for forming the lower transverse threads. These two materials may, for example, be introduced in a longitudinal direction alternately behind one another on the running side, wherein the polyester is primarily useful for mechanically stabilizing the fabric, while the polyamide is used mainly to increase abrasion resistance and thus for extending the operating time. Both materials have generally different properties which are also reflected in the respective behavior of the threads within the fabric.
[0006] Fabrics/Screens are known, in which the lower transverse threads are always bound consistently or all with the same course with respect to the longitudinal threads extending in the lower fabric layer. When using different materials for the lower transverse threads, this may result, for example, in an inconsistent contact of the particular material groups/threads with the paper machine (due to the different behavior of the threads in the fabric), which may negatively affect both the running of the screen and the paper quality. In other words, the selection of the different materials is, in this case, very limited and the materials should be selected in such a way that both materials and the threads formed therefrom, respectively, behave as harmoniously as possible in the total fabric. If the both different threads and materials are badly adjusted, this may, for example, lead to a different projection on the running side by the lower transverse threads.
[0007] With fabrics/screens having consistently bound lower transverse threads made from different materials, it is possible to grind the screen level on the running side following its formation (e.g. after weaving and successive thermosetting), in order to reduce/preempt different/inconsistent projection of the lower transverse threads in a downward direction. This, however, will result in loss of material and an uneven running side may reoccur in a wet state.
[0008] A fabric is known, for example, from U.S. Pat. No. 6,244,306 B1 (see FIG. 2 ) or from US 2012/0145348 A1 (see FIG. 1 ). U.S. Pat. No. 6,244,306 B1 shows a consistent double binding of the lower transverse threads resulting in a long transverse thread float on the running side (a transverse thread float or “transverse-bridge” over seven successive lower longitudinal threads). Both binding positions are respectively separated by (exactly) one lower longitudinal thread extending over the respective lower transverse thread (in a plan view onto the lower fabric layer). US 2012/0145348 A1 too shows a consistent double binding of the lower transverse threads resulting in a long transverse thread float on the running side (a transverse thread float over ten successive lower longitudinal threads), wherein both of the binding positions of the respective transverse thread here are arranged directly next to each other, i.e. are not separated by a longitudinal thread extending over the respective lower transverse thread (in a plan view onto the lower fabric layer).
[0009] Illustratively, one aspect of various embodiments can be seen to provide a paper machine screen with a running side that is/can be formed such that it has a long operating time and/or a suitable operating behavior.
[0010] Illustratively, one additional or alternative aspect of various embodiments can be seen to provide a paper machine screen with a running side that is/can be formed such that it can ensure high paper quality, especially over a long period of time.
[0011] Illustratively, one additional or alternative aspect of various embodiments can be seen to provide a paper machine screen with a running side that is/can be formed such that it has a high mechanical stability and/or high abrasion resistance.
[0012] Illustratively, one additional or alternative aspect of various embodiments can be seen to provide a paper machine screen with a running side that is/can be formed consistently, e.g. with a substantially consistent projection of the lower transverse threads.
[0013] Illustratively, one additional or alternative aspect of various embodiments can be seen to provide a paper machine screen that can be easily produced.
[0014] Illustratively, one additional or alternative aspect of various embodiments can be seen to provide a paper machine screen that can be produced without or with relatively little loss of material.
SUMMARY OF THE INVENTION
[0015] The invention provides a paper machine screen according to claim 1 . Additional embodiments/configurations of the invention are described in the dependent claims.
DETAILED DESCRIPTION OF THE INVENTION
[0016] According to various embodiments the lower transverse threads are, different from the above mentioned prior art, not bound into the lower fabric layer consistently but inconsistently.
[0017] According to various embodiments the inconsistent binding of the lower transverse threads can compensate a different behavior of the threads in the fabric (e.g. when different materials have been used for the threads and/or the threads have different thermosetting properties), for example in a manner such that the lower fabric has a substantially geometrically consistent appearance especially on the outer side/running side, particularly with a substantially consistent projection of the lower transverse threads (without the necessity of grinding the running side).
[0018] This means, according to various embodiments, a different binding/incorporation of the lower transverse threads can counteract, for example, a different projection resulting from a different shrinking behavior of two lower transverse threads, and/or, for example, lower transverse threads with different diameters may be provided, that still have a substantially consistent projection on the running side, wherein the thicker diameter can be selected, for example, according to a higher required standard concerning stability or anticipated operating time.
[0019] In addition or alternatively according to various embodiments, due to a different binding of the lower transverse threads, different materials may be used for the lower transverse threads, said different materials causing the problems in the prior art initially mentioned. The range of suitable different materials for the lower transverse threads is thus enlarged or extended according to various embodiments.
[0020] In addition or alternatively according to various embodiments, the seam strength can be increased by means of a modified course of the lower longitudinal thread within the lower fabric.
[0021] According to various aspects, a paper machine screen (e.g. sheet forming screen) can be formed as a multi-layer fabric having an upper fabric layer and a lower fabric layer. For example, the multi-fabric layer can consist of the upper fabric layer and the lower fabric layer. The upper fabric layer and the lower fabric layer are connected to each other by means of binding threads (e.g. binding transverse threads).
[0022] According to various embodiments, for example, the so-called paper side is formed by the upper side/outer side of the upper fabric layer, whereas the so-called running side is formed by the bottom side/outer side of the lower fabric layer. A multi-layer configuration hereby allows for a different configuration of the paper side and running side according to various embodiments, so that both sides are/can be adapted to the respective intended purpose. For example, the longitudinal threads, realizing the circulation of the screen according to various embodiments, may be protected against wear on the running side by significantly projecting or protruding transverse threads. On the paper side, for example by providing a balanced ratio of longitudinal threads and transverse threads, a good depositing possibility for the paper fibers can be ensured. With respect to the fiber support, but also with respect to the tendency to marking of the screen, the simplest and at the same time the oldest basic weave of textile engineering has proven of value for the upper fabric and thus for the paper side, namely the so-called plain weave. Although the plain weave is very well suited for forming a paper sheet and is hence very well suited for the paper side, it is usually not suited very well for the machine side. If a paper machine screen is provided with a plain weave paper side, it can therefore be advisable to provide a second fiber layer underneath the plain weave, forming the machine side of the screen, which gives the screen sufficient stability and wearing potential.
[0023] The upper fabric layer as well as its binding to the lower fabric layer are not limited to a certain configuration and may be selected according to the respective requirements/case of application. Possible examples of configuration, which are in no way to be understood as limiting, are mentioned below.
[0024] The lower fabric layer has (e.g. consists of) a plurality of uniformly structured lower weave repeats, each of which comprising (e.g. consisting of):
longitudinal threads (e.g. formed as lower longitudinal threads) extending in the lower fabric layer and lower transverse threads extending exclusively in the lower fabric layer and being interwoven with the longitudinal threads that extend in the lower fabric layer (e.g. thereby completely forming the lower weave).
[0027] At least the lower transverse threads are hence formed as threads that remain/extend exclusively in one fabric layer (namely the lower fabric layer). The longitudinal threads extending in the lower fabric layer can basically be formed as alternating threads (e.g. in the form of so called functional longitudinal thread pairs) and/or as threads remaining/extending exclusively in one fabric layer, i.e. as lower longitudinal threads. For example, all structuring threads of the lower fabric (i.e. contributing to the forming of the weave of the lower fabric) extending in a transverse direction can be formed as lower transverse threads.
[0028] In the respective lower weave repeat the lower transverse threads are each bound into the lower fabric layer by exactly two longitudinal threads extending in the lower fabric layer as a first longitudinal thread extends under the respective lower transverse thread at a first binding position and a second longitudinal thread extends under the respective lower transverse thread at a second binding position (in a plan view onto the top side/inner side of the lower fabric layer, i.e. in a plan view onto the side of the lower fabric layer facing away from the running side). This means that every lower transverse thread is bound in/integrated twice in the lower weave repeat.
[0029] Further, in the respective lower weave repeat the lower transverse threads are bound into the lower fabric layer differently, thereby forming first lower transverse threads and second lower transverse threads, wherein at the first lower transverse threads a shortest distance in transverse direction between the first and the second binding position is larger than at the second lower transverse threads so that the first lower transverse threads form a shorter float on the running side than the second lower transverse threads.
[0030] According to various embodiments, the shortest distance in transverse direction between the first and the second binding position for each first lower transverse thread can, for example, be substantially equal in size and the shortest distance in transverse direction for each second lower transverse thread can also be substantially equal in size. The same applies for the floats, i.e. the floats of the first lower transverse threads can be substantially equal in size/length and the floats of the second lower transverse threads can also be substantially equal in size/length.
[0031] According to various embodiments, the screen can, for example, be formed as a long floating screen with lower transverse threads that all form/have long floats on the running side. That is, each lower transverse thread then forms on the running side within the lower weave repeat a long transverse thread-float or transverse thread-bridge extending over more than half of the longitudinal threads with which the respective lower transverse thread is interwoven or under or over which the respective lower transverse thread extends in the lower fabric within the lower weave repeat.
[0032] According to various embodiments, the float on the running side of each lower transverse thread in the lower weave repeat can, for example, also be referred to as longest or longer distance in transverse direction between the first and second binding position. In this case, counting/measuring is performed in transverse direction beyond the edge of the lower weave repeat, as further weave repeats may (directly) follow to the left and to the right of the lower weave repeat. For example, for each lower transverse thread the shortest distance is smaller than the longer distance, such that all lower transverse threads have/form long floats on the running side.
[0033] According to various embodiments, the larger shortest distance in transverse direction at the first lower transverse threads can, for example, be achieved by the fact that at the first lower transverse threads between the first and the second binding position at least one longitudinal thread extending in the lower fabric layer and running over the lower transverse thread (especially in a plan view onto the upper side/inner side of the lower fabric layer, that is, in a plan view onto the side facing away from the running side) more is arranged than at the second lower transverse threads. Here a case should be included and incorporated, where at the first lower transverse threads between the first and second binding position only one and hence at the second lower transverse threads none longitudinal thread, extending in the lower fabric layer and over the lower transverse thread, is provided; see below. For example, there can be exactly one longitudinal thread more or exactly two longitudinal threads more being arranged at each of the first lower transverse threads (or exactly one or exactly two “additional” longitudinal threads, respectively).
[0034] According to various embodiments, the number of longitudinal threads extending in the lower fabric layer, that extend over the respective transverse thread between the first and the second binding position, may hence be different at the first lower transverse threads from the corresponding number at the second lower transverse threads.
[0035] According to various embodiments, at the first lower transverse threads the shortest distance in a transverse direction—expressed by longitudinal threads positioned therebetween, extending in the lower fabric layer and extending over the lower transverse thread—is, for example, one longitudinal thread or two longitudinal threads, wherein at the second lower transverse threads the shortest distance—expressed by longitudinal threads positioned therebetween, extending in the lower fabric layer and extending over the lower transverse thread—is zero longitudinal threads or one longitudinal thread (in a plan view onto the top side of the lower fabric layer).
[0036] According to various embodiments, in the lower weave repeat at the first lower transverse threads, for example, respectively exactly one longitudinal thread, extending in the lower fabric layer and extending over the lower transverse thread, can be arranged between the first and the second binding position, wherein in the lower weave repeat at the second lower transverse threads between the first and the second binding position, no longitudinal thread, extending in the lower fabric layer and extending over the lower transverse thread, is arranged respectively so that both binding positions are located immediately adjacent to each other.
[0037] According to various embodiments, the different shortest distance in transverse direction can, for example, be/is achieved/obtained by the fact that the first lower transverse threads are introduced/bound into the lower fabric layer with a course (or a binding pattern or overlapping pattern, respectively) different from the second lower transverse threads with respect to the longitudinal threads extending in the lower fabric layer, wherein all of the first lower transverse threads have, in principle, the same course and only the arrangement of the binding positions in transverse direction varies (i.e., for example, a so-called “pitch” of the binding pattern being neglected), and wherein all of the second lower transverse threads have, in principle, the same course and only the arrangement of the binding positions varies in transverse direction. Such a course may, for example, indicate under or over how many longitudinal threads the respective lower transverse thread extends in the lower weave repeat and at what sequence this takes place. A course of the first lower transverse threads with respect to the longitudinal threads extending in the lower fabric layer may, for example, be as follows: under seven successive longitudinal threads, over one longitudinal thread, under one longitudinal thread and over one longitudinal thread (in a plan view onto the top side of the lower fabric layer). A course of the second lower transverse threads with respect to the longitudinal threads extending in the lower fabric layer may, for example, be as follows: under eight successive longitudinal threads and over two successive longitudinal threads. Counting is performed here in transverse direction beyond the edge of the repeat. The respective “starting point” or the binding positions, respectively, may, as stated before, vary in transverse direction.
[0038] According to various embodiments, in the lower weave repeat the binding positions of a respective first lower transverse thread can be arranged, for example, offset in a transverse direction to the binding positions of the two first lower transverse threads adjacently arranged in longitudinal direction, for example, offset to the binding positions of every other first lower transverse thread of the lower weave repeat.
[0039] According to various embodiments, in the lower weave repeat the binding positions of a respective second lower transverse thread can be arranged, for example, offset in a transverse direction to the binding positions of the two second lower transverse threads adjacently arranged in transverse direction, for example, offset to the binding positions of every other second lower transverse thread of the lower fabric layer.
[0040] According to various embodiments, in the lower weave repeat the binding positions of two first lower transverse threads, arranged directly next to each other in longitudinal direction, can, for example, be arranged offset in a transverse direction always by the same amount of longitudinal threads extending in the lower fabric layer and in the same direction (i.e. with a constant pitch).
[0041] According to various embodiments, in the lower weave repeat the binding positions of two second lower transverse threads, arranged next to each other in longitudinal direction, can, for example, be arranged offset in a transverse direction always by the same amount of longitudinal threads extending in the lower fabric layer and in the same direction.
[0042] For example, the pitch in the case of 10 lower longitudinal threads per lower weave repeat for the first lower transverse threads can be “three longitudinal threads to the left” (in a plan view onto the top side of the lower fabric layer). For example, the pitch in the case of 10 lower longitudinal threads per lower weave repeat for the second lower transverse threads can also be “three longitudinal threads to the left” (in a plan view onto the top side of the lower fabric layer).
[0043] According to various embodiments, the ratio of first lower transverse threads to second lower transverse threads in the lower weave repeat can, for example, be 1:1, for example at a directly alternating arrangement in longitudinal direction, or 2:1, for example at a repeating sequence in longitudinal direction of two first lower transverse threads, arranged directly adjacent to each other, and one following second lower transverse thread, or 1:2, for example at a repeating sequence in longitudinal direction of one first lower transverse thread and two following second transverse threads, arranged directly adjacent to each other.
[0044] According to various embodiments the first lower transverse threads can, for example, have thermosetting properties different from those of the second lower transverse threads, for example have a different shrinking behavior than the second lower transverse threads.
[0045] According to various embodiments, the different float-length of the first lower transverse threads and the second lower transverse threads on the running side can take into account or counteract and, e.g. substantially compensate, for example a different thermosetting behavior, e.g. shrinking behavior. In other words, according to various embodiments the thermosetting properties of the first lower transverse threads and the second lower transverse threads are/can be selected/set such that a difference in projection of the lower transverse threads on the running side, resulting from the different float-length, is/can be compensated or at least is/can be reduced by the different thermosetting properties.
[0046] According to various embodiments, the first lower transverse threads may, for example, have a cross sectional shape and/or a diameter different from the second lower transverse threads, and/or the first lower transverse threads may be made of a material different from the material of the second lower transverse threads, and/or the first lower transverse threads and the second lower transverse threads may be treated differently with influence on their thermosetting behavior, for example, differently mechanically treated, e.g. differently stretched. Different materials can, for example, mean a material pair of: polyamide and polyester, or a first polyamide (e.g. PA 6.6) and a second polyamide (e.g. PA 6.10 or PA 6.12 or PA 10 or PA 12), or a first polyester and a second polyester different from the first polyester. According to the latter alternative (different treatment), polyester may be used, for example, for both the first and the second lower transverse threads, wherein the first lower transverse threads are being stretched differently during their production than the second lower transverse threads.
[0047] According to various embodiments, the different cross sectional shape and/or the different diameter and/or the different material and/or the different treatment can, for example, result in the above-mentioned different thermosetting properties.
[0048] For example in the case of different diameters, the lower transverse threads can also substantially have the same thermosetting properties, and/or a screen can be provided that is not thermoset. According to various embodiments, the different float-length of the first lower transverse threads and second lower transverse threads on the running side may, for example, be selected such that it counteracts and at least partially, for example substantially completely compensates a different projection on the running side resulting from the different diameters. In other words, according to various embodiments the diameter of the first lower transverse threads and the diameter of the second lower transverse threads can, for example, be selected such that a difference in the projection of the lower transverse threads on the running side resulting from the different float-length, is/will be compensated or at least reduced by the different diameters.
[0049] According to various embodiments, the paper machine screen can for example be formed as a synthetic fabric, for example, as a thermoset synthetic fabric, with at least the lower transverse threads being formed as synthetic threads, for example, also the longitudinal and transverse threads extending in the upper fabric layer as well as the longitudinal threads extending in the lower fabric layer.
[0050] According to various embodiments, a respective lower transverse thread/synthetic thread can, for example, be made of polyamide or of polyester. For example, the first lower transverse threads can be made of one of polyamide and polyester, whereas the second transverse threads are made of the other of polyamide and polyester. That is to say that, for example, the first lower transverse threads can be made of PA, whereas the second lower transverse threads are made of polyester (or vice versa).
[0051] According to various embodiments, the paper machine screen can, for example, be formed as a transverse thread-bound multi-layer fabric, in which the binding threads are formed from transverse threads. For example, the binding between the upper and lower fabric layer can be performed exclusively by transverse threads. The invention is, however, not limited to this and the binding of the upper and lower fabric layer can, for example, additionally or alternatively be performed with longitudinal threads.
[0052] According to various embodiments, the binding threads can, for example, be formed from transverse threads extending in the upper fabric layer and, on the one hand contributing to forming the upper weave and, on the other hand, descending in sections into the lower fabric layer to extend under at least one of the longitudinal threads extending in the lower fabric layer and thereby bind the lower fabric layer to the upper fabric layer. For example, the binding transverse threads only contribute to completing/forming the upper weave and not to completing/forming the lower weave. The invention, however, is not limited thereto and the binding of the upper and lower fabric layer can, for example, additionally or alternatively be performed by separate, pure binding threads that neither in the upper nor in the lower fabric layer contribute to the forming of the respective binding.
[0053] According to various embodiments, the longitudinal threads extending in the lower fabric layer can, for example, be formed as lower longitudinal threads (completely or partially), extending exclusively in the lower fabric layer and, for example, being interwoven with the lower transverse threads, thereby completely forming the lower weave.
[0054] According to various embodiments, the respective lower weave repeat may, for example, comprise at least 8 longitudinal threads, extending in the lower fabric layer, for example exactly 8 or exactly 10 or exactly 12, for example exactly 8 or exactly 10 or exactly 12 lower longitudinal threads. This may, according to various embodiments, facilitate the forming of long transverse thread-floats on the running side.
[0055] According to various embodiments, the ratio of lower transverse threads to longitudinal threads, extending in the lower fabric layer, for example lower longitudinal threads, can e.g. be 2:1, for example exactly 16:8 or exactly 20:10 or exactly 24:12.
[0056] According to various embodiments, when seen in a longitudinal direction, in the lower weave repeat always a transverse thread-binding to the upper fabric layer can be provided between two lower transverse threads arranged immediately next to each other, for example formed by exactly one binding transverse thread extending temporarily in the lower fabric layer and thereby extending under at least one or exactly one longitudinal thread extending in the lower fabric layer.
[0057] According to various embodiments, the diameter of the lower transverse threads can, for example, be larger than the diameter of the transverse threads extending in the upper fabric layer and/or larger than the diameter of the binding threads, and/or the diameter of the lower transverse threads can, for example, be larger than the diameter of the longitudinal threads extending in the lower fabric layer, for example of the lower longitudinal threads, and/or the lower transverse threads can, for example, have the largest diameter of all threads in the total repeat.
[0058] As initially mentioned, the upper fabric layer is not limited to a certain configuration and a suitable paper side may be used for the respective purpose.
[0059] According to various embodiments, the fabric may, for example, have such a total repeat comprising exactly one lower weave repeat and one or more upper weave repeats. The above given information concerning the lower weave repeat shall then also apply in the same way for the total repeat.
[0060] According to various embodiments the upper fabric layer can, by way of example, be formed from (e.g. consist of) a plurality of uniformly structured upper weave repeats, each of which comprises (e.g. consists of):
upper longitudinal threads extending exclusively in the upper fabric layer, upper transverse threads extending exclusively in the upper fabric layer and being interwoven with the upper longitudinal threads, thereby partially forming the upper weave, and binding transverse threads that, on the one hand, complete the upper weave and, on the other hand, descend in sections into the lower fabric layer to extend under at least one longitudinal thread extending in the lower fabric layer and thereby bind the lower fabric layer to the upper fabric layer.
[0064] According to various embodiments, the fabric can have, for example, a total repeat in which the ratio of upper longitudinal threads to lower longitudinal threads is 1:1, for example exactly 8:8 or exactly 10:10 or exactly 12:12.
[0065] According to various embodiments, the upper fabric layer can, for example, be formed with a plain weave which can, for example, be formed from upper longitudinal threads being interwoven with upper transverse threads as well as with imaginary continuous upper transverse threads provided by functional transverse thread pairs, wherein, for example, in longitudinal direction successively alternating one upper transverse thread and one functional transverse thread pair are arranged on the paper side. One or both transverse threads of a functional pair may be formed as binding transverse threads.
[0066] According to various embodiments, the term longitudinal threads refers to threads of the screen/fabric that extend in a longitudinal direction or longitudinal extension, of the screen. According to various embodiments, the longitudinal threads may, during operation, be arranged in a running direction of the paper machine. The respective longitudinal thread can, according to various embodiments, thus for example be referred to as running direction-thread or machine direction-thread (i.e. MD-thread for “machine direction”). For example, the respective longitudinal thread is formed as a warp thread.
[0067] Additionally or alternatively, according to various embodiments, the term transverse thread refers, for example, to threads of the screen/fabric that extend in a transverse direction of the screen. According to various embodiments, the transverse threads can be arranged across the running direction of the paper machine during operation. The respective transverse thread may therefore, according to various embodiments, also be referred to as cross machine direction-thread (i.e. CMD-thread for “cross machine direction”). For example, the respective transverse thread is formed as a weft thread.
[0068] Additionally or alternatively, according to various embodiments, a fabric layer can be understood as a one layer-fabric comprising or consisting of interwoven transverse and longitudinal threads.
[0069] Additionally or alternatively, according to various embodiments, the upper side (or the outward facing side, respectively) of the upper fabric or the upper fabric layer, respectively, can form the paper side of the screen on which the paper fiber layer is formed. The upper layer can, for example, be a fabric layer which is formed (particularly) fine. For example, the weave of the upper fabric layer is a plain weave.
[0070] Additionally or alternatively, according to various embodiments, the lower side (or the outward facing side, respectively) of the lower fabric or the lower fabric layer, respectively, can form the running side of the screen which is in direct contact with the driving elements and draining elements of the paper machine that cause wear. The lower fabric may, for example, be a fabric layer that is formed (particularly) robust. For example, the weave of the lower fabric layer is a weave having long transverse thread-floats on the running side. A long transverse thread-float is understood to be, for example, a float over more than half of the longitudinal threads extending in the lower fabric layer, i.e. at 8 lower longitudinal threads per weave repeat, for example, a float over at least 5 successive lower longitudinal threads.
[0071] Additionally or alternatively, according to various embodiments, upper longitudinal threads can be threads that extend exclusively in the upper fabric and are there interwoven with transverse threads extending in the upper fabric, thus not leaving the upper fabric and not changing into the lower fabric, respectively.
[0072] Additionally or alternatively, according to various embodiments, upper transverse threads can be threads that extend exclusively in the upper fabric and are there interwoven with longitudinal threads (e.g. upper longitudinal threads) extending in the upper fabric, thus not leaving the upper fabric and not changing into the lower fabric, respectively.
[0073] For example, according to various embodiments, upper transverse threads and upper longitudinal threads may together partially form the weave of the upper fabric layer (=first or upper weave), said weave being completed by binding transverse threads (see below).
[0074] Additionally or alternatively, according to various embodiments, lower longitudinal threads can be threads that are situated exclusively in the lower fabric and are there interwoven with transverse threads extending in the lower fabric, thus not leaving the lower fabric and not changing into the upper fabric, respectively.
[0075] Additionally or alternatively, according to various embodiments, lower transverse threads can be threads that are situated exclusively in the lower fabric and are there interwoven with longitudinal threads (e.g. lower longitudinal threads) extending in the lower fabric, thus not leaving the lower fabric and not changing into the upper fabric, respectively.
[0076] For example, according to various embodiments, lower transverse and lower longitudinal threads may together completely form the weave of the lower fabric layer.
[0077] Additionally or alternatively, according to various embodiments, binding transverse threads can be threads extending both in the upper fabric layer and in the lower fabric layer thus binding the lower fabric layer to the upper fabric layer.
[0078] Additionally or alternatively, according to various embodiments, a functional transverse thread pair can be formed by two transverse threads arranged immediately next to each other, wherein the two transverse threads of a functional transverse thread pair together form on the paper side a virtually (uninterrupted) upper transverse thread that integrates/fits into the binding pattern of the upper fabric layer, i.e. they alternately complete the first weave while each is extending over one or a plurality of upper longitudinal threads or longitudinal threads extending in the upper fabric layer, respectively. Those thread portions of the functional pair which are currently not required for forming the virtually uninterrupted transverse thread on the paper side can be used for binding the lower fabric to the upper fabric. In this respect, either both transverse threads or only one transverse thread of a respective functional transverse thread pair may be formed as binding transverse threads.
[0079] Additionally or alternatively, according to various embodiments, the total weave repeat of the fabric may be a recurring binding pattern/thread overlapping pattern of the entire fabric (including upper and lower fabric), especially the smallest repeating unit in the entire fabric, wherein the course of all threads (e.g. upper and lower longitudinal threads, upper and lower transverse threads, binding transverse threads) is being taken into consideration, especially the course of the respective thread in all/both layers. According to various embodiments, knowing the total repeat, the complete fabric or screen may thus be produced. That is to say, the screen or fabric may consist of a plurality of total repeats directly strung together.
[0080] Additionally or alternatively, according to various embodiments the weave repeat of the upper fabric or the so-called upper weave repeat may be a recurring pattern or a repeating unit in the upper fabric, especially the smallest repeating unit in the upper fabric. In a plan view onto the upper fabric or the paper side of the screen, a plurality of such upper weave repeats can be seen in the longitudinal and transverse directions of the screen. The upper weave repeat can, for example, thus represent (especially also when considering the changing positions of the functional pairs, if existing) the recurring overlapping pattern of the upper fabric formed in the plan view of the upper fabric by the upper longitudinal threads, upper transverse threads and binding transverse threads (if structuring). In other words, the upper weave repeat can regard the course of the upper transverse threads and binding transverse threads with respect to the upper longitudinal threads and the therefrom resulting overlapping pattern, wherein the course of the binding transverse threads with respect to the lower longitudinal threads is of no importance for determining the upper weave repeat. When, for the respective functional transverse thread pair, considering only the virtual/imaginary transverse thread formed by said functional transverse thread pair (without considering the changing position(s)), one receives the so-called virtual/imaginary upper weave repeat that, for example, can be realized as a plain weave.
[0081] Additionally or alternatively, according to various embodiments, the weave repeat of the lower fabric or the lower weave repeat may be a recurring pattern or a repeating unit in the lower fabric, e.g. the smallest repeating unit in the lower fabric. In a plan view onto the top side of the lower fabric layer or the running side of the screen, a plurality of such lower weave repeats can be seen in a longitudinal direction and a transverse direction of the screen, for example immediately adjacent to each other. The lower weave repeat can hence represent (especially without considering the binding positions by the binding transverse threads as they normally do not contribute to forming the second, lower weave) the recurring overlapping pattern of the lower fabric formed in the plan view onto the top side of the lower fabric layer or the running side of the screen by the lower transverse threads and the longitudinal threads extending in the lower fabric layer (e.g. lower longitudinal threads). In other words, the lower weave repeat can regard the course of the lower transverse threads with respect to the longitudinal threads extending in the lower fabric layer (e.g. lower longitudinal threads) and the therefrom resulting overlapping pattern, wherein the course of the binding transverse threads in the lower fabric is of no importance for determining the lower weave repeat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0082] Various exemplary embodiments will hereinafter be described in more detail with reference to the drawings. In the drawings in schematic representation:
[0083] FIGS. 1 to 4 show a paper machine screen formed as a multi-layer fabric, especially sheet forming screen (or forming screen), according to a first embodiment (so-called 10-shaft configuration), wherein FIGS. 1 a )- 1 d ) represent various cross sections through the total repeat of the fabric, wherein the comparatively wide binding of the lower transverse thread 181 and the comparatively narrow binding of the lower transverse thread 182 can be seen, which results in a comparatively short float-length for the thread 181 and a comparatively long float-length for the thread 182 .
[0084] FIG. 2 shows the upper weave repeat in a plan view onto the top side of the upper fabric layer (=paper side of the screen), wherein the lower fabric layer has been cut off to improve depiction.
[0085] FIG. 3 shows the lower weave repeat in a plan view onto the top side of the lower fabric layer (=side of the screen facing away from the running side) with the upper fabric layer having been cut off.
[0086] FIG. 4 shows again the lower weave repeat, here in a bottom view onto the bottom side of the lower fabric layer or the running side of the screen, respectively.
[0087] FIG. 5 shows—in a representation corresponding to FIG. 4 —the lower weave repeat (especially its running side) of a paper machine screen, especially sheet forming screen (or forming screen), formed as a multi-layer fabric according to a second embodiment (so-called 8-shaft configuration).
[0088] FIG. 6 —in a representation corresponding to FIG. 4 —shows the lower weave repeat (especially its running side) of a paper machine screen, especially sheet forming screen (or forming screen), formed as a multi-layer fabric according to a second embodiment (so-called 12-shaft configuration).
[0089] In the FIGS. 2 to 6 , threads extending from top to bottom are longitudinal threads and threads extending from left to right are transverse threads.
[0090] In the FIGS. 1 a ) to 1 d ) the longitudinal threads are shown with a circular appearance (they extend perpendicularly to the paper plane and towards the viewer) and the transverse threads again extend from the left to the right.
[0091] In the Figures identical or similar elements have identical references, where appropriate.
DETAILED DESCRIPTION OF THE DRAWINGS
[0092] In the below detailed description reference is made to the accompanying drawings which form a part thereof and in which, by way of illustration, specific embodiments are being shown in which the invention may be practiced. In this regard directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc. is used with reference to the orientation of the Figure(s) being described. Because components of embodiments can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting.
[0093] It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. It is to be understood that features of the various exemplary embodiments described herein may be combined with each other, unless specifically indicated otherwise. The following detailed description is therefore not to be taken in a limiting sense with the scope of the present invention being defined by the appended claims.
[0094] FIGS. 1 to 4 show a paper machine screen/sheet forming screen (below referred to as “screen”) formed as a multi-layer fabric, according to a first embodiment of the invention.
[0095] As can be seen, for example, in FIGS. 1 a ) to 1 d ), the screen is formed as a multi-layer fabric with an upper fabric layer L 1 and a lower fabric layer L 2 that are connected to each other by means of binding threads (see transverse thread 123 in FIG. 1 b ) as well as the transverse thread 126 in FIG. 1 d )). The paper side PS of the screen is formed by the upper fabric layer L 1 , whereas the running side LS of the screen is formed by the lower fabric layer L 2 .
[0096] The lower fabric layer L 2 is formed by a plurality of uniformly structured lower weave repeats (and consists, for example, of those) each of which containing longitudinal threads 111 - 120 extending in the lower fabric layer L 2 and lower transverse threads 181 - 200 (e.g. the respective repeat consists of said threads) that extend exclusively in the lower fabric layer L 2 and which are interwoven with the longitudinal threads 111 - 120 extending in the lower fabric layer.
[0097] As shown in the Figures, the longitudinal threads extending in the lower fabric layer can, for example, be formed as lower longitudinal threads 111 - 120 extending exclusively in the lower fabric layer L 2 and, for example, being interwoven with the lower transverse threads 181 - 200 thereby completely forming the lower weave. Hence reference is made below to lower longitudinal threads, even though the longitudinal threads 111 - 120 extending in the lower fabric layer can also be configured differently.
[0098] As shown in FIG. 3 , in the lower weave repeat the lower transverse threads 181 - 200 are each bound into the lower fabric layer by exactly two longitudinal threads 111 - 120 as a first longitudinal thread 111 , 115 , . . . extends under the respective lower transverse thread 181 , 182 , . . . at a first binding position “x” and a second longitudinal thread 133 , 116 , . . . extends under the respective lower transverse thread 181 , 182 , . . . at a second binding position “x”. For example, the longitudinal thread 111 extends under the lower transverse thread 181 at a first binding position “x” and the longitudinal thread 113 extends under the lower transverse thread 181 at a second binding position “x” (see also FIG. 1 a )). Figuratively speaking thread 181 cannot fall downward out of the fabric/screen due to it being bound in twice. The longitudinal thread 115 , however, extends under the lower transverse thread 182 at a first binding position “x” and the longitudinal thread 116 extends under the lower transverse thread 182 at a second binding position “x” (see also FIG. 1 c )).
[0099] As can be further seen in FIG. 3 , in the respective lower weave repeat the lower transverse threads 181 - 200 are bound into the lower fabric layer differently, thereby forming first lower transverse threads I and second lower transverse threads II, wherein at the first lower transverse threads I a shortest distance (see also FIG. 4 : distance A I ) in transverse direction Q between the first and the second binding position x is larger than at the second lower transverse threads II (see FIG. 4 : distance A II )
[0100] As shown in FIG. 4 , the different binding has the result that the first lower transverse threads I form on the running side LS a shorter float F I than the second lower transverse threads II whose float in FIG. 4 is designated F II . The float can, for example, be understood/referred to as the longest transverse thread-portion extending on the running side over an amount of successive lower longitudinal threads (i.e. between two binding positions). At the repeat in FIG. 4 , counting/measuring is performed beyond the edge as, according to this embodiment, in transverse direction to the right and to the left respectively one further repeat is arranged directly next to the repeat shown. The float F 1 is particularly easy to recognize for the thread 181 and the float F II is particularly easy to recognize for the thread 198 . As shown, the float at the first lower transverse threads may, according to various embodiments, extend over seven lower longitudinal threads, whereas the float at the second lower transverse threads may extend over eight lower longitudinal threads.
[0101] The different shortest distance as well as the different float-length resulting therefrom are also indicated in FIGS. 1 a ) and 1 c ). From those images it can also be seen that the different float or the different binding of the lower transverse threads, respectively, may initially/generally result in a different “sagging” of the lower transverse threads which, in turn, may cause a different projecting of the lower transverse threads on the running side.
[0102] According to various embodiments, this situation is used, however, to at least partially compensate, e.g., a different behavior or different properties of the first and second lower transverse threads in the fabric, and/or to be able to accommodate different diameters and/or materials in the lower fabric. It is, for example, possible to have the transverse thread in FIG. 1 c ) that hangs further downward, shrunk more during a thermosetting of the screen than the transverse thread of FIG. 1 a ) that does not hang down that far.
[0103] As can be seen in FIG. 3 (see also FIGS. 1 a ) and 1 c )), the larger shortest distance A I in transverse direction Q at the first lower transverse threads I can, for example, be achieved by the fact that at the first lower transverse threads between the first and the second binding position x at least one longitudinal thread 111 - 120 more, extending over the lower transverse thread, is arranged than at the second lower transverse threads II, for example, exactly one longitudinal thread more or one additional longitudinal thread, respectively.
[0104] As can further be seen in FIG. 3 (see also FIGS. 1 a ) and 1 c )), at the first lower transverse threads I the shortest distance A I in transverse direction Q—expressed by lower longitudinal threads 111 - 120 positioned therebetween, extending over the lower transverse thread—can, for example be exactly one longitudinal thread, wherein at the second lower transverse threads II the shortest distance A II —expressed by lower longitudinal threads 111 - 120 positioned therebetween, extending over the lower transverse thread—is zero longitudinal threads.
[0105] This means, in the lower weave repeat at the first lower transverse threads I between the first and the second binding position x, exactly one lower longitudinal thread 111 - 120 , extending over the lower transverse thread, can be arranged, wherein in the lower weave repeat at the second lower transverse threads II between the first and the second binding position x no lower longitudinal thread 111 - 120 , extending over the lower transverse thread, is arranged respectively so that both binding positions are located immediately adjacent to each other.
[0106] As can further be seen in FIG. 3 (see also FIGS. 1 a ) and 1 c )), the different shortest distance in transverse direction Q may, for example, be achieved by the fact that first lower transverse threads I are introduced/interwoven into the lower fabric layer with a course different from the second lower transverse threads II with respect to the lower longitudinal threads 111 - 120 , wherein all of the first lower transverse threads I in the lower weave repeat have, in principle, the same course and only the arrangement of the binding positions x in transverse direction Q varies, and wherein all of the second lower transverse threads II in the lower weave repeat have, in principle, the same course and only the arrangement of the binding positions x in transverse direction Q varies.
[0107] As can be seen in FIG. 3 (see also FIGS. 1 a ) and 1 c )), the course of the first lower transverse threads I with respect to the lower longitudinal threads can, for example, be as follows: under seven successive longitudinal threads, over one longitudinal thread, under one longitudinal thread and over one longitudinal thread. The course of the second lower transverse threads II with respect to the lower longitudinal threads can, for example, be as follows: under eight successive longitudinal threads, and over two successive longitudinal threads. In this matter, counting is performed respectively in transverse direction beyond the edge of the lower repeat. The respective “starting point” or the binding positions, respectively, may, as mentioned before, vary in transverse direction; this does not change the above described basic course of the transverse threads with respect to the lower longitudinal threads.
[0108] As can be seen in FIG. 3 , in the lower weave repeat the binding positions x of a respective first lower transverse thread I may be, for example, arranged offset in a transverse direction to the binding positions of the two first lower transverse threads adjacently arranged in longitudinal direction L, for example offset to the binding positions of every other first lower transverse thread of the lower weave repeat. See, e.g. the first lower transverse thread 183 and the two first lower transverse threads 181 and 185 arranged adjacently in longitudinal direction L.
[0109] As can also be seen in FIG. 3 , in the lower weave repeat the binding positions x of a respective second lower transverse thread II may also be arranged offset in a transverse direction to the binding positions of the second lower transverse threads adjacently arranged in longitudinal direction L, for example offset to the binding positions of every other second lower transverse thread of the lower weave repeat. See, for example the second lower transverse thread 184 and the two second lower transverse threads 182 and 186 arranged adjacently in longitudinal direction L.
[0110] As can be seen in FIG. 3 , in the lower weave repeat the binding positions x of two first lower transverse threads I, arranged directly next to each other in longitudinal direction L, may be arranged offset in a transverse direction always by the same amount of longitudinal threads 111 - 120 extending in the lower fabric layer and in the same direction. The same holds true for the second lower transverse threads. In FIG. 3 a pitch of “three lower longitudinal threads to the left” was selected by way of example for both the first lower transverse threads and the second lower transverse threads. See, e.g. the second lower transverse thread 182 and the second lower transverse thread 184 , at which the binding positions x, arranged adjacently to each other, are respectively arranged offset to the left by three lower longitudinal threads 112 - 114 and 113 - 115 , respectively. It is comprehensible, that a different pitch might be selected or that the binding positions may be arranged offset in an irregular manner.
[0111] As can be seen in FIGS. 3 and 4 , the ratio of first lower transverse threads I to second lower transverse threads II in the lower weave repeat may be, for example 1:1, e.g. at a directly alternating arrangement in longitudinal direction L, i.e. at a recurring sequence in longitudinal direction L of one first lower transverse thread I and a successive second lower transverse thread II. It is comprehensible, that a different ratio might be selected, e.g. a ratio of 1:2 or 2:1.
[0112] According to various embodiments, the first lower transverse threads I may have thermosetting properties different from the second lower transverse threads II, e.g. a different shrinking behavior than the second lower transverse threads. This is made possible by the different binding of first and second lower transverse threads, which can be selected such, that it at least partially compensates the different thermosetting properties.
[0113] According to various embodiments, the first lower transverse threads I may have a diameter different from the second lower transverse threads II, and/or the first lower transverse threads I may be made from a material different from the second lower transverse threads II, and/or the first lower transverse threads I and the second lower transverse threads II may be treated differently with influence on their thermosetting behavior, e.g. differently mechanically treated, e.g. differently stretched.
[0114] According to various embodiments, the screen can be formed as a synthetic fabric, e.g. as a thermoset synthetic fabric. In the synthetic fabric at least the lower transverse threads 181 - 200 , e.g. also the longitudinal threads 101 - 110 and transverse threads 121 - 180 extending in the upper fabric layer (see below as well as FIG. 2 ) and/or the lower longitudinal threads 111 - 120 , are formed as synthetic threads.
[0115] A respective of the lower transverse threads 181 - 200 can, e.g. be made of polyamide or polyester. For example, the first lower transverse threads I can be made of one of polyamide and polyester, wherein the second lower transverse threads II are made of the other one of polyamide and polyester. Alternatively, the first lower transverse threads I may, for example, be made of a first polyamide, wherein the second lower transverse threads II are made of another polyamide. Further alternatively, the first lower transverse threads I and the second lower transverse threads II can, for example, be made of the same synthetic material (e.g. polyamide 6.6), wherein the first lower transverse threads I and the second lower transverse threads II are stretched differently with influence on their thermosetting behavior. Further alternatively, the first lower transverse threads I and the second lower transverse threads II can, for example, be made of the same synthetic material (e.g. polyamide 6.6), wherein the first lower transverse threads I and the second lower transverse threads II have different diameters.
[0116] As can be seen in the FIGS. 1 b ) and 1 d ) as well as FIGS. 2 and 3 , the screen can, for example, be formed as a transverse thread-bound multi-layer fabric in which the binding threads are formed by transverse threads. See binding transverse threads 123 , 126 , 129 , etc. It is to be understood, however, that also a different or additional form of layer binding might be selected, e.g. by using binding longitudinal threads.
[0117] As shown in the FIGS. 2 and 3 , the binding threads can, for example, be formed from transverse threads 123 , 126 , . . . extending in the upper fabric layer L 1 and, on the one hand contributing to forming/completing the upper weave and, on the other hand, descending in sections into the lower fabric layer L 2 to extend under at least one (here by way of example exactly one; see FIG. 3 ) lower longitudinal thread and thereby bind the lower fabric layer to the upper fabric layer.
[0118] As shown in the FIGS. 3 and 4 , the lower weave repeat can, for example, contain exactly 10 lower longitudinal threads 111 - 120 . In the above described arrangement of the binding positions, this may, according to various embodiments, lead to a long transverse thread-float on the running side; see FIG. 4 .
[0119] As shown further in the FIGS. 3 and 4 , in the lower weave repeat the ratio of lower transverse threads 181 - 200 to lower longitudinal threads 111 - 120 can, for example, be 2:1 or exactly 20:10, respectively. It is comprehensible that a different suitable ratio might be selected. The comparatively high number of lower transverse threads (which form the transverse thread-floats arranged on the running side) can, according to various embodiments, lead to an especially stable, durable running side and a sufficient and suitable number of lower transverse threads is provided, to which, for example, the different materials and/or different diameters can be distributed.
[0120] As shown in FIG. 3 , in the lower weave repeat, seen in a longitudinal direction L, always a transverse thread-binding to the upper fabric layer L 1 can be provided, for example, between two transverse threads 181 - 200 arranged immediately next to each other, here by way of example, formed by exactly one binding transverse thread 123 , 126 , . . . extending temporarily in the lower fabric layer and thereby extending under at least one (here, by way of example, exactly one) longitudinal thread 111 - 120 . For example, between the lower transverse threads 181 and 182 a transverse thread binding to the upper fabric layer L 1 is provided, which is formed by the binding transverse thread 123 extending temporarily in the lower fabric layer L 2 and thereby extending under the lower longitudinal thread 118 . According to various embodiments, the upper and the lower fabric layer can thus be connected to each other consistently. It is comprehensible, that the transverse thread bindings may be distributed on the lower fabric layer in a different way.
[0121] According to various embodiments, the diameter of the lower transverse threads 181 - 200 can, e.g. be larger than the diameter of the transverse threads 121 - 180 extending in the upper fabric layer and/or be larger than the diameter of the binding threads 123 , 126 , . . . , and/or the diameter of the lower transverse threads 181 - 200 can be larger than the diameter of the lower longitudinal threads 111 - 120 , and/or the lower transverse threads 181 - 200 may have the largest diameter of all threads in the total weave. According to various embodiments, the lower transverse threads can thus be formed robustly and durably, whereas the paper side may be formed finely. According to various embodiments, the binding transverse threads may thus be shielded by lower transverse threads from the wear-causing components of the paper machine. According to various embodiments, an interference/interruption of the lower binding/weave structure by the binding transverse threads may thus at least be reduced.
[0122] The upper fabric layer L 1 is not limited to a certain configuration and, depending on the intended purpose, a suitable/appropriate paper side may be selected. With reference to FIG. 2 , a possible configuration example is described below, which, however, is in no way to be understood as limiting. In other words, the running side according to FIGS. 3 and 4 (as well as the running side according to FIG. 5 or the running side according to FIG. 6 ) can also be combined with a different paper side or a different upper fabric layer and be attached/bound thereto.
[0123] As shown in FIG. 2 , the upper fabric layer L 1 can, e.g. be formed from a plurality of uniformly structured upper weave repeats (e.g. consist thereof) each of which comprising (e.g. consisting of):
upper longitudinal threads 101 - 110 extending exclusively in the upper fabric layer L 1 (here, by way of example, in a number of 10 threads), upper transverse threads 121 , 122 , 124 , 125 , . . . , (here, by way of example, in a number of 40 threads), extending exclusively in the upper fabric layer and being interwoven with the upper longitudinal threads 101 - 110 , thereby partially forming the upper weave, and binding transverse threads 123 , 126 , . . . , (here, by way of example in a number of 20 threads) that, on the one hand, complete the upper weave and, on the other hand, descend in sections into the lower fabric layer L 2 to extend under at least one of the longitudinal threads extending in the lower fabric layer and thereby bind the lower fabric layer to the upper fabric layer.
[0127] As shown in the FIGS. 2 and 3 , the lower repeat and the upper repeat may be, for example, formed the same size, so that the total repeat comprises exactly one upper repeat and exactly one lower repeat. It is, however, also conceivable that the upper repeat is, e.g. smaller than the lower repeat. For example, the running side may be formed as a genuine plain weave (without using functional pairs), i.e. with an upper repeat of only 2 upper longitudinal threads and 2 upper transverse threads, wherein the running side is bound to the lower fabric layer by means of separate binding threads. In this case the total repeat would comprise one lower weave repeat and a plurality of upper weave repeats. It is also conceivable that the upper repeat is, e.g. larger than the lower repeat.
[0128] As shown in FIGS. 2 and 3 (see also FIGS. 1 a )- 1 d )), the fabric may, for example, have a total repeat, in which the ratio of upper longitudinal threads 101 - 110 to lower longitudinal threads 111 - 120 is 1:1, e.g. exactly 10:10.
[0129] As shown in FIG. 2 , the upper fabric layer L 1 can, for example, be formed with a plain weave that, e.g. is formed from upper longitudinal threads 101 - 110 being interwoven with upper transverse threads 121 , 124 , . . . , as well as with imaginary uninterrupted upper transverse threads, provided by functional transverse thread pairs 122 , 123 ; 125 , 126 ; . . . , wherein, for example in longitudinal direction L one upper transverse thread and one functional transverse thread pair are arranged alternatingly behind each other.
[0130] FIG. 5 shows the lower weave repeat of a paper machine screen, especially sheet forming screen (or forming screen respectively) formed as a multi-layer fabric according to a second embodiment (so-called 8-shaft configuration).
[0131] The (not shown) paper side or upper fabric layer of the paper machine screen according to the second embodiment can, as described for the first embodiment, be selected appropriately and be, e.g. formed with a plain weave (e.g. with a plain weave formed following the example set by FIG. 2 ). A different appropriate upper fabric layer or upper weave can, however, be provided.
[0132] The binding of the (not shown) upper fabric layer to the lower fabric layer can, analogously to the first embodiment, be realized by means of binding transverse threads. The binding or connecting, respectively, of the two fabric layers can, however, also be performed differently, e.g. by means of separate binding threads and/or binding longitudinal threads.
[0133] Thus, only the lower fabric layer L 2 ′ and its lower weave repeat are described in detail below. Emphasize is being put on the differences to the first embodiment, in parts omitting repetition of identical or similar aspects with reference to the first embodiment.
[0134] The lower fabric layer L 2 ′ of the screen according to the second embodiment is formed by (and, e.g. consists of) a plurality of uniformly structured lower weave repeats, each of which comprising longitudinal threads 501 - 508 extending in the lower fabric layer L 2 ′ and lower transverse threads 521 - 536 (e.g. the respective repeat consists of the mentioned threads), extending exclusively in the lower fabric layer L 2 ′ and being interwoven with the longitudinal threads 501 - 508 extending in the lower fabric layer.
[0135] As shown in FIG. 5 , the longitudinal threads extending in the lower fabric layer can be formed, e.g. as lower longitudinal threads 501 - 508 extending exclusively in the lower fabric layer L 2 ′ and being, for example, interwoven with the lower transverse threads 521 - 538 thereby completely forming the lower weave. In the following, reference is thus made to lower longitudinal threads even though the longitudinal threads 501 - 508 extending in the lower fabric layer may be configured differently.
[0136] Analogously to the first embodiment, in the lower weave repeat the lower transverse threads 521 - 536 are respectively bound into the lower fabric layer each by exactly two lower longitudinal threads as a first longitudinal thread extends under the respective lower transverse thread at a first binding position “x” and a second longitudinal thread extends under the respective lower transverse thread at a second binding position “x”. As FIG. 5 shows a bottom view of the lower fabric layer, here both “binding longitudinal threads” of each lower transverse thread extend over the allocated transverse thread.
[0137] Also analogously to the first embodiment, in the respective lower weave repeat the lower transverse threads 521 - 536 are bound into the lower fabric layer differently, thereby forming first lower transverse threads I and second lower transverse threads II, wherein at the first lower transverse threads I a shortest distance in transverse direction Q between the first and the second binding position x is larger than at the second lower transverse threads II.
[0138] As shown in FIG. 5 , the different binding results in the first lower transverse threads I forming a shorter float on the running side LS than the second lower transverse threads II. Cf., for example, the float of thread 530 to the float of thread 521 .
[0139] As can be seen in FIG. 5 , the larger shortest distance in transverse direction Q at the first lower transverse threads I can, e.g. be achieved by the fact that at the first lower transverse threads between the first and the second binding position x at least one longitudinal thread extending over the lower transverse thread (in a plan view onto the top side of the lower fabric layer) more is arranged than at the second lower transverse threads II, for example exactly one longitudinal thread more or one additional thread, respectively.
[0140] As can further be seen in FIG. 5 , at the first lower transverse threads I the shortest distance in a transverse direction Q—expressed by lower longitudinal threads 501 - 508 positioned therebetween, extending over the lower transverse thread—is, for example, exactly one longitudinal thread, wherein at the second lower transverse threads II the shortest distance—expressed by lower longitudinal threads 501 - 508 positioned therebetween, extending over the lower transverse thread—is zero longitudinal threads (respectively in a plan view onto the top side of the lower fabric layer).
[0141] This means, in the lower weave repeat at the first lower transverse threads I respectively exactly one lower longitudinal thread 501 - 508 extending over the lower transverse thread can be arranged between the first and the second binding position x, wherein in the lower weave repeat at the second lower transverse threads II between the first and the second binding position x no longitudinal thread 501 - 508 extending over the lower transverse threads is arranged respectively, so that both binding positions are located immediately adjacent to each other (respectively in the plan view onto the top side of the lower fabric layer).
[0142] As can further be seen in FIG. 5 , the different shortest distance in transverse direction Q can, e.g. be achieved by the fact that the first lower transverse threads I are introduced/interwoven into the lower fabric layer with a course different from the second lower transverse threads II with respect to the lower longitudinal threads 501 - 508 , wherein all of the first lower transverse threads I in the lower weave repeat have, in principle, the same course and only the arrangement of the binding positions x in transverse direction Q varies, and wherein all of the second lower transverse threads II in the lower weave repeat have, in principle, the same course and only the arrangement of the binding positions x in transverse direction Q varies.
[0143] As can be seen in FIG. 5 , the course of the first lower transverse threads I with respect to the lower longitudinal threads (in the plan view onto the top side of the lower fabric layer) can, e.g. be as follows: under five successive longitudinal threads, over one longitudinal thread, under one longitudinal thread and over one longitudinal thread. The course of the second lower transverse threads II with respect to the lower longitudinal threads (in the plan view onto the top side of the lower fabric layer) can, e.g. be as follows: under six successive longitudinal threads and over two successive longitudinal threads.
[0144] As can be seen in FIG. 5 , in the lower weave repeat the binding positions x of a respective first lower transverse thread I can be arranged, for example, offset in a transverse direction to the binding positions of the two first lower transverse threads adjacently arranged in longitudinal direction L, for example, offset to the binding positions of every other first lower transverse thread of the lower weave repeat. See, for example, the first lower transverse thread 523 and the two first lower transverse threads 521 and 525 arranged adjacently in longitudinal direction L. The same holds true for the second lower transverse threads II.
[0145] As can further be seen in FIG. 5 , in the lower weave repeat the binding positions x of two first lower transverse threads I, arranged directly next to each other in longitudinal direction L, can, for example, be arranged offset in a transverse direction always by the same amount of longitudinal threads 501 - 508 extending in the lower fabric layer and in the same direction. The same holds true for the second lower transverse threads. In FIG. 5 , for both, the first lower transverse threads and the second lower transverse threads, a pitch of “one lower longitudinal thread to the left” has been selected (in the plan view onto the lower fabric layer thus a pitch of “one lower longitudinal thread to the right”).
[0146] As can further be seen in FIG. 5 , the ratio of first lower transverse threads I to second lower transverse threads II in the lower weave repeat, analogous to the first embodiment, can be, for example, 1:1, e.g. with a directly alternating arrangement in longitudinal direction L.
[0147] Analogously to the first embodiment, according to various embodiments, the first lower transverse threads I may have thermosetting properties different from the second lower transverse threads II, e.g. have a different shrinking behavior compared to the second lower transverse threads.
[0148] Analogously to the first embodiment, according to various embodiments, the first lower transverse threads I may have a diameter different from the second lower transverse threads II, and/or the first lower transverse threads I may be made of a material different from the second lower transverse threads II, and/or the first lower transverse threads I and the second lower transverse threads II may be treated differently with influence on their thermosetting behavior, e.g. mechanically treated differently, e.g. stretched differently.
[0149] Analogously to the first embodiment, the screen can, according to various embodiments, be formed as a synthetic fabric, e.g. as a thermoset synthetic fabric. In the synthetic fabric, at least the lower transverse threads 521 - 536 , e.g. also the lower longitudinal threads 501 - 508 , are formed as synthetic threads.
[0150] As shown in FIG. 5 , the lower weave repeat may, for example, contain exactly 8 lower longitudinal threads 501 - 508 ; a so-called 8-shaft configuration, because the respective course of lower transverse threads is repeated after 8 lower longitudinal threads.
[0151] As shown further in FIG. 5 , in the lower weave repeat the ratio of lower transverse threads 521 - 536 to lower longitudinal threads 501 - 508 may, for example be 2:1 or be exactly 16:8, respectively.
[0152] Analogously to the first embodiment, according to various embodiments, the diameter of the lower transverse threads 521 - 536 can, for example, be larger than the diameter of the transverse threads extending in the upper fabric layer (not shown) and/or be larger than the diameter of the binding threads (also not shown), and/or the diameter of the lower transverse threads 521 - 536 can be larger than the diameter of the lower longitudinal threads 501 - 508 , and/or the lower transverse threads 501 - 508 can, in the total repeat, have the largest diameter of all threads.
[0153] FIG. 6 shows the lower weave repeat of a paper machine screen formed as a multi-layer fabric according to a third embodiment (so-called 12-shaft configuration).
[0154] Regarding the upper fabric layer and its binding to the lower fabric layer, the information given in the description of the second embodiment shall apply. Thus, only the lower fabric layer L 2 ″ and its lower weave repeat are described in detail below. Emphasize is being put on the differences to the first and second embodiment, in parts omitting repetition of identical or similar aspects with reference to the first/second embodiment.
[0155] The lower fabric layer L 2 ″ of the screen according to the third embodiment is formed by (and, e.g. consists of) a plurality of uniformly structured lower weave repeats, each of which comprising longitudinal threads 601 - 612 extending in the lower fabric layer L 2 ″ and lower transverse threads 621 - 644 (e.g. the respective repeat consists of the mentioned threads), extending exclusively in the lower fabric layer L 2 ″ and being interwoven with the longitudinal threads 601 - 612 extending in the lower fabric layer.
[0156] As shown in FIG. 6 , the longitudinal threads extending in the lower fabric layer can be formed, e.g. as lower longitudinal threads 601 - 612 extending exclusively in the lower fabric layer L 2 ″ and being, for example, interwoven with the lower transverse threads 621 - 644 thereby completely forming the lower weave. In the following, reference is thus made to lower longitudinal threads even though the longitudinal threads 621 - 644 extending in the lower fabric layer may be configured differently.
[0157] The lower transverse threads 621 - 644 are, analogously to the first and second embodiment, each bound twice into the lower fabric layer in the lower weave repeat, i.e. by exactly two lower longitudinal threads.
[0158] Also analogously to the first and second embodiment, in the respective lower weave repeat the lower transverse threads 621 - 644 are bound into the lower fabric layer differently, thereby forming first lower transverse threads I and second lower transverse threads II, wherein at the first lower transverse threads I a shortest distance in transverse direction Q between the first and the second binding position x is larger than at the second lower transverse threads II.
[0159] As shown in FIG. 6 , the different binding has the result that the first lower transverse threads I form a shorter float on the running side LS than the second lower transverse threads II. Cf., e.g. the float of thread 638 with the float of thread 621 .
[0160] As can be seen in FIG. 6 , in the lower weave repeat at the first lower transverse threads I between the first and the second binding position x, e.g. exactly one lower longitudinal thread 601 - 612 , extending over the lower transverse thread, can be arranged respectively, wherein in the lower weave repeat at the second lower transverse threads II between the first and the second binding position x no lower longitudinal thread 601 - 612 , extending over the lower transverse thread, is arranged respectively so that both binding positions are located immediately adjacent to each other (respectively in the plan view onto the top side of the lower fabric layer).
[0161] As can further be seen in FIG. 6 , the different shortest distance in transverse direction Q can, e.g. be achieved by the fact that the first lower transverse threads I are introduced/interwoven into the lower fabric layer with a course different from the second transverse threads II with respect to the lower longitudinal threads 601 - 612 , wherein all of the first lower transverse threads I in the lower weave repeat have, in principle, the same course and only the arrangement of the binding positions x in transverse direction Q varies, and wherein all of the second lower transverse threads II in the lower weave repeat have, in principle, the same course and only the arrangement of the binding positions x in transverse direction Q varies.
[0162] As can be seen in FIG. 6 , the course of the first lower transverse threads I with respect to the lower longitudinal threads (in the plan view onto the top side of the lower fabric layer) can, for example be as follows: under nine successive lower longitudinal threads, over one longitudinal thread, under one longitudinal thread, and over one longitudinal thread. For example the course of the second lower transverse threads II with respect to the lower longitudinal threads (in the plan view onto the top side of the lower fabric layer) can be as follows: under ten successive longitudinal threads and over two successive longitudinal threads.
[0163] As can be seen in FIG. 6 , in the lower weave repeat, the binding positions x of a respective first lower transverse thread I can, for example, be offset in a transverse direction to the binding positions of the two first lower transverse threads adjacently arranged in longitudinal direction L, e.g. offset to the binding positions of every other first lower transverse thread of the lower weave repeat. See, e.g. the first lower transverse thread 623 and the two first lower transverse threads 621 and 625 arranged adjacently in longitudinal direction L. The same holds true for the second lower transverse threads II.
[0164] As can further be seen in FIG. 6 , in the lower weave repeat the binding positions x of two first lower transverse threads I, arranged directly next to each other in longitudinal direction L, can be arranged offset in a transverse direction always by the same amount of longitudinal threads 601 - 612 extending in the lower fabric layer and in the same direction. The same holds true for the second lower transverse threads. In FIG. 6 , a pitch of “five lower longitudinal threads to the left” was selected by way of example for both the first lower transverse threads and the second lower transverse threads (in the plan view onto the lower fabric layer thus a pitch of “five lower longitudinal threads to the right”).
[0165] As can further be seen in FIG. 6 , the ratio of first lower transverse threads I to second lower transverse threads II in the lower weave repeat can, analogously to the first and second embodiment, e.g. be 1:1, for example with a direct alternating arrangement in longitudinal direction L.
[0166] Analogously to the first and second embodiment, the first lower transverse threads I may, according to various embodiments, have thermosetting properties different from the second lower transverse threads II, e.g. a different shrinking behavior than the second lower transverse threads.
[0167] Analogously to the first and second embodiment, the first lower transverse threads I may, according to various embodiments, have a diameter different from the second lower transverse threads II, and/or the first lower transverse threads I may be made of a material different from the second lower transverse threads II, and/or the first lower transverse threads I and the second lower transverse threads II may, with influence on their thermosetting behavior, be treated differently, e.g. differently mechanically treated, e.g. differently stretched.
[0168] Analogously to the first and second embodiment, the screen may, according to various embodiments, be formed as a synthetic fabric, e.g. as thermoset synthetic fabric. In the synthetic fabric at least the lower transverse threads 621 - 644 , e.g. also the lower longitudinal threads 601 - 612 are formed as synthetic threads.
[0169] As shown in FIG. 6 , the lower weave repeat may, for example, comprise exactly 12 lower longitudinal threads 601 - 612 ; so-called 12-shaft configuration, in which the respective course of transverse threads is repeated after 12 lower longitudinal threads, i.e. the respective transverse thread repeats, in the not-shown lower repeat arranged in transverse direction to the right of the lower repeat shown, its course shown in FIG. 6 .
[0170] As shown further in FIG. 6 , in the lower weave repeat the ratio of lower transverse threads 621 - 644 to lower longitudinal threads 601 - 612 may, for example, be 2:1 or exactly 24:12, respectively.
[0171] Analogously to the first and second embodiment, according to various embodiments, the diameter of the lower transverse threads 621 - 644 can, for example, be larger than the diameter of the transverse threads extending in the upper fabric layer (not shown) and/or be larger than the diameter of the binding threads (also not shown), and/or the diameter of the lower transverse threads 621 - 644 can be larger than the diameter of the lower longitudinal threads 601 - 612 , and/or the lower transverse threads 621 - 644 can have the largest diameter of all threads in the total weave. | A sheet-forming wire with a lower fabric layer formed from a multiplicity of identically constructed lower weave repeats, each of which contains longitudinal threads extending in the lower fabric layer, and lower cross threads, with the lower cross threads extend only in the lower fabric layer. The lower cross threads are tied into the lower fabric layer in each case by exactly two longitudinal threads extending in the lower fabric layer, in that each particular lower cross thread is run under by a first longitudinal thread at a first tying-in point (x) and is run under by a second longitudinal thread at a second tying-in point (x). The lower cross threads form first lower cross threads (I) and second lower cross threads (II). The first lower cross threads form a shorter float on the running side than the second lower cross threads. | 3 |
[0001] This is a continuation of copending application Ser. No. 09/841,649 filed on Apr. 23, 2001 and claims the benefit of the filing date of that applicalton.
RELATED APPLICATIONS
[0002] The present invention is related to the application entitled COLLAPSIBLE STRUCTURAL FRAME STRUT WITH POP-IN-CONNECTOR, filed on the same date as the present invention with the same inventor and under Ser. No. ______ Attorney Docket Number 2058-301, the disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0003] The present invention relates to the field of collapsible support structures.
BACKGROUND OF THE INVENTION
[0004] It is well known in the art to provide collapsible support structures for a variety of applications; e.g., supporting other structures, e.g., expandable antennae, e.g., for transportation into and use in outer space, ease of construction of relatively rigid building frames, and supporting such things as tents and other structures having forms composed of panels of material, e.g., cloth, canvas, plastic or other pliable fabrics and fabric-like material, including synthetics, e.g., Orlon, Gore-Tex and the like.
[0005] U.S. Pat. Nos. 3,968,808 and 4,026,313, each entitled COLLAPSIBLE SELF-SUPPORTING STRUCTURE, issued to Ziegler, respectively on Jul. 13, 1976 and May 31, 1977 each disclose collapsible structural support frames having a geodesic form. The '808 patent discloses: “ . . . a collapsible, self-supporting structure is disclosed wherein the structure is made up of a network of rod elements pivotally joined at their ends and forming scissors-like pairs in which rod element crossing points are pivotally joined. The network consists of a plurality of pairs of inner and outer apical points where groups of radiating rods are pivotally joined. The outer apical points lie on a surface of revolution such as a spherical section and each group of rods radiating from an inner apical point lie essentially in a common plane whereby to effect the self-supporting action. For any pair of apical points the group of rods defining the inner apical point radiate in their common plane and join rods of other groups at the surrounding outer apical points.” Abstract. The '808 patent states that “ . . . a preferred universal pivotal connection at the apical points is illustrated in FIGS. 12-14. As shown, each element has a double-ended fan flot 130 through which a wire ring 132 passes so as to allow universal movement of the rod elements. In the embodiment of FIG. 1, there may be as few as three elements intersecting at an apical point and as many as six elements, as shown.” Col 5, line 66-Col. 6, line 4. The '808 patent also notes that: “ . . . rferring more particularly at this time to FIG. 25, certain principles of the construction according to FIG. 1 will be apparent therefrom. The FIG. 1 construction may be further explained in terms of conventional geodesic nomenclature. Specifically, the FIG. 1 embodiment is constructed as a four frequency icosahedron in which one of the triangular regions is illustrated in FIG. 25 and, in FIG. 26, all of the triangular regions are shown but laid out in flat form so as to give a better understanding of the elements involved.” Col. 7, lines 53-61. Similarly, the '313 patent discloses a “ . . . self-supporting structures and panels of diverse shapes are disclosed in which basic assemblies of crossed rod elements are employed to achieve the desired shape. Further, the crossing points of crossed rod elements in the structure involved may include limited sliding connections which effect transfer of collapsing force to other crossing points which are pivotally joined. An improved hub structure for pivotally joining ends of the rod elements at the outer and inner apical points is also disclosed.” Abstract.
[0006] U.S. Pat. No. 6,089,247“ . . . a collapsible frame for use in erecting tents, insect screen rooms, shade awnings, canopies and the like at camp sights, back yard patios and other outdoor venues. The collapsible frame includes a plurality of telescopic legs for providing vertical structural support and a plurality of corner pin joints with one of the pin joints fixedly mounted upon a corresponding one of each of the telescopic legs. A plurality of horizontal support arms is included with one of the arms positioned between every adjacent pair of telescopic legs and attached to the corresponding corner pin joints. A mid-span hinge which includes a sliding sleeve is centrally positioned along each of the horizontal support arms. The mid-span hinge is flexibly collapsible when the sleeve is disengaged and is rigidly inflexible when the sleeve is engaged. A bottom slider is adjustably mounted upon each of the telescopic legs and is attached to the horizontal support arms which are connected to the corresponding corner pin joint. Finally, a plurality of top support members is included where each is anchored in a corresponding corner pin joint for stabilizing the frame. In the present invention, the telescopic legs, mid-span hinges and bottom sliders each cooperate to collapse the frame.” Abstract. The '247 patent also disclosed that “ . . . centrally positioned along each of the four horizontal support arms 162 is a mid-span hinge 188 clearly shown in FIGS. 1, 3 and 4. Each of the four horizontal support arms 162 is circular and comprised of a lightweight material such as, for example, aluminum. The length of each of the four horizontal support arms 162 is interrupted approximately at the center of the span thereof forming two opposing, open-ended mid-span terminal ends 190 and 192 as shown in FIG. 3. Extending outward from each of the open-ended terminal ends 190 and 192 is a pair of connectors 194 and 196 having penetrations formed therethrough. Connectors 194 and 196 may be comprised of plastic having an outer surface which exhibits a low coefficient of friction such as Teflon. Positioned between the pair of connectors 194 and 196 is a pair of parallel positioned plates 198 and 200 swivelly attached to the corresponding connectors 194 and 196, respectively, of each of the horizontal support arms 162. The parallel positioned plates 198 and 200 are attached to each of the corresponding connectors 194 and 196 as by, for example, use of a pair of rivets 202 through the penetrations formed in the connectors 194 and 196 as is shown in FIG. 3. Mounted over each of the horizontal support arms 162 and the mid-span hinge 188 is a sliding sleeve 204 shown in FIGS. 1, 3 and 4. The sliding sleeve 204 is cylindrical in shape and can be comprised of aluminum or a high strength plastic material such as polyvinylchloride (PVC). Further, the sliding sleeve 204 can have an inner surface (not shown) coated with a low friction material such as Teflon to minimize resistance to sliding. In the view of FIG. 3, the sliding sleeve 204 is disengaged and the mid-span hinge 188 is exposed and capable of swivelling. Under these conditions, the mid-span hinge 188 is flexibly collapsible and cooperates with the telescopic legs 108 and the bottom slider 130 to enable the collapsible frame 100 to collapse into the reduced size posture as clearly shown in FIG. 9. Located on the surface of the horizontal support arm 162 is a first mechanical stop 206 as shown in FIG. 3. The first mechanical stop 206 serves to limit the travel of the sliding sleeve 204 away from the mid-span hinge 188.” Col 7, line 47-Col. 8, line 11.
[0007] The '247 patent goes on to explain that “ . . . each of the top support members 174 comprise two portions best shown in FIG. 6. An outer portion 220 is shown fitting over the end of an inner portion 222 at a lip 224. With this arrangement, the inner portion 222 can be separated from the outer portion 220 under pressure. Running the length through the interior of each of the top support members 174 is an elastic cord 226 as shown in FIG. 6. The elastic cord 226 can be connected on each of its ends to the interior of each of the top support members 174 in any suitable manner such as, for example, by tying. The function of the elastic cord 226 is to urge the mating of the outer portion 220 with the inner portion 222 of the top support member 174 while simultaneously enabling them to be separated. This design facilitates the collapsing of the superstructure 106 but also prevents the outer portion 220 from being separated from the inner portion 222.” Col. 9, lines 7-22.
[0008] U.S. Pat. Nos. 5,797,412 and 5,632,293, each entitled COLLAPSIBLE SHELTER WITH FLEXIBLE, COLLAPSIBLE CANOPY, Aug. 25, 1998 and May 27, 1997 to Carter, disclose that “ . . . the collapsible shelter includes a truss and canopy framework that permits a flexible, collapsible canopy to be moved between a raised position and a lowered position. The collapsible shelter includes at least three legs supporting flexible poles removably mounted to the tops of the legs and forming the framework of the canopy. X-shaped truss pairs of link members are connected to each of the legs on each side of the shelter between adjacent legs.” Abstract. The '412 and '293 patents also disclose that “the present invention provides for a collapsible shelter with a flexible, collapsible canopy framework that can be raised to provide increased headroom, strength and stability, and can be lowered to provide a reduced profile to the wind. The invention provides for a collapsible shelter having at least three legs supporting a collapsible canopy supported by flexible poles removably mounted to the tops of the legs. At least two perimeter truss pairs of link members are connected to each of the legs on each side of the shelter between two adjacent legs. Each of the X-shaped perimeter truss pairs of link members are essentially identical, and include two link members connected together by a central pivot, with the first link member having an outer end connected to the upper end of one leg, and the second link member having an outer end slidably connected to the leg. The first and second link members are pivotally connected together in a scissors configuration so as to be extendable from a first collapsed position extending horizontally between two of the legs to a second extended position extending between the legs. The two perimeter truss pairs of link members on each side are connected together at their inner ends. The collapsible shelter preferably has four legs, but can also have three, five, or more legs. At least two flexible pole members are also provided that are removably mountable to the upper ends of the legs of the shelter to extend across the shelter to form a structure for a flexible, collapsible canopy. The canopy also preferably includes a cover secured to the upper ends of the legs. In a currently preferred embodiment of the invention, the flexible pole members comprise a plurality of segmented poles formed from a plurality of pole sections that are removably connectable together, and that are removably mounted in indexing holes in hinge means affixed to the upper ends of the legs, and the pole members are similarly removably connected together by a central hub that is preferably permanently connected to an inner end of one of the pole members. When the pole members are connected together and inserted in the hinge means of the legs, the pole members forming the canopy can flex and move between a normal raised position and a lowered position by exertion of a downward force on the top of the canopy, such as by a strong wind, to reduce the profile of the shelter that would be exposed to the wind and still provide rain run off. To facilitate this aspect of the invention the flexible poles in a currently preferred embodiment are made of a composite material such as fiberglass, but a variety of materials such as metal tubing and other composites can be used for such purposes. Col. 1, line 53-Col. 2, line 34.
[0009] The '412 and '293 patents go on to disclose that “ . . . an the currently preferred embodiment, four flexible pole members 82 are provided, corresponding to the number of legs, as is illustrated in FIGS. 6, 7 and 12. While a variety of materials such as metal tubing, composite tubing (tubing made of resin impregnated fibers) or solid composite poles may be used, the flexible pole members currently preferably each comprise segmented flexible poles formed from two fiberglass pole sections 84 that are removably connectable together, with an inner end 86 of one of the pole sections bearing a metal jacket 88, made of aluminum or steel for example, into which the adjacent inner end 90 of the other pole section is insertable, to join the pole sections together. The pole sections are preferably hollow, and an elastic cord 92 runs through the longitudinal centers of the pole sections. An outer end 94 of the cord of each pole member extends through an indexing aperture 96 in the hinge means, and is secured to the hinge means such as by a knot. The inner end 98 of the cord is secured to the inner end 100 of the pole member, such as by a knot, so that the pole sections of the pole member are biased together. The pole members are removably receivable for mounting in the indexing apertures 96 in the hinge means affixed to the upper ends of the legs. In a currently preferred embodiment, a central hub member 102, having four symmetrically located indexing holes 104 for removably receiving the inner ends of three pole members, and for permanently receiving the inner end of a fourth pole member, mounted in a hub indexing hole, such as by an adhesive such as epoxy, for example, for joining the pole members together.” Col 5, lines 14-38.
[0010] U.S. Pat. No. 4,074,682, entitled COLLAPOSIBLE TENT FRAME, issued to Yoon on Feb. 21, 1978 discloses “ . . . a collapsible tent frame has all of its parts permanently connected to one another to provide a complete single unit and is easily changeable between a fully deployed condition, a partially deployed condition and a compact collapsed condition by simple manual manipulations. In either its fully deployed condition or its partially deployed condition, the frame is adapted to receive and support a tent fabric or other covering to provide a shelter lending itself to a variety of uses.” Abstract. The '682 patent also discloses that “ . . . the frame is unitized insofar as all of its parts are permanently connected with one another and it is shiftable between a compact collapsed condition and at least one deployed condition.” Col 1, line 67-Col. 2, line 2. In addition the disclosure of the '682 patent notes that “ . . . a more specific aspect of the invention resides in each leg of the frame including an inboard section, an intermediate section and an outboard section with the outboard section being pivotally connected with the intermediate section for movement relative to the intermediate section between a folded condition and a spread condition. The intermediate section is also pivotally connected to the inboard section for pivotal movement between folded and spread conditions relative to the inboard section; and likewise, as previously mentioned, the inboard section is movable relative to the hub between deployed and collapsed positions. When all of the inboard sections are deployed relative to the hub and all of the intermediate sections are spread relative to the inboard sections, the outboard sections may be either spread relative to the intermediate sections to provide a fully deployed frame providing one form of structure, or the outboard sections may be folded relative to the intermediate sections to provide a partially deployed frame providing another form of structure. In either the fully deployed condition or the partially deployed condition of the frame, struts extending between adjacent pairs of legs aid in controlling the angular spacing of the legs and in thus rigidifying the frame, the struts each being made of two arms pivotally connected to one another and to their associated legs to permit collapsing of the frame.” Col 2, lines 26-51. The specification of the '682 patent goes on to say that “ . . . In the deployed condition of the frame, the arms 74, 74 of each strut are locked in their relatively aligned positions shown in FIGS. 2 and 16 by a suitable releasable locking means such as the sleeve 80 shown in FIGS. 13, 14 and 15. That is, in the aligned and locked arm situation of FIG. 13, the sleeve 80 fits over the joint between the two arms to prevent relative pivotal movement between such arms; but, the sleeve is slidable to the position of FIG. 15 at which the joint is freed to allow relative rotation between the arms. A spring 82 in the sleeve frictionally holds the sleeve to whatever position it is moved.” Col 5, lines 32-41.
[0011] U.S. Pat. No. 5,930,971, entitled BUILDING CONTRRUCTION WITH TENSION SUPPORT SYSTEM, issued to Ethridge on Aug. 3, 1999 discloses “ . . . a structural system for a building wherein multiple elongate rigid structural members, in the nature of posts and beams, include internal tensioning cables which, upon an end joining of the structural members, are interlocked and tensioned to each other and relative to a fixed foundation.” Abstract. The specification of the '971 patent goes on to say that “ . . . basically, the construction system utilizes a plurality of rigid, compression-accommodating structural members, preferably tubular, defining upright support posts, roof beams, cross beams, and the like. The rigid structural members are stabilized by elongate tension members, generically herein referred to as cables, received through each of the structural members and end joined, upon a proper tensioning thereof, at or immediately adjacent the adjoining ends of the structural members. The joined cables ultimately extend through uprights and are in turn anchored to an underlying foundation either in the nature of a solid cast concrete slab with anchoring loops extending therefrom, or individually cast footings associated with each upright.” Col. 1, lines 40-53.
[0012] U.S. Pat. Nos. 6,028,570, entitled FOLDING PERIMETER TRUSS REFLECTOR, ISSUED TO Gilger et al. on Feb. 22, 2000 discloses a “collapsible support structures, fold-up perimeter trusses, principally for deployable high frequency parabolic antennas used in spacecraft.” Col. 1, lines 5-7. U.S. Pat. No. 5,871,026, issued to Lin on Feb. 16, 1999, entitled UMBRELLA SHAPE TWO LAYERS FOLDABLE TENT, disclosed a “two layers half automatic foldable tent is comprised of a framework, an umbrella surface, and a tent cloth. The framework is enclosed on the outside of the tent, while the umbrella surface is expanded on the framework above the tent cloth, wherein the framework is presented as an expanding structure. The opening and closing of the umbrella frame is completed by a controlling rope. Any user may easily install the tent, the lower primary frame of the umbrella frame may be folded upwards as the framework is closed, thus it may be stored conveniently and may be carried. Another, since in the present invention, the umbrella surface and tent cloth are designed as the two layers type thus the sunlight, rain water and snow will not contact the tent directly, and the people within the tent will be safe and comfortable and the lifetime of a tent is prolonged.” Abstract.
[0013] U.S. Pat. No. 4,998,552, entitled GEODETIC TENT STRUCTURE, issued to Niksic et al on Mar. 12, 1991, discloses a “self supporting collapsible tent structure having a tension bearing polygonal shaped floor member defining a first tent level, a plurality of hub members each carrying a plurality of sockets which are pivotal about axes which are co-planer and are interrelated one to the other as the sides of polygon, a series of said hub members disposed in a plane at a second tent level which is spaced apart from said first tent level and whose sockets are pivotal in a first direction, and additional series of said hub members disposed in a plane at a third tent level which is spaced apart from said second tent level and whose sockets are pivotal in a second direction, opposite to the said first direction, a single, apex forming hub member disposed at a fourth tent level and whose sockets are pivotal in said first direction, a first plurality of compression rods, the ends of which are seated in the said sockets of the hub members in slightly curved polygonal planes defined and bounded by the rod members and a second plurality of compression rods, one end of which are seated in sockets of the hub members at the second tent level and the other end of which are connected to the perimeter of the floor member.” abstract.
[0014] U.S. Pat. No. 4,583,956, issued to Nelson on Apr. 22, 1986, entitled RIGID AND TELESCOPING STRUT MEMBERS CONNECTED BY FLEXIBLE TENDONS, discloses a “construction kit consisting of rigid or telescoping elongate strut members which may be attached together by flexible tendons to form a variety of designs and model structures. The invention places no limits on the number of struts which can be attached at one vertex or their relative angles, and the length of each strut may be varied within broad limits. Furthermore, the end of one strut may be attached not only to the end of another, but to any point along its length. Accordingly, an almost unlimited variety of constructions is possible.” Abstract.
[0015] U.S. Pat. No. 4,438,876 discloses a “back pack frame is comprised of tubular frame members which upon separation permit extraction of pairs of tent frame components stowed therein. The frame members and tent frame components are thereafter rejoinable to provide a geodesic tent frame. The tent frame components, upon extraction from a stowed position within the back pack frame members, are positioned in a divergent manner as permitted by a wire hinge component interconnecting the paired tent frame components. The back pack frame members are slotted at their ends to permit such divergent positioning of the associated tent frame components and include limit stops to prevent complete separation of the tent frame components from their frame member. The back pack frame members themselves are coupled to one another by flexible wire inserts and, in a modified form, by molded socket members. A back pack bag may be supported either externally on the back pack frame or, alternatively, over frame members.” Abstract. The disclosures of the above referenced prior art are hereby incorporated by reference.
[0016] None of the foregoing discloses or suggests solutions to the problems with the foregoing which do not fully satisfy the needs for s compact, light weight, fully portable and exceptionally strong, once assembled, collapsible support structure. The present invention satisfies those needs more effectively than the above described prior art.
SUMMARY OF THE INVENTION
[0017] A method and apparatus is described for providing a collapsible support structure, which may comprise a plurality of interconnected frame sections each of which may comprise a first elongated rigid member having a first end and a second end; a second elongated rigid member having a first end and a second end; wherein the first end of the first elongated rigid member and the second elongated rigid member are hingedly joined; a collapsible elongated member which may comprise an elongated flexible tensioning member connected between the second end of the of the first elongated rigid member and the second end of the second elongated rigid member; a first hollow tubular rigidizing member extending along a portion of the length of the elongated flexible tensioning member; a second hollow tubular rigidizing member extending along essentially the remainder of the length of the elongated flexible tensioning member; and a rigidizing sleeve member slideably mounted on the first or the second hollow tubular member and sized to slideably engage the other of the first and second hollow tubular when the first and second hollow tubular rigidizing members are essentially axially aligned and the rigidizing sleeve member is positioned to slideably engage each of the hollow tubular rigidizing members to form a collapsible elongated tubular member extending essentially between the second ends of each of the first and second elongated rigid members and having the elongated flexible tensioning member axially disposed therein. The apparatus and method may employ the interconnected frame sections on the form of a triangle or a parallelogram, and may form a portion of a geodesic structure, such as a truncated icosahedron, which in turn may have first and second lesser circle polygonal shapes, with the hingedly joined first ends of the first and second elongated rigid members being joined at a corner of the first lesser circle polygonal shape and the collapsible elongated tubular member forming a side of the second lesser circle polygonal shape. The method and apparatus may use one-piece elongated rigid members. The sections may form parallelograms using first, second and third elongated rigid members and first and second rigidizing means, with each of the rigidizing means in each section forming a side of a separate one of the lesser circle polygonal shapes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 shows a basic structure for a collapsible support structure frame according to an embodiment of the present invention;
[0019] [0019]FIG. 2 shows schematically the geodesic structural relationship of opposing vertical members in a level of a geodesic structure according to an embodiment of the present invention;
[0020] [0020]FIG. 3 shows a geodesic structural relationship of portions of the structure according to the embodiment of the present invention shown in FIGS. 1 and 2 in relation to lesser circles circumscribing the structure in horizontal planes at certain levels of the structure,
[0021] FIGS. 4 ( a ) and 4 ( b ) show in more detail a rigidizing means according to an embodiment of the present invention.
[0022] [0022]FIG. 5 is a more detailed view of an embodiment of an upper terrminal junction according to the present invention.
[0023] [0023]FIG. 6 is a perspective view of a portion of the present invention showing an entire vertical section from the ground to the apex of an embodiment of a collaplible support structure according to the present invention.
[0024] [0024]FIG. 7 is a plan view of an embodiment of a collapsible support structure according to the present invention in its erected state.
[0025] [0025]FIG. 8 shows a partially cut away side view of an embodiment of a collapsible support structure according to the present invention in an intermediate stage of being collapsed and stored.
[0026] [0026]FIG. 9 shows a side view of the embodiment of FIG. 8 in the next succeeding stage of being collapsed and stored.
[0027] [0027]FIG. 10( a ) shows the embodiment of FIGS. 8 and 9 in a final stage of being collapsed for storage and FIG. 10( b ) shows the stage of being placed into a storage bag.
[0028] [0028]FIGS. 11, 12 and 13 show alternative possible improved embodiments for the eyelet joiners shown in earlier illustrated embodiments according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Turning now to FIG. 1 there is shown a basic structure for a collapsible support structure frame 10 according to an embodiment of the present invention. The structure 10 may be a truncated icosahedron geodesic structure. Geodesic domes are sliced from a complex polyhedra which has a large number of triangular faces, all approximately, but not quite, equilateral. See. Kenner, Geodesic Math and How to Use It, University of California Press Berkeley, 1976, Chapter 7, the disclosure of the entire volume of which is hereby incorporated by reference. In the structure of the present inventions, however, the triangular faces on the side walls of the structure may be equilateral. The struts bounding the triangular faces in a geodesic dome may follow the paths of great circles that are concentric with the center of the domed structure, some whole, but more often interrupted. The cohesion of the whole, like that of a Tensegrity, is both compressive and tensile, with the tension system running along the outer surfaces of the struts, which are at the same time in compression. The structure 10 as shown may include a plurality of generally vertical sections 12 . Each of the sections 12 a, b, c, d and e may include a first elongated rigid member 14 a , a second elongated rigid member 14 b and a third elongated rigid member 14 c where the third elongated rigid member 14 c may also comprise the first elongated rigid member in an adjoining section 12 b , which may also contain a second elongated rigid member 14 b ′ and a third elongated rigid member 14 c ′. Each of the sections 12 a, b, c, d and e may have an upper collapsible member 30 a, b, c, d and e and a lower collapsible member 32 a, b, c, d and e , more fully described below. Each of the sections 12 a, b, c, d and e may have a roof section 20 a, b, c, d and e , which may be comprised of a first roof rigid member 22 a and a second roof rigid member 22 b , where the second roof rigid member 22 b may be the first roof rigid member in the adjoining roof section 20 b which can also include a second roof rigid member 22 c . It can bee seen that each of the sections 12 a, b, c, d and e form the essentially vertical side walls of the structure with the collapsible members 30 a, b, c, d and e and the collapsible members 32 a, b, c, d and e forming the sides of a pentagon polygon. The collapsible sections 32 a, b, c, d and e can form the base of the collapsible support structure 10 and the collapsible members 30 a, b, c, d and e may form the top of the essentially vertical side walls of the support structure 10 formed by the adjoining sections 12 a, b, c, d and e.
[0030] As shown in FIG. 2, a characteristic of a geodesic structural form such as the icosahedron of FIGS. 1-3 is that the respective upper and lower ends of the opposing vertical sides rigid members, e.g., 14 c and 14 b ′″ form equivalent opposing arcs of a greater circle concentric with the geometric center of the structure 10 if it were not truncated to form the base with the collapsible members 32 a, b, c, d and e , i.e., if it had a structure equivalent to the roof structure attached to the base members 32 a, b, c, d and e in the nature of a complete icosahedron.
[0031] Turning now to FIG. 3 there is shown another characteristic of a truncated icosahedron 10 according to such structures as employed in accordance with the present invention. Each of the upper and lower collapsible members, respectively 30 a, b, c, d and e and 32 a, b, c, d and e for the sides of a pentagon which is circumscribed by a lesser circle in the plane of the pentagon and intersected by the corners of the pentagon. it will also be appreciated by those skilled in the art that the respective pentagons formed by the collapsible members 30 a, b, c, d and e and 32 a, b, c, d and e may be of the same size or of a different size, and in the latter event, the vertical walls of the structure as shown in FIGS. 1-3 could slant slightly inwardly or slightly outwardly toward the top portion of the wall formed by the collapsible members 30 a, b, c, d and e , accordingly. In the truncated icosahedron 10 at six points along the top of the vertical walls formed by the sections 12 a, b, c, d and e five triangles meet at each vertex, e.g., 80 a or 80 b shown in FIGS. 1-3. At the vertexes along the base formed by the collapsible members 32 a, b, c, d and e , only three triangles meet at each vertex. Each of the five vertices of five intersecting triangles in a geodesic structure is called a pent after the pentagons that surround them. From each of the pents radiate portions of five great circles each of which has its center at the geometric center of the structure, were it a full icosahedron as opposed to a truncated one as shown. Each of the great circles sets of about 63.5° before intersecting the opposite end of the rigid structural member, e.g., 14 c or 14 b ′″ as shown in FIG. 2, radiating from the pent, generally in the plane of the great circle. Following the lead of either of the pentagon edges forming the base or the top of the vertical walls formed by sections 12 a, b, c, d and e one may trace a circuit around the geodesic sphere forming a lesser circle with its center at the center of the pentagram, girdling the sphere in generally parallel planes, e.g., like the trop latitudes on the globe of the earth. In the pure geodesic dome, the struts forming the arcs of the lesser circles are almost, but not quite coplanar. Of course, the vertically extending struts can be adjusted as necessary and desired to correct this lack of co-planarity. Truncated dome design of the present invention is completed by placing the base formed by the collapsible members 32 a, b, c, d and e on the ground with the collapsible members 32 a, b, c, d and e and 30 a, b, c, d and e in the rigidized configuration.
[0032] Turning now to FIG. 4( a ) the apex 82 b of the section 12 a of the vertical walls of the structure 10 is shown in more detail to explain the interrelationship between the rigid members 14 a, b and c , and the collapsible members 30 a and by example 30 b forming the section 12 a . Each of the elongated rigid members 14 a, b , and c may consist of an elongated wooden dowel 16 . Each of the elongated rigid dowels 16 may have attached to either end thereof an eyelet, e.g., a screw-in eyelet 18 . An upper flexible circumferential tensional support member, e.g., a length of rope (not shown) may extend through the eyelets 18 on the upper ends of the dowels 16 (not shown)-forming the elongated rigid structural members 14 a and 14 b , which may be positioned adjacent to each other forming an upright triangular portion 50 a (FIG. 2) of the section 12 a along with the lower collapsible member 32 a . A lower flexible tensional circumferential support member, e.g., a length of rope 42 or cable, may extend through the lower collapsible support member 32 a (shown in phantom by dotted/dashed lines) and through the pair of eyelets 18 on the lower ends of the dowels 16 forming the elongated rigid members 14 b and 14 c . Similarly the upper length of rope (not shown) extends through the upper collapsible member 30 a between the joined ends of the elongated rigid structural members 14 a and 14 b and the upper end of the elongated rigid structural member 14 c , and the lower length of rope 42 extends between the eyelets 18 on the lower ends of the elongated rigid structural members 14 b and 14 c that are joined together thereby, such that the elongated rigid structural members 14 b and 14 c along with the upper collapsible member 30 a form an inverted triangular portion 52 a (FIG. 2) of the section 12 a . Thus it can be seen that the section 12 a can be in the form of a parallelogram, with the corners of the parallelogram formed by upper junctions 80 a and b and the lower junctions 82 a and b , with the upper collapsible member between 80 a and b forming the base of the inverted triangular portion 52 a and the lower collapsible member 32 a forming the base of the upright triangular portion 50 a of the section 12 a.
[0033] In the embodiment shown in FIG. 4( a ) it can be seen that the collapsible member 30 a and 32 a (not shown in FIG. 4) may be formed by a pair of hollow cylindrical tubes 62 and 64 and an outer tubular sleeve 70 . In the embodiment shown in FIG. 4 the pair of tubes 62 , 64 extend substantially the length of the base of the respective upright and inverted triangular portions 50 a and 52 a and the outer sleeve 70 slideably engages both the tube 60 and the tube 62 when the respective upper or lower collapsible member, e.g., lower collapsible member 32 a is in the rigidized configuration. The abutment of the tubes 60 and 62 at junction 72 is illustrated in FIG. 4( a ). This abutment serves to hold the rigidized collapsible member 32 a in compression when the tensile forces exerted, e.g., by tightening the rope 42 around the lesser circle traveled by the rope 42 (along with the similar action of the upper rope (not shown) gives the structure 10 its structural rigidity.
[0034] Turning now to FIG. 4( b ) it can be seen that the outer sleeve 70 is of a length that it can be slideably moved to enclose only the one or the other of the two tubes 60 , 62 , such that the rigidity provided by the sleeve 70 engaging both the tubes 60 and 62 is eliminated. This enables the respective ends of the elongated rigid structural members, e.g., 14 a, b and c , the former two of which were maintained in separation by the collapsible member 32 a being rigidized, to move toward each other, enabling collapsing and folding of the structure 10 , when done in conjunction with similarly removing the rigidity of each of the collapsible members 30 a, b, c, d and e and 32 a, b, c, d and e.
[0035] Turning now to FIG. 5 there is shown a more detailed view of an embodiment of an upper terrminal junction or apex 80 ( a ) according to the present invention. The eyelets 18 for each of the dowels 16 forming verticle poles 14 a and 14 b and roof pole 22 a are joind by having the rope of cable 40 forming the upper flexible circumferential support member threaded through them and passing through the adjacent hollow tubes 64 of the upper collapsible member 30 e and 62 of the upper collapsible member 30 a , with the verticle poles 14 a and 14 b forming a triangular portion of section 12 a and roof pole 22 a extending to the top of the structure 10 . This is shown in further detail in FIG. 6. Turning to FIG. 6 there is shown a perspective view of a portion of the collapsible stgructure 10 according to the present invention showing an entire vertical section from the ground to the apex of the embodiment 10 . FIG. 6 shows that the roof poles 22 a, b, c, d and e are joined at the top apex of the structure, e.g., by an apex ring 120 . The apex ring may be, e.g., s ring that has a hinged opening allowing the ring to be inserted through the eyelets 18 and the upper ends of each of the roof poles 22 a, b, c, d and e . Alternatively the apex ring 120 may simply be a piece of rope or cable threaded through the eyelet 18 openings.
[0036] Turning now to FIG. 7 there is shown a plan view of an embodiment of a collapsible support structure 10 according to the present invention in its erected state.
[0037] Turning now to FIG. 8 there is shown a partially cut away side view of an embodiment of a collapsible support structure according to the present invention in an intermediate stage of being collapsed and stored. In this view one section containing portions bottom collapsible support members 32 b and 32 c and upper horizontal collapsible support members 30 b and 30 c are omitted. In the view of FIG. 8, there are shown a pair of anchor rings 130 . The anchor rings 130 may be in the form of a circular ring containing crossed members. The anchor rings 130 are constructed so as to easily connect one end of an upper horizontal flexible circumferential support 40 or lower horizontal flexible circumferential support 42 , e.g., a cable or rope, to the anchor ring, as by tying, welding, crimp locking or the like, and such that the anchor ring will not pass into the adjacent hollow tube 62 or 64 , as the case may be. It will also be understood that the anchor ring 130 , on the lower circumferential support 42 , except for necessary tightening due to loosening or shifting over time in use, may be essentially permanently affixed to the other end of the lower circumferential support 42 , whereas, unless the roof struts 22 a - e are constructed to enable, e.g., telescoping, the anchor ring 130 on the upper circumferential support may need to be undone each time to enable the roof struts 22 a - e to extend toward an apex position from the storage collapsed position due to their rigid length and the circumference of the upper circumferential support 40 in its tightened position.
[0038] As shown in FIG. 8 the sections 12 a, b, c, d and e are laid out with the anchor rings tight against the apexes 82 a a\nd 80 a respectively and with the upper and lower horixontal flexible circumferential support cable or ropes 40 and 42 extending out of one half of the apex 82 e and out of the apex 80 e , and through upper collapsible structural support member 30 e.
[0039] Turning now to FIG. 9 there is shown the initial stage of folding the collapsible horizontal support members between the respective adjacent vertical poles. The roof posts 22 a, b, c, d and e are then folded downwardly to the inside of the collapsed structure as shown in FIG. 10( a ), with the lower horizontal flexible support member 42 pulled to tighten the bundle, and with the portion of the upper horizontal flexible support structure wrapped around the upper portion of the collapsed bundle to further tighten the collapsed bundle prior to insertion of the bundle into the storage bag as Shown in FIG. 10( b ). It will be understood that the folding operation discussed in this paragraph can occur both with the apex ring in place (not shown) or not in place as shown.
[0040] [0040]FIGS. 11, 12 and 13 show alternative possible improved embodiments for the eyelet joiners shown in earlier illustrated embodiments according to the present invention. In FIG. 11 and FIG. 12 there is shown one version of a pop-in connector 160 , which consists of a loop 162 and a pair of straight leg portions 164 , along with a protrusion 166 at the terminal end of the straight leg portion 164 . In the embodiment shown in FIG. 11 the loop 162 can used in conjunction with a locking insert 165 . The locking insert 165 is constructed to have a diameter along at least one axis that allows the structure, which may be constructed of a rigid though partially flexible material such as nylon, so as to fit snuggly within the end of a hollow tube. In the case of FIG. 11 the hollow tube is shown to have replaced the wooden dowels 16 as, e.g., the vertical structural members. In operation the pop-in connector of FIG. 11 is constructed to have a spring-like mode of operation with the protrusions biased to press against the inner surface of the hollow tube 16 . Insertion into the grooves 167 of the locking insert 165 , the protrusions are forced even more toward engagement with the inner surface of the hollow tube 16 . In addition, depending upon the direction of the spring action of the leg portions, they may be biased against the surface of the respective groove 167 to further frictionally hold the pop-in connector 160 . In the embodiment of FIG. 12, the hollow tube has a pair of opposing holes 168 and in this case the legs 164 of the loop 162 of the pop-in connector 160 are springedly biased outwardly so as to engage the protrusions 166 in the holes 168 to hold the pop-in connector in place.
[0041] As shown it can be seen that the pop-in connectors 160 can be of great use, e.g., if a pole/strut, e.g., 14 or 16 were to break while the structure is erect. Without having to essentially disassemble the structure frame 10 by unthreading the entire, e.g., upper flexible circumferential support 40 or lower flexible circumferential support 42 to rethread it through an eyelet such as the eyelets 18 discussed above, the pop-in connector can be used to selectively engage one of the supports 40 , 42 at the respective end of a pole/strut at only the specific location of the pole/strut being replaced.
[0042] One possible disadvantage of the pop-in connector 160 described above is that over time the flexible support 40 , 42 , if it is made of fiber as opposed to being a metal cable, could fray on the ends of the tubular pole/strut. alternatively, the metal capable used as a flexible support 40 or 42 may wear down the tubular ends of the pole/strut. To prevent either of these, at the loss of flexibility in replacing poles/struts while the structure is erected, a pop-in connector such as the pop-in connector 170 shown in FIG. 13 may be employed. The pop-in connector of FIG. 13 has two loops, keeping the flexible circumferential support 40 , 42 away from the tubular end of the respective pole/strut.
[0043] It will be understood that the tensioning means at, e.g., the base and the top of the vertical side walls of the structure 10 may be formed by rope or cable or the like and may be brought into tension simply by pulling on the rope or cable at a vertex, e.g. 80 b and similarly, e.g., 82 b , with the rope or cable attached, e.g., to an eyelet 18 on one of the dowels 18 forming part of the vertex, and looped through the other eyelet at the vertex, such that the tensionizing rope or cable exerts tension between each of the vertices, while the collapsible members 30 a, b, c, d and e , or 32 a, b, c, d and e , as applicable, are placed in compression. It will also be understood that the compactibility of the structure 10 of the present invention may be increased, and the height of the vertical walls formed by the sections 12 a, b, c, d and e maintained by making the rigid members, e.g., 14 a, b and c , themselves collapsible, e.g., by forming them of a two piece hinged construction as is known in the art for such supporting struts for collapsible structures and frames. In addition, the height of the vertical walls may be increased by adding a third or a fourth or more set of sections defined by another pair of adjacent lesser circle pentagons connected by rigid struts, e.g., in the triangular pattern as shown in FIGS. 1-3. It will also be understood that the roof struts 22 a, b, c, d and e must be joined at the apex 88 of the structure 10 shown in FIGS. 1-3, which may be accomplished by simply as looping a rope through eyelets 18 at the terminal ends of the roof struts 22 a, b, c, d and e meeting at the apex 88 , or by any of the well known mechanical structures for forming such a roof apex in collapsible structure frames known in the art. It will be understood, however, that the making of this vertex at the apex 88 of the structure will ordinarily need to be formed before vertical side walls of the structure 10 are rigidized and will ordinarily need to be broken down before the structure 10 is collapsed, since the length of the roof struts 22 a, b, c, d and e will prevent the apex 88 from collapsing through the plane of the lesser circle formed by the top of the vertical wall, i.e., by collapsible sections 30 a, b, c, d and e , as shown in FIGS. 1-3 while remaining joined in abutted ends at the apex 88 .
[0044] The collapsible support structure of the present invention provides a number of advantages beyond simply being collapsible and storable in a relatively compact form in a storage bag and being relatively easy to assemble and rigidize and collapse and store. No ropes or tie downs are needed to hold the erected structure having placed over it one of a number of forms of plastic, fabric or hybrid covers to form, e.g., a tent or other generally water tight enclosure. The ropes inside the collapsible frame structure of the present invention provide the hold down function simply by the weight of the cover over the structure, or alternatively, if, e.g., because of high winds, etc. weighted bags filled with, e.g., sand or water can be place over the bottom horizontal collapsible members. this can be especially beneficial on surfaces that are exceptionally hard, e.g., pure rock, or exceptionally soft, e.g., sand, where tie downs are difficult if not impossible to anchor. The structure is also adaptable to a large variety of terrains, including relatively steep slopes, and the ability to suspend hammocks from the upper vertices of the structure are not impacted by the structure being on such a slope. Furthermore if the structure, once assembled needs to be moved, e.g., having been initially erected over an ant hill, it can be lifted and moved fully assembled relatively easily due to its rigidity and light weight.
[0045] In use the collapsible support structure of the present invention can be a form of rapidly deployable emergency shelter. The ability to hang hammocks from the vertices of the frame enable use in wet conditions even if the frame does not support a covering forming a tent with an integral floor.
[0046] In operation the collapsible support structure of the present invention can be erected by the following process. The structure is first removed from the storage bag. The user can simply open the carrying bag and stand the collapsed structure in the veticle collapsed position. The five lower horizontal collapsible members will naturally fall away from the vertical poles, with the upper horizontal collapsible members remaining suspended from the upper ends of the vertical poles. the user can then spread tot lower horizontal collapsible support members to form the lower pent by moving the vertical poles outwardly from the stored compacted assembly. Leaving the upper collapsible horizontal support members in the broken down condition, the user can rigidize the lower horizontal collapsible members to form a rigidized pent at the bottom of the structure. With the apex of the roof poles connected by an apex ring as described above and the upper horizontal collapsible members remaining un-rigidized, and or un-tightened, the roof poles can be moved to above the horizontal plane of the upper horizontal collapsible members. The upper horizontal collapsible members can then be rigidized. Both the lower horizontal collapsible members and upper horizontal collapsible members can be rigidized by, e.g., threading the respective upper or lower flexible circumferential support member, e.g., rope or cable through an anchor ring at the opposite end of the cable or rope and held in place at one of the apexes/vertexes 80 a, b, c, d and e or 82 a, b, c, d and e and tightening the rope or cable by hand or with a mechanical tightener so that the respective horizontal lesser circle is in compression. This can be done, e.g., with the user standing inside of the frame under assembly and holding the roof poles upward to form a roof apex, while tightening the upper collapsible horizontal support members. The upper apexes will be generally centered over the centers of the lower collapsible support members and the upper collapsible structural members will be centered generally over the junctions between the bottom collapsible support structural members.
[0047] A further application of the present invention to form a collapsible structure support can include other geodesic structures that are able to be formed and broken down according to the present invention, e.g., icosa, octa, tricon, etc., especially in multi-frequency large structures, e.g., using cables with somewhat heavier hardware.
[0048] The present invention has been described with respect to preferred embodiments. It will be understood by those skilled in the art that many variations and modification of the disclosed preferred embodiments may be made without changing or departing from the scope and spirit of the present invention, e.g., other forms of sleeves and tubes apart from those illustrated which maintain compression by the abutment of the inner tubes within the outer sleeve may be employed as known in the art, e.g., a sleeve with flouted ends and a more narrow central section such that the tubes coact with the narrowed center portion of the sleeve to create the compressive force. IN addition, the sleeve itself could be the internal tubular structure, e.g., having a protrusion that slides along a slot in one or the other of the two tubes running the length of a collapsible member, e.g., 32 a , so as to be able to be moved from a position in which the sleeve (now an internally disposed sleeve) slideably internally engages both of the other tubes to one in which it so engages only one of the other tubes, similarly to the configuration as shown in FIG. 5. Other such modifications may be made to the mechanical structural elements of the present invention, e.g., the dowels could be replaced with solid or hollow metal rods, or even generally flat struts, particularly if a hinged construction of the struts is desired, all of which may be made, e.g., of metal, e.g., made of aluminum, and/or the eyelets could be replaced with holes bored through the rigid structural members, whether such are wooden of metal, hollow or tubular or flat in construction. the present invention, therefore, should not be limited to any preferred embodiments disclosed in this application and should be considered described and claimed only through the following claims: | An apparatus and method is disclosed for providing a collapsible support structure strut, which may include a strut member; a hollow tubular terminal end portion of the strut member having an inner surface; and a detachable looped eyelet having at least one loop and a pair of extending legs, the legs being springedly biased to engage the tubular terminal end of the strut, thereby frictionally holding the looped eyelet in place at the terminal end of the strut. The apparatus and method may also employ a holding plug, with first and second holding groove opposingly placed in the periphery of the holding plug, having at least a portion thereof that is shaped and sized to frictionally engage the inner surface of the tubular terminal end of the strut, to frictionally hold the holding plug in engagement with the strut. The detachable looped eyelet may also have at least two loops. | 4 |
TECHNICAL FIELD
[0001] The principles disclosed relate to improvements to round balers used for harvest of agricultural crops. The invention relates particularly to a method and apparatus for determining a weight of a bale of hay after it is formed, a moisture content of the bale, projecting a size of a bale at a set point weight, and calculations and data display.
BACKGROUND
[0002] Large, cylindrical balers have been on the market for a number of years. Typically, the forming of a bale is terminated according to a diameter criterion. Depending on the crop and its moisture level, the weight of bales and the dry matter content can vary widely, even in the same field.
[0003] A variety of sensors are incorporated into a large, cylindrical bale baler in U.S. Pat. No. 5,622,104. In particular, the use of a bale size sensor is disclosed. Additional sensors are suggested for bale RPM, crop moisture, horsepower demands, belt tension, and bale weight.
[0004] Wild et al. reported a hay yield monitoring system for round balers with strain gages on the tongue and axle of the vehicles, which provided a measure of the weight of the baler and the bale. They also added accelerometers to measure vertical accelerations during operation and determined stationary loads within 2% of actual weight. Measurements under dynamic conditions are still under investigation. (Wild, K., H. Auernahammer, J. Rottmeier, 1994. “Automatic Data Acquisition on Round Balers,” ASAE Technical Paper No. 94-1582, presented at 1994 ASAE International Meeting, Atlanta, Ga. Dec. 13-16, 15 pp.)
[0005] A cylindrical bale baler system was disclosed in U.S. Pat. No. 6,378,276. The system comprises an electronic evaluation unit for processing signals from displacement sensors and a pendulum, transmitting the bale weight to an output unit with which the data are displayed or stored, such as on a yield card. Additionally, a control device may control various baler functions. Further, a moisture sensor for crop material may be connected with the evaluation unit for an automatic conversion to weight of the dry mass of the big round bale.
[0006] There is, therefore, a need for a cylindrical baling system providing a volume average of the moisture level, a bale weight for each bale, consistent bale weight and size, and an identification label, ultimately providing bale weight, moisture, baling date, and field location for each bale.
SUMMARY
[0007] A general object of the present invention is to provide data for each bale made in a large cylindrical (big round) baling operation for decision making, display, archival, and automatic control.
[0008] Parameters sensed by the present invention include bale diameter, bale weight, moisture content, and geographical location.
[0009] Moisture measurements will be taken after a bale has reached a predetermined diameter. Readings will be available as volume averaged moisture content of the bale as the bale diameter increased from the predetermined value to the terminal value.
[0010] Finished bales will be weighed before ejection from the baler. A history of recent bale weights will be stored and used to adjust future bale densities to achieve desired terminal weights and sizes. To effect varying densities, a variable fluid pressure relief valve is provided to the belt tensioner, thus the resistance of the tensioner arm to rotation away from the bale is variable.
[0011] Various forms of identification with which to associate a particular bale with its data are available. A simple alphanumeric ID may be stamped in ink or paint on the bale or wrapping. A printout of an ID and/or bale data on a slip of paper or cardstock may be dropped between the crop material and the binding material. A Radio Frequency (RF) chip or chips may be incorporated in bale wrapping, twine, or simply dropped between the crop material and the wrapper. Other electronic chips may also be used, including transponders. Bale data may be stored on the electronic media, or only an ID, which may be cross referenced in archived data.
[0012] An object of this invention is to provide volume-averaged moisture content readings of a bale beginning after a predetermined bale diameter has been achieved. Another object of this invention is to utilize bale size and weight histories to adjust a bale density to achieve both a terminal size and weight. Still another object is to provide an identification system for large round bales after they have been formed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a side elevation view of a round baler;
[0014] FIG. 2 is a partial isometric view of a round baler;
[0015] FIG. 3 is a side elevation view of a round baler with a partially formed bale;
[0016] FIG. 4 is a side elevation view of a round baler with a fully formed bale;
[0017] FIG. 5 is a rear elevation view of a round baler;
[0018] FIG. 6 is a side elevation view of a round baler pulled by an agricultural tractor;
[0019] FIG. 7 is a flow diagram of the process of the present invention;
[0020] FIG. 8 is a flow diagram of a calculation for determining a volume averaged moisture content;
[0021] FIG. 9 is a flow diagram of a calculation for determining bale dry matter;
[0022] FIG. 10 is a plot of bale weight, W, versus fluid relief valve pressure, x;
[0023] FIG. 11 is a flow diagram showing how bale weight and fluid relief valve pressure histories are used to determine a new relief valve pressure set point;
[0024] FIG. 12 is a perspective view of a cylindrical bale with an ID marking;
[0025] FIG. 13 is a perspective view of a cylindrical bale and an identifying page;
[0026] FIG. 14 is a perspective view of a cylindrical bale with a transmitter attached to the bale wrap;
[0027] FIG. 15 shows a length of twine bale wrapping material with transmitters attached at intervals;
[0028] FIG. 16 is a schematic diagram of a first bale density pressure relief/control system;
[0029] FIG. 17 is a schematic diagram of a second bale density pressure relief/control system;
[0030] FIG. 18 is a schematic diagram of a coupling between the belt tensioner and a hydraulic damper;
[0031] FIG. 19 is a flow diagram of information to an identifying page; and
[0032] FIG. 20 is a flow diagram of information to a transmitter or transponder.
DETAILED DESCRIPTION
[0033] With reference now to the various figures in which identical elements are numbered identically throughout, a description of various exemplary aspects of the present invention will now be provided. The preferred embodiments are shown in the drawings and described with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the embodiments disclosed. Any references, herein, to directions will be determined by facing in the direction of travel of the baler during normal operation.
[0034] A cylindrical bale baler 100 is shown in FIGS. 1-6 . Crop material 110 feeds into a bale forming chamber 120 where the crop material is rolled into a bale 310 . In the preferred embodiment, the baler 100 is outfitted with a tongue load cell 130 and axle load cells 510 at each end of the axle 210 . Signals from these load cells are combined to obtain a weight of the bale 310 . Additionally, at least one moisture sensor 140 is provided near a crop material inlet 150 . The moisture sensor 140 provides a signal proportional to the percentage by mass of water in the incoming crop material 110 as follows:
[0000]
M
=
Mass
of
water
in
crop
material
Total
mass
of
crop
material
[0035] In FIGS. 1 , 3 , and 4 , the baler 100 is shown lifting forage material 110 , inserting it through the inlet 150 , and forming a bale 310 . As seen especially in FIGS. 5-6 , the baler is supported at three points: by right and left side wheels 220 and by a tongue 165 . The load cells 510 engaged to the axle 210 are shown in FIG. 5 . The tongue load cell 130 is shown in FIGS. 1 , 3 , and 4 . The load cells are produced by Digistar® as PN 2.125 DA-21 Drawing no 403993. Each load cell 130 , 520 will generate a signal that is proportional to the load supported at that point. The generated signal is transferred in any manner to a controller 620 . The method of communication illustrated in the present embodiment includes a wire connection via a wiring harness 630 . Wireless communication is an alternative. The controller 620 may be mounted on/in the tractor 610 or on the baler 100 .
[0036] The large round baler is shown in perspective from the right rear corner in FIG. 2 . The moisture sensor 140 is shown from the inside. The right wheel 220 has been removed.
[0037] FIG. 6 illustrates a round baler 100 being towed by a tractor 610 in the normal fashion.
[0038] A flow diagram of the process of gathering bale data is shown in FIG. 7 . The bale 310 begins to form 700 by the introduction of crop material 110 into the baler 100 . As crop material 110 continues to be added to the bale 310 , the bale size, measured by the diameter, d, increases 705 . The baler system senses the diameter, d, 710 . The instantaneous diameter, d, is compared to a lower threshold diameter, d 0 , in a first comparator block 715 . If the instantaneous diameter, d, is less than the threshold diameter, d 0 , the bale is allowed to continue to grow 705 . If the instantaneous diameter, d, is greater than or equal to the threshold diameter, d 0 , the instantaneous diameter, d, is stored in d_ 1 and moisture readings are begun 725 . The bale diameter, d, continues to be sensed 730 and at increments of Δd 735 , the bale moisture content is volume averaged 740 (see FIG. 8 ). The bale diameter, d, is compared to the terminal diameter, d T 745 , at which addition of crop material 110 is to be terminated. When the bale diameter, d, has reached the terminal diameter, d T , the bale 310 is bound 750 , weighed 755 , and ejected 760 . Binding can be accomplished in any way known in this art such as twine 1510 (see FIG. 15 ) or netwrap. The present invention is not limited to any particular binding method or material. This process will usually be repeated until all the crop material 110 is baled, or until conditions are such that baling should be terminated, as is well known by those skilled in the art.
[0039] Moisture measurement is made possible during baling by the pad 120 on at least one side of a baler as disclosed in U.S. Pat. No. 4,812,741 to Stowell and herein incorporated by reference. FIGS. 1-4 and 6 illustrates one such moisture sensor 120 mounted on the left side panel. In the preferred embodiment, a moisture measurement is received by the controller 620 at intervals in time. As illustrated in the flow diagram of FIG. 8 , the moisture content is displayed as a number between zero and one, and is calculated as:
[0000]
M
_
N
=
∑
n
=
1
N
M
n
(
d
n
2
-
d
n
-
1
2
)
∑
n
=
1
N
(
d
n
2
-
d
n
-
1
2
)
[0040] where M n is the n th moisture reading, d n is the n th diameter, and represents the diameter at the time of the n th moisture reading, M n . The n th moisture reading, M n , may be an average of the moisture readings taken while the bale diameter increased from d n-1 to d n , or it may be a single, representative reading taken during the growth of the bale from the diameter, d n-1 , to the diameter, d n .
[0041] Knowing the moisture content of a finished bale, M, and the weight of the bale, W, the total weight of dry matter of the bale may be calculated as shown in FIG. 9 :
[0000] Dry Matter=W(1-M).
[0042] The plot in FIG. 10 shows a set of bale weights plotted against the associated manipulated variable such as a pressure relief valve setting, frequency of intermittent valve opening, or duration of intermittent valve opening. These data are used in FIG. 11 to determine a new fluid manipulated variable set point, x sp , to realize a target bale weight W target in the next bale 310 . As more bales are completed and, thus, more data are available, the curve fit is improved. Curve fits are well known in the art and include polynomial fits using linear regression analysis, conventional spline fits, including linear interpolation, and Hermite cubic splines. These and other methods may be found in any of a plethora of numerical analysis textbooks, such as Applied Numerical Analysis 2 nd ed. by Curtis F. Gerald, Addison-Wesley Publishing Company, 1980, herein incorporated by reference.
[0043] As shown in FIG. 11 , the fluid manipulated variable set point, x sp , calculated by interpolation or extrapolation from bale histories, is used to adjust the manipulated variable through which hydraulic fluid must pass as the belt tensioner 170 rotates with the growth of the bale 310 .
[0044] Systems for varying the resistance to pivoting of the belt tensioner 160 are shown in FIGS. 16 and 17 . In FIG. 16 , a hydraulic damper 1610 is connected by its shaft 1620 to the belt tensioner 160 . When the belt tensioner 160 is lowered, the hydraulic damper 1610 travels in its down direction, and hydraulic fluid passes through a check valve 1630 , which provides little resistance to flow. When the belt tensioner 160 is raised, the check valve 1630 disallows flow through itself. Hence, the hydraulic fluid must pass through an adjustable relief valve 1640 , by which the pressure at a pressure gage or transducer 1650 is limited at an upper value to the relief valve pressure set point, x sp .
[0045] Therefore, as the bale 310 grows, the belt tensioner 160 applies a pressure to the hydraulic damper 1610 . In order, then, for the belt tensioner to pivot upwardly, the pressure at the pressure gage or transducer 1650 must reach the relief valve pressure set point, x sp .
[0046] A control system to estimate the pressure relief valve setting to achieve the desired bale density applies the algorithm previously described and illustrated in FIGS. 10 and 11 provides adjustment to the relief valve 1640 by any method and means well known by those of ordinary skill in the art. For instance, a stepper motor 1660 may be used to rotate a spring-force adjustment screw 1670 , the spring force ultimately providing the resistance to flow.
[0047] A more involved pressure control system is schematically illustrated in FIG. 17 . In this embodiment, a second pressure relief valve 1710 is provided. The second pressure relief valve 1710 has a lower set point than the first pressure relief valve 1640 , and only affects the flow if a solenoid valve 1720 is open. In this embodiment, the belt tensioner 160 is permitted to rise intermittently by intermittent opening of the solenoid valve 1720 . When the solenoid valve 1720 is closed, the pressure at the pressure gage or transducer 1650 is, at most, the value at which the first relief 1640 valve is set. Hence, the density of the bale may be controlled by the frequency and/or duration of the intermittent opening of the solenoid valve 1720 , and the relief valves 1640 , 1710 do not require adjustability. In this case, the manipulated variable, x sp , of FIGS. 10 and 11 is represented by a frequency or duration of opening of the solenoid valve 1720 .
[0048] An additional embodiment is realized by measuring a value related to the belt tension in place of the manipulated variable, x sp . Such values include hydraulic system pressure, as illustrated in FIGS. 16 and 17 , or a load cell reading, as depicted in FIG. 18 which shows a load cell 1810 arranged to detect a force between the hydraulic damper 1610 and a mounting surface.
[0049] Once moisture and weight data are collected for a given bale 310 , the bale may be provided with an identification number, symbol, transponder or transmitter. As shown in FIG. 12 , an ID symbol or alphanumeric series 1210 may be painted or inked onto the outside of the bale wrap 1320 (see FIG. 13 ) on the outside of the bale 310 . In FIG. 13 , an identifying page 1310 made of paper, cardstock, plastic, fabric, or other material is inserted beneath the bale wrap 1320 . Such an identifying page 1310 may include the following data: GPS location, dry matter content, moisture content, weight, customer, operator, and baling date, as depicted in FIG. 19 . The identification may be printed to the ID page 1310 , or a transmitter or transponder may be attached to the page. A transmitter or transponder 1410 is shown in FIG. 14 attached to the bale wrap. In either of the cases where a transmitter or transponder 1410 is used, the transmitter or transponder 1410 may have the bale data, such as GPS location, dry matter content, moisture content, weight, customer, operator, and baling date, written to it, as depicted in FIG. 20 , before the bale 310 is ejected from the baler 100 . Alternatively, the transmitter or transponder 1410 may only contain a unique ID that is correlated to the data stored in the baler's control system 620 . At a later date, the ID stored on the transmitter or transponder 1410 may be read in the field and the data found in a lookup table on a personal computer, for instance. Note that both netwrap and twine 1510 may be manufactured with transmitters or transponders 1410 preattached at predetermined intervals, as shown in FIG. 15 , or the attachment may be done in the baler 100 .
[0050] With regard to the forgoing description, it is to be understood that changes may be made in detail, especially in matters of the construction materials employed and the size, shape and arrangement of the parts without departing from the scope of the present invention. As used herein, the term “netwrap” is intended to include all sheet-type wrapping materials including tackified plastic materials and untackfied plastic materials. The term “bale wrap” as used herein is intended to include sheet-type bale wrapping materials as well as twine. It is intended that these specific and depicted aspects be considered exemplary only, with a true scope and spirit of the invention be indicated by the broad meaning of the following claims. | A large round baler equipped with moisture sensing apparatus and a bale scale to improve information useful in baling and using bales. Moisture sensing begins after the bale reaches a predetermined diameter. A history of bale weights is used to estimate how much tension to apply to a belt tensioner to achieve both a target bale weight and a target bale size. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application for a utility patent claims the benefit of U.S. Provisional Application No. 60/471,784, filed May 20, 2003, which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to skateboards, and more particularly to a mounting assembly for use with swiveling axle frames (i.e., “trucks”) mounted to an underside of a skateboard.
2. Description of Related Art
A typical skateboard includes a pair of swiveling axle frames called trucks attached to an underside of a wooden deck. Each truck includes a baseplate and an axle assembly attached to the baseplate via a pair of resilient bushings and a substantially vertical bolt called a king pin. The baseplate is attached to the underside of the deck. Bearings and wheels are attached to opposite ends of the axle assemblies. The axle assembly may be rotated within a limited range of motion about a substantially vertical axis passing through the baseplate, allowing the skateboard to turn. When the axle assembly is rotated, the resilient bushings are compressed, providing stability and maneuverability.
In the typical skateboard, multiple sets of nuts and screws are used to attach the baseplate of each of the two trucks to the underside of the deck. In general, a screw is a fastener with a head and threaded shaft. It is noted that a fastener with a head and a threaded, non-tapered shaft is often called a bolt. As used herein the term “screw” refers to a fastener with a head and threaded shaft, wherein the shaft may or may not be tapered.
In attaching the baseplate of one of the trucks to the underside of the deck, each of multiple screws is passed through a hole in the deck and a hole in the baseplate, and nuts are threaded onto the threaded shafts of the screws. A wrench or socket is typically used to hold each of the nuts in place while the corresponding screw is tightened using a screwdriver or an Allen wrench.
During use of the skateboard, the screws attaching the baseplates of the trucks to the underside of the deck often tend to work loose. In this situation a wrench or socket is typically needed again to hold one or more of the nuts in place while the corresponding screws are tightened.
It would be advantageous to have an assembly for mounting a truck to an underside of a deck (e.g., a deck of a skateboard) that does not require a wrench or socket to hold each of multiple nuts in place while corresponding screws are tightened.
SUMMARY OF THE INVENTION
An assembly is disclosed for mounting a truck having multiple mounting holes passing therethrough. The assembly includes a pair of removable fasteners and a body having a pair of spaced apart holes. Each of the holes passes through the body, corresponds to a different one of the mounting holes of the truck, and is adapted to receive one of the removable fasteners. A described method for making the assembly includes providing a solid block of a hard substance. A pair of spaced apart holes are formed in the block, wherein each of the holes passes through the block and corresponds to a different one of the mounting holes of the truck. Each of the holes in the block is adapted to receive a removable fastener. A method for attaching a truck to a mating surface via the assembly is also disclosed.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawings illustrate the present invention. In such drawings:
FIG. 1 is a perspective view of one embodiment of a skateboard including two trucks attached to an underside surface of a deck via four truck mounting assemblies;
FIG. 2A is a side elevation view of the skateboard of FIG. 1 ;
FIG. 2B is a view of a first portion of FIG. 2A including one of the trucks and a corresponding one of the truck mounting assemblies;
FIG. 2C is a view of a second portion of FIG. 2A including the other truck and a corresponding one of the truck mounting assemblies;
FIG. 3 is a perspective view of the truck mounting assembly of FIG. 2B ; and
FIG. 4 is a side elevation view of the truck mounting assembly of FIG. 2B .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of one embodiment of a skateboard 10 including two trucks 12 A and 12 B attached to an underside surface 14 of a deck 16 via four truck mounting assemblies 18 A– 18 D. The truck 12 A is mounted near one end of the deck 16 , and the truck 12 B is mounted near an opposite end of the deck 16 . The truck 12 A is attached to the underside surface 14 of the deck 16 via the truck mounting assemblies 18 A and 18 B, and the truck 12 B is attached to the underside surface 14 of the deck 16 via the truck mounting assemblies 18 C and 18 D.
In the embodiment of FIG. 1 , the deck 16 has four spaced apart holes 20 near one end for mounting the truck 12 A, and another four spaced apart holes 22 near the opposite end for mounting the truck 12 B. The holes 20 and 22 extend between an upper surface 24 of the deck 16 and the underside surface 14 . As indicated in FIG. 1 , the holes 20 and 22 are spaced by a distance “D 1 ” along a width dimension “W” of the skateboard 10 , and by a distance “D 2 ” along a length dimension “BL” of the skateboard 10 . The truck 12 A has four spaced apart mounting holes corresponding to the holes 20 , and the truck 12 B has four spaced apart mounting holes corresponding to the holes 22 .
In general, and as described in more detail below, each of the truck mounting assemblies 18 A– 18 D includes two removable fasteners and a body having a pair of holes adapted to receive the fasteners. The two holes in the body correspond to two of the mounting holes in the deck 16 and the trucks 12 A and 12 B. Portions of the removable fasteners pass through the corresponding mounting holes of the deck 16 and the trucks 12 A and 12 B and are received by the holes in the bodies of the truck mounting assemblies 18 A– 18 D.
FIG. 2A is a side elevation view of the skateboard 10 of FIG. 1 . FIG. 2B is a view of a first portion of FIG. 2A including the truck 12 A and the truck mounting assembly 18 A of FIG. 1 . In the embodiment of FIG. 2B , the truck mounting assembly 18 A includes two flat head machine screws 30 A and 30 B and a body 32 A having a pair of threaded holes for receiving the screws 30 A and 30 B. The threaded holes in the body 32 A correspond to two of the four mounting holes 20 in the deck 16 and in the truck 12 A.
Each of the flat head machine screws 30 A and 30 B has a head and a threaded shaft. As shown in FIG. 2B , the threaded shafts of the screws 30 A and 30 B pass through the corresponding two of the four mounting holes 20 of the deck 16 and the truck 12 A, and are received by the threaded holes in the body 32 A of the truck mounting assembly 18 A.
In the embodiment of FIG. 2B , the truck mounting assembly 18 B of FIG. 1 also includes two flat head machine screws and a body having a pair of threaded holes for receiving the screws. The threaded holes in the body correspond to the other two of the four mounting holes 20 in the deck 16 and in the truck 12 A. The threaded shafts of the screws pass through the corresponding two of the four mounting holes 20 of the deck 16 and the truck 12 A, and are received by the threaded holes in the body.
FIG. 2C is a view of a second portion of FIG. 2A including the truck 12 B and the truck mounting assembly 18 C of FIG. 1 . In the embodiment of FIG. 2C , the truck mounting assembly 18 C includes two flat head machine screws 30 C and 30 D and a body 32 B having a pair of threaded holes for receiving the screws 30 C and 30 D. The threaded holes in the body 32 B correspond to two of the four mounting holes 22 in the deck 16 and in the truck 12 B.
Each of the flat head machine screws 30 C and 30 D has a head and a threaded shaft. As shown in FIG. 2C , the threaded shafts of the screws 30 C and 30 D pass through the corresponding two of the four mounting holes 22 of the deck 16 and the truck 12 B, and are received by the threaded holes in the body 32 B of the truck mounting assembly 18 C.
In the embodiment of FIG. 2C , the truck mounting assembly 18 D of FIG. 1 also includes two flat head machine screws and a body having a pair of threaded holes for receiving the screws. The threaded holes in the body correspond to the other two of the four mounting holes 22 in the deck 16 and in the truck 12 B. The threaded shafts of the screws pass through the corresponding two of the four mounting holes 22 of the deck 16 and the truck 12 B, and are received by the threaded holes in the body.
The threaded shafts of the screws 30 A– 30 D may or may not be tapered. As noted above, fasteners with heads and threaded, non-tapered shafts are often called bolts. Thus in general the removable fasteners of the truck mounting assemblies 18 A– 18 D of FIG. 1 may be screws or bolts. It is noted that other types of removable fasteners may also be used.
FIG. 3 is a perspective view of the truck mounting assembly 18 A of FIG. 2B , and FIG. 4 is a side elevational view thereof. In the embodiment of FIGS. 3–4 , the truck mounting assembly 18 A includes the two flat head machine screws 30 A and 30 B and the body 32 A. The heads of the screws 30 A and 30 B are labeled 40 A and 40 B, respectively, the threaded shafts of the screws 30 A and 30 B are labeled 42 A and 42 B, respectively, and the threaded holes of the body 32 A are labeled 44 A and 44 B, respectively. Each of the threaded holes 44 A and 44 B passes through the body 32 A. The threaded holes 44 A and 44 B are provided for receiving the threaded shafts 42 A and 42 B of the screws 30 A and 30 B, respectively. The threaded holes 44 A and 44 B are spaced about by the distance D 2 of FIG. 1 , and thus correspond to two of the four mounting holes 20 in the deck 16 and in the truck 12 A. (See FIGS. 1 and 2B .)
In one embodiment, the screws 30 A and 30 B include a locking material 62 that functions to lock the screws 30 A and 30 B in the threaded holes 44 A and 44 B of the body 32 A, to prevent them from inadvertently coming loose. In the present embodiment, the locking material 62 is a strip that is positioned in a slot 60 in the threaded shafts 42 A and 42 B of the screws 30 A and 30 B. The strip of locking material 62 may be Nylon® or similar material. The locking material 62 can be frictionally engaged in the slot 60 , or the screws 30 A and 30 B can be preheated so that the locking material 62 is heat bonded within the slot 60 .
While the present embodiment illustrates the locking material 62 being attached to the slot 60 in the screws 30 A and 30 B, these terms are expressly defined to include the inverse embodiment, wherein the slot 60 is in the threaded holes 44 A and 44 B of the body 32 A. Such an alternative is expressly considered within the scope of the invention, as claimed. Furthermore, other alternative embodiments could also be used. The locking material 62 could be made of another suitable material, an in another shape or embodiment. For example, the locking material 62 could also be provided by the material sold by Henkel Loctite Corporation under the trademark LOCTITE®. In this alternative embodiment, the slot 60 is not required.
In the embodiment of FIG. 3 , the body 32 A has two opposed ends 46 A and 46 B and a major length dimension “L” extending between the ends 46 A and 46 B. The threaded hole 44 A passes through the end 46 A, and the threaded hole 44 B passes through the end 46 B. The threaded hole 44 A has an axis 48 A, and the threaded hole 44 B has an axis 48 B. The axes 48 A and 48 B are substantially parallel to one another and substantially perpendicular to the length dimension L of the body 32 A. The ends 46 A and 46 B of the body 32 A are preferably rounded as shown in FIG. 3 to prevent the body 32 A from catching on external objects (e.g., curbs, handrails, ramps, etc.) during use of the skateboard 10 of FIG. 1 .
In general, the body 32 A may be formed from, or cast into, a solid block of a hard substance. The hard substance could be a metal such as aluminum, or metal alloy such as steel. The body 32 A may also be formed from a hard plastic material or a synthetic resin such as nylon, or any other material having qualities suitable for these purposes.
In the embodiment of FIGS. 3 and 4 , a portion 50 of the body 32 A between the two ends 46 A and 46 B has been removed to allow for an uneven adjacent and corresponding surface of the truck 12 A. For example, the adjacent and corresponding surface of the truck 12 A may have structures protruding therefrom, and the removed portion 50 provides clearance between the body 32 A and the structures. It is noted that in a preferred embodiment the truck mounting assemblies 18 B– 18 D of FIG. 1 are similar to the truck mounting assembly 18 A of FIG. 3 .
The truck mounting assembly 18 A of FIG. 3 may be formed by starting with a solid block of a suitable hard substance as described above. The portion 50 of the block between the two ends 46 A and 46 B may have already been removed. The pair of spaced apart holes 44 A and 44 B may be formed in the block (e.g., by drilling), wherein each of the holes passes through the block and corresponds to a different one of the mounting holes in the truck 12 A. The holes 44 A and 44 B may then be adapted to receive the screws 30 A and 30 B, respectively. For example, the holes 44 A and 44 B may be tapped to receive the screws 30 A and 30 B, respectively. FIG. 4 is a side elevation view of the truck mounting assembly 18 A of FIG. 2B .
One method of attaching the truck 12 A of FIG. 1 to the underside surface 14 of the deck 16 of FIG. 1 via the truck mounting assembly 18 A of FIGS. 3 and 4 includes positioning the truck 12 A against the underside surface 14 such that the corresponding mounting holes of the deck 16 and the truck 12 A are aligned. The body 32 A of the truck mounting assembly 18 A is positioned against the truck 12 A such that the pair of threaded holes 44 A and 44 B of the body 32 A are aligned with the corresponding mounting holes of the truck 12 A. A thread lock material is preferably applied to the threaded shafts 42 A and 42 B of the respective screws 30 A and 30 B. The threaded shafts 42 A and 42 B of the respective screws 30 A and 30 B are passed through the corresponding mounting holes of the deck 16 and the truck 12 A, and are threaded into the corresponding threaded holes 44 A and 44 B of the body 32 A. The screws 30 A and 30 B are tightened by turning the respective heads 40 A and 40 B, thereby attaching the truck 12 A to the underside surface 14 of the deck 16 .
The truck mounting assemblies 18 A– 18 D of FIG. 1 advantageously eliminate the need for a tool such as a wrench or socket to hold nuts in place while corresponding screws are tightened. For example, the threaded shafts of the two screws of one of the truck mounting assemblies 18 are preferably passed through corresponding mounting holes of a deck and a truck and threaded into the corresponding threaded holes of the body before being tightened. A first of the two screws is tightened while the other screw advantageously maintains alignment between the corresponding mounting holes of the deck and the truck and the corresponding threaded hole of the body. The other screw prevents the body from moving (i.e., spinning) while the first screw is being tightened. After the first screw is tightened, the other screw is tightened. It is also noted that the bodies of the truck mounting assemblies 18 A– 18 D may be manufactured to be advantageously lighter than the traditional steel nuts currently used to secure skateboard trucks to underside surfaces of decks.
While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims.
All patents, patent applications, and other documents and printed matter cited or referred to in this application is hereby incorporated by reference in full. | An assembly is disclosed for mounting a truck having multiple mounting holes passing therethrough. The assembly includes a pair of removable fasteners and a body having a pair of spaced apart holes. Each of the holes passes through the body, corresponds to a different one of the mounting holes of the truck, and is adapted to receive one of the removable fasteners. A described method for making the assembly includes providing a solid block of a hard substance. A pair of spaced apart holes are formed in the block, wherein each of the holes passes through the block and corresponds to a different one of the mounting holes of the truck. Each of the holes in the block is adapted to receive a removable fastener. A method for attaching a truck to a mating surface via the assembly is also disclosed. | 0 |
This disclosure is based upon French Application No. 99/15791, filed on Dec. 10, 1999 and International Application No. PCT/FR00/03463, filed Dec. 8, 2000, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to chip cards, also referred to as microcontroller cards or integrated circuit cards, and more generally open programmable data processing means able to be loaded with applications written in high-level programming languages.
An open chip card, as presented for example in the document WO 98/19237, manages several applications, for example a customer account for a shop, a bank account or an electronic purse. Some applications loaded in the card sometimes cooperate for example in order to pay for a purchase from the shop, and/or also cooperate with applications executed outside the card.
Cooperation of the applications makes it possible to establish access right rules, the applications not necessarily trusting each other. For example, the customer account managed by the shop must not appropriate data managed by the electronic purse.
In a data processing environment, management of the access control consists in associating rights of access with objects managed in the environment for each user, and checking that these access rights are complied with.
Management of the access control is shown schematically in FIG. 1 by the management of an access matrix MA. The rows in the matrix MA correspond to the rights of J objects O 1 to OJ and the columns in this matrix correspond to the rights of I users U 1 to UI. A box in the matrix at the intersection of a row and column gives access rights Dij of a user Ui to an object Oj, with 1=i=I and 1=j=J, for example a right to read from, write to or execute a file.
In practice, the matrix MA is partially empty, users often having no right over many objects, and has one of the two configurations consisting of a grouping of the access rights by row and a grouping of access rights by column.
Grouping by row amounts to associating with each object Oj an access list indicating the access rights D 1 j to DIj over the object respectively for the users U 1 to UI. In a management by lists of accesses respectively associated with objects, only the owner of an object Oj modifies the access list D 1 j to DIj associated with the object; such a modification takes place explicitly by invoking an operation on the object requiring the modification of its access list. The protection schemes based on access lists are then termed static, the modification of the access rights being complex and the users having a tendency to oversize the access rights of their objects. This runs counter to the principle of least privilege (known in English as the need to know principle) according to which access rights are granted only as needs occur.
Grouping by column associates with each user UI a list of capabilities indicating the access rights Di 1 to DiJ of the user respectively for the objects over which the user has a right. Each element (Oj, Dij) in the list is called a capability. A capability is a descriptor containing the identification of an object Oj and a definition of access rights Dij over this object. In management by capabilities, a user has a list of capabilities, a capability being able to be compared with a token giving the right to carry out an operation on the object. A capability identifies an object, but also includes a definition of the rights of access over the object. A capability can then be utilised as an object identifier which an application can pass as a parameter to another application, following a conventional programming mode, with the limitation that this identifier does not enable all operations on the designated object.
The result is that the modification of the access rights is more natural with capabilities: granting to an application or a user access rights to an object amounts to passing to it as a parameter of an operation the identity of the object in the form of a capability.
Capabilities afford greater dynamics in the management of the access control, the access rights being able to be easily exchanged between the users of the environment. However, when a user or an application must pass as a parameter a capability on an object, the user or the application must decide in advance on the rights to be transferred with the capability. An operation makes it possible in general to reduce the rights associated with the capability if necessary, before passing it as a parameter.
In the prior art, hardware implementations and software implementations of the capabilities comparable to tokens are known. The first hardware implementations were based on specialist machines in the 1970s. The addressing mechanism of these machines directly established the concept of capability: an address register serving to address an object also contains the rights of access to the object (the register containing the token). The values of these registers could be exchanged between users, but could not be forged, the hardware not permitting this. The software implementations, more recent in the 1980s, were based on enciphering for the protection of the capabilities. A capability was signed and could be created only by the owner of the object.
Thus the document U.S. Pat. No. 5,781,633 illustrates a prior technique allowing filtering, by means of capabilities, of exchanges of object references between different processes. Cryptographic methods are used to guarantee mainly the integrity of the references exchanged. Cooperation between processes is achieved by the transmission of a reduced view of an object of a process, to a second process. The filter thus created is located within the process requesting access. In a context of the “mutually mistrusting process” type, the method disclosed by the document is inoperative. This is because the process requesting access may as it pleases modify the filter which was transmitted to it and thus access methods which are however prohibited to it.
SUMMARY OF THE INVENTION
The invention more particularly concerns an access control mechanism based on a protection scheme by capabilities for managing cooperation between applications in the context of a chip card. This is because the context of the chip card is characterised by cooperations between applications not provided for in advance. It is therefore difficult to satisfy a protection scheme such as access lists where the access rights are usually pre-established. The dynamics of the scheme based on capabilities is a real need.
In current solutions in the context of the chip card, a programmer must manage capabilities “in the hand” in the code of the application, which results in a complexity in programming the protected applications.
The invention establishes a capability model in the context of the chip card in order to pursue two objectives:
Preserving the programming simplicity of the JAVA language in the context of the JAVA card. To do this, the invention aims to make the code of the applications independent of the protection. The specification of the protection policy, that is to say the management of the capabilities, is separate from the code of the applications. To allow cooperation between applications in the card, but also between applications in the card and applications outside the card. This makes it necessary to consider the operating system in the card as a secure environment and the outside of the card as a hostile environment.
Achieving these two objectives by means of the invention affords great simplicity in programming of the access control, which also reduces the cost of developing and maintaining the code, as well as the risks of error in programming the protection.
The first objective results in separating the development of the application and the management of the access rights, thus simplifying the complexity. The applications programmer programs applications without being concerned about the management of the access rights. The latter is specified separately in a simple and very intuitive formalism.
For the second objective, the invention offers a uniform model for managing access rights whilst the underlying constraints are very different when operating in the card or outside the card.
The two objectives respond to the same motivation consisting in masking the complexities inherent in the protection and in the card, and simplifying the programming of protected cooperating applications.
To achieve these objectives, the invention provides a method for generating applications characterised in that it comprises:
a step of developing an application comprising an object or several objects, without restriction of access; a step of defining the rules for access rights to the object or objects, included within the application, from a second application or from several other applications; a step of transforming the application comprising the object or objects by adding to the said application means of filtering the accesses to the said object or to the said objects in order to implement an access control method ensuring the cooperation of the applications; a step of establishing the transformed application with a data processing means.
According to a first embodiment, the data processing means is included in a chip card.
In a second embodiment, the data processing means is included in a station accepting the chip card.
In addition, according to the invention, the method of access control between two applications each cooperating by means of capabilities on objects belonging to the other application, the applications cooperating through at least one operating system, is characterised by the following step:
when one of the applications, referred to as the access-requesting application, is given access to an object belonging to another application, referred to as the access-providing application;
creating two capabilities respectively in the said access-requesting and providing applications, as objects;
the capability created in the access-providing application for limiting access to the said object, and the capability created in the access-providing application for associating the access-requesting application with the capability created in the access-providing application.
According to another aspect of the invention, during access to an object belonging to one of the applications, if a second object belonging to one of the applications has passed to this application, the method comprises the step of adding two other capabilities respectively in the applications in order to protect access to the second object.
In practice, the capability for access to the second object belonging to one of the applications has passed as a parameter or as a result to the other application.
According to a first embodiment, the applications can be established in a common data processing means, for example in a chip card or a terminal. In the case of a chip card, the verifications of the code loaded in the chip card make it possible to ensure that a capability cannot be created by a pirate programmer.
According to a second embodiment, the applications are established in two distant data processing means exchanging messages for access to distant objects. The step of adding two other capabilities can then preferably comprise the storage of a secret word in the other two capabilities, passed to these by the two capabilities previously created at the creating step, in order to validate access to the second object.
The data processing means can be included respectively in a chip card and a station accepting the chip card, or in two distinct chip cards, or in two controllers of a chip card or of a terminal.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the present invention will emerge more clearly from a reading of the following description of several preferred embodiments of the invention with reference to the corresponding accompanying drawings, in which:
FIG. 1 shows a matrix of access rights, already commented on;
FIG. 2 is a block diagram showing interfaces between a bank application and a client application;
FIG. 3 is a block diagram showing interfaces of two cooperating applications according to the invention;
FIG. 4 is a block diagram showing the establishment of filtered objects between two cooperating applications at an initial step of the method according to the invention;
FIG. 5 is a block diagram showing the addition of two filters during the call by an application of the method to a first object in another application, according to a first embodiment of the method according to the invention; and
FIG. 6 is a block diagram similar to FIG. 5 , showing the addition of two filters during the call by an application in a station invoking the method on a first object in another application in a chip card, according to a second embodiment of the invention.
DESCRIPTION OF THE INVENTION
The general concept underlying the invention is the management of capabilities, that is to say the management of elementary access rights, separate from an application.
When two applications cooperate, this cooperation follows a pre-established cooperation protocol. This cooperation protocol generally takes the form of a common interface enabling the applications to call each other. More precisely, in the context of the JAVA card, each application which wishes to call another application does so using a JAVA interface which is the one which is deemed to be provided by the application called.
With reference to the example illustrated in FIG. 2 , a bank BA, that is to say a bank application in a server, manages accounts for customers. When a customer CL connects to the bank through a Till object OG, the bank returns to him a reference Ref on its object Account in bank OC so that he can read the state of his account. Each of the bank and customer applications knows the cooperation interfaces IG and IC which are those of the Till and Account objects. The interface of the Till object IG enables the client to connect to the bank by giving his name and an access code, such as a personal identity code PIN (Personal Identity Number), and to return to it the reference Ref to the Account object OC. The interface of the Account object IC provides two methods respectively for reading and writing the balance of the account in the bank, the syntax used being that of the JAVA language.
The requirements in terms of protection in this example are presented below. The bank has all the rights over its own objects. However, it is unthinkable for the bank to grant all the rights to its customers. A customer can read the balance of his account in the bank, but must not be enabled to arbitrarily write the balance of his account. This is why, in a scheme of protection by capabilities, the bank returns, as a result of the connection operation, a capability corresponding to the reference on the Account object, but with rights which allow only the invocation of the account reading operation. The bank, which possesses all the rights over its own objects, including the Account object, creates a capability authorising only reading on this object and returns this capability to its customer.
Given that the first objective to which the invention relates is to separate the definition of the protection policy and the code of the application, the invention more particularly aims to provide rules for the exchanges of capability between the applications at the interfaces used for cooperating.
In the example shown in FIG. 2 , the supply of the access control by programming is situated at the interface of the Till object OG of the bank BA. According to a first aspect of the invention, this programming tool specifies in the interfaces used the capability which it is necessary to transfer during a parameter transmission between applications. A “protected” interface called a view is obtained, which takes the following form in JAVA language, the word “String” designating a character string object:
till view {
Customer_account connection {String name,
String pin-code);
}
Customer_account view {
Read balance ( );
NOT void write (Balance s);
}
The specification of these two views indicates that the bank BA allows only capabilities making it possible to read the balance of the accounts to leave. The bank application and customer application code therefore remains completely independent of the protection.
In more general terms, the programming tool enables each of the applications, the bank application and the personal application according to the previous example, to define its own protection rules. When an application AA has a capability to an object OB or an application AB as shown in FIG. 3 , the capability includes the protection rules defined by the application AA and grouped together in a “view” protected interface IA and the protection rules defined by the application AB and grouped together in a “view” protected interface IB. View IB has two roles: limiting the methods which the application AA can invoke the object OB and associating the view chosen by the application AB with the capabilities entering in and leaving the application AB when the object OB is invoked. The view IA fulfils only the second role for the capabilities entering into and leaving the application AA.
Thus, for each capability exchanged as a parameter of the call from the application AA to the application AB, or from the application AB to the application AA, the view IA associates a view IA′ with this capability and the view IB associates a view IB′ with this capability.
Another aspect of the invention is the integration of the programming tool in the context of the chip card. In the context of an open chip card, applications are loaded in the card. These applications, known as internal applications, interact with each other, but also with applications, known as external applications, executed in an accepting station, such as a bank terminal, a point of sale or a mobile telephone terminal, in which the card is inserted. This involves capabilities being exchanged between internal applications and external applications. The programming tool associated with the invention is put in place whilst considering the following parts of this context related to the card and the accepting station:
The JAVA Card chip card is a protected environment in the sense that the JAVA code loaded in the chip card is checked before it is actually loaded. This check aims to ensure that the code to be loaded does indeed possess certain properties of the JAVA code, principally related to security. JAVA language does not make it possible to directly manipulate addresses and therefore to arbitrarily overwrite memory, which provides a certain degree of security when various programs are stored in the same virtual JAVA machine. The location of the protection scheme of the invention takes account of this context internal to the card for the location of the capabilities in the card. The accepting station in which the card is inserted is not necessarily a protected environment. This is because the card may be inserted in any accepting station, and the accepting station may very well send fabricated data in order to deceive the card. When they are propagated outside the card, the capabilities are, according to the invention, protected by secrets which make it possible to verify the validity of the capabilities used by applications external to the card.
The invention thus relates to a programming tool for programming the management of the access rights between the cooperating applications executed in the chip card or in the accepting station. The definition of the access rights management rules is separate from the applications code, which confers greater clarity. The integration in the context of the JAVA Card chip card requires managing the capabilities differently in the chip card and outside it.
The programming tool associated with the invention specifies the rules for protecting an application separately from the code of the application.
It is assumed that a first application Aa written in JAVA language cooperates with a second application Ab also written in JAVA language through a cooperation interface Iab located in a single data processing means, for example a chip card with a specific operation system and the JAVA virtual machine:
interface Iab {
void meth1 (I1 p1);
I2 meth2 ( );
void meth3 ( );
}
The interface Iab contains the definitions of three methods meth 1 , meth 2 and meth 3 . The method meth 1 takes as a parameter p 1 a reference to an object of the interface type I 1 and returns no result. The method meth 2 takes no parameter and returns a result of the interface type I 2 . The method meth 3 takes no parameter and returns no result.
Each application then specifies protection interfaces known as views, for example the following views Iab_V, I 1 _V 1 and I 2 _V 2 :
view Iab_V{
void meth1 (I1_V1 p1);
I2_V2 meth2 ( );
NOT void meth3 ( );
}
When the application Aa has a capability on an object belonging to the application Ab, the applications Aa and Ab have the possibility of specifying the protection to be associated with this capability by associating a view with this capability.
The view Iab_V indicates that only the methods meth 1 and meth 2 are enabled. It also indicates that, if the method meth 1 is invoked, then the application, which may be an invoking application or an invoked application, protects itself by associating with the capability passed as a parameter the view I 1 _V 1 . Finally, it indicates that, if the method meth 2 is invoked, then the application protects itself by associating the view I 2 _V 2 with the capability passed as a result.
When the application Aa has a capability to an object of the application Ab, the view which the application Aa associates with this capability enables the application Aa to check the capabilities which enter and leave it, that is to say to associate a view with these capabilities. Conversely, the view which the application Ab associates with this capability enables the application Ab to check the capabilities which enter and leave it, but also to limit the methods which can be invoked on the object of the application Ab.
In general, the first exporting of an access capability from the application Ab to the other application Aa and the first importing of this capability by the other application Aa, passes through a name server. The application Ab exports the access capability by associating it with a symbolic name, such as a character string, and the application Aa imports the exported access capability by interrogating the name server with the symbolic name. The application Ab exports the capability by explicitly specifying the view which the application Ab associates therewith. The application Aa imports the exported capability by explicitly specifying the view which the application Aa associates therewith. For the application Aa as for the application Ab, the specific view indicates, for all the capability exchanges as a parameter resulting from this first exchange, the view which will be associated with these capabilities passed as a parameter.
As a result, except for this first access capability message exchange, the protection policy of each application according to the invention, that is to say the manner of exchanging the capabilities, is specified at the interfaces and is not embedded in the code of the application.
The establishment of the protection policy according to the invention is based on the concept of filter objects, “illustrating” capability objects (signifying aptitudes or abilities), which are inserted between the applications Aa and Ab. For each view defined by an application, a filter class is generated and an instance of this class is inserted at the execution in the access chain to an object whose capability is exported. As shown in FIG. 4 , if at an initial step E 0 access to an object Ob belonging to an application Ab is given to the application Aa, the view of the application Aa for the capability of this access is established by a filter Fa and the view of the application Ab for this capability is established by a filter Fb.
A filter class defines all the methods declared in the view which the filter establishes. Its role is to retransmit the method invocation to its successor in the access chain of the object. According to the example shown in FIG. 4 , the filter Fa retransmits the core to the filter Fb and the filter Fb to the object Ob.
On the other hand, a filter class establishes the protection policy defined by the view from which it is generated: the filter Fb allows only the methods enabled by the view of the application Ab to pass; and the filters Fa and Fb also establish the association of the views with the capabilities passed as a parameter. According to the above example of views, the view Iab_V indicates the association of the view I 1 _V 1 with the parameter p 1 of the method meth 1 . The association of the view with the capability is established by inserting in the access chain to the object passed as a parameter a filter object corresponding to the view.
With reference to FIG. 5 , for two applications Aa and Ab established in a chip card CP, the application Aa has at the initial step E 0 a capability towards the object Ob of the application Ab, and as in FIG. 4 , the subsequent accesses to the object Ob are protected by the filter Fa(Ob) of the application Aa and by the filter Fb(Ob) of the application Ab. At a first step E 1 , during the invocation by the application Aa of the method meth 1 on the object Ob belonging to the application Ab, that is to say during access to the object Ob, a capability on an object Oa belonging to the application Aa is passed as a parameter to the other application Ab. In order to implement the protection specified by the application Aa in its view at a second step E 2 , the filter Fa(Ob) adds the filter Fa(Oa) and passes is as a parameter of the method meth 1 in place of the direct reference to the object Oa. Likewise, to implement the protection specified by the application Ab in its view, the filter Fb(Ob) adds the filter Fb(Oa) and passes it as a parameter of method meth 1 in place of the parameter received.
The filter objects Fa(Ob) and Fb(Ob), when they are invoked, are therefore responsible for installing filter objects Fa(Oa) and Fb(Oa) for the references passed as a parameter; in other words, two capabilities illustrated by the filters Fa(Oa) and Fb(Oa) protecting access to the object Oa are added respectively in the applications Aa and Ab.
There is indicated below an example of a filter class F_Iab_V generated for the view Iab_V given previously, stated below:
view Iab_V {
void meth1 (I1_V1 p1);
I2_V2 meth2 ( );
NOT void meth3 ( );
}
For the views I 1 _V 1 and I 2 _V 2 there are created respectively filter classes F_I 1 _V 1 and F_I 2 _V 2 . It is assumed that the two applications Aa and Ab which cooperate are situated in the same JAVA environment and the following lines are also written in JAVA code, in which the key word public signifies that the following declared method is accessible for all classes, the key word void signifies that the following declared method, once executed, returns no result, and the key word new designates a class creation operation:
public class F_Iab_V implements Iab {
Iab obj;
public F_Iab_V (Iab o) {
obj = o;
}
public void meth1 (I1_V1 p1) {
obj.meth1 (new F_I1_V1 (p1));
}
public I2_V2 meth2 ( ) {
return (new F_I2_V2 (obj.methd2( )));
}
public void meth3 ( ){
// propagate an exception
}
}
The variable obj is a reference to the following entity in the access path to the object, the second filter or the real object. It is used to retransmit the call if it is authorised.
The method F_Iab_V is the constructor method of the filter class. It initialises the variable obj. When the application Aa imports a capability of the name server and wishes to associate with it the view Iab_V, it invokes the constructor method whilst passing to it as a parameter the JAVA reference received.
The method meth 1 retransmits a call which is therefore authorised, but it must associate with the capability passed as a parameter p 1 the view I 1 _V 1 . The method meth 1 creates by the operator new a filter F_I 1 _V 1 from the parameter received, and then retransmits the call by passing as a parameter p 1 the reference to the created filter.
The method meth 2 retransmits the call and receives a capability in return. It has to associate therewith the view I 2 _V 2 . The method meth 2 therefore creates an instance of the class F_I 2 _V 2 from the received parameter and returns, by means of the instruction return, the reference to the filter object created in return for the method meth 2 .
The method meth 3 does not retransmit the call since it is not authorised, and therefore propagates an exception.
The establishment when the cooperating applications Aa and Ab are both in the chip card complies with the principles described above. On the other hand, when one of the two applications is outside the card, the establishment is substantially different.
The invocations of methods between an accepting station SA, such as a terminal, and a chip card CP as shown schematically in FIG. 6 are established from messages, called application protocol data units APDU, between the accepting station SA and the chip card CP, these method calls being effected only in the direction from accepting station to the card. This is because the accepting station and the chip card, or as a variant two chip cards or two controllers and a chip card or a terminal, comprise microcontrollers constituting data processing means which are respectively master and slave and which dialogue according to an asynchronous data exchange protocol which obliges the accepting station to periodically interrogate the card so that the latter triggers in response an action in the accepting station.
As a variant, the accepting station is hereinafter replaced by another chip card, that is to say the cooperating applications Aa and Ab are established respectively in two chip cards, or more generally in two controllers.
The asynchronous data exchange protocol means that, for a call relating to an object Ob 1 from the application Aa in the accepting station SA to the application Ab in the card CP to which the object Ob 1 belongs, when there is retransmission of a call between two filter objects Fa(Ob 1 ) and Fb(Ob 1 ), relating to the object Ob 1 , this retransmission of the call takes the form of a message exchange between the accepting station and the card. An accepting station of unknown origin (a pirate) is then capable of establishing a message corresponding to a method call although it is not actually authorised to make this method call. This amounts to creating a capability, which is not possible in the protection scheme according to the invention.
In order to protect the capabilities against these attacks, secrets, such as passwords mdp, possibly based on enciphering methods, are used.
As shown in FIG. 6 , when at a first step E 3 the application Aa in the accepting station SA invokes the method meth 2 on an object Ob 1 belonging to the other application Ab in the card CP, that is to say during access to the object Ob 1 , and when at a second step E 4 the result of this method invocation returns an access capability on an object Ob 2 belonging to the application Ab, the filter Fb(Ob 1 ) creates the filter Fb(Ob 2 ) in the operating system of the card CP for this access capability. According to the invention, the filter Fb(Ob 1 ) then generates a secret, such as a password mdp, which is stored in the filter Fb(Ob 2 ) and returned to the filter Fa(Ob 1 ), which also stores it. Thus, when the filter Fa(Ob 1 ) creates the filter Fa(Ob 2 ) in the accepting station SA for the returned access capability, the filter Fa(Ob 1 ) passes to the filter Fa(Ob 2 ) the password mdp which is stored therein. In other words, access to the object Ob 2 is protected in the applications Aa and Ab respectively by two added capabilities illustrated by the filters Fa(Ob 2 ) and Fb(Ob 2 ).
When at step E 4 this capability returned as a parameter is used to invoke a method on the object Ob 2 , the call between the filters Fa(Ob 2 ) and Fb(Ob 2 ) includes the password in the message APDU, which enables the filter Fb(Ob 2 ) to check that the access capability to the object Ob 2 is valid.
The invention thus creates by naming a correspondence between an object and a capability illustrated by a filter, managed by the operating systems in the data processing means, such as an accepting station and chip card. If an object is omitted in an application, the respective operating system destroys the corresponding filter.
Thus the cooperation between an application Ab in the card with any application requires managing capabilities which may take two formats, with a password if the application of any nature is exported from the card and without a password if it remains in the card.
The above protection scheme uses references, kinds of pointers, to JAVA objects which are almost capabilities. This is because, given that JAVA language is secure, it is not possible in a JAVA program to establish a reference to an object and to invoke a method on this object. This implies that, if an object O 1 creates an object O 2 , the object O 2 is not accessible from the other objects in the JAVA environment, as long as the object O 1 does not explicitly transmit to the object O 2 a reference to these other objects. This reference transmission can take place only by the passing of a parameter when an object invokes the object O 1 or when the object O 1 invokes another object. | The invention relieves an application programmer of the responsibility for managing access rights, by providing application code that is independent of the protection in a chip card. When an application, for example in a docking station, is given access to an object pertaining to another application in a chip card, two capabilities are created respectively in the applications, as objects, to protect all subsequent accesses to the object by filtering them through the two capabilities. On accessing an object pertaining to an application, if a second object pertaining to the other application is passed on to the latter, two other capabilities are added in the applications to protect access to the second object. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a compound sound generator for an information equipment such as a portable telephone.
[0002] The compound sound generator has a speaker for converting a call signal into a sound and a receiver for converting a sound signal into a sound. The sound emitted from the receiver is heard with user's ear close to the telephone and the sound emitted from the speaker is heard even when the telephone is away. Thus the speaker generates sounds of larger volume than the receiver.
[0003] [0003]FIG. 6 is a sectional view of a conventional compound sound generator set in a case 20 of an information equipment.
[0004] The compound sound generator has a flat circular or ellipse shape and is set in a case 20 having substantially a shape of a box. In the case 20 , there is provided an annular frame 1 made of synthetic resin on which various parts of the compound sound generator are mounted, and a common yoke 2 made of a magnetic material is mounted in the frame 1 .
[0005] The yoke 2 comprises a flange 2 a formed on an upper periphery of a cylindrical portion 2 b having a bottom 2 c. An annular first magnet 3 for the speaker is secured to the underside of the flange 2 a, and a second magnet 8 for the receiver having disc shape is secured to the bottom 2 c of the yoke 2 . An annular first top plate 4 made of a magnetic material is secured to the underside of the first magnet 3 , and a second top plate 9 having a disc shape is secured to the upper surface of the second magnet 8 .
[0006] A first diaphragm 6 is secured to the underside of the frame 1 , thereby forming a relatively small back chamber 22 a between the diaphragm 6 and the yoke 2 . A second diaphragm 11 is secured to the upper surface of the frame 1 , thereby forming a relatively small back chamber 22 b between the diaphragm 11 and the yoke 2 . A first voice coil 5 and a second voice coil 10 are secured to inside surfaces of the first and second diaphragms 6 and 11 , respectively. The first diaphragm 6 and the first voice coil 5 compose a first sound production device as a speaker, and the second diaphragm 11 and the second voice coil 10 compose a second sound production device as a receiver. Protectors 7 and 12 each having a dish shape and made of a thin metal plate are secured to the underside and upper surface of the frame 1 for protecting the diaphragms 6 and 11 .
[0007] There is formed sound discharge holes 7 a formed in the protector 7 , sound discharge holes 12 a in the protector 12 .
[0008] The outer peripheries of the protector 7 and the diaphragm 6 are inserted and press fitted in an annular recess formed in a lower projection 1 a of the frame 1 . The outer peripheries of the protector 12 and the diaphragm 11 are inserted and press fitted in an annular recess formed in an upper projection 1 b of the frame 1 .
[0009] The compound sound generator is assembled into the case 20 with other parts. Cushioned annular spacers 21 are disposed between each of the protectors 7 and 12 at outer portions of the sound discharge holes 7 a and 12 a and the inner surface of the case 20 .
[0010] The external case 20 has a plurality of sound discharge holes 20 a formed in the bottom thereof and a sound discharge hole 20 b formed in the upper surface thereof.
[0011] Sound produced by the diaphragm 11 is discharged through the sound discharge holes 12 a and further outside through the sound discharge hole 20 b as shown by an arrow a . Similarly, sound produced by the diaphragm 6 is discharged through the sound discharge holes 7 a and further outside through the sound discharge holes 20 a as shown by an arrow b. Mixing of sounds emitted from the back chambers 22 a and 22 b with the sounds emitted through the sound discharge holes 7 a and 12 a are prevented. The spacers 21 are provided to enhance the air-tightness, thereby separating the sounds from one another.
[0012] In order to allow the vibration of the diaphragms and to improve the acoustic characteristics such as volume and sound quality, the back chambers 22 a and 22 b are communicated with atmosphere. Namely, as shown by arrows c and d, air in the back chamber 22 b flows through openings 1 d partially formed in the projection 1 b into the inner space of the case 20 . Air in the back chamber 22 a flows into the inner space of the case 20 through air passages 1 c formed in the shoulder of the frame 1 as shown by arrows e and f.
[0013] In the conventional compound sound generator, the back chambers 22 a and 22 b are thus communicated with the entire inner space of the case 20 . Therefor, a part of the airflow from one of the hack chambers 22 b and 22 a may flow into the other back chamber through the openings 1 d or the passages 1 c as shown by arrows g and h. Hence, when the diaphragm 6 for the speaker is vibrated, the produced sound causes the air pressure to change, thereby vibrating the diaphragm 11 for the receiver so that sound is also emitted from the receiver. If a large sound is emitted from the receiver with user's ear close to the telephone, user's ear may be hurt. In another case, telephone conversation may leak out and be heard by others through the receiver.
SUMMARY OF THE INVENTION
[0014] An object of the present invention is to provide a compound sound generator which prevents sound leaking and causing vibration of the other diaphragm.
[0015] According to the present invention, there is provided a sound generator for an information equipment comprising a case of the equipment, a frame set in the case, a speaker and receiver provided in the frame, the speaker having a first diaphragm and the receiver having a second diaphragm, a first back chamber behind the first diaphragm of the speaker and a second back chamber behind the second diaphragm of the receiver, and a baffle formed on a part of the frame for dividing the inner space of the case so as to separate the first and secondback chambers of the compound sound generator from each other.
[0016] One of the first and second back chambers of the speaker and the receiver is opened to the outside of th ca e, the other chamber is opened to the inner space of the case.
[0017] The first back chamber of the speaker is opened to the outside of the case.
[0018] The second back chamber of the receiver is opened to the outside of the case at a same surface as a surface where a sound discharge opening of the speaker is formed.
[0019] The first back chamber of the receiver is opened to the outside of the case at a surface different from a surface where a sound discharge opening of the speaker is formed.
[0020] These and other objects and features of the present invention will become more apparent from the following detailed description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0021] [0021]FIG. 1 is a sectional view showing a compound sound generator according to a first embodiment of the present invention, set in a case of a portable telephone;
[0022] [0022]FIG. 2 is a plan view showing an upper part of the compound sound generator of the first embodiment;
[0023] [0023]FIG. 3 is a sectional view taken along a line III-III of FIG. 2;
[0024] [0024]FIG. 4 is a plan view showing an underside of the compound sound generator;
[0025] [0025]FIG. 5 is a sectional view showing a second embodiment of the present invention; and
[0026] [0026]FIG. 6 is a sectional side view showing a conventional compound sound generator set in a case of a portable telephone.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] [0027]FIG. 1 is a sectional view of a compound sound generator of a first embodiment according to the present invention, set in a case of a portable telephone, FIG. 2 is a plan view of the sound generator, FIG. 3 is a sectional view taken along a line III-III of FIG. 2, and FIG. 4 is an underside view.
[0028] The compound sound generator of the present invention is set in an ellipse shaped case 50 . In the case 50 , there is provided a frame 31 made of synthetic resin, on which various parts of the sound generator are mounted, and a common yoke 32 made of a magnetic material is mounted in the frame 31 .
[0029] The yoke 32 comprises a flange 32 a formed on an upper periphery of a cylindrical portion 32 b having a bottom 32 c. An annular first magnet 33 is secured to the underside of the flange 32 a with an adhesive, and a second magnet 38 having disc shape is secured to the bottom 32 c of the yoke 32 . An annular first top plate 34 made of a magnetic material is secured to the underside of the first magnet 33 , and a second top plate 39 having a disc shape is secured to the upper surface of the second magnet 38 .
[0030] A first diaphragm 36 is secured to the underside of the frame 31 , thereby to form a back chamber 43 a between the diaphragm 36 and the yoke 32 . A second diaphragm 41 is secured to the upper surface of the frame 31 , thereby to form a back chamber 43 b betwe n the diaphragm 41 and the yok 32 . The first diaphragm has a larger size approximate to the protector 37 , and the second diaphragm has a smaller size approximate to the protector 42 . A first voice coil 35 and a second voice coil 40 are secured to inside surfaces of the first and second diaphragms 36 and 41 , respectively. The first diaphragm 36 and the first voice coil 35 compose a first sound production device as a speaker, and the second diaphragm 41 and the second voice coil 40 compose a second sound production device as a receiver. First and second protectors 37 and 42 , each having a dish shape and made of a thin metal plate, are secured to the underside and upper surface of the frame 31 for protecting the diaphragms 36 and 41 .
[0031] The first protector 37 has a sound discharge holes 37 a so as to discharge sounds generated by the first diaphragm 36 in the downward direction. The second protector 42 has sound discharge holes 42 a so as to discharge sounds generated by the second diaphragm 41 in the upward direction.
[0032] The frame 31 has a lower projection 31 a and an upper projection 31 b. In the lower projection 31 a, an annular recess is formed so that the outer peripheries of the protector 37 and the diaphragm 36 are inserted and press fitted therein. In the upper projection 31 b, an annular recess is formed so that the outer peripheries of the protector 42 and the diaphragm 41 are inserted and press fitted therein. In a shoulder 31 c of the frame 31 , an air passage 31 d is formed. An opening 31 e is formed in the lower portion of the upper projection 31 b at the opposite side of the air passage 31 d.
[0033] In accordance with the present invention, the frame 31 further has an integrally formed U-shaped baffle 52 so as to surround the opening 31 e as shown in FIG. 2. The baffle extends vertically through the entire inner height of the case 50 , thereby forming an air passage 53 as shown in FIG. 1.
[0034] The sound generator is assembled into the case 50 with other parts. Annular spacers 51 are disposed between each of the protectors 37 and 42 and the case 50 at the outer portions of the sound discharge holes 37 a and 42 a, Upper and lower spacers 54 are interposed between the upper and lower ends of the baffle 52 and the case 50 .
[0035] The case 50 has a plurality of sound discharge holes 50 a formed in the bottom thereof at a portion inside the spacers 51 and a sound discharge hole 50 b formed in the upper surface thereof. Another sound discharge hole 50 c is formed in the bottom opposing the lower end of the air passage 53 .
[0036] Referring to FIG. 2, metal terminal electrodes 45 are molded in the frame 31 . Grooves 44 a and 44 b are formed in the frame 31 at a position lower than the protection 31 b and at a position upper than the projection 31 a, respectively, so as to allow the end portions of the voice coils 35 and 40 to be connected to the electrodes.
[0037] Sounds generated by the diaphragm 41 are discharged through the sound discharge holes 42 a of the protector 42 and further outside of the case 50 through the sound discharge hole 50 b as shown by the arrow a . Similarly, sounds generated by the diaphragm 36 are discharged through, the sound discharge holes 37 a of the protector 37 and further outside the case through sound discharge holes 50 a as shown by the arrow b. As shown by the arrow c, air in the back chamber 43 b flows through the opening 31 e formed in the projection 31 b into the air passage 53 and further out of the case 50 through the opening 50 c as shown by an arrow i. Air in the back chamber 43 a flows into the inner space of the case 50 through air passages 31 d formed in the shoulder 31 c of the frame 31 as shown by the arrows e and f. Namely, the back chambers 43 a and 43 b are not communicated with each other so that the air in one of the chambers is prevented from entering the other chamber through the space in the case 50 . It is assumed that the vibrations of the diaphragms are not affected by the sounds outside the case.
[0038] Thus, in the present invention, the sound from the speaker is only emitted from the sound discharge holes 50 a and the sound from the receiver is only emitted from the sound discharge hole 50 b. Hence the problems of injury to the ear and leaking of conversation do not occur.
[0039] [0039]FIG. 5 shows a second embodiment of the present invention wherein the frame 31 has a horizontal baffle 52 a integral thereto. In the present embodiment, a sound discharge hole 50 d is formed in the side wall of the case 50 so that the back chamber 43 b is communicated with the atmosphere through the opening 31 e and the discharge hole 50 d as shown by an arrow j. The present embodiment provides a wider range of design choice in manufacturing the compound sound generator.
[0040] The present invention is not limited to the embodiments described above. For example, the back chamber of the receiver may be communicated with a sealed space of a predetermined volume formed in the case instead of with the atmosphere. Alternatively, the back chamber of the speaker may be communicated with the atmosphere. Various modifications of structure of the baffle and air passage and acoustic separating method and the material thereof are further possible.
[0041] The present invention provides a compound sound generator where the back chambers of each of the speaker and the receiver are effectively separated from each other by a simple and inexpensive means of providing a baffle. Accordingly, injury to the ear and leaking of conversation are prevented.
[0042] While the invention has been described in conjunction with preferred specific embodiment thereof, it will be understood that this description is intended to illustrate and not limit the scope of the invention, which is defined by the following claims. | A case of the information equipment is provided for setting various parts in. A speaker and receiver are provided in the frame. A first back chamber is formed in the speaker and a secondback chamber is formed in the receiver. A baffle is formed on a part of the frame for dividing the inner space of the case so as to separate the first and second back chambers from each other. | 7 |
TECHNICAL FIELD
The present invention relates to a fan blade for an aero engine, and is concerned particularly with a fan blade having a winglet.
BACKGROUND
In a ducted fan, such as is commonly used in an aero engine for example, a fan is disposed coaxially within a duct and is driven to rotate within the duct to direct air rearwardly through the duct.
For efficiency and stability of the fan blades, the gaps between the tips of the blades and the inner casing of the duct, within which the fan rotates, must be kept to a minimum so as to minimise the leakage of air around the tips of the blades.
For a conventional fan blade, in order to eliminate damage to the blade and ultimately maximise its longevity, there would be a sizeable clearance gap between the blade tip and the fan case, to ensure that even under heavy manoeuvre loading there would be no contact with the inner surface of the fan case. However, an increased clearance gives a large specific fuel consumption penalty due to aerodynamic losses at the tip of the fan blade. Tip leakage is caused by the working fluid (i.e. air) tending to migrate from the concave or “pressure” surface to the convex or “suction” surface of the aerofoil through the gap between the tip of the blade and the stationary casing. The leakage occurs because of a pressure differential, and leakage causes flow disturbances over a large proportion of the aerofoil surface. These flow disturbances across the blade surface also cause a reduction in efficiency of the blade which results in a reduction of performance of the fan system.
Such flow disturbances also contribute to noise, and increasingly noise legislation places severe constraints upon engine design, with a key component of engine noise being that generated by the fan itself.
For previously considered fan systems, a so called “tip rubbing” solution is used in which the duct casing is provided with a lining comprising a sacrificial abradable layer which in certain operating conditions is designed to be cut or rubbed away by the blade tips as the fan blade passes the surface of the fan casing. The liner is sometimes referred to as a fan track liner (FTL). This approach helps to minimise the gap between the static casing and the rotating blade, thereby reducing tip leakage. However, this approach can only provide optimal sealing at maximum speed, when the blades are at maximum elongation, and not at cruise speeds where in a long haul flight the engine will spend most of its time and use most of its fuel.
For aerofoils such as wings, it is known that winglets improve the aerodynamic performance of the wing and hence of the aircraft. A winglet is typically a relatively small wing surface disposed on the tip of the main wing at right angles to the spanwise direction of the wing. The use of winglets at the tip of the wing reduces wing vortices and also noise, and lengthens the effective wing.
Previously considered winglet systems include those employed in turbine blades. Adaptation of such winglet designs for use with fan blades would require major changes to the fan architecture. More mass would be located at the tip of the fan blade, again requiring considerable redesign of the blade itself. Although turbine systems do rotate at similar rotational speeds to fans they are much smaller and much lighter. The forces on a similar system for a fan blade would be very large due to the extra mass and much greater radius of the fan blade as compared with a turbine blade. For a fan blade of composite material these problems would occur to a greater degree than with conventional metallic blades. The addition of further components to the blade would also affect stress concentrations and lead to potential initiation sites for damage and delamination within the composite fan blade.
Winglet systems have also be previously considered for cooling fans. However, these are low speed, low mass systems usually of plastic material and typically with a large clearance between the fan and its casing. An injection moulded plastic fan would be impractical and unworkable for a large turbofan engine since such blades have low strength, low integrity, low fatigue life and poor impact resistance. They also suffer unduly from “creep”—i.e. elongation under centrifugal forces.
Previously considered winglet systems, if used in fan systems, would also likely be uncontained by current so called “containment systems”. These are typically structures which are employed in the fan casing to contain fragments of detached fan which may, in very exceptional circumstances, be released for example when a fan blade is struck by an object, such as a bird, leading to a so called fan blade off (FBO) event. The width of the tip, increased by the presence of a winglet, would reduce the pressure energy of the fan blade fragment significantly, which could then prevent the fan blade fragment from penetrating the liner of the casing, which is necessary for it to be retained and contained by the fan case.
SUMMARY
The present invention has been devised with the foregoing in mind, and embodiments of the invention aim to address at least some of the aforementioned problems.
The present invention is defined in the attached independent claims to which reference should now be made. Further, preferred features may be found in the subclaims appended thereto.
According to the invention there is provided a fan blade for a turbofan aero engine, the fan blade comprising a blade body including a root for engagement with a rotor, and a tip, wherein the tip is provided with a winglet.
The winglet may extend transversely with respect to the span-wise direction of the blade body.
The winglet preferably extends towards a suction side of the blade body in use.
Alternatively or additionally the winglet may extend towards a pressure side of the blade body in use.
The winglet may be substantially planar or may be curved.
In a preferred arrangement the winglet is frangible.
The winglet may be arranged to become detached from the blade body upon collision with a casing liner of an aero engine.
The winglet may be shaped so as to initiate disintegration of the blade body upon collision with a casing liner of an aero engine.
The winglet may be integrally formed with the fan blade body.
Alternatively the winglet may be attached to the fan blade body by attachment means.
The fan blade body and winglet may both be of composite material.
The fan blade body and winglet may both be of metal.
One of the fan blade body and winglet may be of composite material and the other of the fan blade body and winglet may be of metal.
The invention also includes a turbofan aero engine comprising a fan blade according to any statement herein.
The invention may include any combination of the features and limitations referred to herein, except combinations of such features as are mutually exclusive.
Preferred embodiments of the present invention will now be described by way of example only with reference to the accompanying diagrammatic drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically a fan blade rotating within a fan case of an aero engine, in accordance with an embodiment of the present invention;
FIG. 2 shows schematically a method of attaching a winglet to a fan blade;
FIG. 3 shows schematically an alternative embodiment of fan blade and winglet, in accordance with the invention;
FIG. 4 shows schematically a further alternative embodiment of fan blade and winglet in accordance with the invention;
FIG. 5 is a perspective view of the fan blade and winglet of FIG. 1 ;
FIGS. 6 a and 6 b show details of alternative designs of winglet trailing edge according to embodiments of the invention;
FIGS. 7 a - 7 c represent schematically a sequence of steps in a fan blade off (FBO) event;
FIGS. 8 a - 8 c represent schematically a sequence of steps of a fan blade off (FBO) event according to an alternative embodiment of blade and winglet; and
FIG. 9 shows schematically a section through a blade tip according to a still further embodiment of the present invention.
DETAILED DESCRIPTION
Turning to FIG. 1 , this shows generally at 10 a fan blade, which can be of a composite material such as a fibre-reinforced material, or else can be of metal alloy, such as titanium alloy. The fan blade is attached at its root to a rotor (not shown) of the fan and rotates in the direction of arrow A within the fan case 12 of an aero engine. At the tip of the blade 10 is a winglet 14 extending towards the suction side 10 a of the blade 10 . This gives the benefit of improved blade performance, potentially higher aerodynamic efficiency, lower tip pressure losses and improvements in fan noise. The winglet can be combined with a metallic tip protection feature (not shown) in order to allow a composite fan blade to rub against an abradable fan track liner. A sharp metallic cutting edge can be incorporated into the winglet to assist in the abrading of the abradable liner.
The winglet could be applied to either a metallic or a composite fan blade. In the case of a composite fan blade the winglet could be manufactured integrally as part of the layup of the blade. Alternatively, if the blade is of a metallic material the winglet can be incorporated as part of the forming and assembly process of the blade.
If the winglet is not manufactured integrally with the blade, it can be bonded, welded, brazed to the blade or mechanically attached by rivets, bolts, screws or other such fixings including a combination of these. These methods other than brazing or welding would allow the winglet to be of a different material to the blade and this could then allow the winglet to be optimised for low mass, high stiffness, abradability and/or strength.
FIG. 2 shows schematically one method of attaching the winglet 14 to the blade 10 . In this example the winglet 14 has a generally T-shaped cross section including a root 14 a which is inserted into a correspondingly shaped groove in the blade tip, and a wing portion 14 b which extends towards both the pressure side 10 b and suction side 10 a of the blade 10 . The winglet is attached by a pair of rivets 16 to the blade 10 . If a tip-rubbing solution is required then the winglet tip can be used to provide protection to the composite blade, thereby minimising the tip clearance to improve performance, whilst improving the efficiency of the blade system.
FIGS. 3 and 4 shows schematically alternative designs of winglet, in which the wing portion 14 b of the winglet 14 is curved. In FIG. 3 , the winglet 14 extends only towards the suction side 10 a of the blade 10 , whereas in FIG. 4 the winglet 14 extends towards both the pressure 10 a and suction 10 b sides of the blade 10 .
FIG. 5 shows the preferred arrangement of the blade 10 of FIG. 1 , in perspective view. The blade 10 has pressure 10 b and suction 10 a faces and a root 10 c for locating in a rotor (not shown) of a fan. The winglet 14 extends towards the suction side 10 a of the blade 10 .
The winglet edge can either be smooth and perpendicular to the flow, or else can be concave or convex, smooth, serrated or saw-tooth in profile. These alternatives in the winglet trailing edge can change the boundary layer flow over the trailing edge and the surface of the blade, potentially allowing the profile of the flow to be optimised over the blade. The change in boundary layer flow could also effect a reduction in the noise generated by the system and also improve the efficiency of the system.
FIGS. 6 a and 6 b depict respectively smooth profile and serrated profile trailing edges of the winglet 14 .
The winglet acts as a barrier to stop tip leakage across the gap between the tip of the blade and the static casing, shroud or liner surrounding it. The pressure drop across the tip is spread across a greater distance and slows the forcing effect of the leakage. It also reduces the formation of tip vortices which are a major cause of the noise generated by the fan blade in use. Existing case treatments to reduce tip leakage and turbulence, such as pump grooves, are still applicable and may be used with the embodiments described herein.
In order to allow the blade to penetrate the casing in an FBO event, the winglet can be made to be frangible. A metallic blade could have a composite winglet that is stiff but brittle, and would break off as an FBO impact begins to occur. The winglet would be designed to impact the fan case first and to break off to allow the main body of the blade fragment to penetrate the fan track liner. A plane of weakness or a stress concentration can be incorporated into the design; this may be particularly useful for metallic blades with metallic winglets.
FIGS. 7 a - 7 c depict a sequence of steps in an FBO event. Blade motion is radially outwards in the direction of arrow B. The winglet ( 14 ) impacts the fan case ( 12 ) first (see FIG. 7 a ), then the force of the fan case exerted on the winglet causes it to bend and fail by brittle fracture (if it is of a composite material) or bend and break through a plane of weakness or a stress concentration (if metallic) (see FIG. 7 b ). Now the blade tip is of a lower area, so the pressure energy available is much higher and the blade will be able to penetrate the liner (see FIG. 7 c ).
The inherent properties of composite components could be exploited to facilitate the desired break-up behaviour. For example, if a composite winglet is combined with a composite blade, then when the winglet hits the casing it is essentially an impact in the out-of-plane direction, which is generally a direction in which composite materials are relatively weak. When the blade hits the casing, by contrast, it is essentially an impact in an in-plane direction, in which composite materials are relatively strong. The tendency will therefore be for the winglet to break, but for the blade to remain intact so that it can penetrate the liner.
Alternatively, for a composite blade, the winglet and the winglet attachment, such as the root 14 a of the winglet, can be made to enhance the process of break-up of the blade itself. The shape of the root 14 a is such that upon impact the root is driven into the end of the blade thereby creating a delamination crack which propagates along the blade length and assists in the crushing and shedding of the local composite material.
If a frangible winglet is not used, then for a composite blade, rather than retain the blade it is desirable to break it into small, low-energy debris. The winglet can act as an initiator of this process in order to achieve break-up of the blade into the smallest possible fragments. This allows a hard wall containing system to be used as the fan track liner. In such a system, no part of the fan blade will penetrate the fan track liner, but the whole blade is contained within it. In order that the blade fragments do not cause damage to components downstream, it is generally necessary to ensure these fragments are as small as possible.
For a composite blade with metal components the carbon components must be broken into the smallest possible fragments and the metallic components must be retained or contained by the containment system. The fan blade tip incorporating the winglet can be used as a damage initiator (see FIG. 8 a ).
Upon impact with the case (see FIG. 8 b ) the metallic tip 14 a of the winglet bends and deflects the blade plus any extra metalwork. Force acting along the radial axis pushes the tip into the composite blade causing it to break up, and inducing crushing of its composite structure.
Referring to FIG. 8 c , the shaped metallic tip of the winglet forces the majority of the composite material at the tip of the blade to splay out, causing further break-up of the blade and further movement of the broken material in the region shown in circle C.
The initiator can have multiple, vertical elements 14 d in order to delaminate the blade at multiple sites, yet provide more resistance to axial impact whilst allowing radial impact to cause delamination, as is shown in FIG. 9 .
The casing and winglet surface features can be utilised to reduce turbulence, reduce leakage and also to provide pumping features.
The blade structures incorporating winglets as described above provide a number of advantages as compared with previously considered blades.
For example, it is known that winglets improve the effective efficiency of an aerofoil by acting as a barrier to reduce tip leakage. The known advantages of winglets can be used in the context of a turbofan blade to improve specific fuel consumption and fuel burn, and reduce fan system noise.
Furthermore, avoiding the necessity for a tip-rubbing solution can offer reduced damage to composite or hybrid blade tips during abnormal operating conditions which leads to fewer repairs and fewer replacement blades and therefore amounts to lower engine operating costs.
If the winglet is co-moulded or laid up as part of the manufacture of the composite blade it can reduce requirements for further fittings and fixtures and therefore assist in the goal of reducing the weight of the system.
A winglet system as described above can allow clearances to be built into the components at the manufacturing stage which provides for easier assembly. The currently used fan track liners need to be machined once they are actually on the engine in order to ensure a good fit with the blade system. The requirement for this is removed if a greater clearance can be allowed.
Installing with a greater clearance also provides for an easier fitment of the fan blades themselves.
A frangible winglet system allows the blades to be retained using existing fan case features and containment structures. The embodiments described above are compatible with a hardwall containment system.
Finally, winglets can be used to provide the blade tip with greater beam strength, which is helpful in resisting the impacts of large birds. | A fan blade ( 10 ) for a turbofan aero engine comprises a blade body including a root ( 10 c ) for engagement with a rotor, and a tip, wherein the tip is provided with a winglet ( 14 ). | 5 |
This is a Divisional of prior application Ser. No.: 09/413,225, filed Oct. 5, 1999 now abandoned.
FIELD OF THE INVENTION
The present invention relates, in general, to ultrasonic surgical clamping instruments and, more particularly, to a multifunctional curved shears blade for an ultrasonic surgical clamping instrument.
BACKGROUND OF THE INVENTION
This application is related to the following copending patent applications: application Ser. No. 08/948,625 filed Oct. 10, 1997 now U.S. Pat. No. 6,068,647; application Ser. No. 08/949,133 filed Oct. 10, 1997 now U.S. Pat. No. 5,947,984; application Ser. No. 09/106,686 filed Jun. 29, 1998 now abandoned; application Ser. No. 09/337,077 filed Jun. 21, 1999 now U.S. Pat. No. 6,214,023; application Ser. No. 09/412,557 now abandoned; application Ser. No. 09/412,996; and application Ser. No. 09/412,257 now U.S. Pat. No. 6,325,811 which are hereby incorporated herein by reference.
Ultrasonic instruments, including both hollow core and solid core instruments, are used for the safe and effective treatment of many medical conditions. Ultrasonic instruments, and particularly solid core ultrasonic instruments, are advantageous because they may be used to cut and/or coagulate organic tissue using energy in the form of mechanical vibrations transmitted to a surgical end-effector at ultrasonic frequencies. Ultrasonic vibrations, when transmitted to organic tissue at suitable energy levels and using a suitable end-effector, may be used to cut, dissect, or cauterize tissue. Ultrasonic instruments utilizing solid core technology are particularly advantageous because of the amount of ultrasonic energy that may be transmitted from the ultrasonic transducer through the waveguide to the surgical end-effector. Such instruments are particularly suited for use in minimally invasive procedures, such as endoscopic or laparoscopic procedures, wherein the end-effector is passed through a trocar to reach the surgical site.
Ultrasonic vibration is induced in the surgical end-effector by, for example, electrically exciting a transducer which may be constructed of one or more piezoelectric or magnetostrictive elements in the instrument hand piece. Vibrations generated by the transducer section are transmitted to the surgical end-effector via an ultrasonic waveguide extending from the transducer section to the surgical end-effector.
Solid core ultrasonic surgical instruments may be divided into two types, single element end-effector devices and multiple-element end-effector. Single element end-effector devices include instruments such as scalpels, and ball coagulators, see, for example, U.S. Pat. No. 5,263,957. While such instruments as disclosed in U.S. Pat. No. 5,263,957 have been found eminently satisfactory, there are limitations with respect to their use, as well as the use of other ultrasonic surgical instruments. For example, single-element end-effector instruments have limited ability to apply blade-to-tissue pressure when the tissue is soft and loosely supported. Substantial pressure is necessary to effectively couple ultrasonic energy to the tissue. This inability to grasp the tissue results in a further inability to fully coapt tissue surfaces while applying ultrasonic energy, leading to less-than-desired hemostasis and tissue joining.
The use of multiple-element end-effectors such as clamping coagulators include a mechanism to press tissue against an ultrasonic blade, that can overcome these deficiencies. A clamp mechanism disclosed as useful in an ultrasonic surgical device has been described in U.S. Pat. Nos. 3,636,943 and 3,862,630 to Balamuth. Generally, however, the Balamuth device, as disclosed in those patents, does not coagulate and cut sufficiently fast, and lacks versatility in that it cannot be used to cut/coagulate without the clamp because access to the blade is blocked by the clamp.
Ultrasonic clamp coagulators such as, for example, those disclosed in U.S. Pat. Nos. 5,322,055 and 5,893,835 provide an improved ultrasonic surgical instrument for cutting/coagulating tissue, particularly loose and unsupported tissue, wherein the ultrasonic blade is employed in conjunction with a clamp for applying a compressive or biasing force to the tissue, whereby faster coagulation and cutting of the tissue, with less attenuation of blade motion, are achieved.
Improvements in technology of curved ultrasonic instruments such as described in U.S. patent application Ser. No. 09/106,686 previously incorporated herein by reference, have created needs for improvements in other aspects of curved clamp coagulators. For example, U.S. Pat. No. 5,873,873 describes an ultrasonic clamp coagulating instrument having an end-effector including a clamp arm comprising a tissue pad. In the configuration shown in U.S. Pat. No. 5,873,873 the clamp arm and tissue pad are straight.
The shape of an ultrasonic surgical blade or end-effector used in a clamp coagulator device defines at least four important aspects of the instrument. These are: (1) the visibility of the end-effector and its relative position in the surgical field, (2) the ability of the end-effector to access or approach targeted tissue, (3) the manner in which ultrasonic energy is coupled to tissue for cutting and coagulation, and (4) the manner in which tissue can be manipulated with the ultrasonically inactive end-effector. It would be advantageous to provide an improved ultrasonic clamp coagulator optimizing these four aspects of the instrument.
Idemoto, et al. discloses a surgical ultrasonic horn used in a surgical operation comprising a horn body and an end plate portion. Cutting portions are provided on an edge and an end of the end portion. A passage for irrigation solution extends in the horn body and the end plate portion. At least one bore opens at the cutting portions by a jet angle of 5.degree. to 90.degree. in respect of a plane of the end plate portion. The irrigation solution passage communicates with the bore, thereby the irrigation solution is sprayed therethrough.
It would be advantageous to deliver ultrasonic power more uniformly to clamped tissue than predicate devices. It would also be advantageous to provide for improved visibility of the end-effector so that a surgeon can verify that the blade extends across the structure being cut/coagulated. It would also be advantageous to provide for improved tissue access with the end-effector more closely replicating the curvature of biological structures. It would also be advantageous to provide a multitude of edges and surfaces, designed to provide a multitude of tissue effects: clamped coagulation, clamped cutting, grasping, back-cutting, dissection, spot coagulation, tip penetration and tip scoring. It would also be advantageous to provide an ultrasonic clamp coagulator that self-tensions tissue during back-cutting, utilizing a slight hook-like or wedge-like action. It would further be advantageous to provide a multifunctional ultrasonic surgical blade using unique geometric features to include: compatibility with a clamping member, sharp features for cutting, curvature for access and visibility, and a more uniform delivery of ultrasonic power than predicate devices. The present invention provides these features and improvements as described below.
SUMMARY OF THE INVENTION
Disclosed is an ultrasonic surgical instrument that combines end-effector geometry to best affect the multiple functions of a shears-type configuration. The shape of the blade is characterized by a radiused cut to form a curved and potentially tapered geometry. This cut creates a curved surface including, in one embodiment, a concave surface and a convex surface. The convex surface transitions into a short, straight, flat surface. The length of this straight portion affects, in part, the acoustic balancing of the transverse motion induced by the curved shape. Relative to straight blade tips, the tip curvature of the present design provides improved visibility of the transection site and improved access to targeted tissues. In one embodiment, an ultrasonic blade is described comprising a broad edge and a narrow edge. The broad edge opposes the narrow edge along a vertical plane, wherein the narrow edge is defined by the intersection of a first surface and a second surface, wherein the first surface is concave.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to organization and methods of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates an ultrasonic surgical system including a plan view of an ultrasonic generator, a sectioned plan view of an ultrasonic transducer, and a partially sectioned plan view of a clamp coagulator in accordance with the present invention;
FIG. 2A is an exploded perspective view of a portion of a clamp coagulator in accordance with the present invention;
FIG. 2B is an exploded perspective view of a portion of a clamp coagulator in accordance with the present invention;
FIG. 3 is a partially sectioned plan view of a clamp coagulator in accordance with the present invention with the clamp arm assembly shown in an open position;
FIG. 4 is a partially sectioned plan view of a clamp coagulator in accordance with the present invention with the clamp arm assembly shown in a closed position;
FIG. 5 is a side view of a collar cap of the clamp coagulator;
FIG. 6 is a front view of a collar cap of the clamp coagulator;
FIG. 7 is a side view of a force limiting spring of the clamp coagulator;
FIG. 8 is a front view of a force limiting spring of the clamp coagulator;
FIG. 9 is a side view of a washer of the clamp coagulator;
FIG. 10 is a front view of a washer of the clamp coagulator;
FIG. 11 is a side view of a tubular collar of the clamp coagulator;
FIG. 12 is a rear view of a tubular collar of the clamp coagulator;
FIG. 13 is a front view of a tubular collar of the clamp coagulator;
FIG. 14 is a side view of an inner knob of the clamp coagulator;
FIG. 15 is a front view of an inner knob of the clamp coagulator;
FIG. 16 is a bottom view of an inner knob of the clamp coagulator;
FIG. 17 is a rear view of an outer knob of the clamp coagulator;
FIG. 18 is a top view of an outer knob of the clamp coagulator;
FIG. 19 is a top view of a yoke of the clamp coagulator;
FIG. 20 is a side view of a yoke of the clamp coagulator;
FIG. 21 is a front view of a yoke of the clamp coagulator;
FIG. 22 is a perspective view of a yoke of the clamp coagulator;
FIG. 23 is a perspective view of an end-effector of the clamp coagulator;
FIG. 24 is a top perspective view of a clamp arm of the camp coagulator;
FIG. 25 is a top view of an end-effector of the clamp coagulator;
FIG. 26 is a side view of an end-effector of the clamp coagulator with the clamp arm open;
FIG. 27 is a top view of a tissue pad of the clamp coagulator;
FIG. 28 is a side view of a tissue pad of the clamp coagulator;
FIG. 29 is a front view of a tissue pad of the clamp coagulator;
FIG. 30 is a perspective view of a tissue pad of the clamp coagulator;
FIG. 31 is a bottom perspective view of a clamp arm of the clamp coagulator;
FIG. 32 is a first cross-sectional view of the clamp arm illustrated in FIG. 31;
FIG. 33 is a second cross-sectional view of the clamp arm illustrated in FIG. 31;
FIG. 34 is a bottom plan view of a blade of the clamp coagulator;
FIG. 35 is a cross-sectional view of a blade of the clamp coagulator;
FIG. 35A is a cross-sectional view of an alternate embodiment of a blade of the clamp coagulator; and
FIG. 36 is a perspective view of an end-effector of the clamp coagulator.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in combination with ultrasonic instruments as described herein. Such description is exemplary only, and is not intended to limit the scope and applications of the invention. For example, the invention is useful in combination with a multitude of ultrasonic instruments including those described in, for example, U.S. Pat. Nos. 5,938,633; 5,935,144; 5,944,737; 5,322,055, 5,630,420; and 5,449,370.
FIG. 1 illustrates ultrasonic system 10 comprising an ultrasonic signal generator 15 with a sandwich type ultrasonic transducer 82 , hand piece housing 20 , and clamp coagulator 120 in accordance with the present invention. Clamp coagulator 120 may be used for open or laparoscopic surgery. The ultrasonic transducer 82 , which is known as a “Langevin stack”, generally includes a transduction portion 90 , a first resonator or end-bell 92 , and a second resonator or fore-bell 94 , and ancillary components. The ultrasonic transducer 82 is preferably an integral number of one-half system wavelengths (nλ/2) in length as will be described in more detail later. An acoustic assembly 80 includes the ultrasonic transducer 82 , mount 36 , velocity transformer 64 and surface 95 .
The distal end of end-bell 92 is connected to the proximal end of transduction portion 90 , and the proximal end of fore-bell 94 is connected to the distal end of transduction portion 90 . Fore-bell 94 and end-bell 92 have a length determined by a number of variables, including the thickness of the transduction portion 90 , the density and modulus of elasticity of the material used to manufacture end-bell 92 and fore-bell 94 , and the resonant frequency of the ultrasonic transducer 82 . The fore-bell 94 may be tapered inwardly from its proximal end to its distal end to amplify the ultrasonic vibration amplitude as velocity transformer 64 , or alternately may have no amplification.
The piezoelectric elements 100 may be fabricated from any suitable material, such as, for example, lead zirconate-titanate, lead meta-niobate, lead titanate, or other piezoelectric crystal material. Each of the positive electrodes 96 , negative electrodes 98 , and piezoelectric elements 100 has a bore extending through the center. The positive and negative electrodes 96 and 98 are electrically coupled to wires 102 and 104 , respectively. Wires 102 and 104 are encased within cable 25 and electrically connectable to ultrasonic signal generator 15 of ultrasonic system 10 .
Ultrasonic transducer 82 of the acoustic assembly 80 converts the electrical signal from ultrasonic signal generator 15 into mechanical energy that results in primarily longitudinal vibratory motion of the ultrasonic transducer 82 and an end-effector 180 at ultrasonic frequencies. When the acoustic assembly 80 is energized, a vibratory motion standing wave is generated through the acoustic assembly 80 . The amplitude of the vibratory motion at any point along the acoustic assembly 80 depends on the location along the acoustic assembly 80 at which the vibratory motion is measured. A minimum or zero crossing in the vibratory motion standing wave is generally referred to as a node (i.e., where motion is usually minimal), and an absolute value maximum or peak in the standing wave is generally referred to as an anti-node. The distance between an anti-node and its nearest node is one-quarter wavelength (λ/4).
Wires 102 and 104 transmit the electrical signal from the ultrasonic signal generator 15 to positive electrodes 96 and negative electrodes 98 . A suitable generator is available as model number GEN01, from ETHICON ENDO-SURGERY Inc., Cincinnati, Ohio. The piezoelectric elements 100 are energized by an electrical signal supplied from the ultrasonic signal generator 15 in response to a foot switch 118 to produce an acoustic standing wave in the acoustic assembly 80 . The electrical signal causes disturbances in the piezoelectric elements 100 in the form of repeat ed small displacements resulting in large compress ion forces within the material. The repeated small displacements cause the piezoelectric elements 100 to expand and contract in a continuous manner along the axis of the voltage gradient, producing longitudinal waves of ultrasonic energy. The ultrasonic energy is transmitted through the acoustic assembly 80 to the end-effector 180 .
In order for the acoustic assembly 80 to deliver energy to end-effector 180 , all components of acoustic assembly 80 must be acoustically coupled to the ultrasonically active portions of clamp coagulator 120 . The distal end of the ultrasonic transducer 82 may be acoustically coupled at surface 95 to the proximal end of an ultrasonic waveguide 179 by a threaded connection such as stud 50 .
The components of the acoustic assembly 80 are preferably acoustically tuned such that the length of any assembly is an integral number of one-half wavelengths (nλ/2), where the wavelength λ is the wavelength of a pre-selected or operating longitudinal vibration drive frequency f d of the acoustic assembly 80 , and where n is any positive integer. It is also contemplated that the acoustic assembly 80 may incorporate any suitable arrangement of acoustic elements.
Referring now to FIGS. 2A and 2B, an exploded perspective view of the clamp coagulator 120 of the surgical system 10 in accordance with the present invention is illustrated. The clamp coagulator 120 is preferably attached to and removed from the acoustic assembly 80 as a unit. The proximal end of the clamp coagulator 120 preferably acoustically couples to the distal surface 95 of the acoustic assembly 80 as shown in FIG. 1 . It will be recognized that the clamp coagulator 120 may be coupled to the acoustic assembly 80 by any suitable means.
The clamp coagulator 120 preferably includes an instrument housing 130 , and an elongated member 150 . The elongated member 150 can be selectively rotated with respect to the instrument housing 130 as further described below. The instrument housing 130 includes a pivoting handle portion 136 , and a fixed handle 132 A and 132 B coupled to a left shroud 134 and a right shroud 138 respectively.
The right shroud 138 is adapted to snap fit on the left shroud 134 . The right shroud 138 is preferably coupled to the left shroud 134 by a plurality of inwardly facing prongs 70 formed on the right shroud 138 . The plurality of prongs 70 are arranged for engagement in corresponding holes or apertures 140 , which are formed in the left shroud 134 . When the left shroud 134 is attached to the right shroud 138 , a cavity is formed therebetween to accommodate various components, such as an indexing mechanism 255 as further described below.
The left shroud 134 , and the right shroud 138 of the clamp coagulator 120 are preferably fabricated from polycarbonate. It is contemplated that these components may be made from any suitable material without departing from the spirit and scope of the invention.
Indexing mechanism 255 is disposed in the cavity of the instrument housing 130 . The indexing mechanism 255 is preferably coupled or attached on inner tube 170 to translate movement of the handle portion 136 to linear motion of the inner tube 170 to open and close the clamp arm assembly 300 . When the pivoting handle portion 136 is moved toward the fixed handle portion 130 , the indexing mechanism 255 slides the inner tube 170 rearwardly to pivot the clamp arm assembly 300 into a closed position. The movement of the pivoting handle portion 136 in the opposite direction slides the indexing mechanism 255 to displace the inner tube 170 in the opposite direction, i.e., forwardly, and hence pivot the clamp arm assembly 300 into its open position.
The indexing mechanism 255 also provides a ratcheting mechanism to allow the elongated member 150 to rotate about its longitudinal axis relative to instrument housing 130 . The rotation of the elongated member 150 enables the clamp arm assembly 300 to be turned to a selected or desired angular position. The indexing mechanism 255 preferably includes a tubular collar 260 and yoke 280 .
The tubular collar 260 of the indexing mechanism 255 is preferably snapped onto the proximal end of the inner tube 170 and keyed into opposing openings 168 . The tubular collar 260 is preferably fabricated from polyetherimide. It is contemplated that the tubular collar 260 may be constructed from any suitable material.
Tubular collar 260 is shown in greater detail in FIGS. 11 through 13. The tubular collar 260 preferably includes an enlarged section 262 , and a bore 266 extending therethrough. The enlarged section 262 preferably includes a ring 272 formed around the periphery of the tubular collar 260 to form groove 268 . The groove 268 has a plurality of detents or teeth 269 for retaining the elongated member 150 in different rotational positions as the elongated member 150 is rotated about its longitudinal axis. Preferably, the groove 268 has twelve ratchet teeth to allow the elongated portion to be rotated in twelve equal angular increments of approximately 30 degrees. It is contemplated that the tubular collar 260 may have any number of teeth-like members. It will be recognized that the teeth-like members may be disposed on any suitable part of the tubular collar 260 without departing from the scope and spirit of the present invention.
Referring back now to FIGS. 2A through 4, the pivoting handle portion 136 includes a thumb loop 142 , a first hole 124 , and a second hole 126 . A pivot pin 153 is disposed through first hole 124 of handle portion 136 to allow pivoting as shown by arrow 121 in FIG. 3 . As thumb loop 142 of pivoting handle portion 136 is moved in the direction of arrow 121 , away from instrument housing 130 , a link 128 applies a forward force to yoke 280 , causing yoke 280 to move forward. Link 128 is connected to pivoting handle portion 136 by a pin 129 , and link 128 is connected to base 284 by a pin 127 .
Referring back now to FIG. 2A, yoke 280 generally includes a holding or supporting member 282 and a base 284 . The supporting member 282 is preferably semi-circular and has a pair of opposing pawls 286 that extend inwardly to engage with the teeth 269 of the tubular collar 260 . It is contemplated that the pawls 286 may be disposed on any suitable part of the yoke 280 for engagement with the teeth 269 of the tubular collar 260 without departing from the spirit and scope of the invention. It will also be recognized that the yoke 280 may have any number of ratchet arms.
Yoke 280 is shown in greater detail in FIGS. 19 through 22. The pivoting handle portion 136 preferably is partially disposed in a slot 147 of the base 284 of the yoke 280 . The base 284 also includes a base opening 287 , an actuator travel stop 290 , and a base pin-hole 288 . The pivot pin 153 is disposed through the base opening 287 . Yoke 280 pawls 286 transfer opening force to inner tube 170 through tubular collar 260 , resulting in the opening of clamp arm assembly 300 .
The yoke 280 of the clamp coagulator 120 is preferably fabricated from polycarbonate. The yoke 280 may also be made from a variety of materials including other plastics, such as ABS, NYLON, or polyetherimide. It is contemplated that the yoke 280 may be constructed from any suitable material without departing from the spirit and scope of the invention.
As illustrated in FIGS. 3 and 4, yoke 280 also transfers a closing force to clamp arm assembly 300 as pivoting handle portion 136 is moved toward instrument housing 130 . Actuator travel stop 290 contacts pivot pin 153 at the bottom of the stroke of pivoting handle portion 136 , stopping any further movement, or overtravel, of pivoting handle portion 136 . Pawls 286 of yoke 280 transfer force to tubular collar 260 through a washer 151 , a force limiting spring 155 , and collar cap 152 . Collar cap 152 is rigidly attached to tubular collar 260 after washer 151 and force limiting spring 155 have been assembled onto tubular collar 260 proximal to enlarged section 262 . Collar cap 152 is illustrated in greater detail in FIGS. 5 and 6. Force limiting spring 155 is illustrated in greater detail in FIGS. 7 and 8, and washer 151 is illustrated in greater detail in FIGS. 9 and 10. Thickness of washer 151 may be adjusted during design or manufacturing of clamp coagulator 120 to alter the pre-load of force limiting spring 155 . Collar cap 152 is attached to tubular collar 260 by ultrasonic welding, but may alternately be press fit, snap fit or attached with an adhesive.
Referring to FIGS. 5 through 10, tubular collar 260 , washer 151 , force limiting spring 155 , and collar cap 152 provide a force limiting feature to clamp arm assembly 300 . As pivoting handle portion 136 is moved toward instrument housing 130 , clamp arm assembly 300 is rotated toward ultrasonic blade 88 . In order to provide both ultrasonic cutting, and hemostasis, it is desirable to limit the maximum force of clamp arm assembly 300 to 0.5 to 3.0 Lbs.
FIGS. 5 and 6 illustrate collar cap 152 including a spring surface 158 . FIGS. 7 and 8 illustrate force limiting spring 155 including a cap surface 156 , a washer surface 157 , and a plurality of spring elements 159 . Force limiting spring 155 is described in the art as a wave spring, due to the shape of spring elements 159 . It is advantageous to use a wave spring for force limiting spring 155 because it provides a high spring rate in a small physical size well suited to an ultrasonic surgical instrument application where a central area is open for ultrasonic waveguide 179 . Force limiting spring 155 is biased between spring surface 158 of collar cap 152 and spring face 165 of washer 151 . Washer 151 includes a pawl face 167 (FIGS. 9 and 10) that contacts pawls 286 of yoke 280 after assembly of clamp coagulator 120 (see FIGS. 2 through 4 ).
Referring now to FIG. 2 and FIGS. 14 through 18, a rotational knob 190 is mounted on the elongated member 150 to turn the elongated member 150 so that the tubular collar 260 rotates with respect to the yoke 280 . The rotational knob 190 may be fabricated from polycarbonate. The rotational knob 190 may also be made from a variety of materials including other plastics, such as a polyetherimide, nylon, or any other suitable material.
The rotational knob 190 preferably has an enlarged section or outer knob 192 , an inner knob 194 , and an axial bore 196 extending therethrough. Inner knob 194 includes keys 191 that attach cooperatively to keyways 189 of outer knob 192 . The outer knob 192 includes alternating longitudinal ridges 197 and grooves 198 that facilitate the orientation of the rotational knob 190 and the elongated member 150 by a surgeon. The axial bore 196 of the rotational knob 190 is configured to snugly fit over the proximal end of the elongated member 150 .
The inner knob 194 extends through an opening 139 in the distal end of the instrument housing 130 . Inner knob 194 includes a channel 193 to rotatably attach inner knob 194 into opening 139 . The inner knob 194 of the rotational knob 190 has a pair of opposing holes 199 . The opposing holes 199 are aligned as part of a passageway 195 that extends through the elongated member 150 , as will be described later.
A coupling member, such as, for example, pin 163 , may be positioned through opposing holes 199 of the passageway 195 . The pin 163 may be held in the passageway 195 of the elongated member 150 by any suitable means, such as, for example, trapped between ribs in housing 130 , or a silicone or cyanoacrylate adhesive. The pin 163 allows rotational torque to be applied to the elongated member 150 from the rotational knob 190 in order to rotate the elongated member 150 .
When the rotational knob 190 is rotated, the teeth 269 of the tubular collar 260 engage and ride up slightly on the corresponding pawls 286 of the yoke 280 . As the pawls 286 ride up on the teeth 269 , the supporting member 282 of the yoke 280 deflects outwardly to allow pawls 286 to slip or pass over the teeth 269 of the tubular collar 260 .
In one embodiment, the teeth 269 of the tubular collar 260 are configured as ramps or wedges, and the pawls 286 of the yoke 280 are configured as posts. The teeth 269 of the tubular collar 260 and the pawls 286 of the yoke 280 may be reversed so that the teeth 269 of the tubular collar 260 are posts, and the pawls 286 of the yoke 280 are ramps or wedges. It is contemplated that the teeth 269 may be integrally formed or coupled directly to the periphery of the elongated member 150 . It will also be recognized that the teeth 269 and the pawls 286 may be cooperating projections, wedges, cam surfaces, ratchet-like teeth, serrations, wedges, flanges, or the like which cooperate to allow the elongated member 150 to be indexed at selective angular positions, without departing from the spirit and scope of the invention.
As illustrated in FIG. 2, the elongated member 150 of the clamp coagulator 120 extends from the instrument housing 130 . As shown in FIGS. 2B through 4, the elongated member 150 preferably includes an outer member or outer tube 160 , an inner member or inner tube 170 , and a transmission component or ultrasonic waveguide 179 .
The outer tube 160 of the elongated member 150 preferably includes a hub 162 , a tubular member 164 , and a longitudinal opening or aperture 166 extending therethrough. The outer tube 160 preferably has a substantially circular cross-section and may be fabricated from stainless steel. It will be recognized that the outer tube 160 may be constructed from any suitable material and may have any suitable cross-sectional shape.
The hub 162 of the outer tube 160 preferably has a larger diameter than the tubular member 164 does. The hub 162 has a pair of outer tube holes 161 to receive pin 163 to allow the hub 162 to be coupled to rotational knob 190 . As a result, the outer tube 160 will rotate when the rotational knob 190 is turned or rotated.
The hub 162 of the outer tube 160 also includes wrench flats 169 on opposite sides of the hub 162 . The wrench flats 169 are preferably formed near the distal end of the hub 162 . The wrench flats 169 allow torque to be applied by a torque wrench to the hub 162 to tighten the ultrasonic waveguide 179 to the stud 50 of the acoustic assembly 80 . For example, U.S. Pat. Nos. 5,059,210 and 5,057,119, which are hereby incorporated herein by reference, disclose torque wrenches for attaching and detaching a transmission component to a mounting device of a hand piece assembly.
Located at the distal end of the tubular member 164 of the outer tube 160 is an end-effector 180 for performing various tasks, such as, for example, grasping tissue, cutting tissue and the like. It is contemplated that the end-effector 180 may be formed in any suitable configuration.
End-effector 180 and its components are shown in greater detail in FIGS. 23 through 33. The end-effector 180 generally includes a non-vibrating clamp arm assembly 300 to, for example, grip tissue or compress tissue against the ultrasonic blade 88 . The end-effector 180 is illustrated in FIGS. 23 and 26 in a clamp open position, and clamp arm assembly 300 is preferably pivotally attached to the distal end of the outer tube 160 .
Looking first to FIGS. 23 through 26, the clamp arm assembly 300 preferably includes a clamp arm 202 , a jaw aperture 204 , a first post 206 A and a second post 206 B, and a tissue pad 208 . The clamp arm 202 is pivotally mounted about pivot pins 207 A and 207 B to rotate in the direction of arrow 122 in FIG. 3 when thumb loop 142 is moved in the direction indicated by arrow 121 in FIG. 3 . By advancing the pivoting handle portion 136 toward the instrument housing 130 , the clamp arm 202 is pivoted about the pivot pin 207 into a closed position. Retracting the pivoting handle portion 136 away from the instrument housing 130 pivots the clamp arm 202 into an open position.
The clamp arm 202 has tissue pad 208 attached thereto for squeezing tissue between the ultrasonic blade 88 and clamp arm assembly 300 . The tissue pad 208 is preferably formed of a polymeric or other compliant material and engages the ultrasonic blade 88 when the clamp arm 202 is in its closed position. Preferably, the tissue pad 208 is formed of a material having a low coefficient of friction but which has substantial rigidity to provide tissue-grasping capability, such as, for example, TEFLON, a trademark name of E. I. Du Pont de Nemours and Company for the polymer polytetraflouroethylene (PTFE). The tissue pad 208 may be mounted to the clamp arm 202 by an adhesive, or preferably by a mechanical fastening arrangement as will be described below.
As illustrated in FIGS. 23, 26 and 28 , serrations 210 are formed in the clamping surfaces of the tissue pad 208 and extend perpendicular to the axis of the ultrasonic blade 88 to allow tissue to be grasped, manipulated, coagulated and cut without slipping between the clamp arm 202 and the ultrasonic blade 88 .
Tissue pad 208 is illustrated in greater detail in FIGS. 27 through 29. Tissue pad 208 includes a T-shaped protrusion 212 , a left protrusion surface 214 , a right protrusion surface 216 , a top surface 218 , and a bottom surface 219 . Bottom surface 219 includes the serrations 210 previously described. Tissue pad 208 also includes a beveled front end 209 to ease insertion during assembly as will be described below.
Referring now to FIG. 26, the distal end of the tubular member 174 of the inner tube 170 preferably includes a finger or flange 171 that extends therefrom. The flange 171 has openings 173 A and 173 B ( 173 B not shown) to receive the posts 206 A and 206 B of the clamp arm 202 . When the inner tube 170 of the elongated member 150 is moved axially, the flange 171 moves forwardly or rearwardly while engaging the post 206 of the clamp arm assembly 300 to open and close the clamp arm 202 .
Referring now to FIGS. 24, 25 , and 31 through 33 , the clamp arm 202 of end-effector 180 is shown in greater detail. Clamp arm 202 includes an arm top 228 and an arm bottom 230 , as well as a straight portion 235 and a curved portion 236 . Straight portion 235 includes a straight T-slot 226 . Curved portion 236 includes a first top hole 231 , a second top hole 232 , a third top hole 233 , a fourth top hole 234 , a first bottom cut-out 241 , a second bottom cut-out 242 , a third bottom cut-out 243 , a forth bottom cut-out 244 , a first ledge 221 , a second ledge 222 , a third ledge 223 , a fourth ledge 224 , and a fifth ledge 225 .
Top hole 231 extends from arm top 228 through clamp arm 202 to second ledge 222 . Top hole 232 extends from arm top 228 through clamp arm 202 to third ledge 223 . Top hole 233 extends from arm top 228 through clamp arm 202 to fourth ledge 224 . Top hole 234 extends from arm top 228 through clamp arm 202 to fifth ledge 225 . The arrangement of holes 231 through 234 and ledges 211 through 225 enables clamp arm 202 to include both the straight portion 235 and the curved portion 236 , while being moldable from a process such as, for example, metal injection molding (MIM). Clamp arm 202 may be made out of stainless steel or other suitable metal utilizing the MIM process.
Referring to FIGS. 30 and 31, tissue pad 208 T-shaped protrusion 212 is insertable into clamp arm 202 straight T-slot 226 . Clamp arm 202 is designed such that tissue pad 208 may be manufactured as a straight component by, for example, injection molding, machining, or extrusion. As clamp arm 202 is inserted into straight T-slot 226 and moved progressively through curved portion 236 , beveled front edge 209 facilitates bending of tissue pad 208 to conform to the curvature of clamp arm 202 . The arrangement of holes 231 through 234 and ledges 211 through 225 enables clamp arm 202 to bend and hold tissue pad 208 .
FIGS. 32 and 33 illustrate how clamp arm 202 holds tissue pad 208 in place while maintaining a bend in tissue pad 208 that conforms to curved portion 236 of clamp arm 202 . As illustrated in FIG. 32, third ledge 223 contacts right protrusion surface 216 providing a contact edge 238 , while left protrusion surface 214 is unsupported at this position. At a distal location, illustrated in FIG. 33, fourth ledge 224 contacts left protrusion surface 214 providing a contact edge 239 , while right protrusion surface 216 is unsupported at this location.
Referring back now to FIG. 2 again, the inner tube 170 of the elongated member 150 fits snugly within the opening 166 of the outer tube 160 . The inner tube 170 preferably includes an inner hub 172 , a tubular member 174 , a circumferential groove 176 , a pair of opposing openings 178 , a pair of opposing openings 178 , and a longitudinal opening or aperture 175 extending therethrough. The inner tube 170 preferably has a substantially circular cross-section, and may be fabricated from stainless steel. It will be recognized that the inner tube 170 may be constructed from any suitable material and may be any suitable shape.
The inner hub 172 of the inner tube 170 preferably has a larger diameter than the tubular member 174 does. The pair of opposing openings 178 of the inner hub 172 allow the inner hub 172 to receive the pin 163 to allow the inner tube 170 and the ultrasonic waveguide 179 to transfer torque for attaching ultrasonic waveguide 179 to stud 50 as previously described. An O-ring 220 is preferably disposed in the circumferential groove 176 of the inner hub 172 .
The ultrasonic waveguide 179 of the elongated member 150 extends through aperture 175 of the inner tube 170 . The ultrasonic waveguide 179 is preferably substantially semi-flexible. It will be recognized that the ultrasonic waveguide 179 may be substantially rigid or may be a flexible wire. Ultrasonic vibrations are transmitted along the ultrasonic waveguide 179 in a longitudinal direction to vibrate the ultrasonic blade 88 .
The ultrasonic waveguide 179 may, for example, have a length substantially equal to an integral number of one-half system wavelengths (nλ/2). The ultrasonic waveguide 179 may be preferably fabricated from a solid core shaft constructed out of material which propagates ultrasonic energy efficiently, such as titanium alloy (i.e., Ti—6Al—4V) or an aluminum alloy. It is contemplated that the ultrasonic waveguide 179 may be fabricated from any other suitable material. The ultrasonic waveguide 179 may also amplify the mechanical vibrations transmitted to the ultrasonic blade 88 as is well known in the art.
As illustrated in FIG. 2, the ultrasonic waveguide 179 may include one or more stabilizing silicone rings or damping sheaths 110 (one being shown) positioned at various locations around the periphery of the ultrasonic waveguide 179 . The damping sheaths 110 dampen undesirable vibration and isolate the ultrasonic energy from the inner tube 170 assuring the flow of ultrasonic energy in a longitudinal direction to the distal end of the ultrasonic blade 88 with maximum efficiency. The damping sheaths 110 may be secured to the ultrasonic waveguide 179 by an interference fit such as, for example, a damping sheath described in U.S. patent application No. 08/808,652 hereby incorporated herein by reference.
Referring again to FIG. 2, the ultrasonic waveguide 179 generally has a first section 182 , a second section 184 , and a third section 186 . The first section 182 of the ultrasonic waveguide 179 extends distally from the proximal end of the ultrasonic waveguide 179 . The first section 182 has a substantially continuous cross-section dimension.
The first section 182 preferably has at least one radial waveguide hole 188 extending therethrough. The waveguide hole 188 extends substantially perpendicular to the axis of the ultrasonic waveguide 179 . The waveguide hole 188 is preferably positioned at a node but may be positioned at any other suitable point along the ultrasonic waveguide 179 . It will be recognized that the waveguide hole 188 may have any suitable depth and may be any suitable shape.
The waveguide hole 188 of the first section 182 is aligned with the opposing openings 178 of the hub 172 and outer tube holes 161 of hub 162 to receive the pin 163 . The pin 163 allows rotational torque to be applied to the ultrasonic waveguide 179 from the rotational knob 190 in order to rotate the elongated member 150 . Passageway 195 of elongated member 150 includes opposing openings 178 , outer tube holes 161 , waveguide hole 188 , and opposing holes 199 .
The second section 184 of the ultrasonic waveguide 179 extends distally from the first section 182 . The second section 184 has a substantially continuous cross-section dimension. The diameter of the second section 184 is smaller than the diameter of the first section 182 . As ultrasonic energy passes from the first section 182 of the ultrasonic waveguide 179 into the second section 184 , the narrowing of the second section 184 will result in an increased amplitude of the ultrasonic energy passing therethrough.
The third section 186 extends distally from the distal end of the second section 184 . The third section 186 has a substantially continuous cross-section dimension. The third section 186 may also include small diameter changes along its length. The third section preferably includes a seal 187 formed around the outer periphery of the third section 186 . As ultrasonic energy passes from the second section 184 of the ultrasonic waveguide 179 into the third section 186 , the narrowing of the third section 186 will result in an increased amplitude of the ultrasonic energy passing therethrough.
The third section 186 may have a plurality of grooves or notches (not shown) formed in its outer circumference. The grooves may be located at nodes of the ultrasonic waveguide 179 or any other suitable point along the ultrasonic waveguide 179 to act as alignment indicators for the installation of a damping sheath 110 during manufacturing.
Still referring to FIG. 2, damping sheath 110 of the surgical instrument 150 surrounds at least a portion of the ultrasonic waveguide 179 . The damping sheath 110 may be positioned around the ultrasonic waveguide 179 to dampen or limit transverse side-to-side vibration of the ultrasonic waveguide 179 during operation. The damping sheath 110 preferably surrounds part of the second section 184 of the ultrasonic waveguide 179 . It is contemplated that the damping sheath 110 may be positioned around any suitable portion of the ultrasonic waveguide 179 . The damping sheath 110 preferably extends over at least one antinode of transverse vibration, and more preferably, a plurality of antinodes of transverse vibration. The damping sheath 110 preferably has a substantially circular cross-section. It will be recognized that the damping sheath 110 may have any suitable shape to fit over the ultrasonic waveguide 179 and may be any suitable length.
The damping sheath 110 is preferably in light contact with the ultrasonic waveguide 179 to absorb unwanted ultrasonic energy from the ultrasonic waveguide 179 . The damping sheath 110 reduces the amplitude of non-axial vibrations of the ultrasonic waveguide 179 , such as, unwanted transverse vibrations associated with the longitudinal frequency of 55,500 Hz as well as other higher and lower frequencies.
The damping sheath 110 is constructed of a polymeric material, preferably with a low coefficient of friction to minimize dissipation of energy from the axial motion or longitudinal vibration of the ultrasonic waveguide 179 . The polymeric material is preferably floura-ethylene propene (FEP) which resists degradation when sterilized using gamma radiation. It will be recognized that the damping sheath 110 may be fabricated from any suitable material, such as, for example, PTFE.
The damping sheath 110 preferably has an opening extending therethrough, and a longitudinal slit 111 . The slit 111 of the damping sheath 110 allows the damping sheath 110 to be assembled over the ultrasonic waveguide 179 from either end. It will be recognized that the damping sheath 110 may have any suitable configuration to allow the damping sheath 110 to fit over the ultrasonic waveguide 179 . For example, the damping sheath 110 may be formed as a coil or spiral or may have patterns of longitudinal and/or circumferential slits or slots. It is also contemplated that the damping sheath 110 may be fabricated without a slit 111 and the ultrasonic waveguide 179 may be fabricated from two or more parts to fit within the damping sheath 110 .
It will be recognized that the ultrasonic waveguide 179 may have any suitable cross-sectional dimension. For example, the ultrasonic waveguide 179 may have a substantially uniform cross-section or the ultrasonic waveguide 179 may be tapered at various sections or may be tapered along its entire length.
The ultrasonic waveguide 179 may also amplify the mechanical vibrations transmitted through the ultrasonic waveguide 179 to the ultrasonic blade 88 as is well known in the art. The ultrasonic waveguide 179 may further have features to control the gain of the longitudinal vibration along the ultrasonic waveguide 179 and features to tune the ultrasonic waveguide 179 to the resonant frequency of the system.
The proximal end of the third section 186 of ultrasonic waveguide 179 may be coupled to the distal end of the second section 184 by an internal threaded connection, preferably near an antinode. It is contemplated that the third section 186 may be attached to the second section 184 by any suitable means, such as a welded joint or the like. Third section 186 includes ultrasonic blade 88 . Although the ultrasonic blade 88 may be detachable from the ultrasonic waveguide 179 , the ultrasonic blade 88 and ultrasonic waveguide 179 are preferably formed as a single unit.
The ultrasonic blade 88 may have a length substantially equal to an integral multiple of one-half system wavelengths (nλ/2). The distal end of ultrasonic blade 88 may be disposed near an antinode in order to provide the maximum longitudinal excursion of the distal end. When the transducer assembly is energized, the distal end of the ultrasonic blade 88 is configured to move in the range of, for example, approximately 10 to 500 microns peak-to-peak, and preferably in the range of about 30 to 150 microns at a predetermined vibrational frequency.
The ultrasonic blade 88 is preferably made from a solid core shaft constructed of material which propagates ultrasonic energy, such as a titanium alloy (i.e., Ti—6Al—4V) or an aluminum alloy. It will be recognized that the ultrasonic blade 88 may be fabricated from any other suitable material. It is also contemplated that the ultrasonic blade 88 may have a surface treatment to improve the delivery of energy and desired tissue effect. For example, the ultrasonic blade 88 may be micro-finished, coated, plated, etched, grit-blasted, roughened or scored to enhance coagulation and cutting of tissue and/or reduce adherence of tissue and blood to the end-effector. Additionally, the ultrasonic blade 88 may be sharpened or shaped to enhance its characteristics. For example, the ultrasonic blade 88 may be blade shaped, hook shaped, or ball shaped.
As illustrated in FIGS. 34, 35 and 36 , the geometry of the ultrasonic blade 88 in accordance with the present invention delivers ultrasonic power more uniformly to clamped tissue than predicate devices. The end-effector 180 provides for improved visibility of the blade tip so that a surgeon can verify that the blade 88 extends across the structure being cut or coagulated. This is especially important in verifying margins for large blood vessels. The geometry also provides for improved tissue access by more closely replicating the curvature of biological structures. Blade 88 provides a multitude of edges and surfaces, designed to provide a multitude of tissue effects: clamped coagulation, clamped cutting, grasping, back-cutting, dissection, spot coagulation, tip penetration and tip scoring.
The distal most tip of blade 88 has a surface 54 perpendicular to a tangent 63 , a line tangent to the curvature at the distal tip. Two fillet-like features 61 A and 61 B are used to blend surfaces 51 , 52 and 54 , thus giving a blunt tip that can be utilized for spot coagulation. The top of the blade 88 is radiused and blunt, providing a broad edge, or surface 56 , for clamping tissues between it and clamp arm assembly 300 . Surface 56 is used for clamped cutting and coagulation as well as manipulating tissues while the blade is inactive.
The bottom surface has a spherical cut 53 that provides a narrow edge, or sharp edge 55 , along the bottom of blade 88 . The material cut is accomplished by, for example, sweeping a spherical end mill through an arc of radius R 1 and then finishing the cut using a second, tighter radius R 2 that blends the cut with a bottom surface 58 of the blade 88 . Radius R 1 is preferably within the range of 0.5 inches to 2 inches, more preferably within the range of 0.9 inches to 1.1 inches, and most preferably about 1.068 inches. Radius R 2 is preferably within the range of 0.125 inches to 0.5 inches, and most preferably about 0.25 inches. The second radius R 2 and the corresponding blend with the bottom surface 58 of blade 88 diminishes the stress concentrated at the end of the spherical cut relative to stopping the cut without this blend. The sharp edge 55 facilitates dissection and unclamped cutting (back-cutting) through less vascular tissues.
The curved shape of blade 88 also results in a more uniformly distributed energy delivery to tissue as it is clamped against the blade 88 . Uniform energy delivery is desired so that a consistent tissue effect (thermal and transection effect) along the length of end-effector 180 is achieved. The distal most 15 millimeters of blade 88 is the working portion, used to achieve a tissue effect. The displacement vectors for locations along the curved shears blade 88 have directions that, by virtue of the improvements of the present invention over predicate instruments, lie largely in the x—y plane illustrated in FIG. 34 . The motion, therefore, of blade 88 lies within a plane (the x—y plane) that is perpendicular to the direction of the clamping force from clamp arm assembly 300 .
Spherical cut 53 on bottom surface 58 of blade 88 creates sharp edge 55 while removing a minimal amount of material from blade 88 . Spherical cut 53 on the bottom of blade 88 creates a sharp edge 55 with an angle of α as described below. This angle α may be similar to predicate shears devices such as, for example, the LCS-K5 manufactured by Ethicon Endo-Surgery Inc., Cincinnati, Ohio. However the blade 88 of the present invention cuts faster than predicate devices by virtue of the orientation of the angle α with respect to the typical application force. For the predicate shears devices, the edges are symmetric, spanning the application force equally. The edges for the present invention are asymmetric, with the asymmetry of the edges dictating how quickly tissue is separated or cut. The asymmetry is important in that it provides for an effectively sharper edge when ultrasonically activated, without removing a significant volume of material, while maintaining blunt geometry. This asymmetric angle as well as the curvature of the blade act to self tension tissue during back-cutting utilizing a slight hook-like or wedge-like action.
Sharp edge 55 of ultrasonic blade 88 is defined by the intersection of surface 53 and a second surface 57 left after bottom surface 58 has received spherical cut 53 . Clamp arm assembly 300 is pivotally mounted on said distal end of outer tube 160 for pivotal movement with respect to ultrasonic blade 88 , for clamping tissue between clamp arm assembly 300 and ultrasonic blade 88 . Reciprocal movement of inner tube 170 pivots clamp arm assembly 300 through an arc of movement, defining a vertical plane 181 . A tangent 60 of spherical cut 53 at sharp edge 55 defines an angle α with a tangent 62 of second surface 57 , as illustrated in FIG. 35 . The bisection 59 of angle α preferably does not lie in vertical plane 181 , but is offset by an angle β. Preferably the tangent 60 of spherical cut 53 lies within about 5 to 50 degrees of vertical plane 181 , and most preferably the tangent of spherical cut 53 lies about 38.8 degrees from vertical plane 181 . Preferably angle α is within the range of about 90 to 150 degrees, and most preferably angle α is about 121.6 degrees.
Looking to FIG. 35A, an alternate embodiment of the present invention is illustrated with an asymmetric narrow edge. A tangent 60 A of a spherical cut 53 A at a sharp edge 55 A defines an angle αA with a tangent 62 A of a second surface 57 A, as illustrated in FIG. 35A. A bisection 59 A of angle αA preferably does not lie in a vertical plane 181 A, but is offset by an angle βA.
Referring now to FIGS. 1-4, the procedure to attach and detach the clamp coagulator 120 from the acoustic assembly 80 will be described below. When the physician is ready to use the clamp coagulator 120 , the physician simply attaches the clamp coagulator 120 onto the acoustic assembly 80 . To attach the clamp coagulator 120 to acoustic assembly 80 , the distal end of stud 50 is threadedly connected to the proximal end of the transmission component or ultrasonic waveguide 179 . The clamp coagulator 120 is then manually rotated in a conventional screw-threading direction to interlock the threaded connection between the stud 50 and the ultrasonic waveguide 179 .
Once the ultrasonic waveguide 179 is threaded onto the stud 50 , a tool, such as, for example, a torque wrench, may be placed over the elongated member 150 of the clamp coagulator 120 to tighten the ultrasonic waveguide 179 to the stud 50 . The tool may be configured to engage the wrench flats 169 of the hub 162 of the outer tube 160 in order to tighten the ultrasonic waveguide 179 onto the stud 50 . As a result, the rotation of the hub 162 will rotate the elongated member 150 until the ultrasonic waveguide 179 is tightened against the stud 50 at a desired and predetermined torque. It is contemplated that the torque wrench may alternately be manufactured as part of the clamp coagulator 120 , or as part of the hand piece housing 20 , such as the torque wrench described in U.S. Pat. No. 5,776,155 hereby incorporated herein by reference.
Once the clamp coagulator 120 is attached to the acoustic assembly 80 , the surgeon can rotate the rotational knob 190 to adjust the elongated member 150 at a desired angular position. As the rotational knob 190 is rotated, the teeth 269 of the tubular collar 260 slip over the pawls 286 of the yoke 280 into the adjacent notch or valley. As a result, the surgeon can position the end-effector 180 at a desired orientation. Rotational knob 190 may incorporate an indicator to indicate the rotational relationship between instrument housing 130 and clamp arm 202 . As illustrated in FIGS. 17 and 18, one of the ridges 197 of rotational knob 190 may be used to indicate the rotational position of clamp arm 202 with respect to instrument housing 130 by utilizing, for example, an enlarged ridge 200 . It is also contemplated that alternate indications such as the use of coloring, symbols, textures, or the like may also be used on rotational knob 190 to indicate position similarly to the use of enlarged ridge 200 .
To detach the clamp coagulator 120 from the stud 50 of the acoustic assembly 80 , the tool may be slipped over the elongated member 150 of the surgical tool 120 and rotated in the opposite direction, i.e., in a direction to unthread the ultrasonic waveguide 179 from the stud 50 . When the tool is rotated, the hub 162 of the outer tube 160 allows torque to be applied to the ultrasonic waveguide 179 through the pin 163 to allow a relatively high disengaging torque to be applied to rotate the ultrasonic waveguide 179 in the unthreading direction. As a result, the ultrasonic waveguide 179 loosens from the stud 50 . Once the ultrasonic waveguide 179 is removed from the stud 50 , the entire clamp coagulator 120 may be thrown away.
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims. | The present invention relates, in general, to ultrasonic surgical clamping instruments and, more particularly, to a multifunctional curved shears blade for an ultrasonic surgical clamping instrument. Disclosed is an ultrasonic surgical instrument that combines end-effector geometry to best affect the multiple functions of a shears-type configuration. The shape of the blade is characterized by a radiused cut to form a curved and potentially tapered geometry. This cut creates a curved surface including a concave surface and a convex surface. The convex surface transitions into a short, straight, flat surface. The length of this straight portion affects, in part, the acoustic balancing of the transverse motion induced by the curved shape. Relative to straight blade tips, the tip curvature of the present design provides improved visibility of the transection site and improved access to targeted tissues. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/471,962, filed May 15, 2012, which claimed priority to U.S. Provisional Patent Application No. 61/519,441, filed May 23, 2011, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to helmets, particularly helmets used to protect the head of a user participating in sports, such as football, or other activities. More particularly, the present invention comprises an improved helmet system for protecting a user from sustaining concussions and other head injuries.
[0003] A key function of sports helmets and football helmets in particular, is to reduce the occurrence of brain concussions. Concussion is the term used for mild traumatic brain injuries, MTBIs for short. Despite the “mild” descriptor, concussions are serious injuries and their effect if more than one is experienced by a player become cumulative and may lead to chronic traumatic encephalopathy, or CTE, with reduced brain function in later life. Plus recent evidence indicates that those with CTE may be fifty times more likely to get amyotrophic lateral sclerosis, or ALS, than the average population (Scientific American, February 2012). The problem today has become nearly epidemic—with an estimated 300,000 football concussions a year among youth, high school, college, and NFL players. Moreover, due to players concealing their injuries and coaches and trainers failing to detect them, many experts believe that number could be low by a factor of two. To counter the concussion problem, the NFL, the colleges, and the helmet manufacturers have attempted some or all of the following: improving the helmet designs; enforcing harsh penalties and severe fines for spearing or other intentional helmet to helmet contacts; identifying concussed players and keeping them sidelined long enough for symptoms to fully subside (sometimes several weeks); trying to better quantify the peak linear and angular acceleration levels of the skull that can lead to concussions; and in a combination of the latter two, measuring the accelerations in real time utilizing multiple miniature accelerometers located against the skull inside the helmets, with the skull acceleration waveforms being transmitted in real time to the sidelines so any player receiving a potential concussion level impact can be immediately identified and removed from the game to be administered predetermined concussion symptom checks, a test which the player must pass before being allowed to reenter the fray. A significant effort has also been made to come up with an optimum metric for characterizing skull impact levels that would accurately predict a resulting concussion. This task began several years ago with the severity index, SI; then the head impact criteria HIC; then head impact power HIP; and most recently the brain impact criteria, BIC and others. However, none of these metrics has yet been shown to be significantly more successful at predicting a concussion than the combination of the maximum linear acceleration value and the maximum angular acceleration value, where the current NFL threshold value being used for the former is 79 Gs, and the current NFL threshold value being used for the latter is 5,757 radians/second 2 .
[0004] Despite recent helmet improvements (mostly better cushioning in the liner area to better reduce head acceleration levels), concussions seem to continue unabated, so the various helmet improvements have not significantly helped to reduce the number of occurrences. One likely reason for the lack of success in reducing concussions is that the helmet improvements made so far have mostly concentrated on the linear acceleration issue, and have mostly or completely ignored the angular acceleration issue.
[0005] The lack of real reductions in concussions may be the result of a simple misconception about what goes on inside the head to cause a concussion. The simplified view is that when the skull is stopped too abruptly, in say a frontal impact, the brain continues on to strike the inside of the skull at the front, and if the impact is severe enough the brain can even rebound and strike the inside of the skull at the rear. The former is termed a coup injury and the latter a contrecoup injury. As a result of the above simple explanation, the main object in making helmet improvements has been to stop the skull less abruptly, i.e., taking steps to reduce its linear deceleration. That is what most of the recent helmet improvements have concentrated on doing. Yet it will be herein shown that nature's own thin layer of cerebrospinal fluid or CSF between the brain and the inside of the skull is extremely effective through its buoyancy effect in mitigating the envisioned impact between the brain and the front of the skull in an abrupt linear stop, even at head deceleration levels that greatly exceed 79 Gs. So, contrary to current thinking, high linear acceleration, or deceleration, does not provide the entire picture, and one needs to look further, particularly at the angular acceleration of the head.
[0006] But angular acceleration is not part of that simplified picture of what happens to the brain in a concussion, so it tends to get ignored. And yet, unlike with linear acceleration, the cerebrospinal fluid is not as effective in eliminating damaging internal impacts of the brain against the inside of the skull in response to an abrupt high angular acceleration of the head. Two contributors to angular acceleration are herein identified which may either add or subtract depending on the direction of the impact and its location, both with respect to the neck position as will be discussed below. Limiting the linear acceleration or deceleration of the head, which current helmet designs do fairly effectively, is helpful in limiting the first contributor to angular acceleration, which is the pendulum motion of the head and neck together. But the current helmet designs do little or nothing to limit the second contributor to angular acceleration, which is the rotational motion of the head at the top of the neck. If this second contributor to angular acceleration could be limited as well, it would go a long way toward reducing the high levels of angular acceleration that appear to lead to concussions. Indeed, the field data show that without this second contributor to angular acceleration, most of the current concussion level football impacts would fall short of the accepted threshold concussion level for angular acceleration. Accordingly, the overall number of football concussions may be significantly reduced if a new helmet design that could additionally significantly lower this second angular acceleration contributor were to be widely implemented.
[0007] Note that regarding the terminology used in the preceding and following discussion and throughout the specification, on occasion the terms acceleration and deceleration are used within their specific intended meanings, but usually the two terms may be interchanged, so when the term acceleration is used it applies equally well to a deceleration and vice versa. Also, within the specification, the terms angular, rotational, circumferential, tangential, and lateral are often used interchangeably, as are the terms linear, radial, centered, straight-on, and normal. The term off-center refers to any direction between centered and tangential. Finally, the terms radial and radially should be interpreted as meaning substantially radial, as it usually relates to a non-spherical surface (object) such as a spheroid, ellipsoid, or ovoid surface.
[0008] To understand how the present invention addresses the concussion problem, it is helpful to first review the results of some comprehensive in-situ football data. In a study conducted by Virginia Tech in 2007, and reported on by Rowson, et al, in the Journal of Biomechanical Engineering, June 2009, Vol. 131, ten six-degree-of-freedom (6DOF) instrumented helmets were used to collect data during both practices and games on offensive and defensive linemen. These biggest players wear the largest helmets which are able to accommodate the instrumentation. Each 6DOF system consists of 6 dual axis micro-electro-mechanical-system (MEMS) accelerometers for a total of 12 independent outputs (a minimum of 9 are needed in a 3, 2, 2, 2 configuration so the extra 3 outputs provide for some redundancy) installed in a Riddell Revolution model football helmet (a recent design for concussion avoidance), a wireless transceiver, and an on-board memory for up to 120 impacts with 8 bit resolution data being acquired continuously at a sample rate of 1,000 Hz per channel. A data set was triggered and saved when any accelerometer experienced an impact level of 10 Gs or more. Impact data sets are 40 milliseconds long (8 ms pre-trigger and 32 ms post-trigger). All of the saved data was transmitted to the sidelines by a commercial computerized helmet impact transmission system, called HITS, to be further analyzed. All of the MEMS miniature accelerometers were held tightly against the skull of the helmet wearer by the foam padding of the helmet to help insure good skull motion data, and the raw data was combined in the following coordinate system: The positive x-axis is directed out of the face (perpendicular to the coronal plane), the positive y-axis is directed out of the right ear (perpendicular to the midsagittal plane), and the positive z-axis is directed out of the bottom of the head (perpendicular to the transverse plane). The origin approximates the center of gravity (c.g.) of the head.
[0009] In all, 1712 impacts were recorded, 570 during games, 1142 during practices. Although 11 peak linear accelerations exceeded 80 g and 12 peak angular accelerations exceeded 6,000 rad/sec 2 , no instrumented player sustained a concussion during the 2007 season. The maximum recorded peak linear acceleration was 135 g and the maximum recorded peak angular acceleration was 9,222 rad/sec 2 , each over 50% more than accepted NFL threshold values. However, in other studies, players who experienced lower values than the NFL threshold values did sustain concussions. Clearly, the situation is far more complex than just the levels of peak acceleration.
[0010] FIG. 1 shows an average linear acceleration response in the Virginia Tech in-situ data. The average peak acceleration value was 23 g and all the acceleration/deceleration waveforms lasted approximately 14 milliseconds as shown. For the larger accelerations (and the larger angular accelerations), the timing remained approximately the same.
[0011] FIG. 2 shows a scatter plot of the change in linear velocity of the head vs. peak linear acceleration for all of the impacts. Only a few impacts represented a change in velocity of up to 20 ft/sec and the vast majority of the rest were less than half that value. Despite a slight offset about the origin, note the approximate linear relationship between change in velocity and peak linear acceleration.
[0012] FIG. 3 shows a scatter plot of the change in angular velocity of the head vs. peak angular acceleration for all of the impacts. Again note the approximate linear relationship.
[0013] FIG. 4 shows a scatter plot of peak angular acceleration vs. peak linear acceleration for all of the impacts. Note that each impact results in both a linear and an angular acceleration. The reference line is 4,300 rad/sec 2 per 100 Gs. But there is little evidence of linearity or correlation between the two accelerations. That is, there can be high angular acceleration at the same time as low linear acceleration, and vice versa. How this can physically happen provides the clue for how to keep the peak angular acceleration value below the concussion threshold value in most cases. As will be discussed, the peak angular acceleration value is what is most damaging to the brain, but the peak linear acceleration value, although not particularly damaging in its own right, is still very important in its role as a contributor to the peak angular acceleration. This apparent dichotomy with respect to the role of peak linear acceleration has likely led to the confusion that's existed among current researchers trying to determine the significance of peak linear and angular accelerations in concussions.
[0014] Before attempting to fully understand FIG. 4 , we need to first explore the head, neck, and body connection. In all head impact cases the forces and torques that eventually halt the impulsive and inertial motions of the head must arise from the more massive body and these forces and torques come through the neck. If the neck were so rigid that the head could not move at all with respect to the massive body, it would be unlikely that any football player could receive enough linear or angular acceleration to cause a concussion. Thus one can assume the stronger the neck connection to that massive body (the stronger the neck muscles), the lesser the impulsive inertial motions of the head will be. That may be why professional football players, who have stronger necks than high school players, do not suffer proportionally more concussions even though they are hit harder. Also, the striking (hitting) players in a collision appear to suffer fewer concussions than the struck (hit) players and one reason might be because the striking players may have tensed their neck muscles in preparation for the impact while the struck players may be caught unawares. Another reason is presented later when it can be better understood. (See paragraph [00128]).
[0015] But since no football player's neck is totally rigid, the allowed motions need to be considered to better understand FIG. 4 , with its non-correlating angular and linear acceleration levels. The neck contains seven cervical vertebrae that connect the skull to the thoracic vertebrae and the rest of the body. The neck can curve one way at the top by the head and another way at the bottom where it joins the more massive body. At the bottom, the neck can bend forward toward the chest or backward toward the back, and also it can bend toward the right shoulder or toward the left shoulder. At the top of the neck (pivoting at about ear level as viewed from the side), the head may independently rotate in any of three planes: first, the shaking of one's head in a vertical midsagittal plane “yes” motion; second, the shaking of one's head in a horizontal transverse plane “no” motion; and third, the cocking of one's head left or right in a vertical coronal plane. As will be shown below, the independent rotation of the head at the top of the neck is the main reason for seeing wildly different angular and linear accelerations in a given impact.
[0016] Based on the above-described allowed head-neck motions, in order to analyze what is going on it is useful to envision the head-neck system as an “apple-on-a-stick,” where the stick (the neck) is able to pivot in two directions (forward and backward and side to side) at its base (where it joins the body) thereby enabling a sort of pendulum motion, and the apple (the head) is able to pivot in all three directions at the top of the stick (in other words: at the top of the neck, at about ear height) thereby enabling an additional rotational motion of just the head. The first motion (the head-neck pendulum motion) contributes to both the linear and the angular acceleration of the head, while the second motion (the rotational motion of just the head at the top-of-the-neck) contributes mostly to just the angular acceleration of the head. These two contributors to angular acceleration, when existing in the same plane, may either add or subtract depending on the direction of the impact and its location, as will be discussed below. When in different planes, the two contributors to the total head angular acceleration also combine but not in a direct fashion. Limiting the linear acceleration or deceleration of the head in response to an impact, which current helmet designs do fairly effectively, is helpful in also limiting the first contributor to head angular acceleration, the head-neck pendulum motion. But current helmet designs do very little to limit the second contributor to head angular acceleration, the independent top-of-the-neck rotational motion of the head. That fact is evidenced by how easily a player's head can be jerked around, for example, when another player yanks his facemask.
[0017] It is a fundamental assertion of the present invention that high angular acceleration of the head is the primary causer of brain injury in a head impact, and, conversely that high linear acceleration of the head is not the main injury causer, except through its contribution to head angular acceleration via the previously described head-neck pendulum motion. At the heart of this assertion largely vindicating linear acceleration is the contention that, contrary to popular belief, when the skull is suddenly stopped in a helmet-to-helmet collision, the brain does not continue on unimpeded to crash against the inside of the skull in the direction of the impact, then to potentially rebound to crash against the inside of the skull in the opposite direction as well. Moreover, this contention is a fact, as will be shown in the following paragraphs.
[0018] It was previously stated, without supporting evidence, that the buoyancy of the brain in the surrounding cerebrospinal fluid is very effective in eliminating an impact of the brain against the inside of the skull wall (the cranium) in very high linear acceleration and deceleration (impact) situations. The following examples and discussion provide the supporting evidence to confirm the foregoing statement.
[0019] Picture a car crashing head-on into a concrete wall. The car's inhabitants (assuming no seat belts and no air bags) will continue to move forward until they smash into one or more of the inside structures of the car (dashboard, windshield, etc.) That is how a concussion is typically described, where the skull plays the role of the car and the brain plays the role of its inhabitants. However, what if the car were filled with water instead of air, and the inhabitants (now properly fitted with SCUBA gear) are neutrally buoyant in the water, like the brain is approximately neutrally buoyant in the surrounding cerebrospinal fluid. Now upon the collision of the car into the immoveable wall, the car, the water, and the inhabitants all come to a stop in short order and none of the inhabitants smash into the windshield or other interior car surfaces. Why?
[0020] By the well proven Equivalence Principle in physics, inside a small windowless room in outer space nothing can tell the difference between an acceleration/deceleration force and a gravity force. Thus, if the deceleration of the car were a constant 1 G, that would be equivalent to simply standing the car on end, front side down, on Earth. In that case, all of the inhabitants in the water-filled car would remain as neutrally buoyant as they were before, suspended in-place like a submarine in the ocean, and no one would crash downward into the windshield or other interior surfaces of the car. If the deceleration were a constant 100 Gs, that would be equivalent to standing the car on end on a planet with 100 times the gravity of Earth, and again everyone would remain neutrally buoyant, suspended in-place, and no one would crash into the windshield. Physically, a linear pressure gradient is formed in the water. On the 1 G Earth, in every body of water, no matter how big or how small, the linear pressure gradient goes from zero at the top surface (plus atmospheric pressure) to a pressure at the bottom equal to the weight density of the water (its mass density times the acceleration of gravity) times the depth of the water (plus atmospheric pressure). For a neutrally buoyant object in the water, the effective pressure gradient (along the object) times the effective area of the object (acted on by the pressure gradient) exactly counters its weight (its mass times the acceleration of gravity). At 100 Gs, the weight of the object is 100 times as much, but the weight density of water is also 100 times as much so the effective pressure gradient is 100 times as much and the object remains neutrally buoyant, and stationary. This is equivalent to what happens under acceleration.
[0021] It is not necessary to just accept this at face value. It can be verified experimentally using a 1 inch diameter solid polystyrene ball which has a specific gravity of 1.040, and a 5.5% saline solution of water which has a specific gravity of 1.040 at 68° F. Place the ball and saline solution in a 2 inch diameter transparent hard plastic tube closed and sealed at both ends. Make sure all the air bubbles have been removed. Then with the ball suspended in the middle of the tube, smack the tube axially into a hard stationary surface as hard as possible and observe how the ball moves. See if the ball which represents a neutrally buoyant brain, suspended in the saline solution which represents the cerebrospinal fluid, crashes into the front impact surface of the tube representing the inside of the skull. It should not. Indeed if what has been stated above is correct—and it is—the neutrally buoyant ball should not move at all—and it doesn't.
[0022] When talking about the brain, however, the brain is not exactly neutrally buoyant in the surrounding cerebrospinal fluid. It is about 3% more dense than the fluid. So the brain will continue to move forward when the forward-moving skull is abruptly decelerated to a stop, but by how much and with what remaining velocity?
[0023] Picture a non-helmeted man running through a darkened space with his head held well forward when suddenly his head strikes a wall while he's running at, for example, 10 ft/sec (which is about an 8 minute mile pace). The key constraint in this example is that the orientation of the man's skull remains unchanged throughout the process, so that there is no angular acceleration. Also, it is assumed the man is fortunate enough to not break his neck, nor fracture his skull, but his skull's limited elasticity when combined with the stiffness of the wall will stop his skull in (say) just 2 milliseconds (a reasonable assumption). We can further simplify the analysis by assuming, in addition, that the deceleration of his skull is constant over those 2 milliseconds, and with that assumption the resulting calculated deceleration will be 155.3 Gs. Note that the peak deceleration would be higher without that assumption.
[0024] Now what happens to the man's brain at the same time? His brain weighs about 3.1 lbs and approximates a 6.8 inch long top-half semi-ellipsoid or ovoid. The weight density of his brain is about 0.0375 lbs/in 3 , and the weight density of the cerebrospinal fluid which surrounds it is about 0.0364 lbs/in 3 . The cerebrospinal fluid CSF decelerates along with the skull resulting in a linear pressure gradient in the CSF (for those 2 milliseconds) that ranges from zero psi gauge pressure at the back of the brain to 38.4 psi gauge pressure at the front of the brain where the skull was impacted (6.8×0.364×155.3=38.4). Thus, acting upon each small segmental surface area of the brain, there is a front/back force on that brain area segment equal to the front/back projection of the area segment times the gauge pressure at that location. This calculation yields a resultant decelerating force of 466.5 lbs. with the resulting deceleration of the 3.1 lb brain being 150.5 Gs. Thus the brain is significantly slowed along with the skull, but not quite as much as the skull.
[0025] The distance the man's skull travels during the deceleration is:
[0000] d sk =V 0 t− ½ a sk t 2 (Equation 1)
[0000] where V 0 =10 ft/sec; t=2 msec; a sk =155.3 Gs→d sk =0.120 inches
[0026] The distance his brain travels during the deceleration is:
[0000] d br =V 0 t− ½ a br t 2 (Equation 2)
[0000] where V 0 =10 ft/sec; t=2 msec; a br =150.5 Gs→d br =0.124 inches
[0027] Thus during those 2 milliseconds of deceleration, the man's brain closes the gap between itself and the front of his skull by only 0.004 inches (about the thickness of a piece of paper). The initial gap is about 0.100 inches (approximately 2.5 mm), consisting of the outer hard dura mater layer, the inner soft pia mater layer which covers the brain, and the filament-like arachnoid layer and the CSF-filled subarachnoid space in between.
[0028] So, at the end of the 2 millisecond skull deceleration period, the speed of the man's skull is 0 ft/sec and the speed of his brain is all the way down to 0.31 ft/sec (from 10 ft/sec). In terms of energy, due to kinetic energy's speed squared relationship, 99.9% of his brain's initial kinetic energy has already been dissipated, leaving just 0.1% of its initial kinetic energy to yet be dissipated. Since the cerebrospinal fluid is no longer decelerating to provide a decelerating force through an acceleration induced linear pressure gradient, the deceleration must be accomplished by squeezing more of the cerebrospinal fluid out of the remaining 0.096 inch space and compressing the compressible pia mater and arachnoid layer. The remaining required deceleration of 0.19 Gs, which corresponds to a decelerating force of only 9.3 ounces, is not very likely to be damaging.
[0029] Before knowing the above analysis one would have assumed that a 155 G deceleration impact on the skull would certainly cause a concussion. In light of the above analysis, however, that seems to no longer be the case, even for a head deceleration level more than two times what the NFL considers to be the linear acceleration/deceleration threshold level for concussions (79 Gs). Why then does a high peak linear acceleration level of the head matter? (Recall that in the above example, the orientation of the cranium was held constant, so there was no angular acceleration of the head.)
[0030] For real-life impacts, however, high linear acceleration levels usually do matter because through the previously described head-neck pendulum motion, the linear acceleration of the head also contributes to the angular acceleration of the head. When the linear acceleration component perpendicular to the neck at the c.g. of the head (located about 8 inches from the lower neck pivot) is at a level of 79 Gs, its contribution to the resulting angular acceleration of the head is 3,816 rad/sec 2 . That is just two-thirds of the NFL threshold angular acceleration level of 5,757 rad/sec 2 . Moreover, only rarely will a measured 79 G peak linear acceleration level occur in a direction perpendicular to the neck (at the c.g. of the head), so in order to attain a 79 G perpendicular component the total peak linear acceleration level would normally need to be even higher. But in order to reach the angular acceleration concussion level, there will usually need to be not just a high peak linear acceleration level (to yield a reasonably high angular acceleration value through the head-neck pendulum effect), there needs to also be a significant and additive head rotational acceleration component present as well. This is the previously mentioned top-of-the-neck second head rotational acceleration component—the one the present invention attempts to further reduce.
[0031] To reinforce all the above and put the numbers in prospective, a second football study is presented. This study, reported on by Broglio, et al, in Medicine and Science in Sports and Exercise, 2010, followed 78 high school football players wearing Riddell Revolution helmets instrumented with the previously described Head Impact Telemetry System, (HITS) through four seasons of practices and games from 2005 to 2008. In all, 54,247 impacts were recorded (the impacts triggered whenever one of the accelerometer channels from the six dual axis units exceeded a threshold of 15 Gs). The data included 13 impacts that resulted in concussions. The recorded average peak linear acceleration levels were about 26 Gs, and the average peak angular acceleration levels were about 1,600 rad/sec 2 , very similar to the previously cited data. But this study is more valuable because it includes data from actual concussion-causing impacts. From the data, the authors developed a concussion predictor “tree.” The tree starts off not surprisingly with an angular acceleration threshold question.
[0032] 1 st Question: Angular Acceleration >5, 582 rad/sec 2
[0033] Answers: (No—53,563 impacts, 0 concussions)—0%
(Yes—684 impacts, 13 concussions)—1.9%
[0035] ↓(yes)
[0036] 2 nd Question: Linear Acceleration >96 Gs
[0037] Answers: (No—525 impacts, 2 concussions)—0.4%
(Yes—159 impacts, 11 concussions)—6.9%
[0039] ↓(yes)
[0040] 3 rd Question: Impact location; front, side, top
[0041] Answers: (No—77 impacts, 0 concussions)—0%
(Yes—82 impacts, 11 concussions)—13.4%
[0043] ↓(yes)
[0044] 4 th Question: Angular Acceleration <8,845 rad/sec 2
[0045] Answers: (No—35 impacts, 1 concussion)—2.9%
(Yes—47 impacts, 10 concussions)—21.3%
[0047] ↓(yes)
[0048] 5 th Question: Linear Acceleration <102 Gs
[0049] Answers: (No—38 impacts, 5 concussions)—13.2%
(Yes—9 impacts, 5 concussions)—55.6%
[0051] For the 13 concussion causing impacts, the key metric was the resultant peak angular acceleration level. A minimum level of 5,582 rad/sec 2 was the indicated value, but the mean level was 7,229 rad/sec 2 . The indicated minimum level of angular acceleration was a necessary, but not sufficient condition for the 13 concussive impacts (out of 54,247 impacts). From the standpoint of identifying better helmet protection, identifying a necessary condition is paramount, but from the standpoint of identifying a predictive metric, the necessary condition is not enough. In other words, 98% of the time (671 times out of 684 times), a player who received an angular acceleration greater than 5,582 rad/sec 2 did not suffer a concussion. So angular acceleration is a poor predictor. However, no player suffered a concussion as a result of receiving any of the 53,563 impacts where the angular acceleration level was less than 5,582 rad/sec 2 . That is a powerful protection identifier—i.e., to simply incorporate a protective measure that will keep the head angular acceleration level below 5,582 rad/sec 2 as much as possible.
[0052] A key point previously made, now bears repeating. For those special cases that exhibit no local rotation of the head at the top of the neck, (envisioning all the motion of the head as just a pendulous apple on a stick pivoting at the base of the neck), a linear acceleration of the head still results in an angular acceleration of the head. For a=79 G, and r=8 inches, angular acceleration α=3,816 rad/sec 2 . So for this very simplified case, a supposed concussion level for linear acceleration does not result in a concussion level for angular acceleration. To reach the concussion level for angular acceleration, there must also be a local angular acceleration (one that causes a local rotation of the head at the top of the neck) that adds to the above pendulum angular acceleration and the total combined angular acceleration value is the true culprit. The fact that in the first study's data (the college study), the measured angular accelerations were all over the map as compared to the measured linear accelerations ( FIG. 4 ) is proof that local rotational accelerations of the head of the same order of magnitude as the head-neck pendulum head angular accelerations exist, and may occasionally fully add or fully subtract from the latter. From the above numbers, without the local angular acceleration contributor (to rotate the head at the top of the neck) it would take a pure 120 G linear acceleration to result in a pendulum angular acceleration that exceeds the 5,757 rad/sec 2 NFL threshold concussion value. Thus it should be clear that if the local rotational angular acceleration contributor could be eliminated (or significantly reduced) by the design of the helmet, then the pendulum angular acceleration all by itself would rarely be able to cause a concussion in a helmeted football player.
[0053] All of the concussed high school football players in the study not only received high resultant peak angular acceleration levels but also high resultant peak linear acceleration levels (the lowest was 74 Gs). But apparently many received the latter without the former and did not get concussions. The mean resultant peak linear acceleration level for the concussed players was 105 Gs. Assuming an average angle of 45° with the neck for the impact direction, and with the cosine of 45°=0.707, that would yield an average component perpendicular to the neck axis of 74 Gs, which by the previously described head-neck pendulum motion would yield a corresponding peak angular acceleration level of 3,575 rad/sec 2 . That is approximately half the indicated mean level of 7,229 rad/sec 2 which the concussed players received, so on average, only about half the resultant peak angular acceleration for those 13 concussed players is the result of the linear acceleration acting through the head-neck pendulum motion. The other half—at least another 3,600 rad/sec 2 on average—must have come from the purely rotational acceleration of the head at the top of the neck that the present invention is intended to reduce.
[0054] A head angular acceleration threshold has been identified below which players seem not to get a concussion. Yet above that threshold they get a concussion only 2% of the time. Why? Does the cerebral spinal fluid CSF still play some sort of protective role for angular acceleration as it does for linear acceleration?
[0055] It was previously shown how the brain's near-buoyancy in the CSF causes a rapid pressure gradient rise in the CSF in synch with and proportional to the skull's rise in linear acceleration/deceleration, with the maximum pressure occurring at the impact location, and it was also shown that the pressure gradient increase causes an almost matching acceleration/deceleration of the brain, so no significant impact of the brain occurs against the inside of the skull. Indeed, researchers using tiny pressure transducers implanted in the brains of cadavers for head impact tests have recorded pressure waveforms near the impact location that exactly match the linear acceleration waveforms of the decelerating skull. Some researchers, who did not appreciate the fact that what they were recording was the brain's protective mechanism against linear acceleration, have conjectured that perhaps the rapid pressure increase is the damaging mechanism. But studies have shown that the brain is not damaged by compression, only by stretching, shearing, or twisting. Since the brain is not being bounced back and forth as commonly pictured, it must be the sudden rotation of the head that is causing the cranium (the portion of the skull that surrounds the brain) to impact the brain at one or more locations which results in that stretching or twisting. However, because the cranium and the brain are not spherical, but instead semi-ovoid and oblong, at the oblong extremities an angular acceleration can resemble a transverse linear acceleration and as a result the CSF can experience quasi-linear acceleration induced pressure gradients at the oblong extremities which tend to gently (over a wide surface area) rotate the near neutrally buoyant brain along with the cranium, and so the CSF is still partially protective against angular acceleration induced internal impacts, just not nearly as effectively as for pure linear accelerations. Just how protective this will be can depend on a host of factors including but not limited to: the cranium and brain's different oblong nature in the different axes, individual physical shape differences, how the brain's undulating surface high regions and low regions line up with the major angular acceleration axis, and how variations in the thickness of the CSF layer locally line up at potential rotational impact points. With all that variability, it is perhaps not surprising that 6,000 rad/sec 2 might result in a concussion in one instance, but 9,000 rad/sec 2 might not result in a concussion in another. It is also not surprising that the CSF would be partially protective against head angular acceleration; otherwise we might all be giving ourselves concussions every time we shake our heads yes or no.
[0056] In a concussion the cranium pushes on the surface of the brain at just a few points which then bear the brunt of having to push the entire jello-like brain mass around to try to follow the sudden cranial motion, and so these points experience the most localized strain and shearing and may suffer the previously cited coup and contrecoup injuries. Thus the coup and contrecoup injuries should not be visualized as a one—two punch caused by the brain first crashing against the inside of the cranium at the “front” then rebounding to later crash at the “rear,” but rather as a virtually simultaneous, locally stressful and strain-full pushing of the brain around at a few widely separated points where it comes into contact with the cranium. And when a concussion occurs these are not as much physical injuries as they are chemical events wherein the momentary stretching of the walls of the brain cells enables potassium ions to suddenly escape and be replaced by calcium ions, which is a very negative event that may take days or even weeks to correct itself. While being pushed around rotationally, the internal regions of the brain may also get stretched and sheared, which, and as noted above, more than any simple compression is what most agree causes serious brain injury. The most severe form of injury is called Diffuse Axonal Injury, or DAI. DAI damage occurs mostly at the juncture between the outer grey matter and the slightly more dense inner white matter toward the brain's interior, as any angular relative motion between the two could stretch and tear the interconnecting axons over a wide ranging (highly diffuse) area. Some brain experts say that at least some degree of DAI is present with any concussion that involves a loss of consciousness. Strain levels (and high strain rates) of more than 10% are considered to be almost always damaging. Indeed the highest degree of correlation to concussion seems to be the product of brain tissue strain and strain rate, something nearly impossible to measure on football players in situ. But from the standpoint of inventing a more protective helmet (against concussions), it is not necessary to understand all the possible damaging or mitigating factors that exist when translating a high peak angular acceleration level into a high product of strain and strain rate in the exterior and interior regions of the brain.
[0057] The liners of most current football helmets already effectively reduce the linear acceleration of the head as compared to the linear acceleration of the helmet shell, which in turn reduces any head angular acceleration contribution that arises through the head-neck pendulum effect. But current helmet liners are not designed to reduce the rotational acceleration of the head that arises from the rotational acceleration of the helmet shell, and this rotational acceleration (from both of the above discussed studies) contributes directly to the total angular acceleration level of the head. Thus, one way to create a better concussion-reducing helmet is to make the helmet liner also reduce any rotational contributor to the total peak angular acceleration of the head which are coming from the rotational acceleration of the helmet shell. Note that for helmet impacts, it is far more likely for a wearer to experience a sudden angular acceleration than an angular deceleration, although the same result would occur either way.
[0058] Looking at the shiny, round, hard plastic surface of a football helmet it may be hard to imagine how a helmet shell can even acquire a large rotational acceleration in a helmet-to-helmet collision. After all, it is so smooth and has a rounded, low friction surface. If one holds two empty football helmets by their facemasks, and bangs them together, they just bounce away with little resulting rotation. So one's initial conclusion may be to assume that all of the forces always lie along a line of contact normal to the two surfaces at their contact point, and thus aren't able to cause any rotation. But that is just for the special case where the initial relative motion also lies along the line of contact. If one bangs the helmets together off-center (not along their line of contact), a totally different story emerges—there is a lot of rotation, even without much friction between the two smooth surfaces. The reason is there is still a normal force component that dimples each helmet shell inward (very significantly) at the point of contact. What is amazing is how rapidly the diameter of the dimpled-in area (an effective flat from the standpoint of the other helmet) can increase, and thereby have its effect brought into play. And its effect, in conjunction with any relative tangential velocity, is to cause a suddenly increasing rotation of each helmet shell with accompanying high rotational acceleration levels.
[0059] Take the case of two football players running or diving at each other at a closing speed of 25.6 ft/sec (or 7.8 m/sec which is faster than any in the college study, see FIG. 2 ), and then impacting helmet-to-helmet, not in a centered collision but in a 45 degree off-center collision. Therefore, their effective relative speed in both the helmet normal direction and the helmet tangential direction is about 18 ft/sec (cos 45°=0.707). Assume the helmet shells' normal speeds are shared 50/50 at 9 ft/sec each and each's normal motion is stopped in 5 milliseconds with an assumed approximate quarter sine wave decelerating force. The calculated resulting normal displacement of each helmet shell (equal to the dimpling-in distance) is approximately 0.3 inches, which corresponds to an elastically flattened diameter of 3.2 inches (a little wider than a hockey puck). In this example, the elastic flattening that takes place in 5 milliseconds returns to its original shape in another 5 milliseconds, after which the shells lose contact and separate. Note that in the normal direction both the helmet shells and the players heads are accelerated/decelerated for the full 10 milliseconds that the helmet shells remain in contact. It can be assumed with no loss in generality that the shells came together with equal speeds then decelerated to zero speed in 5 milliseconds, and then in the next 5 milliseconds they were accelerated back up to separation speeds equivalent to their speeds at initial contact but in the opposite directions. Meanwhile, thanks to the liners, the heads may take advantage of the full 10 milliseconds to decelerate to a stop and then the heads (via the neck muscles) can decelerate the shells back to zero speed at lower acceleration levels over a longer time after the shells lose contact with each other. To the heads, that looks like a continued low level acceleration in the same direction as during contact, which is the reason for the long descending plateau region of FIG. 1 .
[0060] Events occurring within ten milliseconds may be too fast to be seen by the human eye. However, that is not too fast for some of the 18 ft/sec differential tangential velocity in the above non-centric impact example to be picked up by both helmet shells. They'd be tangentially accelerated in the same rotational direction by an oppositely directed friction force exerted on each by the other which is generally proportional to their shared oppositely directed normal force, so the resulting angular acceleration might be expected to have the same sort of waveform as the linear acceleration and be synched to it. If the two shells share that tangential velocity gain equally, then each 9 inch diameter helmet shell could pick up a circumferential velocity of up to 9 ft/sec, which using the same waveform characteristic and same timing would correspond to a maximum peak top-of-the-neck angular acceleration component of up to about 4,000 rad/sec 2 . That value is right in the ballpark of what might be expected to encompass the actual value for an off-center impact of that intensity, and is consistent with most of the cited football data. The resulting calculated circumferential displacement of the helmet shell is less than half an inch. That establishes the design parameter for what must be accommodated in terms of relative circumferential displacement between the outer shell and the head cap (i.e., by the liner) at not more than an inch.
[0061] Note, for those impacts that are near a full 90 degrees off-center (a grazing impact) the relative tangential speed component may be very high, but the normal speed and force components are very low by comparison, so the dimpling-in is small and the time to take-on the tangential speed (via any tangential force) is also small. Also for impacts that are near 0 degrees off-center (a near normal impact) the normal speed and force components may be very high and the dimpled-in time may be also high, but the relative tangential speed is very low by comparison so the tangential speed that can be taken on is limited.
[0062] The present invention provides an improved helmet system which contains three essential parts: an inner head cap that is attachable and detachable to the head of a user and moves with the head; an outer impact resistant hard shell which moves independently from the head cap and user's head; and a returnable, energy absorbing liner located in-between the head cap and the outer shell which is compliant both radially and circumferentially in all directions. The returnability feature may be manual for use in sports or other activities where the expected impacts are rare such as bicycling, but automatic for use in sports or other activities, such as football, where the impacts are numerous and repetitive.
[0063] The preferred embodiments of the present invention employ an energy absorbing viscoelastic polymeric foam material (PU, EVA, EPP, or the like) to form the liner between the outer shell and the head cap. The liner is configured to be able to reduce linear accelerations and decelerations of the head compared to those of the outer shell as effectively as current prior art helmets. In addition, with the present invention the viscoelastic polymeric foam material of the liner is specially configured to be able to reduce angular accelerations of the head compared to those of the outer shell. To not compromise the latter function, the chin strap with its attached chin protector is fastened to the head cap, which is conformal to and moves with the head, and the chin strap is not fastened or otherwise attached to the outer shell, which has been enabled by the special configuration of the connecting viscoelastic polymeric foam material to be able to move relative to the head cap and the head both linearly and angularly. After an impact, where the outer shell has moved linearly and angularly relative to the head cap and the head, the specially configured liner either causes the outer shell to automatically return to its initial pre-impact start position relative to the head cap and the head, or it enables that return to be manually completed.
[0064] In a first preferred embodiment of the present invention, wherein the return is automatic, the special configuration of the viscoelastic foam liner is comprised of a plurality of side-by-side, long and narrow foam columns with their long sides generally radially-oriented so they are slightly tapered (with their wider ends outward). The long narrow foam columns span and nearly fill the space between the outer surface of the head cap and the inner surface of the outer helmet shell, with each column being adhered at each end to each surface. The cross sections of the columns may be triangular, rectangular, pentagonal, hexagonal, round, oval, or other suitable shape, but in all cases should have sufficiently effective length-to-width ratios for the necessary transverse compliance, in addition to the necessary linear compliance, which gives the liner the ability to reduce the angular accelerations of the head.
SUMMARY OF THE INVENTION
[0065] Briefly stated, the present invention comprises a protective helmet including a head cap, which surrounds at least a portion of the cranial part of a wearer's head, and is sufficiently securable thereto to substantially match a motion of the surrounded cranial portion of the head during an impact to the helmet. An outer shell surrounds at least a portion of the head cap, and is spaced from the head cap at a preset initial relative position prior to an impact to the helmet, the outer shell being movable both radially and circumferentially relative to the head cap in response to an impact to the helmet. A liner is located between and attached to both the head cap and the outer shell. The liner establishes the preset initial relative position and spacing between the head cap and the outer shell and enables the outer shell to be fully returned to the initial relative position with the head cap following an impact to the helmet in one of two ways: (1) automatically by the liner, and (2) manually by the user. The liner also exhibits energy absorbing radial compliance to reduce a first contributor to angular acceleration of the wearer's head which results from the normal force of an impact to the helmet. The liner also exhibits at least one of energy absorbing circumferential compliance to reduce a second contributor to angular acceleration of the wearer's head which results from the tangential force of an off-center impact to the helmet, and lesser circumferential compliance to lessen the potential reduction of the second contributor to angular acceleration of the wearer's head in response to the tangential force of an off-center impact when the tangential force is located and directed such that the second contributor when summed with the first contributor would reduce the angular acceleration of the wearer's head.
[0066] The present invention also comprises a protective helmet including a head cap, which surrounds at least a portion of the cranial part of a wearer's head, and which is sufficiently securable thereto to substantially match a motion of the surrounded cranial portion of the head during an impact to the helmet. An outer shell surrounds at least a portion of the head cap, and is spaced a predetermined distance from the head cap at a preset initial relative position prior to an impact to the helmet. The outer shell is movable both radially and circumferentially relative to the head cap in response to an impact to the helmet. An energy absorbing flexible liner is located between at least a portion of the head cap and at least a portion of the outer shell. The liner includes a radial outer surface attached to an inside surface of the portion of the outer shell and a radial inner surface attached to an outer surface of the portion of the head cap. Neither the head cap nor the head of the wearer is otherwise attached to the outer shell. The liner establishes the preset initial relative position and spacing between the head cap and the outer shell and compliantly absorbs energy imparted to the outer shell during an impact to the helmet to enable the outer shell to move relative to the head cap during the impact to the helmet and to be returned to the initial relative position with the head cap following the impact to the helmet.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0067] The foregoing summary, as well as the following detailed analyses of the physical principals and detailed descriptions of the preferred embodiments will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, particular arrangements and methodologies of preferred embodiments are shown in the drawings. It should be understood, however, that the invention is not limited to the precise arrangements or instrumentalities shown or the methodologies of the detailed description. In the drawings:
[0068] FIG. 1 is a diagram which shows an average linear head acceleration response for a telemetry based in-situ head impact of a college football study;
[0069] FIG. 2 is a diagram which shows, for the same study, a scatter plot of the change in linear velocity of the head vs. peak linear acceleration for all of the inputs;
[0070] FIG. 3 is a diagram which shows, for the same study, a scatter plot of peak angular acceleration vs. peak angular acceleration for all of the impacts;
[0071] FIG. 4 is a diagram which shows, for the same study, a scatter plot of the peak angular acceleration vs. peak linear acceleration for all of the impacts;
[0072] FIG. 5 is a perspective view (selectively cut-away for illustration purposes) of a first preferred embodiment of a football helmet system in accordance with the present invention;
[0073] FIG. 6 is a diagram which shows a side view of a 5V 8/15 icosahedron geodesic dome pattern;
[0074] FIG. 7 is a horizontal cross-sectional top plan view of an ellipsoid shaped (long axis front to back) football helmet system in accordance with a preferred embodiment and the user's head and brain (all sectioned approximately 1 inch above the eyes and near the maximum cross sectional circumferences of the inner head cap and the outer shell) illustrating the alignment and position of the components of the helmet system and the essentially radially-oriented foam columns in the pre-impact condition;
[0075] FIG. 8 is the same horizontal cross-sectional top plan view of FIG. 7 , about 10 milliseconds after the initiation of a significant centered helmet-to-helmet impact to the right front quadrant of the helmet system, indicated by the large arrow between reference points C′ and D′;
[0076] FIG. 9 is the same horizontal cross-sectional top plan view of FIG. 7 , about 10 milliseconds after the initiation of a significant off-center helmet-to-helmet impact to the right front quadrant of the helmet, indicated by the large arrow between points C′ and D′;
[0077] FIG. 10 is a horizontal cross-sectional top plan view of an ellipsoid shaped (long axis front to back) prior art football helmet having an outer shell and compliant liner elements and the user's head and brain (all sectioned approximately 1 inch above the eyes near the maximum cross sectional circumference of the outer shell) to illustrate the alignment and position of these features in the pre-impact condition;
[0078] FIG. 11 is the same horizontal cross-sectional top plan view of FIG. 10 , about 10 milliseconds after the initiation of a significant centered helmet-to-helmet impact to the right front quadrant of the helmet, indicated by the large arrow between points C′ and D′;
[0079] FIG. 12 is the same horizontal cross-sectional top plan view of FIG. 10 , about 10 milliseconds after the initiation of a significant off-center helmet-to-helmet impact to the right front quadrant of the helmet, indicated by the large arrow between points C′ and D;
[0080] FIG. 13 is a diagram which shows a hypothetical version of the previously discussed FIG. 4 diagram (from the college study) of angular acceleration vs. linear acceleration assuming that the Riddell Revolution helmet in the college study has been replaced by the first preferred embodiment of the helmet system of the present invention;
[0081] FIG. 14 is an elevational view which shows two football players, an offensive lineman and a defensive lineman who are about to collide helmet-to-helmet due to the offensive lineman lunging upwardly toward the defensive lineman, both players wearing prior art helmets;
[0082] FIG. 15 is a vertical midsagittal plane cross sectional elevational view taken along section line W-W of FIG. 16 (see below) of the outer shell, a two part liner, and head cap of a manual return type helmet in accordance with a second preferred embodiment of the present invention; and
[0083] FIG. 16 is an approximate transverse plane cross sectional top plan view taken along section line U-U of FIG. 15 of the outer shell, two part liner, and head cap of the manual return type helmet of FIG. 15 .
DETAILED DESCRIPTION OF THE INVENTION
[0084] FIG. 5 is a perspective view (selectively cut-away for illustration purposes) of a first preferred embodiment of a helmet system in accordance with the present invention, illustrated as a football helmet assembly or system 2 . The preferred embodiment of the football helmet system 2 is comprised of a hard impact-resistant outer shell 4 , an inner head-follower head cap 6 , a self-returning linear-acceleration-reducing, angular-acceleration-reducing (LAR/AAR) liner layer 8 located between the head cap 6 and the outer shell 4 , an adhesion or other securing or attachment material or device 10 to securely affix the LAR/AAR liner 8 to the outside of the head cap 6 and to the inside of the outer shell 4 , so the outside surface of the LAR/AAR layer remains fixed with respect to the outer shell 4 and the inner surface of the LAR/AAR liner 8 remains fixed with respect to the head cap 6 , an adjustable chin strap assembly 12 having an attachment/detachment device 14 attached to the head cap 6 but not to the outer shell 4 to enable a wearer or user to secure and unsecure the head cap 6 and thereby the entire helmet system 2 to the user's head, a head-follower shell sub-liner 16 to take up any existing space between the user's head and the inside of the head cap 6 , a chin protector assembly 18 moveably located along the chin strap assembly 12 , and a face guard assembly 20 , with an attachment device 22 secured to the outer shell 4 .
[0085] For football helmets a chin strap assembly 12 is a necessary feature. Its attachment/detachment device 14 may take many forms, including but not limited to, a snap 15 , a buckle, a pinch device, and a Velcro® mating surface. For hockey helmets, an under-the-chin or jaw strap (not shown) is typically used. But for some other sports and activities where dislodging impacts are rare, the fit of the head cap 6 itself (with its potential sub liner 16 ) may be sufficient to hold the helmet 2 in place on the head of the user.
[0086] The outer shell 4 is preferably formed of a polycarbonate polymer for its unsurpassed impact resistance, the same material utilized in most modern (prior art) football helmets, though an impact resistant polymer-fiber composite or a generic impact resistant material is acceptable. As with prior art helmets, the shape of the outer shell 4 is a partial spheroid or ellipsoid (sphere-like or ellipse-like, but not necessarily a precisely spherical or elliptical surface), and its diameter and thickness are about the same as current helmets (approximately 9 to 10 inches in diameter and approximately 0.150 inches thick). And to accommodate the effect of its angular displacement on the head, the outer shell 4 may contain regions along its lower rim that are fitted with a soft bumper (not shown) made of elastomer, polymer, elastomeric polymer, or the like.
[0087] Likewise, the faceguard assembly 20 may be essentially the same as those utilized with most modern football helmets and it may have essentially the same type attachment device 22 to for securing it to the outer shell 4 . The faceguard assembly 20 may be made of steel or aluminum, or a composite of either of these with a polymer covering for a degree of compliance, and attachment may be through a spring or a polymeric or elastomeric grommet for additional compliance. Alternatively, the faceguard assembly 20 may be made of polycarbonate, and potentially molded along with the outer shell 4 . With hockey helmets, the face shield is typically a transparent polycarbonate.
[0088] The head cap 6 is a partial surface of similar shape to that of the outer shell 4 , but obviously smaller in diameter than the outer shell 4 , and may have lesser thickness. Also, the head cap 6 need not be impact resistant so almost any polymer, not just polycarbonate, may be used. Other possible materials for the head cap 6 include but are not limited to elastomer, elastomeric polymer, fabric, polymer impregnated fabric, elastomer impregnated fabric, laminated fabric such as Gore-Tex®, polymer fiber composite, leather, synthetic leather, and even thin metal. Additionally, the head cap 6 is preferably perforated for breathability. Most human heads are not partial spheroids but are generally longer than they are wide, and wider toward the rear than the front. Thus the head cap 6 and outer shell 4 may be partial ellipsoids, or even partial ovoids (egg shaped surfaces), rather than partial spheroids. An ellipsoid in the horizontal plane is the most common helmet shape. Also most human heads are not alike in their shape. Therefore, there will usually be at least a small space between the user's head and the head cap 6 . Since the purpose of the head cap 6 is to engage and closely follow the motion of the user's head it is desirable to fill much or all of the space with a sub-liner 16 that is either custom fitted to the particular user, or preferably is conformal to any shape head inside one of a handful of head cap sizes (S, M, L, XL, and XXL), each size pre-mated with a matching outer shell size. To achieve good conformability, a PU (polyurethane) viscoelastic open-cell foam sub-liner material is preferable if the PU foam is of the polyether polyol type (rather than the polyester polyol type) for better moisture resistance. It is also preferable that the foam of the sub-liner 16 be reticulated so that its more open pore structure can provide for greater air circulation. Also, one ore more air bladders (not shown), whether pump-able or not, may be used in the sub-liner 16 to further enhance the customized fit of the head cap 6 . It will be appreciated that in some applications no sub-liner 16 is needed.
[0089] The LAR/AAR liner 8 has both energy absorbing linear compliance and energy absorbing angular compliance (inner surface vs. outer surface). The first preferred embodiment is comprised of a plurality of long, narrow, side-by-side radially-oriented columns 24 , also preferably made of a viscoelastic open-cell foam. The LAR/AAR material may be a PU foam of the polyether type like the conformal sub-liner 16 discussed above, and it too may be reticulated for lower weight and better air circulation. Other suitable materials may be acceptable as well. The slender, tapered columns 24 that preferably make up the LAR/AAR liner 8 (the taper being necessitated by their radial orientation) may be individually molded or cut out and assembled in place, however, it is more preferable for the individual columns 24 to be formed by either molding-in the column-forming grooves, or cutting column-forming grooves in one surface of a molded partial ellipsoid foam annulus that fits between the head cap 6 and the outer shell 4 .
[0090] To most efficiently fill the available space with similar columns 24 , a good groove designing approach is to treat the grooves as if they were the struts of a geodesic dome, where the number of indicated struts would be the number of mating (and hence rubbing) surfaces between the columns 24 and the indicated number of faces would be the number of columns 24 . From the published geodesic dome literature (e.g., Geodesic Dome Notes by Rene Mueller, latest update Jan. 15, 2009), scores of possible designs are feasible. One good candidate design is a 5V 8/15 icosahedron dome. FIG. 6 is a side elevational view of a 5V 8/15 geodesic dome pattern. An icosahedron is a twenty sided polyhedron. The 5V means that each triangular side is further subdivided into 25 (or 5 squared) triangles. In the approximately 8/15 the of a full sphere, there are 275 triangular cross section columns (the would-be triangular faces on a true dome) and 425 cut mating flat surfaces (the would-be struts on a true dome). Constructing an actual dome could be problematic with 9 different size struts. But for different size cuts (not struts) there is no problem, especially for a computer controlled cutter. Furthermore, as can be seen in FIG. 6 , the cuts are of mostly continuous lines. Also, there ends up being 7 different kinds of triangular cross section columns, but that too is not a problem. In forming a geodesic dome, all of the triangles' intersection points on the polyhedron surface are normalized by projecting them to the surface of a sphere. If the helmet 2 is to be ellipsoid shaped, normalization would project the triangles' intersection points to the surface of the ellipsoid after aligning its center with the otherwise would-be sphere.
[0091] The columns 24 have slightly different slenderness ratios, SRs, (7 different SRs in the above case) and thus slightly different bending and compression characteristics, but what is important are their combined bending and compression characteristics, not any minor individual column differences. Though it may seem odd to be talking about slenderness ratios for columns 24 made of foam, not steel, concrete, or wood, it is still a key metric since foam columns 24 that are too wide, with too low a slenderness ratio, might not have the necessary circumferential compliance between the inner head cap 6 and the outer shell 4 . Also columns that are too wide would mean fewer surfaces to rub against each other, and thus provide less energy-absorbing friction beyond the foam's own basic viscoelastic characteristic. At the other end of the argument, having columns that are too narrow would mean having too many columns to be practical, and indeed there is likely an identifiable minimum average SR and an identifiable maximum average SR. From just simple “gut feel,” the likely minimum average SR seems to be about 3, and the likely maximum average SR seems to be about 30. SR is defined as the effective column length divided by the radius of gyration of the column's cross-section. The theoretical effective length and engineering effective length differ and both vary with the end conditions, but for the purpose of the above indicated ranges, the effective length is taken to be the actual length. The radius of gyration of a triangular cross section is approximately equal to 0.3 times the average width of its sides.
[0092] Viscoelastic open-cell foams have been used for many years in prior art football helmets and are well proven to be effective as a compliant energy absorbing material. Reticulated foams are characterized by a complex three dimensional skeletal structure with very few or no membranes between strands. In compression, the strands initially deform elastically, then upon further deformation they begin to buckle (but not all at once), and finally while being bunched all together they begin “densification.” When graphically describing the compression characteristic of any given foam, the usual practice is to plot compressive stress vs. compressive strain for the total compression cycle. Typically, the plot slopes upwardly in normal elastic fashion for perhaps 10% of the compression, then it slopes upwardly at a much shallower slope during the buckling phase for about another 50 to 60%, and finally during densification it slopes upwardly again at a steepening angle. The trick is to match the characteristic to the necessary cushioning requirement so that on the one hand it is not too stiff to result in unnecessary force, and on the other it is not too weak as to cause the densification region to come into play with its resulting high force. This is a feasible task that is successfully achieved in most modern helmets, sometimes using more than one type of foam. So no new technology is involved in that aspect. However, with the present invention, the foam columns 24 are not just compressed, they are also stretched opposite the impact point and bent and stretched at places in between. Therefore, high elongation capability (>120%), and high tensile strength (>12 psi) are also requirements for the foam in the present invention. With full densification on the impact side probably maxing out at about 80%, the required stretching or elongation on the other side may be up to 80%. Thus 120% elongation represents a 50% safety factor and a 160% elongation foam, which is well within the capability of a great many available foams, would represent a full 2× safety factor. With an effective area of 50 square inches or more, the 12 psi minimum tensile strength means at least 600 lbs of force would be required to pull the outer shell 4 off of the inner head cap 6 , and the chin strap connection 14 would likely open well before that happened. The 12 psi minimum tensile strength requirement is also easily met by many potential candidate foams. The foam would act like a memory foam, with the initial compression and extension taking place within about 15 milliseconds and the full return taking place within a few thousand milliseconds (a few seconds) which would be well before the next play in football, for instance. Since not just compression is involved with the present invention, but extension as well, where there is little buckling of the individual columns 24 , the foam liner 8 of the present invention is effectively more resilient, that is it will return to normal faster than if its active elements were all in compression. One commercially available foam that would meet all the above technical requirements is EZ-DRI™ reticulated foam by Crest Foam Industries.
[0093] The foam liner elements 24 need to be well adhered to both the outer surface of the head cap 6 and the inner surface of the outer shell 4 , and several adhesives are commercially available that can accomplish that purpose. One such adhesive that may be used is 3M Super 74 Foam Fast Adhesive specially formulated for bonding flexible polyurethane foam to metals and plastics.
[0094] FIG. 7 is a horizontal cross-sectional top plan view of an ellipsoid shaped (long axis front to back) football helmet system 2 in accordance with the first preferred embodiment of the present invention and the user's head 30 showing the scalp portion (not numbered), cranium 36 , and brain 32 (all sectioned approximately 1 inch above the eyes and near the maximum cross sectional circumferences of the inner head cap 6 and the outer shell 4 ) to illustrate the alignment and position of the helmet components and the essentially radially-oriented foam columns 24 of the liner 8 in a pre-impact condition. The section is taken near the centers of gravity of both the head 30 and brain 32 . There are also two cutout regions (not shown) in the head cap 6 below the cross sectional plane to accommodate the ears and the donning of the helmet 2 , thus no foam columns 24 exist in the cutout areas. Notice that point A on the inner head cap 6 is aligned with point A′ on the outer shell 4 , and point B is aligned with B′, C with C′, and D with D′, and all are initially generally aligned with the inertial axes, XX and YY. Also notice that the brain 32 is aligned with the head 30 and the cerebrospinal fluid 34 exists all around the brain 32 . The symmetrical structures near the middle of the brain section are the top portions of the ventricles that supply and replenish the cerebrospinal fluid 34 .
[0095] FIG. 8 is the same horizontal cross-sectional top plan view of FIG. 7 , about 10 milliseconds after the initiation of a significant centered helmet-to-helmet impact to the right front quadrant of the helmet 2 , indicated by the large arrow 40 between points C′ and D′. Note that the impact is in the cross-sectional plane. The term “centered” means the closing velocity is directed toward the center of the helmet 2 and “closing velocity” means the velocity vector of the impacting helmet minus the velocity vector of the impacted helmet just prior to the impact. As a result, notice both the outer shell 4 and the head cap 6 have been moved away from their initial positions ( FIG. 7 ) in their inertial frame, in the direction of the impact, with the outer shell 4 moving about twice as much as the head cap 6 , the compliant liner columns 24 symmetrically taking up (absorbing) the difference. The indicated X and Y change is the linear position change of the head 30 . The foam columns 24 between points C and D have been mostly compressed, while those between points A and B have been mostly stretched, and those between points B and C, and points D and A, have been mostly deformed into S curves. For the two latter groups especially, all of the stretching convex surfaces have rubbed against all of the adjacent compressing concave surfaces for greater energy absorption. With such a change in the position of the head cap 6 and virtually no change in its orientation, the head position and its orientation remain substantially unchanged relative to the head cap 6 which is held snugly in place on the head 30 by the relatively stiff inner sub-liner 16 . Also the brain position and its orientation remain substantially unchanged relative to the head 30 in the horizontal plane since the impact velocity vector is centered through the head, so there is no angular acceleration of the head 30 in the horizontal plane. There is only a linear acceleration of the head 30 in the horizontal plane which has been significantly reduced by the compliance of the liner 8 . The already reduced linear acceleration of the head 30 has been further mitigated by the linear accelerating cranium 36 accelerating the trapped cerebrospinal fluid 34 , which in turn results in a pressure gradient in the fluid 34 which accelerates the just-slightly higher density brain 32 to nearly keep up with the acceleration of the head 30 , as discussed above. There is, however, as a result of the remaining linear acceleration of the head 30 some angular acceleration of the head 30 in the plane that contains the impact velocity vector and the vertical ZZ axis (not shown) through the neck—the so-called head-neck pendulum contributor to angular acceleration—and this angular acceleration slightly tilts the cranium 36 upwardly in the region between points C and D, and downwardly in the region between points A and B. That results in a reduced clearance between the brain 32 and the cranium 36 at the bottom in the region between points C and D, and a reduced clearance between the brain 32 and the cranium 36 at the top in the region between points A and B. Finally, because the impact velocity vector is centered through the head 30 , there is no rotational contributor to angular acceleration in this plane either, just the aforementioned head-neck pendulum contributor.
[0096] FIG. 9 is the same horizontal cross-sectional top plan view plane of FIG. 7 , about 10 milliseconds after the initiation of a significant off-center helmet-to-helmet impact to the right front quadrant of the helmet 2 , indicated by the large arrow 42 between points C′ and D′. The term “off-center” means the closing velocity is not directed toward the center of the helmet 2 , but the impact is still in the cross-sectional plane and “closing velocity” means the velocity vector of the impacting helmet minus the velocity vector of the impacted helmet just prior to the impact. As with FIG. 8 , both the outer shell 4 and the head cap 6 have been moved away from their initial positions ( FIG. 7 ) in their inertial frame, still substantially (but a bit less than in the previous case) in the direction from the point of impact toward the center of the helmet 2 , with the outer shell 4 again moving about twice as much as the head cap 6 , with the liner columns 24 again taking up or absorbing the difference, but this time un-symmetrically. Again the indicated change in X and Y is the linear position change of the head 30 . The reason the outer shell 4 has rotated in the horizontal plane is because of the off-center nature of the impact (with the driving frictional force acting via the previously discussed temporarily dimpled-in impacting surfaces), yet the head cap 6 has rotated hardly at all because of the circumferential compliance of the foam liner columns 24 . The foam columns 24 between points C and D have been mostly compressed, while those between points A and B have been mostly stretched, and all of the columns 24 have been deformed into S curves. For all of the columns 24 , all of the convex surfaces have rubbed against the adjacent concave surfaces for greater energy absorption.
[0097] Though the outer shell 4 has moved linearly and also rotated, the multi-columned foam liner's linear compliance has limited the change in the position of the head cap 6 and its circumferential compliance has resulted in almost no change in the orientation of the head cap 6 . Thus, everything from the head cap 6 inward remains as it was in the previous case, but with slightly less linear head acceleration and therefore slightly less angular head acceleration from the slightly less pendulum head-neck contributor in the plane containing the ZZ axis (not shown). As with FIG. 8 , the head position and its orientation remain substantially unchanged relative to the head cap 6 , being held snugly in place by the relatively stiff inner sub-liner 16 . The position and orientation of the brain 32 relative to the head 30 in the horizontal plane remain substantially unchanged since there is little direct angular acceleration of the head 30 in the horizontal plane. There is only a linear acceleration of the head 30 in the horizontal plane which has been reduced by the off-center nature of the impact and the linear compliance of the helmet liner 8 , and then the already reduced linear acceleration of the head 30 , as before, is further mitigated by the linear accelerating cranium 36 accelerating the trapped cerebrospinal fluid 34 , which in turn results in a pressure gradient in the fluid 34 which accelerates the just-slightly higher density brain 32 to nearly keep up with the acceleration of the head 30 , as discussed above. And as before, there is still, as a result of the remaining linear acceleration of the head 30 , some angular acceleration of the head 30 in the plane that contains the impact velocity vector and the vertical ZZ axis (not shown) through the neck—the so-called head-neck pendulum contributor to angular acceleration—and this angular acceleration slightly tilts the cranium upwardly in the region between points C and D, and downwardly in the region between points A and B. That still results in a reduced clearance between the brain 32 and the cranium 36 at the bottom in the region between points C and D, and a reduced clearance between the brain 32 and the cranium 36 at the top in the region between points A and B. Finally, the off-center impact is such that it results in no local, (vertical) rotation at the top of the neck so there is no other rotational contributor to the angular acceleration in this plane, just the aforementioned head-neck pendulum contributor.
[0098] Next, it will be useful to compare the above results using the preferred embodiment of the present invention with those that might occur with a prior art helmet.
[0099] FIG. 10 is a horizontal cross-sectional top plan view of an ellipsoid shaped (long axis front to back) prior art football helmet 102 having an outer shell 104 and a compliant liner 108 . Also shown are the user's head 30 and brain 32 (all sectioned approximately 1 inch above the eyes near the maximum cross sectional circumference of the outer shell 104 ) to illustrate the alignment and position of the helmet components and user features in the pre-impact condition.
[0100] FIG. 11 is the same horizontal cross-sectional top plan view of FIG. 10 , about 10 milliseconds after the initiation of a significant centered helmet-to-helmet impact to the right front quadrant of the helmet 102 , indicated by the large arrow 140 between points C′ and D′. As a result, notice that both the outer shell 104 and the head 30 have been moved away from their initial positions in their inertial frame, in the direction of the impact, with the outer shell 104 moving about twice as much as the head 30 , the various elements of the liner 108 generally symmetrically taking up or absorbing the difference. Once again, the indicated change in X and Y is the linear position change of the head 30 . The elements of the liner 108 between points C and D have been mostly compressed and deformed, while those between points A and B have moved away from the head 30 , and those between points B and C, and D and A, are little affected by the impact. Only the elements of the liner 108 in the quadrant around the impact are substantially involved.
[0101] As expected, with the centered impact there is just a change in the position of the head 30 and virtually no change in its orientation. Also the brain 32 position and its orientation remain substantially unchanged relative to the head 30 in the horizontal plane since the impact velocity vector is centered through the head 30 , so there is no angular acceleration of the head 30 in the horizontal plane. There is only a linear acceleration of the head 30 in the horizontal plane, which has been significantly reduced by the compliance of the elements of the helmet liner 108 , and the already reduced linear acceleration of the head 30 has been further mitigated by the linear accelerating cranium 36 accelerating the trapped cerebrospinal fluid 34 , which in turn results in a pressure gradient in the fluid 34 which accelerates the only slightly higher density brain 32 to nearly keep up with the acceleration of the head 30 , as previously pointed out. There is, however, as a result of the remaining linear acceleration of the head 32 some angular acceleration of the head 32 in the plane that contains the impact velocity vector and the vertical ZZ axis (not shown) through the neck—the so-called head-neck pendulum contributor to angular acceleration—and this angular acceleration slightly tilts the cranium 36 upwardly in the region between points C and D, and downwardly in the region between points A and B. That results in a reduced clearance between the brain and the cranium at the bottom in the region between C and D, and a reduced clearance between the brain 32 and the cranium 36 at the top in the region between points A and B. Finally, because the impact velocity vector is centered through the head 30 , there is no rotational contributor to angular acceleration in this plane either, just the aforementioned head-neck pendulum contributor. All of this is very similar to what happens with the present invention in response to a centered impact ( FIG. 8 ). But most helmet-to-helmet impacts are not strictly centered.
[0102] FIG. 12 is the same horizontal cross-sectional top plan view of FIG. 10 , about 10 milliseconds after the initiation of a significant off-center helmet-to-helmet impact to the right front quadrant of the helmet 102 , indicated by the large arrow 142 between points C′ and D′. And as with the centered impact ( FIG. 11 ), both the outer shell 104 and the head 30 (see X and Y) have been moved away from their initial positions in their inertial frame, in the direction from the point of impact toward the center of the helmet 102 , with the head 30 again moving about half as much as the outer shell 104 , with the compliant elements of the liner 108 again taking up or absorbing the difference. But the linear head acceleration and resulting displacement are still reduced compared to the centered case because only the normal component of the impact vector can drive the linear motion.
[0103] Just as before, as far as any damaging effect on the brain 32 is concerned, the affect of the reduced linear acceleration is mitigated by the linear accelerating cranium 36 accelerating the trapped cerebrospinal fluid 34 , which in turn results in a pressure gradient in the fluid 34 which accelerates the only slightly higher density brain 32 to nearly keep up with the acceleration of the head 30 , as previously pointed out. So there is no brain 32 contact with the cranium 36 directly as a result of the reduced linear acceleration of the head.
[0104] But there is still, as a result of the reduced linear acceleration of the head 30 , some angular acceleration of the head 30 in the vertical plane that contains the normal (inward) impact velocity vector and the ZZ axis (not shown) through the neck—the so-called head-neck pendulum contributor to angular acceleration—and this angular acceleration slightly tilts the cranium 36 upwardly in the region between points C and D, and downwardly in the region between points A and B. And that results in a reduced clearance between the brain 32 and the cranium 36 at the bottom in the region between points C and D, and a reduced clearance between the brain 32 and the cranium 36 at the top in the region between points A and B.
[0105] Finally, as can also be seen in FIG. 12 , with a prior art helmet 102 , there is the potential for a much more serious angular acceleration component in the case of an off-center impact. As with the case of the present invention's response to an off-center impact ( FIG. 9 ), the outer shell 104 has been rotated in the horizontal plane due to the off-center nature of the impact (with the driving frictional force acting via the previously discussed temporarily dimpled-in impacting surfaces). This time, though, the head 30 too has been angularly accelerated horizontally (and rotated) almost as much as the outer shell 104 due to the initial snugness of the helmet liner 108 around the head 30 , the tight chin strap connection, and the natural cupping shape of the deforming liner elements, all typical in prior art helmet designs. Note that in FIG. 12 (from point C), the player's nose, although slightly offset to the impact side, is still pointing in the same general direction as the facemask, and so is his head 30 . But the cerebrospinal fluid 34 cannot move the brain 32 around as efficiently with an angularly accelerating head 30 , as it does with a linearly accelerating head through the pressure gradient mechanism. So rotationally, the brain 32 tends to remain nearly fixed in its inertial plane while the cranium 36 rotates around it. The resulting relative motion can be very damaging. As can be seen clearly in FIG. 12 , at the impact location there is a coup contact between the brain 32 and the cranium 36 near the impact point and at one or more places opposite the impact location (two in this case, see the arrows) there are contrecoup contacts—the start of a concussion event—and with any further rotation of the cranium 36 , the interior brain tissues may be subjected to high strains and strain rates that could compound the severity of the mild traumatic brain injury MTBI, and even lead to diffuse axonal injury DAI.
[0106] Because of the previously discussed head-neck pendulum contributor to the angular acceleration, the actual coup and contrecoup points are likely not exactly located in the horizontal sectioned plane. The resulting reduced clearance between the brain 32 and the cranium 36 at the bottom in the region between points C and D means the coup impact point is likely located below the indicated section plane and the reduced clearance between the brain 32 and the cranium 36 at the top in the region between points A and B means the indicated contrecoup points are likely located above the indicated section plane.
[0107] It is clear by comparing FIG. 9 with FIG. 12 , that a helmet design that uses the principles of the present invention, which is to employ both linear and angular compliance in the helmet liner design, would likely prevent a concussion while a prior art helmet design would not.
[0108] Note that the FIG. 12 off-center impact was located and directed such that it resulted in a horizontal rotational angular acceleration at the top of the neck, and no vertical rotational angular acceleration at the top of the neck. Thus, in a vertical plane, the aforementioned head-neck pendulum contributor is the only contributor to angular acceleration.
[0109] In trying to picture the resulting total head angular acceleration, the angular acceleration in the vertical plane (in this case, just from the head-neck pendulum contributor) can be first separated into its pitch and roll components, and then those components can be combined with a yaw component which is the previously discussed head angular acceleration in the horizontal plane.
[0110] The combination can be crudely approximated through a “square root of the sum of the squares” procedure for components in orthogonal planes, but this is not a good accurate mathematical process for combining orthogonal angular accelerations (which requires using quarternions or the equivalent for computing accurate total angular acceleration), and it is not the process used in coming up with the HITS waveforms or the peak angular acceleration values in the two cited studies. Nevertheless, it provides a “feel” for how the gross magnitudes might sum. Three example cases will now illustrate this. In these examples, the terms horizontal and vertical mean “relative to the head.” Case 1, for an angular acceleration in the vertical plane that is half of what it is in the horizontal plane, the total angular acceleration would be only increased approximately 12% over what it is in the horizontal plane. Case 2, for an angular acceleration in the vertical plane that is equal to the angular acceleration in the horizontal plane, the total angular acceleration would be increased approximately 41% over what it is in the horizontal plane. Case 3, for an angular acceleration in a vertical plane that is combined with a second angular acceleration in the same vertical plane, then they either directly add, or directly subtract, depending on whether they are in the same direction, or in opposite directions. For two equal additive angular accelerations, it would double. Note that the actual impact itself need not be vertically directed, and most likely would not be vertically directed.
[0111] A Case 3 situation occurs whenever an off-center (non-normal) surface impact is in a centered vertical plane—one that goes through the center of the head. Though in a vertical plane, the impact itself could be horizontal, or could come from some other elevation above or below the horizontal. The centered vertical plane could be the midsagittal plane (through the nose), the coronal plane (through the ears), or any other centered vertical plane in between. From the previously noted reduced affect on the head-neck rotational head angular acceleration contributor of “glancing” and “near-normal” surface impacts, the Case 3 helmet-to-helmet impact that is most likely to result in a large total head angular acceleration would be one that is oriented approximately 45° from the impact surface (such an impact would be about 3½ inches off-center, measured as the shortest perpendicular distance from the extended impact vector to the center of the helmet or head). The top-of-the-neck rotational head angular acceleration contributor arises from the surface tangential component of the impact vector. It can be substantial with prior art helmets, yet may be near zero with a present invention helmet 2 due to the large circumferential compliance of its liner 8 . The head-neck pendulum head angular acceleration contributor arises from the horizontal component of the surface normal component of the impact vector. As such, for a 45° surface impact, one at the vertical midpoint of the head 30 (and helmet 2 ) results in the maximum horizontal component of the surface normal component for maximum head-neck pendulum head angular acceleration. Furthermore, if the impact is directed 45° upward, rather than 45° downward, it will be additive (not subtractive) with the top-of-the-neck rotational head angular acceleration for maximum total head angular acceleration. A hit like this would correspond to a quarterback being hit upward from behind on the back of his helmet by the helmet of a defensive lineman, which is not uncommon and is possibly one reason why quarterbacks suffer so many concussions. With the present invention helmet 2 , there would be little or no top-of-the-neck rotational head angular acceleration for a much lower total head angular acceleration, and thus much less chance of a concussion.
[0112] An upwardly directed facemask impact is another potentially serious additive Case 3 impact. One example was the well publicized, upward tangential impact to DeSean Jackson's facemask in the Eagles-Falcons game on Oct. 18, 2010, from which Jackson suffered a severe concussion with several minutes of unconsciousness and memory loss. With a present invention helmet 2 , however, even for a facemask impact, the top-of-the-neck rotational head angular acceleration contributor would be reduced to near zero due to the large circumferential compliance between the outer shell 4 and the head cap 6 . The helmet 2 (specifically the outer shell and portions of the liner 8 ) would still be rotated but the head cap 6 (and head 30 ) would not be rotated, or at the least, would be rotated by a much smaller amount.
[0113] In the first preferred embodiment of the present invention's football helmet design, that circumferential compliance comes about in large part because of the significantly reduced lateral stiffness of the individual foam columns 24 of the liner 8 . With most current helmet designs, for example the latest Revolution helmet by Riddell, the individual foam elements are wide blocks rather than narrow columns, and therefore, even though they are still made of foam, they cannot manifest the same degree of lateral compliance. To determine the elastic lateral compliance of a column 24 , or a block, it may be modeled as a vertical beam which is side-loaded at the top. Its compliance (or displacement per unit force) is then proportional to the cube of its height (h); and inversely proportional to its elastic modulus (E), its effective width (b), and the cube of its effective depth (d) in the force direction. If one then bisects the block vertically in two directions, thereby cutting it into four equal columns, the new lateral compliance of each column becomes 16 times that of the original block, and so the total lateral compliance of the four columns together becomes 4 times that of the original block. If alternatively, one were to trisect the original block vertically in two directions thereby cutting it into nine equal columns, the new lateral compliance of each column would be 81 times that of the original block and so the total lateral compliance of the nine columns together becomes 9 times that of the original block. Thus, as a general rule, the column lateral compliance of the present invention compared to the old block lateral compliance is approximately equal to the number of columns 24 divided by the number of old blocks in the same given area. Going back to the 275 columns of the 5V 8/15 icosahedron geodesic dome pattern and comparing the resulting 275 columns with the approximately 20 blocks inside a prior art Revolution helmet, the lateral compliance of the preferred embodiment of the present invention would be about 15 times greater for the same stiffness foam material. And still other possible geodesic dome patterns yield 400 or more columns—for example a 7V 11/22 icosahedron geodesic dome pattern yields 525 columns. However, as shown in FIG. 8 and FIG. 11 , all of the column elements in the present invention participate in the linear stiffness of the LAR/AAR liner 8 in some manner, whereas in the Revolution helmet only about ¼ of the foam blocks (those directly around the impact) are involved in the linear (compressive) stiffness. Thus, for the same linear (normal direction) compliance, the PU foam in the present invention could be far less stiff (perhaps by a factor of one-quarter) than the foam in the prior art Revolution helmet, and so the lateral (circumferential direction) compliance of the LAR/AAR liner 8 in the present invention could be of the order of up to 60 times greater (not just 15 times greater) than the lateral (circumferential) compliance of the prior art Revolution helmet (and even greater if divided into more columns as indicted above). That is very significant and very important for being able to nearly eliminate the top-of-the-neck head angular acceleration contributor. Actually, the foam blocks used in the prior art Revolution helmet are a sandwich of two different foams having different stiffness, but the same reasoning still applies.
[0114] The prior art Riddell Revolution helmet, and its successors the prior art Revolution Speed and later Riddell 360 incorporate a significant linear (normal) compliance in the liner to protect against high linear acceleration of the head, but everything else, by purposeful design, is to keep a player's head snugly in-place angularly relative to the helmet shell by incorporating features that preclude lateral (circumferential) compliance in the liner. This includes inflatable bladders in the sides and back of the liner for a snugger “customized” fit. Other competitive prior art helmets on the market, also by design, preclude circumferential compliance between the helmet shell and the head, thereby imparting unabated, most, if not all, of any top-of-the-neck, helmet shell rotational angular acceleration to the head, which adds, often directly, to the head-neck pendulum motion that arises from the horizontal portion of a surface normal component at the impact point.
[0115] The second leading football helmet manufacturer, after Riddell, is Schutt Sports. The Schutt ION 4D and DNA Pro+ models utilize Thermoplastic Urethane TPU liners made by SKYDEX. TPU is a polymer but it can act and feel like an elastomer. The molded-in individual dual elements of the liner collapse within each other axially in the helmet radial direction (a process they call Twin Hemisphere Technology) to provide the desired linear compliance and a fair degree of impact absorption. However, the radial nesting process precludes any circumferential motion between the individual dual TPU elements, and thus the liner provides virtually no lateral (circumferential) compliance between the helmet shell and the head.
[0116] A third, and newer company, Xenith, also makes football helmets. Their helmet, the X1, uses for its liner, about eighteen individual hollow air-filled puck-shaped elastomer cylinders each with a valve that slowly lets the air out to linearly cushion a player's head when the cylinders are compressed in a helmet collision. That provides the desired linear (radial) compliance between the helmet and the head. But like the Riddell and Schutt helmets above, the squat, puck-like cylinders provide little or no lateral (circumferential) compliance for the Xenith X1 helmet.
[0117] Moreover, the fitting instructions for all of the above prior art helmets stress snug fit and proper tightening of the chin strap, so that when the user's head is held firmly still, the user cannot jiggle the helmet shell around it. Clearly, “snug fit and proper tightening of the chin strap” sounds like a correct procedure—and for any football helmet it should be. But only with the present invention, “snug fit, and proper tightening of the chin strap” applies to the head-following head cap 6 and not the helmet shell 4 . Then when a user holds his head firmly still and tries to jiggle the helmet shell 4 , the helmet shell 4 jiggles, but the head cap 6 remains firmly unmoved, along with the head 30 . That is the quick test for large circumferential compliance, and the test for reduced chance of concussion.
[0118] Summarized herein are the main points for why the present invention is needed; why, as shown by new insights presented herein, prior art helmets aren't as concussion resistant as one might hope; and how the present invention incorporates those new insights in a novel and practical way to make a more concussion resistant helmet.
[0119] There are an estimated 300,000 football concussions a year—which is an annual incidence rate of about 6% of the estimated nearly 5 million players at all levels. Helmets have been substantially improved, yet the percentage of concussions has not been substantially lowered (though some of the new helmet models claim to show limited reductions). The number of the concussions reported by the NFL for the 2011 season exceeded 10% of the number of players. The helmet improvements have largely been to reduce the linear acceleration levels experienced by a player's head in an impact. However, the helmet improvements have not correspondingly reduced the angular acceleration levels experienced by a player's head in an impact.
[0120] The cerebrospinal fluid (CSF) 34 that surrounds the brain 32 is not merely a liquid cushion against the brain crashing into the cranium 36 in response to a (high G) linear acceleration (or deceleration) of the head. The CSF's own corresponding acceleration (or deceleration) creates a pressure gradient within the CSF that simultaneously accelerates (or decelerates) the brain 32 at approximately the same rate, thereby keeping the brain from crashing into the cranium. Thus the main concussion causer in a helmet-to-helmet impact must be high angular acceleration of the head 30 , where the CSF is a less effective mitigator.
[0121] Two contributors to high angular acceleration of the head are identified. Ironically, because of the existence of a head-neck pendulum motion, the first contributor is high linear acceleration of the head in the horizontal direction. As a result, high linear acceleration of the head still needs to be reduced by high linear compliance of the helmet liner 8 , especially in the head horizontal direction. The second contributor to high angular acceleration of the head is a rotational angular acceleration at the top of the neck caused by an off-center helmet impact. This confirms that not just the location of an impact is important, but the direction of the impact is also important. The data show that the magnitudes of two contributors to total head angular acceleration may be generally in the same ballpark. Thus, when the two contributors to the total head angular acceleration are in the same centered vertical plane, the second contributor could directly add to the first contributor for twice the impact. The second contributor to the total angular acceleration of the head can be reduced by adding concurrent circumferential compliance to the helmet liner. Significant circumferential compliance can be incorporated into a foam helmet liner 8 , without altering its already high linear compliance, by segmenting the liner into a plurality of narrow, radially-oriented foam columns 24 for vastly improved lateral compliance of the columns and resulting circumferential compliance of the liner. The chin strap, if still connected to the outer shell 4 , could compromise the newly gained circumferential compliance by forcing the head to follow the outer shell motion, and so the chin strap is transferred to the inner head cap 6 which follows only the head motion. The head-follower head cap 6 moves with the head 30 , and a combined linearly and angularly compliant, linear acceleration reducing, angular acceleration reducing (LAR/AAR) liner 8 lets the outer shell 4 move both radially and circumferentially relative to the head 30 .
[0122] FIG. 13 is a diagram which shows a hypothetical version of the previously discussed FIG. 4 diagram (from the college study) of angular acceleration vs. linear acceleration. In FIG. 13 , it is assumed that the prior art Revolution helmet has been replaced by the first preferred embodiment helmet 2 of the present invention. Comparing FIG. 13 with FIG. 4 , the effect of using the present invention helmet 2 is dramatic. Note that the 4,300 rad/sec 2 per 100 G reference line in FIG. 4 has been included in FIG. 13 . to aid the comparison. With the helmet shell 4 now being able to rotate easily relative to the head 30 , the second contributor to head angular acceleration (the top-of-the-neck head rotational acceleration) is substantially eliminated, and only the head-neck pendulum contributor still comes through. Using an assumed pendulum distance of 8 inches, its contribution could be as high as 4,830 rad/sec 2 per 100 Gs for a straight horizontal impact at mid helmet height, but for the majority of impacts, which would be about 45° from the surface normal, that relationship would reduce to about 3,400 rad/sec 2 per 100 Gs at mid helmet height, reduce down to about 2,400 rad/sec 2 per 100 Gs on average for a 45° impact elsewhere on the helmet 2 , and finally reduce all the way down to 0 rad/sec 2 for a straight vertical impact to the very top of the helmet 2 .
[0123] It would certainly still be possible to get into the concussion range of >5,500 rad/sec 2 , but that would likely require a straight mid helmet height hit of nearly 120 Gs, and even greater if not a straight mid helmet hit. The above numbers clearly demonstrate that the widespread use of the present invention helmet 2 —where the radial compliance of the liner 8 is maintained and circumferential compliance is added to significantly reduce the top-of-the-neck rotational contributor to head angular acceleration—could conceivably reduce the incidence of football concussions by a potentially very large amount.
[0124] That should not be surprising since up to now, the various helmet liner improvements have addressed only linear head acceleration levels, which affect just the head-neck pendulum contributor to total head angular acceleration. Also, the improvements have been just incremental in scope, so the improvements in outcomes have been incremental as well. But now, by making the liner address the certainly equally significant top-of-the-neck rotational head angular acceleration contributor for the first time while maintaining the improvements in reduced linear head acceleration, a breakthrough improvement in outcome is possible.
[0125] However, FIG. 4 and FIG. 13 also show that the reduction of the top-of-the-neck rotational head angular acceleration contributor can be a double edged sword. The reductions in head angular acceleration at the high end can be large and significant, but so can some increases at the low end be large but they are not significant. In football, with current prior art helmets, helmet-to-helmet collisions that cause the top-of-the-neck contributor to add to the head-neck pendulum contributor for one colliding player may cause it to subtract for the other. With present invention helmets, that subtraction would be less. Yet that appears to be a very acceptable situation for football. The situation and logic are best illustrated by an example.
[0126] See FIG. 14 —a current prior-art football helmet 102 example: An offensive lineman (OL) and a defensive lineman (DL) collide helmet-to-helmet. For each player, the point of impact is at the front of his helmet in the midsagittal plane just above his face guard. The OL gets lower than the DL and the impact occurs when the OL lunges forwardly and upwardly (as shown by the unlabeled arrow) at the DL (in their joint midsagittal plane) which is also the plane of FIG. 14 , where the OL is shown on the left and the DL on the right. From this viewpoint, the head horizontal components of the normal force angularly accelerate the DL's head clockwise (CW) and the OL's head counterclockwise (CCW) about the base of their necks (the head neck pendulum contributor). However, during the approximate 10 millisecond period of the impact while the two helmets very locally deform inwardly and then outwardly again, the OL's helmet continues to push upwardly and to the right, thereby exerting a surface tangential friction force on the DL's helmet which angularly accelerates the DL's helmet and head CW about the top of his neck (the top-of-the-neck contributor), and this adds directly to the CW angular acceleration from the head-neck pendulum contributor, thus the DL sees an increased angular acceleration as a result of the top-of-the-neck contributor. While all that is going on, the equal and opposite tangential friction force on the OL's helmet likewise angularly accelerates the OL's helmet and head CW about the top of his neck which subtracts directly from the CCW angular acceleration from the head neck-pendulum contributor and so the OL sees a decreased angular acceleration as a result of the top-of-the-neck contributor. Thus, in this example, with current helmets the striking player (the OL) is much less likely to suffer a concussion than the struck player (the DL).
[0127] This outcome which favored the striking player (in this case the OL) had nothing to do with who was moving and who was not. That's because from a physics standpoint, the inertial plane of either player could've been considered stationary. Instead, the outcome was solely the result of the impact location and the direction of impact and how they related to the location of the player's neck (and body).
[0128] In the example, the impact location and how it related to the player's neck and body was exactly the same for both players. And the impact occurred in the midsagittal plane for both players. Yet the outcome for the two players was very different. That difference arose from the direction of the impact. The direction of impact can be thought of as the direction from which a flea sitting on the one player's helmet at the impact point would see another flea coming who is sitting on the other player's helmet at the impact point just before the two fleas get crushed out of existence. For the DL, the direction of impact was from the lower left, directed roughly at a right angle to his neck and body, while for the OL the direction of impact was from the upper right and directed downward toward his body.
[0129] In a helmet-to-helmet collision, the striking player (the one leading with his helmet), in most cases will see the impact generally directed inwardly toward his body, thus for an off-center impact above the c.g. plane of the head the resulting tangential force typically gives rise to a top-of-the-neck rotational contributor which opposes the head-neck pendulum angular acceleration contributor from the normal force. With current helmets which transmit virtually all the resulting top-of-the-neck rotational acceleration unabated to the head, that top-of-the-neck contributor would then subtract from any head-neck pendulum contributor to provide the striking player a reduced concussion probability as an undeserved reward. So with current helmets, players who inflict helmet hits on other players often walk away unscathed.
[0130] But the present invention could alter that picture. It substantially reduces the top-of-the-neck contributor, thereby not only reducing the probability of a concussion in any given helmet-to-helmet collision, but also reducing the present unfair skewing of the probability of a concussion (which with current helmets tends to protect the player who leads with his helmet), so based on the loss of that unfair protection the new helmet concept would no longer encourage the practice of leading with one's helmet.
[0131] That should alleviate any risk compensation concerns a behavioral psychologist might have with a concussion reducing helmet—a concern that players might then feel so safe they would tackle helmet first. But in this case, just the opposite would be true. A player would actually be less safe tackling helmet first, and that fact could be pointed out to all players warning them not to get reckless with their new safer helmets. Still they would likely walk away unconcussed from most self-initiated helmet-first tackles, just not as often as before. In the cited example, if the OL and DL were wearing present invention helmets, the OL would be more likely to be concussed than before, but he'd still be less likely to be concussed than the DL who would now be much less likely to be concussed than before.
[0132] Thus the present invention might offer the best of both worlds for football—for a given helmet-to-helmet hit it would lower the probability of anyone sustaining a concussion, plus it would provide an inherent behavioral modification incentive for those perennial helmet-first tacklers to alter their ways. Taken together, that might substantially reduce the unacceptable number of football concussions.
[0133] The present invention, however, is not limited to football helmets. The broad inventive concepts described herein may be applied to protective helmets for other sports as well, including but not limited to hockey, lacrosse, bicycling, baseball, and other endeavors such as motorcycling, snow sports, and even horseback riding, anywhere a helmet is used for protecting the head from impacts. But in these other endeavors (except perhaps hockey) helmet-to-helmet collisions are non-existent. So there may be a philosophical difference in how the helmet should best function.
[0134] In a football helmet-to-helmet collision, even when one player is running at top speed, the head-neck pendulum contributor is kept by the energy absorbing linear compliance of most current prior art helmets below the threshold concussion level of 5,500 rad/sec 2 , yet it may be close. So it is very important that a large top-of-the-neck contributor not be added in additive cases, but it is far less important if a large top-of-the-neck contributor is not being subtracted in subtractive cases. Thus it makes sense in football helmets where the impact speed is somewhat limited to reduce the top-of-the-neck contributor to the head angular acceleration at all times (as is accomplished with the first preferred embodiment), whether it is being added or being subtracted. But that is not the case for the other applications, where a cyclist could be thrown over the handlebars at very high speed, or a jockey could be thrown off his horse at very high speed, or skier could be knocked off his skis at very high speed, so when they all impact the ground their helmets should reduce the top-of-the-neck contributor to their head's angular acceleration only if they happen to impact in such a way that it would add to the head-neck-pendulum contributor. If they were to impact the ground or some other object in such a way that it would subtract from the head-neck pendulum contributor, they might need that extra now-protecting subtractive top-of-the-neck contributor not to be reduced. The previous football example provides a clue as to how the helmet can “know” whether the top-of-the-neck contributor will be adding or subtracting in a given impact, and as a result know whether to reduce the top-of-the-neck contributor, or not. Incredibly, this does not involve the use of any sensors or computer chips—it involves just a novel design modification to the liner.
[0135] All the above applications are non-repetitive impact applications, so the modified liner does not need to be of the automatic return type previously described for football and illustrated by the above described first preferred embodiment, but instead it can be the manual return type, wherein following an impact the user can, himself or herself return the outer shell to its initial position relative to the head cap. In a second preferred embodiment, hereinafter described, the liner provides that capability and reduces the top-of-the-neck contributor only when the nature of the impact makes it additive and the same liner does not reduce the top-of-the-neck contributor when the nature of the impact makes it subtractive. Thus a helmet in accordance with the second preferred embodiment would reduce brain injury as much as possible in either case. What is being accomplished in both cases is the maximum reduction in total resultant head angular acceleration for the given impact.
[0136] By contrast, some other helmet patents which aim to address those same non-repetitive but potentially high impact applications, claim to recognize the negative effect of high total resultant head angular acceleration on the brain, but seem not to recognize the two separate contributors to that resultant head angular acceleration as described in the present application, and so they attribute most or all of that angular acceleration to what is described herein as the top-of-the-neck contributor. Thus their solution to the problem is to always reduce the top-of-the-neck contributor regardless of the nature of the impact, apparently unaware that sometimes (when the two contributors are subtractive) their touted “more-protective” feature may actually be doing more harm than good. For example, take the case of a motorcyclist wearing one of the prior art helmets being thrown over the handlebars and impacting against the hard pavement head first. If his impact resembles what the defensive lineman (DL) of FIG. 14 sees (from his perspective, the pavement rushing up at him from his lower front), that's an additive situation for the top-of-the-neck contributor and so a helmet which always reduces that top-of-the-neck contributor will be helpful in reducing the total head angular acceleration. However, if his impact resembles what the offensive lineman (OL) of FIG. 14 sees (from his prospective, the pavement coming down on him from his top front), that is a subtractive situation for the top-of-the-neck contributor and so a helmet which always reduces the top-of-the-neck contributor will be hurtful to him, because it will not reduce his total head angular acceleration as much as a normal prior art helmet would without that special feature.
[0137] One of those helmet patents that describes a means to always reduce the top-of-the-neck contributor to head angular acceleration for an off-center impact is U.S. Pat. No. 6,658,671. It is widely licensed worldwide for skier protection, motorcyclist, and bicyclist protection, and equestrian protection. The licensees include many popular helmet providers such as POC, Scott, Sweet protection, TSG, RED, and Lazer sport. Referred to as “MIPS technology,” for Multi-Directional Impact Protection System, the patent teaches, and the licensed helmet systems make use of, a very low friction oil, teflon, or microsphere sliding layer located just inside the outer shell which enables the outer shell to rotate very easily in response to an off-center impact. (It rotates way too easily for any football application.) Also, these helmets are relatively close fitting, and with the sliding layer taking up some of that reduced (compared to football helmets) liner thickness, they tend to provide less protection against head linear acceleration and its resulting head-neck pendulum contributor. And finally, some embodiments of this patent are inherently “one-event” helmets, either because the foam in the liner does not totally return to its initial position, or there are permanently deforming rotation-limiting strips at the edges of the shells, or there are rotation-limiting strips that work by wedging into the foam, all of which should preclude its use for more than one impact.
[0138] Other similar patents and patent applications include the following: (1) U.S. Pat. No. 7,930,771 for a bicycle helmet application teaches a helmet with an inner layer for contacting the head, and an intermediate layer made of anisotropic foam material to provide some tangential compliance. All of the foams cited are rigid or semi-rigid foams which may not be fully returnable to the pre-impact condition and therefore should be for one impact only. (2) US patent application US 2002/0023291 A1 for a bicycle helmet application teaches a helmet having multiple layers that include an inner polyurethane layer, a gel layer, a polyethene layer, and an outer polycarbonate layer. According to the application, the gel layer allows for tangential relative motion but how the gel stays in place and enables a return to the initial position after an impact is not explained or claimed. (3) European patent application EP 1142495 A1 for a motorcycle or racecar helmet application teaches ten embodiments. In embodiments 1 thru 8 and 10, rotational slippage occurs along a spherical surface between inner and outer sections of the liner. In embodiment 9, the slip surface is non-spherical in order to inhibit excess relative rotation. In none of the embodiments are the inner and outer shells returnable to their pre-impact position. (4) International patent application WO2004/032659 A1 for a recreational sports and bicycle application teaches a helmet with two basic embodiments. In one embodiment two rigid foam sections form a spherical surface and between them is an intermediate layer which may be a distensible flexible envelope containing a silicone fluid, an oil, a gel, or solid spherical particles to enable tangential motion between the inner and outer surfaces of the bladder, or alternatively a gel layer may replace the bladder. The second embodiment shows a tangential relative motion enabling layer (or layers) positioned right below a spherical outer shell. No returnability mechanisms to the initial position are discussed. Also in many of the described helmet patents or applications, the indicated type of foam used in the liners is not one that fully returns to its initial shape following an impact. Plus in most cases the thickness of the foam is less than with current football helmets, so the linear acceleration attenuation and the resulting reduction in the head-neck pendulum angular acceleration may be insufficient to prevent concussions especially when the impact is large, as it might be for the intended applications.
[0139] Finally, none of the above patents and patent applications discuss the possibility that, depending upon the nature of the impact, it might be desirable or even possible for the helmet to be able to limit its rotational or tangential compliance in those specific high impact situations where the top-of-the-neck rotational contributor would subtract from the head-neck pendulum contributor in order to achieve less total resultant head angular acceleration for the user.
[0140] By contrast, the second preferred embodiment of the present invention does manage to accomplish that unique feat through its novel design. FIG. 15 and FIG. 16 are cross sectional views of a helmet 41 , which has a flexible foam inner liner portion 43 and a flexible foam outer liner portion 45 of similar thickness, and wherein the inner portion nests within the outer portion in one preset initial pre-impact relative position. The basic shape of the mating surface of the two liner portions 43 , 45 need not be perfectly spherical but is generally spheroid or ellipsoid, yet can still slip in response to a non-centered impact because of the flexibility of the foam materials. The outer surface of the outer foam portion 45 is adhered to the inner surface of the outer shell 47 with an adhesive layer 49 , while the inner surface of the inner foam portion 43 is adhered to the outer surface of the head cap 51 with an adhesive layer 53 . FIG. 15 is a vertical plane section WW (midsagittal plane) showing the outer shell 47 , two-portion liner 43 , 45 , and head cap 51 , and FIG. 16 is an approximate transverse plane section near the c.g. of the head along line UU, showing the outer shell 47 , two-portion liner 41 , 43 , and head cap 51 . For simplicity sake, not shown in either figure is anything interior to the head cap 51 or otherwise attached to it such as a chin strap, jaw strap, or sub-liner, or exterior to the outer shell 47 such as a face shield.
[0141] The outer foam portion 45 shown in both FIG. 15 and FIG. 16 preferably contains six horizontally oriented regions approximately evenly spaced around the periphery, each about 3 inches wide and spaced about 1 to 1½ inches from each other by six intermediate regions. Starting about 0.6 inches above the aforementioned transverse plane the six 3 inch wide regions gradually taper radially inwardly about 0.2 inches (sloping ˜0.33 in/in) as they extend downwardly toward the rim, then suddenly they return to the original mating radius of the intermediate regions near the indicated transverse plane UU ( FIG. 16 ), thereby creating six shelves.
[0142] The inner foam portion 43 preferably contains six matching horizontally oriented regions with matching width and positioning and matching gradual inwardly taper and sudden outward shelf-forming feature of the outer foam portion 45 . Also for both the outer and inner portions 43 , 45 of the liner, starting approximately a half inch in from each end of the six 3 inch wide horizontal regions, they gradually taper outwardly toward the mating radius of the intermediate regions at both ends. The key features are the matching gradual tapers and mating shelves, herein 0.2 inch wide, in the six nearly 3 inch long shelves. But other numbers and other positions and other dimensions that accomplish essentially the same functions (to be described in the subsequent paragraphs) are also feasible. Note that as a modification to the above described second preferred embodiment, there may be one or more similar additional mating horizontal regions located above the ones described, but typically proportionally smaller in dimension.
[0143] Both the shape and the locations of the six horizontal regions are what give the helmet 41 the ability to reduce the top-of-the-neck rotational contributor to total head angular acceleration for impacts where the top-of-the-neck contributor would be additive to the head-neck pendulum contributor, and at the same time to not reduce the top-of-the-neck rotational contributor for impacts where the top-of-the-neck contributor is subtractive with the head-neck pendulum contributor and therefore helpful in limiting the total head angular acceleration. The key functional features are the flat bottoms (or shelves) of the horizontal regions along with their tapered sides and tapered tops.
[0144] Three potential non-centered high impact situations are herein analyzed and these are illustrated in FIGS. 15 and 16 , impacts A and B in FIG. 15 and impact C in FIG. 16 .
[0145] Impact A could be of a motorcyclist hurtling forward at 40+ MPH over the handlebars and striking the pavement on the upper forehead area of his helmet while his upper body is oriented slightly downward so the impact is directed along vector A in FIG. 15 . From the normal force he would experience a large (backward) CCW head-neck pendulum angular acceleration contributor proportional to approximately A cos 2 45°, and the normal force would also push the outer shell 47 and outer liner portion 45 inwardly toward the lower left of the figure. From the tangential force he would experience a large (forward) CW top-of-the-neck rotational angular acceleration contributor which is proportional to approximately A cos 45°. This contributor still exists because the outer foam portion 45 of the liner is getting crushed into the inner foam portion 43 of the liner in the right half of the figure and that now precludes the outer portion 45 of the liner from slipping downwardly past the inner portion 43 of the liner at their shared shelf interface location. It is the shelf-like nature of the interface that causes it to act like a one-way abutment, especially when the two liner portions are being pushed into one another. That enables almost all the top-of-the-neck CW rotational contributor to be subtracted from the head-neck pendulum CCW contributor for a much reduced total head angular acceleration. Notice that the motorcyclist impact herein described is analogous to the current prior-art helmet impact situation for the offensive lineman (OL) depicted in FIG. 14 . Had the motorcyclist been wearing a MIPS helmet, the now protective (for this particular case) top-of-the-neck rotational contributor could have been much reduced, and the high speed motorcyclist could therefore have suffered greater total head angular acceleration and brain trauma as a result.
[0146] Impact B could be of the same motorcyclist hurtling forward at 40+MPH, but this time he catches a heavy horizontal tree limb, with the impact occurring against his upper forehead area as shown at the right in FIG. IS being directed along vector B while he is still oriented in an upward upper body orientation. So from the normal force he would experience a large (backward) CCW head-neck pendulum angular acceleration contributor proportional to approximately B cos 2 45° that would force the outer shell 47 and outer liner portion 45 inwardly toward the lower left of the figure. And from the tangential force he'd experience a large (also backward) CCW top-of-the-neck rotational angular acceleration contributor which is proportional to approximately B cos 45°. If the outer liner portion 45 could not slip relative to the inner liner portion 43 the two contributors would add unabated, yielding a high total head angular acceleration. But fortunately, because of the gentle taper just above the shared shelf location in the region near where the outer and inner helmet liner portions 43 , 45 are being crushed together at the right, the outer liner portion 45 can slip upwardly CCW relative to the inner liner portion 43 . And at the back of the helmet (the opposite left hand side of the figure), the outer liner portion 45 has moved radially away from the inner liner portion 43 thereby disengaging in the shelf region and the outer liner portion 45 can move downward CCW relative to the inner liner portion 43 . Thus the additive CCW top-of-the-neck contributor has been automatically decoupled from the head by the slipping, and only a much reduced top-of-the-neck contributor is added to the head-neck pendulum contributor for a much reduced total head angular acceleration.
[0147] Impact C depicted in FIG. 16 is much the same as the non-centered impacts depicted in FIG. 9 and FIG. 12 . The impact is still in the same approximate transverse plane as the e.g. of the head, but now the impact, still off-center at the right-front, is directed straight back as shown. The situation could be of the above high speed motorcyclist, now impacting head first against a suddenly stopped, sideways-turned edge of his own windscreen. From the normal force he would experience a large (backward, toward the left rear of his head) head-neck pendulum angular acceleration proportional to approximately C cos 45°, the motion occurring in a vertical plane, and the normal force would also push the outer shell 47 and outer liner portion 45 toward the left rear of his head (the top left of the figure), causing no relative slippage. But from the tangential force he would experience a large CW top-of-the-neck rotational angular acceleration about his head's vertical axis that would be approximately proportional to C cos 45°. If the outer liner portion 45 were not able to slip in the transverse plane relative to the inner liner portion 43 the two angular accelerations would add approximately as the square root of the sum of the squares, yielding a high total head angular acceleration. But fortunately, because of the gentle taper at the ends of the 3 inch wide horizontal regions, the outer liner portion 45 is able to slip against the inner liner portion 43 and the so the transverse plane angular acceleration is not fully transmitted to the head to become one of the “squares” in the above square root of the sum of the squares relation, thereby reducing the otherwise high total head angular acceleration.
[0148] In each of the above discussed three impact scenarios there was slippage or at least the possibility of slippage between the outer liner portion 45 and the inner liner portion 43 (note that with impact A, slippage may have occurred at the side opposite the impact). So following the impact and before any reuse the outer shell 47 and its attached outer liner portion 45 must be manually returned to their initial positions relative to the head cap 51 and its attached inner liner portion 43 . That process is straightforward, since in the approximate correct initial position, there is only one way the two liner portions 43 , 45 can slide back into place. That is in contrast to other helmets with foam liners that may not fully return to their initial shape following an impact, in which case the user might unknowingly continue to wear the helmet although its performance might now be compromised.
[0149] A key purpose of the present invention is to reduce concussions on the football field and elsewhere by reducing the resultant peak head angular acceleration for the helmet wearer. But there are two interrelated questions that must be answered. The first question is, to reduce the resultant peak head angular acceleration to what level? That question has already been answered by the second study that was herein presented. And the second question is, to accomplish that level of reduction in response to what level and type of impact? Based upon the answers to the second question, there need to be numerical performance criteria specified that are at least partially met in order to achieve a level of concussion reduction that is significant. The following paragraph is helpful in answering the first part of the second question about what the level of impact might be.
[0150] In a recent interview, the manager of R&D for one of the largest football helmet manufacturers said that based on his own careful analysis of NFL films, 17.5 MPH (miles per hour) is the mean helmet-to-helmet velocity at which concussions occur, meaning it is the closing velocity for a 50% probability of concussion. By using 40 yard dash numbers for comparison, 17.5 MPH is 7.8 meters/second, and 40 yards is 36.6 meters, and so dividing 36.6 by 7.8 would yield a time of 4.69 seconds for a 40 yard dash. That is at or close to top speed for most football players, so it seems his 17.5 MPH number could make sense. The R&D manager then used an impact test rig to demonstrate a 17.5 MPH helmet-to-helmet collision of two instrumented dummy heads wearing the latest helmets and the interviewer described the impact as sounding like a gunshot. Based on the gathered internal accelerometer data the SI (severity index) was computed by the test rig software to be 432. If one assumes a 10 millisecond half sine acceleration waveform the corresponding peak head linear acceleration can be backed out, and it comes to 98 Gs. Even if all of that acceleration were in the transverse plane containing the c.g. of the head, that would translate to a head-neck pendulum peak angular acceleration of just 4,733 rad/sec 2 based upon an 8 inch distance between the head c.g. and the lower neck pivot. In the previously cited (above) high school study, the mean peak head linear acceleration for the 13 concussion impacts was 105 Gs, which reassuringly is not too dissimilar (within about 7%) from the computed 98 Gs for the above 17.5 MPH impact, thus tending to confirm the R&D manager's insight. But for the high school data, the concussion impacts had a mean peak head angular acceleration of 7,229 rad/sec 2 , and therefore those impacts required an additional top-of-the-neck contributor as well. If the impacts were located at the transverse plane containing the c.g. of the head but were directed on average at an angle of 45° from it, the corresponding head-neck pendulum contributor could have been less than 3,600 rad/sec 2 , so the contribution from the top-of-the-neck contributor for the 13 concussion impacts was likely on average another 3,600 rad/sec 2 if coplanar and purely additive, and likely over 6,000 rad/sec 2 if at right angles to the head-neck pendulum plane, in order to reach a mean peak total head angular acceleration level of 7,229 rad/sec 2 .
[0151] In either case, it can be concluded that if sufficient circumferential compliance had been added to the high school players' helmet liners to reduce the top-of-the-neck rotational contributor to half the above values it would have brought the mean total head angular acceleration level below the concussion threshold of 5,500 rad/sec 2 , and thereby would have eliminated at least half of the concussions—there were no concussions from any of the 53,563 impacts with angular accelerations below 5,500 rad/sec 2 .
[0152] Using the above paragraphs as a guide, if a closing velocity of 7.8 m/sec between two instrumented helmeted heads is used as the basis of a helmet-to-helmet impact test, and if the impact is such that the closing velocity vector is 45 degrees off-center to represent a typical impact, which in reality could be anywhere from 0° representing a centered impact to 90° representing a grazing impact, and if the measured resultant peak head angular acceleration is less than 5,500 rad/sec 2 as a result of both the radial and circumferential compliance of the liner, that could represent at least a 50% potential concussion reduction for the particular 45° off-center impact location and direction used in the test. The greater the number of different 45° off-center locations and directions for which the resultant peak head angular acceleration turns out to be 5,500 rad/sec 2 or less, the more likely the total concussion rate will have a demonstrated potential for a 50% reduction or more.
[0153] The same logic can be utilized in what has become the standard test for helmets which involves dropping an instrumented helmeted head a set distance onto an anvil having a flat surface with a half inch polyurethane elastomer covering. The standard drop distance for football is 60 inches to obtain a closing speed of 5.5 m/sec at impact. The obvious question is: how equivalent is this to a helmet-to-helmet impact with a closing speed of 7.8 m/sec? It is completely intuitive to see that a car crashing into an immoveable wall at 30 MPH is exactly equivalent to the car crashing head-on into a like car at a combined closing speed of 60 MPH. With that analogy, one may conclude that a drop onto an anvil at 3.9 m/sec would be more equivalent to the 7.8 m/sec helmet-to-helmet collision. But the half inch polyurethane elasomer covering makes a big difference, and the extra give it provides indeed does make the 5.5 m/sec closing speed against the anvil fairly equivalent to the 7.8 m/sec helmet-to-helmet impact. For supporting evidence, in the cited interview above, the R&D manager also conducted a 5.5 m/sec impact velocity test against a standard anvil and came up with similar results for the measured (and computed) SI index. In standard tests the drop velocity vector is always normal to the anvil surface. However, in the equivalent off-center test herein proposed, the drop velocity vector must be at 45° to the anvil surface. And since the drop velocity vector is always vertical, the anvil must be mounted such that its covered impact surface is 45° from both true vertical, and thus true horizontal too.
[0154] Based on the previously cited data, calculations, and discussions, a concluding summation can be made regarding the novel teachings of the present specification and novel features of the present invention, and what performance criteria should be achieved and achievable as a result. The present invention specifically addresses concussion-reducing helmets for sports and activities where impacts to the helmet can be numerous and repetitive, such as football, hockey, and lacrosse, as well as helmets for sports and activities where helmet impacts are rare but impact velocities can be large, such as motorcycling and cycling, snow sports, and equestrian sports. A major teaching of the specification is that the linear acceleration of the head is not the direct cause of concussions, yet is still a key factor. The teaching is that the direct cause is the angular acceleration of the head, and that this has two contributors: a head-neck pendulum contributor which arises from the transverse linear acceleration and is driven by the horizontal coordinate of the normal force on the helmet, and a top-of-the-neck rotational contributor which is driven by the tangential force on the helmet in an off-center collision. Depending upon the location of the impact on the helmet, and its direction, the two contributors may, if in the same plane either directly add or directly subtract, or if in perpendicular planes add approximately as the square root of the sum of the squares. Football has both the most concussions and the most data relating measured head accelerations to concussions. One set of field data of 54,247 impacts found a head peak angular acceleration threshold of 5,582 rad/sec 2 , below which occurred no concussions and above which the concussion rate was 2%. The same data reveals a mean head peak angular acceleration level of 7,222 rad/sec 2 for the concussive impacts. An analysis of the data indicates that on average half or more of the concussive angular acceleration was from a top-of-the-neck additive contributor, and that if hypothetically one had reduced that contributor by at least half by adding circumferential compliance to the liners of the prior art helmets while maintaining their radial compliance (the present invention requires and provides for both) one could have reduced the concussions by at least half. Combining information from another source, the unknown mean concussive closing velocities of the above study are shown to be consistent with a helmet-to-helmet closing velocity of 7.8 m/sec and an impact velocity of 5.5 m/sec against a polyurethane elastomer covered steel anvil in a 60 inch drop test. Thus it is meaningful to use these standard impact tests and speeds, but to impact at 45° off-center to excite the top-of-the-neck contributor (not excited by current centered tests) and do so in a way that it adds to the head-neck pendulum contributor. Then mean resultant head angular acceleration levels below 7,200 rad/sec 2 would be evidence of improvement and mean levels below 5,500 rad/sec 2 would be evidence of substantial improvement. The first preferred embodiment is for the cited repetitive impact applications, and the liner 8 automatically returns the outer shell 4 to its initial position relative to the head cap 6 (and head) after each impact. The second preferred embodiment is for those cited applications with rare but potentially high speed impacts, and the liner enables the user to manually (and completely) return the outer shell 47 and head cap 51 to their initial relative position following an impact. This is in contrast to some current helmets which employ elements that may suffer at least a slight permanent set following an impact and thus the user may unknowingly continue to use it although its performance might be impaired as a result. The first preferred embodiment liner 8 always exhibits circumferential compliance for maximum reduction of the top-of-the-neck contributor, even when the nature of the impact causes the two contributors to be subtractive. However, the second preferred embodiment's unique two piece liner design exhibits circumferential compliance except when the nature of the impact causes the two contributors to be subtractive. From the motorcyclist example (Impact A), that allows a large top-of-the-neck contributor to remain and subtract from the head-neck pendulum contributor when the latter might be very large due to a high speed impact against the ground or other immovable object. For football, the head neck pendulum contributor is rarely large enough by itself to cause a concussion, so when the nature of the impact is such that the two contributors are subtractive, subtracting a large top-of-the-neck contributor is not necessary. This should hold true for hockey and lacrosse as well, where the hits aren't helmet-to-helmet but are hits from opposing sticks and elbows, and in the case of hockey impacts against the wooden boards (and attached glass) which have a lot of give.
[0155] The present invention is not limited to the types of helmets cited herein. The broad inventive concepts described herein may be applied to protective helmets of all sports and activities, even certain military helmets, anywhere a helmet is used for protecting the head from impacts. Also, the invention is not limited to the first preferred embodiment described herein where the circumferential compliance and linear (radial) compliance of the helmet liner 8 was obtained by segmenting the liner's foam into a multitude of narrow radial columns 24 . Nor is it limited to the second preferred embodiment described herein where the circumferential compliance was obtained by the slip-ability between the two portions of the liner. The basic inventive principle is to employ a liner having both angular (circumferential) compliance and linear (radial) compliance, and having the ability to enable a full return to the pre-impact condition following an impact, and other structures or methods of achieving such dual compliance of sufficient degree and full return-ability would still come under the broad teachings of the present invention. And in the second preferred embodiment case, there is the ability of the liner to automatically preferentially manifest or not manifest that circumferential compliance based on the nature of the impact. Other structures or methods of achieving the necessary dual liner compliance and automatic preferential manifestation of the circumferential compliance based upon the nature of the impact and full return-ability following an impact according to the present invention are also covered under the broad teachings of the present invention. For both cases, the other structures or methods may include, but are not be limited to, the use of a cup-shaped bladder located between and attached to the head cap and outer shell, wherein the bladder may have its own elastic properties for full return-ability and may contain other elastic and energy absorbing elements such as compressible/extensible finger-like elements, fibrous elements, metal spring elements, polymer spring elements, elastomer spring elements, air spring elements, curved bristle-like elements, stretchable filament elements, viscous fluid elements, frictional filler elements, inertial filler elements, density reducing filler elements, and the like, plus the use of any of the above elements without the bladder, as long as the liner enables the head cap and the outer shell to be returned to their initial pre-impact relative position following an impact, either automatically or manually, so as to be ready for another impact.
[0156] Finally, although the first preferred embodiment and the second preferred embodiment of the improved helmet system have been described in significant detail for the helmet applications addressed herein, not just alternate arrangements but other applications which are still within the scope of the present invention may be feasible. It will also be appreciated by those skilled in the art that alternate uses may be found that differ from the proposed use, and changes or modifications could be made to the above-described embodiments without departing from the broad inventive concepts of the invention. Therefore it should be appreciated that the present invention is not limited to the particular use or particular embodiments disclosed but is intended to cover all uses and all embodiments within the scope or spirit of the described invention. | A protective helmet for successive impacts includes a head cap adapted to surround and move with a wearer's head and an outer shell which surrounds the head cap. An energy absorbing flexible liner predominantly comprised of radially oriented foam columns is attached to both the head cap and outer shell. The liner establishes a preset initial relative position and spacing between the head cap and the outer shell and compliantly absorbs energy imparted to the outer shell during a helmet impact to enable the outer shell to move linearly and angularly relative to the head cap during the helmet impact and to be returned to the initial relative position with the head cap following the impact. | 0 |
This is a continuation of application Ser. No. 08/083,904 filed on Jun. 25, 1993, now abandoned.
BACKGROUND TO THE INVENTION
This invention relates to a work station which includes a liquid collection surface with a drain outlet, and to a ventilated work station.
Work stations which can accommodate liquid or other waste for disposal can be required to be capable of being used for many tasks, including washing, draining, preparation of materials and so on. Frequently, the requirements placed on the configuration of the work station change according to the particular task that is to be performed.
SUMMARY OF THE INVENTION
The present invention provides a work station in which a work facility is provided which can be removed so that it can be interchanged with another facility.
Accordingly, in one aspect, the invention provides a work station which comprises:
(a) a support unit which includes a liquid collection surface with a drain outlet, and which provides a support surface; and
(b) at least one work facility mounted removably in the support unit on the support surface, the work facility having a drain outlet through which liquid can drain from the work facility onto the collection surface of the support unit, for collection for the drain outlet provided therein.
The work station of the invention has the advantage that it can be adapted easily to suit a particular task that is to be performed at it, while still allowing liquid waste (or other waste that can be disposed of with liquid waste) from the work facility in use to be collected. Work facilities can be placed on the support unit, and interchanged or moved relative to one another and the support unit as required. Thus for example, it might be appropriate for one task for the work station to accommodate one sink and a drainage surface. In another situation, it might be appropriate for the work station to accommodate two sinks, each of which might, for example, include an integral drainage surface. The work station can be adapted between these two configurations simply by replacement of the work facilities that provide the sinks and the drainage surfaces, as the case might be.
The work station can include two or more work facilities mounted removably in the support unit, of which at least one has a drain outlet through which liquid can drain from the work facility onto the collection surface of the support unit, for collection for the drain outlet provided therein. The work station can include one or more removable support elements which can be placed between adjacent work facilities to support them.
The work facility can comprise a sink, which might, for example, have a draining surface formed integrally with it on which articles can be placed for liquid to drain from them.
The work facility can comprise a drainage surface, on which articles can be placed for liquid to drain from them.
The work facility can comprise a substantially flat surface, for example such as might be used for preparation of materials, perhaps when the materials need to be cut. The flat surface might include formations, such as a groove around its perimeter for collection of liquid which must be drained from the facility.
Preferably, the work station includes openings formed in the support unit for ventilation of the atmosphere in the vicinity of the work facility. The openings can be formed in the support surface of the support unit, along one or more edge portions of the support surface, for example along two opposite edges of a rectangular support unit. More preferably, openings are provided around approximately the entire periphery of the support surface. When the work station includes more than one work facility, it can be preferred for ventilation openings to be provided between adjacent work facilities. Such openings can be provided in a support element which extend across the work station between adjacent work facilities.
The ventilation openings can be provided in an upstanding wall.
Preferably, the openings in the support unit communicate with a plenum chamber.
The work station can include a device for ventilating the work facility, such as a fan.
Preferably, the liquid collection surface is a surface of the plenum chamber.
Preferably, the work station includes at least one valve, such as a tap or faucet, by which the supply of fluid to the work facilities can be controlled. The fluid might be, for example, water or another solvent, or a cleaning material such as a detergent.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic isometric view of a work station;
FIG. 2 is a cross-section of the upper regions of the work station shown in FIG. 1; and
FIG. 3 is a cross-section through a flat working facility which can be used on the work station shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a generally rectangular cabinet 11 whose upper regions are closed by a plenum chamber 12 which comprises a flange 12a, the outer edge regions of which are supported by the cabinet 11, with a central depression 12b within the flange 12a.
The flange 12a defines an outwardly extending flange 12c and an inwardly directed flange 12d. The outwardly directed flange 12c seats on top of a frame 11a for the cabinet 11 and the flange 12d extends inwardly from the wall of the recess 12b and includes ventilating apertures 13.
The flange parts 12c and 12d lie in a common, substantially horizontal plane, and the central opening into the plenum chamber 12, defined by the inner peripheral edge of flange 12d, is closed by two work facilities 14 and 15.
The work facility 14 presents a relatively flat top and conveniently comprises a shallow metal trough defined by a base 14a, upstanding parallel walls 14b and 14c, and flanges 14d and 14e outwardly depending. The flanges 14d and 14e lie parallel to the base 14a and the trough is so arranged that the depressed central region, defined by base 14a, and upstanding walls 14b and 14c, fits neatly into the central opening defined by the inner edge of flange 12d, with the flanges 14d and 14eresting on the flange 12d.
A block of solid material 16, preferable inert with respect to the work tasks to be performed thereon, fits neatly into the recess defined by the trough 14.
The block 16 may present its upper surface in the plane of the upper surface of the flanges 14d and 14e, as illustrated, or the said upper surface of the block 16 may be slightly below the upper surface of the flanges 14d and 14e, to facilitate washing of the block 16.
The trough 14 is open at both its side edge regions.
In another embodiment, the block 16 and the base 14a are perforated, to allow atmosphere above the block 16 to be drawn into the plenum chamber, whilst in another embodiment, the work facility may comprise a simple perforated metal plate.
The second work facility 15 comprises a sink, with flanges 15aand 15b along its rear and forward edge regions respectively, the sink has a front to rear dimension which allows it to enter the central aperture in the plenum chamber, defined by the inner edge of the flange 12d, and the flanges 15a and 15b rest on the flange 12d to support the sink.
With the work facilities 14,15 located in the central opening of the plenum chamber 12, said central opening is substantially closed and, when the plenum chamber is connected to an evacuating source, as by a duct 17 having an inlet 17a open to the plenum chamber 12, atmosphere above the flange 12a is drawn into the plenum chamber 12 to remove contaminates from the atmosphere above said work facilities 14 and 15.
It should be observed that, when correctly located in the central opening in the flange 12d, the sink 15 has a depth which is less than that of the plenum chamber 12, the sink 15 does have a drain outlet 18 but does not have a drain connected thereto, and the plenum chamber 12 includes a liquid drain 21 therefore. Thus, the sink 15 has no permanent connections with the work station.
The work facilities 14, 15 have a combined width, relative to the cabinet 11, which is slightly less than the width of the central opening defined by the flange 12d and, as both work facilities 14 and 15 have no permanent connections with the work station, said work facilities are readily interchangeable.
In a work station having two work facilities, as illustrated in FIGS. 1 and 2, the cabinet may include two swivel taps 19, mounted on or adjacent the mid-width regions of the flange 12d, whereupon the sink 15 may be charged with water in both its possible work locations.
In another embodiment one or both taps 19 may be replaced by a flexible hose of a length to allow water to be supplied to any location on the upper surface of the cabinet 11.
In another embodiment in accordance with the invention the cabinet may support three or more work facilities and, by way of example, the cabinet 11 may support two flat work facilities, similar to work facility 14, and said work facilities 14 may be arranged with the sink 15 between them or with the two flat work facilities 14 in side by side relationship, with the sink 15 at one end or the other end thereof.
With such an arrangement three swivel taps 19 may be provided, one for each work facility, or a flexible extension pipe, may be connected to, or may replace, one or more taps 19, to allow the sink 15 to be filled in any of its three locations. For some such embodiments the flexible pipe may discharge through a spray device.
Further, whilst the block 16 has been illustrated as having a top surface 16a in the plane of the upper surface of flanges 14d and 14e the block 16 may not be rectangular and said block 16 may present any desired configuration on its top surface.
Vertical ventilated walls are well known in the art and one such ventilated wall be located along the rear of the cabinet 11 to increase the amount of air evacuated from above, the work facilities. | A work station comprising a support unit which includes a liquid collection surface with a drain outlet, and which provides a support surface; at least at least one work facility, such as a sink or a drainage surface, mounted removably in the support unit on the support surface, the work facility having a drain outlet through which liquid can drain from the work facility onto the collection surface of the support unit, for collection for the drain outlet provided therein. | 4 |
[0001] This application claims priority from provisional application Serial No. 60/347,363, filed Jan. 11, 2002, incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an articulating tool assembly. More particularly, the present invention relates to an articulating tool assembly of the socket driver type having an articulating head portion that is selectively movable into a plurality of angular orientations with respect to a body portion. The present invention also relates to an articulating tool assembly having a body portion including one or more articulating members.
[0004] 2. Description of the Related Art
[0005] It is often necessary to install a nut onto or remove a nut from a machine bolt in a confined area or to perform some other task using a tool in a confined area. For example, conventional ratchet wrenches are not suitable for use in confined areas because restricted access to the confined space interferes with the back and forth motion of the wrench handle or because a mechanic cannot access the confined area in such a way as to transmit the necessary torque to the wrench handle to facilitate the nut installation or removal process. Accordingly, there is a need for a simple, convenient, economical tool, such as a wrench, capable of adapting to use in a confined area to allow a user to operate the tool and perform the necessary tasks, e.g., the removal or installation of nuts.
SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a novel type of articulating tool assembly, which is simple to manufacture and convenient to use. In one preferred embodiment, the articulating tool assembly includes an articulating ratchet wrench assembly including a socket driver.
[0007] In accordance with the present invention, the articulating tool assembly has an elongated body portion having a handle section and a yoke section with first and second opposed yoke arms. Preferably, at least one of the yoke arms has a toothed aperture. A head portion includes a head section and a head retaining section having a bore which partly consists of teeth. An actuation member defines an axle shaft with two spaced apart sprockets. The axle shaft extends through the toothed apertures of the two yoke arms and the bore of the head retaining section. In an engaged position, the first sprocket of the axle shaft engages the toothed aperture of the first yoke arm and a first toothed area of the bore of the head retaining section, while the second sprocket engages the toothed aperture of the second yoke arm and a second toothed area of the bore of head retaining portion. In this position, the actuation member prevents articulation of the head portion of the tool assembly in relation to the elongated body portion. In the disengaged position, the second sprocket is rotatably positioned within a raceway area of the bore of the head retaining portion while the first sprocket engages only the toothed aperture of the first yoke arm. In this position, the head portion is free to articulate in relation to the elongated body portion. Alternatively, in the disengaged position, the first sprocket may engage only the raceway area of the bore of the head retaining section while the second sprocket may engage only a toothed aperture of the second yoke arm.
[0008] It is envisioned that two or more yoke sections may be provided along the length of the elongated body portion to provide a tool having a plurality of areas of articulation.
[0009] Therefore, users can easily utilize the adjustable articulating tool for accessing a confined area by using the articulated movements of the tool head portion with respect to the elongated body portion to perform a desired task, e.g., to tighten and loosen bolts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above objects and other advantages of the present invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0011] [0011]FIG. 1 illustrates a perspective view of an articulating ratchet wrench assembly constructed in accordance with a preferred embodiment of the present invention;
[0012] [0012]FIG. 2 illustrates a plan view, in partial cut-away, of a yoke section, a wrench head portion, and an actuation member disposed in an engaged position of the ratchet wrench assembly of FIG. 1;
[0013] [0013]FIG. 3 illustrates a plan view, in partial cut-away, of a yoke section, a wrench head portion and an actuation member moved into a disengaged position to permit movement of the wrench head portion relative to the elongated body portion of the ratchet wrench assembly of FIG. 1;
[0014] [0014]FIG. 4 illustrates a plan view, in partial cut-away, of a yoke section, a wrench head portion and an actuation member moved into another disengaged position to permit movement of the wrench head portion relative to the elongated body portion of the ratchet wrench assembly of FIG. 1;
[0015] [0015]FIG. 5 illustrates a side elevational view showing various selected positions of the wrench head portion of the ratchet wrench assembly of the present invention;
[0016] [0016]FIG. 6 illustrates a perspective view of an actuation member of the ratchet wrench assembly of the present invention;
[0017] [0017]FIG. 7 illustrates an exploded perspective view of the ratchet wrench assembly of the present invention;
[0018] [0018]FIG. 8 is a schematic diagram of a linkage assembly for remotely actuating the actuation member of the presently disclosed wrench assembly;
[0019] [0019]FIG. 9 is a side view of another preferred embodiment of the presently disclosed invention; and
[0020] [0020]FIG. 10 is a side view of the actuation member of the embodiment of the invention shown in FIG. 9.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] A preferred embodiment of the present invention will be described hereinbelow with reference to the accompanying drawings. In the following description, like reference numerals identify similar or identical elements throughout the several views, while well-known functions or constructions are not described in detail so as not to obscure the invention in unnecessary detail. Although this description refers specifically to an articulating wrench assembly, it is to be understood that this disclosure may be incorporated into other tool assemblies, e.g., screw drivers, magnetic retrieval devices, prying devices, hammers, paint brushes, a variety of different medical and/or surgical tools, articulating devices, etc.
[0022] Referring to FIG. 1, the articulating wrench assembly 10 essentially comprises an elongated body portion 12 , a wrench head portion 20 and an actuation member 30 . The elongated body portion 12 defines an ergonomically configured wrench handle section 13 along a major portion thereof and a yoke section 14 at a front or distal end thereof. The yoke section 14 of the elongated body portion 12 has two opposed yoke arms 14 A, 14 B. The wrench head portion 20 includes a socket adaptor 26 , a wrench head section 24 and a wrench head retaining section 22 . The elongated body portion 12 may include an additional yoke section or sections along the length thereof to provide multiple areas of articulation on the tool assembly. Each area of articulation would preferably include an actuation member to control articulation of the tool assembly.
[0023] Referring now to FIGS. 6 and 7, the yoke section 14 of the elongated body portion 12 has two opposed yoke arms 14 A, 14 B, at least one of which includes an engagement area, e.g., a toothed aperture 16 , 18 which extends at least partially through a respective yoke arm 14 A, 14 B. In a preferred embodiment, both yoke arms 14 A and 14 B include toothed apertures. The wrench head portion 20 includes a wrench head section 24 and a wrench head retaining section 22 which has a bore 40 consisting of first and second spaced apart engagement areas, e.g., annular toothed areas 42 and 44 (See FIGS. 2, 3 and 4 ) and an annular raceway area 28 with no teeth positioned between annular toothed areas 42 and 44 . Actuation member 30 includes an axle shaft 32 extending through the toothed apertures 16 and 18 of two yoke arms 14 A and 14 B and the bore 40 of the wrench head retaining section 22 (See FIGS. 1 and 7). The actuation member 30 is utilized to control articulated movement of the wrench head portion 20 with respect to the elongated body portion 12 (See FIG. 5) and includes first and second locking members or sprockets 34 and 36 . Each sprocket 34 and 36 has a plurality of annularly disposed gear teeth which are configured to interact with complementary toothed engagement areas 16 , 18 , 42 , 44 formed within the yoke arms 14 A and 14 B and the wrench head retaining section 22 . Alternately, the number of teeth provided on the sprocket may differ from the number of teeth provided on the yoke arms and/or the wrench head retaining portion, i.e., only a single tooth may be provided on the sprocket (or the yoke arms and/or the wrench head retaining portion). Toothed areas 16 and 18 of the aperture of yoke arms 14 A and 14 B and toothed areas 42 and 44 of bore 40 of wrench head retaining section 22 should be configured to receive sprockets 34 and 36 . In a preferred embodiment, sprockets 34 and 36 provided on axle shaft 32 have the same number of teeth formed thereon as the toothed areas 16 , 18 , 42 and 44 . Alternately, only one sprocket may be provided on the axle shaft and only a single toothed area may be provided on each of retaining section 22 and yoke section 14 . In such an embodiment, the teeth of the one sprocket are dimensioned to simultaneously engage the teeth on both retaining section 22 and one of yoke arms 14 A and 14 B. The number of the spaced apart annular toothed areas and the spaced annular raceway areas of the bore 40 will be determined based upon the number of sprockets. The size and the number of teeth of the first sprocket 34 may be different from those of the second sprocket 36 provided each sprocket is configured to engage apertures or recesses of a corresponding yoke arm or arms 14 A and 14 B and the toothed areas 42 and 44 of bore 40 of the wrench head retaining section 22 , respectively. The axle shaft 32 may define a tapered shape to prevent sliding of the axle shaft 32 out of one side of yoke section 14 . Any type of interlocking teeth can be used on the toothed areas 16 , 18 , 42 , 44 , and sprockets 34 , 36 . For example, the gear teeth may be triangular, spherical, conical, etc. FIGS. 2, 3, and 4 illustrate the positions of the axle shaft 32 with spaced apart sprockets 34 and 36 which extend through toothed apertures 16 and 18 of yoke arms 14 A and 14 B and bore 40 of wrench head retaining section 22 . Sprockets 34 and 36 are provided on axle shaft 32 for controlling incremental articulation of wrench head portion 20 with respect to elongated body portion 12 . The width of each of sprockets 34 and 36 is narrower than that of spaced annular raceway area 28 of wrench head retaining section 22 to permit articulation of wrench head portion 20 in relation to elongated body portion 12 when one of the sprockets 34 and 36 is moved into raceway area 28 .
[0024] As seen in FIG. 2, when moved into an engaged position, first sprocket 34 simultaneously engages toothed aperture 16 of first yoke arm 14 A and first toothed area 42 of bore 40 of wrench head retaining section 22 , while the second sprocket 36 simultaneously engages toothed aperture 18 of second yoke arm 14 B and second toothed area 44 of bore 40 of wrench head retaining section 22 . At such a time, the wrench head portion 20 is locked against rotation of any desired position and the wrench can be used for installing or removing a nut or performing some other mechanical operation. Alternately, only a single sprocket need be provided.
[0025] As seen in FIG. 3, when axle shaft 32 is pushed in a first direction indicated by arrow “A”, first sprocket 34 disengages from first toothed area 42 of bore 40 of wrench head retaining section 22 and is engaged only in toothed aperture 16 of first yoke arm 14 A, and second sprocket 36 moves into raceway area 28 of bore 40 of wrench head retaining section 20 where there are no teeth to engage. In this position, i.e., the disengaged position, wrench head portion 20 can be freely articulated relative to body portion 12 of articulating wrench assembly 10 , since wrench head portion 20 can be rotated about axle shaft 32 to change the angular position of wrench head portion 20 in relation to body portion 12 can be adjusted.
[0026] Alternatively, as seen in FIG. 4, actuation shaft 32 can be moved into the disengaged position by moving axle shaft 32 in a direction indicated by arrow “B” such that second sprocket 36 disengages from second toothed area 44 of bore 40 of wrench head retaining section 22 and engages toothed aperture 18 of second yoke arm 14 B, while first sprocket 34 disengages from toothed aperture 16 of first yoke arm 14 A and from first toothed area 42 of bore 40 of wrench head retaining section 22 , and moves into raceway area 28 of bore 40 where there are no teeth. Wrench head portion 20 can also be freely articulated relative to body portion 12 of the articulating wrench assembly 10 in this position. Thereupon, the wrench head portion can be moved into a desired angular orientation and thereafter retained in the desired position via movement of actuation member 30 to the position shown in FIG. 2.
[0027] The two disengaged positions can be selected by manually pushing or pulling on actuation member 30 . Actuation member 30 can be pushed or pulled by the user or by other means, such as a mechanism including a biasing spring or a remotely actuated mechanism. For example, a linkage assembly may be provided to facilitate movement of actuation member 30 between engaged and disengaged positions from handle section 13 . One preferred embodiment of the linkage assembly illustrated in FIG. 8 includes a linear translatable link 80 and a pivotal lever 82 . Link 80 is slidably positioned within a bore (not shown) in elongated body portion 12 and includes a proximal end 80 a and a distal end 80 b . Proximal end 80 a preferably includes a finger engagement member 81 which is accessible from handle section 13 to facilitate translation of link 80 from a retracted to an advanced position. Distal end 80 b of link 80 is pivotally secured to one end 82 a of pivotal lever 82 . A central portion 82 b of lever 82 is pivotally secured about pin 90 to elongated body portion 12 . The other end 82 c of lever 82 is slidably secured to actuation member 30 by a pin 84 slidably positioned within a slot 86 formed in actuation member 30 . Wrench head portion 20 must be adapted to facilitate connection of lever 82 to actuation member 30 (not shown). In use, when link 80 is advanced in the direction indicated by arrow “C”, lever 82 is pivoted about pin 90 in the direction indicated by arrow “D” such that pin 84 urges actuation member 30 in the direction indicated by arrow “E”. As actuation member 30 moves in the direction indicated by arrow E, pin 84 moves upwardly in slot 86 .
[0028] It is also envisioned that axle shaft 32 may have protrusions or extensions, e.g., a gripping member or O-ring, at the either or both ends thereof so that the actuation member 30 can be more easily manipulated. In an alternate embodiment, a protrusion or protrusions 60 may be formed and positioned on the wrench retaining section 22 (and/or yoke section 14 ) to contact an inner wall of yoke section 14 , e.g., a rubber surface, etc. Contact between protrusions 60 and the inner wall of yoke section 14 provides a frictional resistance to articulation when the actuation shaft is in the disengaged position to prevent head portion 20 from flopping around in relation to body portion 12 . Alternately, a resilient pad may be substituted for protrusions 60 to increase the frictional contact between retaining section 22 and yoke section 14 .
[0029] [0029]FIG. 5 shows various selectively adjustable positions of wrench head portion 20 relative to body portion 12 of wrench assembly 10 . The number of articulated positions of the wrench assembly will depend upon the number of teeth provided on sprockets 34 and 36 on the axle shaft 32 , and/or in bore 40 and/or apertures 16 and 18 of yoke 14 . The number of teeth may vary, preferably from as few as one to as many as fifty. Depending on the number of teeth, the number of the selective positions of the articulating wrench is decided. In a preferred embodiment of the present inventions, twenty-six teeth are provided on each sprocket of the axle shaft 32 so that the wrench head portion 20 can be oriented into an incremental position every 13.85°. Alternately, more or fewer teeth may be provided to provide a greater or lesser increments of articulation of head portion 20 .
[0030] It is envisioned that a movable actuator such as described above may be suitable for use in a variety of other types of articulatable devices to control articulation of a component of the device. For example, in one preferred embodiment a hinge 200 shown in FIGS. 9 and 10, includes a first hinge member 202 , a second hinge member 204 and an actuation member or hinge pin 206 . Each hinge member includes a plurality circular lobes 208 for receiving actuation member or hinge pin 206 . At least one and, preferably a plurality of circular lobes 208 on each hinge member includes engagement structure (not shown). Hinge pin 206 also includes engagement structure 210 positioned to releasably engage the engagement structure of circular lobes 208 . Hinge pin 206 is movable between a first position in which the engagement structure of the at least one circular lobe of each hinge member 202 and 204 is engaged by engagement structure 210 of hinge pin 206 and a second disengaged position in which engagement structure 210 engages the engagement structure of only one of the first and second hinge members. In the second disengaged position, first hinge member 202 can be articulated with respect to second hinge member 204 . In the first position, engagement structure 210 prevents articulation of first hinge member 202 in relation to second hinge member 204 . As discussed above, the engagement structure 210 on hinge pin 206 and the engagement structure on circular lobes 208 of hinge members 204 and 206 preferably includes an annular array of teeth. As discussed above, the engagement structure may include other known interlocking configurations.
[0031] Hinge pin 206 can be manually moved between the engaged and disengaged positions. Alternately, a link 212 can be used to fasten one or both ends of pin 206 to a suitable drive mechanism, e.g., motor, solenoid, etc. Although illustrated as a hinge assembly, the assembly shown in FIGS. 9 and 10 may be formed integrally with any articulation assembly. For example, the first hinge member may be in the form of a door, whereas the second hinge member may be in the form of a door jam.
[0032] Although the invention has been described in its preferred form with a certain degree of particularity, variations and modifications may be made therefrom within the scope of the accompanying claims without departing from the principle of the invention and without sacrificing its chief advantages. | There is provided an articulating tool assembly for performing a mechanical task in a confined area, e.g., applying the torque to install or remove nuts threaded onto machine bolts or other hooks in confined or recessed areas. The articulating tool assembly has an elongated body portion having a handle section and a yoke section, a head portion including a head section and a head retaining section, and an actuation member defining an axle shaft with two spaced apart sprockets. The actuation member is provided for effectuating incremental articulating movements of the wrench head portion with respect to the elongated wrench body portion. | 5 |
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
This invention relates generally to the field of laser devices, and more specifically to laser mirrors having a circulating water heat exchanger adjacent the mirror or as an integral component of the mirror structure to cool the mirror during laser operation.
Certain conventionally used laser mirrors, and particularly certain high energy laser (HEL) mirrors are fabricated of molybdenum and comprise thin-walled molybdenum tubing or other passageway defining a heat exchanger brazed to the mirror for the purpose of conducting water therethrough for cooling the mirror during laser operation. The cooling means may be conventionally brazed to the mirror support structure using a high strength braze. In operation of the HEL using typical mirrors constructed as just described, and using such conventional coolant as deionized water, serious corrosion problems have been encountered. Corrosion by general attack on the molybdenum in the heat exchanger by the deionized water used as coolant in conventional HEL mirror has been observed to proceed at the rate of 0.002 inch per year or more. Galvanic corrosion between the molybdenum and the braze material may accelerate the deterioration process, seriously affecting the physical integrity of the heat exchanger. Since laser mirror faceplates, and supporting structures, and the heat exchanger brazed thereto, are by design conventionally thin (approximately 0.020 inch or less) in order to exhibit good heat transfer characteristics, such mirrors may be rapidly destroyed by corrosion of the water.
Molybdenum HEL mirrors of the kind just described are frequently and conventionally used and cost many thousands of dollars. Exact cost depends on mirror size, materials, and design requirements and complexity of structural configuration. Further, by reason of the corrosion processes just described, to which the laser mirror may be subjected, its useful operational life may be unacceptably short. Despite numerous attempts to solve the problem of molybdenum mirror structural deterioration, the problem has heretofore persisted without satisfactory solution.
The invention described herein provides an improved laser mirror, such as the HEL type, having a water cooled heat exchanger comprising water conducting passageways that are tungsten coated, which provide superior resistance to the general corrosive process of the coolant water, and eliminates galvanic attack and stress corrosion cracking in the molybdenum structure of the mirror. The tungsten coating to the inside surface of the molybdenum channels may be provided by such as the chemical vapor deposition (CVD) process disclosed herein, although other coating methods may be applied, as might occur to one with skill in the field of chemical vapor deposition techniques. Therefore, other metal coatings, such as tantalum, as might be applied using a process analogous to that disclosed herein may result in a mirror having suitable corrosive resistance. The process disclosed herein provides a laser mirror having a continuous tungsten coating on the interior surfaces of the molybdenum heat exchanger components which prevents several forms of corrosion by the coolant water on the molybdenum structure. The physical and mechanical properties of CVD tungsten or tantalum materials are similar to the properties of molybdenum, and, therefore, the coating adds structural strength to the mirror without presenting problems of thermal conductivity or thermal expansion mismatch between coating and structure.
Therefore, providing a laser mirror having a protective coating on the molybdenum heat exchanger passageways greatly extends the mirror life by substantially eliminating the corrosion problem associated with using circulating water as coolant. Corrosion by general attack does not stop entirely since tungsten is corroded by water though at a much slower rate. The coating may be replenished periodically according to the methods described herein at low cost to extend mirror life indefinitely.
These and other objects of the present invention, as might occur to one with skill in the field of this invention, will become apparent as the detailed description proceeds.
SUMMARY OF THE INVENTION
In accordance with the foregoing principles and objects of the present invention an improved high energy laser (HEL) mirror is provided wherein the internal surfaces of the molybdenum structure of the mirror defining passageways for water coolant flow are plated with a substantially continuous coating of tungsten by chemical vapor deposition (CVD) techniques described by the invention herein. The mirror is thereby made resistant to the corrosive action of the circulating coolant water on the molybdenum structure comprising the laser mirror.
DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood from the following detailed description of specific embodiments thereof read in conjunction with the accompanying drawings wherein:
FIG. 1 is a schematic cross-section of one embodiment of a laser mirror used to demonstrate this invention.
FIG. 2 is a schematic cross-section of a portion of the coated molybdenum wall of the mirror of FIG. 1 taken along section A--A showing the relative thickness and uniformity of the tungsten coating on the molybdenum structure of the mirror.
FIG. 3 is a schematic of a system used for applying a tungsten coating to the interior surfaces of the heat exchanger of an improved laser mirror herein.
DETAILED DESCRIPTION
Referring now to the accompanying drawings, FIG. 1 shows a schematic cross-section of a high energy laser mirror used in demonstration of this invention, including the molybdenum heat exchanger having passageways or channels and suitable inlets and outlets (not shown) for conducting flow of coolant water through the heat exchanger. The mirror 10 of this invention typically may comprise such as a substantially totally reflecting mirror surface 11, supported by faceplate 12 to support and preserve the contour of mirror surface 11. The mirror surface 11 may comprise a surface of dielectric enhancer, a reflector, and a binder, or other conventional mirror surfaces, deposited on the polished metallic surface of the faceplate 12. Faceplate 12 may typically be of molybdenum, tungsten, copper, graphite or any other material which meets heat transfer requirements and suitably matches the physical properties of the materials used in the design of mirror 10. Upper channels 13 defined by metallic (molybdenum) fins, corrugations, posts or ribs 14, for conducting coolant water near the faceplate 12 provide primary cooling to the mirror surface 11. Lower channels 16, defined by metallic (molybdenum) walls 17, provide for gross secondary cooling of mirror 10. The channels 13 and 16 may be of any convenient size consistent with the type, size, and thermal requirements for laser mirror 10, and may range in size from about 0.020 inch to about 0.080 inch. As discussed below, satisfactory tungsten coatings may be provided on the walls of channels 13 having size down to about 0.010 inch. Splitter plate 15 of this design of molybdenum. Backing plate 18 provides further structural support and heat sink capability to laser mirror 10, and may be of molybdenum, tungsten, or other suitable materials for the purpose thereof to be served. The various components of laser mirror 10 may be joined at their respective interfacing surfaces using a high strength braze, such as copper-gold alloy, or other suitable brazes.
Unconventional tungsten coating 19 on the walls 14 defining upper channels 13 and tungsten coating 20 on the walls 17 defining lower channels 16, may be applied using the techniques hereinafter described and provide the desired corrosion protection for the molybdenum walls 14 and 17 from action of the coolant (deionized) water which is circulated through mirror 10 during use. Tantalum coatings applied by techniques similar to that described herein for tungsten may also be applied with satisfactory results. As discussed above, the size of upper channels 13 and lower channels 16 are sufficiently small as to preclude coating the interior wall surfaces with a protective coating using conventional techniques. Flawless, uniform coatings 19 and 20 of tungsten on surfaces of walls 14 and 17, respectively, were successfully applied to sufficient and desirable thicknesses of about 0.0015 inch (0.0381 mm), without clogging the passageways represented in FIG. 1 by upper channels 13 and lower channels 16.
Scanning electron microscope (SEM) examination of samples of coated heat exchangers of this invention revealed no pores or voids and no discontinuities in the coatings. FIG. 2 is a schematic reproduction of a micrograph of a typical section of a passageway of an HEL mirror such as taken along section A--A of FIG. 1, showing the high quality and continuity characteristic of the tungsten coating of the laser mirror 10 of this invention. As shown in FIG. 2, a portion of a molybdenum wall 21 separating two channels for flow of coolant has applied on each side thereof tungsten coating 22 and 23 of superior uniformity.
Apparatus which may be used successfully to apply the desired coatings to the interior walls of the heat exchanger of such as laser mirror 10 is shown schematically in FIG. 3. The apparatus comprises hydrogen (H 2 ) supply 31 and tungsten hexafluoride (WF 6 ) supply 32. The flow of hydrogen may be controlled by such as regulator or metering valve 33, and, similarly, the flow of WF 6 may be controlled by regulator or metering valve 34. The H 2 and WF 6 are mixed within inlet line 35 and directed through the heat exchanger of laser mirror 30 through inlet port 36 of vacuum furnace 37; the gaseous products are exhausted from the heat exchanger or mirror 10 through outlet port 38 of furnace 37 and exhaust line 39 by the action of vacuum pump 40.
A successful procedure for providing the desired tungsten coating may be summarized as follows: a previously cleaned mirror such as that shown partially in FIG. 1, including the heat exchanger portion thereof, may be prepared for coating using the following procedure and the apparatus of FIG. 3:
a. place the mirror 30 in vacuum furnace 37 and connect the inlet and outlet ports of the heat exchanger of mirror 30 to the feed-through connections in the walls of furnace 37 represented by inlet port 36 and outlet port 38;
b. evacuate vacuum furnace to about 10 -4 torr;
c. fill vacuum furnace 37 to about 220 torr with inert gas;
d. heat mirror 30 to about 510° C.;
e. flow hydrogen gas through heat exchanger at about 2000 cc/min for about 20 minutes.
The foregoing procedure, it was found, sufficiently conditions the molybdenum surfaces to successfully accept the tungsten coating. The desired coating of tungsten of about 1.5 mils may then be applied to the interior surfaces of the heat exchanger as follows:
f. maintain the temperature of the mirror 30 within vacuum furnace 37 at about 510° C.;
g. flow tungsten hexafluoride (WF 6 ) at seven gram/minute and hydrogen gas at 4000 cc/minute for about 5 minutes;
h. shut off flow of WF 6 ;
i. maintain flow of hydrogen only for several minutes;
j. reduce the temperature of the vacuum furnace 37 at the rate of about 40° C./min until the mirror 30 is cool.
Various coating thicknesses may be obtained by varying the plating time, gas mixture and plating temperature. However, it should be noted that a temperature of as much as 600° C. results in plating out of the tungsten too near the inlet of the heat exchanger without sufficient plating further downstream in the heat exchanger passageways. Similarly, a lower temperature (at about 500° C.) combined with a lower flow rate may result in excessive and premature plating at the inlet of the heat exchanger. Therefore a balance in flow rate, gas mixture, and plating time must be maintained to obtain the desired result. A flow rate of the WF 6 , far in excess (5 to 10 times) of the rate needed to provide plating out of the tungsten must be maintained, to ensure sufficient available WF 6 to plate out downstream in the heat exchanger passageways, and to flush reaction products of the plating process which contaminate and inhibit the plating process downstream. To further ensure uniform plating throughout the heat exchanger passageways, a supply of hydrogen of from about 5 to 10 times the stoichiometric requirement for the WF 6 +3H 2 →W+6HF reaction was required, depending on the diameter, length, and circuitry of the passageways to be coated.
For a mirror the heat exchanger of which has already been exposed to water, it may be necessary to remove corrosion products and other surface contamination from the inside surfaces of the passageways to be coated with tungsten. The following cleaning process was shown to be successful:
a. flush channels with a mild cleanser; Oakite 91A, a commercial product of the Oakite Company, at about pH 11 and 85° C. proved acceptable;
b. rinse with low pressure water;
c. flush channels with 10% solution of sulfuric acid;
d. rinse again with low pressure water;
e. flush with acetone;
f. flush with isopropal alcohol and vacuum dry;
g. bake out at 50° C. in soft vacuum.
There is, therefore, described herein an improved laser mirror comprising a heat exchanger for conducting coolant water therethrough and having an internal coating of tungsten to prevent corrosion of the water on the molybdenum of which the heat exchanger components are constructed and with which the water may come into contact. It is understood that certain modifications to the invention as hereinabove described may be made, as might occur to one with skill in the field of this invention, within the scope of the appended claims. Therefore, all embodiments contemplated hereunder have not been shown in complete detail. Other embodiments may be developed without departing from the spirit of this invention or from the scope of the appended claims. | An improved high energy laser (HEL) mirror is provided wherein the internal surfaces of the molybdenum structure of the mirror defining passageways for water coolant flow are plated with a substantially continuous coating of tungsten by chemical vapor deposition (CVD) techniques described by the invention herein. The mirror is thereby made resistant to the corrosive action of the circulating coolant water on the molybdenum structure comprising the laser mirror. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to improvements in the field of windrow elevators used in an asphalt paving machine to pick up, process, and provide a ready supply of asphalt-based material. More specifically, the present invention comprises an apparatus and a method, for fragmenting agglomerated pieces of rubberized asphalt material and re-mixing the fragmented pieces with smaller pieces of the same material, to achieve an acceptably homogeneous consistency in the material readied for immediate use by the asphalt paving machine.
2. Description of the Prior Art
A material commonly known as Hot Mix Asphalt (“HMA”) is widely used in roadway construction and resurfacing. HMA is comprised of a mixture of asphalt oil binder, sand, small rocks, and other filler material, processed at a batch plant. Ideally, the batch plant is located close to the paving site, so the HMA will stay hot and workable until it is applied on the roadway. A short transportation distance also minimizes the phenomenon known as material segregation. Because HMA is composed of different sized aggregate and fill material, agitation and gravity act on these pieces of HMA differently. The larger, heavier pieces and the smaller, lighter pieces tend to separate and collect in like groups during transport. When the dump trailer deposits the HMA material on the roadway in a windrow, the smaller particles are concentrated in the central, elevated region of the windrow and the larger particles are concentrated in the lateral, lower regions of the windrow.
U.S. Pat. No. 6,481,922, issued to Boyd, provides a solution to the above-noted material segregation problem. The '922 Patent discloses an apparatus and a method for re-mixing the large particles with the small particles, so that a more uniform mixture of those particles is achieved before the HMA is applied onto the roadway. Through the use of a pair of lateral augers which continuously deliver the larger particles into a centrally positioned stream of the smaller particles, the HMA is re-mixed into a homogeneous mixture before being delivered into a collection hopper for subsequent application on the roadway.
However, as a roadway material, HMA is not without its faults. The asphalt oil binder used to coat and hold the aggregate particles together, plays a critical role in the performance and longevity of the roadway. The adhesive and agglomerating properties of the binder are affected by temperature, the amount and rate of road loading, and aging. Over a period of time, the surface of well-used roads, particularly in harsh environments, begins to crack and delaminate from lower support layers. To mitigate these effects, various additives have been proposed and tested with existing asphalt binders.
One of the most promising and successful additives used so far is rubber, recycled from used motor vehicle tires containing a high content of natural rubber. The tires are ground up into small particles known in the industry as “crumb rubber”. Pieces of the steel belts used in the manufacture of tires are removed from the ground up tires, before the crumb rubber is ready for further processing and incorporation into an asphalt based road material. The resultant product is variously known in the paving industry as Rubberized Asphalt, Rubberized Asphalt Concrete (“RAC”), and Asphalt-Rubber.
Two basic methods have been used to make the rubberized asphalt. The first method, known as the “wet process”, calls for the crumb rubber to be mixed with the binder (approximately 80% asphalt cement and 20% rubber) in a field blending unit. This first step occurs prior to the addition of the mixture to the other materials at a separate hot mix plant. In a second method, rubberized asphalt can be produced directly, using a terminal blended process where the crumb rubber is added at the refinery or at the asphalt cement terminal. The advantage of the latter method is that no specialized and costly rubberized blending plant is required, and the asphalt binder can be shipped to the hot mix plant just as a standard binder would be.
Irrespective of how it is manufactured, rubberized asphalt has been proven a superior roadway material over unmodified HMA in several significant areas. Rubberized asphalt is highly-skid-resistant, quieter than HMA or concrete, and resistant to rutting and cracking. In the process of making rubberized asphalt, used tires are consumed and utilized for a new purpose. A two-inch thick roadway resurfacing project can consume approximately 2000 waste tires per lane per mile. Thus, land-fill can be reduced and environmental concerns associated with the storage of flammable stores of waste tires are alleviated. Research has established that 4″ thick conventional HMA roadway can be replaced with 2″ thick rubberized asphalt, and achieve the same fatigue life. Rubberized asphalt provides excellent long-lasting, color contrast, for road striping and marking. Lastly, rubberized asphalt can generally be applied using conventional road-paving equipment and methods.
The last mentioned feature of rubberized asphalt has several exceptions, however. Rubberized asphalt is made using smaller and more uniform aggregate, typically on the order of ¼″ to ⅜″, or so, in diameter. This results in a material which is much less susceptible to the segregation problem caused by material transport, characteristic of HMA. But rubberized asphalt cools at a different rate than HMA, and it has a tendency to agglomerate in ways that HMA does not. Between the batch plant where the rubberized asphalt is manufactured and the roadway job site, cooling of the material occurs, especially in areas contingent and adjacent the sidewall and floor of the material hopper.
When rubberized asphalt has cooled a sufficient amount before it is even deposited into a windrow on the roadway, it may agglomerate into relatively large balls or sheets of material of irregular size and shape known as “clingers”. For example, a sheet of such agglomerated material may be 2″ to 3″ thick, 4″ to 5″ wide, and 12″ to 18″ long. These large pieces of agglomerated material are randomly dispersed through the windrow.
The present practice is to remove such agglomerated material manually from the windrow, before material pickup and application of the rubberized asphalt to the roadway occurs. This method is labor intensive, and also relies upon the workers finding and removing all of the offending clingers. If not removed, such large chunks of agglomerated material may jam in the paving machine or be deposited into the roadway and remain an unintegrated surface component.
SUMMARY OF THE INVENTION
The present invention comprises an apparatus and a method for fragmenting agglomerated pieces of rubberized asphalt material, and then re-mixing the smaller fragmented pieces with the smaller loose material prior to applying the re-mixture to a road surface. The agglomerated pieces are formed from smaller pieces of rubberized asphalt material which have cooled together to form the agglomerated pieces, during transport to the job site. A random mixture of agglomerated pieces and the rubberized asphalt material is delivered to the job site, forming a windrow along the middle of the roadway. A pickup machine passes over the windrow, and an elevator picks up the mixture. The elevator carries the mixture upwardly, and delivers it to the upper portion of a generally cylindrical housing mounted on the pickup machine.
In a first embodiment, an auger and tine assembly having a common drive shaft, is mounted for rotation within the housing. The assembly includes first and second auger sections, mounted along the drive shaft in spaced relation. A rotating tine section is mounted on the drive shaft between the auger sections. The auger sections have converging, opposite handedness, effective to transport the agglomerated pieces and the material inwardly toward the rotating tine section. A fixed tine section is mounted in the housing in interdigitized relation with the rotating tine section.
In a second embodiment, a rotating tine section extending the entire length of the drive shaft, is provided within the housing. A fixed tine section is also provided within the housing, having a length corresponding to that of the rotating tine section. As with the first embodiment, the fixed tine section is arranged in interdigitized relation with the tines of the rotating tine section.
In both embodiments, the agglomerated pieces and the material are deposited into a fragmenting and re-mixing zone adjacent and around the rotating and fixed tine sections. The spacing between adjacent fixed and rotating tines is such that a pre-determined maximum size is established for agglomerated pieces fragmented by the action of the tines. These smaller fragmented pieces are concurrently re-mixed with the other material resulting in rubberized asphalt having a size and composition appropriate to form a road surface.
The first embodiment of the invention can also be used advantageously with HMA paving material, to alleviate the material segregation. In other words, without making any modifications or changes to its structure or operation, the same apparatus which fragments and re-mixes rubberized asphalt material will also re-mix size and weight segregated HMA into a homogeneous material ready for instant use by a paving machine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, showing a road paving machine incorporating the apparatus for fragmenting and re-mixing agglomerated pieces of rubberized asphalt material of the present invention;
FIG. 2 is a fragmentary top plan view of the road paving machine, with portions of the cover and the housing broken away to show the windrow elevator, the auger sections, and the tine section;
FIG. 3 is a fragmentary cross-sectional view, taken through the longitudinal axis of the windrow elevator of FIG. 2 , showing the delivery of rubberized asphalt material into the auger and tine housing;
FIG. 4 is a fragmentary perspective view showing the upper end of the elevator and the auger and tine housing of the first embodiment;
FIG. 5 is a view as in FIG. 4 , but with a portion of the housing broken away to show the arrangement of the auger sections and the tine sections;
FIG. 6 is a side elevational view of the auger and tine housing, showing discharge of the fragmented and re-mixed rubberized asphalt material;
FIG. 7 is a fragmentary perspective view showing the upper end of the elevator and the tine housing of the second embodiment;
FIG. 8 is a view as in FIG. 7 , but with a portion of the housing broken away to show the tine section; and,
FIG. 9 is a front elevational view of the tine housing, showing discharge of the fragmented and re-mixed rubberized asphalt material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1 , the fragmenting and re-mixing apparatus 11 of the present invention is shown in combination with a windrow elevator 12 and a paving machine 13 . At the job site depicted in FIG. 1 , the paving machine 13 is re-paving a roadway surface 14 with a mat 15 of rubberized asphalt 16 .
At an off-site batch plant, the rubberized asphalt material 16 is manufactured from first combining a hot and liquid asphalt cement binder with particles of rubber. Generally, the amount of rubber in the mixture will vary from approximately 15% to 25%, or so, by weight. The rubber is preferably in the form of recycled “crumb rubber”, made from used automobile and small truck tires which have been shredded to a crumb-like size and consistency. At the plant, this crumb rubber has been heated to a sufficient amount that it physically swells, enabling it to combine and integrate with the asphalt cement. Next, this asphaltic combination is mixed with aggregate, such as crushed rock. The aggregate used in making rubberized asphalt is fairly small and uniform in size, ranging from ¼″ to ⅜″, or so, in diameter. This hot mixture is then loaded into a belly dump trailer, and the trip to the job site begins.
The best case scenario for transporting rubberized asphalt is a short trip during the hottest part of the day during the summer season. Deviations from those circumstances during transport will cause varying amounts of greater cooling to the rubberized asphalt mixture. The most critical areas for cooling tend to be around the floor and sidewalls of the trailer, where the mass of the metal plates and the trailer frame can absorb heat from the mixture. In contrast to HMA, rubberized asphalt cools and agglomerates more quickly. With more paving and re-paving jobs occurring during evening hours to avoid traffic delays, the problem with material agglomeration has become worse for rubberized asphalt jobs.
Upon arrival at the job site, the belly dump trailer deposits its load of rubberized asphalt material 16 in a windrow 17 . Under circumstances where the material had sufficiently cooled during transport, agglomerated pieces 18 in various shapes and sizes known as “clingers” have formed. As shown in FIG. 1 , these pieces may be globular or sheet-like in configuration. Reports indicate that the sheet pieces appear to peel off the floors and sidewalls of the trailer, and these pieces may be 2″ to 3″ thick, 4″ to 5″ thick, and 12″ to 18″ in size. The agglomerated pieces are randomly dispersed throughout the windrow, with some pieces exposed and others located within the body of the windrow out of sight. Heretofore, these pieces have been manually removed from the windrow, by workers who pick through the windrow before the paving machine 13 reaches the freshly dumped rubberized asphalt material.
A paving machine 13 fitted with the fragmenting and re-mixing apparatus 11 of the present invention does not need additional workers to remove clingers or agglomerated pieces 18 from the windrow 17 . Instead, the apparatus 11 aboard the paving machine 13 is capable of processing the agglomerated pieces in such a way that it can be intermixed with the remainder of the material and incorporated directly into the mat 15 . To that end, as the paving machine 13 advances over the windrow 17 , the windrow elevator 12 picks up the rubberized asphalt material 16 including the agglomerated pieces 18 in the usual way and delivers it to an upper discharge end 19 of the windrow elevator 12 .
As shown in the various Figures, the apparatus 11 is located at the discharge end 19 , and comprises an auger and tine assembly 21 having a first helical auger section 22 and a second helical auger section 23 . First auger section 22 has a top portion 24 and an inner portion 26 . Second auger section 23 has a top portion 27 and an inner portion 28 opposing inner portion 26 . As shown most clearly in FIG. 5 , auger section 22 and auger section 23 are mounted in spaced relation over respective ends of a rotatable drive shaft 29 .
A rotating tine section 30 having a top portion 32 is mounted on drive shaft 29 between inner portions 26 and 28 . The rotating tine section 30 is comprised of a plurality of tines 31 , arranged in a plurality of rows, extending perpendicularly from drive shaft 29 . Each of the rotating tines comprises an inner shank portion and an enlarged outer head portion, especially adapted for fragmenting agglomerated pieces 18 . It should be noted that the first and second auger sections are of converging, opposite handedness, so as to advance rubberized asphalt material 16 and the agglomerated pieces 18 inwardly toward the rotating tine section 30 .
Apparatus 11 further comprises an auger and tine housing 33 having an upper portion with a material inlet 34 and a lower portion with a material discharge 36 . Housing 33 also includes a first endwall 37 and a second endwall 38 . Auger and tine assembly 21 is mounted for rotation within the lower portion of housing 33 between said first endwall 37 and second endwall 38 . A fixed tine section 39 is mounted in housing 33 in interdigitized relation with rotating tine section 30 . Tine section 39 is comprised of a plurality of fixed tines 41 , welded to a plate bolted to auger and tine housing 33 . Fixed tines 41 are arranged in a row, extending in perpendicular fashion from the axis of drive shaft 29 . Preferably, material discharge 36 is located just below tine section 39 .
The spacing between fixed tines 41 and an adjacent rotatable tine 31 is approximately 1″ to 1½″, or so, thereby establishing a maximum transverse dimension for agglomerated pieces as they are forced between the two structures. This dimension can be changed as the circumstances demand. For example, smaller fragmented pieces may be achieved by reducing the spacing between the rotating and stationary tines. This will provide the paving machine with an even more homogeneous mixture, as the fragmenting process will produce smaller pieces. The downside of such a modification, is that the material “throughput” of the apparatus 11 will be reduced. This will necessarily reduce the speed of the paving machine 13 .
Material inlet 34 in housing 33 allows rubberized asphalt 16 and agglomerated pieces 18 to be delivered into the top portions of the first and second auger sections and the rotating tine section. The remainder of auger and tine housing 33 substantially surrounds the first auger section 22 , the second auger section 23 , the rotating tine section 30 , and the fixed tine sections 39 . The first auger section and the second auger section acting in conjunction with the housing 33 , transport and direct asphalt 16 and agglomerated pieces 18 to the rotating tine section 30 . Housing 33 further defines a fragmenting and re-mixing zone 42 adjacent and around rotating and fixed tine sections 30 and 39 .
Drive means 43 , preferably a hydraulic motor, is provided for rotating drive shaft 29 and auger and tine assembly 21 at the desired speed. If more aggressive fragmenting and re-mixing is desired or necessary, the speed of drive means 43 may be increased. This might be appropriate, for example, where more than the usual number of agglomerated pieces 18 are found in a particular load. A hydraulic motor 44 is included on drive shaft 46 of windrow elevator 12 , to provide a continuous stream of rubberized asphalt material 16 and agglomerated pieces 18 into the material inlet 34 . In operation, agglomerated pieces and material entering the material inlet are advanced inwardly toward the center of housing 33 , and deposited onto the rotating tine section and the fixed tine section in the fragmenting and re-mixing zone 42 . In this manner, the agglomerated pieces are fragmented and re-mixed with the asphalt material before passing through the material discharge 36 .
The fragmented pieces 47 and the rubberized material 16 are deposited as a substantially homogeneous mixture into a hopper 48 , in readiness to be utilized by the paving machine 13 . The size and physical shape of the pieces 47 is such that when the mat 15 is laid by the paving machine 13 and subsequently compressed by a street roller, all of the rubberized asphalt forms a uniform and structurally integrated surface that is durable and long-lasting.
Apparatus 49 , comprising a second embodiment of the invention, is shown in FIGS. 7-9 . For the sake of clarity, the same element numbers will be used in describing this embodiment, where the structure and operation of those elements are identical to those in the first embodiment, set forth above. It should also be noted that this second embodiment is also an apparatus for fragmenting and re-mixing rubberized asphalt material containing agglomerated pieces, and may be used interchangeably in the same application as the apparatus of the first embodiment. Therefore, since the structure and operation of the upstream and downstream components, such as the windrow elevator, hopper, and paver devices have already been described, this discussion will not be repeated.
Apparatus 49 includes a rotating tine section 50 , mounted on a rotatable drive shaft 51 . Rotating tine section 50 comprises of a plurality of tines 31 , arranged in a plurality of rows, extending radially from drive shaft 51 . For ease of construction, tine section 50 may be welded to a pipe or tube (not shown) which fits over and is bolted to drive shaft 51 . Alternatively, the tines may be welded directly to shaft 51 . Tine section 50 also includes a top portion 52 , into which incoming rubberized asphalt 16 and agglomerated pieces 18 are deposited.
Apparatus 49 also includes a fixed tine section 53 . As is shown most clearly in FIG. 9 , fixed tine section 53 is substantially coextensive in length with rotating tine section 50 . Fixed tine section 53 is comprised of a plurality of tines 41 , arranged in a row and extending perpendicularly from drive shaft 51 . Each of the rotating and fixed tines comprises an inner shank portion and an enlarged outer head portion, especially adapted for fragmenting agglomerated pieces 18 . It should also be noted that the enlarged outer head portions of the rotating and fixed tines are arranged in opposing relation, to enhance the fragmentation and re-mixing process.
Apparatus 49 also includes a tine housing 54 , having an upper portion with a material inlet 56 and a lower portion with a material discharge 57 . Tine housing 54 further has a first endwall 58 and a second endwall 59 . Rotating tine section 50 is mounted for rotation within the lower portion of housing 54 , between the first and second endwalls. FIG. 9 shows that fixed tine section 53 is mounted in tine housing 54 , in interdigitized relation with rotating tine section 50 . The spacing between adjacent rotating and fixed tines is selected to ensure a maximum acceptable size for the fragmented pieces discharged from the apparatus 49 .
Tine housing 54 substantially surrounds rotating tine section 50 and fixed tine section 53 , but leaves the top portion 52 of the rotating tine section exposed to material inlet 56 . Rubberized asphalt and agglomerated pieces of asphalt are thereby delivered into the rotating tine section. Tine housing 54 further defines a fragmenting and re-mixing zone 61 adjacent and around the rotating tine section 50 and the fixed tine section 53 .
Drive means 43 is also provided, for rotating tine section 50 at an appropriate speed. Preferably, a hydraulic motor is used for drive means 43 , as the speed of the rotating tines can easily be changed by the operator independently either from the forward speed of the paving machine 13 or from the speed of the windrow elevator 12 .
In operation, rubberized asphalt material 16 and agglomerated pieces 18 entering the material inlet 56 are deposited onto the rotating tine section 50 and the fixed tine section 53 in the fragmenting and mixing zone 61 . The agglomerated pieces which are larger than the space between the rotating tines and the fixed tines are fragmented and re-mixed with the asphalt material 16 before the homogeneous mixture passes through the material discharge 57 . In all other respects, the operation and general function of the second embodiment, represented by the apparatus 49 is identical to that of the first embodiment, represented by the apparatus 11 . | An apparatus and method for fragmenting and re-mixing agglomerated pieces of rubberized asphalt prior to applying same to a road surface. Agglomerated pieces and rubberized asphalt material are delivered to the upper portion of a housing. In a first embodiment, an auger and tine assembly having a common drive shaft, is mounted for rotation within the housing. The assembly includes first and second auger sections, mounted along the shaft in spaced relation and having converging, opposite handedness. A rotating tine section is positioned between the auger sections. A fixed tine section is mounted in the housing in interdigitized relation with the rotating tine section. In a second embodiment, the entire drive shaft includes a rotating tine section, and a corresponding interdigitized fixed tine section is provided within the housing. Passing through apertures defined by the fixed and rotating tine sections, agglomerated pieces are fragmented and re-mixed with the other material. | 4 |
This is a continuation of application Ser. No. 07/464,379 filed Jan. 12, 1990 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of this invention lies within the art of diving. More particularly, it lies within the art of diving with the utilization of a snorkel. The utilization of the snorkel can be with or without a self-contained breathing apparatus. The snorkel finds use both for skin diving (i.e. without self-contained breathing apparatus when one swims on the surface and utilizes usually a mask and fins) as well as when one dives to certain depths using self-contained underwater breathing apparatus.
2. The Prior Art
The prior art with respect to snorkels comprises a myriad of breathing apparatus. Generally, they try to accomplish the ability of a diver while swimming on the surface with a snorkel to breath freely and easily without the introduction of water into the mouthpiece.
The introduction of water into the mouthpiece has been a constant problem for divers using snorkels. The prior art has tried to solve it in years' past through various valves and purge systems. Some simple flotation valves used a pingpong type ball and a cage which partially prevented the flow of water into the mouthpiece. Subsequent sophistication provided for purge systems which incorporate the utilization of purge valves. Such purge valves have been utilized at mid-points along the snorkel tube as well as at the ends. In the utilization of such purge valves at the mid-points and ends, it has been common to allow the purge system to use a mushroom type valve or round flapper having a stem. The round flapper with a stem is seated over an open work or grid. When strong exhalation takes place for the purge of water, it drives against the resilience of the purge valve flapper so that it opens and allows the purging of water with the air therefrom.
The utilization of a purge valve has been such wherein it has also been incorporated in separate lateral conduits and bifurcations to allow for the orientation of the purge system in a manner so that it traps water in a presumably optimum manner. Certain purge valve systems have been utilized along a mid-portion of a snorkel conduit.
Recent purge valve systems for snorkels have incorporated a baffle. The baffle usually bifurcates the purge valve conduit from the inlet of the mouthpiece. In doing so, the water is assumed to drain through the purge valve inlet into the purge valve area and be expelled therefrom. The snorkel baffle supposedly eliminates the intake of water into a user's mouth by trying to bifurcate and exclude the water from a user's intake conduit into the mouthpiece. Although this method of elimination of water from a user's mouthpiece for the snorkel has been somewhat successful, it has not provided a snorkel capable of eliminating water in the best possible manner. This is due to the fact that the water tends to sometimes slosh back or become oriented in a manner whereby it is implaced above the baffle toward the mouthpiece. In the alternative it can be of such magnitude due to the nature of the conduit that a user tends to breathe the water inwardly along with the air because the baffle does not protect the inlet to the mouthpiece.
It is believed that the design of this particular purge valve system for a snorkel and its orientation in the preferred embodiments, as well as in the broad conceptual aspects is a significant step over the art. The mouthpiece and purge system have proven to be particularly adaptable and successful in eliminating water from the mouthpiece of the snorkel. Additionally, it has significantly limited the amount of water one breathes in inadvertently by eliminating baffles and making sure there is a clear and unobstructed passage from the main elongated tube of the snorkel toward the mouthpiece. To this end, it eliminates the baffle concept and the various parallel and dual conduits which have been a problem with respect to the utilization of snorkels.
The attendant result is a purge valve system which easily purges water that has entered the snorkel. Also, a substantial capability of breathing is enhanced by the configuration of the unobstructed flow passage of the snorkel, by eliminating baffles and various conduits that have previously been utilized to provide for a purge valve system.
Consequently, it is believed that this invention is a significant step over the art, both from the standpoint of its structural difference, as well as the nature of its operational features thereby providing significant results over that of the prior art.
SUMMARY OF THE INVENTION
In summation, this invention comprises a new and improved snorkel purge valve system incorporating an elongated chamber uniquely offset at an angle from the axis of the mouthpiece and having an introductory conduit for connection to an elongated tube of a snorkel.
More particularly, it incorporates a snorkel having an elongated tube. The elongated tube has an opening at one end for the inlet and outlet of breathing air when it is above the surface of the water. A mouthpiece is provided at the other end that is connected to the elongated tube by means of a fitting. The fitting can be in the form of a connection member incorporating the purge system.
An outlet purge chamber is connected to the mouthpiece in an orientation such that it allows for drainage of water to flow thereinto, rather than the mouthpiece. This is accomplished by creating an elongated chamber having a purge valve at the end of it distal from the mouthpiece. the purge valve at the end of the chamber allows for ejection and purging of water therein that has been drained from either the elongated tube, the inlet connection, or for that matter, the mouthpiece.
In preferable embodiments, the outlet chamber extends from the mouthpiece in a manner whereby it is canted slightly in one direction away from the mouthpiece axis. When in use it is angled toward the chin of a user. The mouthpiece is also such wherein the introductory conduit connected to the elongated tube of the snorkel is canted downwardly slightly away from the mouthpiece so as to provide for drainage away from the mouthpiece into the outlet purge chamber and then through the purge valve.
The entire orientation of the angular relationships of the purge valve chamber, the mouthpiece, and the introductory conduit all provide for superior and improved performance over the prior art. Additionally, the orientation of the respective three elements of the terminal region for breathing through the mouthpiece are such wherein they are functionally different from that seen in the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood by reference to the description below taken in conjunction with the accompanying drawings:
FIG. 1 shows an elevation view of the snorkel of this invention wherein the mouthpiece is shown in an upper position with the purge valve chamber in the lower position which would be a general orientation for usage.
FIG. 2 shows a view of the purge valve and mouthpiece area of the snorkel as seen in the direction of lines 2--2 of FIG. 1.
FIG. 3 shows a view of the purge valve and attendant portions surrounding it in the direction of lines 3--3 of FIG. 1.
FIG. 4 shows a mid-line sectional view through the purge valve area as seen in the direction of lines 4--4 of FIG. 2.
FIG. 5 shows a view similar to FIG. 2, but including center lines or the axis for orienting the invention.
FIG. 6 shows a view similar to FIG. 4 with the axial lines drawn over the figure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Looking more particularly at FIG. 1, it can be seen that a snorkel 10 is shown having an elongated tube 12. The elongated tube can be in the form of any particular plastic or elastomeric tubular member having any adaptable cross section. Various tubes can be those that are well known in the art that can be made of such plastics as ABS, polystyrenes, and polymers of different types, including well known plastics in the art having various cross sections such as a circular, rectangular, or triangular cross section.
The elongated tube 12 has a first end 14 which is open. The first end 14 can have a diameter of approximately five eighths of an inch to one and one half inches to be effective. It is believed that this dimension with regard to the diameter of a cross sectionally round snorkel provides sufficient air, while at the same time not overburdening a user with a large tube mass. However, other ranges can be utilized when considering the fact that sufficient air must be brought through the opening 14 to a user.
Generally, the elongated tube 12 is only used when the diver is swimming along the surface and breathing with the tube end opening 14 extended above the water. The first end of the tube opening 14 terminates angularly and bends at a bend 16. It bends again at a second bend 18 and finally, at an L or lower bend 20. At the second end of the snorkel, a second or lower opening 22 is shown. Air passes from the first end opening 14 to the lower or second end opening 22. The intermediate portion such as at the bends 16, 18 and 20 or therebetween, can also have secondary purge means or other connections which are known in the art. The thrust of this invention is toward the lower purge chamber which will be expanded upon hereinafter.
Looking more particularly at the second end or opening 22 of the elongated tube 12, it can be seen that a circular pair of flanges 24 and 26 are shown. These flanges seat within grooves 28 and 30 respectively. The grooves 28 and 30 respectively receive the flanges 24 and 26 so that a tightened connection for the snorkel can be provided therein. At the same time, a rubber gasket or O Ring 32 can be provided in a groove 34 of the elongated tube. This groove 34 allows for the seating of the O Ring 32 therein so that a relatively airtight and watertight passage can be maintained to the connection.
Looking more particularly at the lower portion of the snorkel, a fixture 38 which can be referred to as a connection means, connection conduit, connector, or connection fixture or interconnect from the elongated tube to the mouthpiece, is shown. The connection fixture 38 which is referred to in part as a connection means or conduit incorporates the grooves 28 and 30 which receive the splines or flanges 24 and 26. These grooves 28 and 30 are cast or molded into a relatively hard plastic forming the connection member 38. The connection member 38 can be in the form of any particular plastic but is preferably a plastic formed of a hard thermosetting plastic in order to provide for a substantially non-deformable member to receive the various portions as they are connected. Such plastics can be formed from the family of ABS plastics produced by Dow, such as Dow HX4000 or other such plastics.
The interconnect or connection member 38 has a conduit 40 or passage formed with an inlet 42 and an outlet generally shown as the area 44. The distance from the inlet to the outlet of the inlet conduit 40 can vary. The conduit can be formed in various configurations to receive the passage of air from the elongated tube 12. This passage of air when delivered from the inlet 42 to the outlet 44 can then be delivered to the inlet of a mouthpiece 50. The mouthpiece 50 comprises a mouthpiece portion 52 which receives the teeth of the user and a flange 54 which is received within the lips of a user. The mouthpiece is described within U.S. Pat. No. 4,862,903, as well as U.S. Pat. No. D303,440.
The attachment of the mouthpiece 50 is in the same manner as described in the foregoing patents with a pair of flanges or grooves received on a mouthpiece mounting member, box or air duct 56. The mouthpiece mounting member or duct 56 forms an inner conduit 58 having an inlet 60 and an outlet 62 into a user's mouth. This inlet and outlet respectively 60 and 62 allow for the breathing of air inwardly and outwardly in a manner such that the air received from the outlet 44 of the connection means 38 passes thereinto.
The mouthpiece 50 as seen in FIG. 6 has an axis 66. The axis 66 is in alignment with the axis of the passage through connection, box or conduit 56 having the passage 58 and outlet opening which is connected to the outlet 62 of the mouthpiece 50.
A purge chamber conduit, sump or drain 70 is shown having a plurality of ribs 72 and grooves 74. The ribs and grooves 72 and 74 are used to provide strength but are not necessarily required. They also provide a certain degree of aesthetic quality and can be used as a grip. The purge chamber 74 is formed of a hard plastic and has an inner flange 78 which is received within a groove 80 in a portion of the connection member 38 for ease of assembly and molding.
The purge chamber 74 has an enlarged purge opening or chamber 84 having a volume of anywhere from 0.6 cubic inches to 1.8 cubic inches from the inlet opening area generally defined at edge 88.
The distal end of the purge chamber has a flapper or mushroom valve 94 made of an elastomeric member therein. The mushroom valve 94 has an elastomeric upstanding stem portion 96 that has an enlarged base 98 and a contracted portion 100 for frictionally fitting within an aperture through a web. The web is provided by web members 106 that can be formed as a spandrel going across the end of the purge chamber outlet for support of the elastomeric valve 94. The elastomeric valve has a valve seat 110 against which the peripheral edge of the elastomeric flapper seats. When seating against the valve seat 110, it generally prevents the inlet of water into the purge chamber 84 while at the same time allowing for the purge of water and air therefrom when opened in the direction of purge (arrow P).
Water is generally let into the elongated tube 12 by virtue of the fact that the tube is under water at times and receives a significant amount of water which must be purged. To do this, the water which arrives within the purge chamber 84 receives a sharp blowdown or exhalation pressure in the direction of arrow P. The pressure is from the mouthpiece inlet 60 that creates an air pressure which opens the elastomeric valve 94 off of its seat 110 in the direction of arrow P. This allows the passage of air and the attendant water trapped in the chamber 84 to be blown therefrom.
The chamber is effectively created by not only the depth and the distal relationship it is from the mouthpiece, but also the overall volume which it provides. The prior art mouthpiece purges have not had a discretely enlarged chamber from which water can be blown in a downward manner. Instead, the purges were generally in close proximity to the mouthpiece, thereby allowing the inlet of water. Also, they did not incorporate the angular relationships detailed hereinafter which provides for the superior function of the invention.
The orientation of the flapper 94 and the webs can be seen more distinctly in FIG. 3 with the flapper 97 removed. The webs 106 can be such wherein they have a partial baffle 120 covering approximately a semicircular area of the purge outlet. This semicircular area of the purge outlet is such where it allows for a stronger pressure to lift the valve member 94 from the seat 110.
It has been found that the orientation of the axes of the mouthpiece 50, purge chamber 70, and inlet connection or conduit 38 are of importance. These general orientations can be oriented with respect to the axis of the mouthpiece, namely axis 66. When referring to lateral or longitudinal relationships with regard to each axis, it is assumed that the mouth of the user when engaging the mouthpiece 50 is holding the mouthpiece along its axis 66 in the orientation of FIG. 1. Starting with this relationship, it can be seen that the axis 66 when the snorkel is in use is directed downwardly and is generally in line with the passage through the center of the connecting box 56 which has a similar axis as axis 66 passing therethrough. These axes are in longitudinal alignment and when extending from the mouth can be defined as longitudinal and when moved to the side are displaced laterally. This axis 66 is in an orientation with regard to the purge chamber 70 and particularly the internal portion of the purge chamber 70. This axis of the purge chamber 70 can be see as axis 140.
Axis 140 or the center line of the symmetrical purge chamber 70 intersects the axis 66 of the mouthpiece and connecting box 56 in a manner whereby the included angle from the axis is forty degrees. In other words, the axis of the mouthpiece 66 is offset longitudinally from the axis of the chamber 70 by forty degrees. This can be seen as the axis extending offset through the elongated tube 12. The angle of the axis 66 and the axis 140 of the chamber between their respective distal ends is one hundred and forty degrees.
It has been found that the relationship of the snorkel is such that the purge chamber 70 should cant backwardly under the diver's chin at approximately forty degrees when in use. However, a substantially excellent operating range would be from thirty to fifty degrees. It has also been found that ranges as high as an angle of sixty degrees toward a user's chin when in use to an angle of twenty degrees in the opposite direction from a user's chin as to the respective axis 66 and 140 is operable. These offsets lie within the offsets of the longitudinal relationship of the axes 66 and 140.
The general ranges of the foregoing angles have been found to be useful particularly in maintaining water within the chamber so that it does not slosh backwardly into a user's mouth, through the mouthpiece opening 60.
In order to provide for a lateral offset which has been found to be helpful, the axis 140 can be offset laterally from axis 66 by approximately ten degrees. However, it has been found that the lateral offset of the chamber 84 can effectively work within a range of zero to thirty degrees. The angle of ten degrees has been shown between the axes 66 and 140 in FIG. 6.
In order to cause the inlet conduit 40 to extend toward the inlet chamber 84, the mouthpiece connection can be canted by twenty degrees such wherein the axis 170 of the inlet connection 38 can be canted so that the result is that it slopes downwardly at approximately twenty degrees. In effect, the axis 66 in relationship to the axis 170 where they intersect results in an included angle of seventy degrees insofar as a lateral offset is concerned. It has been found that this range can be from five to forty-five degrees in order to allow for the sloping and drainage from the inlet connection conduit 40 into the purge chamber 84.
The foregoing ranges of angular orientation are such wherein they can provide and generally function in a manner so that the purge chamber 84 is maintained in a manner whereby it does not cause the inhaling of water in a ready manner from the chamber through the mouthpiece 50 into a user's mouth. The result is that the general angular ranges are such wherein during operating conditions for the snorkel it maintains the purge chamber 70 in a location with respect to the chin and the lateral relationships of the various axes such that it effectively helps to prevent the inhalation of water.
This is not to say that water will not be inhaled when an effective purge has been provided which is completely dry. However, it has been found that within the ranges of prior art operating conditions, the axial configuration, orientation of the distal purge chamber 70 from the mouthpiece opening and the capacity of the purge chamber in consideration of the size of the inlet connection 38 and the elongated tube 12 provide the parameters for relatively substantially improved operation over the prior art.
Accordingly, this invention should be read broadly as to the orientation of the distal purge and the ranges in which the axis of the respective elements of the invention are shown. | The specification discloses a diver's snorkel having an elongated tube with a fitting at the end incorporating a mouthpiece. Distal from the mouthpiece is a water drainage purge chamber extending away from the mouthpiece. The entrance conduit interconnecting the elongated tube to the mouthpiece and the purge chamber is at an angle sloping downwardly from the mouthpiece during use. The purge chamber is angled inwardly toward a diver's chin when in use so that the axis thereof is at an angle to the axis of the mouthpiece. The purge chamber has a purge valve distal from the mouthpiece and incorporates a chamber of significant volume for drainage from the mouthpiece and the elongated tube in an unobstructed manner. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Divisional Application of U.S. patent application Ser. No. 11/885,808, filed Sep. 6, 2007, which is a 371 of International application PCT/EP2006/002164, filed Mar. 9, 2006, which claims priority of DE 10 2005 011 532.2, filed Mar. 10, 2005, and DE 10 2005 023 745.2, filed May 24, 2005, the priority of these applications is hereby claimed and these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention concerns a method for producing a continuous casting mold, in which machining is carried out on at least one surface which is in contact with molten material during the normal use of the mold. The invention also concerns a continuous casting mold.
[0004] 2. Description of the Related Art
[0005] Continuous casting molds are known which are characterized by a special surface modification, especially for the purpose of favorably affecting heat transfer from the steel into the mold wall.
[0006] EP 1 099 496 A1 proposes that mold plates be completely or partially provided with surface texture to reduce heat flow. The texture is preferably produced by sand blasting or shot peening after machining. This makes it possible to increase the roughness of the surface of the mold that is in contact with molten material during normal use of the continuous casting mold.
[0007] JP 10 193 042 A describes a continuous casting mold in which longitudinal grooves are systematically formed in the surface of the broad-side plates. This is intended to reduce the heat flux density in the liquid metal level in order to avoid longitudinal cracks.
[0008] JP 02 020 645 A discloses a continuous casting mold in which longitudinal grooves and transverse grooves are formed in the broad-side plates in a predetermined grid pattern. The goal here is also to reduce the heat flux density in the liquid metal level and thus to reduce the risk of longitudinal cracks.
[0009] The grooves that are formed are in the range of 0.5 to 1.0 mm; the grid spacing is about 5-10 mm.
[0010] AT 269 392 discloses a continuous casting mold in which the goal is likewise to reduce the heat flux density, especially in the upper part of the mold. This is achieved by a greater wall thickness in the upper part of the mold or by the use of more strongly insulating material in this area. In this regard, the upper area of the mold either can consist entirely of this material or can be coated with this material on the water side.
[0011] FR 2 658 440 describes a continuous casting mold in which local reduction of the heat flux density is realized by forming grooves in the hot side of the mold and filling these grooves with a second material of lower thermal conductivity. In addition, the entire surface of the mold is coated with this second material.
[0012] JP 06 134 553 A and JP 03 128 149 A describe roughening the surface of casting rolls, which is intended in this application to reduce the heat flux density.
SUMMARY OF THE INVENTION
[0013] The previously known measures are intended to bring about improved thermodynamic behavior of the mold and especially its walls and improved suitability for use in continuous casting. In general, one strives for good adhesion of the casting flux to the mold plate and uniform distribution of the heat flow over the entire mold.
[0014] The thickness and the structure of the casting flux layer between the mold wall and the strand shell are critical determinants of the magnitude of the heat flux density between the steel and the mold and thus of the thermal load on both the strand shell and the mold material. Therefore, strong stresses can arise in the strand shell due to local changes and changes over time in the casting flux layer, and these stresses can cause longitudinal cracks, especially in steel grades that are susceptible to cracking. However, the surface of the mold is also subject to strong mechanical stresses due to alternating thermal loading. Therefore, the maximum heat flow in the area of the liquid metal level should be low and as uniform as possible in order to reduce the risk of cracking, especially in steel grades that are susceptible to longitudinal cracking.
[0015] An additional goal is to keep the friction between the broad sides and the narrow sides of the mold as low as possible during adjustment of the narrow sides. Finally, it is desirable to reduce the thermal stress in the liquid metal level by means of a low heat flux density for the purpose of increasing the service life of the mold.
[0016] The measures that have previously been proposed achieve these goals only partially or at relatively high production expense.
[0017] Therefore, the goal of the invention is to develop a continuous casting mold and a method for producing it, with which the aforementioned desired characteristics can be achieved as effectively as possible, with the least possible production expense, and thus at low cost.
[0018] In accordance with the invention, the solution to this problem with respect to a method is characterized by the fact that machining that produces an anisotropically textured surface is carried out as the last processing step or as one of the last processing steps in the production of the surface of the mold.
[0019] This is preferably accomplished by employing a milling process or a grinding process as the last processing step.
[0020] Anisotropy is understood to mean that the surface characteristics vary with the surface direction in which they are determined. In connection with the mold surface in question here, this means especially that various parameters, such as roughness, have different values when measured in the casting direction from their values perpendicular to the casting direction, i.e., in the direction transverse to the casting direction.
[0021] In accordance with the invention, the continuous casting mold, which has at least one machined surface that has contact with molten material during its normal use, is characterized by the fact that at least part of the surface has an anisotropic structure.
[0022] In one embodiment of the invention, the surface of the mold has greater roughness in the casting direction than in the direction transverse to the casting direction, in each case as viewed in the plane of the surface.
[0023] The anisotropically textured surface can have elevations and depressions formed and oriented in rows that run in the direction transverse to the casting direction. The elevations and depressions can be formed as corrugations, whose peaks and valleys run in the direction transverse to the casting direction; in this connection, the corrugations preferably have an essentially rounded shape in cross section. It has been found to be effective if the height of the corrugations is 2 μm to 250 μm, and especially 10 μm to 50 μm.
[0024] The height of the corrugations on the surface can remain constant or can be varied in the casting direction and/or in the direction transverse to the casting direction.
[0025] The proposal of the invention is thus aimed at producing the desired anisotropic surface structure in the last step of the machining operation to shape the surface of the mold. In this regard, the machined surface can be shaped in such a way that the macroscopic structure produced in the casting direction is different from that produced transverse to the casting direction. The microscopic roughness of the surface can also be formed differently in the casting direction and the direction transverse to the casting direction.
[0026] Greater roughness in the casting direction and a macroscopic structure of the surface with elevations running in rows transverse to the casting direction result in better adhesion of the casting flux layer to the mold plate near the liquid metal level, so that it is not so easily rubbed off—completely or only locally—by the strand. At the same time, both the increased roughness and the macroscopic structure of the surface cause the heat flow to be reduced and evened out, which also results in a reduction of the tendency towards longitudinal cracking. In addition, the reduction of the heat flux density in the liquid metal level reduces the thermal stresses in the mold plate, which increases the service life of the mold plates.
[0027] Furthermore, it is advantageous that the desired surface texture is produced during the machining of the mold surface. This means that further processing steps, e.g., forming grooves in the surface, coating the surface in the area of the liquid metal level, or roughening the surface by sand blasting or shot peening, are not necessary, which makes the proposal of the invention economical. The advantageous anisotropic surface texture can thus be produced without great expense not only during the production of the molds but also during each reworking of the mold surface, which is necessary at certain intervals of time.
[0028] In addition, the shaping of the mold surfaces in the manner described with macroscopic elevations oriented transversely to the casting direction, or the roughness that is greater in the casting direction than in the direction transverse to the casting direction, also reduces the friction between the broad sides and the narrow sides during adjustment of the narrow sides in the case of molds that consist of individual mold plates (e.g., slab, thin slab).
BRIEF DESCRIPTION OF THE DRAWING
[0029] In the drawing:
[0030] FIG. 1 shows a schematic representation of a mold plate with an anisotropic surface and an enlarged view of the surface topology.
[0031] FIG. 2 shows a schematic three-dimensional view of the profile of the surface of the mold plate.
[0032] FIG. 3 shows an enlarged view of section A-B in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0033] FIG. 1 shows a view of that surface of a mold plate of a continuous casting mold 1 which is in contact with molten material (steel) or the solidified strand shell during the use of the continuous casting mold 1 . The strand shell passes the mold plate in casting direction G. To achieve the advantages explained above, the surface 2 is provided with a special texture: The surface topology, especially the roughness, of the surface 2 is anisotropically formed, i.e., different roughness values are measured in casting direction G and in direction Q transverse to the casting direction G.
[0034] In this connection, the mold plate is provided with large numbers of elevations and depressions, which are shown in FIG. 1 in a highly schematic way. These elevations and depressions are produced during the last machining operation in the production of the mold plate. In the last machining step, the surface of the mold plate is milled by traverse milling, for example, with the use of a milling cutter with a diameter of 100-150 mm, which is provided with standard indexable cutter inserts, e.g., made of cemented carbide alloy. The material removal during the last machining step is less than 1 mm, and preferably less than 0.5 mm. Impressions and the structure of the elevations and depressions on the surface of the mold can be systematically adjusted according to the selected material removal and other milling parameters, such as speed of rotation, feed rate, peripheral speed, spacing of the milled rows, coolant, milling direction, and angle of attack of the tool relative to the surface of the plate (set angle).
[0035] Alternatively, the desired surface texture can be produced by a grinding process. As in the case of milling, the surface can be ground in rows. In this regard, the shape of the wavelike elevations and depressions can be produced by the surface contour of the grinding disk or by the angle of attack of the grinding disk relative to the surface of the plate.
[0036] FIG. 2 shows a three-dimensional view of the profile of the surface after the final machining. Here it is apparent that the roughness of the surface is greater in the casting direction G than in the direction Q transverse to the casting direction G. The mold plate is thus provided with a large number of elevations and depressions, which are shown only in a highly schematic way in FIG. 1 . These elevations and depressions are produced during the last machining operation in the production of the mold plate.
[0037] The height H of the elevations and depressions, which are oriented in rows, is seen in FIG. 3 and is typically in the range of 2 μm to 250 μm, which can be controlled by the choice of milling parameters. | A continuous casting mold having at least one mechanically machined surface that is in contact with molten material during normal use of the mold in order to achieve a uniform distribution of the heat flux over the mold. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. patent application Ser. No. 13/039,214 filed Mar. 2, 2011, entitled, “Non-intrusive Power Management,” by Aaron Rallo, and which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The disclosed embodiments relate generally to power management in any pool of computing devices that are logically grouped to provide a common set of functionality. More particularly, the disclosed embodiments relate to power management in server pools, interchangeably referred to as server clusters, typically found in large computing establishments like data centers.
BACKGROUND
[0003] The proliferation of the Internet, devices that access it, and consequently, Internet based services are driving an insatiable thirst for computational power. To meet this need, large data centers have been set up. Typical data centers house hundreds, maybe even thousands of servers, and serve as the backbone for a variety of Internet services. The services hosted by data centers typically come with the requirement of high availability, close to 99.9% up time, which is usually supported by replicating servers and maintaining spare capacity. Furthermore, data centers are designed for a peak loads which are both occasional and short lived. As a result, data centers tend to consume large amounts of power. In phases that the data center is not fully loaded, idle servers can be shutdown without substantial loss in performance. When the load increases, powered off servers can be booted-up to service the requests and maintain Quality of Service (QoS).
[0004] Reducing the power consumption of a data center contributes to reduced operational expense, and allows the data center operator to invest in newer hardware and supporting infrastructure, to save money and/or to provide improved services to customers. Prior studies have reported that servers can draw close to 60% of their peak power consumption when idle, and that the global electricity costs for data centers have been reported as running into the billions. Therefore, substantial reduction in power consumption can be achieved by shutting down idle servers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] For a better understanding of the aspects of the invention as well as embodiments thereof, reference should be made to the description of embodiments below, in conjunction with the following drawings in which like reference numerals refer to corresponding parts throughout the figures.
[0006] FIG. 1 is a high-level block diagram illustrating power management of a pool of computing devices that are logically grouped to provide a common set of functionality, according to certain embodiments of the invention.
[0007] FIG. 2 is a block diagram showing some of the high-level steps for obtaining correlation information associated with the servers in the server pool, according to certain embodiments of the invention.
[0008] FIG. 3 is a block diagram that illustrates a power management method, according to certain embodiments of the invention.
[0009] FIG. 4 illustrates the class diagram of the central classes used for implementing the power manager, according to certain embodiments of the invention.
[0010] FIG. 5 illustrates the class diagram for the LoadInformation class hierarchy, according to certain embodiments of the invention.
[0011] FIG. 6 illustrates the class diagram for the UtilizatonPredictor class hierarchy, according to certain embodiments of the invention.
[0012] FIG. 7 illustrates the class diagram for the ResourcesMeasureMethod class hierarchy, according to certain embodiments of the invention.
[0013] FIG. 8 illustrates the class diagram for the LoadBalancer class hierarchy, according to certain embodiments of the invention.
DESCRIPTION OF EMBODIMENTS
[0014] Methods, systems and other aspects of the invention are described. Reference will be made to certain embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the embodiments, it will be understood that it is not intended to limit the invention to these particular embodiments alone. On the contrary, the invention is intended to cover alternatives, modifications and equivalents that are within the spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
[0015] Moreover, in the following description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these particular details. In other instances, methods, procedures, components, and networks that are well known to those of ordinary skill in the art are not described in detail to avoid obscuring aspects of the present invention.
[0016] The embodiments described herein are in reference to servers in data centers. However, the embodiments apply to any pool of computing devices that are logically grouped to provide a common set of functionality.
[0017] According to certain embodiments, the problem associated with power consumption in data centers can be effectively managed by turning off or turning on servers in response to the load experienced by the data center. Servers are turned on when the load increases and turned off when load decreases. Load can be defined by the number and/or size of requests that are being received by the server pool per unit time interval, for example.
[0018] According to certain embodiments, a new server or device is characterized to understand how the resource utilization changes as the number of requests being serviced changes by the server/device. The characterization, using statistical analysis techniques, can be used to predict the utilization of the server/device for a given load. The correlation function associated with the characterization is stored in a database, for example. A power management server can retrieve the correlation function during initialization. The power management server takes decisions at regular time intervals to shutdown a server/device, power-on a server/device or maintain status quo in the pool of servers/devices based on the predicted utilization.
[0019] According to certain embodiments, a non-intrusive mechanism is used to power down servers or devices. In contrast, existing power management solutions typically require that the data center operators install software, firmware or hardware on the servers/devices for power management. Such power management decisions are taken by a centralized administrative software component which communicates with the software installed in the individual servers, which then initiate the action. The custom software typically sends information that the centralized entity can use for decision making. Such an approach is intrusive unlike the non-intrusive approach as described in the embodiments herein. The embodiments described herein do not require any such additional software, firmware or hardware installation on each server/device in the data center.
[0020] According to certain embodiments, a centralized entity takes power management decisions and initiates them on the servers/devices without the need for custom software, hardware or firmware. The centralized entity uses information exported by the OS only of the servers/devices. Such an approach requires little or no downtime for installation, does not require custom software to be installed, or require any major system reconfiguration.
[0021] Further, unlike vendor specific solutions, the embodiments are not restricted to hardware vendors (processor or OEM) or to operating systems.
[0022] FIG. 1 is a high-level block diagram illustrating power management of a pool of computing devices that are logically grouped to provide a common set of functionality, such as servers in a data center, according to certain embodiments of the invention. In FIG. 1 , system 100 includes an application delivery controller 104 that receives HTTP requests 102 from client devices, and a computer 106 that executes the power manager. Application delivery controller 104 sends the HTTP requests 102 to the server pool 108 and also receives the responses to the HTTP requests from server pool 108 . The power manager implemented in computer 106 receives information from application delivery controller 104 and information from the server pool 108 to make power management decisions. The power manager may be implemented on multiple computers as in a distributed computer system, according to certain embodiments. Application delivery controller 104 may be a commercial off-the-shelf load balancer, according to certain embodiments. Similarly, computer 106 can be an off-the-shelf computer on which the power management solution is installed and executes. Server pool 108 or server cluster comprises server machines or nodes that service requests from client devices via application delivery controller 104 . An application delivery controller is hardware or software that manages requests received from client devices and distributes such requests to the computing devices in the server pool. A non-limiting example of an application delivery controller is a load balancer.
[0023] HTTP requests initiated by client devices reach application delivery controller 104 which redirects the requests to an appropriate server in the server pool 108 . According to certain embodiments, application delivery controller 104 is configured to use a round robin policy. Consequently, server nodes in server pool 108 service a comparable number of requests. The power manager interacts with application delivery controller 104 to obtain information including but not limited to:
Information on the number of requests being executed by each server in server pool 108 , the average response time by each server in server pool 108 , and information on server state.
[0027] The power manager does not service any requests from client devices. The power manager's job is to make power management decisions and initiate such decisions, while maintaining consistency between actual server state and information at application delivery controller 104 .
[0028] According to one aspect of certain embodiments, each server of at least a subset of servers in the server pool is characterized for the utilization behaviour of that particular server. Characterization involves measuring on the server to be characterized, the utilization of various resources as the number of requests being executed by the server varies. Such measurement information is utilized to draw correlations between the number of requests being serviced by the server that is being characterized and its utilization of resources, according to certain embodiments. The power manager (computer 106 ) can remotely query the servers in server pool 108 to obtain resource utilization information using standardized protocols like Simple Network Management Protocol (SNMP) for any OS or Windows Management Instrumentation (WMI) for MS Windows. The correlation drawn can be used to predict the utilization of a given server for any given number of HTTP requests being serviced per minute, according to certain embodiments. According to certain embodiments, the characterization is performed using the same application that the server to be characterized is expected to execute in production because a server can be expected to show differences in behaviour with different application types.
[0029] According to certain embodiments, correlation information is obtained using well established statistical analysis techniques such as linear regression. The statistical analysis can be performed using any commercially/freely available statistical analysis software such as R statistical software. According to certain embodiments, the correlation information is an expression that correlates the number of requests to the CPU utilization. According to some embodiments, this correlation information is XML serialized and inserted into a database along with other information that the power management solution requires. XML serialization is the process of converting a binary object in memory into an XML representation that can then be stored on disk (files or database). For purposes of simplicity, the statistical analysis is done in the background and the results are stored in the database. The process of deriving correlations can be made real time, according to certain embodiments.
[0030] FIG. 2 is a block diagram showing some of the high-level steps for obtaining correlation information associated with the servers in the server pool, according to certain embodiments of the invention. At block 202 , a fixed workload is executed against a given server that is to be characterized. At block 204 , the information on resource utilization, workload and other related information is logged for analysis. At block 206 , statistical analysis is performed on the information to obtain correlation information. At block 208 , the correlation information for the given server is stored in the database. If the database already contains correlation information for the particular server, then the correlation information is updated. At block 210 , the power manager retrieves correlation information for making power management decisions.
[0031] The power manager runs at regular intervals. For example, the power manager can run every 10 seconds. At each iteration of the power manager solution, a decision is taken as to whether a server needs to be powered on or powered off. The power manager also identifies which server must be powered on or off based on a server selection policy. The server selection policy is described herein.
[0032] FIG. 3 is a block diagram that illustrates the power management method, according to certain embodiments of the invention. After initialization at block 302 , correlation data is retrieved from the database at block 304 . At block 308 , on each iteration, the power manager checks if all the servers in the server pool are above a pre-configured utilization threshold called the overload threshold, according to certain embodiments. According to certain other embodiments, the utilization threshold is determined dynamically rather than being pre-configured. If all the servers are above the utilization threshold, then at block 310 , the power manager determines if all the servers in the server pool are powered on. If all the servers are powered on, then at block 306 , the status quo of the server pool is maintained. If not all servers in the server pool are powered on, then at block 314 , the power manager identifies which server is to be powered on, if more than one server is not powered on in the server pool. At block 316 , the power manager initiates power-on process for the selected server. At block 318 , the power manager waits for the resume duration. At block 320 , the power manager updates the state information for the selected server that was just powered on. At block 322 , the server that was just powered on is marked on the application delivery controller as available for servicing requests.
[0033] If at block 308 , it is determined that not all the servers in the server pool are above the utilization threshold, then at block 312 a check is made to identify if any server in the server pool can be powered off safely. If none of the servers in the server pool can be powered off safely, then the status quo is maintained at block 334 .
[0034] If there are servers in the server pool can be powered off, then at block 324 , the power manager identifies a server to be powered off. The server identified to be powered off is referred to as a candidate server. A decision to power off is taken only if the load on the candidate server can be migrated to the remaining power-on servers in the server pool without causing such remaining power-on servers to cross an overload threshold associated with a given server. At block 326 , the server identified to be powered off is marked as unavailable on the application delivery controller. At block 328 , the state information of the server to be powered off is updated. At block 330 , the power manager waits for the number of requests sent to the server to be powered off drops to zero. At block 332 , the power manager initiates the power-off process for the server to be powered off.
[0035] Powering servers on or off can be done using existing mechanisms supported by operating systems of the servers. For example, Windows Management Instrumentation (WMI) on Microsoft Windows or ssh based remote command execution on Linux/Solaris can be used for powering servers on or off.
[0036] According to certain embodiments, a staggered suspend and boot up process is used at a given point in time. In other words, exactly one server is suspending or resuming at a given time. The staggered suspend ensures that there is capacity in the server pool to handle any spikes in the load and thus is a conservative approach. Staggered resume ensures that the load on the power supply for the server does not go high because computers typically draw higher power during the boot up phase.
[0037] According to certain embodiments, the power management method can include the following features:
Predicting the demand: Historical data can be analysed to predict the demand that the server pool will experience in the next time interval. The prediction can augment the decisions taken by the power manager. Existing statistical methods like Auto Regressive Moving Average can be used for the time based trend analysis and prediction. Predict the number of servers or devices required to support a given workload. Chart the response time and performance of a server or a device under a given workload. Moving server nodes across pools: The power management method described herein can be extended to multiple pools using a global power management scheme. In such a global power management scheme, it is possible to move servers across pools to serve the needs of various pools. Depending on the demand, servers can be either moved across pools or turned on/off.
[0042] The Advanced Configuration and Power Interface (ACPI) specification defines the following server states, according to certain embodiments. Other suitable standards for defining server states can also be used. The embodiments are not restricted to the ACPI standard.
[0000] TABLE 1 ACPI Server States Server Global state State Description S0 G0 Server is powered on and operational. S1 and S2 G1 Undefined and unused. S3 G1 Suspended to RAM - Operating system context stored in RAM and most components powered down. Typically RAM and NIC are active in this state. S4 G1 Suspend to Disk - Operating system context is written to disk and server is powered down. S5 G2 Soft off - Server is powered down, no OS context is retained. S5 G3 Mechanical off - Server is powered down and main power supply is cut off.
According to certain embodiments, servers are switched between S0 and S5.
[0043] If all the servers in the server pool have similar properties like operating frequency, RAM, disk space etc, the choice of server to shutdown/resume become trivial because any server can be chosen. However, if the server pools are heterogeneous pools, where servers differ in their properties, then a server selection policy is needed in order to select an appropriate server to power on or off. According to certain embodiments, policies that can be used to select servers if multiple servers are available for shutdown/resume are described below:
[0044] Polices for server power off include but are not limited to:
1. Lowest Frequency: Power off the server that operates at the lowest frequency. 2. Highest power: Power off the server that consumes the highest power. 3. Max post-utilization: Power off the server that will result in other servers having high utilization. 4. Types of applications running on the system (application capabilities).
[0049] The policies for server power on include but are not limited to:
1. Lowest power: Power on the server that consumes lowest power. 2. Highest frequency: Power on the server that runs at the highest frequency. 3. Shortest Resume Time: Power on the server that takes the shortest time to boot up.
[0053] As a non-limiting example, suspend policy 3 (max post-utilization) and resume policy 2 (highest frequency) can be used, according to certain embodiments. It is possible to support any combination of policies, but the power management mechanism must ideally be configured to use the ones that provide high power savings without significant loss in performance. Further, different combinations of suspend and resume policies will show different power/performance characteristics.
[0054] At any point in time, at least one server will be active in the pool. The reasoning behind having at least one server active is to have available computational capacity to handle requests while other servers are resuming.
[0055] As a non-limiting example, turning servers off is achieved by issuing a remote shutdown command using WMI (as our cluster is currently MS Windows based). Remote command execution requires that appropriate services are enabled on the server and appropriate ports are kept on in the firewall. Alternate techniques can be used for Linux and Solaris. Servers are turned on using Wake-On-LAN (WoL), an industry standard technique to resume computers that are currently suspended. A WoL packet is a specially crafted network packet which contains a WoL header and the MAC address of the target server repeated 16 times WoL packet definition is standardized. WoL must be supported by the network interface card (NIC) and also enabled by the operating system driver. Modern NICs typically support WoL.
[0056] Such a non-intrusiveness approach does not require any additional software components to be installed on the individual servers in the server pool for the power manager to work. At most, it requires certain standard operating system services which might be turned off by default (like ssh, snmp) to be turned on.
[0057] FIG. 4 illustrates the class diagram of the central classes used for implementing the power manager, according to certain embodiments. FIG. 4 shows ServerMachine class 402 , ServerLoadInformation class 404 , Resource class 406 , ResourceMeasureMethod class 408 , ImmutableServerProperties class 410 , UtilizationPredictor class 412 , NetworkResource class 414 , DiskResource class 416 , and CPUResource class 418 . The central data structure to the application is a ServerMachine class 402 that holds information about a server in the server cluster. The ServerMachine class contains the immutable server properties (like MAC address, maximum operating frequency, power consumption etc) and dynamically created objects for measuring resource utilization (see FIG. 7 ), predicting the utilization ( FIG. 6 ), storing load information ( FIG. 5 ) etc. A server contains resource objects—CPU, Disk, network, and memory, and is a resource in itself. The utilization predictor for each server is read from on disk storage (a database, for example) as an XML serialized stream and then de-serialized to get the object.
[0058] Some of the hierarchies of other classes used in the implementation of the power manager are described herein with reference to FIGS. 5-8 .
[0059] FIG. 5 illustrates the class diagram for the LoadInformation class hierarchy, according to certain embodiments. LoadInformation class defines classes that are used to store information on connections/requests queried at regular intervals from the load balancer or server. FIG. 5 shows that LoadInformation class 502 includes LocalHTTPLoadInfo class 504 , PoolLoadInformation class 506 , and ServerLoadInformation class 508 . ServerLoadInformation class 508 includes VirtualServerLoadInformation class.
[0060] FIG. 6 illustrates the class diagram for the UtilizationPredictor class hierarchy, according to certain embodiments. UtilizationPredictor class 602 includes LinearRegressionBased class 604 .
[0061] FIG. 7 illustrates the class diagram for the ResourcesMeasureMethod class hierarchy, according to certain embodiments. ResourcesMeasureMethod class 702 includes WMIAdaptor class 704 and SNMPAdaptor class 706 .
[0062] FIG. 8 illustrates the class diagram for the LoadBalancer class hierarchy, according to certain embodiments. LoadBalancer class 802 includes F5Adaptor class 804 . The load balancer class hierarchy is used to define classes that can be used to query and control the load balancer. s
[0063] According to certain embodiments, a simple database with a single table is used to store information about individual servers.
[0064] The characterization phase requires utilization information to be gathered from servers for later analysis. According to certain embodiments, this information is stored in a database. The utilization information of each resource is stored in a separate file with the format shown in Table 2 Utilization Information, as non-limiting example.
[0000]
TABLE 2
Utilization information
Date-Time
Resource utilization
Weighted Moving average
stamp
(varying from 0-100%)
utilization (0-100%)
[0065] The weighted moving average is used to help smoothing any sharp fluctuations in the measured utilization. An example for CPU utilization on a dual core machine, measured using WMI is given below.
[0000]
Date-Time
Core 0
Core 1
Total
Moving
Moving
Moving
stamp
Avg
Avg
Avg (Total)
(Core 0)
(Core)
[0066] The level of detail—per core utilization—is not provided by SNMP implementations. However, overall system utilization is available and the power manager implementation uses the overall utilization for analysis and decision making. | A method and system for managing power consumption of a pool of computing devices are disclosed. One aspect of certain embodiments includes managing resource utilization for each computing device without installing customized software, firmware or hardware on the computing device and dynamically selecting, one or more candidate computing devices for altering their respective power states based on at least real-time information on the quantity of requests. | 8 |
This invention was made with Government support under Contract No. DE-AC05-84OR21400 awarded by the U.S. Department of Energy to Martin Marietta Energy Systems, Inc. The Government has certain rights in this invention.
This application is a division of application Ser. No. 07/921,538, filed 29 Jul. 1992, now U.S. Pat. No. 5,338,625.
BACKGROUND OF INVENTION
1. Field of Invention
The invention is directed to a thin-film battery and a method for making same. More particularly, the invention is directed to a new thin-film lithium battery having a novel electrolyte permitting a battery to be fabricated having greatly enhanced energy density and specific energy over conventionally available batteries. The invention is also directed to a novel cathode permitting a battery to be fabricated having significantly enhanced energy densities over conventionally available batteries.
Conventional electro-optical devices known as "smart windows" are typically formed as a layered structure having a first electrode such as an anode layer, an electrochromic layer, an electrolyte or conductive layer and a second electrode such as a cathode layer, all of which are optically transparent. A limitation of such conventional electro-optical devices is that the electrolyte or conductive layer tends to be unstable and react with the electrodes. Any of such conventional electro-optical devices may be made choice of conventional materials for the electrodes and electrochromic layers by one skilled in the art and using the novel electrolyte claimed by Applicants for the conventional electrolyte layer. The enhanced stability of Applicants' novel electrolyte arising from the inclusion of nitrogen provides for electro-optical devices having enhanced performance over conventional devices.
2. Description of Prior Art
A battery is one of two kinds of electrochemical devices that convert the energy released in a chemical reaction directly into electrical energy. In a battery, the reactants are stored close together within the battery itself, whereas in a fuel cell the reactants are stored externally. The attractiveness of batteries as an efficient source of power is that the conversion of chemical energy to electrical energy is potentially 100% efficient although the loss due to internal resistance is a major limiting factor. This potential efficiency is considerably greater than the conversion of thermal energy to mechanical energy as used in internal combustion engines, which always results in heat transfer losses. Moreover, the additional disadvantages of contaminants emitted into the atmosphere as byproducts of incomplete combustion and dwindling availability of fuel supplies have intensified research into batteries as an alternative source of energy.
One limitation of conventional batteries is that they use toxic materials such as lead, cadmium, mercury and various acid electrolytes that are facing strict regulation or outright banning as manufacturing materials. Another limitation is that the amount of energy stored and/or delivered by the battery is generally directly related to its size and weight. At one end of the development spectrum, automobile batteries produce large amounts of current but have such low energy densities and specific energies due to their size and weight and such relatively lengthy recharge times that their usage as a source of propulsion is impractical. At the other end of the development spectrum, small, light, lithium batteries used to power small electronic appliances and semiconductor devices have much higher energy densities and specific energies but have not had the capability to be scaled up to provide the high energy for high power applications such as use in automobiles. Further, these small, light, lithium batteries have low charge-discharge cycle capability, limited rechargeability and, even where scaled down for microelectronics applications, size that frequently is many times larger than the semiconductor chip on which they are used.
Thin-film battery technology is foreseen as having several advantages over conventional battery technology in that battery cell components can be prepared as thin, e.g. 1 micron, sheets built up in layers using techniques common to the electronics industry according to the desired application. The area of the sheets can be varied from sizes achievable with present lithographic techniques to a few square meters providing a wide range in battery capacity. Deposition of thin films places the anode close to the cathode resulting in high current density, high cell efficiency and a great reduction in the amount of reactants used. This is because the transport of ions is easier and faster in thin film layers since the distance the ions must move is lessened.
Most critical to battery performance is the choice of electrolyte. It is known that the principle limitation on rechargeability of prior batteries is failure of the electrolyte. Battery failure after a number of charge-discharge cycles and the loss of charge on standing is caused by reaction between the anode and the electrolyte, e.g. attack of the lithium anode on the lithium electrolyte in lithium batteries. An extra process step of coating the anode with a protective material adds to the complexity, size and cost of the battery.
The power and energy density of a battery is also dependent upon the nature of the cathode. To achieve optimum performance, the open circuit voltage and current density on discharge should be as high as possible, the recharge rate should be high and the battery should be able to withstand many charge-discharge cycles with no degradation of performance. The vanadium oxide cathode of the present invention has a much higher capacity per mole than the crystalline TiS 2 of prior art cathodes.
The present invention avoids the limitations of present battery design and provides a novel battery having application as a battery used with manufacture of semiconductor components and as a high energy, high current macrobattery with appropriate scale-up of the described processes. The present invention includes a novel electrolyte having a good conductivity but more importantly it has electrochemical stability at high cell potentials and requires no protective layer between it and the anode during battery fabrication or use. The present invention also includes a novel cathode having a microstructure providing excellent charge/discharge properties.
SUMMARY OF THE INVENTION
A primary object of invention is to provide a new thin-film battery and a method for making same.
A second object of invention is to provide a new electrolyte for a thin-film battery in which the electrolyte has good ionic conductivity and is not reactive with the battery anode.
Another object of invention is to provide a method for making an improved electrolyte for a thin-film battery.
A yet further object of invention is to provide a new cathode having improved microstructure for a thin-film battery and a method for making same.
These and other objects are achieved by depositing a pair of current collecting films on a substrate; depositing an amorphous cathode layer on the larger of the two collecting films; depositing an amorphous lithium phosphorus oxynitride electrolyte layer over the cathode; and depositing a metallic anode layer over the electrolyte.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of a thin-film battery deposited onto a semiconductor chip package with current leads extending to a semiconductor chip.
FIGS. 2A-2D illustrates the layers in plan view to form a thin-film battery according to the present invention.
FIG. 3 schematically illustrates a cross-sectional view of a thin-film battery made according to the present invention.
FIG. 4A is a micrograph of a vanadium oxide cathode formed by a sputtering process where the target is aged due to prior sputtering and the process gas flow rate is less than about 15 sccm.
FIG. 4B is a micrograph of a vanadium oxide cathode formed by a sputtering process where the target is fresh and the process gas flow rate is greater than about 15 sccm.
FIG. 5 illustrates the charge-discharge performance for a microbattery made according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
There are many possible uses for a thin-film, rechargeable battery as a primary or standby power source for low current electronic devices. A thin-film cell could be fabricated directly onto the semiconductor chip, the chip package or the chip carrier and could be fabricated to any specified size or shape to meet the requirements of a particular application. Referring to FIG. 1, a possible application is shown in which a thin-film cell 10 is deposited onto a semiconductor chip package 12 with current leads 14 extending to the chip 16. A Li-VO x cell about 8 microns thick occupying an area of 1 square centimeter as shown has a capacity of 130 microAmp-hours and could supply a current of up to 100 microAmps at a voltage ranging from 3.7 volts at full charge to about 1.5 volts near the end of its discharge. If a larger battery were deposited over the unused area of the package, the capacity and current density of the battery could of course be increased.
With reference to FIGS. 2A-D, the steps in fabricating such a single cell are shown. Two current collectors, vanadium for example, are deposited as a larger and a smaller 0.5 micron thick film, 18 and 20 respectively, on a substrate 22 such as glass, alumina, sapphire or various semiconductor or polymer materials. The films may be deposited by rf or dc magnetron sputtering or diode sputtering of vanadium in Argon, vacuum evaporation or other such film deposition techniques common to the semiconductor electronics industry. Similarly, an amorphous vanadium-oxide, VO x , cathode 24 is deposited as a 1 micron thick film over the larger current collector 18 by sputtering vanadium in Argon+14%O 2 . An amorphous oxynitride lithium electrolyte film 26 is then deposited over the cathode 24 by sputtering of Li 3 PO 4 , lithium orthophosphate, in 20 milliTorr of N 2 and a total gas flow of 14 sccm. As before, various film deposition techniques may be used for fabrication of the vitreous electrolyte film 26 although reactive DC sputtering is not available when lithium orthophosphate is the target as it is an insulator material and would accumulate charge until the deposition process stopped. Example targets for the described microbattery measured 25 millimeters in diameter by 3 millimeters thick and were prepared by cold pressing lithium orthophosphate powder followed by sintering of the pressed disc in air at 900° C. Deposition of a 1 micron thick film was carried out over a period of 16-21 hours at an average rate of 8-10 Angstroms per minute. The film 26 has the composition Li x PO y N z where x has the approximate value of 2.8; 2y+3z has the approximate value of 7.8; and z has the approximate value of 0.16 to 0.46. Deposition of a film 28 of lithium over the vitreous electrolyte film 26, the intervening substrate 22 and the smaller current collector 20 completes the cell. A typical film thickness for the lithium film 28 is about 5 microns. FIG. 3 is a schematic cross-section view of FIG. 2D.
Example performance characteristics of such a battery as described above are an open circuit voltage of 3.6 to 3.8 volts and, for a 1 micron thick cathode, a capacity of about 130 microAmp-hours per square centimeter for a discharge to 1.5 volts. The battery is capable of producing a discharge current of up to 2 milliAmps per square centimeter and can be recharged at a current of at least 20 microAmps per square centimeter. The battery has been subjected to more than 100 charge/discharge cycles with no degradation in performance and, after the first few cycles, the efficiency of the charge/discharge process was approximately 100%. Further, the vitreous oxynitride lithium electrolyte 26 has demonstrated long-term stability in contact with the lithium anode 28 such that the battery does not require the extra protective film, typically lithium iodide, to prevent reaction of the lithium anode with the electrolyte.
Performance of thin-film batteries has been critically limited by the properties of the chosen electrolyte. For rechargeable lithium batteries, the electrolyte should have a high lithium ion conductivity and it must be chemically stable in contact with lithium. Films deposited by sputtering or evaporation of inorganic compounds onto substrates held at ambient temperatures are usually amorphous. This is advantageous because, for many lithium compounds, the lithium ion conductivity of the amorphous phase is orders of magnitude higher than that of the crystalline phase and the conductance of the amorphous film is often adequate for use an as electrolyte. As many of these amorphous materials have acceptable low electronic conductivities, there is a wide choice of materials available for possible application in thin-film cells which meet the first two requirements. However, instability in contact with lithium eliminates many materials from consideration and has limited development of a thin-film lithium cell. The amorphous lithium phosphorus oxynitride film 26 of the present invention is made by sputtering Li 3 PO 4 in pure N 2 and has both the desired electrical properties and the stability in contact with lithium for fabrication of electrochemical cells.
A comparison of the conductivities at 25° C. for several electrolyte compositions in the lithium phosphosilicate system achieved by sputtering lithium silicates and lithium phosphates in Ar and Ar+O 2 is shown in Table 1. The lithium phosphosilicate listed had the highest conductivity of the films in the Li 2 O:SiO 2 :P 2 O 5 system. Several of the more highly conductive lithium phosphosilicate films with different compositions were investigated as the electrolyte for lithium cells. In each case, the lithium anode 28 reacted with the electrolyte film 26. However, the electrolyte of the present invention was found to be stable in contact with the lithium anode although it contained only about 2 to 6 at. % nitrogen. Moreover, as shown in Table 1, the conductivity is more than 30 times greater than that of the film deposited by sputtering Li 3 PO 4 in 40% O 2 in Argon. Incorporation of nitrogen into the thin films of the present invention increases conductivity at least five times greater than similarly prepared films containing no nitrogen. The increase in conductivity is due to an increase in lithium ion mobility rather than an increase in the number of charge carriers brought about by a change in the structure of the electrolyte. Further, such cells appear to be stable indefinitely, exhibiting only a small voltage loss which is considered to occur due to the electronic conductivity of the electrolyte.
TABLE 1______________________________________Comparison of amorphous lithium phosphate,phosphosilicate, and phosphorus oxynitride electrolyte films. Film σ(25° C.) × E.sub.2Target Process Gas Composition 10.sup.8 (S/cm) (eV)______________________________________Li.sub.3 PO.sub.4 40% O.sub.2 in Ar Li.sub.2.7 PO.sub.3.9 7 0.68Li.sub.3 PO.sub.4 + " Li.sub.4.4 Si.sub.0.23 PO.sub.5.2 20 0.57Li.sub.4 SiO.sub.4Li.sub.3 PO.sub.4 N.sub.2 Li.sub.3.3 PO.sub.3.8 N.sub.0.22 240 0.56______________________________________
The enhanced conductivity, superior mechanical properties of nitrided glass(e.g. hardness, resistance to fracture) and chemical stability of the oxynitride lithium electrolyte of the present invention could also be used to fabricate enhanced electro-optic devices using electrochromic layers, i.e. so called smart windows, because of the increased resistance to attack from water vapor.
The performance of the lithium microbattery of the present invention is also very dependent on formation of the cathode. Consideration of the microstructure of the cathode is equally as important as consideration of the composition. Typical of prior thin-film batteries is the use cathodes having a characteristic crystalline microstructure. The microstructure is dependent on substrate temperature, extent of the erosion of the target material due to prior sputtering and the pressure and composition of the process gas during deposition. At substrate temperatures of 400° C., vanadium oxide cathodes, for example, consist of crystalline platelets standing on edge while films deposited onto substrates at about 50° C. consist of clusters of crystalline fibrous bundles. With reference to FIG. 4, two distinct types of microstructure are shown for vanadium oxide films deposited by reactive sputtering of vanadium. When deposited from an eroded target, the cathode films 28 were characterized by a high density of micron-sized fibrous clusters in FIG. 4A of crystalline V 2 O 5 . When a fresh target surface is used and the flow rate is increased to about 20 sccm, the microstructure of the cathode 28 has the smooth microstructure shown in FIG. 4B. The advantage achieved with the amorphous structure over the crystalline structure is that at least three times more lithium ions can be inserted into cathode 28 having such amorphous structure, thus resulting in a lithium cell of much higher capacity.
As the sputtering target, e.g. vanadium, ages, the microstructure of the films deposited with higher flow rates gradually evolves to that of the films having fibrous clusters characteristic of deposition at the lower flow rates. This change in the films is evident by a decrease in sputtered target voltage (at constant power) and as much as a 30% decrease in deposition rate.
Lithium cells fabricated with crystalline or amorphous vanadium oxide cathodes had open circuit voltages of 3.6 to 3.7 volts. However, compared with amorphous cathodes, the rates of discharge and charge that the cells with the crystalline cathodes could sustain without excessive polarization are significantly lower, usually less than 3 microAmps per square centimeter. This probably results from poor transport across the interface between the electrolyte 26 and the cathode 28 since the electrolyte 26 does not conformably coat the fibrous clusters of the crystalline cathode 28 but rather covers just the top portion, resulting in a relatively small contact area.
Lithium cells made according to the present invention having the lithium phosphorus oxynitride electrolyte 26 and the smooth amorphous cathode 28 may be discharged at rates of up to 3 milliAmps per square centimeter. With reference to FIG. 5, a set of charge-discharge curves for one cycle of such a cell is shown. The total charge passed through this cell between 3.64 volts and 1.5 volts is about 575 milliCoulombs. The capacity of the cell over this voltage range is 130 microAmp-hours per square centimeter with an energy density of 1.2×10 6 Joules per kilogram based on combined masses of the cathode, electrolyte and anode.
The greatly enhanced energy density achievable with thin-film batteries made according to the present invention may, with suitable scaling of process parameters, permit fabrication of high energy thin-film macrobatteries. For example, according to the present teachings, a 25-kWh thin-film lithium battery could be constructed by connecting in series approximately 46 large-area thin-film cells. Such a battery would have an average voltage of 165 volts, a weight of 67 kilograms, a volume of 36 liters, a specific energy of 370 Watt-hours per kilogram and an energy density of 690 Watt-hours per liter.
While there has been shown and described what is at present considered the preferred embodiment of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. | Described is a thin-film battery, especially a thin-film microbattery, and a method for making same having application as a backup or primary integrated power source for electronic devices. The battery includes a novel electrolyte which is electrochemically stable and does not react with the lithium anode and a novel vanadium oxide cathode Configured as a microbattery, the battery can be fabricated directly onto a semiconductor chip, onto the semiconductor die or onto any portion of the chip carrier. The battery can be fabricated to any specified size or shape to meet the requirements of a particular application. The battery is fabricated of solid state materials and is capable of operation between -15° C. and 150° C. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the National Stage of International Application No. PCT/NL2012/050217, filed Apr. 2, 2012, which claims the benefit of Great Britain Application No. GB 1105755.1, filed Apr. 5, 2011, the contents of which is incorporated by reference herein.
FIELD OF THE INVENTION
The invention relates to a method of forming a substrate for a sports surface of a sports pitch.
The invention also relates to a substrate obtained with the method according to the invention.
Furthermore the invention also relates to a sports pitch provided with such substrate.
BACKGROUND OF THE INVENTION
Many sports, such as field hockey, tennis, American football etc are currently played on artificial turf (grass) sports pitches, which in general comprising a carrier as well as artificial fibres extending from said carrier. Said carrier is placed on a substrate which forms a stable subsurface base construction for the complete pitch installation.
Examples of sports that utilise such artificial turf pitch (ATP) constructions are:
Soccer American Football Australian Rules Football Gaelic Football/Hurling (GAA) Rugby Union/League Hockey Cricket outfields etc
In addition to sports pitches, the basic methodologies explained above also apply to other smaller areas in which artificial turf maybe used. For example:
Play grounds Landscape/leisure areas Cricket wickets Bowls rinks Tennis courts Futsul courts Education multiple use areas
The traditional base construction methodology for artificial turf systems has historically been based around the excavation of the existing sub-base and the subsequent replacement of this sub-base with graded rock and specially designed drainage systems.
There has been substantial development in construction methodologies and systems that are designed to limit and/or replace the use and design of traditional base construction system. These systems have been primarily designed to reduce the cost and to simplify the work untaken.
Due to the increasing awareness of human activity on the environment, the issue and practice of recycling has become more popular. In many cases governments are now legislating for the increased practice of recycling end of life and waste materials. This practice is seen at all levels of society and business, from road side recycling of household waste to legal obligations and quotas on businesses to recycle or dispose of waste in an environmentally responsible manner. This has also become a key political issue and the general trend of thinking is to reduce waste, carbon footprint, as well as waste to traditional landfill. National and local governments, plus private contractors have developed large infrastructures in order to divert some materials away from landfill for the purpose of recycling.
A new industry has developed which has been improving and developing methods of collection, separation and industrial processes that increase the ability to reclaim key materials from waste sources. One of the largest parts of the recycling industry is the recycling of plastics. However, these companies tend to process materials that are easy to convert and have the highest grades and re-sale value.
The vast majority of waste plastics is mixed (co-mingled) and as such is difficult to identify, sort, separate, clean and recycle and is therefore too expensive to process. In addition, the grades of these materials are very low and therefore have little re-sale value and are therefore regarded as “end of life” plastics.
Such ‘end of life’ plastic materials are typically in the form of packaging materials, moulded articles, products, profiles, sheet, coatings, fabrics or fibers and are found in general industrial, manufacturing, building and household waste etc. They can broadly be described as:
Plastic granules, beads, pellets, slivers, flakes, chips and noodles derived from recycling plastics. These types of plastics cover all families of polymers defined as plastics, such as, but not limited to the families of Polyolefin, Polyesters, Polyamides, Poly Vinyl Chlorides (PVC's), Polystyrenes and Polyurethanes found in general industrial, manufacturing, land transportation, aerospace, agricultural, horticultural, food and general packaging, building and household waste. Also, sources such as material reclaimed from landfill and material retrieved/harvested from the oceans in the form of flotsam and jetsam. Plastic granules, beads, pellets, slivers, flakes and noodles derived from recycling artificial grass surfaces, domestic and industrial floorings. The types of plastics cover of the families of Polyolefin, Polyesters, Polyamides, PVC's, Polystyrenes and Polyurethanes.
This material is referred to as “Feedstock” and there are vast quantities of this material available. Feedstock will generally consist of a random mix of plastic types, sizes, densities, colours; in a form of being flexible, rigid, semi rigid, filled or expanded in character or nature and are likely to include thin sheets, film, fibers, etc.
As such, to be made suitable for use in the formation of the invention the feedstock material must be processed using mechanical methods which result in a granulate with a more consistent size, bulk density and volume. Such processes are known as densification or agglomeration.
Densification or agglomeration is a process well known in the recycling plastics industry, in which plastics are chopped into fine flakes and then fed into a machine which uses friction to convert them into a semi molten state. The fine flakes join together increasing the mass and density of the material flowing through the machine. The mass of plastics exiting the machine is cooled, chopped, granulated or otherwise comminuted to a predetermined size. The densifying process includes one or more sieving stages whereby granulate which is considered to be outside the predetermined useful range is automatically returned to the infeed of the densifying process. In the vast majority of plastics recycling the aim for the processor is to ensure the plastic material been put into the process is of the same polymer type and the material is totally free from other polymer types and totally clean. As explained previously this requires a great deal of pre-processing to ensure that the final granules are fit for sale to the plastic industry, much of the waste plastic collected is either to dirty, too mixed or be at the end of the ability to re-recycle to be of any commercial value, and is therefore landfilled and burnt.
SUMMARY OF THE INVENTION
For the purposes of the invention the plastic material (referred to above as Feedstock) used in the agglomeration process can be any type of plastics and the presence of some foreign materials which are non-plastic (e.g. wood, paper, fibres) are not an issue, therefore the amount of pre-processing is reduced and increased quantities of material due for landfill or burning are reused.
To be considered suitable for use in the formation of the invention, the densified plastic granulate shall be of a size whereby the ratio of the largest dimensional plane of each granule (x) and its perpendicular dimensions (y and z) are at least 30% to 100% of the largest dimensional plane.
The cornerstone of the invention is to use the Feedstock plastic, which is then agglomerated into granules and then used in the construction of base construction profiles in the applications described in the background section above.
The basis of the invention is to create a system which provides an option for either an in-situation or a pre-formed module which has the properties of base point loading, compression strength, in-built porosity and controlled/managed drainage, plus in-built shock absorption.
The system is designed to limit the environmental impact and carbon footprint of the base construction element while reducing the financial cost of the project. The system will reduce the amount of spoil removed from site by reducing the required excavation depths (depending on pre-existing geological conditions). Although certain aspects of the traditional base profile will still be required, the amount of rock required to build up the base profile will be significantly reduced. There will still be a requirement for the geo-textile membrane and the non-porous capping layer.
In order the achieve the desire properties, balanced against the existing geological conditions and the reduction of environmental construction impacts, the invention uses the granules as the aggregate material which in turn is bound together in order to stabilise the structure, resulting in a substrate layer according to the invention.
The binding materials can be Polyurethane, Bitumen or Polyofin displacements, which are mixed (either hot or cold) with the granules at ratios depending on application and property requirements. Such binders are characterised to impart thermal stability, hydrolytic stability, having no significant change in properties upon being submerged in water or exposed to changing humidity and temperature environments. Thus the desired structural integrity and physical properties remain on standing and when in use.
The granules are in a loose granule form and depending on the application and properties required the size range of the granules is between 0.5 mm to 20 mm. The ratio or particle range of these sizes is adjusted depending on the properties required. Added to this is the binding material which is added using formulas based on weight of the granules. These ratios range between 8% binder by weights to 30% binder by weight.
The invention will be made in a porous permeable form by using proportions of granules and binder so that sufficient void or interstitial space remains between the granules. This void space can vary in amount in accordance with the particulate which is used for example between 15% to 60% by volume. Such void space will be an advantage to allow drainage in all directions, vertically and laterally.
Void space can also be used to provide storage or attenuation of water if is so necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be discussed in the detailed figurative description below, wherein:
FIG. 1 represents the cross-section of a typical, known dynamic base construction profile according to the state of the art;
FIG. 2 represents the cross-section of a typical, known engineered base construction with shock pad profile;
FIG. 3 represents the cross-section of another typical, known engineered base construction with in-situation shock pad profile;
FIG. 4 represents the cross-section of another typical, known engineered base construction with preformed shock pad profile;
FIG. 5 represents the cross-section of an in-situation sub-grade course construction profile according to the invention;
FIG. 6 represents the cross-section of a preformed sub-grade course in panel format construction profile according to the invention;
FIG. 7 represents the cross-section of an in-situation sub-grade course and performance course construction profile according to the invention;
FIG. 8 represents a cross-section of a pre-formed dual-density performance course plus sub-grade course in panel format construction profile according to the invention;
FIG. 9 represents the cross-section of an in-situation composite course construction profile according to the invention;
FIG. 10 represents the cross-section of a preformed Composite course in panel format construction profile according to the invention; and
FIG. 11 represents the cross-section of an in-situation sub-grade course and performance course construction profile over an existing brown field substrate according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
For example FIG. 1 represents the cross-section of a typical, known dynamic base construction profile according to the state of the art:
1 . Turf surface 2 . Loose stone binding 3 . Grade rock sub-base 4 . Non-porous capping layer 5 . Natural soils 6 . Field water drains
When constructing an ATP according to the state of the art, many projects are referred to as ‘full build’ projects, which are defined as new-build pitches constructed on a virgin site and include the construction of a stable sub-grade, drainage system, porous base, optional shock absorption layer and finally the artificial turf surface.
The start of the construction process is to remove a pre-determined depth of existing sub-soils 5 . This depth is determined by a geological survey which measures and classifies the conditions on that particular site. These conditions relate to the make up of the existing sub grades, plus local drainage, rainfall and general location factors. From this data the depth of excavation and the profile of the base construction can be designed.
The depth and therefore the volume of spoil 5 removed can be quite wide-ranging. However an average of 0.5 meters depth of removal is usually performed. It is also assumed that the average sized ATP would be 6000 square meters (m 2 ). As a consequence, the amount of spoil to be removed from a 6000 m 2 pitch construction would be 3000 m 3 . Typically, all spoil is transported to landfill, hence a large cost in transportation, landfill fees and impact on the environment.
In order to prevent water movement from the sub-soil base into the new base construction, a capping layer of geo-textile 4 and specially graded rock/dust 3 must be installed before the main body of the new base is constructed. Over the top of this capping layer 4 is installed a drainage system 6 , which is designed to remove water permeating down through the upper rock sub-base by means of drainage pipes in the field pattern. These pipes lead the water off the playing area into ring main land drains or similar water drainage control systems. In some cases water is piped into storage facilities and re-circulated back on to the pitch, either as part of the turf system performance or for use as cooling during hot weather.
The excavated area (with capping layer 4 ) now needs to be in filled with layers of specially graded rock 2 and 3 which will provide a stable, free draining platform on which to install the playing surface 1 . The rock has to be sourced and graded to a particular specification and this rock needs to be transported to site, in filled, levelled and compacted. In some cases the correct rock specification may only be available in certain quarries, which in turns adds to the cost and environmental impact.
Most standard ATP systems are designed to have either a ‘dynamic’ or ‘engineered’ base construction. However there are some variations which are deemed acceptable in some localised markets around the world.
Dynamic bases (also known as un-bound bases) are defined as base profiles that have a loose rock construction 2 throughout and are topped with a compacted, rock binding layer. This binder layer consists of fine graded rock dust and is designed to be stable and free draining.
FIG. 2 represents the cross-section of a typical, known engineered base construction with shock pad profile:
7 . Asphalt wearing course 8 . Asphalt load bearing layer 3 . Graded rock sub-base 4 . Non-porous capping layer 5 . Natural soils 6 . Field water drains
Although engineered bases (also known as bound bases) still have the loose rock construction 2 as described above with reference to FIG. 1 , instead of being topped with the loose binding layer, they are typically topped with two layers of porous asphalt, indicated with reference numerals 7 and 8 .
The first layer or levelling/load bearing layer 8 consists of a certain consistent rock grade bound with bitumen laid at an average depth of 25 millimeters (mm). The second layer, known as the wearing course 7 is paved over the first asphalt layer 8 and consists of a finer graded rock bound with bitumen.
There are strict tolerances required when installing this upper wearing course 7 which ensures the finished surfaces is level and free from ridges, dips and bumps. This critical element requires expensive paving machinery which is operated by highly skilled workers and is a considerable cost in the overall base construction. Furthermore, it is a time consuming process.
It is a common occurrence for the upper wear layer 7 to be installed outside acceptable tolerances and therefore requires extensive remedial works. These works add un-budgeted cost to the project and impact on the project on time completion mandates.
Depending on the type of artificial turf system to be installed a shock absorption layer 9 or 10 (see FIGS. 3 and 4 ) maybe required over the completed base construction 7 - 8 - 3 - 4 . There are a very wide range of ‘shock pad’ systems available that generally fall into two main categories:
In-situation as shown in FIG. 3 Pre-formed as shown in FIG. 4
FIG. 3 represents the cross-section of a typical, known engineered base construction with in-situation shock pad profile:
1 . Turf surface 9 . In-situation shock pad 7 . Asphalt wearing course 8 . Asphalt load bearing layer 3 . Graded rock sub-base 4 . Non-porous capping layer 5 . Natural soils 6 . Field water drains
The in-situation pads 9 of the FIG. 3 embodiment are defined as pads that are installed on-site by a machine directly onto the base construction. The vast majority of in-situation pads are paved directly onto the dynamic or engineered base construction and use a combination of rubber granules mixed with a Polyurethane binder.
The rubber granules used in such pads are generally sourced from recycled/granulated car and truck tyres and are referred to as Styrene-Butadiene-Rubber (SBR) granules. In some markets a small ratio of pea gravel is mixed with the rubber and again bound with Polyurethane binder. The mixture is laid onto the base construction with a specialised paving machine, which controls the depth and evenness of the shock pad.
An advantage of this form of installation is that the pad 9 is attached to the base construction 7 - 8 - 3 - 4 and is therefore dimensionally stable both during installation and during the play life of the pitch. There are no seams or joints in this form of pad and therefore limited potential for failure.
This process requires highly specialised equipment, operated by highly skilled workers. As in the laying of the asphalt wear layer 7 the tolerances required are very strict and often remedial work is required.
FIG. 4 represents the cross-section of a typical, known engineered base construction with preformed shock pad profile:
1 . Turf surface 10 . Preformed Shock pads 7 . Asphalt wearing course 8 . Asphalt load bearing layer 3 . Graded rock sub-base 4 . Non-porous capping layer 5 . Natural soils 6 . Field water drains
Pre-formed shock pads 10 are pads that have been manufactured away from the work site by companies who specialise in this area. Although this form of shock pad 10 can also be produced from SBR rubber and Polyurethane binder, other pre-formed systems use a much wider range of materials. These alternative systems comprise many other shock absorbent materials such as open and closed cell foams, felts, three-dimensional random or woven matrices, all of which can be constructed with either virgin of recycled materials.
As pre-formed products are made in a controlled factory environment the tolerances of thickness, density and performance can be controlled. The system can be made into a variety of formats, but the most common are rolls or panels. These rolls or panels 10 are delivered to the work site and installed onto the base construction by various techniques by the workers who generally install the turf. Little specialised installation equipment is required and the work skill level is reduced. As the products are manufactured under controlled environments the strict tolerances of conformity are easier to meet with limited remedial work required.
However, the drawbacks for this type of pad tend to be around the added cost of transportation from the manufacturing site to the work site. These pad formats tend to be quite bulky and this in turn limits the how many square meters can be loaded per container or truck.
In addition, pre-formed pads 10 can suffer from dimensional instability and movement during turf installation and during the playing life of the pitch. There is also a potential for failure in the joints or seams 10 a created during installation. Furthermore, any small undulations in the base/sub-base 7 - 8 - 3 - 4 cannot be ‘masked’ or levelled by the pre-formed layer 10 as they are a constant thickness.
In general terms pre-formed shock pads 10 ( FIG. 4 ) are a more expensive system when compared to in-situation pads 9 ( FIG. 3 ).
It is worth noting that the base construction profiles and methodologies described above accounts for approximately 40-50% of the entire cost of the project.
Due to surface usage demands and the sports/bio-mechanical requirements specified by sports governing bodies, the use of shock pads under artificial turf is becoming more common, especially in the increasing volume markets of contact sports such as Soccer, American Football, Rugby, Australian Rules football and Gaelic Football.
Most forms of shock pad can be engineered to provide satisfactory performance for the sports/bio-mechanical performance for certain sports but this can often compromise the performance requirements of other sports. Therefore the ability to design a turf system which is a true ‘cross code’, multiple use surfaces is limited.
For example, a surface which conforms to the highest Soccer performance criteria will not offer the required performance characteristics for a top level Australian Rules football surface.
The follow are examples of possible ratios of granules granule size range and binder content by weight, based against application:
Example 1
A structure consisting of particle sizes form 0.5 mm to 5 mm and a binder content of 10% by weight of granules will deliver increased properties for bio-mechanical values but decrease the civil engineering values. This kind of ratio suits areas where the underlying geology is stable, either from exist sub-soils/grades or where existing ATP are been renovated, hence the pre-existence of a stone base layer.
The layer offers a shock absorbent and safety value which still offers the properties of water management and some civil engineering values such as point and spread loading, allow some reduction in base construction depth, depending on the depth of the layer according to the invention.
Example 2
A structure consisting of particle sizes form 5 mm to 10 mm and a binder content of 15% by weight of granules will deliver good properties for bio-mechanical values and good values for civil engineering values. This kind of ratio suits the vast majority of applications as the required properties are balanced while offer excellent water management properties. The structure allows for a significant reduction in base construction depth, depending on the depth of the layer according to the invention.
Example 3
A structure consisting of particle sizes from 10 mm to 20 mm and a binder content of 20% by weight of granules will deliver decreased properties for bio-mechanical values but increased the civil engineering values. This kind of application suits areas where the underlying geo-graphical is un-stabile, or the demands of the end use require high civil values for point loading. The layer offers some shock absorbent value which still offers the properties of water management and increased ability for water storage within the layer according to the invention. The strength of this structure further reduces the base construction depth depending on the thickness of the layer according to the invention.
The example listed above represent a Soft, Medium and Hard structures, but the adjustment of the granules granule size spread with the 0.5-20 mm range, plus the ratio of binder content, plus the depth of the layer gives the ability to design and formulate, tailor made solutions in all applications and environments. In some instances the layer according to the invention would benefit from the inclusion of non-plastic materials, such as rubber ganules, recycled glass chippings, stone chipping, lava stones and pea gravel. These inclusion will help assist added values in either sports performance values or civil enginnering values.
Depending on the playing surface design and requirements the system would either be a single layer of material according to the invention; which would replace the standard ‘dynamic’ base construction profile. This layer is now referred to as the ‘sub-grade course’.
In the case that the system requires a shock pad then a second layer (herein referred to as the ‘performance course’) would be placed on top of the sub-grade course.
Some applications may allow a composite single layer which would offer the required values for sub-grade and performance courses.
The sub-grade course is designed to act as the load bearing and drainage layer and replaces the vast majority of excavation depth and subsequent volume of rock required in standard construction profiles. The thickness of this layer can range from 10 mm to 100 mm depending on the underlying geological conditions. The layer can be composed using granules at granule size ratios which are formulated depending on the performance required, while parameters are influenced by the existing geological and drainage conditions, point loading and stability requirements. The nature of this layer allows the free flow of water both horizontally and vertically, therefore a standard field drainage system is not required.
If required, base profiling and design could allow water to be held within the sub-grade course. The benefit of this water retention would have a double benefit; firstly to create a mini artificial aquifer, thus allowing water to be retained and re-circulated to water fully-synthetic (water-based) Hockey pitches. Secondly, for pitches with infill systems, to help assist in cooling the playing surface; either by re-circulating water from the mini aquifer onto the playing surface, or through retaining moisture in the infill materials from the sub-grade layer up.
The two methods of installation of this sub-grade course would be:
1. Direct installation of the sub-grade course (in-situation method as described above) as shown in FIG. 5 , and 2. Indirect installation of the sub-grade course (pre-formed method as described above) as shown in FIG. 6 .
FIG. 5 represents the cross-section of an in-situation sub-grade course construction profile:
1 . Turf surface 11 . In situation sub-grade course 4 . Non-porous capping layer 5 . Natural soils
The materials are mixed together in the pre-determined ratios and a binding agent is added and mixed with the materials. The resulting mixture is paved directly onto the capping layer 4 in the same manner as asphalt, utilising the same machinery. While the skill level required ensuring correct levels and smoothness is still important, it is an existing skill with no new special requirements or training.
FIG. 6 represents the cross-section of a preformed sub-grade course in panel format construction profile:
1 . Turf surface 11 . Performed sub-grade course in panel format with inter-locking profile. 4 . Non-porous capping layer 5 . Natural soils
The sub-grade course 11 can be manufactured off-site in panel format and then installed over the capping layer 4 . The materials are mixed together in the pre-determined ratios and a binding agent is added and mixed with the materials. This resulting mixture can be extruded or moulded or formed as a mass and cut sliced or otherwise divided into separate panels, boards or tiles 11 which can have inter-locking faces 11 a - 11 b to allow the panels 11 to be close fitting or locked together during on site installation.
The benefit of this delivery method is that the consistency of the layer 11 can be controlled under strict manufacturing conditions. The design of the panels 11 also allows quick and easy installation in all weather conditions with no specialised equipment required.
In a further improvement an additional performance course 12 ( FIGS. 7 and 8 ) can be implemented in the overall construction. The performance course 12 is designed to act as a stable shock absorption layer with added point loading, replacing the wearing asphalt course and the in-situation or pre-formed shock pad. The thickness of this layer 12 can range from 5 mm to 100 mm depending on the shock absorption characteristics required. The layer can be composed of one or more of the materials described above, mixed in various ratios. These ratios are formulated depending on the performance required. The layer 12 is porous and displays the same water control and management characteristics as the sub-grade course described above.
The two methods of installation of this sub-grade course 12 would be:
1. Direct installation of the performance course onto sub-grade course (in-situation method described above) as shown in FIG. 7 ; 2. Indirect installation of the performance course onto sub-grade course (pre-formed method described above) as shown in FIG. 8 .
FIG. 7 represents the cross-section of an in-situation sub-grade course and performance course construction profile:
1 . Turf surface 12 . In situation performance course 11 . In situation sub-grade course 4 . Non-porous capping layer 5 . Natural soils
The materials are mixed together in the pre-determined ratios and a binding agent is added and mixed with the materials. The resulting mixture 12 is paved directly onto the sub-grade course 11 in the same manner as asphalt, utilising the same machinery. The binder in the performance course 12 reacts with the cured binder in the sub-grade course 11 during installation so that both layers 11 and 12 are firmly locked together. While the skill level required ensuring correct levels and smoothness is still important, it is an existing skill with no new special requirements or training.
FIG. 8 represents a cross-section of a pre-formed dual-density performance course 12 plus sub-grade course 11 in panel format construction profile 20 :
1 . Turf surface 20 . Dual density panel format with inter-locking profile. 4 . Non-porous capping layer 5 . Natural soils
As with the off-site manufacture of the sub-grade course 11 (described above with reference to FIG. 6 ) the separate panels 11 and 12 can be manufactured as ‘dual density’ panels 20 . The materials for the sub-grade course 11 are still mixed together in the pre-determined ratios and a binding agent is added and mixed with the materials. This resulting mixture is extruded or moulded into panels 11 as before. However, there is a second step in which materials for the performance course 12 is still mixed together in the pre-determined ratios and a binding agent is added and mixed with the materials. These materials are then extruded or moulded on top of the sub-grade course or layer 11 to form two distinct layers within the same panel 20 .
The panel now has all the properties required of the two courses 11 and 12 . These panels are designed to have inter-locking ‘male’ and ‘female’ profiles 20 a - 20 b . These profiles allow the separate panels 20 to be locked together during on site installation.
The benefit of this delivery method is that the consistency of the layer 20 can be controlled under strict manufacturing conditions. The design of the panels 20 also allows quick and easy installation in all weather conditions with no specialised equipment required.
Depending on the geological and sport performance specifications the system can be designed as a composite grade. The composite grade is one layer 13 which offers the performance of both the sub-grade course/layer 11 and performance course/layer 12 . The performance is pre-determined by the selection of materials and the mixing ratios of those materials. This layer 13 can be installed either by the in-situation of pre-formed methods described above. The thickness of this layer can range from 5 mm to 100 mm depending on the characteristics required. The layer 13 is porous and displays the same water control and management characteristics as the other methods described above.
The two methods of installation of this composite course would be:
1. Direct installation of the composite course (in-situation method described above) as shown in FIG. 9 ; 2. Indirect installation of the composite course (pre-formed method described above) as shown in FIG. 10 .
FIG. 9 represents the cross-section of an in-situation composite course construction profile:
1 . Turf surface 13 . In-situation composite course 4 . Non-porous capping layer 5 . Natural soils
The materials are mixed together in the pre-determined ratios and a binding agent is added and mixed with the materials. The resulting mixture 13 is paved directly onto the capping layer 4 in the same manner as asphalt, utilising the same machinery.
While the skill level required ensuring correct levels and smoothness is still important, it is an existing skill with no new special requirements or training.
FIG. 10 represents the cross-section of a preformed composite course 13 in panel format construction profile:
1 . Turf surface 13 . Pre-formed composite course in panel format with inter-locking profile. 4 . Non-porous capping layer 5 . Natural soils
The composite course 13 can be manufactured off-site in the panels 13 ′ and then installed over the capping layer 4 . The materials are mixed together in the pre-determined ratios and a binding agent is added and mixed with the materials. This resulting mixture is extruded or moulded into panels 13 ′ which are designed to have inter-locking ‘male’ and ‘female’ profiles 13 a - 13 b . These profiles allow the panels 13 ′ to be locked together during installation.
The benefit of this delivery method is that the consistency of the layer 13 can be controlled under strict manufacturing conditions. The design of the panels 13 also allows quick and easy installation in all weather conditions with no specialised equipment required.
In another embodiment shown in FIG. 11 it is now possible to construct ATP's on ‘brown field’ sites. Brown field sites can be defined as areas which have previously been used for some other purpose i.e. old landfill sites, disused industrial sites, education and housing areas etc. It is important to note that these areas of different from ‘green field’ sites, which are defined as areas that have had no previous usage apart from agriculture and/or natural land.
FIG. 11 represents the cross-section of an in-situation sub-grade course and performance course construction profile 14 over an existing brown field substrate 4 - 5 :
1 . Turf surface 14 . Retaining curb stones 13 . In situation or preformed sub-grade course 4 . Non-porous capping layer 5 . Exist brown field sub structure
The preservation of green field areas is a high priority for national and local governments and it is preferable to re-use areas which have been made redundant. As a standard ATP base construction profile requires the excavation and removal of existing substrates below the level of the proposed pitch, this can pose a problem on brown field sites (depending on local conditions etc). If, for example, the proposed site is on an area of demolished industrial units, it is likely that the concrete and foundation will still be in-situation. Normally this would require complicated and costly removal. The principal system being proposed allows the pitch to be constructed over the existing ground without any removal.
The construction, base profiles and the installation methods described above (in-situation and pre-formed) remain the same and the capping layer 4 is formed over the exist ground 5 . The composition and the thickness of the system depend over what type of surface is being constructed. For example, a construction over an existing concrete or rubble floor will already have a great deal of load bearing and spread capacity, therefore the design of the layers can be designed to concentrate on shock absorption and drainage.
As has been indicated in the preceding description of the invention there are significant opportunities for reducing the amount of excavation on green field sport sites and for avoiding the need to break up existing flat substrates, such as concrete floors, on brown field sites.
According to the invention a substrate is formed from granular plastics material, which has been coated in binder to form a stable, substantially incompressible, water permeable or water retaining substrate. Surprisingly it has been proven that a particularly suitable material for this purpose is “end of life” plastics material, which is the plastics material that current processes cannot any longer recycle, because of its chemistry, because it is has already been recycled, because it is dirty or otherwise difficult to sort. Not only does this have environmental advantages, because the material no longer has to go to landfill or incineration, the material is also preserved for future reuse, re-processing or recycling.
As is indicated this sub-base may be formed as preform parts, but it is particularly advantageously used by forming appropriate layers in situ using existing pavement pavers, which typically lay down a 2½ meter wide layer of self levelling material, without, essentially any compaction, the only pressure on the material being that of the grader or scraper bar. This not only enables the system to be used with existing technology and existing skills, it is readily open to a range of uses in accordance with local practices and will level out minor undulations in the surface on which it has been laid.
The absence of compaction means that the granular material will adhere to where it contacts other granular material leaving a pattern of voids through the material so that it is pervious to water. If it is laid on an impermeable surface, the nature of the material formed is such that water will become subject to lateral capillary action whereby the water is ejected through the side edges of the substrate frequently avoiding the need for drains to be formed underneath the substrate location. It also means that the substrate can be laid flat, without the need for drainage grading, which occurs in most existing arrangements.
The binding materials can be Polyurethane, Bitumen or Polyofin displacements and may form between 8 and 20% of the substrate. It is desirable that the granules have a range of sizes in order to provide a good pattern of voids. | A method of forming a substrate for a sports surface of a sports pitch includes the steps of: a) Agglomerating plastics materials; b) Granulating the agglomerated plastics materials to form granules having a predetermined range of sizes; c) In situ coating the granules with a binding material so that they form a fluent material; d) Forming a layer of the fluent material on the site of the sports pitch; and e) Setting the laid material such that the granules adhere where they contact each other to form a voided water permeable structure. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 12/123,850 filed May 20, 2008 and entitled “Strain Gauge Pump Switch” which claims the benefit of the filing date of U.S. Provisional Application Ser. No. 60/939,453 filed May 22, 2007 and entitled “Strain Gauge Pump Switch”. The disclosures of these applications are fully incorporated herein by reference.
FIELD
The invention pertains to solid state pump control switches. More particularly, the invention pertains to such switches which incorporate a strain gauge as a transducer to convert an environment condition, such as a level of a fluid, to an electrical signal.
BACKGROUND
Various types of switches have been developed for use in turning pumps on and off in response to an external ambient condition, such as water level. Such switches tend to be used in relative harsh environments such as in tanks of water, or, sump pits which are used to collect foundation water. Other environments include industrial fluids which might be caustic or acidic, as well as high or low temperatures.
While known switches can be useful and function properly over a period of time, they are always subject to failure. Switch failures in turn translate into non-running pumps which can result in flooded commercial, industrial and residential locations. Alternately, non-running pumps can result in water supply deficiencies, or failures to supply commercial or industrial fluids for various applications.
One switch configuration has been disclosed in U.S. Pat. No. 7,307,538, issued Dec. 11, 2007, and entitled “Pump Connector System”. The '538 patent is assigned to the assignee hereof and is incorporated herein by reference.
There is an on-going need for control switches usable in such environments which exhibit greater reliability and longer lifetimes than do known switches. Preferably, such improved switches would be price competitive with known switches and readily substitutable therefore.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a switch assemblage in accordance with the invention;
FIG. 2 is a side sectional view of an exemplary switch housing as in FIG. 1 ;
FIG. 3 is an end view of an embodiment of a transducer in accordance with the invention; and
FIG. 4 is a block diagram of control circuits in accordance with an embodiment of the invention.
FIG. 4A is a perspective view of an electrical cable and AC connector in accordance with the invention.
DETAILED DESCRIPTION
While embodiments of this invention can take many different forms, specific embodiments thereof are shown in the drawings and will be described herein in detail with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention, as well as the best mode of practicing same, and is not intended to limit the invention to the specific embodiment illustrated.
Embodiments of the invention incorporate a strain gauge as a transducer to sense the presence of a fluid either through displacement, buoyancy of a structure or by fluid pressure deforming a strain gauge platform. Such embodiments can be implemented as solid state structures which can be digitally calibrated for various settings or pressure.
In one aspect of the invention, such transducers can be coupled to electronic control and switching circuitry which can switch electrical energy to activate a load, such as an electric motor for a pump. Advantageously, motor starting inrush currents are diverted away from the transducers in such embodiments. Further, such transducers can accurately respond to changing conditions, such as level or pressure, resist vibration and can withstand harsh operating environments.
The control and switching circuitry can include relatively high power semiconductor switches which are controlled by one or more programmable processors which in turn are coupled to one or more solid state transducers, preferable strain gauges. The processor(s) can digitally calibrate one or more strain gauges.
In another aspect of the invention, a solid state switch, such as a triac, can be coupled in parallel with a relay to a pump motor connector. The switch and relay can be independently controlled by control circuits in the unit. In response to signals from the strain gauge, the control circuits can bias the switch to a low impedance state to couple electrical energy to the pump connector. In this state, the switch can couple the motor start up, inrush, current without arcing or the like to the pump connector to start the motor. Once the inrush currents have subsided, for example after a time interval such as two or three seconds, the control circuits can activate the relay which changes state and provides a closed contact pair to carry the motor current as an alternate to the solid state switch. The relay contacts shunt the motor current away from the switch enabling it to cool off as needed.
When the strain gauge indicates that the lower water level has been reached, the control circuits de-energize, turn off, the relay which open circuits the motor current circuit through those contacts. Subsequently, after another time interval, such as two or three seconds, the solid state switch is biased off, or placed in a high impedance state by the control circuits. When the switch turns off it, and not the relay contacts, absorbs any turn off current or voltage transients which might otherwise cause arcing at the relay contacts. Those contacts are thus protected from electro-ablation, contact burning.
With respect to FIGS. 1-4 , a pump control system 10 includes a water tight housing 12 with an open end 12 a closed by a diaphragm 16 . A ring 14 is located in the housing 12 between the diaphragm 16 and a circuit board 40 . Housing 12 is placed in the sump along with a pump having a motor 24 to be switched on and off.
An electrical cable 20 couples housing 12 to a double sided AC connector 22 . As shown in FIG. 4A , connector 22 carries a pump AC receptacle 22 a at one end and AC outlet prongs 22 b at the other end. In operation, a pump AC connector is plugged into receptacle 22 a . Prongs 22 b are plugged into a local utility supplied AC outlet.
The ring assembly 14 has an annular shape with molded radial members 14 - 1 , - 2 , - 3 , and - 4 . Radial member 14 - 4 carries an elongated, deflectable, metal plate 32 which supports a strain gauge 34 . A pressure sensing plate 28 carries a connector prong 30 . A centered perforation 36 in a free end of plate 32 receives the connector prong 30 with a friction fit and supports pressure plate 28 for axial motion in response to applied fluid pressure.
A printed circuit board 40 carries sensing and control circuits 42 . Surge suppressing circuits 44 are coupled to a DC supply 46 . A digital circuit regulator 48 and analog circuit regulator 50 feed digital circuits 56 and differential amplifier 52 respectively.
The differential amplifier 52 is coupled to strain gauge 34 via connectors 34 a . Movement of the plate 28 in a first direction in response to increasing fluid pressure generates a signal of a first polarity at amplifier 52 . Movement of plate 28 in the opposite direction, in response to decreasing fluid pressure generates a signal of the opposite polarity at amplifier 52 .
Digital control circuits 56 include a programmable processor or computer 58 a , and associated storage, random access memory, EEPROM and Flash memory indicated generally at 58 b . Software, or, control programs stored in EEPROM or Flash memory can be executed by processor 58 a in carrying out the above described switching process.
Circuits 56 can be accessed via a programming interface 58 e . A factory calibration port 58 f is also provided.
Digital output circuits 58 c are respectively coupled to Triac driver 62 a and Triac 62 b , and relay driver 64 a and relay 64 b . As described above, electrical energy from connector 22 is switched by Triac 62 b and relay 64 b to provide a switched AC output 20 c which can be coupled to pump motor 24 via pump receptacle end 22 a.
A vent tube 20 d extends from within housing 12 , via cable 20 and terminates at connector 22 . Tube 20 d maintains pressure in the housing 12 at local atmospheric pressure.
From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. | A control switch incorporates a solid state transducer, a strain gauge. The transducer responds to a local environmental condition, such as fluid level, or pressure and exhibits a parameter change which can be detected as an electrical output. Control circuits coupled to the transducer can sense the parameter change and switch a source of electrical energy to a load in response thereto. | 5 |
BACKGROUND OF THE INVENTION
The invention concerns a blind-stitch sewing machine having a fabric bender to bulge the material to be sewn into the arcuate path of a sewing needle.
Such blind-stitching machines having plate-shaped fabric benders are known as represented by U.S. Pat. No. 2,355,904 and German Offenlegungsschrift 20 37 502. In these prior arrangements, the fabric bender is rotatably supported approximately at its center or at an end and is loaded by a tension or compression spring in a direction away from a solid drive shaft for the fabric bender. The drive shaft is rotatably supported in a fabric-support arm of the blind-stitching machine and during sewing pivots to-and-from in synchronization with the to-and-fro pivoting arc needle of the machine and with a correspondingly timed stepwise advance of the sewing material. The fabric bender is received in a slot of a support assembly projecting perpendicularly from the drive shaft, which slot extends transverse to the drive shaft in an end of the support assembly remote from the drive shaft.
The tension spring is extended between an end of the centrally supported fabric bender and an arm of the support assembly. This arm and the support assembly are radial to the drive shaft. The tension spring forces the fabric bender against the bottom of the slot in the support assembly. From this position the fabric bender can pivot against the force of the tension spring while its other end moves away from the path of the arc needle toward the drive shaft of the fabric bender. During sewing, when a thicker portion of the sewing material arrives near the fabric bender, a sewing-material sensor causes the pivoting of the fabric bender. The sewing-material sensor takes the form of a lateral stud secured to the other end of the fabric bender and contacts the sewing material on one side of the bulge formed therein by the fabric bender.
The compression spring is mounted in a longitudinal borehole of the support assembly and rests at one end on an adjustment screw threadable into the borehole to change the bias of the compression spring and at the other end through a ball on that end of the fabric bender which is remote from its pivot axis. To limit the range within which the fabric bender can be pivoted inside the slot, the support assembly comprises a stop pin extending transversely in the slot through an elongated and arcuate hole in the fabric bender that is concentric with the pivot axis of the fabric bender. The compression spring urges the fabric bender against the stop pin. The fabric bender can pivot from this position against the force of the compression spring until the other end of its elongated hole contacts the stop pin, the end of the fabric bender which is near the compression spring moving away from the path of the arc needle toward the drive shaft of the fabric bender. The fabric bender pivots to leave the first-stated position whenever, during sewing, a thicker sewing material portion arrives between the fabric bender and a stop at a throat plate of the blind-stitching machine. The fabric bender makes the sewing material bulge against the stop which is spring-loaded toward the sewing material so the stop will yield and move against the spring action by an amount which can be adjusted by means of an adjustment screw.
Moreover, blind-stitching machines are known having such a fabric bender urged by means of a compression spring into the normal position in a support assembly and cooperating with a stop similar to the one discussed above, and further comprising a second, also plate-shaped fabric bender pivoting to-and-fro which, however, is rigidly joined to its associated drive shaft and cooperates with a stop located at the throat plate of the blind-stitching machine which is spring-loaded toward the sewing material but not adjustable with respect to the amount of yielding. The two fabric benders are mounted next to each other and alternatingly make the sewing material bulge, each against the associated stop. This type of blind-stitching machine is described in U.S. Pat. No. 3,747,546.
In another known arrangement, as shown in U.K. Pat. No. 1,331,476, two bar-shaped fabric benders can be shifted axially to-and-fro by means of an associated drive shaft. Each fabric bender in this arrangement is elastically supported through a compression spring in a bushing connected to the drive shaft. The bias of the compression spring is adjustable by means of an adjustment screw. The drive shaft of one of the fabric benders is hollow and rotably supported on the drive shaft of the other fabric bender which, in turn, is rotatably supported in a fabric-support arm of the blind-stitching machine. This fabric-support arm is spring-loaded into the sewing position to abut a stop whose position can be adjusted by means of an adjustment screw through a linkage to change the distance between the fabric-support arm in the sewing position and the path of the blind-stitching machine arc needle, i.e. to adjust the stitch-depth of the arc needle in the sewing material made to bulge by the fabric benders. The two fabric benders make the sewing material bulge against a common stop mounted on a throat plate of the blind-stitching machine. The common stop is spring-biased toward the sewing material in order to be able to yield and to move against the spring action by an amount determined by the position of an adjustment screw.
SUMMARY OF THE INVENTION
The object of the invention is to provide a blind-stitch sewing machine in which the fabric bender and its support assembly can be extraordinarily narrow while enabling accommodation of an extremely level characteristic spring acting between the fabric bender and the support assembly. The arrangement also permits changing of the spring bias within an extraordinarily wide range and setting the bias at different values. The narrow design of the fabric bender and of the support assembly also makes it possible to mount sewing-material advance devices with a very short mutual spacing on both sides of the fabric bender and of the support assembly. By the present invention, it is also possible to add an additional fabric bender without entailing any substantial changes in the narrow assembly of the sewing-material advance devices.
Further advantages of the blind-stitching machine of the present invention will become apparent from the following detailed description of two embodiments illustrated in the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the front view of a blind-stitch sewing machine of the invention;
FIG. 2 is the section along the line II--II of FIG. 1,
FIG. 3 is the same sectional view as in FIG. 2, but with the fabric bender of the present invention pivoted counterclockwise;
FIG. 4 is the front view similar to that of FIG. 1 of a second embodiment of the blind-stitch sewing machine of the invention with two fabric benders; and
FIG. 5 is a side view of this blind-stitch sewing machine taken in the direction of arrow V of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
The blind-sttching machine shown in FIGS. 1 through 3 comprises an arc needle 1, a throat plate 2, a fabric bender 3 and two feed belts 4. The arc needle 1 and the throat plate 2 are mounted on the head of the blind-stitching machine, and the fabric bender 3 and the feed belts 4 are mounted on its fabric-support arm 5. During sewing, the arc needle 1 swings to-and-fro in the direction of the arrows 6 and 7, the fabric bender 3 oscillates in the direction of the arrows 8 and 9 and the feed belts 4 move stepwise in the direction of the arrows 10. The pivoting motion of the arc needle 1, the oscillation of the fabric bender 3 and the displacement steps of the feed belts 4 are synchronized in relation to one another, whereby the arc needle 1, the fabric bender 3 and the feed belts 4 act in the required sequence on a piece of material extending between the throat plate 2 and the feed belts 4.
The fabric bender 3 comprises a substantially rectangular plate and extends in a plane defined by the line II--II in FIG. 1, i.e., a plane perpendicular to the arcuate path of the arc needle 1. Fabric bender 3 is oscillated in this plane in the direction of the arrows 8 and 9 by means of a drive shaft 11 which extends perpendicular to this plane. The drive shaft 11 is rotatably supported in the fabric-support arm 5 and comprises an arm 12 at the end of shaft 11 remote from fabric bender 3. Arm 12 is linked by a bolt 13 to a bar 14 allowing pivoting of the drive shaft 11 to-and-fro by means of the arm 12 in the direction of the arrows 8 and 9. Fabric bender 3 is connected by a support assembly 15 to drive shaft 11.
Support assembly 15 for fabric bender 3 consists of two parallel plates 16 and 17 having substantially identical triangular contours and being connected by one bolt 18 at each of the three apices of the triangular contours. Plates 16 and 17 extend perpendicular to drive shaft 11 with which they are mounted concentrically. Due to this arrangement, the three bolts 18 extend parallel to drive shaft 11 and are approximately equal distances from it. The plates 16 and 17 define a slot 19 arranged to receive the plate-shaped fabric bender 3. The width W of slot 19 corresponds to the thickness B of fabric bender 3, and the slot 19 extends transversely in front of the adjacent end of drive shaft 11. Plate 17 of support assembly 15 is fastened to this end of drive shaft 11 by means of a clamping screw 20. Clamping screw 20 is threaded into a radial borehole 21 formed in a hub portion 22 of plate 17 and is tightened against drive shaft 11.
Drive shaft 11 is hollow and comprises a continuous borehole 23 in which a cylindrical pin 24 is rotatably supported and in which is disposed a torsion spring 25. Cylindrical pin 24 comprises, at one end, a radially projecting cam 26 which extends into slot 19 of support assembly 15 and an axially extending projection 27 of small diameter which is received in a borehole 28 of matching diameter in plate 16. Torsion spring 25 acts on the other end of the cylindrical pin 24 as will be more fully explained below.
Torsion spring 25 is a helical spring with two ends 29 and 30 arranged to extend transverse to the longitudinal axis of this helical spring. Each end is seated in a cross-slot 31 and 32 respectively formed in the adjacent end of pin 24 and in the adjacent end of a holder 33 (see FIGS. 1 and 4). Holder 33 is cylindrical and rotatably supported in borehole 23 of drive shaft 11 and comprises four circumferentially spaced, longitudinal grooves 34. A clamping screw 35, threaded into a radial borehole 36 of drive shaft 11, engages a longitudinal groove 34 and secures holder 33 in place relative to the drive shaft 11.
The fabric bender 3 is pivotably supported in slot 19 of support assembly 15 and is biased by torsion spring 25 through pin 24 in a direction away from drive shaft 11 and toward the path of arc needle 1. The bolt 18 of support assembly 15, which is adjacent to the throat plate 2 and which, upon rotation of the support assembly 15 in the direction of the arrow 8, moves toward throat plate 2, serves to support the fabric bender 3. This bolt 18 passes through a corresponding support borehole 37 formed in fabric bender 3 at that corner 38 thereof which is adjacent throat plate 2 and which is trailing when fabric bender 3 is pivoted by means of the drive shaft 11 through support assembly 15 in the direction of arrow 8, as best shown in FIGS. 2 and 3. Fabric bender 3 also comprises an aperture 39 receiving the cam 26 and the associated end of pin 24. The aperture 39 is shaped in such a way that a projection 40 and two stop edges 41 and 42 are present at the fabric bender 3, the functions of which will be described below.
Cam 26 of pin 24 cooperates with projection 40 of the fabric bender 3 to force the fabric bender 3, by means of the torsion spring 25, into the position shown in FIG. 2 relative to the support assembly 15. In this position, the stop edge 41 of fabric bender 3 abuts the cam-side end of the pin 24, and from this position, fabric bender 3 can pivot counterclockwise, namely against the action of the torsion spring 25 with corresponding rotation of cam 26 resting against projection 40 and rotation of pin 24 in borehole 23 of drive shaft 11 until arriving at the position of the fabric bender 3 shown in FIG. 3. In the FIG. 3 position, the stop edge 42 of the fabric bender 3 abuts the cam-side end of the pin 24. The two stop edges 41 and 42 of fabric bender 3 therefore set the range within which fabric bender 3 may pivot inside slot 19 of support assembly 15.
The force by which torsion spring 25 loads fabric bender 3 into the position shown in FIG. 2 relative to support assembly 15 can be adjusted. To set the desired bias of the torsion spring 25, clamping screw 35, which cooperates with holder 33 of the torsion spring 25 as previously discussed, is loosened in order to permit rotation of holder 33 by means of a screwdriver or other device inserted in a cross-slot 43 formed in holder 33 located at an end away from the torsion spring 25. The holder 33 can be rotated until another longitudinal groove 34 of the holder 33 is aligned with the clamping screw 35. Clamping screw 35 can then be tightened to engage longitudinal groove 34 and to fix the desired bias of torsion spring 25.
From the above discussion, it can be readily seen that the two feed belts 4 extend on both sides of and parallel to the plane defined by the line II--II of FIG. 1, the fabric bender 3 and its support assembly 15 can be pivoted to-and-fro by the drive shaft 11, and the fabric bender 3 can be pivoted relative to support assembly 15. As best shown in FIG. 5, each endless feed belt 4 extends over a pressing lever 44, a guide wheel 45 and a drive wheel 46. The pressing lever 44 is pivotably supported at one end on a shaft 47 of the fabric-support arm 5 and is spring-biased toward throat plate 2. The guide wheel 45 is rotatably supported on a shaft 48 of the fabric-support arm 5. Each drive wheel 46 is affixed to a drive shaft 49 which itself is rotatably supported in the fabric-support arm 5. The two shafts 47 and 48 and also drive shaft 49 extend parallel to the drive shaft 11 of the fabric bender 3.
Because of the extraordinary narrowness of the fabric bender 3 and support assembly 15, the two feed belts 4 can be mounted very tightly against each other, so that their mutual spacing is very slight. In the preferred embodiment, the fabric bender 3 may have a thickness B of about 1.2 mm and the two plates 16 and 17 of support assembly 15 each may be about 0.8 mm thick.
During sewing, the feed belts 4 move the sewing material stepwise in the direction of the arrows 10 (FIGS. 1 and 4) and the fabric bender 3 makes the sewing material bulge, following each step of advance, through a slot 50 in the throat plate 2 and extending in the direction of advance 10 of the sewing material and thereupon the arc needle 1 enters the bulged sewing material. Depending upon the degree of bulge imparted by the fabric bender 3 to the sewing material beyond the arcuate path of the arc needle 1, i.e. depending on the thickness of the bulged sewing material and on the proximity to which the fabric bender 3 approaches the path of the arc needle 1 when being pivoted by the drive shaft 11 through the support assembly 15 in the direction of the arrow 8, the depth at which arc needle 1 will pierce the sewing material will vary. Since the gap between the two feed belts 4 pressing the sewing material on both sides of the fabric bender 3 by means of the pressing levers 44 against the throat plate 2 is comparatively narrow, the sewing material will be held in a reliable, consistent manner throughout the sewing operation.
In order to set the depth of penetration of the arc needle 1 into the sewing material bulged by the fabric bender 3, fabric-support arm 5 is adjustable relative to the head of the blind-stitching machine such that the fabric bender 3 may approach the path of the arc needle 1 to a distance as necessary for the derived penetration depth in view of the normal thickness of the particular sewing material, when the fabric bender 3 and the support assembly 15 are pivoted in the direction of arrow 8, mutually positioned as shown in FIG. 2. The set depth-of-penetration will be retained even when, during sewing, a thicker sewing material portion, for instance a cross-seam, arrives within the range of the fabric bender 3 because fabric bender 3 then will be pivoted from the position relative to the support assembly 15 shown in FIG. 2 through a corresponding angle toward the position relative to the support assembly 15 shown in FIG. 3 against the force of the torsion spring 25 which has a very level characteristic. This force depends on the bias of torsion spring 25 which bias is matched to the sewing material by correspodingly setting holder 33 of torsion spring 25 relative to the drive shaft 11 of the fabric bender 3.
FIGS. 1 through 3 show the position of the fabric-support arm 5 of the blind-stitching machine relative to its head wherein the two sewing-material feed belts 4 are located in the vicinity of the pressing levers 44 directly against the throat plate 2 and wherein the minimum distance between the fabric bender 3 and the path of the arc needle 1 is zero. The support assembly 15 and the drive shaft 11 of the fabric bender 3 are shown in the position which they assume at the end of pivoting in the direction of the arrow 8 and at the beginning of the pivoting motion in the direction of the arrow 9 respectively.
Essentially, the blind-stitch sewing machine embodiment depicted in FIGS. 4 and 5 differs from that of FIGS. 1 through 3 only in that a second fabric bender 3' is provided. With respect to design, mounting and operation, second fabric bender 3' is identical to first fabric bender 3 except that the drive shaft 11', support assembly 15', pin 24' and torsion spring 25' of the second fabric bender 3' are mirror-symmetrical in design and in mounting to the drive shaft 11, support assembly 15, pin 24 and torsion spring 25 of the first fabric bender 3. The same applies to holder 33' for the torsion spring 25' of second fabric bender 3' and the holder 33 for torsion spring 25 of first fabric bender 3. The two hollow drive shafts 11 and 11' extend therefore in mutually aligned manner on both sides of fabric benders 3, 3', i.e., each drive shaft 11 or 11' away from support assembly 15 or 15' of associated fabric bender 3 or 3'. During sewing the two fabric benders 3 and 3', which are very tightly mounted next to each other between the two feed belts 4, become alternatingly operational in order to bulge the sewing material into the path of the arc needle 1 of the blind-stitching machine.
The hollow drive shaft 11' of the second fabric bender 3' rests rotatably in a support 51 and is connected by a toothed-belt drive to an additional drive shaft 52 which is mounted parallel to the two hollow drive shafts 11 and 11'. The toothed-belt drive consists of a toothed-belt gear 53 affixed to the hollow drive shaft 11', a toothed-belt gear 54 affixed to the additional drive shaft 52, and an endless toothed belt 55 looping the two toothed-belt gears 53 and 54. The additional drive shaft 52 includes an arm 12' located at the end away from the toothed-belt drive. Arm 12' is linked by a bolt 13' to a bar 14' by means of which the drive shaft 52 can be pivoted through the arm 12' to-and-fro. In this manner the two fabric benders 3 and 3' can be driven from the same side, namely from the side which is on the right in FIG. 4 and which is away from the free end of the fabric-support arm 5.
Support 51 is pivotably carried by fabric-support arm 5 and comprises a hollow pivot shaft 56 located on the side which is remote from the toothed-belt drive and adjacent the pair of fabric benders 3,3'. The additional drive shaft 52 for second fabric bender 3' is rotatably supported in a borehole 57 of hollow pivot shaft 56. Borehole 57 also passes through support 51 and extends transversely thereto. In turn, pivot shaft 56 is rotatably supported in a longitudinal borehole 58 of fabric-support arm 5.
As shown in FIG. 5, fabric-support arm 5 is rotatably supported through a shaft 60 on the housing 59 of the blind-stitching machine and is loaded by a helical tension spring 61 into the sewing position shown. In this position, fabric-support arm 5 rests through a first adjustment screw 62 on the housing 59. Screw 62 is threaded into a downward extension 63 of a forward longitudinal wall 64 of fabric-support arm 5. Shaft 60 is parallel to drive shafts 11, 11' and 52 for the fabric benders 3 and 3' and the helical tension spring 61 acts at one end on the extension 63 and at the other end on the housing 59. Support 51 of the drive shaft 11' for the second fabric bender 3' is pivotable about the common longitudinal axis of the additional drive shaft 52 for the second fabric bender 3' and of its own pivot shaft 56 which is coaxial with the additional drive shaft 52. Support 51 is biased by a helical compression spring 65 bearing at one end against a downward projection 66 of support 51 and at the other end against housing 59 of the blind-stitching machine. Functionally, the other end of helical compression spring 65 could bear against fabric-support arm 5 instead of housing 59. Compression spring 65 biases projection 66 on pivot shaft 56, shown in FIG. 4 next to the arm 12' of the additional drive shaft 52, against a second adjustment screw 67 threaded into the extension 63 of the fabric-support arm 5. Accordingly, the depth of penetration of the arc needle 1 into the sewing material made to bulge by the first fabric bender 3 can be set independently of the depth of penetration of the arc needle 1 into the sewing material made to bulge by the second fabric bender 3', by appropriately setting the fabric-support arm 5 relative to the housing 59 of the blind-stitching machine using the first adjustment screw 62 or the support 51 relative to the fabric-support arm 5 using the second adjustment screw 67, respectively.
It should be recognized that the above description is directed to preferred embodiments of the invention and that various changes/modifications can be made without departing from the spirit of the invention. For instance, it is possible to have the fabric bender 3 or the two fabric benders 3 and 3' cooperate with one stop or with separate stops at the throat plate 2, or to provide the fabric bender 3 or each of fabric benders 3 and 3' with a sewing-material sensor. Further, other material advancing mechanisms may be used in place of the two feed belts 4. Therefore, the invention can be modified within the limitations of the following claims. | The invention pertains to a blind-stitch sewing machine with a plate-shaped fabric bender to make a sewing material bulge in to the arcuate path of an arc needle. The fabric bender extends in a plane perpendicular to the path of the arc needle and is pivotable to-and-fro in this plane by means of a drive shaft extending perpendicular to this plane. The fabric bender is rotatably supported in a slot of a support assembly projecting from the drive shaft to pivot about an axis parallel to this drive shaft, and furthermore is spring biased away from the drive shaft. To achieve a narrow construction of the fabric bender and of its support assembly, the drive shaft is hollow and a torsion spring is provided to load the fabric bender. The torsion spring is mounted in the borehole of the hollow shaft where adequate space is available to install the spring. | 3 |
RELATED APPLICATIONS
This patent is a continuation of U.S. patent application Ser. No. 11/496,535, which was filed on Jul. 31, 2006, which is a continuation of U.S. application Ser. No. 11/027,935, which was filed on Jan. 3, 2005, which is a continuation of International Patent Application Serial No. PCT/EP2003/005926, which was filed on Jun. 5, 2003, the disclosures of the parent applications are incorporated herein by reference.
FIELD OF THE DISCLOSURE
This disclosure related generally to firearms, and, more particularly to, machine guns having detachable barrels, a latch to facilitate the attachment and removal of a barrel, and a foldable carrying handle mounted near the latch.
BACKGROUND
Positional terms such as “rear” or “top”, “right” or “left” are used in this patent with reference to a weapon positioned in a shooting position, That is, with reference to a weapon positioned to shoot “forward” (i.e., away from the shooter), in a generally horizontal plane.
Conventional light weight machine guns often have a carrying handle that is mounted near the rear end of the barrel, (i.e., in proximity to the gun's center of gravity). The handle can be moved between a rest position and a working position. In the rest position, the carrying handle is folded down and rests against the jacket of the machine gun. In its working position, the carrying handle protrudes upwards from the machine gun and is positioned to serve for transporting the gun.
In general, such machine guns should be as light as possible and be able to handle long rounds and a high overall number of shots. Each shot fired produces heat and the gun barrel may become over-heated during use. To address this issue, these machine guns usually have devices that allow one to quickly exchange one barrel for another.
Such devices are usually designed as latches that snap into place. After the latch is opened, the barrel can be removed, for example, with asbestos-clad gloves or by means of a heat-insulated manual handle (see CH 116,607). Subsequently, a new barrel is inserted, and the latch is closed again. In its closed position, the latch should be firmly locked and hold the barrel in its proper position during the next round of firing.
There are several disadvantages with the above described prior art design. First, if the asbestos-clad gloves are not within easy reach or if there is a failure, the machine gun operator may inadvertently use his free hand to remove the hot barrel and injure himself. Second, in the excitement of a fight, it is easy to forget about the need to always carefully check and make sure that the latch is properly locked. If the latch is not properly locked, it could unexpectedly open, thereby permitting the barrel to fall out of the gun. One could conceive of a separate safety catch that would only allow the gun to fire when the latch has properly snapped into place. However, such a safety catch would disable the weapon if the barrel becomes loose and, at any rate, would be very complicated and, thus prone to failure.
It would also be possible to equip the snap-in latch with a secondary latch. However, such a secondary latch would require additional operations to exchange a barrel and, thus, delay and complicate the exchange process.
Detachable barrels on machine guns with carrying handles are known in the prior art. For example, U.S. Pat. No. 2,131,716 illustrates a device for removal and/or insertion of a barrel that can be provided in addition to a carrying handle on a machine gun. However, the actuation of the device shown in U.S. Pat. No. 2,131,716 is independent from the position of the carrying handle and/or can only occur when the carrying handle is in position B (see FIG. 2 of U.S. Pat. No. 2,131,716).
A transversally arranged eccentric rod used to hold a barrel of an automatic firearm in a detachable connection is known from U.S. Pat. No. 2,423,854.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an example universal machine gun equipped with an example barrel exchange latch mechanism.
FIG. 2 is a longitudinal cross-sectional view of the example barrel exchange latch mechanism shown in its ready-to-shoot state in which a barrel exchange is precluded, with portions shown in block diagram form.
FIG. 3 is a longitudinal cross-sectional view of the example barrel exchange mechanism of FIG. 2 , but shown in its release position in which a barrel exchange is permissible.
FIG. 4 is an enlarged view of the check plate that rests on the end of the eccentric bar in the example barrel exchange mechanism of FIGS. 1-3 .
DETAILED DESCRIPTION
FIG. 1 illustrates an example machine gun (e.g., a US M60), which is equipped with an example barrel exchange latch mechanism 3 and an exchangeable barrel 1 . Other than the inclusion of the barrel exchange mechanism 3 , the remainder of the illustrated machine gun is largely conventional. Those portions of the weapon not described in the following are well known to persons of ordinary skill in the art.
To enable the removal of the barrel 1 , the weapon of FIG. 1 is further provided with a removable gas piston device 5 . The gas piston device 5 is typically removed to exchange the barrel 1 for a new barrel (which, although not separately shown, is identical to the barrel shown in FIG. 1 ) when the barrel 1 become hot from use.
The machine gun of FIG. 1 also includes a carrying handle 7 . The carrying handle 7 is mounted on the machine gun such that it can be folded between a rest position and a carrying position. FIG. 1 illustrates the handle 7 in an example carrying position. In this position, the carrying handle 7 may obstruct the line of sight. In such an example, the handle 7 should be folded down to the rest position before shooting.
When removing a hot barrel 1 , the user actuates the barrel-exchange latch mechanism 3 , grabs the barrel 1 with an insulated glove, (e.g., an asbestos-clad glove), and pulls the barrel 1 , along with the bipod 9 , forward in the direction of firing. In this process, the gas piston device 5 is separated into two parts, with one part remaining on barrel 1 and the other part remaining on the machine gun.
FIG. 2 is a cross-sectional view of the example barrel-exchange latch mechanism 3 of FIG. 1 . Note that in FIG. 1 the machine gun points to the right, while in FIGS. 2 and 3 , the machine gun points to the left.
As shown in FIG. 2 , the exchangeable barrel 1 of the illustrated weapon comprises an expanded rear end 11 . The rear end 11 is in communication with the magazine and is inserted into the front of a fitting borehole in the jacket/housing 41 of the machine gun.
The upper part of the rear end 11 includes a recess 13 . A transversally extending eccentric bar 15 is mounted in the gun jacket 41 near the recess 13 . The eccentric bar 15 is rotatable. In the position illustrated in FIG. 2 , the rear part of the eccentric bar 15 protrudes into the recess 13 of the barrel 1 . This engagement between the eccentric bar 15 and the barrel 1 prevents the barrel from moving forward, (i.e., blocks the barrel from being removed). Thus, when the eccentric bar 15 is in the position of FIG. 2 , the weapon is in a ready-to-shoot position.
A handling device 14 (e.g., a lever) is located on the end of the eccentric bar 15 and shown in FIGS. 2 and 3 in block diagram form.
A slider 17 is located within a cavity defined in the housing 41 above the eccentric bar 15 . The slider 17 is longitudinally movable and is pushed to the back by a spring 19 . The slider 17 includes a slider block 43 on the bottom and a slider lug 23 , which extends the slider 17 towards the front. The slider lug 23 can emerge from the housing/jacket 41 . In the illustrated example, the slider lug 23 is formed in one piece with the slider block 43 . A transversally extending recess 21 , which opens forward, is disposed in the upper side of the eccentric bar 15 .
In the position shown in FIG. 2 , the slider block 43 sits in the recess 21 . The slider block 43 , which forms a part of the slider 17 , interacts with the recess 21 of the eccentric bar 15 to substantially prevent the eccentric bar 15 from turning clockwise beyond the position shown in FIGS. 2 and 3 . When the slider lug 23 and, thus, the slider block 43 , are moved sufficiently forward against the force of the spring 19 (i.e., by pivoting the eccentric bar 15 with the handling device 14 ), the eccentric bar 15 turns counter-clockwise from the position shown in FIG. 2 and exits the recess 13 . As a result, the barrel 1 can be pulled out of the housing 41 toward the front of the weapon. If the handling device 14 connected with the eccentric bar 15 is subsequently released, the eccentric rod 15 and the slider block 43 return to the position shown in FIGS. 2 and 3 under the influence of the spring 19 . A new barrel may then be pressed from the front into the borehole in the jacket 41 .
When a new barrel is so inserted, it rotates the eccentric bar 15 counter-clockwise against the force of the spring 19 . When the new barrel is sufficiently inserted, the eccentric bar 15 snaps back into the position shown in FIG. 2 . When the eccentric bar 15 snaps back into the position of FIG. 2 , the slider lug 23 re-enters the jacket 41 , and the barrel 1 is completely fit into the borehole. A sloping edge/camming surface on the top of the rear end 11 of the barrel 1 facilitates this snap-in procedure.
Further toward the front, the barrel 1 has a gas borehole (not shown) that extends radially from the bottom and connects to a gas channel 33 located within a gas discharge element 35 . An axial gas discharge element 37 is attached in a well known fashion to the open end of the radial gas discharge element 35 . The angular gas channel 33 continues to the rear in this gas discharge element 37 . The gas discharge channel 33 ends in a plug-in block 39 which is structured as a piston. This plug-in block 39 is detachably inserted from the front into a gas cylinder 27 . The gas cylinder 27 includes a movable gas piston 29 . This piston 29 transfers its backward movement to a rod assembly 31 which, in turn, transfers its movement to a closure mechanism (not numbered) to initiate unlocking of the bolt head of the breech. The bolt head and breech mechanism are partially shown in FIG. 3 . For more details of this structure, the interested reader is referred to U.S. patent application Ser. No. 11/027,934, which is hereby incorporated by reference in its entirety.
To release the eccentric bar 15 from the recess 13 in the rear end 11 of the barrel 1 , the lever 14 coupled to the eccentric bar 15 is used to rotate the eccentric bar 15 counter-clockwise. After the eccentric bar 15 exits the recess 13 , the barrel 1 can be pulled forward and out of the machine gun. Concurrently, the plug-in block 39 of the gas piston device 5 is pulled out of the gas cylinder 27 . The illustrated gas cylinder 27 may be implemented as an expendable part that can be exchanged at any time.
As shown in FIG. 2 , a horizontal axle 45 is attached to the housing/jacket 41 just in front of, and beneath, the slider 17 . The axle 45 is the support pivot for the carrying handle 7 . Attached to the bottom of the carrying handle 7 is a stop block 25 . The stop block 25 faces the slider 17 , and lies directly in front of the slider lug 23 when the carrying handle 7 is folded down in the ready-to-shoot state as shown in FIG. 2 . When the stop block 25 is in this position, it prevents the slider lug 23 from exiting the jacket 41 and, thus, prevents the slider 17 from moving forward. The handle 7 may be structured with a snap-in connection, wherein the slider lug 23 fixes the carrying handle 7 in its ready-to-shoot position by a spring-biased engagement in a recess in the stop block 25 .
When the carrying handle 7 is rotated up to the position shown in FIG. 3 (e.g., for transporting the weapon as the shooter changes his/her position), the stop block 25 swivels past the slider lug 23 and releases it for forward longitudinal movement. (The stop block 25 is not visible in FIG. 3 because it lies before the plane of the drawing.) The barrel 1 can only be exchanged when the carrying handle 7 is in this position (i.e., the position of FIGS. 1 and 3 ). In the ready-to-shoot position shown in FIG. 2 , the barrel 1 may not be exchanged because the eccentric bar 15 may not be turned out of the recess 11 because it rests, through the slider 17 and the slider lug 23 , against the stop block 25 of the carrying handle 7 . The eccentric bar 15 can only be turned when the stop block 25 is not located in front of the slider 17 and the slider lug 23 is, thus, free to move forward (i.e., when the handle 7 is in the position shown in FIG. 3 ). This approach provides added security because the barrel 1 may only be exchanged when the carry handle 7 is rotated up, into a position obstructing the gun operator's view (i.e., where the weapon is not in a ready-to-shoot fire state).
FIG. 4 is an enlarged top view of the end of the eccentric bar 15 . This top view is from the right side of the machine gun; thus, in this drawing, the direction of shooting is to the right.
To limit the range through which eccentric bar 15 can turn, a check plate 47 is mounted in a recess 51 in the jacket 41 . This check plate 47 is sized to allow the eccentric bar 15 to turn only between its two end positions in the shortest path and prevents the eccentric bar 15 from turning beyond these end positions.
The check plate 47 is associated with two snap-in devices 49 in the recess 51 of the jacket 41 . These snap-in devices 49 may be implemented by, for example, spring-mounted snap-in balls. The snap-in devices 49 stop the check plate 47 and, thus, limit the rotation of the eccentric bar 15 in each of its two end positions.
From the foregoing, persons of ordinary skill in the art will appreciate that the illustrated example machine gun has a barrel 1 which can be exchanged as quickly as in conventional firearms, but in a safer and more reliable fashion. To this end, the illustrated example device 3 that permits exchanging of the barrel 1 can only be brought into the release position when the carrying handle 7 is in the carrying position. Furthermore, the illustrated device 3 is simpler, or at least not more complex, than what is known in the art.
In the illustrated example, the eccentric bar 15 cannot extend beyond its end positions or, at least, cannot exceed them substantially. A person of ordinary skill in the art will appreciate that the illustrated example uses a locking piece 25 to prevent the eccentric bar 15 and the carrying handle 7 from unexpectedly moving from one end position towards the other. This locking piece 25 stops the eccentric bar 15 and the carrying handle 7 in an end position. The eccentric bar 15 and the carrying handle 7 can be moved beyond the stopped position through the exertion of additional force. This not only ensures the usability of the machine gun both in the rest and in the ready-to-shoot position, but it also avoids any situation where the eccentric bar 15 is wrongly turned with the barrel 1 removed so that a new barrel 1 cannot be simply inserted.
While the mechanism in the illustrated example prevents the end positions of the eccentric bar 15 from being exceeded, it does not prevent the possibility of the eccentric bar 15 being heavily stressed during a rush operation and possibly damaged as a result. Therefore, the illustrated example utilizes a check plate 47 on the eccentric bar 15 in order to absorb such stress in the end position and, thus, relieve the mechanism of that stress and the potential for damage.
A person of ordinary skill in the art will appreciate that the carrying handle 7 of the illustrated example is also used as a safety device. In particular, the illustrated carrying handle 7 guarantees that the machine gun can only shoot when the inserted barrel 1 is fully locked in place. When the carrying handle 7 is in its ready/carry position, it is not possible to aim the machine gun since the carrying handle 7 is directly in the gun operator's field of view and, therefore, it is difficult to shoot. This decreases the likelihood of a shot being fired from a misassembled weapon.
A person of ordinary skill in the art will further appreciate that the illustrated example helps the gun operator avoid injury during the changing of a hot barrel 1 . During the exchange of the barrel 1 , the gun operator usually has one hand on the carrying handle 7 . In order to exchange the barrel 1 , the operator grabs the hot barrel 1 at a heat-insulated handle or using some protective gear, (e.g., an asbestos-clad glove), while his other hand holds the carrying handle 7 . As a result, the temptation to assist with the other hand—and injure it, while doing so—is reduced.
In a further example, the machine gun has a carrying handle 7 that can only be brought into its rest position when the device 3 that releasably secures the barrel 1 is in its ready position. However, it is preferred that, during the transfer of the carrying handle 7 from its position of use (i.e., the carry position) to its rest position, the device 3 that releasably secures the barrel 1 is pressed into its ready position. As a result should the aforementioned device 3 become stiff to operate, (e.g., due to some dirt), it can still be brought into its locked position by means of the carrying handle 7 without facing the risk that the barrel 1 is not properly locked in.
In a preferred example, a weapon jacket/housing 41 defines a longitudinal borehole that receives the rear end 11 of the barrel 1 . The rear end 11 of the barrel 1 has a transversally extending recess 13 . Also, the weapon jacket 41 carries a transversally running eccentric bar 15 that can turn to—with the barrel 1 inserted—engage or disengage in the recess 13 . The carrying handle 7 is operatively coupled with the eccentric bar 15 when the eccentric bar 15 is engaged with the recess 13 , but is uncoupled from the eccentric bar 15 when the eccentric bar 15 is disengaged from the recess 13 .
An operation lever 14 is mounted on the eccentric bar 15 , and may be used to turn the eccentric bar 15 . The lever 14 must be long enough to ensure that the unlocking of the device 3 that releasably secures the barrel 1 is easily possible, even after an accumulation of dirt and rust. Furthermore, the recess 13 can be fabricated in a simple and inexpensive fashion so that the costs related to an exchangeable barrel 1 are minimized. Should the exchangeable barrel 1 be dirty, the recess 13 can be wiped off, without any extraordinary effort, by hand or with a piece of rag.
In the illustrated example, a slider 17 is pressed into engagement with the eccentric bar 15 by a spring 19 . The slider 17 can be pushed back away from the eccentric bar 15 when the carrying handle 7 is in its use/carry position. However, when the carrying handle 7 is in the rest position, it blocks the slider 17 from being pushed back. Thus, due to the slider 17 , the eccentric bar 15 is automatically blocked and cannot be released as long as the carrying handle 7 is in its rest position. Therefore, the gun operator can always be sure that the barrel 1 of his machine gun is secured in its proper place by observing the position of the carrying handle 7 .
A person of ordinary skill in the art will appreciate that the illustrated example latch can be used, for example, in a delayed recoil repeater gun, whose breech block is locked in the manner of the Swiss assault rifle 57 or the German G3. Furthermore, it is particularly advantageous to use the latch with gas-pressure repeater guns because, during the exchange of the barrel 1 , the connection between the barrel 1 and the gas channel 33 must also be separated, which is easy to do because the barrel 1 is inserted into its retaining borehole from the front in the direction of the centerline of the borehole.
A person of ordinary skill in the art will further appreciate that it is especially advantageous for an extension to be mounted on the barrel 1 between its muzzle and its rear end 11 . In the illustrated example, the extension comprises a gas borehole in communication with the barrel 1 . The gas borehole includes a free end that is offset backwards, and which extends parallel to the barrel 1 and ends in a plug-in block 39 . Furthermore, it is advantageous if the machine gun includes a gas channel 33 that is open in the forward direction and that, with the barrel 1 inserted, can be closed by the plug-in block 39 . The plug-in block 39 may only loosely be inserted into the gas channel 33 . However, it is also possible, and under certain circumstances advantageous, to equip the plug-in block 39 with sealing rings and insert it into the gas channel 33 so that it seals it off, especially in the case of small or weak cartridges, in which the developed gas quantity is relatively small.
Although certain example methods, apparatus and articles of manufacture have been described herein, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents. | Machine guns having detachable barrels and methods of operating the same are disclosed. An illustrated example firearm includes a housing; a removable barrel; a latch to releasably secure the barrel in the housing, the latch having a released state and a secured state; and a carrying handle movable between a rest position and a carry position. The carrying handle cooperates with the latch such that the latch can only be moved into the released state to permit removal of the barrel when the carrying handle is at least substantially in the carry position. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is the U.S. national phase application of PCT International Application No. PCT/EP2007/060897, filed Oct. 12, 2007, which claims priority to German Patent Application No. DE 10 2006 049 100.9, filed Oct. 13, 2006, German Patent Application No. DE 10 2007 002 569.8, filed Jan. 17, 2007, and German Patent Application No. DE 10 2007 007 283.1, filed Feb. 14, 2007, the contents of such applications being incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a vehicle and a method for identifying vehicles in the surroundings of the vehicle.
2. Description of the Related Art
Devices and methods for performing vehicle dynamics control in a motor vehicle are known. For example, the paper International Congress and Exposition, Feb. 27-Mar. 2, 1995, Detroit, Mich., SAE Paper 950759, 1995 describes a device and a method for performing vehicle dynamics control in a motor vehicle. The vehicle dynamics controller is a system for keeping the motor vehicle stable and in its lane. This is achieved through selective braking of individual wheels of the motor vehicle. For this purpose, the driver's request, that is to say the set point behavior of the motor vehicle, and the behavior of the vehicle, that is to say the actual behavior of the motor vehicle, are determined by means of sensors. In a processing unit/control unit the difference between the set point behavior and the actual behavior is acquired as a control error and the individual actuators, for example the wheel brakes, are controlled with the objective of minimizing the control error. In particular yaw rate sensors, lateral acceleration sensors, steering wheel angle sensors, admission pressure sensors and wheel speed sensors, are used as sensors. There are no indications here of using at least one image sensor system composed of at least two image sensors which pick up essentially the same scene.
In order to assist the driver of a motor vehicle and to actuate the safety means, use is made of surroundings sensors with which, in particular, the distance from objects such as, for example, other vehicles or obstacles can be determined. The sensors in this context are generally embodied as radar, infrared or ultrasonic sensors. Furthermore, it is known that a combination of distance sensors and camera sensors produce a relatively high level of efficiency in the positioning of objects and their classification, and therefore permit additional functions such as detection of pedestrians.
“Handbook of Computer Vision and Applications Volume 1-3” discloses using 3D sensors, such as stereo cameras, to acquire image and position information on objects, therefore permitting wide-ranging safety functions. Furthermore, from the cited volumes it is apparent that a point of interest (POI) can be identified as a relevant region in a scene of the image area from a mono camera image by means of algorithms such as sequence analysis, or analysis of the visual flow can be used indirectly to acquire distances from other road users.
In the text which follows, a device for vehicle-to-vehicle communication and/or for communication between two vehicles over a central infrastructure is referred to as a telematics unit.
DE 102004022289 discloses a method for performing vehicle dynamics control in a motor vehicle. In this context, a sensor senses a measured value and an actuator for performing vehicle dynamics control is actuated as a function of one of the measured values. For the purpose of vehicle dynamics control, image information from the surroundings of the motor vehicle is generated by means of an image sensor system, wherein two image sensors are provided which pick up the same scene. As a result, in order to assist the driver of a motor vehicle, a camera system is used in order to carry out comfort functions or cross-control functions of the motor vehicle which do not require a safe distance signal for objects.
DE 69033962 T2 discloses a method and a device for determining positions having satellite navigation devices. The latter have sufficient precision to be able to use vehicle-to-vehicle communication or communication between two vehicles via a central infrastructure to calculate the relative positioning and relative movement of vehicles with the level of precision which allows driver assistance systems to be operated.
In the text below, a device for vehicle-to-vehicle communication and/or for communication between two vehicles via a central infrastructure is referred to as a telematics unit.
However, the main problem here is that the information on the basis of which the respective application implements its technical control measures on the vehicle is not sufficiently reliable since it is not possible to ensure that further vehicles or objects are not located between the vehicle which is sensed by the telematics unit and the driver's own vehicle. Furthermore, the precision of satellite navigation is not sufficient to assign vehicles, whose approximate position is known from vehicle-to-vehicle communication, in a camera image in order to merge the data items with one another.
The information from a mono camera without a distance sensor is in many cases insufficient for comfort functions or safety functions since the distance from other vehicles cannot be determined reliably enough.
SUMMARY OF THE INVENTION
An object of the present invention is to make available a vehicle and a method which permit reliable determination of vehicles in the surroundings of the vehicle.
The invention relates to the idea that a vehicle which is registered and recognized by means of a camera system is identified such that it is determined whether the registered vehicle is the closest object or whether there are also further vehicles between the registered vehicle and the driver's own vehicle, in order to ensure that there is a free driving tube between the driver's own vehicle and a second vehicle so that, in the case of a vehicle cutting in from the side, it is possible to detect this and abort a closed-loop control process.
There is provision here that a transmitting vehicle is embodied in such a way that the telematics unit transmits both position information and other additional information about the movement of the vehicle or the state of the vehicle but also the (vehicle) registration information such as, for example, the vehicle license number. At the same time, in the vehicle of the type mentioned at the beginning the camera image is evaluated to determine whether the vehicle traveling in front is completely visible and whether its registration license number corresponds to that of the vehicle sensed by the telematics unit.
In this case it can be assumed that there are no objects located between the driver's own vehicle and the vehicle which is sensed by the telematics unit. If this is the case, for example adaptive cruise control (ACC) closed-loop control processes and/or emergency braking functions and/or a lane change warning and/or other function which are usually carried out by means of a distance sensor system are carried out solely on the basis of the communication data which is received and transmitted by the telematics unit and whose plausibility is checked by the camera.
In one advantageous embodiment of the invention, there is provision for the method according to the invention to be expanded with an additional object identification algorithm which already identify a vehicle cutting in before overlapping occurs with the target vehicle, and which switches off the functionality of the driver assistance system.
According to one particularly advantageous embodiment of the invention there is also provision for the absolute positioning of the telematics unit to be improved by the lateral positioning of the camera. In this case, what is referred to as a fusion of the information from the camera and of the vehicle-to-vehicle communication takes place.
On the basis of the abovementioned embodiment of a combination of the camera with the vehicle-to-vehicle communication system, it is possible to expand the closed-loop control methods for an ACC system in an advantageous way compared to transmitting vehicles. It is possible to implement what are referred to as “higher value” methods such as, for example, the well-known ACC Stop&Go method in a simple form. On the basis of this identification it is possible, in the event of imminent accident situations, to address all the functionalities which are referred to by APIA (Active Passive Integration Approach) for actuating passive and active safety measures including a lane change assistance. APIA is to be understood as referring to the networking of active and passive safety systems and the integration of a surroundings sensor system in order to produce vehicles which are as resistant as possible to accidents and injury. The probability of an accident is determined, for example, in a hazard calculator for the current traffic situation and graduated measures for protecting the vehicle occupants and other road users are initiated.
In a further advantageous embodiment of the invention there is provision for satellite navigation information to be improved with the assignment of the relative velocities, the relative acceleration or other data the efficiency of assistance systems which already have distance information of reduced quality.
Further advantages, particular features and expedient developments of the invention emerge from the exemplary embodiments which are described below with reference to FIGS. 1 and 2 .
An exemplary embodiment of the invention is illustrated in the drawing and will be described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read in connection with the accompanying drawing. Included in the drawing are the following figures:
FIG. 1 shows the identification of a vehicle by means of a camera which is designed to sense the surroundings and a telematics unit which is designed to receive and transmit the registration information, and
FIG. 2 shows the inventive sequence for generating distance and relative velocity information for driver assistance systems.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows here a schematic illustration of the identification of a vehicle by means of a surroundings-sensing system which is embodied as a camera and which has a telematics unit for transmitting and receiving registration information. The first vehicle ( 1 ) transmits the vehicle's own current position, the registration information and further information such as the velocity of the vehicle, the brake signal or the like.
As is indicated in the applications DE 102006029096.8 and DE 102006023339.5 by the patent applicant, information which is used in this invention can be implemented by means of the method described in the two applications. The content of these two abovementioned applications form part of the present application.
The receiving vehicle ( 2 ) receives the data. At the same time, the vehicle detects or searches for vehicles in the immediately surrounding area by means of the camera ( 3 ) and, if a vehicle has been identified, the license number ( 4 ) is acquired and read. It is furthermore checked whether the rear surface of the vehicle is completely visible.
In the search for further vehicles situated in the surroundings, a video monitoring method, which utilizes, for example, optical character recognition (OCR) to identify license numbers of vehicles, is advantageously employed. As a result, a vehicle at a velocity of up to 160 km/h can be registered. According to aspects of the invention, either existing mono video monitoring cameras, cameras in radar equipment or compact camera devices which have been specially developed for that purpose and which are used in various frequency spectra are used. According to aspects of the invention, consideration has been given to camera systems interacting with automated velocity and distance measurement systems for distance control for driver assistance systems. The method step “search for vehicle” ( 5 ) is configured in such a way that color, shape and graphic layout of different kinds of vehicle license plates can be searched for and identified. When searching under limited light conditions, infrared light is preferably used in order to carry out visual registration of the surroundings independently of the time of day and therefore of the light conditions.
At first, when the vehicles which are in the surroundings are registered, the relevant image area (POI) is defined. For example the registration information in the form of the vehicle license number plate is selected and segmented as a relevant image area and this area is registered visually, standardized optically and qualitatively improved, and subsequently character identification is carried out in order to obtain the alphanumeric text.
This is carried out in real time for each identified lane. This information can be transmitted in an automated fashion and/or stored for further processing later. Furthermore, according to aspects of the invention consideration has been given to storing both the individual images and/or sequences acquired by the camera and the identified text on a data carrier which is permanently installed in the vehicle or a mobile data carrier. The storage is carried out by transmitting data via a data bus which is located in the vehicle, this being, for example, the CAN bus, and/or by means of mobile data transmissions such as, for example, Bluetooth.
FIG. 2 shows the processing steps of the system in the receiving vehicle. In step ( 5 ), vehicles are first searched for in the capture range of the camera. If vehicles are detected, their license numbers are read in step ( 6 ) and compared, by means of a similarity measure, with vehicles sensed by the telematics unit. If the license number fits the vehicle, in step ( 7 ), it is checked whether further objects can be seen in front of the vehicle.
If no unambiguous identification is possible, when, for example, other vehicles or trailer hitches, towing bars or similar objects which are attached to the respective vehicles and which conceal the view of one or two characters on the license plate, according to aspects of the invention information which is acquired by means of the camera is not used for the plausibility checking.
If unambiguous identification is possible, the data acquired in steps ( 8 ) and ( 9 ) are made available as sensor data ( 10 ) to the driver assistance system. In this exemplary embodiment, it is not possible to accept any small faults. If a surroundings-sensing system is used, the incorrect identification of an individual character, or a failure to identify such a character, cannot be tolerated. It is to be ensured that the entire license number is identified correctly since this is a precondition for the functioning of the entire system architecture.
It is possible to apply more wide-ranging method steps to the selected and segmented image areas in order to identify the text in the license numbers. The selected image area is firstly adjusted to a uniform contrast and brightness (standardization) and then segmented for the OCR. Then, the license number is localized and the position of the license plate in the image area is identified. The orientation of the individual elements of the vehicle license number, such as, for example, the size, the differences in the spatial position and the size of the entire vehicle license number, is then determined. During the character segmentation, the individual elements of the license number are acquired and identified. Alphanumeric character recognition is thus carried out.
The quality of each individual step influences the precision of the entire system. For this purpose, filters can in particular be used in order to compensate for optical interference.
Many countries use retro-reflective license numbers. These reflect back the light in the direction of the source, as a result of which a better contrast is produced. Non-reflective characters are also often used, and these also increase the contrast under poor light conditions. Infrared cameras are also well suited for use in such systems, in conjunction with an infrared radiator and a normal light filter in front of the camera.
Unfocussed images make character recognition more difficult. It is therefore advantageously possible to use cameras with a very short exposure time in order to minimize the lack of focus due to movement. The exposure time is preferably 1/1000 sec. If the camera is mounted at a very low position or if the traffic moves relatively slowly, this time can also be made longer.
In the second embodiment, the embedding of RFID tags in, for example, the vehicle license number makes it possible to identify the registration information. The license number plates are configured in such a way that they cannot be removed without destroying them. These RFID tags are equipped with batteries so that they themselves continuously transmit their identifier, which also comprises the actual license number of the vehicle, for at least ten years after activation. In contrast to passive RFID systems with ranges of only a few meters, the identifier can therefore be read up to a distance of approximately 100 meters with corresponding sensors which are provided in a mobile fashion. The radio identifier is encrypted and can be read out and identified unambiguously.
In this embodiment, the signals of the RFID tags are therefore evaluated instead of the visual sensing. The associated reading devices which are integrated in the telematics unit permit up to two hundred identifiers to be read out simultaneously, even in vehicles which are moving past at high speeds.
In a third embodiment, the registration license number is output in encoded form via the lighting means on the rear of the vehicle. In this context, the lighting means can pass on the encoded registration information with their flashing frequency and their brightness. LED lights are advantageous here, and conventional lighting means can also be used in this context. The camera system recognizes the encoded (light) signals and then checks their plausibility compared to the registration information which is received via the telematics unit.
In a fourth embodiment, the three described methods are combined with one another in such a way that the visually identifiable registration information and the registration information which is emitted by the RFID tag, evaluated by means of the camera system, and the (light) signals at the rear of the vehicle traveling in front evaluated by means of the telematics unit and the camera system. When all three information items correspond, unambiguous identification occurs. If a difference is present, the telematics unit can be used to inform the driver that identification is not possible. A possible reason is, for example, that the stolen license plate has been attached to a vehicle and two different registration license numbers are present here. The telematics unit can be used to inform relevant security authorities.
While preferred embodiments of the invention have been described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. It is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention. | Vehicle having a surroundings-sensing system which makes available information on the surroundings to a closed-loop and open-loop control unit of the vehicle, and a closed-loop and/or open-loop control process changes the driving behavior as a function of the acquired information on the surroundings, wherein the vehicle has a registration information system which receives the registration information for vehicles in the surroundings, and in that the registration information system compares the received registration information with the registration information acquired by a surroundings-sensing system and changes the closed-loop and/or open-loop control process as a function of the result of the comparison. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to power loaders adapted to be mounted on tractors and is more particularly concerned with quick attachment type loaders which are self-supporting when detached from a tractor.
2. Description of the Prior Art
Front end power loaders are today commonly used as attachments mounted on tractors. It is therefore desirable that such loaders be simple and easily mounted and detached and that the effort and time required for mounted or detaching be minimized.
In the past, power loaders were secured to tractors by means which required time consuming effort to mount and then subsequently detach each time the tractor was required for use other than with the loader. Such loaders were often bolted to the tractor frame, or in another form, mounting plates were first secured to the tractor and the loader then attached to the mounting plates. These methods not only resulted in excessive operator downtime, but also required that the operator have readily available whatever miscellaneous hand tools as might be necessary.
Storage of many detachable loaders was often accomplished by supporting the loader on a stand or other supplemental apparatus. Not only did this arrangement require that each loader be provided with its own stand, but in addition, whenever the operator wanted to store the loader or remove it temporarily, the loader had to be either transported to the location where the stand was or the stand had to be moved to the desired storage location. To align this type loader with the tractor during mounting or demounting required that the loader be supported. As a result, makeshift or temporary stands were often made, these stands were often unsteady and created an unsafe mounting or demounting situation. Similarly, these same stands were then used to store the loader, thereby causing an unsafe storage situation from which injuries could easily result.
Another type of loader apparatus provided for securing the loader to the sides of the tractor frame, alongside the engine compartment. This means of securing the loader to the tractor resulted in the transfer of those forces encountered while operating the loader to the tractor frame sides or top. Such loading can cause severe structural deformation to the tractor.
Another type of self-supporting loader apparatus utilizes the frame of the loader apparatus as both the supporting structure when mounted on the tractor and as a supporting stand when detached from the tractor. In this type of loader, the main frame is manipulated from a working position horizontal alongside the tractor to an inclined ground-engaging and self-supporting position. This manipulation is effected as the tractor moves relative to the frame by extending and retracting the hydraulic cylinders normally used for operating the implement and its supporting boom structure. With this type of self-supporting implement, it often is necessary for the hydraulic pistons to be extended for undetermined lengths of time wherein the pistons are adversely exposed to the elements and are therefore subject to accellerated corrosion and pitting.
The present invention provides a structure which requires little effort to mount or dismount it, and can be mounted or dismounted very quickly. No supplementary mounting plates, bolts, or tools are required, and one man can easily and simply perform the loader mounting or dismounting. No mounting plates or channels project from the tractor side or front.
The present structure requires no supplemental apparatus such as a stand for storage. The loader is stored with the frame level on the ground thereby avoiding unstable and unsafe storage situations. This permits mounting and dismounting of the loader to the tractor to be accomplished at any chosen site, by a single person or operator and without the use or necessity of providing additional or supplemental auxillary equipment such as stands or jacks.
The loader when mounted is attached to the tractor undercarriage and thereby transfers loading forces directly to the tractor main frame. Accordingly, a smaller tractor can be used with the loader and no structural damage will result to the tractor.
It is therefore highly desirable and an object of this present invention to provide a power loader having a frame or base which rests level with ground when dismounted and which is easily mounted to the undercarriage of the tractor.
It is further an object of the present invention to provide a stable support structure requiring no stands or other supplemental apparatus, such that upon receipt of an inadvertent bump when in a stored condition, the loader will maintain its stability.
Yet another object of the present invention is to provide means enabling one man to easily and simply attach the loader to the tractor undercarriage in a short time and without requiring any miscellaneous equipment or hand tools.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a loader having mounting apparatus for quick attachment and detachment to a tractor. The loader is adapted to be mounted on the tractor undercarriage from a resting or stored position on the ground by a combination of virtually labor-free operations. The loader frame is constructed such that the usual loader cylinder piston assemblies are used to raise the loader up to the bracket members carried by the tractor frame whereat releasable fastening means secure the loader in place.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings which illustrate an embodiment of the invention:
FIG. 1 is a side view of the power loader in a self-supporting parked position.
FIG. 2 is a side view of the power loader and tractor illustrating the loader in a partially mounted position.
FIG. 3 is a side view of the power loader mounted on the tractor.
FIG. 4 is a top view of the tractor and mounted loader illustrating in dotted lines the loader frame relationship to the tractor frame illustrated in solid lines.
FIGS. 5 and 6 are enlarged fragmentary side views illustrating the rear mounting bracket and loader base rearwardly portion.
FIG. 7 is an enlarged fragmentary cross section taken along lines A--A and illustrating the loader forward frame sections fastened in the front mounting bracket.
FIG. 8 is an enlarged fragmentary top view taken along lines B--B and illustrating the rear bracket positioning and fastening means.
FIG. 9 is an enlarged fragmentary rear view taken along lines C--C and illustrating the rear bracket positioning and fastening means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the embodiment illustrated in the drawings, there is generally shown at 10 a power loader for attachment to and detachment from a tractor 12. The power loader 10 is comprised generally of a frame 14 including a base 16 and a mast 18, a lift boom 20, a first power means 22 acting between the boom and frame, a working tool or bucket 24 mounted on the boom, a second power means 26 acting between the boom and working tool, and mounting apparatus between the tractor 12 and loader 10 for positioning the loader on the tractor and mounting and supporting the loader thereon.
As can be seen in FIG. 1, the loader frame 14 is comprised of a base 16 secured to an upstanding mast 18. This base 16 includes two transversely spaced apart and fore-and-aft extending beams or members 28 for mounting the loader on the tractor and supporting it therefrom. Each member 28 also serves to cooperate with the bucket 24 in supporting the loader while it is in a parked or demounted position. Extending between the base members 28 at their rearwardly ends and secured perpendicular thereto is a cross member 30. Extending between and secured perpendicular to the base members 28 at their forwardly ends and comprising the mast base member is a second cross member 32. To this second cross member 32 are secured the upwardly and rearwardly extending side members or posts 34 which form the main part of the mast 18.
In FIG. 1, the loader is shown in a demounted and parked position with the base members 28 resting level on the ground and the bucket 24 resting flat on the ground. As can be seen from the drawings, no parking stand or parking legs are required.
To the upper ends of the mast posts 34 are pivotally connected by pins 36 the loader boom arms 38. Each boom arm 38 extends forwardly and downwardly terminating in an end pivotally connected to the bucket or working tool 24. A boom cross member 40 extends transversely between the boom arms 38 spaced between the mast 18 and bucket 24 to provide lateral support for the boom arms 38. Pivotally attached to the rearward portion of each boom arm 38 is the ram end of a hydraulic lift cylinder 22. The base end of each hydraulic lift cylinder 22 is attached to the mast 18. A single hydraulic tilting cylinder 26 acts between the boom 20 and bucket 24, having its base end secured to the boom cross member 40. The ram end of the tilting cylinder 26 is pivotally connected to the bucket 24.
The loader 10 is mounted to and supported on the tractor 12 as hereinafter described in detail, by a first 42 and second 44 set of transversely spaced apart bracket means. These bracket means are provided for positioning the loader beneath and supporting it from the tractor and are designed to permit the loader to be mounted to any size tractor.
Cooperating with the bracket means 42 and 44 and necessary to the mounting or demounting sequence is a trunnion means 46. In the disclosed construction, loader base 16 mounted trunnion means 46 in the form of trunnions or pivot pins 48 are receivably positioned in trunnion supports 50 that depend from the tractor main frame. When the pivot pins 48 are supported in the trunnion support 50, there is provided a pivotal axis about which the loader frame is rotated between the demounted tilted position shown in FIG. 2 and the horizontally mounted position illustrated in FIG. 3.
In the disclosed construction, the first bracket means 42 includes a pair of U-shaped downwardly and fore-and-aft opening brackets 52 provided with means for releasably fastening the loader to the tractor (see FIG. 7). Each bracket 52 is secured to a tractor mounted plate 54 which can be adapted to fit any size tractor. The plate is attached to the tractor with bolts 56 or other suitable means. Receivably positioned in each bracket 52 as the loader is elevated into a tractor-mounted position, is its respective base member 28. To secure the base member 28 within the bracket 52, removable pins 58 are inserted through apertures 60 in each opposite leg 62 of the bracket 52 (see FIG. 7). These first bracket means 42 not only position and support the loader forward end but also serve as a fulcrum about which the rearward loader base frame is rotated into position to be fastened after the frame base forward portion is fastened.
The second bracket means 44 includes a pair of brackets 64 depending from a mounting plate 66 bolted to the tractor main frame rearwardly of the first bracket means 42. That mounting plate 66 can also be adapted to permit the loader to be mounted on any size tractor.
From each side of the mounting plate 66 depends a U-shaped downwardly and fore-and-aft opening bracket 64 provided with means for releasably fastening the loader to the tractor. To each end of loader's rearwardmost cross member 30 are secured fore-and-aft extending and generally triangularly-shaped bracket plates 68 adapted to be receivably positioned within their respective depending bracket 64. Located above the cross member 30 in each bracket plate 64 are openings 70 compatible with openings 72 in each leg 74 of the bracket 64. Removable pins 76 are positioned within the openings 70 and 72 to secure each triangularly-shaped plate 68 in its respective bracket after the loader base rear is elevated into its bracket 64 and the openings 70 and 72 are aligned.
To assist in mounting and demounting the loader from the tractor, the trunnion means 46 is provided between the rearward portion of each base member 28 and the tractor. Provided as a part of the second bracket means 44 is the trunnion support 50 or shelf 78 having a U-shaped and upwardly opening cradle 80. Receivably positioned upon this shelf 78 during the mounting and demounting sequence are the pivot pins 48 which are transversely secured to their respective plate 68. Each pin 48 is secured to its plate 68 rearwardly of and horizontal with the openings 70 wherein the removable pins 76 are positioned. In this location, the pivot pin 48 can be easily positioned on the shelf 78 as the tractor is slowly advanced over the loader during the mounting sequence. The brackets 64 further include vertically elongated openings 82 extending upwardly from the cradle 80 to permit vertical movement of the pivot pin 48 between the cradle 80 and the upper portion of the elongated opening 82.
The method by which the loader is transfered between parked and tractor mounted positions is illustrated by the sequence of steps shown in FIGS. 1; 2 and 5; and 3, 6 and 7. In FIG. 1, the loader is shown in a parked, demounted storage position with the bucket 24 resting on the ground. The boom arms 38 are tilted downwardly and the bucket 24 tilted to allow the bucket surface 84 to rest level on the ground. Because the loader center of mass is located forwardly of the base frame forward ends, the bucket 24 must rest on the ground to provide a stable storage configuration. As is apparent from the drawings, no stand or storage rack is required to store the loader.
To mount the loader onto the tractor in the underslung fashion illustrated, the operator first drives the tractor over the parked loader aligning the loader pivot pins 48 with their respective trunnion support shelves 78 on the tractor. The hydraulic fluid supply lines 86 are then connected with the tractor. The loader is then pivoted about the forward end 88 of the base members to the position shown in FIG. 2. To pivot the loader to this position, the operator slowly extends the lift cylinder 22 to raise the bucket 24 from the ground or reduce the force exerted on the ground by the bucket. Because the loader center of mass is located forwardly of the base members forward end 88, the loader will slowly rotate to the position shown in FIG. 2. When the pivot pins 48 have been elevated sufficiently, the operator inches the tractor ahead to receivably guide the pins 48 along edge structure 90 and position the pins 48 in the elongated slot 82 as shown in FIGS. 2 and 5. With the pivot pin 48 positioned above the shelf 78, the operator next retracts the lift cylinder 22 to rotate the base members rear portion downwardly and seat the pin 48 in the cradle 80. As the operator continues to retract the lift cylinder 22, the loader will rotate about the pivot pin 48 which is supported on the shelf 78 and the frame base members 28 will be guided by flanges 92 into the U-shaped brackets 52 at the forward end of the tractor. The removable pins 58 are then inserted through the openings 60 to releasably fasten the loader forward portion within the brackets 52 and cotter pins 94 are inserted through the pins 58 to hold them in place.
The openings 70 in plates 68 are next aligned with those openings 72 in the second brackets 64. To raise the loader frame rear base portion, the operator will extend the lift cylinder 22 to cause the loader frame to rotate about the forward pins 58 and the pivot pin 48 to move to the upper portion of the elongated opening 82. Pins 76 are then inserted through the openings 70 and 72 to releasably fasten the plate 68 to the bracket 64.
To detach or demount the loader from the tractor requires that the operator follow the converse sequence of steps or order of procedure. The lift cylinder 22 is first extended to cause the loader rear portion to rotate upwardly. The rear pins 76 are then removed. The lift cylinder 22 is then retracted to cause the loader rear portion to rotate downwardly and the pivot pins 48 to seat in the cradles 80. With the rearward end of the loader supported on the bracket shelf 78 and the forward portion of the loader frame raised off the forward pins 58, the forward pins 58 are removed. The operator next extends the lift cylinder 22 to permit the base member forward end to be lowered to the ground as shown in FIG. 2. Next the lift cylinder 22 is extended to cause the pivot pins 48 to raise out of the cradle 80. The operator then backs the tractor up a few inches until the pivot pins 48 are clear of the support 50 and then retracts the lift cylinder 22 to return the base members to the position shown in FIG. 1. The hydraulic hoses 86 are then disconnected and the loader is in a stable position to be stored for either short or long periods.
From the foregoing, it is clear that the loader can be quickly mounted and demounted in a brief period with little manual exertion by the tractor operator. The tractor can be used for other purposes while the loader sits idle in a parked position. | A detachable front end loader for a tractor constructed to not only be easily mounted and demounted from a tractor, but to also be self-supporting when demounted. A loader frame having a rectangularly-shaped base rests level on the ground when demounted and is mounted flush with the tractor main frame when mounted. By a combination of expanding and contracting the hydraulic lift cylinder and moving the tractor ahead, the loader can be elevated into a mounted position beneath the tractor and secured thereto. Means for releasably fastening the loader to the tractor main frame are easily manipulated by the operator. | 4 |
This application is a U.S. National Phase Application under 35 USC 371 of International Application PCT/JP00/02631 (not published in English) filed Apr. 21, 2000.
FIELD OF THE INVENTION
The present invention relates to a hydraulic pump with a built-in electric motor in which an electric motor and a pump unit that are disposed in tandem along the axis of rotation are received in a common housing.
BACKGROUND OF THE INVENTION
As disclosed, for example, in JP-A-0988807, a hydraulic pump with a built-in electric motor of the type in which an oil-immersed electric motor and a hydraulic pump unit are disposed in tandem along the axis of rotation and interconnected by a common shaft whereby a drain oil discharged from the hydraulic pump unit within a common housing is introduced into and discharged to the outside of the oil-immersed electric motor to thereby cool the electric motor with the pump drain oil, has been known in the art.
Although the hydraulic pump with a built-in electric motor of the type in which the built-in electric motor is immersed and cooled with the drain oil from the pump unit is excellent in cooling efficiency due to the fact that structurally the electric motor coils which are subject to cooling is in direct contact with the hydraulic oil or the cooling medium, in the case where water is introduced into the hydraulic oil or the hydraulic oil itself is an aqueous hydraulic oil, difficulties are encountered in that not only there is the danger of causing such trouble as an electric short-circuiting inside the electric motor, but also very fine metal foreign particles produced within the rotating electric motor tend to enter the hydraulic oil thus making a filter treatment unavoidable for the recirculation of the drain oil and requiring additional time and labor for the maintenance of the hydraulic system including a frequent changing of filters, etc.
Further, in the conventional hydraulic pump with a built-in electric motor, the electric motor-is of the oil immersed construction and its installation posture is permanently fixed so that not only there is a limitation to the installation place within machinery which utilize such pump, but also a piping connection to the hydraulic oil reservoir tank is required thus making it necessary to suffer a certain degree of complication in the construction of the installation portion.
SUMMARY OF THE INVENTION
In view of the foregoing deficiencies in the prior art, it is the primary object of the present invention to provide a hydraulic pump with a built-in electric motor capable of not only simultaneously achieving the cooling of a built-in electric motor and the prevention of contamination of a hydraulic oil due to the rotation of the electric motor, but also preventing the occurrence of electrical troubles with the built-in electric motor even if a water-containing hydraulic oil or aqueous hydraulic oil is fed and discharged. Also, it is another object of the present invention to increase the degree of freedom of design for selecting the installation positions or to make it possible to eliminate the need for piping connection to a reservoir tank.
In accordance with the present invention, there is thus provided a hydraulic pump with a built-in electric motor in which an electric motor and a pump unit are arranged in tandem fashion and accommodated within a common housing. More particularly, the housing is in the form of a metal box having a rectangular parallelepiped external shape and forms an electric motor frame fixedly accommodating a stator of said electric motor therein. A space in the metal box on the electric motor side is separated as a dry or atmospheric space from the internal space of the pump unit by a seal mechanism. At least one hydraulic oil receiving chamber is formed in the peripheral wall of the metal box, and that the hydraulic oil receiving chamber is communicated with a passage for receiving a return oil from the outside and a passage leading to the suction port of the pump unit.
Here, the so-called seal mechanism of the present invention means all kinds of oil leakage seal mechanisms capable of transmission of rotation, e.g., those which smoothly transmit the rotation of the electric motor to the rotor of the pump unit and prevent the leakage of the oil from the internal space of the pump unit to the space on the electric motor side. As regards specific examples of such seal mechanism, where the rotary shaft of the electric motor and the pump unit is composed of a single common shaft, for example, it is possible to cite an annular oil seal disposed adjacent to a bearing in a pump unit case between the electric motor and the pump unit, or alternatively, where the rotary shaft of the electric motor and the rotor rotating shaft of the pump unit are disconnected separate shafts, it is possible to cite a magnetic coupling with an oil leakproof seal so designed that magnets are disposed on the inner peripheral surface of a coupling socket provided on the forward end of the rotary shaft of the electric motor, that corresponding magnets are also disposed on the end of the rotor rotating shaft of the pump unit that is inserted in the socket through a diametrical gap, that the end of the rotor rotating shaft is covered with a seal cap through an annular gap between the magnets and that the opening flange of the seal cap is sealingly fixed to the case side of the pump unit.
In the hydraulic oil pump with a built-in electric motor according to the present invention, the housing forms the electric motor portion and also the electric motor portion within the housing is disposed in the dry space separated from the internal space of the pump unit by the seal mechanism whereby the hydraulic oil sucked into the pump unit flows through the hydraulic oil receiving chamber disposed in the housing peripheral wall separately from the dry space and it does not contact with the rotating parts of the electric motor; thus, there is no danger of the hydraulic oil being contaminated with metal foreign particles emitted from the rotating electric motor and also there is no danger of electrical troubles being caused within the electrical motor due to the hydraulic oil even if the hydraulic oil contains water or the hydraulic oil itself is an aqueous hydraulic operational fluid. Moreover, in the hydraulic pump with a built-in electric motor according to the invention, the housing itself forms a liquid-cooling jacket for cooling the electric motor and therefore the cooling of the electric motor is attained effectively. While, in this case, the generation of heat from the electric motor is caused mainly by the windings of its stator, the stator is attached to the metal box forming the housing and thus the heat generated from the stator windings is directly transmitted to the metal box by heat conduction, thereby ensuring an effective cooling owing to not only the heat dissipation effect of the outer surface of the metal box itself but also the fact that the heat is absorbed through heat conduction by the hydraulic oil in the hydraulic oil receiving chamber through the metal box.
The pump unit is driven by the rotation of the electric motor so that the hydraulic oil sucked from the hydraulic oil receiving chamber is discharged as a pressurized oil and this-pressurized oil is returned as return oil to the hydraulic oil receiving chamber after it has performed a work in an external load actuator connected to the pump. Preferably, the drain oil from the pump unit is also introduced into the hydraulic oil receiving chamber so that although the amount of the drain oil is very small as compared with the return oil, it is sufficient to always cause a flow of the hydraulic oil in the hydraulic oil receiving chamber during the operation of the pump and therefore it is effective not only in cooling the electric motor the flow of the hydraulic oil in the hydraulic oil receiving chamber but also in raising the temperature of the hydraulic oil during the warming-up operation in the cold time such as the winter season.
In order to perform the cooling of the electric motor more effectively, it is effective to add a fan radiator which utilizes the rotation of the electric motor. In this case, the fan radiator is mounted to lie along the end plate of the housing (the metal box) on the electric motor side and the fan radiator is rotated by directly connecting it to the end of the rotary shaft of the electric motor. The return oil and the drain oil flowing into the hydraulic oil receiving chamber are passed through the radiator so that the hydraulic oil within the radiator is air-cooled from the outside of the metal box by an air stream caused by the fan. Note that in this case, it is preferable to add a suitable air stream deflecting structure such as a hood to the fan radiator so that the air stream by the fan flows along the housing surface and it is also preferable to further additionally form heat dissipation fins or grooves in the housing outer surface so as to increase the surface area.
In the hydraulic pump with a built-in electric motor according to the present invention, the housing in the form of the electric motor frame having the electric motor stator internally attached thereto is composed of the metal box of the rectangular parallelepiped external shape so that in the section perpendicular to its axis of rotation, there are four areas of substantially triangular shape at the four corners, respectively, between the external contour of substantially rectangular parallelepiped, preferably square shape and the internal circular space for disposing the electric motor and the pump unit therein and therefore these areas can be utilized for the formation of hydraulic oil receiving chambers.
For instance, assuming that the external dimensions of the square section of the metal box are about 280 mm*280 mm, the inner diameter of the internal space for disposing the electric motor, etc., therein is about 160 mm and the axial length is about 280 mm, the hydraulic oil receiving chambers constituted by the four spaces of substantially triangular sectional shape formed in conformity to the four corner in the peripheral wall of the metal box can be utilized as a reservoir having an inner volume of about 10 liters in total. In the event that a reservoir of a greater volume is required, it is possible to increase the volume by mounting an auxiliary tank to lie on the housing by utilizing the fact that the housing is of the rectangular parallelepiped external shape.
In the hydraulic pump with a built-in electric motor according to the present invention, the housing is rectangular parallelepiped in external shape so that the pump can be installed by selecting either of vertical and horizontal arrangements each selectively using one or the other of the adjoining two sides of the housing as its top surface and the installation posture corresponding to the installation space can be selected. In this case, preferably an opening capable of selectively and detachably mounting therein an air breather and an oil level measuring window is formed in each of the two sides so that as for example, the air breather is mounted in the opening formed in one of the sides serving as the top surface and the oil level measuring window is attached to the opening in the other side in the case of the vertical arrangement, whereas in the case of the horizontal arrangement the mounting of the air breather and the oil level measuring window is reversed with each other. Similarly, when mounting an auxiliary tank, one of these openings is used for communicating the tank with the hydraulic oil receiving chamber and the tank is formed with openings each for selectively mounting the air breather and the oil level measuring window therein in place of the opening used for such communicating purposes.
The foregoing and other objects, features and advantages of the present invention will become more apparent from the following detailed description of its embodiments made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an explanatory diagram which is partly cut away to show, as viewed from the side, the principal construction of a hydraulic pump with a built-in electric motor according to a first embodiment of the present invention;
FIG. 2 is a half-cut explanatory diagram showing, as viewed from the back, the right-side half of the housing of the hydraulic pump with a built-in electric motor shown in FIG. 1;
FIG. 3 is a front view showing the external appearance of the hydraulic pump with a built-in electric motor according to the first embodiment;
FIG. 4 is a left side view showing the external appearance of the hydraulic pump with a built-in electric motor according to the first embodiment;
FIG. 5 is a rear view showing the external appearance of the hydraulic pump with a built-in electric motor according to the first embodiment;
FIG. 6 is a plan view showing the external appearance of the hydraulic pump with a built-in electric motor according to the first embodiment;
FIG. 7 is a left side view of a hydraulic pump with a built-in electric motor according to a modified embodiment additionally including a fan radiator;
FIG. 8 is a circuit diagram showing the construction of the modified embodiment by means of graphical hydraulic circuit symbols;
FIG. 9 is a side view showing an example of a vertically arranged pump with the addition of an auxiliary tank;
FIG. 10 is a front view of the vertically arranged pump with the addition of an auxiliary tank;
FIG. 11 is a front view of the horizontally arranged pump with the addition of an auxiliary tank; and
FIG. 12 is a principal sectional view of another modified embodiment showing another exemplary seal mechanism.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1 to 6 , in a hydraulic pump with a built-in electric motor according to a preferred embodiment of the present invention, a housing is formed by a casted metal box 1 having a substantially square shaped external contour in cross section and end covers 2 and 3 so that a rotor 5 of an electric motor and a rotor 6 of a pump unit are fixedly arranged in tandem fashion along a single-shaft common rotary shaft 4 which is rotatably supported by the end covers within the housing, and a stator 7 of the electric motor is directly attached to the inner surface of the metal box 1 at the position corresponding to the rotor 5 ; also, the rotor 6 is enclosed by a case 8 of the pump unit which is attached to the front-side end cover 2 so as to be received within the housing thereby accommodating the electric motor and the pump unit within the common housing.
The metal box 1 is a box member having a cubic external shape with its interior forming a cylindrical space, thus forming the peripheral wall of the housing as an electric motor frame having the electric motor stator 7 attached to its inner surface. The electric motor-side space in the metal box 1 is an atmospheric space separated from the space in the case 8 of the pump unit by an oil seal 9 which is an example of a seal mechanism mounted on the rotary shaft 4 in the tail end portion of the pump unit case 8 .
As shown in FIG. 2, four hydraulic oil receiving chambers 10 a to 10 d are in the peripheral wall of the metal box 1 , and connected to the hydraulic oil receiving chambers are passages for receiving a return oil from the outside through the end cover 2 and passages leading to the suction port and the drain port of the pump unit. In the meal box 1 forming the housing of the hydraulic pump with a built-in electric motor according to the present embodiment, as viewed in the cross section perpendicular to the rotary shaft 4 , there are four areas of substantially triangular shape at the four corners between the external contour of substantially square shape and the internal cylindrical space, and these area are utilized as the areas for forming the hydraulic oil receiving chambers 10 a to 10 d.
Note that in the present embodiment the external dimensions of the square section of the metal box 1 are about 280 mm×280 mm, the inner diameter and axial length of its internal cylindrical space are respectively about 160 mm and about 280 mm, and the four hydraulic oil receiving chambers 10 a to 10 d having substantially triangular sectional shape and formed at the four corners in the peripheral wall of the metal box 1 can be utilized as a reservoir having an inner volume of about 10 liters in total.
The end cover 2 on the housing front side is a pump cover fastened to the pump case 8 by flange joining with bolts and, as shown in FIG. 6, this pump cover is provided with a tank port 11 (on the left side as viewed from the front), a drain port 12 (similarly on the right side) on the housing top surface side and a discharge port 13 (FIG. 3) on the housing front side for external connection purposes. The tank port 11 and the internal drain port are communicated with the hydraulic oil receiving chamber 10 b on the top left side, and the suction port of the pump unit is communicated with the hydraulic oil receiving chamber 10 a on the top right side. Also, arranged on the front side of the pump cover 2 are a delivery rate adjusting screw 14 , a pressure regulating screw 15 and a pressure gauge 16 for the pump unit with the gauge 16 having its display face turned upward. It is to be noted that mounted about the center of the housing left side face is a terminal block case 17 for the electric wirings provided mainly for the electric motor.
The end cover 2 is provided with internal passages (not shown) for respectively connecting the upper and lower hydraulic oil receiving chambers 10 b , 10 c and 10 a , 10 d of the metal box 1 on the left and right sides, whereas the end cover 3 on the housing back side is provided with an internal passage for internally connecting the lower left and right hydraulic oil receiving chambers 10 c and 10 d of the metal box 1 with each other. By virtue of the connection of the respective hydraulic oil receiving chambers by the internal passages of the end covers 2 and 3 , a continuous path is formed so that the return oil directed to the tank port 11 from the outside and the internal drain oil of the pump unit are sequentially passed through the respective hydraulic oil receiving chambers so as to reach the suction port of the pump unit. In the illustrated embodiment, this path is in the order of the hydraulic i receiving chambers 10 b , 10 c , 10 d and 10 a.
As will be best seen from FIG. 4, an opening concurrently serving as an oil filling port is formed in the housing top so as to communicate with the hydraulic oil receiving chamber 10 a through the peripheral wall of the housing and an air breather 18 is removably mounted in this opening in the illustrated condition. Similarly, another opening concurrently serving as an oil filling port is also formed in the left side face of the housing at the position corresponding to the previous opening so as to communicate with the hydraulic oil receiving chamber 10 b through the housing peripheral wall, and an oil level measuring window 19 is removably mounted in this opening in the illustrated condition. These openings respectively formed in the housing top and left side face are concurrent openings in which the air breather 18 and the oil level measuring window 19 can be changeably mounted, and also the housing top opening having the air breather 18 mounted therein in the illustrated condition can be used as a through hole which provides a communication between an auxiliary tank ( 20 : FIGS. 10 and 11) and the hydraulic oil receiving chamber 10 a when the auxiliary tank is additionally installed as will be described later.
In the hydraulic pump with a built-in electric motor according to the present embodiment, the housing constitutes the electric motor frame and the electric motor portion within the housing is in the dry space separated from the internal space of the pump unit by the oil seal 9 , with the result that the return oil arriving the tank port 11 and the drain oil flow by passing sequentially through the respective hydraulic oil receiving chambers arranged in the housing peripheral wall independently of the dry space and are sucked into the suction port of the pump unit, thereby causing the housing itself to serve as a liquid-cooling jacket for cooling the electric motor. While the heat generation of the electric motor is mainly produced from the windings of the stator 7 , the stator is attached to the inner surface of the metal box 1 forming the housing so that the heat generated from the stator windings is directly transmitted by heat conduction to the metal box 1 and the generated heat is absorbed by heat conduction by the hydraulic oil in the respective hydraulic oil receiving chambers through the metal box 1 in addition to the heat dissipation effect of the outer surface of the metal box itself, thereby making it possible to effectively cool the electric motor. Also, in this case, the hydraulic oil does not contact with the rotating parts of the electric motor so that there is no danger of the hydraulic oil being contaminated with metal foreign particles produced from the rotating electric motor and also there is no danger of causing any electric trouble e.g., a short-circuiting in the electric motor even in the case where the hydraulic oil contains water or the hydraulic oil itself is an aqueous hydraulic oil.
When the rotor 6 of the pump unit is driven by the rotation of the rotor 5 of the electric motor, the pump unit discharges the hydraulic oil sucked from the hydraulic oil receiving chambers as a pressurized oil from the discharge port 13 and the pressurized oil is returned as a return oil to the hydraulic oil receiving chambers through the tank port 11 after it has performed a work in an external load actuator (not shown) connected to the pump. The drain oil from the pump unit is also introduced into the hydraulic oil receiving chambers so that although the amount of the drain oil is very small as compared with the return oil, it is sufficient to always cause a flow of the hydraulic oil in the hydraulic oil receiving chambers during the operation of the pump and therefore not only the cooling of the electric motor by the flow of the hydraulic oil in the hydraulic oil receiving chambers is made effective but also it is effective raising the oil temperature of the hydraulic oil during, for example, the warming-up operation a cold time such as the winter season.
While a plurality of fins or grooves 21 are formed in the left and right side faces of the metal box 1 constituting the housing outer peripheral surface so as to increase the heat dissipation area, a fan radiator 22 utilizing the rotation of the electric motor can be added as shown in FIG. 7 so as to perform the cooling of the electric motor more effectively. In this case, it is only necessary to replace the motor-side end plate 3 of the housing (the metal box) with a radiator mounting end plate 23 of a special specification and the fan radiator 22 is assembled to lie along the end plate 23 so as to rotate a fan 24 of the radiator by directly connecting it to the end of the rotary shaft 4 of the electric motor by a socket joint system, for example. The end plate 23 contains therein passages for communication between the respective hydraulic oil receiving chambers and the interior of the radiator so that the interconnection between the left and right hydraulic oil receiving chambers 10 a , 10 b and 10 c , 10 d , respectively, are effected within the radiator in place of the end plate 3 . The return oil and the drain oil flowing into the hydraulic oil receiving chambers pass through the interior of the radiator so that the hydraulic oil within the radiator is air-cooled by an air stream caused by the fan 24 . A hood 25 is also mounted on the fan radiator so as to deflect the generated air stream to flow along the housing outer peripheral surface from the back side to the front side and this makes a more effective cooling possible. The construction of this modified embodiment is as shown by the hydraulic circuit diagram of FIG. 8 and the corresponding component elements are designated by the same reference numerals.
As mentioned previously, in the present embodiment the metal box 1 itself forms the hydraulic oil receiving chambers of about 10 liters in volume; however, in the event that a reservoir of a greater volume is required in the pump utilizing the same housing, the fact that the external shape of the housing is rectangular parallelepiped is utilized so that an auxiliary tank 20 is mounted by placing it on the housing as shown in FIGS. 9 to 11 to increase the volume of the reservoir. Formed in the top of the auxiliary tank 20 are openings of the same specifications as the openings respectively formed in the top and left side faces of the metal box 1 so as to concurrently serve as oil filling ports and selectively mount therein the air breather 18 and the oil level measuring window 19 , and also formed through the bottom surface of the auxiliary tank is an opening which is connected with the opening in the top of the metal box 1 to form a communicating opening when the auxiliary tank is placed on the top of the metal box 1 .
FIGS. 9 and 10 show an example of a vertically arranged posture in which the hydraulic pump shown in FIGS. 1 to 6 is used in its posture as such and the auxiliary tank 20 is arranged to lie on the top of the metal box 1 ; thus, the auxiliary tank 20 is communicated with the interior of the hydraulic oil receiving chamber 10 a through the opening in the top of the metal box 1 from which the air breather 18 has been removed and the air breather 18 which had been on the top of the metal box 1 is now mounted in the similar opening (serving concurrently as an oil filling port) in the top of the auxiliary tank 20 . In the case of the present embodiment, the auxiliary tank 20 has a volume of about 10 liters thereby realizing a reservoir volume of about 20 liters in total.
In the hydraulic pump with a built-in electric motor according to the present invention,its housing has a rectangular parallelepiped external shape so that it is possible to install the pump by selectively using a vertically installed arrangement and a horizontally installed arrangement each of which selectively utilizes as its top one or the other of the adjoining two sides of the housing and the desired installation posture can be selected in conformity with the installation space. Of these arrangements, an example of the vertically installed arrangement is as shown in FIGS. 9 and 10, and an example of the horizontally installed arrangement is as shown in FIG. 11 .
In the case of the horizontally installed arrangement, the end plates 2 and 3 (or the end plate 23 ) are left in their positions as such and the metal box 1 alone is tilted 90 degrees about the rotary shaft 4 to rearrange such that the previous top is now the right side face and the previous left side face is now the top. Thus, the opening having the air breather 18 mounted therein in FIGS. 1 to 6 is now the opening for connection with the auxiliary tank 20 and the air breather 18 is mounted in the opening having previously mounted therein the oil level measuring window 19 (the opening concurrently serving as the oil filling port); also, the oil level measuring window 19 is mounted in the top opening of the auxiliary tank 20 in which the air breather is mounted in the case of the vertically installed arrangement.
FIG. 12 shows another example of the seal mechanism. This modified embodiment uses a separate shaft construction in which a rotary shaft 4 a of an electric motor and a rotor rotating shaft 4 b of a pump unit are separated from each other, and attached to the forward end of the electric motor rotary shaft 4 a is a coupling socket 26 having attached to the inner peripheral surface thereof a plurality of circumferentially split magnet pieces 27 a.
An external bearing 28 rotatably supports the forward end of the coupling socket 26 at the end of a pump case 8 and an internal bearing 29 rotatably supports the rotor rotating shaft 4 b . The rotor rotating shaft 4 b of the pump unit is inserted in the socket 26 through a diametrical gap and attached to the end of the shaft 4 b are a plurality of magnet pieces 27 b which correspond to but differ in number from the magnet pieces 27 a . The magnet pieces 27 a and 27 b constitute a magnetic coupling which transmits a rotary torque by magnetic attractive force between the magnet pieces 27 a and 27 b through an annular gap so that the rotor rotating shaft 4 b of the pump unit is driven into rotation by the rotary shaft 4 a of the electric motor.
The end of the rotor rotating shaft 4 b projects to the outside of the pump case 8 and its outer side is covered in an oil-tight manner by a seal cap 30 . The seal cap 30 is made from a nonmagnetic material such as stainless steel, copper alloy or plastic material which is formed into a bottomed cylindrical shape with an externally extended flange portion at its opening edge and it has a thickness which seals against the leakage of the oil with a sufficient mechanical strength without any loss of the magnetic attractive force between the magnet pieces 27 a and 27 b . The opening edge of the seal cap 30 is sealingly attached to the end face of the pump case 8 so that the seal cap 30 is a nonrotating part with its peripheral wall portion positioned in the annular gap between the magnet pieces 27 a and 27 b , and the external and internal magnet pieces 27 a and 27 b are in a relatively rotatable relation with each other.
It is to be noted that the foregoing embodiments and modifications are only for the purpose of showing some typical embodiments of the present invention and it should be understood that any other modifications which are obvious to those skilled in the art belong to the technical scope of the present invention. For instance, it is of course possible to make such modifications including one in which a return filter unit 32 is mounted on the side face of the metal box 1 as shown in FIGS. 9 to 11 , another in which various oil pressure control valve, pressure regulating valve, selector valve, manifolds, etc., are stacked up and arranged on the outer surface of the pump cover by utilizing the fact that the pump unit is collectively arranged on the end cover 2 side, and still another in which a delivery rate sensor required for electrically controlling the hydraulic pump, such as, a potentiometer for detecting the tilt angle of a swash plate in the case of the pump unit composed of an axial piston pump assembly, a pressure sensor for producing an electric signal indicative of the delivery pressure or the like is incorporated in the pump cover.
As described hereinabove, by virtue of the fact that in the hydraulic pump with a built-in electric motor according to the present invention the housing forms the electric motor frame, that the electric motor portion in the housing is in the dry space separated from the internal space of the pump unit by the seal mechanism and that the hydraulic oil sucked into the pump unit flows through the hydraulic oil receiving chambers arranged in the housing peripheral wall independently of the dry space and so it does not contact with the rotating parts of the electric motor,there is no danger of any metal foreign particles produced by the rotating electric motor entering the hydraulic oil and also there is no danger of electric troubles being caused within the electric motor due to the hydraulic oil containing water or an aqueous hydraulic oil constituting the hydraulic oil itself. Moreover, the housing itself forms a liquid-cooling jacket for cooling the elect motor with the result that the heat generated from the electric motor is absorbed through heat conduction by the hydraulic oil in the hydraulic oil receiving chambers through the metal box in addition to the heat dissipation effect of the outer surface of the metal box itself and therefore the electric motor can be effectively cooled by this fact coupled with the flowing of the hydraulic oil in the hydraulic oil receiving chambers.
In addition, a fan radiator utilizing the rotation of the electric motor can be added so as to cool the electric motor more effectively, and also a still increased cooling effect can be attained by causing the return oil and the drain oil flowing into the hydraulic oil receiving chambers to pass through the radiator so as to air-cool the hydraulic oil in the radiator from the outside of the metal box by an air stream caused by the fan.
Further, in the hydraulic pump with a built-in electric motor according to the present invention the housing in the form of the electric motor frame having the electric motor stator internally attached thereto is composed of the metal box of the rectangular parallelepiped external shape so that in the section perpendicular to its axis of rotation, there are four areas of substantially triangular shape at the four corners between the external contour of substantially rectangular parallelepiped shape, preferably square shape and the circular space for disposing the electric motor and the pump unit therein and thus these areas can be used for its hydraulic oil receiving chambers so as to provide a hydraulic pump with a built-in electric motor having a compact external shape and including a reservoir; moreover, where a reservoir of a greater volume is required, it is possible to increase the volume by mounting an auxiliary tank so as to lie on the housing by utilizing the fact that the external shape of the housing is rectangular parallelepiped, and in this case there is also the advantage that the installation can be effected by making a selection between a horizontally installed arrangement and a vertically installed arrangement each utilizing one or the other of the adjoining two faces of the housing of the rectangular parallelepiped external shape as its top face, and the installation posture can be selected in accordance with the installation space. | A hydraulic pump with a built-in electric motor wherein an electric motor and a pump unit are arranged in tandem fashion and accommodated within a common housing. In this pump, the housing is in the form of a metal box having a rectangular parallelepiped external shape and forms an electric motor frame fixedly accommodating a stator of the electric motor therein. A space in the metal box on the electric motor side is separated as a dry space from an internal space of said pump unit by a seal mechanism. At least one hydraulic oil receiving chamber is formed in a peripheral wall of the metal box, and the hydraulic oil receiving chamber is communicated with a passage for receiving return oil externally and another passage communicating with a suction port of the pump unit. The pump is capable of simultaneously achieving the cooling of a built-in electric motor and the prevention of contamination of hydraulic oil due to the rotation of the electric motor, without any possibility of electrical troubles with the built-in electric motor even if a water-containing hydraulic oil or aqueous hydraulic oil is fed and discharged. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a sheet, especially for use in the building sector, with a planar sheet body.
2. Description of Related Art
Sheeting and film products in the most varied applications must be fastened to undersurfaces. In the building sector, this relates, for example, to sheets which are used for sealing (airtightness and watertightness) of a building shell (for example, sealing sheets, facade sheets, air and vapor barriers, underlay sheets). If there is wood or wood material in the undersurface, fastening is generally performed mechanically, for example, by tacking, nailing, screwing and/or shooting. The latter three methods are also used in undersurfaces of plasterboard, concrete, plaster and rock. Here, the sheets are perforated such that the sealing function at the perforation site is no longer maintained.
At present, the sealing function is manually restored in a complex manner by subsequent sealing by means of sealing masses, sealing strips or adhesive tapes. One special case is the sealing of nails through counter laths. This is achieved by interposed foam strips (nail sealing strips).
The aforementioned known methods constitute a major additional effort and moreover entail the risk that undetected perforations and damage will continue to cause leaks.
SUMMARY OF THE INVENTION
Therefore, the object of this invention is to avoid the disadvantages of the prior art.
In one embodiment of this invention, it is provided that the sheet body has at least one elastic layer as a sealing layer. Here, the material of the layer has an elasticity and a restoring force such that, when the elastic layer is penetrated by a fastener, the material of the elastic layer surrounding the fastener encompasses the fastener and seals in the region of the fastener.
To achieve the aforementioned object, in one alternative embodiment, it is provided in accordance with the invention that the sheet body contains a material which, in the case of a perforation of the sheet body, emerges or swells automatically out of the sheet body to close and/or seal the perforation opening.
Ultimately, this invention is a self-sealing or self-healing sheet which automatically recloses perforations or perforation openings. Here, the term “perforation” means openings of any type which arise when the sheet is fastened to the undersurface or which are due to damage. This includes perforation openings which arise during fastening, such as unintentional tears or other damage to the sheet.
Otherwise, this invention relates fundamentally to sheeting of any type as well as film products, where the sheet body is made of plastic.
The basic idea of an embodiment of the invention lies in that the elasticity and restoring properties of the material of at least one elastic layer of the sheet body is used in order either to eliminate or close minor damage of the sheet body itself or to seal on the fastener which is penetrating the sheet by corresponding elastic contact itself. In another embodiment, the approach involves the body of the sheet contains a closing or sealing material which in the unperforated state of the sheet remains in the sheet body and is inactive. When the sheet body is perforated/damaged and especially when water and/or air enters, automatic activity of the material arises causing the material to emerge from the sheet body at the perforation site, i.e., runs out and/or swells out, and then, contributes to closing the perforation opening, and in the best case, closes it completely.
In all alternatives, a perforation opening can mean a complete opening or also an annular opening when there is, for example, a nail or fastener in the perforation.
The effect in accordance with the invention can be achieved by the following different principles:
1. Use of Adhesive-containing Microcapsules in the Sheet.
When a fastener penetrates into the sheet, the capsules are destroyed, the adhesive emerges and seals the site. In this case, different alternatives are possible:
a) The microcapsules contain a single-component adhesive. It sets physically or chemically. Preferably, reaction partners in chemical setting are (penetrating) water, oxygen and/or reactive groups of the surrounding matrix material.
b) The microcapsules contain a binary adhesive. The reaction partners react with one another only after release.
c) The contents of the microcapsules react with the material (for example, steel) of the fastener (for example, nails) and form a sealing mass.
d) Two different types of microcapsules are used which contain different reaction partners (for example, resin and curing agent). When the fastener is inserted both types of capsules are destroyed, the reaction partners emerge, react with one another and seal.
e) Use of split microcapsules, for example, a core with a first material (resin) and a shell with a second material (curing agent).
2. Use of Flowing Sealants in Microcapsules.
When the fasteners are inserted, the capsules are destroyed, the sealant flows out and seals the site. Depending on the sealant the following processes can arise:
a) The solvent evaporates, the sealing mass becomes hard.
b) A dispersion is present, the liquid evaporating. Then, the viscosity of the sealing mass rises.
c) There is a swollen and thus easily flowable rubber. The swelling agent evaporates or is taken up and drawn off by the underlay sheet material.
3. Swelling Material in the Microcapsules.
When water enters, the material emerging from the capsules swells up and seals. In doing so, the diameter of the original perforation opening is narrowed, and in the best case, completely closed.
4. Incorporation of at Least One Flowing (Intermediate) Layer.
When the sheet is perforated/damaged the flowing resin emerges from the inner intermediate layer and flows together at the corresponding site and seals.
5. Incorporation of at Least One Swelling (Intermediate) Layer.
When the sheet is perforated/damaged, water enters and leads to swelling of the inner intermediate layer, and thus, to sealing. In doing so, the effect is the same as in alternative number 3.
6. Use of an Elastic Layer as Sealing Layer.
When a fastener (for example, a nail) is inserted, a layer of an elastic layer material surrounds the fastener, presses radially against it and seals in the region of the fastener. In conjunction with the elastic layer as the sealing layer, there are, among others, the following possibilities:
a) The sheet is formed of a multilayer composite of individual function layers. The sealing layer is made preferably of an elastomer. In this connection, both conventional and also thermoplastic elastomers are possible for use as the layer material. During elongation or under pressure, elastomers briefly change their shape, and after stress, return to their original shape. This effect is used for permanent sealing between the sealing layer and the perforation medium.
b) The sheet as the sealing layer has at least one layer of a closed-cell elastic foam. Here, the restoring force of the elastic material is also used. It is even possible to combine several function layers in only one single layer.
c) A layer of a viscoelastic gel is used as the sealing layer.
It is pointed out, first of all, that the aforementioned alternatives can each be used by itself or also in any combination with one another. Thus, for example, microcapsules according to alternative 1 can be provided in conjunction with a flowing intermediate layer according to alternative 4 and/or a supplementary elastic layer according to alternative 6. However, this is only one example of the possible layer structures.
In conjunction with the alternatives of an elastic layer as a sealing layer in accordance with the invention as mentioned under 6a) the following features by themselves or in any combination acquire importance:
There is a multilayer composite of the sealing layer and at least one other layer, especially of at least one membrane and/or at least one mechanical protective layer. The membrane has the function of a water vapor-permeable film or foam film, made preferably of thermoplastic elastomers such as thermoplastic polyurethanes (TPE-U) or thermoplastic polyester elastomer (TPE-E), thermoplastic polymers, such as, for example, polypropylene (PP), cellophane (cellulose film) or a water vapor-permeable coating, for example, based on polyurethane or acrylate or another water vapor-permeable layer of another type. The layer thickness of the membrane is between 10 μm and 1000 μm, any individual value and any intermediate interval being fundamentally possible even if this is not specifically mentioned. The layer composite, i.e., the sheet, as such, ensures watertightness and is made such that it withstands a hydrostatic water pressure of greater than 100 mm, preferably greater than 200 mm, furthermore preferably, greater than 1000 mm and even more preferably greater than 1500 mm. Here, any individual value within the indicated ranges is also possible. The sealing layer is designed for sealing to the perforation medium which is, for example, a nail. The sealing layer made preferably of elastic materials, such a films, foams, nonwovens, knits or woven fabrics. The material of the sealing layer is especially conventional and thermoplastic elastomers.
Among conventional elastomers are all types of synthetic and natural rubbers which can be irreversibly chemically crosslinked. The crosslinking takes place, for example, by vulcanization with sulfur, by means of peroxides or metal oxides. Examples for conventional elastomers are natural rubber (NR), acrylonitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), chloroprene rubber (CR), butadiene rubber (BR) and ethylene-propylene-diene rubber (EPDM).
Thermoplastic elastomers (TPE) are elastomers which are reversibly chemically crosslinked. At room temperature they show behavior similar to conventional elastomers. At elevated temperatures the physical crosslinking is cancelled so that these elastomers show a typical processing behavior of thermoplastics. Thermoplastic elastomers include elastomer alloys/polymer blends having polyolefins and uncrosslinked or partially crosslinked types of rubber (TPE-V, TPE-O) and also multiblock polymers (TPE-E, TPE-A, TPE-U, TPE-S).
Materials of the sealing layer are especially thermoplastic polymers such as PE, PP, PET, EVA, PA in crosslinked or uncrosslinked form, thermoplastic elastomers (TPE) such as for example, TPE-U, TPE-S, TPE-A, TPE-O or TPE-E, elastomers such as EPDM or natural rubber. The weight per unit of area of the sealing layer is between 10 and 3000 g/m 2 , preferably between 50 and 500 g/m 2 , any individual value and any intermediate interval within the indicated range boundaries being possible. The layer thickness of the sealing layer is between 10 μm and 3000 μm, any individual value and any intermediate interval within the range boundaries being possible. The layer thickness is conventionally greater than 50 μm, preferably greater than 150 μm, and more preferably is between 250 to 800 μm. The modulus of elasticity of the material of the sealing layer is between 0.001 and 20 kN/mm 2 , preferably between 0.005 and 1 kN/mm 2 , in this case, any individual value and any intermediate interval within the range boundaries also being possible. The restoring force of the material of the sealing layer is in the range between 1 and 2000 N/5 cm, preferably, between 20 and 500 N/5 cm, here, any individual value within the range boundaries being possible. Depending on the material and layer thickness, the elastomer layer can, fundamentally be open to diffusion or closed to diffusion. Thermoplastic elastomers such as representatives of the elastomer types TPE-E, TPE-A and TPE-U are already open to diffusion in films of a certain thickness, i.e., they have a watertight but water-vapor permeable nature. In other elastomer types such as conventional elastomers and some representatives of thermoplastic elastomers (TPE-O, TPE-V and TPE-S) or in the case of insufficient vapor diffusion, for example, due to the layer thickness, the diffusion-open property can be ensured by an additional planar perforation. This can take place in particular by mechanical or electrostatic perforation, by heat perforation, laser perforation and/or water jet perforation and/or punching of the film. The mechanical perforation or punching takes place for example, by needle materials, roll materials, plate or sheet materials and can thus have different hole shapes. The sealing layer or the material of the sealing layer has a water vapor permeability (WDD) between 10 and 10,000 g/m 2 d. Here, any individual value and any intermediate interval within the range boundaries are also possible. The material of the sealing layer can by nature have an open-pore character (intrinsic) and can be made, for example, as a nonwoven, woven fabric or knit. Alternatively, an open surface portion can be generated by punching or needle perforation. The portion of the open surface in the total area can be between 2% and 85%, preferably, between 10% and 60%. In this case, any individual value and any intermediate interval within the range boundaries are also possible. It is decisive that the diameter of the hole of the perforation or the mesh width of the woven fabric/knit/nonwoven be below the diameter of the perforation medium. The diameter of the hole of the perforation or the mesh width should be between 10 mm and 4 mm, preferably, less than 2 mm, and especially, in the range from 0.1 to 2.0 mm, here also, any individual value and any intermediate interval within the range boundaries being possible. In order to achieve an optimum sealing effect, the diameter of the holes of the perforations should, preferably, be less than 90% of the diameter of the fastener, preferably less than 75%, and more preferably, in the range less than 50%. In order to guarantee watertightness in an elastic layer with a large-pore perforation, additional backing/coating with a diffusion-open layer can be done. Other backings or coatings, for example, with layers of nonwovens, can contribute to planar stability of shape of the film. Furthermore, there is at least one mechanical protective layer which is designed mainly to protect the membrane against mechanical damage, such as for example, by wood splinters during perforation by nailing or screwing. Preferably, there are two protective layers which are located on the outer side, and thus, also the elastic sealing layer is protected against unnecessary mechanical damage. The mechanical protective layer can be made of nonwoven fabrics, woven fabrics, knits, films and/or open-cell or closed-cell foamed films. Materials for the mechanical protective layer can be thermoplastic polymers such as, for example, PE, PP, PET, EVA, PA in crosslinked or uncrosslinked form, thermoplastic elastomers such as for example, TPE-U, TPE-S, TPE-A, TPE-O or TPE-E, elastomers such as ethylene propylene diene monomer (EPDM) or natural rubber, but also natural or semi-synthetic materials, such as, for example, cotton, hemp, jute or viscose. Materials as blends of the aforementioned materials are also possible. The density of the material of the protective layer is between 1 and 2200 kg/m 3 , preferably between 5 and 500 kg/m 3 , any individual value and any intermediate interval within the range boundaries also being possible here. The layer thickness of the mechanical protective layer is between 30 μm and 3000 μm, any individual value and any intermediate interval within the range boundaries also being possible here. The weight per unit of area of the mechanical protective layer is between 10 and 1000 g/m 2 , preferably between 50 and 500 g/m 2 , with any individual value and any intermediate interval within the range boundaries also being possible here. It goes without saying that the protective layer must be water vapor-permeable when the sheet, therefore the composite, is used as a water vapor-permeable underlay sheet. In this case, the water vapor permeability (WDD) should be between 10 and 3000 g/m 2 d, preferably, between 100 to 1500 g/m 2 d, with any individual value and any intermediate interval within the range boundaries being possible. The individual layers of the multilayer composite, which is preferably provided in the sequence protective layer—membrane—sealing layer—protective layer, are joined by bonding, cement backing, extrusion coating or dispersion coating. Combinations of the methods are also easily possible. Thus, for example, adjacent layers can first be connected to one another by a certain method, and then, other layers can be connected to the pertinent prelaminate via another method. The technique of joining the layers must be matched to the application. If the sheet is being used as a water vapor-permeable composite, the joining of the layers should not, at least largely should not, adversely affect the water vapor permeability. The water vapor permeability of the multilayer composite should be between 10 and 3000 g/m 2 d, preferably, between 100 to 1500 g/m 2 d, with any individual value and any intermediate interval within the range boundaries being possible.
In the alternative named under 6b), the sealing layer is made in the form of a foam layer of a closed-cell elastic foam. The following features by themselves or in combination can also be implemented in conjunction with other aforementioned features:
The foam layer can be part of a multilayer composite, as has been described above. Reference is made expressly hereto. However, it is also fundamentally possible for several function layers to be combined in the foam layer. Thus, for example, a foamed TPE-U or TPE-E or even other layers can at the same time assume the function of the mechanical protective layer and/or the membrane and/or one or even several sealing layers. The material of the sealing layer is preferably a polymer foam layer which forms the seal to the fastener or the perforation means when the sheet is perforated/damaged. The polymer foam can consist of thermoplastic elastomers or blends, preferably of water vapor-permeable TPE-U or TPE-E which are foamed with chemical or physical propellants or by gases such as air, nitrogen, and/or carbon dioxide. The density of the material of the foam layer is between 1 and 2200 kg/m 3 , preferably between 5 and 500 kg/m 3 , with any individual value and any intermediate interval within the range boundaries being possible. The layer thickness of the material of the sealing layer is between 30 μm and 5000 μm, any individual value and any intermediate interval within the range boundaries being possible. The weight per unit of area of the foam layer is between 10 and 1000 g/m 2 , preferably between 50 and 500 g/m 2 , with any individual value and any intermediate interval within the range boundaries being possible. The water vapor permeability (WDD) is between 10 and 3000 g/m 2 d, preferably between 100 to 1500 g/m 2 d, with any individual value within the range boundaries being possible. The modulus of elasticity of the material of the sealing layer is between 0.01 and 20 kN/mm 2 , preferably between 0.05 and 1 kN/mm 2 , here any individual value and any intermediate interval within the range boundaries also being possible. In the implementation of a foamed elastomer layer, a perforation as mentioned above is otherwise possible. Here, the cell or pore diameter of the foam material should be smaller than the expected hole diameter due to the fastener. Preferably, alternatively, open-pore elastomer foam can be used, and thus, an additional perforation can be omitted.
In the embodiment described under 6c) the use of a viscoelastic gel as an elastic layer or sealing layer is provided. When the sheet is perforated or damaged, the flexible and highly elastic gel is displaced into the surface. In contrast to purely viscous media as described in the embodiment according to number 2, or a purely elastic layer, i.e., the use of an ideal elastomer, viscoelastic materials cover the transition region in which the properties of the two materials apply.
Even if an intermediate layer of a viscoelastic gel is not an ideal elastomer, it is still subsumed under the term “elastic layer”.
Due to their stability of shape, viscoelastic materials, such as gels, try to return to the initial shape and compared to pure elastomers thus provide for an additional flowing seal to the fastener or the perforation means. In this way, the viscoelastic gel has self-adhesive properties, and thus, provides for a further bond to the fastener/perforation means.
In conjunction with the use of a sealing layer of a viscoelastic material, the following features for themselves or in any combination with the aforementioned features of the other alternatives can also be used with one another:
Fundamentally, the sealing layer of a viscoelastic gel can be integrated in a multilayer composite according to alternative 6a), the layer of elastic material, as such, then being replaced by the gel layer. Reference is made expressly to the above described features. The viscoelastic gel for the sealing layer can also be binary or single-component polyurethane systems, silicone gels or PMMA-based gels. Instead of the aforementioned layer composites, the viscoelastic intermediate layer can also be combined with one or more (carrier) layers in order to increase stability. The carrier layers can be films, nonwovens, woven fabric, knits of materials such as thermoplastic polymers, for example, PE, PP, PES, EVA or the like. The gel film can be applied to a carrier, for example, by spraying, doctoring or rolling. The degree of hardness of the viscoelastic gel is in the range of Shore A 15 to Shore A 30, any individual value and any intermediate interval within the range boundaries being possible. The application weight of viscoelastic gel in the sealing layer is between 50 and 1000 g/m 2 , preferably, in the range between 100 and 400 g/m 2 , with any individual value and any intermediate interval within the interval limits being possible. To reduce the weight of the gel layer, fillers whose weight is less than that of the gel, such as, for example, hollow microspheres, can be used, or loading with air or other gases can be performed. The water vapor permeability of the gel layer, when the layer composite is to be completely permeable to water vapor, is between 10 and 3000 g/m 2 d, preferably, between 100 and 1500 g/m 2 d, any individual value and any intermediate interval within the range boundaries being possible. Fundamentally, the self-adhesive nature of the gel can also be used to cement the film sheets among other another. Thus, in the region of the edge of the sheet above the gel layer, the outer protective/carrier layer can be shortened on the side of the longitudinal edge so that a longitudinally running outer edge strip of the gel layer arises which is preferably covered by means of a protective film, for example, in the form of a polyurethane film or a polyurethane-enamel system. The protective film is removed for installation so that, on the edge side, the self-adhesive surface appears over which the following sheet can be cemented.
In this connection, it is fundamentally possible, on the opposing longitudinal edge, on the same or the other side of the sheet, to provide a corresponding formation in which the gel layer except for the protective film is likewise exposed on the edge side.
In all embodiments of the alternatives according to number 6, preferably, the following is provided by itself or in combination with one another or other of the aforementioned features:
The characteristic for the amount of sealing (MDA) of the sealing layer computed from the product of the restoring force F r [N/5 cm] and the thickness of the sealing layer d [μm] according to the following formula
MDA=F r ×D
is between 3 N/5 cm×μm and 10000 kN/5 cm×μm, and preferably, between 10 N/5 cm×μm and 5000 kN/5 cm×μm and especially between 50 N/5 cm×μm to 2000 N/5 cm×μm, with any individual value within the indicated value range being possible.
Preferably, the restoring force of the sealing layer should be in the range between 0.1 and 2000 N/5 cm, preferably, between 20 and 500 N/5 cm, with any individual value and any intermediate interval within the range boundaries being possible.
Furthermore, it is pointed out that, especially for alternatives 1 to 3, it is also possible to use corresponding unencapsulated material particles instead of microcapsules. In this connection, it should then be provided that these particles are embedded into the matrix of the sheet body, therefore are not freely accessible on the outside. Accessibility, and thus, the possibility of a reaction arise only in the case of a perforation. In this case, then, the reaction partners can be air or water. Therefore, it is also important that the microparticles, which preferably are made of a solid material in the unperforated state of the sheet, are completely incorporated into the sheet matrix and are not accessible on the outside.
In conjunction with the layers according to alternatives 4 and 5, it is pointed out that it is fundamentally possible, according to the execution of the microcapsules with different reaction partners, to provide two inner reaction layers which are then separated from one another via a separating layer. In the case of a perforation or damage to the sheet, the reaction partners of the individual layers, which have been separated beforehand via the separating layer, become joined to one another so that the above described reaction can occur.
Otherwise, it goes without saying that the above described sealing function layers, regardless of whether they are made as an intermediate layer or contain microcapsules or microparticles, can be combined with any other layers. The sheet body can therefore be easily built up from a multilayer material.
The chemical basis of the microencapsulated adhesives (core materials) is, for example, acrylates, polyesters, epoxy resins or polyurethanes.
A dedicated choice of the wall material, the core material and the method for microencapsulation can influence the desired properties of the microcapsules, such as the capsule diameter and wall thickness. Wall material and wall thickness are important characteristics for the mechanical, thermal and chemical stability. They also determine whether the core material is continuously or preferably suddenly released and dictate the storage stability of the material.
Thus, depending on the encapsulation technique which has been used, capsule diameters between 0.1 and 300 μm, preferably between 1 to 100 μm and especially between 10 and 50 μm can be used. Fundamentally, typical wall materials, such as, for example, amino resins, polyamides, polyurethanes, polyureas, polyacrylonitrile or gelatins are available.
The method used for producing sheets, such as extrusion, casting, coating or fiber spinning must be matched to the size and the stability of the microcapsules or particles, so that a premature release of the core material by excess mechanical, thermal or chemical stress in the sheet production process is avoided.
Furthermore, it must be considered that the concentration of the capsules (average number of capsules per unit of area) is chosen such that, in the case of diffusion-open sheets, the diffusion capacity of the sheet in the required magnitude is maintained.
Ageing of the sheet under the conditions which correspond to the application should not lead to damaging of the wall material of the capsules, and thus, to a planar distribution of the adhesive and to an associated general adverse effect on the diffusion capacity of the sheet.
Locally destroying the capsules and achieving the accessibility of the embedded parts or layers should only take place by relatively high mechanical pressure, for example, by perforation and damage as a result of nailing-through.
The adhesive which is released from the damaged capsules after the curing process establishes a water-impermeable bond to the perforation medium.
Swellable materials are preferably polymers of acrylic acid/acrylic salts (superabsorbers) and/or bentonites. However, polyurethanes, polyether esters, polyether block amides, polyacrylic acid esters, ionomers and/or polyamides with corresponding water absorption are also suitable.
The water absorption of the swellable materials at 23° C. in water when using superabsorbers and bentonites is between 10-1000 times. The water absorption for other polymers, especially for intermediate layers, is between 1 and 30%, preferably, between 3 and 15%, and more preferably, between 5 and 10%.
In one special case, the microcapsules are worked into a polymer (homopolymers or copolymers of polyethylene, polypropylene or polyester), this mixture is extruded and then stretched. In doing so, a microporous, diffusion-open membrane (breathable film) with self-sealing properties is formed. Some of the microcapsules can be replaced by conventional fillers such as chalk, talc, marble, limestone, titanium oxide or quartz powder.
The weights per unit of area of the sealing function layers or of the microcapsules/particles for an at least essentially uniform distribution over the surface of the sheet or in the diffusion-open case are between 5 to 150 g/m 2 , preferably, 10 to 100 g/m 2 , and more preferably, 20 to 80 g/m 2 . The respective weight per unit of area can depend especially on the respective application. Conversely the total weight per unit of area, i.e., the weight of the matrix material of the sheet body including the weight per unit of area of the sealing function layer/microcapsules/particles in the diffusion-closed case is between 30 to 1000 g/m 2 , preferably, 50 to 500 g/m 2 and more preferably 100 to 300 g/m 2 .
The concentration of the capsules/particles is between 5 to 70%, preferably, 10 to 50% and furthermore 20 to 30%. The aforementioned percentages can relate especially to the volume (% by volume) and also the weight (% by weight).
The sheet in accordance with the invention can be both open to diffusion and also closed to diffusion. For sheets open to diffusion, the sd value is in the range between 0.01 to 0.5 m, preferably, between 0.01 to 0.3 m, and furthermore, 0.02 to 0.15 m. In the diffusion-closed version, the sd value is between 0.5 to 1000 m, preferably, between 2 to 200 m.
In conjunction with this invention, it has otherwise been ascertained that the watertightness of the sheet in accordance with the invention after perforation with a nail or a screw is such that there is a tightness for a static water column>200 mm, preferably >500 mm, especially preferably >1000 mm, and furthermore, preferably, >1500 mm. Depending on the type and amount of the function material, the ratio of the watertightness of the sheet in accordance with the invention after perforation to the undamaged sheet is greater than 50%, preferably, greater than 70% and more preferably, greater than 90%. Ultimately, the invention can ensure almost a watertightness as in an undamaged sheet.
The sheets or strips of all alternatives outfitted, in this way, preferably, are used in the sealing of buildings, especially in the diffusion-open version, as an underlay sheet or as a facade sheet.
The diffusion-closed sheets are used as vapor brakes, vapor barriers, gas barriers (for example, against radon, methane), masonry barriers and vertical (walls) and horizontal seals (floors, flat roofs).
It is expressly pointed out that all of the aforementioned range data comprise all individual values and all intermediate values within the indicated range limits, even if they are not given in particular. All unnamed individual values and intermediate ranges are regarded as encompassed by the invention.
Exemplary embodiments of the invention are described below. All described and/or illustrated features by themselves or in any combination form the subject matter of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction of a first embodiment of a sheet in accordance with the invention,
FIG. 2 is a schematic depiction of a second embodiment of a sheet in accordance with the invention,
FIG. 3 is a schematic depiction of a microcapsule,
FIG. 4 is a schematic depiction of a third embodiment of a sheet in accordance with the invention,
FIG. 5 is a schematic depiction of a fourth embodiment of a sheet in accordance with the invention,
FIG. 6 is a schematic depiction of a fifth embodiment of a sheet in accordance with the invention,
FIG. 7 is a schematic depiction of a sixth embodiment of a sheet in accordance with the invention,
FIG. 8 is a schematic depiction of the sheet from FIG. 1 in the perforated state,
FIG. 9 is a schematic depiction of the sheet from FIG. 1 with a counter lath in place in the perforated state,
FIG. 10 is a schematic depiction of the sheet from FIG. 6 in the perforated state,
FIG. 11 is a schematic depiction of a seventh embodiment of a sheet in accordance with the invention without fasteners,
FIG. 12 is a schematic depiction of the sheet from FIG. 11 with fasteners,
FIG. 13 is a schematic depiction of an eighth embodiment of a sheet in accordance with the invention,
FIG. 14 is a top view of the sheet from FIG. 13 , with the uppermost layer removed,
FIG. 15 is a schematic cross sectional view of another embodiment of a sheet in accordance with the invention and
FIG. 16 is a perspective partial view of another embodiment of a sheet in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 & 2 as well as FIGS. 4 to 10 each show a respective embodiment of sheets 1 which are intended for use in the building sector. The sheets 1 can be, for example, sealing or facade sheets, air barriers and vapor barriers. Depending on the application, the sheets 1 can be open to diffusion or closed to diffusion. Here, the term “sheet” also includes strips or film products. In any case, the sheet 1 has a planar sheet body 2 which has an extrudable or castable plastic as a matrix material. Conventionally, the sheet body 2 has an elongated shape and is wound up when not in use for handling purposes. The length of the sheet body 2 , the width and the thickness are dependent on the application. Conventional thicknesses of the sheet body 2 are between 100 and 300 μm, and the thickness range can vary fundamentally between 50 μm and 2000 μm, any individual values between the aforementioned range limits being fundamentally possible.
In all embodiments, it is such that the sheet body 2 contains a material which is inactivate when not in use and which can be activated, and which, in the case of a perforation of the sheet body 2 , emerges from the sheet body 2 , and in doing so, is intended for closing or for sealing the perforation opening.
FIGS. 1 & 2 as well as FIGS. 4 to 7 show different embodiments of sheets 1 . In the embodiment as shown in FIG. 1 , in the matrix material of the sheet body 2 there are microcapsules 3 which contain a single-component adhesive. When the sheet body 2 is perforated by a fastener 4 , for example, in the form of a nail, the microcapsules 3 , which are located in the region of the perforation, are destroyed. In doing so, the adhesive emerges from the capsules 3 . Then, the adhesive can set physically or chemically. Reaction partners can be, for example, water which is penetrating from the outside, oxygen and/or reactive groups of the surrounding matrix material. Ultimately, a seal 5 ( FIGS. 8-10 ) is formed by the adhesive being released in the region of the perforation opening between the fastener 4 and the matrix material of the sheet body 2 ; the seal 5 seals the annular perforation opening between the fastener 4 and the surrounding matrix material of the sheet body 2 . In doing so, it can also be otherwise provided that the adhesive of the microcapsules 3 reacts with the material of the fastener 4 so that seal 5 occurs in that way.
In the embodiment according to FIG. 2 , there are two different types of microcapsules 3 which are identified here as light and dark. The two types of microcapsules 3 contain different reaction partners. When a fastener 4 is inserted, the microcapsules 3 are destroyed and the reaction partners emerge. In doing so, then, there is a reaction forming corresponding seal 5 , as is shown in FIG. 8 .
FIG. 3 schematically shows a microcapsule 3 . It has a core 6 of a first material and a shell 7 of a second material. The first material can be a resin, the second material a curing agent.
FIG. 4 shows an embodiment in which, instead of using microcapsules, solid particles 8 are embedded into the matrix material of the sheet body 2 . The particles 8 are a comparatively solid or grainy material. Since the particles 8 react when air and/or water enters, they are not located on the outside of the sheet body 2 , but in the middle region so that an unintentional reaction is precluded. A reaction takes place only when the sheet 1 is perforated.
FIG. 5 shows an alternative embodiment in which there are different particles 8 which are, likewise, embedded in the middle region of the matrix material of the sheet body 2 . The different particles are identified as light and dark. A reaction of the particles 8 of the different materials takes place only when air and/or water enters; this occurs only when the sheet 1 is perforated.
FIG. 6 shows an embodiment in which the sheet body 2 is built up in layers. Here, there are three layers, specifically an upper layer 9 , an intermediate layer 10 and a lower layer 11 . The sealing/swelling material is located in the inner intermediate layer 10 . The intermediate layer 10 can have a layer thickness between 0.1 to 300 μm, preferably between 1 to 100 μm and especially between 10 and 50 μm. When the sheet 1 is perforated by a fastener 4 , as is shown in FIG. 10 , the material of the intermediate layer 10 emerges in the region of the perforation opening, and in doing so, fills the region between the fastener 4 and the surrounding matrix material of the sheet body 2 so that a seal 5 is formed there, as is shown in FIG. 10 .
FIG. 7 shows an embodiment in which the sheet body 2 is made with five layers. Here the reactive intermediate layer 10 is composed of two reaction layers 12 , 13 and one separating layer 14 which is provided between the reaction layers 12 , 13 and which separates them. When the sheet body 2 is perforated the separating layer 14 is also perforated so that the materials of the reaction layers 12 , 13 react with one another and can assume their self-sealing or self-healing function in the region of the perforation opening.
FIG. 9 shows a situation as often occurs in the roof region. Wood 15 , for example, a counter lath which is connected to the undersurface via a fastener 4 , is placed on the sheet 1 . The fastener 4 goes through the wood 15 and the sheet 1 . In doing so, then, the effect of seal 5 shown in FIG. 8 arises via the material of the microcapsules 3 which has been destroyed during the perforation, the sealing 5 taking place between the fastener 4 and the surrounding matrix material of the sheet body 2 and in the region of the wood 15 .
In all embodiments, it is otherwise such that the microcapsules 3 /microparticles are distributed at least essentially uniformly over the base surface of the sheet body 2 . On the edge side, there should be no access to the capsules 3 /particles or exposure.
FIG. 11 shows one embodiment of a sheet 1 which has an intermediate layer 10 of a swelling material. The sheet body 2 is perforated, therefore has a perforation 16 . Air and/or water travels through the perforation 16 to the swelling material of the intermediate layer 10 so that this material swells into the perforation 16 and reduces the free diameter of the perforation relative to the diameter in the upper layer 9 or the lower layer 11 . The swelling of the material therefore provides for a narrowing of the cross section of the perforation which can even proceed so far that the perforation 16 in the region of the intermediate layer 10 is completely closed.
FIG. 12 shows an exemplary embodiment in which the fastener 4 is located in the perforation 16 . The material of the intermediate layer 10 has expanded in the region of the perforation opening or of the fastener 4 and presses against the fastener 4 which penetrates the sheet body 2 . In the region of the perforation 16 , the intermediate layer 10 thickens due to the swelling of the material in the intermediate layer 10 .
FIGS. 13 and 14 show another embodiment of the sheet 1 in accordance with the invention. The sheet body 2 here has an elastic layer as the sealing layer 17 which is provided with a plurality of through openings 18 . The diameter of the through openings 18 is smaller than the diameter of the fastener 4 . Since the through openings 18 have relatively large pores, the sheet body 2 has an upper layer 9 which is open to diffusion but which can also be closed to diffusion. Moreover, there is a lower layer 11 which can be, for example, a nonwoven layer which contributes to the planar stability of shape of the sheet body 2 .
If the sheet 1 is penetrated by the fastener 4 , due to the elastic properties of the elastic layer material and the use of through openings 18 whose diameter is smaller than the diameter of the fastener 4 , there is sealing contact of the elastic material with the fastener 4 .
It goes without saying that, for certain applications, it is fundamentally possible for the sheet body 2 , when using an elastic or sealing layer 17 , to be made only with one layer, so that it has only the sealing layer 17 . Fundamentally, the through openings 18 can also be omitted. For diffusion-open applications, the embodiment shown in FIG. 13 should be chosen, the lower layer 11 not being unconditionally necessary as a stability or support layer.
FIG. 15 shows an embodiment of a sheet 1 in which the sheet body 2 is made as a multilayer composite. There are an upper layer 9 and a lower layer 11 each of which forms a mechanical protective layer. Between the two protective layers 9 , 11 , there are a sealing layer 17 and a membrane layer 19 .
Otherwise, sheets are also possible in which the structure of the film composite is different.
Thus, the following exemplary embodiments of sheets and their respective production which are also possible.
Film Composite 1
A silicone gel of 50 μm is applied by means of a doctor blade to a calendared PP nonwoven material with a weight per unit of area of 150 g/m 2 and is laminated with a TPE-E film 90 μm thick.
Film Composite 2
A TPE-U film of 119 μm is extruded between two viscose nonwoven materials of 120 g/m 2 weight per unit of area each.
Film Composite 3
An EPDM film which has been perforated with holes (hole diameter 2 mm, open area 70%) is extrusion-coated with a TPE-E membrane of 134 g/m 2 . Then, cement lamination onto the membrane side is done with a heat-calendered PET nonwoven material.
Film Composite 4
A perforated PP foam film 200 μm thick with an open area of 47% is extrusion coated with a TPE-E membrane of 91 μm. This composite is cement-laminated on both sides with PP nonwovens of 120 g/m 2 each.
Film Composite 5
A mixture of an adhesive and superabsorber-filled microcapsules is applied to a PP nonwoven material that is 89 μm thick and then cemented by means of a second PP nonwoven material that 67 μm thick.
FIG. 16 shows an embodiment in which the sealing layer 17 is located between an upper layer 9 and a lower layer 11 which each form carrier layers. The three-ply layer composite of the sheet 1 is shortened on at least one longitudinal edge in the region of the upper layer 9 . In the same way, the lower layer can be shortened on the opposite longitudinal edge. The sealing layer 17 is made of a viscoelastic gel which has self-adhesive properties. On the exposed edge region of the gel layer, there is a covering protective film 20 which is pulled off for installation of the sheet. The self-adhesive properties of the gel layer 17 easily enable cementing of the sheet to an adjacent sheet in the edge region. In this embodiment, the sealing layer 17 has a dual function, specifically, on the one hand, the sealing action in the case of damage/perforation, and on the other hand, the function of joining to the next sheet which is to be installed. | A sheet ( 1 ), preferably for use in the building sector, and in particular, for sealing the shell of a building, comprising a planar sheet body ( 2 ) that has at least one elastic layer as a sealing layer ( 17 ) made of a material of such elasticity and such restoring force that, when the sealing layer ( 17 ) is penetrated by a fastener ( 4 ), the material of the sealing layer ( 17 ) surrounding the fastening means ( 4 ) encloses the fastener ( 4 ) and provides sealing in the region of the fastener ( 4 ). Alternatively, the sheet body contains a sealing material which, upon perforation of the sheet body, is able to automatically emerge or swell to an extent sufficient to close or seal the perforation. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of co-pending U.S. application Ser. No. 14/643,843 filed Mar. 10, 2015, which is a continuation of U.S. application Ser. No. 13/190,078 filed Jul. 25, 2011, now U.S. Pat. No. 8,985,221, issued Mar. 24, 2015, which is a continuation-in-part of U.S. application Ser. No. 12/001,152 filed Dec. 10, 2007, now U.S. Pat. No. 8,006,756, issued Aug. 30, 2011, which applications are hereby incorporated by reference for all purposes in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
REFERENCE TO MICROFICHE APPENDIX
[0003] N/A
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates to production systems and methods deployed in subterranean oil and gas wells.
[0006] 2. Description of the Related Art
[0007] Many oil and gas wells will experience liquid loading at some point in their productive lives due to the reservoir's inability to provide sufficient energy to carry wellbore liquids to the surface. The liquids that accumulate in the wellbore may cause the well to cease flowing or flow at a reduced rate. To increase or re-establish the production, operators place the well on artificial lift, which is defined as a method of removing wellbore liquids to the surface by applying a form of energy into the wellbore. Currently, the most common artificial lift systems in the oil and gas' industry are down-hole pumping systems, plunger lift systems, and compressed gas systems.
[0008] The most popular form of down-hole pump is the sucker rod pump. It comprises a dual ball and seat assembly, and a pump barrel containing a plunger. A string of sucker rods connects the downhole pump to a pump jack at the surface. The pump jack at the surface provides the reciprocating motion to the rods which in turn provides the reciprocal motion to stroke the pump, which is a fluid displacement device. As the pump strokes, fluids above the pump are gravity fed into the pump chamber and are then pumped up the production tubing and out of the wellbore to the surface facilities. Other downhole pump systems include progressive cavity, jet, electric submersible pumps and others.
[0009] A plunger lift system utilizes compressed gas to lift a free piston traveling from the bottom of the tubing in the wellbore to the surface. Most plunger lift systems utilize the energy from a reservoir by closing in the well periodically in order to build up pressure in the wellbore. The well is then opened rapidly which creates a pressure differential, and as the plunger travels to the surface, it lifts reservoir liquids that have accumulated above the plunger. Like the pump, the plunger is also a fluid displacement device.
[0010] Compressed gas systems can be either continuous or intermittent. As their names imply, continuous systems continuously inject gas into the wellbore and intermittent systems inject gas intermittently. In both systems, compressed gas flows into the casing-tubing annulus of the well and travels down the wellbore to a gas lift valve contained in the tubing string. If the gas pressure in the casing-tubing annulus is sufficiently high compared to the pressure inside the tubing adjacent to the valve, the gas lift valve will be in the open position which subsequently allows gas in the casing-tubing annulus to enter the tubing and thus lift liquids in the tubing out of the wellbore. Continuous gas lift systems work effectively unless the reservoir has a depletion or partial depletion drive, which results in a pressure decline in the reservoir as fluids are removed. When the reservoir pressure depletes to a point that the gas lift pressure causes significant back pressure on the reservoir, continuous gas lift systems become inefficient and the flow rate from the well is reduced until it is uneconomic to operate the system. Intermittent gas lift systems apply this back pressure intermittently and therefore can operate economically for longer periods of time than continuous systems. Intermittent systems are not as common as continuous systems because of the difficulties and expense of operating surface equipment on an intermittent basis.
[0011] Horizontal drilling was developed to access irregular fossil energy deposits in order to enhance the recovery of hydrocarbons. Directional drilling was developed to access fossil energy deposits some distance from the surface location of the wellbore. Generally, both of these drilling methods begin with a vertical hole or well. At a certain point in this vertical well, a turn of the drilling tool is initiated which eventually brings the drilling tool into a deviated position with respect to the vertical position.
[0012] It is not practical to install most artificial lift systems in the deviated sections of directional or horizontal wells or deep into the perforated section of vertical wells since down-hole equipment installed in these regions may be inefficient or can undergo high maintenance costs due to wear and/or solids and gas entrained in the liquids interfering with the operation of the pump. Therefore, most operators only install down-hole artificial lift equipment in the vertical portion of the wellbore above the reservoir. In many vertical wells with relatively long perforated intervals, many operators choose to not install artificial lift equipment in the well due to the factors above. Downhole pump systems, plunger lift systems, and compressed gas lift systems are not designed to recover any liquids that exist below the downhole equipment. Therefore, in many vertical, directional, and horizontal wells, a column of liquid ranging from hundreds to many thousands of feet may exist below the down-hole artificial lift equipment. Because of the limitations with current artificial lift systems, considerable hydrocarbon reserves cannot be recovered using conventional methods in depletion or partial depletion drive directional or horizontally drilled wells, and vertical wells with relatively long perforated intervals. Thus, a major problem with the current technology is that reservoir liquids located below conventional down-hole artificial lift equipment cannot be lifted.
[0013] There is a need to provide an artificial lift system that will enable the recovery of liquids in the deviated sections of directional or horizontal wellbores, and in vertical wells with relatively long perforated intervals.
[0014] There is a need to provide an artificial lift system that will enable the recovery of liquids in vertical wells with relatively long perforated intervals and in the deviated sections of directional and horizontal wellbores with smaller casing diameters.
[0015] There is a need to lower the artificial lift point in vertical wells with relatively long perforated intervals and in wells with deviated or horizontal sections.
[0016] There is a need to provide a high velocity volume of injection gas to more efficiently sweep the reservoir liquids from the wellbore.
[0017] There is a need to provide a more efficient, less costly wellbore liquid removal process.
[0018] There is a need for a less costly artificial lift method for vertical wells with relatively long perforated intervals and for wells with deviated or horizontal sections.
[0019] There is a need for a less costly and more efficient artificial lift method for wells that still have sufficient reservoir energy and reservoir gas to lift liquids from below to above the downhole artificial lift equipment.
[0020] Finally, there is a need to provide a more efficient gas and solid separation method to lower the lift point in wells with deviated and horizontal sections and for vertical wells with relatively long perforated intervals.
BRIEF SUMMARY OF THE INVENTION
[0021] A gas assisted downhole system is disclosed, which is an artificial lift system designed to recover by-passed hydrocarbons in directional, vertical and horizontal wellbores by incorporating a dual tubing arrangement. In one embodiment, a first tubing string contains a gas lift system, and a second tubing string contains a downhole pumping system. In the first tubing string, the gas lift system, which is preferably intermittent, is utilized to lift reservoir fluids from below the downhole pump to above a packer assembly where the fluids become trapped. As more reservoir fluids are added above the packer, the fluid level rises in the casing annulus above the downhole pump installed in the adjacent second tubing string, and the trapped reservoir fluids are pumped to the surface by the downhole pump. In another embodiment, the second tubing string contains a downhole plunger system. As reservoir fluids are added above the packer, the fluid level rises in the casing annulus above the downhole plunger installed in the adjacent second tubing string, and the trapped reservoir fluids are lifted to the surface by the downhole plunger system.
[0022] A dual string anchor may be disposed with the first tubing string to limit the movement of the second tubing string. The second tubing string may be removably attached with the dual string anchor with an on-off tool without disturbing the first tubing string. A one-way valve may also be used to allow reservoir fluids to flow into the first tubing string in one direction only. The one way valve may be placed in the first tubing string below the packer to allow trapped pressure below the packer to be released into the first tubing string. The valve provides a pathway to the surface for the gas trapped below the packer. The resulting reduced back pressure on the reservoir may lead to production increases.
[0023] In another embodiment, the second tubing string may be within the first tubing string, and the injected gas may travel down the annulus between the first and second tubing strings. The second string may house a fluid displacement device, such as a downhole pumping system or a plunger lift system. A bi-flow connector may anchor the second string to the first string and allow reservoir liquids in the casing tubing annulus to pass through the anchor to the downhole pump. In one embodiment, the bi-flow connector may be a cylindrical body having a thickness, a first end, a second end, a central bore from the first end to said second end, and a side surface. A first channel may be disposed through the thickness from the first end to the second end. A second channel may be disposed through the thickness from the side surface to the central bore, with the first channel and second channel not intersecting. Injected gas may be allowed to pass vertically through the bi-flow connector to lift liquids from below the downhole pump to above the downhole pump. The bi-flow connector prevents the injected gas from contacting the reservoir liquids flowing through the bi-flow connector. Also contemplated are multiple channels in addition to the first channel and multiple channels in addition to the second channel.
[0024] In yet another embodiment, gas from the reservoir lifts reservoir liquids from below the fluid displacement device, such as a downhole pump or a plunger, to above the fluid displacement device. A first tubing string may contain the fluid displacement device above a packer assembly. A blank sub may be positioned between an upper perforated sub and a lower perforated sub in the first tubing string below the fluid displacement device. A second tubing string within the first tubing string and located below the lower perforated sub may lifts liquids using the gas from the reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] For a further understanding of the nature and objects of the present invention, reference is had to the following figures in which like parts are given like reference numerals and wherein:
[0026] FIG. 1 depicts a directional or horizontal wellbore installed with a conventional rod pumping system of the prior art.
[0027] FIG. 2 depicts a conventional gas lift system in a directional or horizontal wellbore of the prior art.
[0028] FIG. 3 depicts an embodiment of the invention utilizing a rod pump and a gas lift system.
[0029] FIG. 4 depicts another embodiment of the invention similar to FIG. 3 except with no internal gas lift valve.
[0030] FIG. 5 depicts yet another embodiment of the invention having a Y block.
[0031] FIG. 6 depicts another embodiment of the invention similar to FIG. 5 except with no internal gas lift valve.
[0032] FIG. 7 depicts another embodiment similar to FIG. 3 , except with a dual string anchor and an on-off tool.
[0033] FIG. 8 depicts another embodiment similar to FIG. 7 , except with no internal gas lift valve.
[0034] FIG. 9 depicts another embodiment similar to FIG. 7 , except with a one-way valve.
[0035] FIG. 10 is the embodiment of FIG. 9 , except shown in a completely vertical wellbore.
[0036] FIG. 11 is an embodiment similar to FIG. 11 , except that an alternative embodiment plunger lift system is installed in place of the downhole pump system, and with no surface tank and no dual string anchor.
[0037] FIG. 12 depicts another embodiment in a vertical wellbore utilizing a bi-flow connector.
[0038] FIG. 13 is the embodiment of FIG. 12 except in a horizontal wellbore.
[0039] FIG. 13A is an isometric view of a bi-flow connector.
[0040] FIG. 13B is a section view along line 13 A- 13 A of FIG. 13 .
[0041] FIG. 13C is a top view of FIG. 13A .
[0042] FIG. 13D is a section view similar to FIG. 13B except with the bi-flow connector threadably attached at a first end with a first tubular and at a second end with a second tubular.
[0043] FIG. 14 is the embodiment of FIG. 13 except that an alternative embodiment plunger lift system is installed in place of the downhole pump system.
[0044] FIG. 15 depicts another embodiment that utilizes gas that emanates from the reservoir to lift liquids from the curved or horizontal section of the wellbore.
[0045] FIG. 16 is the embodiment of FIG. 15 except it is shown in a vertical wellbore.
[0046] FIG. 17 is the embodiment of FIG. 16 except that an alternative embodiment plunger lift system is installed in place of the downhole pump system.
DETAILED DESCRIPTION OF THE INVENTION
[0047] FIG. 1 shows one example of a conventional rod pump system of the prior art in a directional or horizontal wellbore. As set out in FIG. 1 , tubing 1 , which contains pumped liquids 13 is mounted inside a casing 6 . A pump 5 is connected at the end of tubing 1 in a seating nipple 48 nearest the reservoir 9 . Sucker rods 11 are connected from the top of pump 5 and continue vertically to the surface 12 . Casing 6 , cylindrical in shape, surrounds and may be coaxial with tubing 1 and extends below tubing 1 and pump 5 on one end and extends vertically to surface 12 on the other end. Below casing 6 is curve 8 and lateral 10 which is drilled through reservoir 9 .
[0048] The process is as follows: reservoir fluids 7 are produced from reservoir 9 and enter lateral 10 , rise up curve 8 and casing 6 . Because reservoir fluids 7 are usually multiphase, they separate into annular gas 4 and liquids 17 . Annular gas 4 separates from reservoir fluids 7 and rises in annulus 2 , which is the void space formed between tubing 1 and casing 6 . The annular gas 4 continues to rise up annulus 2 and then flows out of the well to the surface 12 . Liquids 17 enter pump 5 by the force of gravity from the weight of liquids 17 above pump 5 and enter pump 5 to become pumped liquids 13 which travel up tubing 1 to the surface 12 . Pump 5 is not considered to be limiting, but may be any down-hole pump or pumping system, such as a progressive cavity, jet pump, or electric submersible, and the like.
[0049] FIG. 2 shows one example of a conventional gas lift system of the prior art in a directional or horizontal wellbore. Referring to FIG. 2 , inside the casing 6 , is tubing 1 connected to packer 14 and conventional gas lift valve 22 . Below casing 6 is curve 8 and lateral 10 which is drilled through reservoir 9 . The process is as follows: reservoir fluids 7 from reservoir 9 enter lateral 10 and rise up curve 8 and casing 6 and enter tubing 1 . The packer 14 provides pressure isolation which allows annulus 2 , which is formed by the void space between casing 6 and tubing 1 , to increase in pressure from the injection of injection gas 16 . Once the pressure increases sufficiently in annulus 2 , conventional gas lift valve 22 opens and allows injection gas 16 to pass from annulus 2 into tubing 1 , which then commingles with reservoir fluids 7 to become commingled fluids 18 . This lightens the fluid column and commingled fluids 18 rise up tubing 1 and then flow out of the well to surface 12 .
[0050] FIG. 3 shows an embodiment utilizing a downhole pump and a gas lift system in a horizontal or deviated wellbore. Referring to FIG. 3 , inside casing 6 , is tubing 1 which begins at surface 12 and contains internal gas lift valve 15 , bushing 25 , and inner tubing 21 . Inner tubing 21 may be within tubing 1 , such as concentric. Bushing 25 may be a section of pipe whose purpose is to threadingly connect pipe joints using both its outer diameter and its inner diameter. Bushing 25 may have pipe threads at one or both ends of its outer diameter, and pipe threads at one or both ends of its inner diameter. Other types of bushings and connection means are also contemplated. Tubing 1 is sealingly engaged to packer 14 . Tubing 1 and inner tubing 21 extend below packer 14 through curve 8 and into lateral 10 , which is drilled through reservoir 9 . Inside casing 6 and adjacent to tubing 1 is tubing 3 , which contains sucker rods 11 connected to pump 5 . Pump 5 is connected to the end of tubing 3 by seating nipple 48 . Tubing 3 is not sealingly engaged to packer 14 .
[0051] The process may be as follows: reservoir fluids 7 enter lateral 10 and enter tubing 1 . The reservoir fluids 7 are commingled with injection gas 16 to become commingled fluids 18 which rise up chamber annulus 19 , which is the void space formed between inner tubing 21 and tubing 1 . The commingled fluids 18 then exit through the holes in perforated sub 24 . Commingled gas 41 separates from commingled fluids 18 and rises in annulus 2 , which is formed by the void space between casing 6 and tubing 1 and tubing 3 . Commingled gas 41 then enters flow line 30 at the surface 12 and enters compressor 38 to become compressed gas 33 , and travels through flow line 31 to surface tank 34 . The compressor 38 is not considered to be limiting, in that it is not crucial to the design if another source of pressured gas is available, such as pressured gas from a pipeline.
[0052] Compressed gas 33 then travels through flow line 32 which is connected to actuated valve 35 . This actuated valve 35 opens and closes depending on either time or pressure realized in surface tank 34 . When actuated, valve 35 opens, compressed gas 33 flows through actuated valve 35 and travels through flow line 32 and into tubing 1 to become injection gas 16 . The injection gas 16 travels down tubing 1 to internal gas lift valve 15 , which is normally closed thereby preventing the flow of injection gas 16 down tubing 1 . A sufficiently high pressure in tubing 1 above internal gas lift valve 15 opens internal gas lift valve 15 and allows the passage of injection gas 16 through internal gas lift valve 15 . The injection gas 16 then enters the inner tubing 21 , and eventually commingles with reservoir fluids 7 to become commingled fluids 18 , and the process begins again. Liquids 17 and commingled gas 41 separate from the commingled fluids 18 and liquids 17 fall in annulus 2 and are trapped above packer 14 . Commingled gas 41 rises up annulus 2 as previously described. As more liquids 17 are added to annulus 2 , liquids 17 rise above and are gravity fed into pump 5 to become pumped liquids 13 which travel up tubing 3 to surface 12 .
[0053] FIG. 4 shows an alternate embodiment similar to the design in FIG. 3 except that it does not utilize the internal gas lift valve 15 .
[0054] FIG. 5 shows yet another alternate embodiment utilizing a downhole pump and a gas lift system in a horizontal or deviated wellbore with a different downhole configuration from FIG. 3 . Referring to FIG. 5 , inside the casing 6 is tubing 1 which contains an internal gas lift valve 15 and is sealingly engaged to packer 14 . Packer 14 is preferably a dual packer assembly and is connected to Y block 50 which in turn is connected to chamber outer tubing 55 . Chamber outer tubing 55 continues below casing 6 through curve 8 and into lateral 10 which is drilled through reservoir 9 . Inner tubing 21 is secured by chamber bushing 22 to one of the tubular members of Y Block 50 leading to lower tubing section 37 . Inner tubing 21 may be concentric with chamber outer tubing 55 . The inner tubing 21 extends inside of Y block 50 and chamber outer tubing 55 through the curve 8 and into the lateral 10 . The second tubing string arrangement comprises a lower section 37 and an upper section 36 . The lower section 37 comprises a perforated sub 24 connected above a one way valve 28 and is then sealingly engaged in the packer 14 .
[0055] Perforated sub 24 is closed at its upper end and is connected to the upper tubing section 36 . Upper tubing section 36 comprises a gas shroud 58 , a perforated inner tubular member 57 , a cross over sub 59 and tubing 3 which contains pump 5 and sucker rods 11 . The gas shroud 58 is tubular in shape and is closed at its lower end and open at its upper end. It surrounds perforated inner tubular member 57 , which extends above gas shroud 58 to crossover sub 59 and connects to the tubing 3 , which continues to the surface 12 . Above the crossover sub 59 , and contained inside of tubing 3 at its lower end, is pump 5 which is connected to sucker rods 11 , which continue to the surface 12 . Annular gas 4 travels up annulus 2 into flowline 30 which is connected to compressor 38 which compresses annular gas 4 to become compressed gas 33 . The compressor 38 is not considered to be limiting, in that it is not crucial to the design if another source of pressured gas is available, such as pressured gas from a pipeline.
[0056] Compressed gas 33 flows through flowline 31 to surface tank 34 which is connected to a second flowline 32 that is connected to actuated valve 35 . This actuated valve 35 opens and closes depending on either time or pressure realized in surface tank 34 . When actuated valve 35 opens, compressed gas 33 flows through actuated valve 35 and travels through flowline 32 and into tubing 1 to become injection gas 16 . The injection gas 16 travels down tubing 1 to internal gas lift valve 15 , which is normally closed thereby preventing the flow of injection gas 16 down tubing 1 . A sufficiently high pressure in tubing 1 above internal gas lift valve 15 opens internal gas lift valve 15 and allows the passage of injection gas 16 through internal gas lift valve 15 , through Y Block 50 and into chamber annulus 19 , which is the void space between inner concentric tubing 21 and chamber outer tubing 55 . Injection gas 16 is forced to flow down chamber annulus 19 since its upper end is isolated by chamber bushing 25 . Injection gas 16 displaces the reservoir fluids 7 to become commingled fluids 18 which travel up the inner concentric tubing 21 .
[0057] Commingled fluids 18 travel out of inner concentric tubing 21 into one of the tubular members of Y Block 50 , through packer 14 and standing valve 28 , and then through the perforated sub 24 into annulus 2 , where the gas separates and rises to become annular gas 4 to continue the cycle. The liquids 17 separate from the commingled fluids 18 and fall by the force of gravity and are trapped in annulus 2 above packer 14 and are prevented from flowing back into perforated sub 24 because of standing valve 28 . As liquids 17 accumulate in annulus 2 , they rise above pump 5 and are forced by gravity to enter inside of gas shroud 58 and into perforated tubular member 57 where they travel up cross-over sub 59 to enter pump 5 where they become pumped liquids 13 and are pumped up tubing 3 to the surface 12 .
[0058] FIG. 6 shows an alternate embodiment of the invention similar to the design in FIG. 5 except that it does not utilize the internal gas lift valve 15 .
[0059] FIG. 7 shows an alternate embodiment similar to FIG. 3 , except that there is a downhole anchor assembly or dual string anchor 20 disposed with first tubing string 1 and installed and attached with second tubing string with on-off tool 26 . Referring to FIG. 7 , first tubing string 1 is inside casing 6 . First tubing string 1 begins at the surface 12 and contains internal gas lift valve 15 , bushing 25 , perforated sub 24 , and inner tubing 21 . Perforated sub 24 is available from Weatherford International of Houston, Tex., among others. Tubing 1 is engaged to dual string anchor 20 and continues through it and is engaged to packer 14 and extends through it. Inner tubing 21 connects to bushing 25 and continues through perforated sub 24 , dual string anchor 20 , packer 14 and terminates prior to the end of tubing 1 . Dual string anchor 20 is available from Kline Oil Tools of Tulsa, Okla., among others. Other types of dual string anchors 20 are also contemplated. Inner tubing 21 may be within tubing 1 . Tubing 1 extends through and below dual string anchor 20 and through and below packer 14 through curve 8 and into lateral 10 , which is drilled through reservoir 9 . Second tubing string 3 is inside casing 6 and adjacent to first tubing string 1 . Second tubing string 3 contains perforated sub 23 , sucker rods 11 , pump 5 , seating nipple 48 , and on-off tool 26 . Second tubing string 3 may be selectively engaged to dual string anchor 20 with on-off tool 26 . On-off tool 26 is available from D&L Oil Tools of Tulsa, Okla. and from Weatherford International of Houston, Tex., among others. Other types of on-off tool 26 and attachment means are also contemplated. On-off tool 26 may be disposed with perforated sub 23 , which may be attached with second tubing string 3 .
[0060] The process for FIG. 7 is similar to that for FIG. 3 . The dual string anchor 20 functions to immobilize the second tubing string 3 by supporting it with first tubing string 1 . Immobilization is important, since in deeper pump applications, the mechanical pump 5 may induce movement to second tubing string 3 which may in turn cause wear on the tubulars. Movement may also cause the mechanical pump operation to cease or become inefficient. On-off tool 26 allows the second tubing string 3 to be selectively connected or disconnected from the dual string anchor 20 without disturbing the first tubing string 1 . The dual string anchor 20 minimizes inefficiencies in the pump and costly workovers to repair wear on the tubing strings. This movement is caused by the movement induced upon the second tubing string by the downhole pumping system.
[0061] FIG. 8 shows another alternate embodiment similar to the design in FIG. 7 except that it does not utilize internal gas lift valve 15 .
[0062] FIG. 9 shows another alternate embodiment similar to the design of FIG. 7 , except that FIG. 9 includes one-way valve 28 disposed on first tubing string 1 below packer 14 . Referring to FIG. 9 , when pressure conditions are favorable, one-way valve 28 opens to allow reservoir gas 27 to pass into chamber annulus 19 . One-way valve 28 may be a reverse flow check valve available from Weatherford International of Houston, Tex., among others. Other types of one-way valves 28 are also contemplated. Although only one one-valve 28 is shown, it is contemplated that there may be more than one one-way valve 28 for all embodiments. One-way valve 28 may be threadingly disposed with a carrier such as a conventional tubing retrievable mandrel or a gas lift mandrel. Other connection types, carriers, and mandrels are also contemplated.
[0063] One-way valve 28 functions to allow fluids to flow from outside to inside the device in one direction only. In FIGS. 9-14 , one-way valve 28 may be placed in the first tubing string 1 below the packer 14 to vent trapped pressure below the packer 14 into the first tubing string 1 . In a vertical well application, this venting may assist the optimum functioning of the artificial lift system. One-way valve 28 has at least two functions: (1) it provides a pathway to the surface for reservoir gas 27 trapped below packer 14 , and (2) it leads to production increases by reducing back pressure on the reservoir. As can now be understood, one-way valve 28 may be positioned at a location on first tubing string 1 , such as below packer 14 , that is different than the location where injected gas 16 initially commingles with the reservoir fluids where inner tubing 21 ends. Injected gas 16 may initially commingle with reservoir fluids 7 at a first location, and one-way valve 28 may be disposed on first tubing string 1 at a second location. One-way valve 28 may be disposed above reservoir 9 , although other locations are contemplated. One-way valve 28 allows the venting of trapped fluids, and allows flow in only one direction.
[0064] FIG. 10 shows the embodiment of FIG. 9 in a completely vertical wellbore.
[0065] As can now be understood, dual string anchor or dual tubing anchor 20 with on-off tool 26 and one way-valve 28 may be used independently, together, or not at all. For all embodiments in deviated, horizontal, or vertical wellbore applications, there may be (1) gas lift valve 15 , dual string anchor 20 , and one-way valve 28 below packer 14 , (2) no gas lift valve 15 , no dual string anchor 20 , and no one-way valve 28 below packer 14 , or (3) any combination or permutation of the above. Surface tank 34 and actuated valve 35 are also optional in all the embodiments.
[0066] FIG. 11 is an embodiment similar to FIG. 10 in which pump 5 and sucker rods 11 have been replaced with an alternative embodiment plunger lift system, and there is no surface tank 34 and no one-way valve 28 . Referring to FIG. 11 , the process is as follows. Initially, actuated valve 37 is open at surface 12 , which allows flow from tubing 3 to surface 12 . Actuated valve 35 is open and actuated valve 36 is closed. Supply gas 46 , which may emanate from the well or a pipeline, is compressed by compressor 38 and compressed gas 33 flows through flow line 31 , through actuated valve 35 and flow line 32 , and into tubing 1 to become injection gas 16 , which then flows down tubing 1 , through gas lift valve 15 , and through inner tubing 21 . At the end of inner tubing 21 , injection gas 16 combines with reservoir fluids 7 to become commingled fluids 18 , which rise up chamber annulus 19 and flow through perforated sub 24 into annulus 2 . Liquids 17 fall to the bottom of annulus 2 .
[0067] As more liquids are added in annulus 2 , they eventually rise above plunger 5 and into tubing 3 and rise above perforated sub 24 , which may cause the injection pressure to rise which signals actuated valve 35 to close, actuated valve 39 to open, and actuated valve 37 to close. Compressed gas 33 then flows through actuated valve 36 and through flow line 30 , and into annulus 2 to become injection gas 16 . When a sufficient volume of injection gas 16 has been added to annulus 2 , the pressure in annulus 2 rises sufficiently to signal actuated valve 37 to open, actuated valve 36 to close, and actuated valve 35 to open. The pressure differential lifts plunger 45 off of seating nipple 48 and rises up tubing 3 and pushes liquids 17 to surface 12 . Some injection gas 16 also flows to surface 12 via tubing 3 . Once the pressure on tubing 3 drops sufficiently, plunger 45 falls back down to seating nipple 48 and the process begins again. Other sequences of the timing of the opening and closing of the actuated valves are contemplated. Surface tank 34 may also be utilized.
[0068] FIG. 12 is another embodiment and utilizes an outer and inner tubing arrangement, such as concentric, incorporating a novel bi-flow connector 43 in a vertical wellbore. The bi-flow connector 43 is shown in detail in FIGS. 13A-13D and discussed in detail below. FIG. 13 is similar to FIG. 12 except in a horizontal wellbore. Although FIG. 13 is discussed below, the discussion applies equally to FIG. 12 . In FIG. 13 , first tubing string 1 begins at surface 12 and is installed inside casing 6 , contains bi-flow connector 43 , bushing 25 , one way valve 29 , and is sealingly engaged to packer 14 . Mud anchor 40 may be connected to bi-flow connector 43 to act as a reservoir for particulates that fall out of liquids 17 , and to isolate the injection gas 16 from liquids 17 . Mud anchor 40 is a tubing with one end closed and one end open, and is available from Weatherford International of Houston, Tex., among others. First tubing string 1 continues below packer 14 and contains one way valve 28 and continues until it terminates in curve 8 or lateral 10 , or for FIG. 12 in or below reservoir 9 . Within first tubing string 1 is second tubing string 21 , which is also sealingly engaged to bushing 25 and continues down through packer 14 and may terminate prior to the end of first tubing string 1 . Third tubing string 3 is within first tubing string, and begins at surface 12 and terminates in on-off tool 26 . On-off tool 26 allows third tubing string 3 to be selectively engaged to first tubing string 1 . On-off tool 26 is sealingly engaged to bi-flow connector 43 . Contained inside first tubing string 3 are sucker rods 11 , pump 5 and seating nipple 48 . Sucker rods 11 are connected to pump 5 which is selectively engaged into seating nipple 48 . Seating nipple 48 is available from Weatherford International of Houston, Tex., among others.
[0069] As shown in FIGS. 13A-13D , bi-flow connector 43 is a cylindrically shaped body with a central bore 112 extending from a first end 105 to a second end 107 and having a thickness 109 . Vertical or first channels 102 pass through the thickness 109 of the bi-flow connector 43 from the first end 105 to the second end 107 . Horizontal or second channels 100 pass from the side surface 111 through the thickness 109 of the bi-flow connector 43 to the central bore 112 . Although shown vertical and horizontal, it is also contemplated that first channels may not be vertical and second channels may not be horizontal. Different numbers and orientations of channels are contemplated. The first channels 102 and second channels 100 do not intersect. Threads 104 , 108 are on the side surface 111 of the bi-flow connector 43 adjacent its first and second ends 105 , 107 . There may also be inner threads 106 , 110 on the inner surface of the central bore 112 adjacent the first and second ends. As shown in FIGS. 12-13 , the mud anchor 40 is attached with the inner threads 110 , and the first tubing string 1 is attached with the outer threads 104 , 108 . In FIG. 13D , the threaded connection between the bi-flow connector 43 between upper tubular 114 and lower tubular 116 is similar to the connection in FIG. 13 between the bi-flow connector 43 and first tubing string 1 .
[0070] Returning to FIG. 13 , the process may be as follows. Injection gas 16 travels down annulus 47 and passes vertically through bi-flow connector 43 and continues down through bushing 25 , packer 14 , second tubing string 21 and out into first tubing string 1 where it commingles with reservoir fluids 7 to become commingled fluids 18 . Reservoir gas emanates from reservoir 9 and may travel through one way valve 28 and become part of commingled fluids 18 , which rise up annulus 19 and travel through one way valve 29 and then separate into liquids 17 and commingled gas 41 . Liquids 17 may enter horizontally through bi-flow connector 43 and up to pump 5 where they become pumped liquids 13 and are pumped to surface 12 . Commingled gas 41 rises up annulus 2 to surface 12 .
[0071] As can now be understood, the bi-flow connector 43 allows downward injection gas to pass vertically through the tool, while simultaneously allowing reservoir liquids to pass horizontally through the tool, without commingling the reservoir liquids with the downwardly flowing injection gas. The bi-flow connector 43 also allows the inner tubing string, such as third tubing string 3 , to be selectively engaged to the outer tubing string, such as first tubing string 1 . The bi-flow connector 43 may be used in small casing diameter wellbores in which the installation of two side by side or adjacent tubing strings is impractical or impossible. The bi-flow connector 43 is advantageous to wells that have a smaller diameter casing. Other non-concentric tubing arrangement embodiments may require larger casing sizes. A plunger system is also contemplated in place of the downhole pump.
[0072] FIG. 14 is the same embodiment as FIG. 13 except that an alternative embodiment plunger lift system is installed in place of the downhole pump system. A pump and a plunger are both fluid displacement devices.
[0073] FIG. 15 is another embodiment using only reservoir gas to lift the reservoir liquids from below the downhole pump to above the downhole pump. This embodiment is similar to FIG. 13 , but no inner tubing, such as third tubing string 3 , is needed to house the downhole pump and no external injection gas is needed. It may also incorporate a one way valve 28 in the tubing string to prevent wellbore liquids from falling back down the wellbore. The one way valve 28 allows the liquids to be trapped above the packer until the pump can lift them to the surface. The smaller diameter of the inner tubing efficiently lifts reservoir fluids by forcing the reservoir gas into a smaller cross-sectional area whereby the gas is not allowed to rise faster than the reservoir liquids. Due to the smaller tubing size, a relatively small amount of reservoir gas can lift reservoir liquids the relatively short distance from the end of the tubing to the one way valve.
[0074] Referring to FIG. 15 , first tubing string 1 begins at surface 12 and contains seating nipple 48 , upper perforated sub 23 , blank sub 42 , lower perforated sub 24 , one way valve 39 , on-off tool 26 , packer 14 , bushing 25 and terminates in curve 8 or lateral 10 . Seating nipple 48 , blank sub 42 , perforated subs 23 , 24 , on-off tool 26 , packer 14 , one way valve 39 , and bushing 25 are all available from Weatherford International of Houston, Tex., among others. Connected to seating nipple 48 is pump 5 which is connected to sucker rods 11 which continue up to surface 12 . Connected to bushing 25 is second tubing string 21 which is connected to one way valve 28 , and continues down the wellbore and may terminate prior to the end of tubing 1 .
[0075] The process may be as follows. Reservoir fluids 7 emanate from reservoir 9 and enter lateral 10 and then enter first tubing string 1 and second tubing string 21 . Gas in reservoir fluids 7 expand inside second tubing string 21 and lift reservoir fluids 7 up and out of second tubing string 21 into first tubing string 1 , through on-off tool 26 , through one way valve 39 and out of lower perforated sub 24 and into annulus 2 . Reservoir fluids 7 separate into liquids 17 and annular gas 4 . Liquids 17 enter into upper perforated sub 23 and then enter into pump 5 where they become pumped liquids 13 and are pumped to surface 12 via tubing 1 . Annular gas 4 rises up annulus 2 to surface 12 .
[0076] FIG. 16 is the embodiment of FIG. 15 except in a vertical wellbore.
[0077] FIG. 17 is the embodiment of FIG. 16 except that a plunger has been installed in place of the sucker rods and pump. The plunger may be operated merely by the periodic opening and closing of the first tubing string 1 to the surface or it may be operated by the periodic or continuous injection of gas down the annulus combined with the periodic opening and closing of the first tubing string 1 to the surface. Both methods will force the plunger and liquids above it to the surface. This embodiment is much less expensive than installing a downhole pump. This design is advantageous for wells that have sufficient reservoir energy and gas production to lift liquids from below the downhole pump to above the downhole pump, yet still require artificial lift equipment to lift these liquids to the surface. This embodiment is less costly to install since no injection gas from the surface is required. Subsequently there is no gas injection tubing, no surface tank, no actuated valve, no compressor, and no dual string anchor. It will also accommodate wellbores with smaller casing diameters.
[0078] The embodiment of FIGS. 15-16 is advantageous for wells that have sufficient reservoir energy and gas production to lift liquids from below the downhole pump to above the downhole pump, yet still require artificial lift equipment to lift these liquids to the surface. This embodiment is less costly to install since no injection gas from the surface is required. There does not have to be any gas injection tubing, surface tank, actuated valve, compressor, or dual string anchor. It will also accommodate wellbores with smaller casing diameters. The embodiment of FIG. 17 is even less expensive because there does not have to be any downhole pump and related equipment.
[0079] An advantages of all embodiments is a lower artificial lift point and better recovery of hydrocarbons. There is better gas and particulate separation in all embodiments. In FIGS. 3-11 , the entry point for the commingled fluids is above the intake of the pump or other fluid displacement device, which helps break out any gas in the fluids since gravity will segregate the gas from the liquids. The same is true for particulates since there is a large reservoir for them to collect in below the pump. In FIGS. 12-17 , the gas is discouraged from entering the perforated subs because of gravity separation.
[0080] Because many varying and different embodiments may be made within the scope of the invention concept taught herein which may involve many modifications in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. | A system and method for lifting reservoir fluids from reservoir to surface through a wellbore having a first tubing string extending through a packer in a wellbore casing. The system includes a bi-flow connector in the first tubing string, a second tubing string in the first tubing string below the bi-flow connector, and a third tubing string in the first tubing string above and connected with the bi-flow connector. A fluid displacement device in the third tubing string is configured to move reservoir fluids to the surface. The first tubing string allows pressured gas to move from the surface through the bi-flow connector to commingle with and lift reservoir fluids through annuli defined by the first and second tubing strings and defined by the casing and the first tubing string. The bi-flow connector is configured to allow simultaneous and non-contacting flow of the downward pressured gas and lifted reservoir fluid. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a container for shaping and molding materials. More particularly, the present invention relates to a pan designed to create various shapes or molds of a particular material.
[0003] 2. Description of the Prior Art
[0004] Cooking pans have been designed to mold cooking edibles into conventional shapes, such as square, rectangle and circle designs. Molded material, even when in conventional shapes is often difficult to remove. Some pans have been improved to include removable walls to assist removal of a baked product. Acknowledging the fact that molding baking materials was very time consuming, some companies reverted to using baking pans with removable walls. A baking pan assembly is illustrated by U.S. Pat. No. 4,644,858 (1987, Liotto et al.). The baking pan is designed to have removable sides and bottom. The circular half sections are pinned or clamped together at the ends holding a circular base that fits in an annular groove. After the food product is baked, the half sections are detached from the base to expose the product. Another pan with removable sections is illustrated with a multiple-purpose cake pan by U.S. Pat. No. 5,537,917 (1996, Schiffer et al.). The cake pan has a removable insert that slides out from the outer rim of the cake pan. A tube cake insert molds the inner hole of a tube cake. Unfortunately, these pans may only be used for circular shapes. The baking pans do not address baking multiple pieces or even unconventional shapes.
[0005] Some pans have been improved to include removable walls to vary the width of the pan. A multi-purpose baking pan with hinged end sections and cover is illustrated by U.S. Pat. No. 5,779,080 (1998, Corse). The pan has a rectangular bottom with two linear sidewalls on opposite edges along the long sides of the rectangular bottom. Two end members are at the short sides of the rectangular bottom having rod-like hinge pins. The pan is also illustrated having a rectangular pan and a divider for varying the size of the two areas. The pan is only good for varying the portions of the two rectangular sections. The pan does not address unconventional shapes or molding more than two sections.
[0006] Other pans have been improved to include surface contours to mold distinctive shapes in one or more of the pan walls. A method of making controlled heating baking pan is illustrated by U.S. Pat. No. 5,094,706 (1992, Howe). The pan may be made to have distinctive surface contours pressed or formed on the wall portions for molding designs in the materials.
[0007] Repetition in molding or forming multiple pieces is labor intensive and cost consuming. To mold or shape materials, the material must be cut into the desired shape before or after cooking or setting the materials. For example, a baker uses cookie cutters to cut dough before baking the cookies or cuts a triangular slice of circular pizza pie after baking a circle shape. Forming the material to the desired shape takes skill and time, whereas cutting the material creates undesired waste. Some companies have manufactured multiple molding units to save time. A baking pan having multiple baking units is illustrated by U.S. Pat. No. 4,941,585 (1990, Hare et al.). The problem with the prior art multiple unit baking pans is that the material must be measured out and poured into each mold separately. This process is slow and labor intensive. Additionally, the manual method of measuring out the material seldom provides uniform pieces. Furthermore, these multiple unit baking pans have the same repeating shape and the pan must be inverted to remove the material from the pan.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the present invention to provide an apparatus that is capable of molding and forming multiple, uniform or variable pieces within one assembly. It is another object of the present invention to provide an apparatus that enables the removal of the finished goods without inverting the apparatus, which may cause damage to the goods. It is still another object of the present invention to provide a device that allows high packing density of odd shapes. It is yet another object of the present invention to provide a device that is fully capable of being broken down to improve the effectiveness of cleaning and to reduce storage space. It is yet another object of the present invention to provide an apparatus that is capable of being used in a conventional or microwave oven. It is yet another object of the present invention to provide an apparatus that is capable of producing goods with uniform shapes and thickness. It is yet another object of the present invention to provide an apparatus that is capable of inserting a stick or handle to the material being molded or baked prior to baking/molding.
[0009] The present invention achieves these and other objectives by providing a device that is capable of shaping and molding material. The present invention is an apparatus for shaping and molding material comprising two sidewalls, two end walls, a bottom plate and one or more partitions. The inside surface of the two sidewalls has one or more grooves or slots spaced along the inside surface at predetermined intervals. One of the side walls, i.e. the first sidewall, has one or more surface portions on its inside surface and the inside surface of the other side wall, i.e. the second sidewall, has at least one more surface portion than the inside surface of the first side wall. For example, if first sidewall has two surface portions, then second sidewall has at least three surface portions. The sidewalls also have a bottom ledge or shelf extending out from the inside surface. Additionally, the sidewalls have one or more apertures or holes positioned adjacent to the grooves or slots that extend through the given side wall where the aperture(s) or hole(s) is located. For example, a hole may be placed between two adjacent grooves or between a groove and the end wall.
[0010] The end walls are removably attached between the ends of the sidewalls. The connection between a side wall and end wall may be attached using a pinned connection, a latch, band, tongue and groove, etc. The bottom plate has a side edge that conforms to the inside surface of the sidewalls. For example, if the inside surface of the sidewalls had multiple arc shapes, then the bottom plate would conform to those arc shapes. One or more partitions are used to divide the material in the pan into smaller shapes. A given partition is sized to slide into the grooves or slots between the two sidewalls. The partition may be single piece for sliding into two opposed grooves or the partition may be a single, continuous piece formed to slide into a multiple of opposed grooves so that only one partition is used to make a plurality of product pieces. If more than one partition is used, two partitions may be inserted into one groove creating a triangular effect between the sidewalls. The partitions may be single-walled or double-walled. The double-walled design may help distribute heat to the material in the pan that requires cooking such as a cake. The double-walled design is also helpful when cooling the material in the pan when chilling is required such as when making flavored gelatin or molding ice cream and the like.
[0011] The bottom plate may be flat, indented to form a “character face” or other design, or have inverted domes that align with the partitions and grooves to create a one-half cone shape. The present invention may also include a bottom support. The bottom support prevents the bottom plate from dropping when disassembling the pan.
[0012] The sidewalls may have multiple embodiments. For instance, one embodiment may have a sidewall with an array of notches spaced at predetermined intervals with a top plate that has an array of matching protrusions spaced at the same predetermined intervals as the notches. Mating of the notches and protrusions of the sidewall and the top plate forms the apertures previously mentioned. This arrangement allows removal of the finished unit on a stick by first removing the top plate, end walls, then pulling out the sidewalls and removing the stick from the notch. A block attached to the top plate may also be sized for plugging the notches not needed in a given arrangement. A second embodiment would also have the notches and protrusions, however, the sidewall is a two piece sidewall where each piece has matching inside surfaces.
[0013] In one embodiment of the present invention the apparatus also includes a lid section that may be placed over the pan, resting on the sidewalls and end walls. The lid is used to cover the material in the pan for shaping the material. Additionally, the lid aids in stacking multiple pans, one on top of the other. Stacking increases the efficiency when baking goods in a commercial oven. The lid may also include one or more design shaping molds affixed to one side. When the lid is placed over the material being shaped or molded, the design-shaping mold on the lid presses into the material. This mold on the lid adds ornamental designs to the surface of the material. The lid section may also include one or more apertures. A stick or handle to hold the molded piece may be added by inserting it through the aperture in the lid. Once the molded piece is set, the stick is affixed to the material providing the handle.
[0014] The device may also include one or more handles attached to one or more of the side walls, the first end wall, the second end wall, the bottom plate, or the partition pieces. Handles may be shaped like a cylindrical rod, a U-shaped bar, a plate structure, etc. The handles make it easier to assemble or disassemble the pan and to remove the finished product.
[0015] Another embodiment of the present invention may further comprise an inside surface that has one or more shaping contours spaced adjacent to the grooves. The shaping contours may include, but is not limited to, an arch shape design, tree shape design, etc. In addition, if an arch shape design is used, the arch shape may have a radius that is substantially equal to a given partition. Arch shape designs may be arranged so that the final product looks as if the pieces were cut from a circle.
[0016] Another embodiment includes a pivot between the walls to assist in assembly and disassembly of the pan. In this arrangement the first end wall is pivotally attached to one end of a sidewall. The second end wall may also be pivotally attached to the end of a sidewall. When the pan is disassembled, the end walls would remain attached to the sidewalls with the pivots. When reassembling the pan, the end walls are rotated into place against the opposite sidewall and then latched at that end to complete the assembly of the pan. The pivot minimizes the time and skill required reassembling the pan.
[0017] To prevent the bottom plate from dropping during disassembly of the pan, another embodiment provides a bottom plate comprising a first section that conforms to the inside surface of the side walls and a second section that is substantially the same thickness as the bottom ledge of the side walls. The first section is removably attached to the second section. In the alternative, the bottom plate may comprise a first section that conforms to the inside surface of the sidewalls and a second section that is greater than the thickness of the bottom ledge of the sidewalls. This way the first section is also removably attached to the second section, but the second section extends under the sidewalls to add further stability to the pan.
[0018] Another embodiment of the present invention may further provide the aperture in the sidewall designed so as to accommodate at least one elongated holding member. The elongated holding member may include, for example, a stick, a rod, a handle, a bar, a tube, etc. The holding member may be made from a variety of different materials, for example, wood, metal, ceramic, plastic, etc. Additionally, the side wall thickness is designed to hold the elongated holding member at a fixed angle or parallel to the bottom plate when inserted through the aperture and into the material. One or more of the apertures may also be sized to match at least one elongated holding member. For example, the aperture may be designed to match the holding member by having a shape of a square, a rectangle, a triangle, a circle, a star, a polygon, a crescent, an oval and the like.
[0019] When an aperture is not required and holding members are not desired in the material, a plug sized to fit into the apertures may be used. Thus, an aperture may be plugged when a holding member is not placed in a given aperture.
[0020] To use the pan after assembly, one would start by spreading or pouring a material into the pan. After evenly spreading the material, at least one partition is inserted into the pan by sliding the partition into two opposed notches in the sidewalls. By pushing the partition until it contacts the bottom of the pan, the material is separated into portions. As many partitions may be inserted into the pan as there exists opposing grooves. It should be noted that the partitions need not be the same shape. Finally, one or more sticks are inserted through a similar number of apertures in the sidewalls and into the material. An alternative is to insert the sticks through the apertures before adding the material to the present invention.
[0021] After the partitions and sticks have been inserted in the pan, a lid may be placed over the pan. This would allow the pans to be stacked and protect the finished goods. Stacking pans optimizes the use of space whether on a table, counter, or an oven, refrigerator or baker's shelves. The lid may also have at least one opening to allow placing at least one elongated holding member through the lid into the material or mixture. The holding member may be placed through apertures in the sidewalls and/or in the lid. This option allows the design of a piece being set to have a holding member hold the piece in a vertical or horizontal plane. The lid may also have at least one design-shaping mold affixed to the inside portion of the lid that would be pressed into the mixture. Character features and other designs may be placed in the material being set.
[0022] Further objects and advantages of this invention will be more clearly apparent during the course of the following description, references being had to the accompanying drawings which illustrate a preferred form of the device of the invention and wherein like characters of reference designate like parts throughout the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a perspective view of an apparatus for shaping and molding material that is constructed in accordance with the present invention.
[0024] [0024]FIG. 2 is a perspective, exploded view of the apparatus in FIG. 1.
[0025] [0025]FIG. 2A is a perspective view of the present invention showing a lid.
[0026] [0026]FIG. 2B is a cross-sectional view of the aperture portion of the present invention showing a plug in the aperture.
[0027] [0027]FIG. 3 is a cross-sectional view of the present invention showing a holding member held in place through an aperture in the sidewall.
[0028] [0028]FIG. 4 is a cross-sectional view of one embodiment of the bottom plate of the present invention.
[0029] [0029]FIG. 5 is a cross-sectional view of another embodiment of the bottom plate of the present invention.
[0030] [0030]FIG. 6 is a perspective view of another embodiment of the sidewall of the present invention having two sections that form the apertures when assembled.
[0031] [0031]FIG. 7 is a perspective view of another embodiment of the side wall of the present invention having two sections where one section is a top plate with downwardly extending blocks.
[0032] [0032]FIG. 8 is a perspective view of various embodiments of the partitions used in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] For the purposes of promoting an understanding of the principles of the invention, references will now be made to the preferred embodiment of the present invention as illustrated in FIGS. 1 - 7 , and specific language used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. The terminology used herein is for the purpose of description and not limitation. Any modifications or variations in the depicted method or device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
[0034] Referring now to FIG. 1, there is shown a perspective view of a container or pan 10 having a first side wall 20 , a second side wall 30 , a first end wall 40 , a second end wall 50 , and a bottom plate 60 . Container 10 is arranged so that the sidewalls 20 and 30 are opposite each other. Sidewalls 20 and 30 have partition channels 26 at spaced intervals along their inside surfaces 24 . Inside surface 24 of sidewall 20 has one or more surface portions 24 ′. Inside surface 24 of sidewall 30 has one more surface portion 24 ′ than the number of surface portions 24 ′ on sidewall 20 . First end wall 40 and second end wall 50 are designed to form a snug fit between sidewalls 20 and 30 and are held in place by latch mechanisms 32 and 34 , respectively. Bottom plate 60 interfaces with the sidewalls 20 and 30 and first end wall 40 and second end wall 50 to complete container 10 . Partitions 70 are arranged between the sidewalls 20 and 30 to section off individual compartments within container 10 . A hole or aperture 80 is placed in side walls 20 and 30 between partition channels 26 or between a partition channel 26 and a first end wall 50 or second end wall 60 . Also shown is bottom support 62 that supports bottom plate 60 during disassembly so as to prevent bottom plate 60 and the molded material within container 10 from falling and wedging the sticks if used.
[0035] Turning now to FIG. 2, there is illustrated container 10 in exploded view to show the individual components. First sidewall 20 and second sidewall 30 have a bottom ledge 22 . Bottom ledge 22 is designed to support bottom plate 60 when container 10 is assembled. Bottom ledge 22 must be strong enough to hold bottom plate 60 in place as well as any baking or molding material placed inside of container 10 . Sidewalls 20 and 30 also have inside surface 24 found along the inner wall of the container 10 . Inside surface 24 may be flat or have a scalloped surface as illustrated. Inside surface 24 may also have a variety of different molding shapes, depending on the effect one wishes to create. FIG. 2A shows a lid or cover 85 sized to fit over pan 10 . Cover 85 is supported by sidewalls 20 , 30 and end walls 40 , 50 . A handle 86 may optionally be affixed to sidewalls 20 and/or 30 to facilitate handling of pan 10 . FIG. 2B is a cross-section along line B-B′ in FIG. 2A. Plug element 92 is used to fill aperture 80 when a holding member is not used. Plug element 92 may have any structure provided that it plugs or fills aperture 80 to prevent any material placed within pan 10 does not leak out of an aperture 80 that does not have a holding member therein.
[0036] Grooves or notches 26 are located between sections of inside surface 24 . Grooves 26 are preferably placed along inside surface 24 at evenly spaced intervals. However, the spaced intervals may be uneven depending on a given mold design. Apertures 80 are located between grooves 26 or between a groove 26 and first end wall 40 or second end wall 50 . Partitions 70 are placed between the sidewalls 20 and 30 , and fit into opposed grooves 26 . Grooves 26 are offset on opposing sidewalls 20 and 30 so that any two adjacent partitions 70 would generally form a “V” shape.
[0037] The bottom plate 60 is shaped to match inside surface 24 of sidewalls 20 and 30 . In this way, bottom plate 60 forms a good fit with sidewalls 20 and 30 to retain the material placed into container 10 . The illustration also shows a detachable bottom support 62 . Bottom support 62 is designed to fit underneath bottom plate 60 in the space between bottom ledges 22 of sidewalls 20 and 30 . However, bottom support 62 is not needed until the finished product is complete and the material is to be removed from pan 10 .
[0038] When the pan 10 is disassembled, locking mechanism 32 and 34 are unlatched so that first end wall 40 and second end wall 50 may be removed. Sidewalls 20 and 30 are then pulled out away from the bottom plate 60 . Bottom support 62 prevents bottom plate 60 from dropping during the disassembly process, which prevents the stick, if used, from wedging and causing the molded material from breaking up. Bottom support 62 is connected to the bottom plate 60 by way of an alignment pin 64 spaced from each end of bottom support 62 . Alignment pin 64 fits into a corresponding hole 66 located on each end of the bottom plate 60 . It should be understood that the use of alignment pin 64 is not necessary, nor is hole 66 required in bottom plate 60 . The use of these features simply makes using pan 10 a little easier. Bottom support 62 and bottom plate 60 may also be made or combined to form one bottom plate 60 . For example, bottom plate 60 may be constructed as a one-piece unit or two-pieces integrally formed. Bottom plate 60 may be machined, molded or cast.
[0039] First end wall 40 and second end wall 50 are hingedly attached to first sidewall 20 in this illustration of the present invention at hinged connections 42 and 52 . Hinged connections 42 and 52 make it relatively easy for a user to assemble container 10 . Using an embodiment that does not have first end wall 40 and second end wall 50 privotally attached to first side wall 20 or second side wall 30 requires a user to fit the parts together in a skillful manner (like a puzzle). Opposite ends 44 and 54 of first end wall 40 and second end wall 50 are connected to the second side wall 30 using latched connections 32 and 34 . Latched connections 32 and 34 hold the side walls 20 and 30 , first end wall 40 , second end wall 50 , and bottom plate 60 together to make container 10 .
[0040] Referring to FIG. 3, a cross-section of container 10 is illustrated showing sidewall 30 and bottom plate 60 . Aperture 80 extends through sidewall 30 and is positioned between two grooves 26 (not shown). Aperture 80 is sized to accommodate a holding member 90 in a horizontal position in container 10 while the material solidifies. The holding member 90 may be a stick, a bar, a tube, or any device used to insert into the material and to hold the material onto holding member 90 . Wooden tongue depressors or craft sticks are examples of useable devices for holding member 90 .
[0041] Referring to FIG. 4, there is illustrated a cross-sectional view of another embodiment of bottom plate 60 . This embodiment shows bottom plate 60 as having a lower section 62 . Bottom plate 60 with lower section 62 may be a unitary piece that is molded or cast as one piece or an integral piece where lower section 62 is attached to bottom plate 60 . This embodiment of bottom plate 60 also prevents bottom plate 60 from falling during disassembly and helps prevent the molded material from breaking up.
[0042] Referring now to FIG. 5, there is shown a cross-sectional view of another embodiment of lower section 62 . This embodiment shows lower section 62 not only supporting bottom plate 60 but also supporting first sidewall 20 and second sidewall 30 . This design gives container 10 more stability.
[0043] Referring now to FIG. 6, there is shown another embodiment of first sidewall 20 and second sidewall 30 of the present invention. First sidewall 20 is shown having two sections, top section 20 a and bottom section 20 b. Top section 20 a has an array of spaced protrusions 21 a and bottom section 20 b has an array of spaced recesses 21 b that fit together like a puzzle to form sidewall 20 . When top section 20 a and bottom section 20 b are fitted together, protrusions 21 a and recesses 21 b form aperture 80 . This embodiment of sidewall 20 allows a molded material having a handle to be more easily removed from container 10 . Top section 20 a and bottom section 20 b may be held together by any convention means, particularly by means that allows for easy assembly and disassembly. It should be understood that top section 20 a and bottom section 20 b may both have matching recesses sized to form aperture 80 , or top section 20 a may be flat with bottom section 20 b having recesses sized to form aperture 80 when top section 20 a is joined to bottom section 20 b.
[0044] [0044]FIG. 7 shows another embodiment of first sidewall 20 . In this embodiment, top section 20 a is a top plate with an array of spaced protrusions 21 a. Bottom section 20 b has an array of spaced recesses 21 b. The difference is that bottom section 20 b is the full depth of container 10 and that top section 20 a does not have a matching inside surface 24 like bottom section 20 b. As in the previous embodiment, protrusions 21 a and recesses 21 b form a plurality of apertures 80 when top section 20 a is fitted to bottom section 20 b.
[0045] Referring now to FIG. 8, there is shown several different embodiments of partition 70 that can be used with the present invention. Partition 70 a is shown as being a straight piece that can be inserted into two opposing grooves 26 of container 10 . Partition 70 b is shown having a scalloped design that may give the molded material the shape of a tree. Partition 70 c is shown having a connected “V” shape. Any number of shapes and designs may be made and used to give the molded material the desired look. As previously stated, partition 70 a, 70 b and 70 c may be double-walled in order to provide more consistent heating or cooling to the individual portions in container 10 . Further, partition 70 may be created as a single piece forming multiple partitions where a plurality of apexes slide into a plurality of corresponding grooves 26 when placed into pan 10 . The component parts of pan 10 may also be coated with anti-stick material to prevent the finished product from adhering to pan 10 .
[0046] Although a specific form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. | An apparatus and method for shaping and molding material having two sidewalls, two end walls, a bottom and at least one partition. The two sidewalls have grooves spaced at predetermined intervals on an inside surface for receiving a partition and a bottom ledge for retaining the bottom. The inside surface has a plurality of openings sized for receiving holding members and may have a variety of shapes. The bottom is shaped to mate with the shape of the inside surface of the sidewalls. The two end walls include locking mechanisms for holding the various components of the apparatus together. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a novel reactive dyestuff, and more particularly relates to a reactive dyestuff with alkylthio-s-triazine.
[0003] 2. Description of the Related Art
[0004] During the period between the 1960's and early 1980's, the art of a reactive dyestuff with mono alkylthio-s-triazinyl reactive group was developed. The development was mainly focused on the art of a reactive dyestuff used thio/sulphur chemistry, which contains s-triazine or pyramine, as disclosed in British Patent No. GB 923068.
[0005] During 1986-1996, the research of a reactive dyestuff was continuously developed but limited to a certain scope of chromophore groups, as disclosed in European Patent No. EP 0264878 and Japanese Patent No. JP 10-001618. A reactive dyestuff taking monochloro triazine and vinylsulfone as the bifunctional reactive group is the mainstream in the present market of 60° C. warm dyeing. However, the activity of the two reactive groups is so different that it mainly uses vinylsulfonyl reactive group to fix the dyes on the cellulose fibers in the application of dyeing. On the contrary, the use of monochloro triazinyl reactive group is relatively low, since the monochloro triazine is a reactive group for 80° C. application. While replacing the monochloro triazine with monofluoro triazine, the activity thereof may be nearly equal to that of the vinylsulfonyl reactive group and the tinctorial yield of the dyestuff may be improved. However, the cost of trifluoro triazine is too high so that the economic benefits of the dyestuffs become low. The present invention provides an alkylthio group as a substituent for monochloro triazine, which makes the activity of the reactive group equal to that of the vinylsulfonyl reactive group and improves efficiently the utilization of the reactive group. Thereby, the dyestuff of the present invention presents properties of high fixation and excellent build up, and has greater economic benefits than that of the dyestuff containing monofluoro triazine. The novel reactive dyestuff of the present invention has improved properties, such as better reactivity, fixing capacity, build up, stable binding between fibers and dyestuffs, excellent wash fastness, light fastness and wet fastness.
[0006] In other words, the present invention provides a novel dyestuff with bifunctional reactive groups, comprising an alkylthio group substituent to improve the activity of monochloro triazine, which has higher reactive selectivity and economic benefits.
SUMMARY OF THE INVENTION
[0007] The present invention provides a reactive dyestuff containing an alkylthio-s-triazinyl reactive group of the following formula (I),
[0000]
[0000] wherein
X, Y and Z are each independently selected from the group consisting of hydrogen, chlorine, hydroxyl, amino, substituted amino, sulfonate, arylazo,
[0008]
[0000] alkyl, alkoxy, α,β-halopropionyl, α-haloacryloyl, —B—SO 2 CH 2 CH 2 W, —B—SO 2 CH═CH 2 , -SO 2 CH 2 CH 2 W and —SO 2 CH═CH 2 ;
[0009] B is —CONH—(CH 2 ) i — or —O—(CH 2 ) j —CONH—(CH 2 ) k —, wherein i, j and k are integers independent of one another between 2 to 4;
W is selected from the group consisting of Cl, —OSO 3 H,
[0010]
[0000] wherein R 9 , R 10 and R 11 are each independently C 1-4 alkyl
Q is C 1-4 alkyl or substituted C 1-4 alkyl;
A is one or more chromophore groups substituted by one or more sulfo;
[0011] a is 1 or 2;
R is hydrogen, C 1-4 alkyl, or C 1-4 alkyl substituted by hydroxyl, C 1-4 alkoxy or carboxyl.
[0012] The reactive dyestuff of formula (I) of the present invention contains one or more chromophore groups, which can connect with one or more sulfo and at least two fiber-reactive groups, wherein one of the fiber-reactive groups must be
[0000]
[0013] In the reactive dyestuff of formula (I) of the present invention, Q is preferable a methyl or ethyl group, which is unsubstituted or substituted by one to three substitutent groups. The substitutent groups of the methyl or ethyl group are independently selected from the group consisting of halogen, hydroxyl, sulfo, cyano, amino, carbonamido, carboxyl, alkoxycarbonyl, acyloxy and alkoxy.
[0014] In the reactive dyestuff of formula (I) of the present invention, the chromophore group A is preferably selected from the group consisting of formazan, anthraquinone, phthalocyanine, triphendioxazine, monoazo, disazo, polyazo and metal complex azo.
[0015] Preferably, the structure of phthalocyanine chromophore group is as the following formula:
[0000]
[0000] wherein Pc is copper phthalocyanine or nickel phthalocyanine; U is —OH and/or —NH 2 ; E is phenylene or ethylene; and c+d≦4.
[0016] The triphendioxazine chromophore group is preferably selected from the group consisting of:
[0000]
[0000] wherein E is phenylene or ethylene.
[0017] The monoazo chromophore group is preferably selected from the group consisting of:
[0000]
[0000] wherein
R 1 is halogen, C 1-4 alkyl, C 1-4 alkoxyl, carboxyl, sulfo, —SO 2 CH 2 CH 2 W or
—SO 2 CH═CH 2 , and W is defined the same as the aforementioned;
R 2 is C 1-4 alkyl, C 1-4 alkoxyl, amino, acetylamino, ureido or sulfo;
R 4 is C 1-4 alkyl or carboxyl; and
[0018] m, o and p are each independently 0, 1, 2 or 3.
[0019] The disazo and polyazo chromophore groups are preferably selected from the group consisting of:
[0000]
[0000] wherein
R 8 is C 1-4 alkyl, C 1-4 alkoxyl, carboxyl, sulfo, acetyl, acetyl amino, ureido,
—SO 2 CH 2 CH 2 W or —SO 2 CH═CH 2 and W is defined the same as the aforementioned;
[0020] q, r, s, t and u are each independently 0, 1, 2 or 3;
R 2 , m, o and p are defined the same as the aforementioned.
[0021] The metal complex azo chromophore group is preferably selected from the group consisting of:
[0000]
[0000] wherein
m and o are defined the same as the aforementioned.
[0022] For describing conveniently, the compound is expressed as free acid in the specification. When produced or used, the reactive dyestuffs of the present invention are often presented as water-soluble salts. The salts suitable for the present invention may be the alkaline metal salts, alkaline earth metal salts, ammonium salts or organic amine salts; preferably, the salts are sodium salts, potassium salts, lithium salts, ammonium salts or triethanolamine salts.
[0023] The dyestuff of the present invention can be applied to dye and print on many kinds of fiber materials, particularly cellulose fiber materials and cellulose-included fiber materials. The examples of the fiber materials are not limited. It can be natural or regenerated cellulose fibers, such as cotton, hemp, linen, jute, amine, mucilage rayon, as well as cellulose-included fiber materials. The dyestuff of the present invention can also be applied to dye and print fiber blended fabrics containing hydroxyl groups.
[0024] The dyestuff of the present invention can be applied to the fiber material and fixed on the fiber in various ways, in particularly in the form of aqueous dyestuff solutions and printing pastes. They can be applied to cellulose fibers by general dyeing methods, such as exhaustion dyeing, continuous dyeing, cold-pad-batch dyeing, printing or digital printing.
[0025] The dyeing or printing of the present invention can be proceeded by the conventional and usually known method. For example, exhaustion dyeing is applied by using separately or mixing the well-known inorganic salts (e.g. sodium sulfate and sodium chloride) and acid-binding agents (e.g. sodium carbonate, sodium hydroxide). The amount of inorganic salts and alkali does not matter. The inorganic salts and alkali can be added either once or several times into the dyeing bath through traditional methods. In addition, dyeing assistant agents (such as leveling agent, suspending agent and so on) can be added according to conventional method. The range of dyeing temperature is from 40° C. to 90° C. Preferably, the temperature for dyeing is from 40° C. to 70° C.
[0026] In the cold-pad-batch dyeing method, the material is padded by using the well-known inorganic salts (e.g. sodium sulfate and sodium chloride) and acid-binding agents (e.g. sodium carbonate, sodium hydroxide). The padded fabric is rolled and stored at room temperature to allow dye fixation to take place.
[0027] In the continuous dyeing method, two different methods exist. In the one-bath pad dyeing method, the material is padded according to the conventional method in the mixture of the well-known acid-binding agents (e.g. sodium carbonate or sodium bicarbonate) and the pad liquid. The resultant material is then dried and color fixed by baking or steaming. In the two-bath pad dyeing method, the material is padded with a dye liquid and then dealt by a known inorganic neutral salt (e.g., sodium sulfate or sodium silicate). The dealt material is preferably dried and color fixed by baking or steaming as usual.
[0028] In the textile printing method, such as single printing method, the material is printed by printing slurry containing the known acid-binding agent (e.g., sodium bicarbonate) and is dried and color fixed by baking or steaming. In the two-phase printing method, the material is dipped in a solution containing inorganic neutral salt (e.g., sodium chloride) and the known acid-binding agent (e.g., sodium hydroxide or sodium carbonate) in a high temperature of 90° C. or above to fix the color. The dyeing or printing methods employed in the process of the present invention are not limited to the above methods.
[0029] The dyestuff of the present invention is a valuable reactive dyestuff for cellulose fibers in the present dyeing industry. The dyestuff has properties of excellent fixing capacity, outstanding build up and high wash-off and is suitable for dyeing in a wide range of temperatures, which make the dyestuff suitable for dyeing cotton/polyester blended fabrics as well. The dyestuff of the present invention is also suitable for printing, particularly when applying in printing cotton or blended fabrics that contain wool or silk. In the dyeing or printing of cellulose fiber materials, dyed products with various fine dyeing properties are obtained; particularly dyeing, printing or batch-up dyeing products with high quality can be obtained in respect of build up and wash fastness.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] The dyestuff of the present invention may be prepared by conventional methods, of which diazotization, coupling and condensation reaction are usually used in the field and can be accomplished by one skilled in the art.
[0031] Hereinafter, the present invention will be further explained. However, it is to be understood that the examples below are only for illustrated, but not to limit the scope of the present invention. The compounds are represented in the form of free acid. However, in practice, they often exist as metallic salts, and most likely alkaline metallic salts, particularly sodium salts. Unless otherwise stated, the parts and percentage used in the following examples are based on weight, and the temperature is in Celsius degree (° C.).
EXAMPLE 1
[0032] (a) 19.45 parts of cyanuric chloride is dispersed in 150 parts of 0° C. water, and then 31.9 parts of 2-amino-5-hydroxy-naphthalene-1,7-disulfonic acid powder is added therein. The pH value of the reaction solution is adjusted to 3 by 15% of Na 2 CO 3 aqueous solution. The temperature of the aqueous solution is raised smoothly to 20° C. and then maintained for 1˜2 hours.
[0033] (b) 9.7 parts of thioglycolic acid is added to the solution obtained from the above (a) step. At 20° C., the pH value of the reaction solution is adjusted to 7˜7.5 by 18 parts of Na 2 CO 3 powder and maintained for 15 minutes, followed by adjusting the pH value of the reaction solution to 6˜6.5 by HCl aqueous solution. The filter cake is obtained by well-known NaCl salting-out and filtration.
[0034] (c) 29.5 parts of 2-methoxy-4-(β-sulfatoethylsulfonyl)aniline and 30 parts of 32% HCl aqueous solution are added to 150 parts of 0° C. water and then the solution is stirred thoroughly, followed by the rapid addition of 7.2 parts of sodium nitrite aqueous solution. Diazotization is carried out for 1.5 hours at 0˜5° C., followed by the addition of the filter cake obtained from the above (b) step. The pH value is adjusted slowly to 6˜6.5 by sodium bicarbonate. After completion of the reaction, the orange product of the following formula (1) is obtained by salting-out, filtration and dryness.
[0000]
EXAMPLE 2
[0035] (a) 19.45 parts of cyanuric chloride is dispersed in 150 parts of 0° C. water, and then 31.5 parts of 1-naphthol-8-amino -3,6-disulfonic acid powder is added therein. The pH value of the reaction solution is adjusted to 3 by 15% of Na 2 CO 3 aqueous solution. The temperature of the aqueous solution is raised smoothly to 20° C. and then maintained for 1˜2 hours.
[0036] (b) 9.7 parts of thioglycolic acid is added to the solution obtained from the above (a) step. At 20° C., the pH value of the reaction solution is adjusted to 7˜7.5 by 18 parts of Na 2 CO 3 powder and maintained for 15 minutes, followed by adjusting the pH value of the reaction solution to 6˜6.5 by HCl aqueous solution. The filter cake is obtained by well-known NaCl salting-out and filtration.
[0037] (c) 29 parts of 4-(β-sulfatoethylsulfonyl) aniline and 50 parts of 32% HCl aqueous solution are added to 150 parts of 0° C. water and then the solution is stirred thoroughly, followed by the rapid addition of 7.2 parts of sodium nitrite aqueous solution. Diazotization is carried out for 1.5 hours at 0˜5° C., followed by the addition of the filter cake obtained from the above (b) step. The pH value is adjusted slowly to 6˜6.5 by sodium bicarbonate. After completion of the reaction, the red product of the following formula (2) is obtained by salting-out, filtration and dryness.
[0000]
EXAMPLE 3
[0038] (a) 19.45 parts of cyanuric chloride is dispersed in 150 parts of 0° C. water, and then 18.8 parts of 1,3-phenylenediamine-4-sulfonic acid powder is added therein. The pH value of the reaction solution is adjusted to 3 by 15% of Na 2 CO 3 aqueous solution. The temperature of the aqueous solution is raised smoothly to 20° C. and then maintained for 1˜2 hours.
[0039] (b) 9.7 parts of thioglycolic acid is added to the solution obtained from the above (a) step. At 20° C., the pH value of the reaction solution is adjusted to 7˜7.5 by 18 parts of Na 2 CO 3 powder and maintained for 15 minutes, followed by adjusting the pH value of the reaction solution to 6˜6.5 by HCl aqueous solution. The filter cake is obtained by well-known NaCl salting-out and filtration.
[0040] (c) 19.5 parts of the filter cake obtained from the above (b) step and 25 parts of 32% HCl aqueous solution are added to 150 parts of 0° C. water and then the solution is stirred thoroughly, followed by the rapid addition of 3.6 parts of sodium nitrite aqueous solution. Diazotization is carried out for 1.5 hours at 0˜5° C., followed by the addition of 16.0 parts of 1-naphthol-8-amino -3,6-disulfonic acid powder. The pH value is adjusted slowly to 3 by 10 parts of sodium bicarbonate. After completion of the reaction, the filter cake is obtained by salting-out and filtration.
[0041] (d) 16.55 parts of 1-aminobenzene-4-(β-sulfatoethylsulfonyl)-2-sulfonic acid and 12.6 parts of 32% HCl aqueous solution are added to 150 parts of 0° C. water and then stirred thoroughly, followed by the rapid addition of 3.7 parts of sodium nitrite aqueous solution. Diazotization is carried out for 1˜2 hours at 0˜5° C. and then the filter cake obtained from the above (c) step is added into the diazonium salt solution. The pH value is adjusted slowly to 5˜6 by sodium carbonate. After completion of the reaction, the navy product of the following formula (3) is obtained by salting-out, filtration and dryness.
[0000]
[0042] According to the synthetic methods of Example 1˜3, the dyestuffs of the following examples 4˜36 are obtained. In the table, the color appearance is the color of the dyestuff dissolved in water.
[0000]
Exam-
color
ple
Structure of dyestuff
appearance
4
BrilliantYellow
5
Yellow
6
Yellow
7
Yellow
8
Yellow
9
Yellow
10
Yellow
11
Yellow
12
Orange
13
Orange
14
Orange
15
Orange
16
Orange
17
Dull Orange
18
Red
19
Red
20
Red
21
Red
22
Red
23
Red
24
Red
25
Red
26
Red
27
Brown
28
Scarlet
29
Rubin
30
Violet
31
Navy
32
Navy
33
Navy
34
Navy
35
Navy
36
Green
EXAMPLE 37
[0043] (a) 19.45 parts of cyanuric chloride is dispersed in 150 parts of 0° C. water, and then 18.8 parts of 1,3-phenylenediamine-4-sulfonic acid powder is added therein. The pH value of the reaction solution is adjusted to 3 by 15% of Na 2 CO 3 aqueous solution. The temperature of the aqueous solution is raised smoothly to 20° C. and then maintained for 1˜2 hours for the next step.
[0044] (b) 9.7 parts of thioglycolic acid is added to the solution obtained from the above (a) step. At 20° C., the pH value of the reaction solution is adjusted to 7˜7.5 by 18 parts of Na 2 CO 3 powder and maintained for 15 minutes, followed by adjusting the pH value of the reaction solution to 6˜6.5 by HCl aqueous solution. The filter cake is obtained by well-known NaCl salting-out and filtration.
[0045] (c) 19.5 parts of the filter cake obtained from the above (b) step and 25 parts of 32% HCl aqueous solution are added to 150 parts of 0° C. water and then the solution is stirred thoroughly, followed by the rapid addition of 3.6 parts of sodium nitrite aqueous solution. Diazotization is carried out for 1.5 hours at 0˜5° C., followed by the addition of 8.0 parts of 1-naphthol-8-amino-3,6-disulfonic acid powder. The pH value is adjusted slowly to 3 by 10 parts of sodium bicarbonate to accomplish the coupling reaction. After completion of the reaction, the dark blue product of the following formula (37) is obtained by salting-out, filtration and dryness.
[0000]
EXAMPLES 38-46
[0046] According to the synthetic method of Example 37, the dyestuffs of the following examples 38˜46 are obtained. In the table, the color appearance is the color of the dyestuff dissolved in water.
[0000]
Example
Structure of Dyestyff
Color appearance
38
Orange
39
Red
40
Red
41
Red
42
Scarlet
43
Navy
44
Green
45
Blue
46
Turquoise
TESTING EXAMPLE 1
[0047] 0.25 parts of the dyestuff as prepared in example 1 is dissolved in 250 mL of water to obtain a dye liquid. To 40 mL of the dye liquid, in a dyeing bottle, 2 parts of cotton fabric is added, followed by addition of 2.4 parts of Glauber's salt, and finally 2.5 mL of 32% alkali solution. The dyeing bottle is placed in a horizontal shaking bath at 60° C. while maintaining the temperature for 60 minutes. The obtained golden fabric is orderly washed with cold water, boiling water for 10 minutes, boiling non-ionic detergent for 10 minutes, and again with cold water and then dried to obtain an orange dyeing product with good build up and tinctorial yield.
TESTING EXAMPLE 2
[0048] 100 parts of Urea, 10 parts of m-nitrobenzene sulfonic acid sodium salt, 20 parts of sodium bicarbonate, 55 parts of sodium alginate, and 815 parts of lukewarm water are stirred in a vessel to obtain a completely homogeneous printing paste.
[0049] 3 parts of the dyestuff prepared in example 2 is sprayed in 100 parts of the above printing paste and stirred to make a homogeneous colored paste. An adequate size piece of twilled cotton fabric is covered with a 100 mesh 45°-twilled printing screen and then painted with the colored paste on the printing screen to give a colored fabric.
[0050] This colored fabric is placed in an oven at 65° C. for 5 minutes until dry and then put into a steaming oven using saturated steam of 102˜105° C. for 10 minutes.
[0051] The obtained rosy fabric is orderly washed with cold water, boiling water for 10 minutes, boiling non-ionic detergent for 10 minutes, again with cold water and then dried to obtain a red fabric with good build up and good tinctorial yield.
TESTING EXAMPLE 3
[0052] 3 parts of the dyestuff prepared in example 3 is dissolved in 100 mL of water to obtain a 30 parts/l padding liquor. 25 ml of alkali solvent (taking 15 ml/l of NaOH (38° Be′) and 30 parts/l of Glauber's salt) is added to the padding liquor and stirred thoroughly. The resultant solution is then put into a pad roller machine. The cotton fabric is padded by the roller pad machine, and batched for 4 hours under room temperature. The obtained orange fabric is orderly washed with cold water, boiling water for 10 minutes, boiling non-ionic detergent for 10 minutes, again with cold water and then dried to obtain a navy fabric with good build up and good tinctorial yield.
[0053] From the foregoing description, the technology according to the present invention achieves the objects of the invention and conforms to the patent requirements of novelty, inventive step and industrial applicability. Although the present invention has been explained in relation to its preferred examples, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the invention as hereinafter claimed. | A reactive dyestuff containing an alkylthio-s-triazinyl reactive group of the following formula (I) is disclosed,
wherein A, X, Y, Z, R, Q, and a are defined the same as the specification. It is suitable for exhaust dyeing, cold batch-up dyeing and continuous dyeing materials that contain hydroxyl group or nitrogen group fibers. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to a closure for a container and particularly to a closure with means for indicating that a closure has been opened at least once.
BACKGROUND OF THE INVENTION
[0002] There is an increasing demand for tamper-indicating systems which ensure that a container is not re-filled with non-original contents. Whilst it is relatively easy to produce some form of tamper-evidence, it is much more difficult to provide tamper-evidence which cannot be either overcome without causing the tamper-evidence system to activate, or activate and then return to a virtually visually identical state so as to appear non-activated.
[0003] A particularly useful method of providing tamper-evidence is to use a system in which a closure is initially located in a first position, but once removed can only be returned to a second position which is visually distinct from the first.
[0004] U.S. Pat. No. 5,738,231 describes a closure with a part which is moved during the opening process so that following opening it cannot pass back over projection on a container finish. The result is that the closure can only return to position which is axially displaced with respect to its original position.
[0005] WO 02/096771 describes a closure in which two parts are initially adjacent each other and during the opening process the structure of the closure is changed so that a gap is generated between the two parts as a visual indication that the closure has been opened at least once.
[0006] WO 2005/049443 and WO 2006/117505 also describe closures which generate a gap to indicate they have been opened at least once. In this case the gap is unobstructed. In other words, two parts of the closure are held apart without the requirement an obstruction.
[0007] Such tamper-evident systems are only effective if they cannot be reversed. For example, in systems which use an obstructing member to hold two parts apart it is possible to cut the obstruction member to allow a gap to be closed. WO 2005/049443 and WO 2006/117505 describe closures which generate unobstructed gaps following relative rotation of one part with respect to another. The closures are provided with some internal mechanism for preventing the two parts from being rotated back to their original relative positions. For example, ratchet arrangements present on the side walls of the parts can be used to prevent unwanted rotation. Such “lateral” ratchet arrangements have been found to be defeatable if sufficient reverse turning torque is applied.
[0008] An additional requirement for some closures is to provide a seal to preserve the contents of an associated container.
SUMMARY OF THE INVENTION
[0009] According to the present invention there is provided a tamper-evident closure for a container, the closure comprising: a first portion including inner and outer parts; and a second portion; the outer part is rotatable relative to the inner part from a first position in which at least part of the first and second portions are adjacent each other to a second position in which there is a gap therebetween, the first portion comprises locking means for irreversibly locking the closure in the second position upon first opening so that the gap cannot be closed, in which the first portion comprises a compressible stopper for sealing the second portion and/or the container.
[0010] By combining gap generator closure with a compressible stopper an improved seal can be provided.
[0011] The stopper may be formed, for example, from natural and/or synthetic material such as cork and/or a synthetic cork-like material.
[0012] The inner part may include a line of weakness which breaks if the outer part is reverse rotated relative to the inner part.
[0013] The line of weakness may consist of a plurality of frangible bridges.
[0014] The line of weakness may transversely split the inner part.
[0015] The inner part and/or outer part may include a top plate and part of the locking means may be carried on or by the plate/s.
[0016] The locking means may comprise or include a ratchet arrangement.
[0017] The second portion may incorporate a pourer.
[0018] The closure may further comprise an outer shell.
[0019] The stopper may extend through the second portion and into the bore of a container neck.
[0020] The stopper may depend from a top region of the first portion.
[0021] The first portion may include a top plate region and the stopper depends and/or extends from and/or through the region.
[0022] The stopper may extend into the inner and/or outer part of the first portion.
[0023] In one embodiment both inner and outer parts of a first portion have respective top plates which include corresponding ratchet parts that engage to prevent relative rotation of the parts. This type of ratchet arrangement may be referred to as a longitudinal ratchet arrangement, as opposed to known lateral arrangements which are positioned on side walls.
[0024] The second portion may be adapted to be connected to a container and the first portion may comprise a cap. Certain industries demand closures with a first potion comprising a cap and a second portion comprising a sleeve which is connected to a container; for example the spirits industry.
[0025] The closure may further comprise a fitment such as a non-return fitment, for example a ball and float. Alternatively the first portion may be adapted to engage a fitment associated with the container. Certain industries, in particular the spirits industry, demand additional measures to prevent tampering. In-bore fitments, such as non-return fitments, are often fitted to containers to prevent re-filling regardless of other tamper-proofing measures.
[0026] The closure may include means for preventing the inner part from moving relative to the second portion until it has reached the second position.
[0027] The gap may be unobstructed. This means that the closure would not have to rely on an obstructing member becoming trapped. By forming an unobstructed gap it is not possible to defeat the tamper-evidence by a simple cutting operation. The gap may be formed at the respective adjacent peripheries of the portions. The inner part may include a section which extends beyond the outer part towards the second portion in the second position; the part may be positioned so as to be visible through the gap.
[0028] The second portion may be permanently fixed in its position on the container. This can be used to prevent the second portion from being moved to close the gap.
[0029] The first portion may further include a lateral ratchet arrangement for locking the inner and outer parts in the second position. This provides increased resistance to re-setting.
[0030] The first portion may include engagement formations and the lateral ratchet arrangement is located above the formations. The first portion may include formations, such as screw threads, for engaging the container or in-bore fitment. In such cases the ratchet arrangement or other locking mechanism may be located above the formations so as to increase the difficulty in accessing and tampering with the locking arrangement.
[0031] Different aspects of the invention may be used separately or together.
[0032] Further particular and preferred aspects of the present invention are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with the features of the independent claims as appropriate, and in combination other than those explicitly set out in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which:
[0034] FIG. 1 is a section of a closure formed according to the present invention in a first, unopened position and shown attached to a container neck;
[0035] FIG. 2 is a side elevation of the closure of FIG. 1 shown prior to attachment to a container neck;
[0036] FIG. 3 shows the closure of FIG. 1 after a first opening stage;
[0037] FIG. 4 shows the closure of FIG. 2 after a first opening stage;
[0038] FIG. 5 shows the closure of FIG. 4 after a second opening stage;
[0039] FIG. 6 shows the closure of FIG. 5 after a top cap has been re-fitted;
[0040] FIG. 7 shows the closure of FIG. 1 following an attempt at reverse opening;
[0041] FIG. 8 is a perspective view of the closure of FIG. 7 ;
[0042] FIG. 9 is a side elevation of a closure formed according to the present invention;
[0043] FIG. 10 is a section of the closure of FIG. 9 ;
[0044] FIG. 11 is a side elevation of the closure of FIGS. 9 and 10 shown following an opening event;
[0045] FIG. 12 is a perspective section view of a top cap component of the closure of FIGS. 9 to 11 ; and
[0046] FIG. 13 is a side elevation of the closure of FIG. 11 when re-closed.
DESCRIPTION
[0047] In FIGS. 1 to 8 a gap generation principle is first described. The principle is applicable to the present invention although it will be appreciated that incorporation of a compressible stopper feature would be required in order to form part of the present invention.
[0048] Referring first to FIGS. 1 and 2 there is shown a closure generally indicated 10 . In FIG. 1 the closure 10 is shown secured onto a container neck 15 . The structure and arrangement is similar to that described in WO2009/010722.
[0049] The closure 10 comprises a main pourer body 20 , an inner part 25 and an outer part 30 . A metal shell 35 forms an outer casing to the closure and is divided into a cylindrical lower part 36 and a cup-shape second part 37 . The parts 36 , 37 are separated at a split line 40 formed by a cutting process once the shell 35 has been applied to the first and second portions of the closure.
[0050] Together the body 20 and the shell part 36 comprise a second portion and the inner and outer parts plus the shell part 37 comprises a cap-like first portion.
[0051] In this embodiment the upper and lower shell parts 36 , 37 are initially joined along the split line 40 by a plurality of frangible bridges which will break if either: i) the lower shell part 36 is rotated before initial opening; or ii) an attempt is made to pull the top part of the closure off without unscrewing.
[0052] The inner part 25 of the closure extends beyond the split line 40 and the open end of the outer part to provide a dog-leg shape terminal portion 90 which rests on a shoulder 20 a on the main body 20 so that one half 92 of the terminal portion fits beneath the upper end of the lower shell part 36 and the other half 94 fits in the upper shell part 37 . Above the shell split line 40 a plurality of frangible bridges (not shown) are formed in the inner part 25 to form a split line 85 .
[0053] The inner part 25 also has a line of weakness 26 provided approximately half way along its side skirt formed by a plurality of frangible bridges 27 . This divides the part into a first portion 28 and a second portion 29 .
[0054] The main body 20 is fixed onto the container neck 15 by clips 45 which project inwardly and engage under a shoulder 50 .
[0055] A valve housing 55 is clipped into the main body 20 and includes a sealing lip 57 which seals against the top surface 16 of the container neck 15 .
[0056] A float valve 65 is housed in the housing 55 and can seal against a valve seat 60 to prevent re-filling of the container. A valve control ball 70 is located on top of the float valve 65 .
[0057] In normal operation the second part 37 of the shell 35 is rotated anti-clockwise and the unscrewing action breaks the bridges on the split line 40 .
[0058] The outer part unscrews together with the second part 37 whilst the inner part remains held on the main body. The unscrewing continues to the position shown in FIGS. 3 and 4 until a ratchet locking mechanism locks the outer part to the inner part 25 .
[0059] With the outer and inner parts locked together the inner part 25 can then be unscrewed from the main body 20 . Because the terminal portion 92 is held under the shell part 36 , when the inner part rotates it breaks along the split line 85 . The result is that the terminal portion 90 of the inner part remains held on the body so that the half 94 produces a visible upstanding band as shown in FIG. 5 .
[0060] When the cap (shell part 37 , outer part 30 , inner part 25 ) is screwed back onto the main body 20 , a gap G is formed between the first and second shell parts 36 , 37 . This is because the outer part 30 cannot be screwed completely back down onto the inner part 25 by virtue of the locking mechanism. In addition, the band 94 of the inner part 25 projects above the shell part 36 so as to be visible in the gap G as shown in FIG. 6 .
[0061] The gap G formed between the shell parts 36 , 37 is unobstructed in the sense that there is no obstruction member trapped between the parts 36 , 37 .
[0062] In FIGS. 7 and 8 the closure of FIGS. 1 and 2 is shown following an attempt to overcome the tamper evidence by reverse opening.
[0063] If the shell part 37 is rotated clockwise the inner part first portion 28 is caused to rotate relative the second portion 29 , which causes the bridges 27 to break. The inner part 25 splits along the line 26 and the shell part can be removed with the outer part and the inner part first portion. In other words, if the closure is deliberately (or accidentally) rotated in the direction opposition to that required for normal operation, in which the gap is generated, then the inner part is caused to break so that thereafter normal operation of the closure is not possible.
[0064] There are no internal screw threads on the first portion 28 so the top cap cannot be screwed back on the main body 20 .
[0065] The break will occur if reverse opening is attempted (deliberately or accidentally) either before or after the gap is generated.
[0066] Other gap generation mechanisms are possible in conjunction with the stopper feature of the present invention.
[0067] Referring now to FIGS. 9 and 10 there is shown a closure 110 formed according to the present invention.
[0068] The closure 110 is similar to the closure 10 shown in FIGS. 1-8 . Accordingly, an outer shell 135 houses a pourer body 120 and inner 125 and outer parts 130 .
[0069] In this embodiment the pourer 120 is a through bore leading directly to the container neck 115 (as opposed to the pourer body 20 which includes a flow regulation feature). In addition, a generally cylindrical stopper 105 is provided on the top cap component, in this embodiment depending from the top plate 134 of the upper shell part 137 . In FIG. 10 the stopper 105 is shown to extend through the bore of the pourer 120 and into the mouth of the neck 115 so as to seal the contents of the container.
[0070] In FIG. 12 the stopper 105 is shown forming part of the top cap and extending from the shell top plate 134 and through the top plate 130 of the outer part 130 . The inner part 125 is not shown for clarity. The top plate 131 of the outer part 130 is formed with a central opening 132 for receiving the head 133 of the stopper, with the stopper shank 138 extending away from the head. In some embodiments the outer part may comprise a holding feature (such as a rib or clip) for locating the stopper. The outer part and stopper can then together be assembled into the shell and, for example, secured using adhesive.
[0071] In use, the top cap, including the stopper 105 is grasped and turned. This activates the gap generation mechanism already described in relation to FIGS. 1-8 so that the cap can be removed as shown in FIG. 11 . When the cap is subsequently replaced the gap G is generated and the band 194 of the inner part 125 projects so as to be visible in the gap, as shown in FIG. 13 . In this position the stopper 105 has re-engaged into the mouth of the neck 115 . Because the stopper 105 is formed from a compressible material, such as cork, an effective seal of the contents of the container is provided.
[0072] Other gap generator mechanisms may be used in conjunction with the compressible stopper feature, for example a mechanism as described in U.S. Pat. No. 5,738,231, WO 2005/049443 or WO 2006/117505.
[0073] Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiments shown and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention as defined by the appended claims and their equivalents. | A tamper-evident closure for a container. The closure comprises a first portion including inner and outer parts, and a second portion. The outer part is rotatable relative to the inner part from a first position in which at least part of the first and second portions are adjacent each other to a second position in which there is a gap therebetween. The first portion comprises locking means for irreversibly locking the closure in the second position upon first opening so that the gap cannot be closed, in which the first portion comprises a compressible stopper for sealing the second portion and/or the container. A tamper-evident closure in combination with a container. | 1 |
[0001] The present invention relates to a device which stimulates the formation of bone tissue, capable of generating vibrations with different frequency components at the same time and which can be applied locally to different parts of the body.
PREVIOUS ART
[0002] Considerable medical opinions suggest that vibrations at determined frequencies and low intensity amplitude generate significant therapeutic effects, for example, scientists have demonstrated that certain vibrations may help osseous formation, bone fracture healing, pain relieving, tendon and muscle repair, etc.
[0003] Body immobility produces loss of bone mass (osteoporosis) due to the lack of muscle stimulus for bone calcification. Studies have demonstrated that muscle activity prevents osteoporosis by producing high frequency and low intensity vibration.
[0004] For the application of these principles in subjects who do not exercise regularly or simply because they are unable to do them due to certain degrees of disability, machines that normally imparts a movement directly to the part of body where vibrations that needs to be stimulated have been developed. This vibration is produced through a movement applied with a rotary axis and a connecting rod. In most cases, the subject stands on a platform which oscillates with the aforementioned mechanism, as described in US patent US2007/0219052, where a machine with a lower platform where a subject must stand on in order to receive vibrations generated by a mechanism located under such platform is described.
[0005] Galileo platform, manufactured in Germany, is known in the previous art. It has a central pivot around which the platform oscillates as a seesaw, the greater the distance from the central axis, the greater the amplitude.
[0006] Therefore, in this type of platform, the intensity may be varied by changing the location of the feet with regard to the central axis.
[0007] This type of vibration will have an intensity (of force) that will depend on the subject's weight and on the amplitude of the platform oscillation. In the case of the Galileo Machine, such amplitude is varied by changing the position of the feet. Its frequency will depend on the speed of rotary axis, and only one frequency can be used at a time.
[0008] Most of the existing solutions are based on platform type static machines where the subject must be standing on them, which do not solve the problems that arise when the subject is unable to stand up, thereby limiting their use for other types of applications.
[0009] In order to solve the problem of a more versatile application, solutions such as the portable model, manufactured by the same manufacturer of Galileo machine, have been developed. Such model is used with the aid of the fist. In that case, the way of operation is similar to the one used by the platform with an important difference: such machine is a reaction-type machine, whereas platforms are action-type machines. This implies that the force exerted on the body depends on the oscillating mass, not on the body weight.
[0010] The way of operating of this equipment (circular oscillating mass) totally relates the intensity of vibration with the frequency, which is not desirable. However, in this equipment the oscillating mass may be changed, by adding o removing small weights. That could solve the mentioned disadvantage.
[0011] Another more versatile solution is observed in the US Patent 2007/01000262, where a bracelet emitting vibrations similar to a cat's purr is described, however its purpose aims at generating rather a psychological effect by emitting not only vibrations transmitted to the exposed tissues but also by emitting a sound at the frequency similar to a cat's purr.
[0012] Finally, it can be said that all platform-type solutions have the following disadvantages:
Subjects must be able to stand in an upright position. The intensity of the vibration depends on the subject's mass. Mainly works with the lower body. Only works with one frequency at a time.
[0017] One of the technical problems addressed by the present invention is the versatility of the device so that the application can be applied to different parts of the body, allowing subjects who are unable to stand up to use the device, therefore its operation is not limited to a platform but to a portable and smaller device which can be attached to any part of the body to generate the vibration which in turn will stimulate osteogenesis (generation of bone tissue) to heal osteoporosis problems and similar conditions (fractures), as well as the prevention thereof.
[0018] Additionally, the invention addresses the problem of generating vibration at different frequencies at the same time.
[0019] The invention comprises a vibration generating machine to be applied in patients with motor problems; wherein such machine is aimed at mimicking the efforts that muscles would normally impart to osseous structure.
[0020] Thus, the invention is a reaction-type vibration machine wherein a mass is made to oscillate at a desired frequency and through reaction a vibratory force is obtained in the part of the body where the machine is attached.
[0021] The machine's shape and size are such that it can be applied to different parts of the body without the patient having to stand up as compared with the platform type devices from previous art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 depicts a perspective view of the variable frequency vibration generator for bone tissue generation.
[0023] FIG. 2 depicts a front view of the variable frequency vibration generator for bone tissue generation.
[0024] FIG. 3 depicts an illustration of the device of the invention upon stimulating the femur.
[0025] FIG. 4 depicts an illustration of the device of the invention upon stimulating the forearm.
[0026] FIG. 5 depicts a close view of the device of the invention upon stimulating the leg.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention relates to an osteogenesis stimulator device (bone tissue generation) capable of generating vibrations with different frequency components of frequency at the same time and which can be applied locally to different parts of the body.
[0028] The device ( 10 ) comprises a small-sized box ( 11 ) within which it is disposed an oscillating mass ( 15 ) to which the ends of two pieces parallel to each other, acting as springs, are attached ( 14 ), at whose opposite ends a permanent magnet ( 13 ) is disposed, this magnet is attached to such springs through an aluminum support ( 16 ), which in turn is attached to a steel support ( 17 ) which holds an electromagnet ( 12 ), the latter facing the permanent magnet ( 13 ).
[0029] In order to make this mass oscillate inside the box ( 11 ) a sinusoidal tension is imparted to the electromagnet ( 12 ) facing the permanent magnet ( 13 ).
[0030] To change the frequency or intensity of the oscillation, the sinusoidal tension of the electromagnet is modified. It is also necessary to modify the characteristics of the spring parts which support the mass when a significant modification of the oscillating frequency is desired.
[0031] The way of operation comprises attaching the equipment to the limb to be treated through any variable fastening means such as elastic belts or Velcro (not illustrated).
[0032] The oscillating mass inside the box moves freely supported by a kind of spring, an electromagnet imparts acceleration to the mass, thereby producing a controlled oscillation. That movement of the mass inside the box produces, through reaction, an oscillating force on the limb supporting the box. In this way, the objective of imparting a high frequency and low intensity effort to the bone structure to be treated is achieved.
[0033] The device may impart vibrations with different frequency components at the same time, better mimicking the efforts that muscles normally impart to bone structures.
[0034] It has fastening means for different parts of the body through variable fastening belts.
EXAMPLE
[0035] Bone osteogenic stimulus is produced thanks to the transmission of high frequency vibrations generated during muscle activity. The exposure of rats to the low magnitude and high frequency vibrating platform was effective to prevent bone loss in ovariectomized rats. These vibrations produce a bone enhancing both on cortical bone and on trabecular bone. Studies of postmenopausal women using this platform have shown bone mass gain in these women as opposed to the bone loss in the placebo group.
[0000] Additionally, it has been demonstrated positive effects on balance, vascular flow, muscle strength and low back pain in adults. A pilot study in children with motor disabilities has shown that children stimulated with vibration had a 15.7% net benefit of volumetric density in the tibia, and 6.7% in the spinal after 6 months using the device 4.4 minutes daily. The disadvantage of this study was a 44% compliance with the planned schedule due to the fact that children had to stand on the vibrating platform which requires an effort.
[0036] This is the first randomized, controlled, double blind study designed to prove the efficiency and tolerance of high frequency and low intensity vibrations in children with disuse osteoporosis. To date, only open studies on this type of intervention have been reported. The hypothesis was demonstrated by showing that vibrations were more effective than the conventional kinetic therapy alone for improving muscle strength, bone mass and the quality of life of these children.
[0037] In this study a net increment of 30% was observed in the placebo group and stimulated with vibrations by bone mineral densitometry in the radius. Additionally, an increment in upper limb muscle forces was observed as well as an increment in the ability to carry out daily self care activities, this item being assessed by the Quality of Life Survey, Cerebral Palsy module, PedsQL.
[0038] The observation of a larger change in BDM and area both at ultra distal radius and radius (33%), into a lower initial BDM and area respectively is an expected fact since in most of the osteoporosis treatment interventions, especially those associated with a decrease in bone resorption, the more severe the osteoporosis, the higher the effect. This represents an advantage for this intervention.
[0039] On the other hand, the finding of a better response on the left limb could be related to a lower variable initial value on the left side because most children were right handed, and thus they had used their right limb more often, therefore they had a lower degree of osteoporosis.
[0040] This last result is significant since self care is the ultimate goal of these children rehabilitation.
[0041] According to the results, the best frequency to use would be 60 Hz. To date, there has been a controversy concerning whether the best frequency to be used is 90 or 60 Hz, and thus testing the device of the invention is the first study that includes this question in the design, and it is a novel contribution to this field.
[0042] In this way, future applications of this type of intervention, both in oteoporosis and in mobility reducing pathologies, such as neurological and rheumatologic pathologies, both in adults and in children especially in the elderly is a promising fact.
[0043] Until now, this is the only high frequency and low intensity vibration stimulator which has demonstrated, through a controlled study, its efficacy and safety in children. | A device that stimulates bone tissue formation capable of generating vibrations with different frequency components at the same time and that can be applied locally to different parts of the patient's body, wherein such device comprises different frequency vibration generating means and variable fastening means to attach to different parts of the body. | 0 |
BACKGROUND OF THE INVENTION
Textile webs in general are subject to curling along an edge or selvage thereof while being handled in open width and often develop curls, pressed folds or creases therealong due to improper handling, web tension, or the like. Knit or other flimsy textile webs in particular, when processed or handled at low tension or generally tensionless conditions tend to curl or roll up along the selvage. In order to produce a good quality roll of a textile web, or to achieve proper web handling along a process line for printing, inspection, drying, extraction of moisture, washing, doubling, tacking or other web treatment, it is most desirable, if not necessary, to ensure that the web is maintained in a flat condition where little or no fabric deformation is present at either selvage during winding or processing as set forth above. Proper package preparation or web handling may thus be achieved in conjunction with apparatus of the present invention that engages the web selvage and due to a particular action, removes curl, folds and creases from the selvage of the web. While the device of the present invention is suitable for curl, fold and crease removal, hereinafter, decurling is intended to refer to all.
Several different classes of decurling devices have heretofore been developed that include static as well as power driven approaches. Among the power approaches to decurling, exemplary of same are a driven type where oppositely opposed discs, rotating fingers, screws, belts or the like are located along a selvage of the web. The elements are driven to produce a motion which, in turn, imparts a spreading effect to the web to remove the curl. Likewise, fluid jets have been directed against the web curl to apply a decurling or uncurling force thereon. The power driven approach to decurling of necessity, requires a motive force for driving the particular decurling elements. Such obviously adds to cost of operation and likewise, leads to the necessity for continuing maintenance and replacement of parts, not to mention a significant initial capital cost.
The improved decurling device of the present invention is a static type structure. Known static systems include principally the decurler described in U.S. Pat. No. 4,217,682 to Young et al over which the present invention represents improvement. The Young et al web edge decurler has been commercially successful and performs the decurling operation in a very suitable fashion. Other known static systems include a pair of spring loaded elements that are disposed above and below the web, with each of the elements being U-shaped where a short leg of the U is presented on the web side and engages the web to strip curl therefrom. Still further, another known static structure includes a planar surface having ridges disposed thereon over which the web passes, with frictional forces produced between the web and the ridges to remove curl from the selvage of the web. Still other decurling devices are disclosed in British Pat. Nos. 105,895 to Canby et al and 117,427 to Greenwood, and in German Pat. No. 276,759 to Spuhr.
Decurling devices according to teachings of the present invention represent definite technological advance in the art which is not believed to be taught or suggested by any of the prior art set forth above, or by any other known prior art.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a device for removing curl, folds and the like from the edge of a moving web.
Another object of the present invention is to provide an improved static device for flattening the selvage of a traveling web to provide a uniform web surface thereat.
Yet another object of the present invention is to provide an improved device for decurling an edge of a moving web that may be positioned immediately adjacent further processing equipment.
Still another object of the present invention is to provide an improved edge decurling device that is uniquely adjustable and is capable of removing all types of curl from the selvage of a wide range of fabrics.
Still another object of the present invention is to provide an improved edge decurling device that may be quickly and easily disassembled to facilitate cleaning and/or inspection of same when necessary.
Yet another object of the present invention is to provide an improved web decurler that is suitable for use in conjunction with a tenter frame and which will accept seams in the fabric being handled without disturbing the tentering operation.
Generally speaking, the device of the present invention for removing curl, folds and the like from an edge of a moving web comprises a top plate, said plate having a plurality of parallel elongated fins associated therewith, said fins being disposed at an angle to an edge of a web traveling thereby, said fins having a smooth angled edge for contact with said web; a bottom plate, said bottom plate having a plurality of elongated fins associated therewith, said fins being disposed at an angle to an edge of a web traveling thereby, said fins having a smooth angled edge for contact with said web and being located immediately adjacent said fins associated with top plate, means to associate said plates whereby said top and bottom fins define a web passageway therebetween; and a plurality of adjustment means located between said top and bottom plate for positionally adjusting the fins associated with said top plate respective to the fins associated with said bottom plate, at least certain of said plurality of adjustment means being interrelated such that adjustment of one of said means simultaneously adjusts other of said at least certain means.
Additionally, the plate association means may be quick release coupling means such that the top and bottom plates may be easily and quickly disassembled for cleaning, inspection or other desirable reasons followed by easy recoupling with a minimum of disruption of process equipment with which the unit is being utilized.
In another embodiment of the instant decurler device, the fins are arranged to accommodate a wide range of fabric weights and constructions. Particularly, such embodiment includes providing a plurality of banks of fins with different spacing between fins in at least certain of the various banks. A first or entrance bank of fins is provided having a fin spacing adequate to accept heavy type webs and initiate decurling of same while also being close enough together to have some initial decurling effect on lighter types of fabric webs. At the exit to the decurler the banks of fins is provided with lesser space between the fins to complete the decurling action for both types of webs. Preferably for tenter frame applications, the bank of fins are separated with an opening through the top and bottom plates located above and below the separation, and through which a sensing mechanism may detect the presence or absence of an edge of the web being decurled for proper positional location of same with respect to the pins or clips of the tenter.
More particularly, the novel adjustment feature of the present invention preferably includes a plurality of elements or studs associated with one of the bottom and top plates and making contact with the other of said plates. The elements are adpated for movement to and from the plate with which they are associated to vary the spacing between the plates and thus define the web passageway between the fins according to the dictates of the material being processed. The adjustment studs are preferably received in a housing secured to one of the plates with an opposite end of at least certain of the studs being receivable in appropriate receiving means at the other of said plates whereby relative lateral movement between the two plates is precluded. In a most preferred arrangement, the adjustment studs are received in a housing secured to the inside surface of the top plate, with each of the studs being received in an appropriate opening within the housing, a portion of which is threaded, and wherein a portion of the length of the stud is threaded for mating engagement with the threaded portion of the housing. The studs are all interengaged by virtue of a drive means making contact therewith, with one of the studs passing through the top plate and being adapted for manual adjustment thereat. Once manual adjustment is made to the one stud, all of the interrelated studs in the housing, through the drive means, are simultaneously adjusted by a like amount. Three such studs may be provided in a triangular pattern with two of the studs located on a line parallel to an outer edge of the decurler and the third, manually adjustable stud being located on a line with one of the first two studs, generally parallel to an entrance to the decurling unit.
In one embodiment of the quick release coupling means for the decurler of the present invention, an elongated element is received through one of the two plates, preferably the top plate, and has a spring means located between the outer surface of the plate and an outer end of the element. An element receiving means is presented at an opposite location on the inside of the opposite plate. When the plates are brought into proper alignment, the elongated element may be depressed against the bias of the spring means, received in the element receiving means in releasable locking engagement, to interlock the top and bottom plates. Disassembly of the top and bottom plates would follow the reverse, i.e., depression of the elongated element in a direction of the plate and manipulation to release same from the receiving means, whereby the two plates may be easily and quickly separated for cleaning, inspection or the like. Preferably in such arrangement, the connector means are located adjacent the adjustment means, at an outer end of the decurler, with the other or opposite end of the decurler being devoid of internal support. With the coupling means properly located, the top plate of the device, along the operative length of the decurler, in effect, floats above the bottom plate and is biasable apart from the bottom plate by seams or other imperfections in the web that pass through the device without interfering with the operation of the device or of processing equipment in connection with which the device is being employed.
In a further embodiment of the quick release coupling means that may be utilized to associate the top and bottom plates of the device, spring means may be secured to one of said plates and extend outwardly towards the other of said plates having a handle means secured to an opposite end of the spring and being contoured to reside, in part, beyond the other of said plates. The handle means has a pressure element secured thereto which extends inwardly towards said other of said plates, whereby when said plates are properly aligned, said spring means biases said pressure means against an outer surface of the opposite of said plates, to hold said plates in operative association. With such arrangement, preferably the pressure means makes contact with the outer surface of the other of said plates at a generally central location with respect to the width of the plate, adjacent an edge of same away from the operative decurling portion of the device. A further, counter spring means may be provided between the plates adjacent the same end of the plate where the pressure element is located, the further spring means providing a spring bias against the pressure element. The relative spring pressures and location of the operative spring elements are preferably such that the operative end of the top plate freely floats above the bottom plate permitting a seam or other web imperfection to pass through the device without disrupting normal operations. For disassembly of the device, an upward lifting motion of the handle removes the pressure element from contact with the other plate, permitting the other plate to be raised slightly, adequate for lateral movement from beneath the pressure element and apart from the bottom plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a decurling device according to teachings of the present invention.
FIG. 2 is a side elevational view of the decurling device as shown in FIG. 1, viewed from the web entrance side of same, and further illustrating a suitable means for mounting the decurling device and a web sensor.
FIG. 3 is an end elevational view of the decurler as illustrated in FIG. 1, viewed from the left side of FIG. 1 or the outer edge of the yarn passageway, and illustrating a further embodiment of a mounting means.
FIG. 4 is a plan view of the inside of the bottom plate of a preferred embodiment of the present invention.
FIG. 5 is a horizontal cross-sectional view of the device as illustrated in FIG. 2, taken along a line V--V.
FIG. 6 is a vertical cross-sectional view of the device as illustrated in FIG. 1, taken along a line VI--VI.
FIG. 7 is a top plan view of a further embodiment of a decurling device according to the present invention.
FIG. 8 is an end elevational view of the decurler illustrated in FIG. 7.
FIG. 9 is a partial vertical cross sectional view of the decurler illustrated in FIG. 7 taken along a line IX--IX.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Making reference to the Figures, preferred embodiments of the present invention will now be described in detail. Insofar as the overall decurler unit is generally concerned, except where inconsistent herewith, the individual elements may be provided as disclosed in U.S. Pat. No. 4,217,682 to Young et al, which is incorporated by reference herein. Operationally speaking, two decurler units D may be located along opposite sides of a passageway for a web W of textile material illustrated for one side only in FIG. 1. Decurler units D may be mounted by means illustrated in FIGS. 2 or 3 as described hereinafter or by any other suitable means. Web edge detector means P may be located along at least one of the outer edges of said passageway (See FIG. 2), such that when utilized in conjunction with means to move the web in a lateral direction upon receipt of a signal from the detector means P, the web may be generally maintained properly with respect to the operative decurling zone of units D for removal of curl C from web W and/or the processing equipment.
In FIGS. 1-6, one preferred embodiment of the decurler unit of the present invention is set forth. The decurling device D of the present invention generally includes a top plate 10 having a group of fins generally 20 associated with an inside surface of same and a bottom plate 30 having a group of fins generally 40 associated with an inside surface of same. Fins making up groups 20 and 40 are preferably secured to the inside surfaces of plates 10 and 30 respectively, and are presented at an angle to a passageway for web W through device D, extending towards an outer edge of device D. When plates 10 and 30 are associated such that groups of fins 20 and 40 are located adjacent each other, a web passageway is defined therebetween through which web W may pass for removal of curl, folds, creases and the like C therefrom. Plates 10 and 30 are held in operative association by a coupling means generally 70 and the particular passageway defined by fin groups 20 and 40 may be set by adjustment means generally 50.
As particularly illustrated in FIG. 4, which is a plan view of bottom plate 30, fin group 40 is provided by a plurality of banks of fins 41 and 42, all of which extend in an angular direction towards an outer edge of the web passageway, with each fin being spaced apart from an adjacent fin by a predetermined distance. Fin group 20 associated with the inside of upper plate 10, likewise is provided by a plurality of banks of fins 21 and 22 which, when superimposed above fin group 40 likewise extend angularly outwardly towards the outer edge of a web passageway. In a most preferred embodiment as illustrated in FIG. 5, fins 21 and 22 when superimposed above fins 41 and 42 are vertically offset therefrom. A tortuous passageway may be provided through the decurler unit where the vertical spacing between fins of the respective plates is such that the fins intermesh. With a fin bank arrangement of the type illustrated in FIGS. 4 and 5, webs of varying weights and constructions may be processed therethrough. Fins 21 and 41 at the entrance to the device are spaced apart from adjacent fins 21 and 41 at a distance that will initiate a decurling action for both light and heavy webs, while fins 22 and 42 located at the exit end of the device have a lesser spacing than between fins 21 and 41 to finalize the decurling action.
In general, the fins utilized in the instant decurler device are preferably tapered along an end of same adjacent an entrance to the decurler unit or an interior bank of fins to facilitate ingress of a web therebetween. All web contact surfaces of the fins are smooth to avoid damage to the web, and in a most preferred embodiment, the fins do not extend away from the respective plates in perpendicular fashion, but are canted in the direction of the outer end of same, i.e., the end of the unit that will be disposed beyond the outer edge of the web passageway. Further, while the fins are illustrated herein as individual elements, spot welded to the respective plates, obviously the fins may be provided in any suitable manner, certain of which are set forth in the previously referred to U.S. Pat. No. 4,217,682.
Specifically as to the device illustrated in FIGS. 1-6, for tenter frame use, top plate 10 defines an elongated opening 12 which is located directly above a like opening 32 defined by bottom plate 30 and through which a web being handled may be visually observed or detected by suitable detection means P. In a most preferred arrangement (See FIGS. 4 and 5), the fin group 40 associated with bottom plate 30 is provided in two banks, one of which includes fins 41 and the other, fins 42, with the two banks being generally separated by opening 32 defined by plate 30. Fins 41 that make up one of fin banks, adjacent an entrance to the device, are spaced apart from adjacent fins 41 by an amount adequate to accept and begin to remove curl, folds, creases and the like from a generally heavy type web, whereas fins 42 that make up the other of the fin banks are spaced apart from adjacent fins 42 by a lesser amount, adequate to further remove curl, folds, creases and the like from either a light or flimsy web or from a heavy web from which most of the curl has already been removed by the wide spaced entry fins. As mentioned hereinbefore, a common spacing between fins throughout a decurler is illustrated in U.S. Pat. No. 4,217,682. Commercially a certain spacing between all of the fins of a decurler has been provided when the decurler is intended primarily for use on heavy type webs, with a lesser spacing between all the fins of a decurler intended for use on light or flimsy type webs. While the same approach may be taken for the decurler of the present invention, utilizing a plurality of banks of fins as described, supra, the device of the present invention is generally suitable for handling all types of webs as mentioned above. A like arrangement is provided on the underside of top plate 10 where a first bank of fins 21 is provided adjacent the entrance to the device having a wide spacing between adjacent fins with a second bank of fins 22 being provided adjacent the exit from the decurler having a lesser spacing therebetween. Such is illustrated in FIG. 5 where fins 21 and 22 are shown in cross section, intermeshing with fins 41 and 42 of bottom plate 30.
Located between top and bottom plates 10 and 30 is an adjustment means generally 50. Adjustment means 50 includes a housing 51 (See FIGS. 5 and 6) that is secured to an inside of top plate 10 and has a plurality of stud receiving openings 52 therethrough, coincident with the number of adjustment studs 56 utilized in the particular device. A portion of the length of openings 52 through housing 51 is threaded at 53 while a further portion of the opening 52 serves as a bearing surface for studs 56 as at 54. One of openings 52 in housing 51 is aligned with an opening 13 defined by top plate 10 for a purpose to be described hereinafter.
A plurality of adjustment studs 56 are received within openings 52 of housing 51, with one adjustment stud 56' extending upwardly through opening 13 of plate 10 and having an adjustment means H illustrated as a handle secured thereto. Studs 56 are threaded along a portion of the length of same at 57 to be received in threaded connection with the threaded portion 53 of openings 52. Beneath the threaded portion 57, a sprocket or other similar means 58 is provided on studs 56 with drive sprocket 58 residing within a recess 59 therefor in housing 51 and in operative association with a drive means 60 as defined hereinafter. Below sprocket 58, studs 56 are received for rotation in bearing surface 54 of housing 51. A lower portion 61 of studs 56 engages a portion of bottom plate 30 with at least certain of studs 56 being received in stud receiving openings 33 located on the inner surface of plate 30. Manually adjustable stud 56' may only make contact with a portion of plate 30. With at least two studs 56 received in respective stud receiving openings 33, lateral movement of plate 10 with respect to plate 30 is precluded.
As illustrated particularly in FIG. 5, in a preferred arrangement, housing 51 is generally triangular shaped, and is located immediately adjacent an edge of plate 10, outside of the path of travel of a web through the device, with each of the studs 56 and 56' being located at a corner of same. Particularly, two studs 56 are located in a line L parallel to an outer end of the device and consequently an outer end of plate 10 while the third, manually adjustable stud 56' is located inwardly with respect to said parallel line and in a line with one of said two studs 56, parallel to the entrance to the decurling device. Line L defines a hinge location for top plate 10 with respect to bottom plate 30, the purpose of which will be described hereinafter. A drive means 60, such as a chain, timing belt or the like passes around sprockets 58 of studs 56 and 56' to interrelate same. When handle H of the manually adjustable stud 56' is rotated to provide adjustment for adjustment stud 56', studs 56 move up or down a like amount such that the positional relationship between the outer web contact surface of the fins associated with plates 10 and 30 may be set at a predetermined position.
In a preferred arrangement for operation of the decurler according to the present invention, there is a slightly greater PG,13 vertical spacing between the respective fins 21 and 41 at the entrance end of the decurler than at the exit end to facilitate ease of entry of the web W thereinto. Such differential spacing may be preset into the device by particular original placement of the adjustment studs 56 and 56', after which, during adjustment, the preset differential spacing will be retained.
While the innermost stud 56' is disclosed as the adjustment stud for the simultaneous adjustment means 50 of the present decurler, obviously any of the other studs could likewise serve as such. Furthermore, with a chain drive means 60 being received around sprockets 58, in a most preferred embodiment, chain 60 is an inextensible, link chain. Should, however, a drive connector 60 be utilized that is not inextensible, a drive means tension control element 62 shown schematically in phantom in FIG. 5, could be employed. In similar fashion, while sprockets are illustrated as a preferred arrangement for interconnection between the drive means and the individual studs, sheaves, pulleys or the like could likewise be suitably employed, so long as same could be utilized in conjunction with drive means 60 without slippage.
As illustrated in the Figures, particularly FIG. 6, the quick release coupling means generally indicated as 70 is located within the area of the adjustment means, and is illustrated in FIG. 6 as an elongated element 71 that extends through an opening 14 in top plate 10, and an opening 63 in housing 51, and has a latch means 72 located adjacent a terminal end of same. Latch means 72 is preferably a member that extends outwardly from both sides of element 71, transverse to the length of same. A latch receiving means 35 is associated with bottom plate 30 to receive latch means 72 and defines a vertical slot 36 therethrough. Along the length of vertical slot 36 is an internal, horizontal slot 37 into which latch means 72 may be removably received against inadvertent removal, whereby top plate 10 may be secured to bottom plate 30 with the adjustment studs 56 being received in the stud receiving means 33. A spring means 73 is located along element 71, between a pair of retainers 74 and 75 to provide a spring bias on latch means 72, holding same against a portion of receiving means 35 that defines an upper wall for horizontal slot 37. As illustrated, an appropriate handle means 76 is located above the spring means 73 to facilitate depression and rotational movement of quick release coupling 70.
Latch means 72 is larger than opening 14 in top plate 10 whereby element 71 remains in place with respect to top plate 10. When it is desirable to associate decurler plates 10 and 30, the plates are brought into proper alignment such that studs 56 are received in stud receiving means 33 and latch means 72 resides in vertical slot 36 of receiving means 35. Depression of handle 76 of coupling means 70 compresses spring means 73 and moves latch means 72 inwardly of slot 36 of latch receiving means 35 to horizontal slot 37. Rotation of element 71 then moves latch means 72 into horizontal slot 37, and once pressure is removed from handle 76, spring 73 expands applying tension on latch means 72, holding same therein.
Once it is desirable to detach top plate 10 from bottom plate 30, it is simply necessary to again depress handle 76 and rotate same adequate to permit latch means 72 to be returned from horizontal slot 37 into entrance slot 36 of latch receiving means 35. Handle 76 is then released and plate 10 can be moved away from plate 30. With vertical slot 36 aligned as illustrated in the figures, parallel to an outer edge of the decurler, top plate 10 may be moved laterally away from bottom plate 30 with little or no vertical displacement. Such is advantageous where, for example, in conjunction with a tenter frame, a sensor P is located above the decurler. In this particular arrangement, quick release coupling means 70 is preferably located adjacent the outer edge of the decurling device, beyond the path of travel of the web with no further internal support other than adjustment means 50, such that top plate 10 "floats" above bottom plate 30 to permit separational movement therebetween in the presence of a seam or other imperfection in the web without disrupting the downstream operation of the processing equipment. Specifically, as illustrated in the Figures, coupling means 70 is preferably located along line L (See FIGS. 4 and 5), the general hinge line between plates 10 and 30, whereby top plate 10 floats above bottom plate 30. With coupling means 70 so positioned, no further internal support is generally necessary or desired. Coupling means 70 may, however, be moved off line L, and if the movement of same is of adequate magnitude, or if the weight of top plate 10 dictates, an internal counter spring means such as at 177 of FIG. 9 may be desired to facilitate the floating condition of top 10.
A further embodiment of a quick release coupling means for the present decurler is illustrated in FIGS. 7, 8 and 9. A decurler device is provided having a top plate 110 and bottom plate 130, both of which are provided with a fin arrangement as shown in U.S. Pat. No. 4,217,682, or as specifically illustrated and described herein, with a web passageway defined by relative fin position. In like fashion, adjustment means generally 150 are likewise preferably provided. Bottom plate 130 has one end of a spring means 171 secured along a particular length of an end edge 133 thereof. A handle means 173 is secured to an end of spring 171 opposite its securement to edge 133. Handle means 173 extends over an outer surface of top plate 110 and has a pressure element 175 secured thereto and depending therefrom in a direction toward top plate 110. Spring means 171 provides a bias to handle means 173 in a direction of top plate 110, whereby pressure element 175 transmits said spring bias to top plate 110 to hold plate 110 in association with bottom plate 130. Preferably pressure element 175 is located on handle means 173 to make contact with plate 110 and 130 to hold plates 110 and 130 at a proper decurling relationship. As shown in FIGS. 7 and 9, counter spring means 177 is located adjacent the adjustment means 150, whereby the portion of the decurler within the fin area has no internal support and top plate 110 floats above plate 130 for the purposes described hereinbefore. In like fashion, counter spring means may be located at different positions between plates 110 and 130, for differing degrees of influence on the effect of the biased pressure element 175. In all arrangements, however, counter spring means 177 when utilized will be located outside the fin area. Counter spring means 177 is preferably secured to an inside surface of one of the plates, preferably bottom plate 130 and has a plate 178 received at an opposite end, contactable with an inside surface of the opposite plate.
Assembly of the embodiment illustrated in FIGS. 7 through 9 involves lifting of handle means 173 by an amount adequate to permit top plate 110 to be moved laterally thereunder until adjustment studs 156 are aligned with receiving means therefor (33 of FIG. 4). Handle means 173 is then released and pressure element 175 is biased by spring 171 into pressure contact with the outside surface of top plate 110, and against the bias of counter spring 177. To disassociate the plates for cleaning or the like, the reverse procedure is followed, all of which may be conveniently accomplished without disruption of placement of plate 130.
In further description of the decurler according to teachings of the present invention, certain additional features should be alluded to with respect to top plate 10 and bottom plate 30. Note, for example, in FIGS. 1, 2, 4 and 5, that bottom plate 30 has an extension wing element 37 that resides on the inside of the decurling unit, beneath the pathway of a web passing thereover. Wing element 37 is particularly contoured in an arcuate fashion extending downwardly with respect to the path of travel such that a web exiting from the decurler unit may follow a downward path of travel, making contact with the downward contour of wing 37 without a danger of wing 37 creating marks on the web or distorting same. In similar fashion, with particular reference to FIGS. 1 and 3, a horizontal web support bar 38 is provided adjacent an exit from the decurling device to afford support to a web exiting therefrom without the danger of same being marked or otherwise affected.
Two types of mounting means are illustrated in FIGS. 2 and 3 for the decurler device according to the present invention. In FIG. 3, for example, a pair of inturned flanges 39 are secured to the outer surface of bottom plate 30, i.e., the surface opposite the surface with which the fins are associated, defining a particular spacing therebetween, such that a support element (not shown) may be received in the space between flanges 39 to securely hold the decurler at a proper location while permitting lateral adjustment along the support to facilitate manual compensation for handling different web widths. In FIG. 2, a mounting means generally 100 is illustrated having a base 101, a vertical element 102 and a horizontally extending element 103. Base 101 and horizontally extending element 103 are parallel to receive the decurler unit therebetween while a further portion of base 101 extends outwardly from the decurling unit beyond the vertical support 102 and may be utilized to secure the overall structure to the process equipment. Upper horizontal element 103 is so positioned that a detector element 105 such as a photodetector P may be secured thereto being located over plate openings 12 and 32 for detection of a web passing through the decurling device. Should lateral adjustment of the decurling unit be necessary, such may be accomplished by varying the length of the base 101, or by utilizing clamps in conjunction with base 101 to secure the overall structure to the process equipment whereby clamps may be released and the base reclamped at a different location.
Having described the present invention in detail, it is obvious that one skilled in the art will be able to make variations and modifications thereto without departing from the scope of the invention. Accordingly, the scope of the present invention should be determined only by the claims appended hereto. | A device for removing curl, folds and the like from a moving web in which elongated fins associated with top and bottom plates cooperate to define a web passageway therebetween. The top plate is preferably associated with the bottom plate such that the top plate is biasable away from the bottom plate by seams, etc., passing therebetween, and may include quick release coupling to facilitate assembly and disassembly of the device without affecting the process with which the device is employed. Relative positions of the top and bottom fins may be adjustably controlled. Preferred different fin spacing permits the handling of webs of varying weights and constructions. | 3 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of German patent application DE P 19955829.9, filed Nov. 20, 1999, herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to an open-end spinning frame having a spinning rotor with a rotor shaft supported so as to be free of axial thrust in a wedge-like bearing area formed between adjacent pairs of support disks and held in place therein by a magnetic axial bearing having a stationary magnetic bearing component fixed in a bearing housing and a rotating magnetic bearing component arranged at the end of the rotor shaft and formed by at least two annular ferromagnetic shoulders which are constituted by recesses in the rotor shaft.
BACKGROUND OF THE INVENTION
Spinning units are known in open-end rotor spinning frames wherein the rotor shaft of the spinning rotor, which typically revolves at a high number of revolutions, is supported in the wedge-like bearing area of a support disk bearing arrangement and is fixed in place by means of a mechanical axial bearing arranged at the end of the shaft. Here, the support disk bearing arrangement comprises two pairs of support disks disposed adjacent one another to define the bearing wedge area therebetween, with the axes of the support disks offset such that an axial thrust is exerted on the rotor shaft to constantly urge the rotor shaft against the mechanical axial bearing arranged at its end.
This type of seating of open-end spinning rotors which, for example, is described in German Patent Publication DE-OS 25 14 734, has proven itself in actual use and makes it possible for the spinning rotors to achieve rotational speeds of greater than 100,000 rpm.
However, because of the offset of the support disks, this type of seating of spinning rotors suffers the disadvantage of increased friction occurring between the bearing surfaces of the support disks and the rotor shaft, which over time leads to heating of the bearing surfaces of the support disks. Not only are the bearing surfaces of the support disks considerably stressed by this frictional heating, but additional energy is also required to overcome this friction. Moreover, the mechanical axial bearings are subjected to not inconsiderable wear, even when properly lubricated.
Therefore attempts have already been made in the past to replace these mechanical axial bearings with wear-resistant magnetic bearings. An axial magnetic bearing arrangement is described in DE 195 42 079 A1, wherein one magnetic bearing element is stationarily fixed in a housing of the axial bearing, and another magnetic bearing element or elements are releasably arranged on the rotor shaft of the spinning rotor. Different variations are proposed in this reference regarding the attachment to the rotor shaft of the magnetic bearing elements so as to thereby rotate integrally with the spinning rotor.
Some of these proposals relate to a frictional fitting of the co-rotating magnetic bearing elements on the shaft, while other proposals relate to an interlocking connection of the co-rotating magnetic bearing elements, which can be easily released if required. Although a correct axial fixation of the rotor shaft on the support disk bearing arrangement is possible with these known magnetic bearing elements, and although it is furthermore assured that the spinning rotor can be installed and removed without problems when required, it has been shown that the frictional connection of the magnetic bearing component with the rotor shaft, which is basically advantageous in that it can be easily released when required, is still capable of improvements. The fastening of the co-rotating magnetic bearing elements on the rotor shaft is particularly problematical in connection with such magnetic bearing devices, because the high number of revolutions of the spinning rotor places great demands on the balancing quality of this connection.
An open-end rotor spinning arrangement with a permanent magnet axial bearing has also become known from Austrian Letters Patent 270 459. In this bearing arrangement, ferromagnetic annular shoulders are arranged at the end of the rotor shaft of a spinning rotor, and pole shoes of a permanent magnet, which is pivotably seated in this area, are placed opposite the annular shoulders. The bundling of the magnetic lines of force of the permanent magnet, which becomes possible by means of such an arrangement, leads to a relatively stiff fixation of the rotor shaft in the bearing wedge of the support disk bearing arrangement.
However, this type of magnetic bearing arrangement has the disadvantage that the annular shoulders arranged on the rotor shaft clearly have a larger diameter than the rotor shaft itself. Since the larger diameter annular shoulders make considerably more difficult or even prevent the installation and removal of the spinning rotor, in particular the mounting of its front, this known magnetic bearing arrangement has been unable to gain acceptance in actual use.
Furthermore, a bearing for a spindle of a textile machine, which rotates at a relatively high number of revolutions, is known from German Patent Publication DE 30 47 606 A1. Here, the spindle is supported in the radial direction by means of a three-point bearing arrangement similar to a support disk bearing, and the spindle is secured in the axial direction by means of a magnetic bearing. At its end, the spindle has a bearing area with a reduced diameter and with two ferromagnetic annular shoulders. A bushing made of a non-magnetic material is fixed in place on the bearing housing, and a ring-shaped permanent magnet element, which is enclosed in lateral pole disks, has been embedded in it. In the installed state of the spindle, the ferromagnetic annular shoulders of the spindle shaft are located opposite the pole disks of the permanent magnet element fixed in the static bearing element. Although this known embodiment permits a relatively problem-free installation and removal of the spindle in the axial direction, this arrangement has not been able to gain acceptance in actual use because of its lack of axial bearing rigidity.
Moreover, other bearings for spinning rotors are known from German Patent Publication DE 197 29 191 A1, or the later published German Patent Publication DE 199 10 279.1, wherein the shaft of the rotor is supported without axial thrust in the bearing wedge of a support disk bearing and is axially fixed in place by means of an axial bearing. In this case the axial bearing has a stationary magnetic bearing component, which can be fixed in place on the bearing housing, and a rotatably arranged magnetic bearing component constituted by ferromagnetic annular shoulders in the area of the end of the rotor shaft. Here, the annular shoulders are constituted by recesses in the rotor shaft, which are subsequently filled with a non-magnetic filler material. In this manner, it is intended to avoid the danger that a coating on the peripheral running surfaces of the support disks might be damaged by sharp-edges of the annular shoulders during the installation or removal of the spinning rotor.
In accordance with German Patent Publication DE 197 29 191 A1, plastic is provided as the filler material but without completely satisfactory results because, at the high speed of rotation of the spinning rotor, the plastic material has a tendency to “flow” after extended periods of operation, which results in an unacceptable imbalance of the spinning rotor.
Although these difficulties could be prevented by filling the recesses with a non-magnetic metallic material as described in German Patent Publication DE 199 10 279.1, this filling of these recesses, for example with copper, can lead to an accumulation of material outside of the bearing area of the rotor shaft, which had a negative effect on the natural oscillation behavior of the spinning rotor, in particular at numbers of revolutions clearly above 100,000 min −1 .
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to further improve the known open-end spinning devices described above and to overcome the disadvantages thereof.
The present invention is basically adapted to any open-end spinning frame of the type having a spinning rotor, a rotor shaft fixed coaxially with the spinning rotor, a support disk bearing arrangement defining a bearing wedge for supporting therein the rotor shaft without imposing axial thrust thereon, and a magnetic axial bearing having a bearing housing, a stationary magnetic bearing component fixed in the bearing housing, and a rotating magnetic bearing component arranged at the end of the rotor shaft. In accordance with the present invention, the aforestated object is attained by forming the rotating magnetic bearing component to comprise at least two ferromagnetic annular shoulders defined by adjacent recesses in the rotor shaft, wherein each annular shoulder has opposed radial faces and a generally rounded outer circumference extending therebetween and each recess has a base circumference connected via rounded annular surfaces with the radial surfaces of the adjacent annular shoulders. In this manner, the annular shoulders have no sharp edges so that the relatively sensitive running surfaces of the support disks are not damaged in the course of installing and removing the spinning rotor. Furthermore, the present invention provides the advantage of minimizing the portion of weight of the rotor shaft projecting past the location of the support disk bearing arrangement.
In a preferred embodiment, the ratio of the length of the rotor shaft to the diameter of the rotor shaft is less than about 12:1, preferably about 11.33:1, which makes it possible to further optimize the spinning rotor such that at high rotational speeds, especially at revolutions greater than 130,000 rpm, the rotor remains outside of its critical natural frequency.
The rotor shaft advantageously has a length greater than about 100 mm, preferably a length of about 93.5 mm. This length is noticeably shortened in comparison with the customary length of conventional rotor shafts, which essentially is due to the area of the magnetic bearing components of the rotor shaft, and advantageously raises the critical natural frequency of the spinning rotor to a level of revolutions which also provides room for further developments.
Thus, the critical natural frequency of the spinning rotor in accordance with the invention lies at a number of revolutions which is clearly above the number of revolutions of rotors which can be expected in the foreseeable future.
In order to preserve the sensitive circumferential running surfaces of the support disks, the general rounding of the annular shoulders reduces substantially the presence of sharp edges in the peripheral areas of the shoulders. For example, the rounding of the shoulders may be accomplished by forming the rounded circumference with curved sections or bevels. On the one hand, such designs assure in a simple manner that the circumferential running surfaces of the support disks are not damaged in the course of the installation or removal of the spinning rotor and, on the other hand, the relatively small curved sections or bevels do not result in any appreciable disruption of the magnetic flux of the axial bearing. For example, the rounded sections arranged on the annular shoulders are of a size of between about 0.1 mm to about 0.5 mm, preferably 0.3 mm.
The curved sections provided in the region of the transitions between the base surfaces of the recesses and the adjoining radial shoulder faces also minimize the danger of breaking of the rotor shaft when turning at high rotational speeds, and in particular remove any possible notching effect in the area of the annular shoulders and recesses. Each of these curved sections has a size of between 0.2 and 1.5 mm, preferably 0.7 mm.
It is additionally preferred that a mechanical emergency bearing be arranged inside the magnetic axial bearing. This emergency bearing is comprised at least partially of a highly wear-resistant ceramic material, for example a ceramic pin, which is inserted into a bore of the bearing bushes of the axial bearing. In this case, the ceramic pin acts together with a contact surface, for example the front face of the rotor shaft, arranged at a distance. Thus, during “normal” spinning operations the stationary ceramic pin does not rest against its oppositely rotating bearing element and, therefore, no additional friction occurs. However, in case of a failure, the emergency bearing prevents the magnetic bearing components from coming into direct physical contact, which would lead to considerable damage of the axial bearing.
Further details, features and advantages of the present invention will be understood from the following disclosure of exemplary embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of an open-end spinning frame in accordance with the present invention, with the rotor shaft of its spinning rotor supported, free of axial thrust, in the bearing wedge of a support disk bearing, and fixed in place at its end by means of a magnetic axial bearing,
FIG. 2 is an enlarged view, partially in side elevation and partially in cross-section, of the axial bearing of FIG. 1, with the end area of the rotor shaft having a magnetic bearing component designed in accordance with the present invention,
FIG. 3 is a side elevational view of the rotor shaft in accordance with the present invention,
FIG. 4 is an enlarged side elevational view of the rotational magnetic bearing component at the end area of the rotor shaft in accordance with the embodiment of FIG. 2, and
FIG. 5 is another enlarged side elevational view of a rotational magnetic bearing component at the end area of a rotor shaft in accordance with an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings and initially to FIG. 1, an open-end spinning unit is identified as a whole by the reference numeral 1 . In a known manner, the spinning unit has a rotor housing 2 , in which the spinning cup of a spinning rotor 3 rotates at a high number of revolutions. The spinning rotor 3 is integrally mounted coaxially to a rotor shaft 4 supported in the bearing wedge of a support disk bearing arrangement 5 , and is driven peripherally by a tangential belt 6 extending over the length of the machine and held frictionally against the shaft 4 by a contact roller 7 . The rotor shaft 4 is axially fixed by means of a permanent magnet axial bearing 18 , shown in detail in FIGS. 2 and 3.
As is customary, the rotor housing 2 is open toward its front and is closed during operation by a pivotably seated cover element 8 , into which a channel plate (not shown in detail) with a seal 9 has been cut. The rotor housing 2 is also connected via an appropriate aspirating line 10 to a suction source 11 , which generates the underpressure required in the rotor housing 2 .
A channel plate adapter 12 is arranged in the cover element 8 , which holds a yarn withdrawal nozzle 13 as well as the mouth area of a fiber guide conduit 14 . A small yarn withdrawal tube 15 follows the yarn withdrawal nozzle 13 . In addition, an opening roller housing 17 is fixed in place on the cover element 8 , which is seated so that it is pivotable to a limited extent around a pivot shaft 16 . On its rear, the cover element 8 additionally has bearing brackets 19 , 20 for seating an opening roller 21 or a sliver draw-in cylinder 22 . In the area of its wharve 23 , the opening roller 21 is driven by a circulating tangential belt 24 extending over the length of the machine, while the drive mechanism (not represented) of the sliver draw-in cylinder 22 preferably is provided via a worm gear arrangement, which is connected with a driveshaft 25 extending over the length of the machine.
FIG. 2 shows the axial bearing 18 in accordance with the present invention in detail in a sectional view. Only a support disk 54 with its shaft 55 of the support disk bearing 5 is represented in FIG. 2. A corresponding pair of support disks is arranged, spaced apart, in the vicinity of the spinning cup of the spinning rotor 3 , as can be seen in FIG. 1 .
The magnetic axial bearing 18 comprises an essentially stationary magnetic bearing component 27 , which is supported in a bearing housing 26 and can be axially adjusted. The active bearing components in the form of permanent magnet rings 41 with pole rings 45 respectively arranged on both sides are arranged within a two-piece bearing bushing 28 , comprised of an inner bushing 28 ′ and an outer bushing 28 ″. The bearing bushing elements 28 ′ and 28 ″ are screwed together by means of a screw thread 30 . The active bearing components 41 and 45 are supported inside the inner bushing 28 ′ and are pressed against an annular shoulder 29 arranged on the outer bushing 28 ″. This results on the one hand in a solid bearing structure, and on the other hand in an unproblematical capability for dismantling the bearing, for example for replacing individual components arranged in the interior of the bearing.
The bearing bushing 28 is seated for axial displaceability within a bore 26 ′ of the bearing housing 26 . As a result, it is possible to adjust the stationary magnetic bearing component exactly to achieve an optimal position in accordance with the spinning technology of the spinning cup.
To prevent twisting of the bearing bushing 28 inside the bearing housing 26 , a pin 32 of a bolt 33 inserted into a bore 34 engages a longitudinal groove 31 of the bearing bushing 28 . The axial adjustment of the static bearing component 27 can be performed in a simple manner by means of a pin 35 of a so-called setting gauge 36 , which engages a groove 59 of the bearing bushing 28 . For this purpose, the setting gauge 36 is inserted into a bore 38 of the bearing housing 26 . The axial position of the static bearing component 27 can be fixed in place by means of a fastening screw 53 , which braces the bearing bushing 28 against the bearing housing 26 .
The rotatable magnetic bearing component 44 of the rotor shaft 4 can be inserted through an opening in the rotor housing 2 , through the bearing wedges of the support disk bearing 5 , as well as a bore 37 of the annular shoulder 29 , into the stationary magnetic bearing component 27 , while the remaining shaft portion 4 ′, which primarily is used for the radial seating of the spinning rotor 3 , remains outside of the axial bearing 18 .
The magnetic bearing component 44 of the rotor shaft 4 essentially consists of recesses 47 , which form disk-like annular shoulders 46 therebetween. The rotor shaft 4 is manufactured of steel with ferromagnetic properties. With the rotor shaft 4 completely inserted into the axial bearing 18 , the annular shoulders 46 are in radially opposed facing relationship with the pole disks 45 , which are arranged on both sides of the permanent magnet rings 41 . Preferably the pole disks 45 have the same width as the annular shoulders 46 . In this case, the width of each of the annular shoulders 46 preferably is approximately 1 mm, and the width of each of the recesses 47 is approximately 3 mm.
In addition, a support device 39 is arranged in the area of the axial bearing 18 , which has a ceramic pin 42 , for example, which has been inserted into a bore of a shoulder 40 of the bearing bushing 28 , preferably into the outer bushing 28 ″.
As indicated in FIG. 2, during “normal” spinning operations the ceramic pin 42 is at a spacing a from the rotor shaft 4 revolving at a high number of revolutions, which assures that no friction will occur between the two components.
In case of interruptions in spinning, in particular during rotor cleaning, during which the contact roller 7 with the tangential belt 6 is lifted off the rotor shaft 4 and the spinning rotor 3 is acted upon by a cleaning element arranged in a piecing cart, the support device 39 prevents the rotor shaft 4 from being pivoted in a clockwise direction, based on the radial force component acting on the rotor shaft 4 in the course of this, and that as a result a contact between the magnetic bearing components of the axial bearings 18 could occur.
As can be further seen in FIG. 2, a mechanical emergency bearing 52 is additionally arranged inside the magnetic axial bearing 18 . This emergency bearing 52 comprises, as indicated for example in FIG. 2, a ceramic pin 56 , which is fixed in place in a bore of the bearing bushing 28 and which in case of emergency acts together with the front face 50 ′ of the rotor shaft 4 . Alternatively, as indicated in FIG. 5, the ceramic pin 56 can also be fastened in a bore of the rotor shaft 4 and would then act together with the bottom surface 57 of the bearing bushing 28 .
FIG. 3 shows a rotor shaft 4 in a general view. Here, the end of the rotor shaft 4 is equipped with the magnetic bearing component 44 of the present invention as shown in FIG. 2 and described above. In this case, the diameter D of the rotor shaft 4 lies between about 8 mm and 9 mm, preferably 8.25 mm. The length L of the rotor shaft 4 is less than about 100 mm, and preferably is 93.5 mm.
The magnetic bearing component 44 is represented in an enlarged scale in FIG. 4, and is comprised of annular shoulders 46 , as well as recesses 47 located therebetween. Here, the exterior diameter of the annular shoulders 46 approximately corresponds to the exterior diameter D of the rotor shaft 4 , while the diameter of the recesses 47 is clearly less and for example is approximately 5 mm.
In accordance with the invention, the sharpness of the annular edges of the shoulders 46 is reduced in the area of their outer circumference by rounding the outer annular edges either in the form of a curved sections 48 , as represented in FIG. 4, or bevels 43 , as indicated in FIG. 5 . As can be seen from FIGS. 4 and 5 in particular, the transitions between the base surfaces 49 of the recesses 47 and the radial faces 50 of the annular shoulders 46 are also rounded. These curved sections identified by 51 are preferably slightly larger than the curved sections 48 in the area of the outer circumference of the annular shoulders 46 .
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | An open-end spinning frame ( 1 ) having a spinning rotor ( 3 ), whose rotor shaft ( 4 ) is supported, free of axial thrust, in the bearing wedge of a support disk bearing arrangement ( 5 ) and is fixed in place by means of a magnetic axial bearing ( 18 ). The axial bearing ( 18 ) has a stationary magnetic bearing component ( 27 ) fixed on the bearing housing ( 26 ), and a rotating magnetic bearing component ( 44 ) arranged at the end of the rotor shaft and having at least two annular shoulders ( 46 ) defined by recesses ( 47 ) in the rotor shaft ( 4 ). The sharpness of the annular shoulders ( 46 ) is reduced in the area between their outer circumference ( 58 ) and the adjoining radial faces ( 50 ) of each annular shoulder, e.g., via curved or beveled surfaces in such area, and the base surfaces ( 49 ) of the recesses ( 47 ) are each connected via rounded sections ( 51 ) with the radial faces ( 50 ) of the adjoining annular shoulders ( 46 ). | 3 |
FIELD
[0001] The present disclosure relates to a mounting arrangement for an exhaust system of a vehicle. More particularly, the present disclosure relates to an exhaust isolator which is mounted directly to a vehicle's frame or underbody, thus eliminating the need for brackets, bolts, welded frame nuts, clipped in frame nuts or the like.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0003] Typically, automotive vehicles, including cars and trucks, have an internal combustion engine which is coupled to at least a transmission and a differential for providing power to the driven wheels of the vehicle. An engine exhaust system which typically includes an exhaust pipe, a catalytic converter, a muffler and a tail pipe is attached to the engine to quiet the combustion process, to clean the exhaust gases and to route the products of combustion away from the engine. The exhaust system is supported by exhaust mounts or isolators which are positioned between the exhaust system and the frame, the underbody or some other supporting structure of the vehicle's body. In order to prevent engine movement and/or vibrations from being transmitted to the vehicle's body, the exhaust mounts or isolators incorporate flexible mounting members or elastic suspension members to isolate the vehicle's body from the exhaust system.
[0004] Typical prior art exhaust mounts or isolators include an upper hanger which is attached to the vehicle's frame or other support structure of the vehicles' body. The upper member extends from the support structure such that it positions an elastomeric isolator at the proper location to accept a lower hanger which extends from the elastomeric isolator to one of the exhaust system's components. The elastomeric isolator is secured in a specific location between the upper hanger and the lower hanger. Typically, the upper hanger includes assembly hardware such as stamped brackets, bolts, welded frame nuts, clip-in frame nuts and/or formed rods which are utilized to secure the upper mount to the frame or other support structure and to secure the elastomeric isolator to the upper mount. This hardware increases the costs and the amount of carbon necessary for the construction and assembly of the vehicle.
SUMMARY
[0005] The present disclosure describes an engine mount or isolator which is mounted directly to the vehicle's frame or other support structure of the vehicle's body. The direct attachment of the exhaust mount or isolator eliminates the need for the upper bracket and all of the associated hardware. The exhaust mount or isolator can be fit directly within a hole formed in the support structure. The elastomeric portion of the exhaust mount or isolator includes a hole which accepts a support rod or lower hanger which is attached to the component of the exhaust system. The support rod or lower hanger can be formed to position the component of the exhaust system in the desired location.
[0006] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0007] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0008] FIG. 1 is a perspective view of an exhaust system attached to a support structure of a vehicle with exhaust isolators in accordance with the present disclosure;
[0009] FIG. 2 is an enlarged perspective view of one of the exhaust isolators illustrated in FIG. 1 ;
[0010] FIG. 3 is a perspective view of the exhaust isolator illustrated in FIGS. 1 and 2 ;
[0011] FIG. 4 is an end view of the exhaust isolator illustrated in FIG. 3 ;
[0012] FIG. 5 is a cross-sectional view of the exhaust isolator illustrated in FIGS. 1-4 with a support rod or lower hanger assembled;
[0013] FIG. 6 is an enlarged perspective view similar to FIG. 2 but illustrating an exhaust isolator in accordance with another embodiment of the present invention; and,
[0014] FIG. 7 is a cross-sectional view of the exhaust isolator illustrated in FIG. 6 with a support rod or lower hanger assembled.
DETAILED DESCRIPTION
[0015] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. There is shown in FIG. 1 , an exhaust mounting system in accordance with the present disclosure which is identified generally by the reference numeral 10 . Exhaust mounting system 10 attaches an exhaust system 12 to a support structure 14 of a vehicle. The vehicle includes an internal combustion engine (not shown), an unsprung mass including wheels and a suspension system (not shown) and a sprung mass which includes a vehicle body (not shown) which is supported by support structure 14 . Exhaust system 12 is connected to the engine of the vehicle and exhaust system 12 routes the products of combustion of the engine to the rear of the vehicle. The internal combustion engine powers the wheels of the vehicle through a transmission (not shown) and a differential (not shown).
[0016] Exhaust system 12 comprises an intermediate pipe 22 , a muffler 24 , a tailpipe 26 and a plurality of exhaust isolator assemblies 30 . Intermediate pipe 22 is typically connected to a catalytic converter (not shown) which is connected to an exhaust pipe (not shown) which is in turn connected to an exhaust manifold (not shown) which is one of the components of the vehicle's internal combustion engine. The catalytic converter may be connected to a single exhaust pipe which leads to a single exhaust manifold or the catalytic converter can be attached to a branched exhaust pipe which leads to a plurality of exhaust manifolds. Also, intermediate pipe 22 can be connected to a plurality of catalytic converters which connect together prior to reaching muffler 24 using a branched intermediate pipe 22 or the vehicle can have a plurality of exhaust manifolds, connected to a plurality of exhaust pipes, connected to a plurality of catalytic converters, connected to a plurality of intermediate pipes, connected to a plurality of mufflers, connected to a plurality of exhaust pipes. The present disclosure is applicable to the above described exhaust systems as well as any other exhaust system known in the art.
[0017] Exhaust system 12 is utilized to route the exhaust gases from the vehicle's engine to the rear area of the vehicle. While traveling from the engine to the rear of the vehicle through exhaust system 12 , the catalytic cleaner cleans the exhaust gases and muffler 24 quiets the noises associated with the combustion process of the vehicle's engine. Exhaust isolator assemblies 30 provide for the support of exhaust system 12 underneath the vehicle and they operate to prevent engine movement and vibrations from being transmitted to the vehicle's body. In addition, exhaust isolator assemblies 30 provide proper positioning and alignment for exhaust system 12 during assembly of exhaust system 12 and during the operation of the vehicle.
[0018] Referring now to FIGS. 2-5 , exhaust isolator assembly 30 comprises an exterior housing or sleeve 40 , an elastomeric isolator 42 , an exhaust rod 44 and an internal sleeve 46 . Exterior housing or sleeve 40 and internal sleeve 46 are both a drawn steel sleeve, a plastic sleeve or any other type of sleeve known in the art. Exterior housing or sleeve 40 includes a flange 50 which facilitates the press-fitting or assembly of exterior housing or sleeve 40 into the vehicle. Exterior housing or sleeve 40 is designed to be press-fit into an aperture 52 defined by support structure 14 of the vehicle (a cross-member as illustrated in FIGS. 1 and 2 ). Press-fitting of exterior housing or sleeve 40 directly into aperture 52 defined by support structure 14 eliminates the typical hardware associated with mounting the prior art exhaust isolators. Exterior housing or sleeve 40 may be pressed into aperture 52 mechanically, hydraulically or pneumatically. This press-fit operation can be conducted during vehicle assembly, it can be conducted during manufacture of support structure 14 or at any time convenient to the vehicle's manufacturer. While exterior housing or sleeve 40 is illustrated as being a circular cylindrical shape, it is within the scope of the present invention to have exterior housing or sleeve 40 be any shape which is desired by the vehicle's manufacturer.
[0019] Elastomeric isolator 42 is disposed within exterior housing or sleeve 40 by being press fit, chemically bonded or secured to exterior housing or sleeve 40 by any other means known in the art. Elastomeric isolator 42 can be formed from silicone (typical for high temperature applications), EPDM (ethylene-propylene-diene-monomer) (typical for moderate temperature applications), natural rubber (typical for low temperature applications) or any other elastomer which meets the requirements of the application. Internal sleeve 46 is typically molded into elastomeric isolator 42 . Elastomeric isolator 42 defines a plurality of voids 56 which are engineered in size, shape and location to control the dynamic rate of exhaust isolator assembly 30 , the insertion force for exhaust isolator assembly 30 , the system durability requirements for exhaust isolator assembly 30 as well as other developmental and performance characteristics for exhaust isolator assembly 30 . Elastomeric isolator 42 defines a through bore 58 through which exhaust rod 44 is inserted during the installation of exhaust system 12 .
[0020] Exhaust rod 44 is a formed rod which can include compound bends such that a first end 60 is positioned to axially engage bore 58 and a second end 62 is designed to mate with and be secured to a component of exhaust system 12 . As illustrated, a different exhaust rod 44 is used for each exhaust isolator assembly 30 but it is within the scope of the present invention to utilize as many common exhaust rods 44 as the design of the specific application allows. Also, each exhaust rod 44 is designed such that each first end 60 , which axially engages a respective bore 58 , is designed such that they engage their respective bore 58 in the fore/aft direction of the vehicle. This fore/aft arrangement of all of exhaust rods 44 simplifies the assembly of exhaust system 12 into vehicle 10 .
[0021] Typically, exhaust rods 44 will each be attached to their respective component of exhaust system 12 . Exhaust system 12 is properly positioned below the vehicle and each exhaust rod 44 is aligned with its respective bore 58 either individually or simultaneously. Exhaust rods 44 are inserted into bores 58 to complete the assembly of exhaust system 12 onto the vehicle. The fore/aft arrangement of all of support rods 44 simplifies this assembly process. An annular barb 66 is formed on the end of each exhaust rod 44 to resist the removal of exhaust rod 44 from its respective bore 58 .
[0022] Referring now to FIGS. 6 and 7 , an exhaust isolator assembly 130 in accordance with another embodiment of the disclosure is illustrated. Exhaust isolator assembly 130 comprises elastomeric isolator 142 and exhaust rod 44 . Elastomeric isolator 142 is the same as elastomeric isolator 42 except that elastomeric isolator 142 is designed to be secured directly to support structure 14 thus eliminating the need for exterior housing or sleeve 40 .
[0023] Elastomeric isolator 142 is disposed within aperture 52 . Elastomeric isolator 142 includes internal sleeve 46 and it defines an annular slot 160 which mates with the surrounding structure forming aperture 52 . Elastomeric isolator 42 can be fit within aperture 52 , press fit within aperture 52 , chemically bonded to support structure 14 or secured to support structure 14 by any other means known in the art. Elastomeric isolator 142 can be formed from silicone (typical for high temperature applications), EPDM (ethylene-propylene-diene-monomer) (typical for moderate temperature applications), natural rubber (typical for low temperature applications) or any other elastomer which meets the requirements of the application. Elastomeric isolator 142 defines the plurality of voids 56 which are engineered in size, shape and location to control the dynamic rate of exhaust isolator assembly 130 , the insertion force for exhaust isolator assembly 130 , the system durability requirements for exhaust isolator assembly 130 as well as other developmental and performance characteristics for exhaust isolator assembly 130 . Elastomeric isolator 142 defines the through bore 58 through which exhaust rod 44 is inserted during the installation of exhaust system 12 .
[0024] Exhaust isolator assembly 130 can be utilized in place of exhaust isolator assembly 30 at any one or all of the locations which support exhaust system 12 . The performance and advantages described above for exhaust isolator assembly 30 apply also to exhaust isolator assembly 130 . | An isolator for an engine mount or an exhaust system is designed to be mounted directly into a hole defined by a supporting structure of a vehicle. A rod extends between an elastomeric isolator disposed in the hole and a component of the vehicle being supported. | 5 |
[0001] The invention relates to a novel nucleic acid sequence encoding a protein that is specifically expressed in Candida albicans and uses thereof.
FIELD OF THE INVENTION
[0002] The present invention relates to a novel nucleic acid and its protein sequence. Specifically the invention describes a novel gene expressed in Candida albicans that could be used as an anti Candida drug target.
BACKGROUND OF THE INVENTION
[0003] Candida albicans is opportunistic yeast that lives in the gastrointestinal and genitourinary tract of most humans. In a healthy human body, the population of Candida is kept in check by the immune system and by the normal microflora of the respective niches in the host microorganisms. When the immune system is compromised, as in AIDS patients and in patients undergoing immunosuppressive therapy, Candida albicans can cause mucosal as well as systemic infection or “Candida mycosis”. If left untreated, such systemic infections frequently lead to the death of the patients. Candida albicans is a species of particular interest to medical professionals and scientists because a very large fraction of all cases of Candida mycosis are caused by this species.
[0004] Two classes of antifungal drugs are used to fight Candida infections. The fungicidal polyene drugs such as amphotericin B act by disrupting membrane function while the fungistatic azoles, such as fluconazole and ketoconazole, act by inhibiting the ergosterol biosynthetic pathway. Amphotericin B is the most effective antifungal drug, but it is more toxic and is less tolerated by the body than the azoles. As a result, azoles have become the drug treatment of choice for many mucosal fungal infections. At present, the therapy principally available for invasive infections is based on relatively few antifungal antibiotics such as the azole derivatives fluconazole and itraconazole or nystatin, amphotericin B and flucytosine. Most of these compounds have serious side effects like tissue toxicity (See Romani et al., Curr. Opin. Microbiol. 6: 338-343, 2003) A serious need in developing newer antifungal drugs has been felt, especially since rise in conditions like AIDS and use of immune suppressive drugs in various medical conditions which has led to significant increase in incidence of Candida infections. Newer drugs, to novel targets in the pathogen could also address a serious problem of drug resistant strains of Candida albicans reported all over the world. Major efforts have been recently focused on identifying newer and unique potential drug targets.
[0005] The present invention provides an isolated polynucleotide sequence coding for a protein that is linked to the morphological transition between the yeast to hyphal state of Candida albicans in vivo as well as its ability to survive engulfment by phagocytic macrophages. Furthermore the invention also provides a novel anti-Candida drug target for treating Candida albicans infection.
SUMMARY OF THE INVENTION
[0006] The invention disclosed herein provides a novel gene designated as CaSRF1 expressed by Candida albicans that is involved in modulating the morphogenetic transformation and virulence upon engulfment by the immune response cells of the host. The use of the gene in developing novel anti-candida drug targets for treating fungal infection is also described.
[0007] One aspect of the invention is to provide an isolated polypeptide of CaSRF1 gene comprising an amino acid sequence of SEQ ID NO: 2. The invention may also include naturally occurring allelic variant of the sequence given by SEQ ID NO: 2. Furthermore, the polypeptide variant includes any amino acid specified in SEQ ID NO: 2 that may be changed to provide a conservative substitution.
[0008] Another aspect of the invention is to provide a nucleic acid molecule comprising a nucleic acid sequence of SEQ ID NO: 1 encoding a polypeptide comprising an amino acid sequence of SEQ ID NO: 2. The invention also includes the nucleotide sequence of the naturally occurring allelic nucleic acid variant of SEQ ID NO: 1. In addition, any single nucleotide polymorphism of SEQ ID NO: 1 is encompassed by the instant invention. The invention also provides a vector comprising the nucleic acid sequence of SEQ ID NO: 1 and a transformed host cell comprising the said vector.
[0009] Yet another aspect of the invention is to provide a method of modifying a nucleic acid sequence of SEQ ID NO: 1 by deletion comprising the steps of:
[0010] a. generating two primers each about 93-94 nucleotides long;
[0011] b. amplifying two different nutritional marker genes URA3 and ADE2;
[0012] c. transforming the PCR products generated with URA3 and ADE2 markers in the WT strain CAI8 and
[0013] d. isolating the transformants
[0014] The primers for the method described herein comprise 5′ terminal sequence of forward primer corresponding to 70 nucleotides immediately upstream of the ATG of the open reading frame of SEQ ID NO: 1 and remaining corresponds to the pUC (forward) primer sequence and the 5′ terminal sequence of the dis(R) primer corresponding to 70 nucleotide sequence immediately downstream of the termination codon TAA of the open reading frame of SEQ ID NO: 1 and the remaining corresponds to the pUC (reverse) primer sequence.
[0015] In another aspect, the invention provides an antifungal drug target including a polypeptide sequence of SEQ ID NO: 2 and a carrier.
[0016] The invention also provides a composition for treating Candida albicans infections comprising an anti-candida drug target of polypeptide sequence SEQ ID NO: 2 and a carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 illustrates the nucleotide sequence of the open reading frame designated as SEQ ID NO: 1.
[0018] FIG. 2 illustrates the deduced amino acid sequence of the open reading frame of SEQ ID NO: 1
[0019] FIG. 3 illustrates the expression analysis of CaSRF1 in yeast versus hyphae favoring conditions.
[0020] FIG. 4 a illustrates the deletion strategy used to generate a homozygous deletion mutant PSC2. FIG. 4 b illustrates primer sequences used for amplification of the nutritional markers for disruption of the CaSRF1 alleles FIG. 4 c effect of the deletion in vitro on membrane stability.
[0021] FIG. 5 illustrates the effect of macrophage engulfment on Casrf1/Casrf1 deletion mutant.
[0022] FIG. 6 illustrates the survival curve for mice infected with 10 7 cells of homozygous deletion mutant PSC2, cph1efg1/cph1efg1, Sc5314 or heterozygous mutant strain PSC1.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention describes a novel polynucleotide of 591 nucleotides length that encodes a protein that is specifically expressed in the yeast form of Candida albicans in effect plays some role in sensing of altered environmental conditions by the pathogen. The sequence of the polynucleotide given in FIG. 1 and designated as SEQ ID NO: 1 is a part of the gene referred to as CaSRF1/IPF9211.5/CA3142/orf6.5311 /orf19.3713 (http://www.candidagenome.org). Since it was identified as a genetic suppressor of temperature sensitivity of mutant of S. cerevisiae gene RPB4, the gene of the present invention is termed as CaSRF1 (Candida Suppressor of Rpb Four) pending approval from the Candida Genome Database (CGD) curators.
[0024] The polynucleotide of the instant invention is capable of encoding a novel polypeptide, which is 196 amino acids in length. The sequence of the polypeptide is given in FIG. 2 and designated as SEQ ID NO: 2. The BLAST analysis (WU-tblastn, V2.0MP-WashU, 13-Dec.-2004) revealed no homologous protein that has significant similarity to the novel protein described herein (SEQ ID NO: 2). The analysis of the sequence using a tool SMART (2) revealed the presence of four trans-membrane domain segments. These segments are hypothesized to be involved in association with cellular membranes.
[0025] The expression analysis revealed that the expression of this novel protein represented as SEQ ID NO: 2 is dramatically reduced in cells undergoing hyphal morphogenesis under a variety of conditions such as growth at 37° C. in YPD containing 10% foetal bovine serum or lee's medium or Spider medium (see Annexure I), RPMI containing 10% fetal bovine serum etc (Example 1).
[0026] Since Candida albicans is a diploid organism with no known stable haploid state, genetic manipulation necessitates eliminating both the copies of the gene in question. Deletion of this sequence from the genome of Candida albicans eliminates the protein being made in the cell and affects the integrity of the cell walls making the cells sensitive to cell wall disturbing agents such as 0.01% SDS and calcofluor 10 μg /ml present in laboratory culture media (See Examples 2 and 3).
[0027] One of the major responses of the C albicans to a variety of environmental conditions is its morphological transition. The transition from the yeast form to the hyphal or pseudohyphal form is tightly associated with the virulence of the organism. The ability of the Candida albicans to form hyphal projections after being engulfed by the phagocytic cells of the immune system contributes greatly to overcoming the cell mediated immunity ensuring its survival in the host and ability to cause infections (Rooney and Klein, 2002, Cell Microbiol 4: 127-137, Gow et al., 2002, Curr. Opin. Microbiol. 5: 366-371)
[0028] Candida albicans is capable of differentiating in a reversible fashion between a bud and a hyphal growth form, which is influenced by environmental conditions. For example, pH and temperature influence the transition between bud and hypha while temperature, UV, white blood cell metabolites and so on affect the morphological transition shown by this organism. The morphological changes made by C. albicans in response to environmental cues indicate that the organism uses a sensory mechanism to register and assess environmental alterations. It was observed that the mutant strain lacked the ability to form hyphae piercing the macrophage cells (see Example 4) indicating the role of homozygous deletion mutant PSC2 of the present invention, especially in the macrophages. The inability of the mutant Candida cells to destroy the macrophage cells is seen as an indication of reduced virulence of the mutant cells thus suggestive of the role of this novel protein in macrophages. Furthermore, the protein of the instant invention (SEQ ID NO: 2) appears to be essential for virulence in disseminated candidiasis as seen in mouse model system described in Example 5.
[0029] The present invention is described further below by reference to the following illustrative examples.
EXAMPLE 1
Expression Analysis And Transcriptional Profile Of CaSRF1
[0030] Composition of the media used for culturing the Candida albicans cells is presented in Annexure I. To test whether transcription of CaSRF1 was regulated during hyphal morphogenesis, Northern blots of total RNA of the SC5314 strain incubated in YPD medium favoring the yeast condition and RNAs from cultures showing various extents of hyphae induced by addition of serum (10% v/v) were probed with the DNA fragment spanning the entire open reading frame spanning sequence. The CaSRF1 transcript was detectable at high level in cultures showing a high fraction of cells in the yeast form. As the cells were shifted to the hyphae inducing condition in presence of serum the levels of transcript of this gene were reduced drastically and rapidly being completely shut off by 2 hrs. This was true for many other hyphae inducing growth conditions ( FIG. 3 ). The converse was found to be true in that the cell cultures induced to be mainly (>90% population) in hyphal state when transferred to conditions favoring yeast form the transcript of this gene reappeared although at much slower kinetics as conversion to yeast form takes much longer and only by about 12 hours can one see the culture mainly containing yeast form cells. Both these analyses were carried out using RT PCR technique with open reading frame specific primers.
EXAMPLE 2
Deletion of CaSRF1in C. albicans Strain CA18
[0031] The strategy used for deletion of both the alleles of the CaSRF1 gene is shown in FIG. 4 a . In order to generate a CaSRF1 deletion cassette, two primers each about 93-94 nucleotides long ( FIG. 4 b ) were generated. The 5′ terminal sequence of forward primer corresponds to 70 nucleotides immediately upstream of the ATG of the open reading frame and the remaining corresponds to the pUCf primer sequence. The 5′ terminal sequence of the dis(R) primer corresponds to 70 nucleotides immediately downstream of the termination codon TAA of the open reading frame and the remaining corresponds to the pUCr primer sequence. This allowed the amplification of two different nutritional marker genes URA3 and ADE2 respectively cloned previously in the vector pPS5 using PCR amplification method (Ausubel et al, CURRENT PROTOCOLS IN MOLECULAR BIOLOGY, Greene Publishing and Wiley-Interscience, New York, 1995). The PCR products generated respectively with URA3 and ADE2 markers flanked by the homologous sequence to the untranslated regions of the CaSRF1 gene are ˜1.4 and ˜2.5 kb respectively.
[0032] These were transformed in the WT strain CA18 C. albicans CAI8 (ade2::hisG/ade2::hisG ura3::imm434/ura3::imm434) (Fonzi and Irwin, 1993, Genetics 143:712-728) by the transformation method employing lithium acetate whereby yeast cells are briefly incubated in buffered lithium acetate and transforming DNA is introduced with carrier DNA. Addition of polyethylene glycol (PEG) and a heat shock trigger DNA uptake (Ausubel et al, CURRENT PROTOCOLS IN MOLECULAR BIOLOGY, Greene Publishing and Wiley-Interscience, New York, 1995). The insertion of the above PCR product in the correct locus in the transformants obtained was confirmed by PCR employing the nutritional marker specific internal primers and a primer upstream of the CaSRF1 gene. The homozygous deletion was confirmed by northern analysis, which showed complete absence of the gene specific transcript as expected.
EXAMPLE 3
Functional Characterization Of The Casrf1/Casrf1 Null Mutant Of Strain CAI8
[0033] To test whether the Casrf1/Casrf1 i.e. homozygous deletion mutant PSC2 is affected in its ability to show morphological variation like its parent strain, testing was carried out as to how the WT strain CAI8 and the clinical isolate SC5314 behave in presence of serum and some of the other conditions under which C. albicans strains are reported to show hyphal transition associated with virulence. The experiments were carried out at 37° C. In all conditions tested, no significant difference in hyphae formation was observed. Especially the serum induced hyphae formation was seen in the mutant having either no copy of the caSRF1 gene or one copy or two copies as in WT. Similarly the solid media such Lee's medium, YPS medium, YEPD+10% serum as well as media in which pH induced hyphae formation is tested showed no difference. While since the protein is predicted to have four transmembrane domains, it is likely that it plays some role in the membrane/ cell wall integrity. Two chemicals, SDS and calcofluor, resistance to which is dependent on the integrity of the cell wall of the yeast cell (Morenoa et al. FEMS Microbiol. Lett. 226, 159-167) were employed to test if there was any defect in the cells lacking the CaSRF1 protein. It was observed that the homozygous strain was sensitive to 0.05% SDS and 5 μg/ml of Calcofluor.
[0034] ADE2 primers referred above are:
[0000]
Forward primer-CAGATCTCAACACCAATAATTGATGAAAC
Reverse primer-CCTCGAGTAAGAAGGGAAAAGCACCAC
[0035] URA3 primers referred above are:
[0000]
Forward primer
(5′-3′)-CAAGCTT AATAGGAATTGATTTGGATGG
Reverse primer
(5′-3′)-TCTAGAAGGACCACCTTTG
EXAMPLE 4
Morphological Changes Of The Homozygous Deletion Mutant PSC2
[0036] The Candida albicans strains (Wt. homozygous or heterozygous srf1Δ strain) were co-incubated with mouse macrophage cell line (or peritoneal macrophages) grown in RPMI+10% FCS in 6 well plastic trays for upto 6 hrs and at one hour interval the morphology of the Candida cells was recorded using Leica bright field inverted microscope.
[0037] The homozygous deletion mutant PSC2 does not have overall defect in forming hyphae, since the cells incubated in media containing serum as well as other hyphae promoting media (listed in Annexure I) show no difference in the ability of forming hyphae when compared with the clinical isolate SC5314 widely used in laboratory research ( FIG. 5 ). On the other hand the mutant cells were observed to be engulfed by the activated macrophage cells of the immune system but unlike the parent strain were unable to form hyphae piercing the macrophage cells. This inability of the mutant Candida cells to destroy the macrophage cells was seen as an indication of reduced virulence of the mutant cells in turn the observation was considered suggestive of the role of this protein specifically in macrophage.
EXAMPLE 5
In Vivo Survival In The Presence Of Homozygous Double Mutant
[0038] 10 7 cells of the mutant Candida albicans strain per animal were injected in five, 4-week old BALB/c mice via tail vein route. As a control 10 7 cells of Candida albicans wild type strain SC5314 were injected in five, 4-week old BALB/c mice. The mice in this control group were unable to survive for more than 5 days consistently in three experiments including 5 mice per group in an experiment. The result of a typical experiment is shown in FIG. 6 wherein mice were injected with homozygous deletion mutant PSC2, cph1efg1/cph1efg1, Sc5314 or heterozygous PSC1. The homozygous deletion mutant PSC2 revealed 100% survival similar to the negative control (cph1efg1/cph1efg1) as against the wild type (Sc5314) and the heterozygous mutant (PSC1).
[0039] All publications and patent applications referred to in this specification are indicative of the level of skill of those in the art to which the invention pertains.
[0040] Other objects, features and advantages of the present invention will become apparent from the foregoing detailed description and examples. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given only by way of illustration.
Annexure I
[0041] Media compositions of the media used for culturing the Candida albicans cells.
[0000]
YPD/YPG
Yeast Extract
1
gm
Peptone
2
gm
Dextrose/Galactose
2
gm
Spider medium
Peptone
1
gm
Yeast Extract
1
gm
NaCl
0.5
gm
Mannitol
1.0
gm
K 2 HPO 4
0.2
gm
Water
100
ml
Lees Medium
(NH 4 ) 2 SO 4
0.5
gm
MgSO 4
0.2
gm
K 2 HPO 4
0.25
gm
NaCl
0.5
gm
Glucose
1.25
gm
Biotin
0.001
gm
DM
20
ml
Water
80
ml
Synthetic Complete + Serum
Dextrose
2
gm
DM
20
ml
FCS
10
ml
Water
70
ml
YPD + Serum
Yeast Extract
1
gm
Peptone
2
gm
Dextrose
2
gm
FCS
10
ml
Water
90
ml | A novel Candida albicans nucleotide and polypeptide, CaSRF1, involved in regulating the morphogenetic transformation and virulence in response to engulfment by the immune response cells of its model host is described. The gene is unique in its ability to affect the virulence-associated morphogenesis in vivo but is not required for the morphogenesis in vitro. The putative membrane localization and its effect on cell wall integrity indicates that it is an ideal anti-candida drug target by virtue of its predicted easy accessibility to lead molecules/chemicals and its ability to affect virulence. | 2 |
The present invention relates to an apparatus and method for inflating and sealing round hollow objects, such as for instance plastic play balls.
BACKGROUND OF THE INVENTION
In the manufacture of plastic play balls which are formed of stretchable plastic material, plastic balls of a predetermined size are received generally in heated condition from for instance an oven. The valve housing of each ball is then impaled upon an inflating needle and inflating fluid, such as air, is inserted into the ball to expand the ball to a predetermined finished size, with the heated stretchable wall material of the ball thinning out as the ball expands. A closure plug is then inserted into the valve opening in the ball after withdrawal of the inflating needle to permanently seal the inflating fluid interiorly of the ball, after which the ball is transported to another location for further handling. Many of these operations are manual and the result is increased costs for producing plastic play balls.
SUMMARY OF THE INVENTION
The present invention provides a novel apparatus and method for automatically inflating an expansible ball by means of an inflation needle inserted through an apertured valve housing in the ball while the ball is being held by the apparatus, and then the needle is automatically withdrawn and a plunger member in conjunction with a slide member automatically positions a plug sealing device over the apertured valve housing and the plunger automatically forces the plug into the valve aperture, to permanently seal the inflating fluid interiorly of the ball, after which the apparatus automatically releases the ball in preparation for receiving another ball and performing another inflating operation thereon.
Accordingly, an object of the invention is to provide a novel apparatus for inflating an expansible or stretchable ball, and for inserting a valve sealing means into the valve aperture of the ball after inflation of the latter, for retaining the inflating fluid interiorly of the ball.
A further object of the invention is to provide an apparatus of the above-described type which comprises a relatively stationary supporting base member having therein transversely disposed superimposed top and bottom guide means with top and bottom slide members slidably received in said top and bottom guide means, with an inflation needle movable as a unit with the top slide member and adapted for reciprocation toward and from a fixed point on the supporting member to project freely below the same for impaling of a ball thereon, together with means actuated in synchronism with retraction of the inflation needle for injecting a closure device into the valve aperture for sealing the aperture and thus maintaining the inflated ball in inflated condition.
A still further object of the invention is to provide an apparatus of the aforegoing type wherein the inflating needle means and a plunger means for inserting the closure device, are mounted on the top slide member and include power means for reciprocating said needle and plunger, together with means for sequentially aligning the needle and the plunger means with the aperture in the valve of the ball, and including ball sizing means for gripping the sides of the ball and aiding in maintaining it in position with respect to the needle and plunger means, and which is adapted to automatically release the ball upon completion of the insertion of the closure plug into the valve aperture.
Another object of the invention is to provide a novel and expeditious method for inflating expansible play balls of plastic or the like, and for permanently sealing the valve aperture of the ball, to retain the ball in inflated condition.
Other objects and advantages of the invention will be apparent from the following description taken in conjunction with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generally diagrammatic, reduced size view of an apparatus embodying the invention, and illustrating a ball member of predetermined size which has been received in heated condition from, for instance, a heating oven, and which has been impaled by the inflating needle of the apparatus, preparatory to inflating the ball;
FIG. 2 is an enlarged, partially sectional, generally diagrammatic, fragmentary view of the needle inflating means and the plunger means for forcing the sealing plug into the valve aperture of the inflated ball, with the sealing plug having been shifted by the lower slide member from a supply thereof into alignment with the overlying plunger, for subsequent movement into the valve aperture upon downward actuation of the plunger;
FIG. 3 is an enlarged, fragmentary, partially broken generally diagrammatic view taken generally along the plane of line 3--3 of FIG. 1, showing the inflating needle inserted into the heated ball and commencing the inflation of the ball;
FIG. 4 is a fragmentary, generally diagrammatic, sectional illustration showing the plunger means having forced the closure plug into the valve aperture of the ball, after the ball has been inflated to predetermined size, for sealing the inflating fluid interiorly of the ball, and alos illustrating the thinned out wall material of the ball which was stretched due to the inflating fluid during the expansion of the ball to predetermined size;
FIG. 5 is a diagrammatic, schematic illustration of fluid and electrical control circuitry which may be utilized to provide for automatic operation of the apparatus.
DESCRIPTION OF PREFERRED EMBODIMENTS
The apparatus shown in the drawings comprises a base 10 provided with a stationary base support 12 defining an upper slot 14 (FIG. 2) in which is supported a slide member 16. Slide 16 is adapted to be reciprocated or actuated by means of a motor unit 18 operatively coupled thereto, which, when actuated, moves the slide 16 longitudinally in the guide passage or slot 14 from a starting to a stop position and vice versa. Motor unit 18 may be a double acting, preferably fluid powered, motor unit for reciprocation of the slide 16. Guide rails 20 disposed in overlapping guiding coaction with the slide 16 may be provided for aiding in retaining the slide in the guiding passage 14 during actuation of the motor unit 18.
Mounted for longitudinal movement with the slide 16 is a reciprocal, generally vertically oriented inflating needle 22 which includes a central vertically oriented passageway 24 therethrough, with passageway 24 being coupled as by means of coupling 26 to a source of inflating fluid, such as for instance air, and as by means of a preferably flexible conduit 28. A reciprocal, double-acting, preferably fluid powered motor unit 30 is operatively coupled to the inflating needle 22, and as by means of collet 31, for reciprocating the inflating needle in a generally vertical path and into and out of generally vertically extending passage 32 through support 12, and which communicates at its upper end with slide passage 14 and at its lower end with the underside of support 12. The distal end of the inflating needle 22 is preferably sharpened as at 33 (FIG. 2), for ready entry into the aperture 36 of the valve portion 34 (FIGS. 3 and 4) of a ball B of stretchable material.
Ball B may be formed of plastic such as for instance polyvinyl chloride, which is received in heated condition, and as for instance from a heating oven (not shown) so that the wall material of the ball is readily stretchable when inflating fluid is inserted into the interior of the ball via valve portion or housing 34. The inflating needle 22 is received through the aperture 36 in the valve portion 34 as shown in FIG. 3 and inflating fluid, such as for instance air, is inserted under pressure into the ball to expand the ball to predetermined diameter size. During inflation of the ball, the heated wall material of the ball is thinned out as can be seen by comparing FIGS. 3 and 4. A sealing plug 48 is then inserted into the valve aperture 36 to retain the inflating fluid interiorly of the ball and thus maintain the ball in inflated condition. The above-described process will be hereinafter described in greater detail.
The ball B may be held or maintained in position beneath the support plate 12 by means of sizing and gripping means 38 which in the embodiment illustrated comprise a pair of laterally disposed spring biased plates 39 which are adapted to engage the ball and yieldingly hold the latter in predetermined aligned condition with respect to the aforementioned aperture 32 in the relatively fixed support plate 12.
Mounted for longitudinal movement with slide member 16 and needle mechanism 22 is a plunger member 42, which, in the embodiment illustrated, includes a plunger rod 42a. Member 42 is operatively coupled as by means of coupling 44, to a double acting reciprocal motor unit 46 which is adapted for reciprocating or actuating the plunger member 42 for the purpose of forcing a closure plug 48 (FIG. 4) into the valve aperture 36 of the ball. As can be best seen in FIG. 2, when the plunger rod 42a is aligned with the aperture 32 in the support member 12, such rod is in position to force the underlying closure plug 48 into valve aperture 36, and thus retain the inflating fluid interiorly of the ball to maintain the latter in its inflated condition.
In the embodiment illustrated, the plug 48 is provided from a supply P (FIG. 3) of plug material in the form of a solid, flexible rod of yieldable plastic or rubber material which could be disposed, for instance, in coil form and power fed as by means of a motor unit 49 (FIG. 5) downwardly through an aperture 50 in the support member 12 and into an opening or recess 52 provided in lower slide member 56.
Lower slide member 56 is operatively mounted for reciprocal movement in a guide slot or passage 58 in support 12. Passage 58 extends lengthwise transverse of upper guide passage 14. As can be best seen in FIG. 3, slide 56 has an opening 59 therein disposed laterally outwardly of aforementioned opening 52 for receiving therethrough the inflating needle 22 during inflation of the ball B, and when opening 59 is axially aligned with opening 32 through the support 12. As can be best seen in FIG. 3, lower slide 56 extends lengthwise transversely of upper slide 16 at an angle of approximately 90° with respect to the lengthwise extension of the upper slide 16. Lower slide 56 is adapted to be reciprocated lengthwise thereof and as by means of a motor unit 60 operatively coupled thereto as at 61 (FIG. 3) with motor unit 60 in the embodiment illustrated being a double acting reciprocal unit powered by any suitable means, such as for instance air.
When motor unit 18 shifts the upper slide member 16 and associated inflation needle 22 and plunger 42 longitudinally and toward the right of the position illustrated in FIG. 1, both motor units 30 and 46 are in retracted condition with the lower ends of both the needle 22 and plunger rod 42a being disposed in a respective opening 62 and 64, which are laterally disposed and extend vertically through the top slide 16. In such finalized shifted position, opening 64 in the top slide 16 is disposed above and axially aligned with opening 32 in the support 12. Moreover, the lower slide is also shifted from the position shown in FIG. 3 to the right, to axially align opening 52 in the lower slide with opening 32 in the support 12. During such shifting movement of the lower slide, the latter shears off a plug 48 of the flexible plastic rod from the end of the latter which extends into opening 52. The lower slide carries the plug of material with it and upon positioning of opening 52 in alignment with opening 32, the plug 48 is disposed in alignment with opening 64 in the upper slide and in alignment with the plunger rod 42a of plunger rod 42. Actuation of motor unit 46 is operable to cause the plunger rod 42a to extend into opening 32 and engage the closure plug 48, for ramming or forcing the plug 48 into the valve aperture 36 to seal the valve aperture, thus retaining the ball in inflated condition.
Since the inflated ball is held by sizing and gripping mechanism 38 against the underside of the stationary support 12 and in alignment with the opening 32 therethrough, the air interiorly of the ball has no opportunity to escape, and when the plug 48 is forced downwardly upon actuation of the motor unit 46, the closure plug positively seals the valve 34 of the ball.
The plunger rod 42a is then drawn upwardly from opening 32 in the support 12 and back to the position shown in FIG. 2 wherein its lower end is disposed intermediate the ends of opening 64 in the top slide, whereupon motor unit 60 is actuated to shift the lower slide 56 back to its starting position, and the supply rod P is activated to force the end thereof into recess 52 in the lower slide 56 to provide for another closure plug and motor unit 18 is reactuated to shift the upper slide 16 back to its starting position, for initiation of another inflation cycle of the apparatus.
Automatic operation of the apparatus may be as follows:
In an initial starting position of the ball inflating apparatus as shown for instance in FIG. 1, for a continuous succession of ball inflating operations, the inflating needle 22 initially projects a predetermined extent below the underside of fixed support 12 as shown in FIGS. 1 and 3, so that an inflatable article, such as the plastic ball B which may have been previously heated, can be manually presented upwardly between the laterally spaced, laterally yieldable ball supporting and sizing discs 39.
The projecting end 33 of the inflating needle is received through the valve aperture 36 of the integral valve housing 34 in the spherical wall of the ball. At the same time, in this initial starting position of the apparatus, the lower slide plate 56 has the lower end of the continuous rod P of plug material presented within the recess or opening 52 in the slide plate 56 and as shown in FIG. 3. In this condition, the ball B is capable of being supported solely by the friction between the inflating needle and the confronting surfaces of the valve housing of the ball, during the ball inflating operation. It will be understood however that spring biased discs 39 also exert a certain degree of holding force on the sides of the ball.
Manual actuation of switch 62 by a workman applies power to the circuitry. Insertion of the deflated ball B onto the needle 22 and between the laterally disposed plates 39 automatically trips limit switch LS9 (FIG. 5) which through start relay R1, activates solenoid valve SV7 to cause inflation air to be supplied from a source 64 of pressurized air and via for instance line 28, to the central passageway 24 through the needle, thus causing the pressurized air to pass via ball valve 34, into the ball and to commence inflation thereof.
As the ball B expands to its predetermined finalized diameter size, the laterally spaced, biased discs 39 are forced apart by the expanding ball, whereupon a limit switch LS7 is activated for shutting off solenoid valve SV7 and stopping the supply of pressurized air via needle 22 into the ball, and at the same time activating solenoid valve SV2 so as to cause actuation of motor unit 30 (FIG. 1) to cause the needle 22 to be raised upwardly from the opening 32 in the support base 12, until the distal end 33 thereof is positioned within opening 62 in the upper slide 16, and as shown in FIG. 2.
When the needle is retracted to its up position, it actuates a limit switch LS2 causing actuation of solenoid valve SV1 thereby actuating motor unit 18 to cause shifting of the upper slide 16 and to which are coupled the needle and the plunger member 42, from the home or start position toward the right to a given stop position, thereby placing the plunger rod 42a of the plunger mechanism in axial alignment with opening 32 in the support base 12, and in overlying relation to the ball.
When the upper slide 16 has completed its shifting movement, the slide causes actuation of limit switch LS5 which in turn activates the solenoid valve SV4 controlling motor unit 60, to cause shifting of the lower slide 56 from its position as illustrated in FIG. 3, toward the right thereof and to a given stop position wherein the plug cavity 52 which contains the plug 48 of material cut off from the end of the supply rod P, is disposed in axial alignment with overlying opening 64 in the upper slide 16 and in axial alignment with the opening 32 in support base 12.
Upon completion of the shifting movement of lower slide 56, the latter actuates a limit switch LS4 which causes actuation of solenoid valve SV3 controlling motor unit 46, which causes the plunger member 42 to move downwardly, thus causing the plunger rod 42a thereof to move into aligned opening 32 in support base 12, and push the plastic plug 48 of material in cavity 52 in the lower slide, through aligned opening 32 into the valve housing 34 in the ball, thus sealing the inflating fluid interiorly of the ball.
Activation of LS4 also causes activation of switch LS8 and timer T1. When the timer T1 times out, the solenoid valve SV6 controlling motor unit 66 is actuated to cause motor unit 66 to move the associated disc 39 away from the opposing disc and return, whereby the inflated and plugged ball drops by gravity onto conveying mechanism for moving the ball away from the apparatus. Moreover, timing out of T1 causes the solenoid valve SV3 to be actuated so as to actuate the motor unit 46 to return the plunger mechanism 42 to raised position, wherein the lower end of the plunger rod 42a is once again disposed in the opening 64 in upper slide 16.
When the plunger has been returned to the up position, a limit switch LS5 is actuated by the plunger which causes actuation of solenoid valve SV4 to cause actuation of motor unit 60, thereby moving the lower slide 56 back to its starting or home position as shown in FIG. 3, whereupon the end of the rod or plug material is fed or urged by continuous feed motor 49 into the cavity or opening 52 in the lower slide.
Upon reaching starting or home position, lower slide 56 actuates limit switch LS1 which causes actuation of solenoid valve SV1 to actuate motor unit 18, thus causing shifting of the upper slide 16 back to starting position, and wherein the opening 62 therein is once again axially aligned with the opening 32 in the support base 12. When slide 16 reaches its home or starting position, a limit switch LS3 is actuated which causes actuation of the solenoid valve SV2 causing the motor unit 30 to extend the needle 22 down through aligned opening 32 in the support base 12 and to extend below the support base. At this time all of the mechanisms are in starting or home position, ready for repeating of the cycle.
While the supply of plug material P has been illustrated as being a continuous rod of flexible plastic material, it will be understood that other types of supply of plug material could be provided for the apparatus, such as for instance a supply of precut or preformed individual plugs which could be sequentially fed down into the recess opening 52 in lower slide 56, for subsequent shifting with the slide into aligned relation with opening 32 and insertion into the valve housing of an inflated ball.
From the foregoing description and accompanying drawings it will be seen that the invention provides a novel ball inflating apparatus and method which is automatically operable through a succession of cycles, and wherein the apparatus comprises a relatively fixed supportive member having therein transversely disposed superimposed top and bottom guide means, with top and bottom slide members slidably received in the guide means, and with an inflation needle and plug injection means coupled to the top slide member for movement therewith, for sequentially inflating an associated expandable ball to a predetermined diameter size, and then inserting a plug into the valve aperture of the ball for retaining the ball in inflated condition, with the plug being supplied into coaction with the ball by shifting movement of one of the slide members.
The terms and expressions which have been used are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of any of the features shown or described or portions thereof, and it is recognized that various modifications are possible within the scope of the invention claimed. | Ball inflating apparatus automatically operable through succession of cycles in each of which a ball inflation needle is momentarily exposed for reception of an end of the same through apertured valve housing of an inflatable ball of stretchable material. In each cycle the ball is also engaged between spaced ball sizing means. Simultaneously with each successive withdrawal of the needle from the valve housing, slide members reciprocated in fixed support base operable to present air sealing device in path of reciprocatable plunger, to urge the sealing device into valve housing aperture for retaining air in the inflated ball. With each withdrawal of inflating needle from fully inflated ball and after insertion of sealing device, full distention of inflated ball actuates ball sizing means to release inflated ball and initiate next successive ball inflation cycle. | 0 |
TECHNICAL FIELD
[0001] The present disclosure relates to device testing, and more particularly to a drop test apparatus.
DESCRIPTION OF RELATED ART
[0002] In drop testing, a container filled with varying contents is dropped from a preset height onto a rigid surface to determine whether the container and its contents can resist the impact. A typical drop test apparatus employed for this purpose includes a support platform and a control device for adjusting a height of the support platform. After the container reaches the predetermined height, the control device withdraws the support platform and the container falls. The container and its contents are checked fro damage. Such a drop test apparatus controls the height from which the container drops, but cannot control the angle at which the container falls.
[0003] Therefore, there is room for improvement within this art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Many aspects of the embodiments can be better understood with references to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0005] FIG. 1 is an isometric and exploded view of a drop test apparatus in accordance with an embodiment.
[0006] FIG. 2 is an assembled view of FIG. 1 .
[0007] FIG. 3 is similar to FIG. 2 , but shows angle adjustment members of the drop test apparatus at another height and angle.
DETAILED DESCRIPTION
[0008] The disclosure is illustrated by way of example and not by way of limitation.
[0009] In the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
[0010] Referring to FIG. 1 , an embodiment of a drop test apparatus includes a base panel 10 , a pair of first angle adjustment members 20 , a pair of second angle adjustment members 30 , two pairs of height adjustment members 40 , four pairs of threaded retainers 50 , and four pivot mounting members 60 . A pair of longitudinal slots 12 is defined in the base panel 10 for mounting the height adjustment members 40 . The longitudinal slots 12 are parallel.
[0011] Each of the first angle adjustment members 20 includes a first support panel 22 , a backrest panel 24 extending upward from the first support panel 22 , and a wedge-shaped mounting block 221 extending from a bottom side of the first support panel 22 . The backrest panel 24 and the mounting block 221 are at opposite ends of the first support panel 22 . A pivot mounting slot 2212 is defined in the mounting block 221 for receiving the pivot mounting member 60 .
[0012] Each of the second angle adjustment members 30 includes a second support panel 32 and a side panel 34 extending downwardly from a side edge of the second support panel 32 . Each of the second support panel 32 and the side panel 34 has a rectangular shape. An angled slot is defined in the side panel 34 .
[0013] Each of the height adjustment members 40 includes a threaded post 42 and a mounting piece 44 protruding from a top thereof. A pivot hole 441 is defined in a top portion of the mounting piece 44 .
[0014] Each of the pivot mounting members 60 includes a pivot shaft 62 and a V-shaped head 64 connected to a distal end of the pivot shaft 62 .
[0015] Referring to FIGS. 2 and 3 , during assembly, the threaded post 42 of each of the height adjustment members 40 is received in one of the longitudinal slots 12 of the base panel 10 . A lower portion of the threaded post 42 of each of the height adjustment members 40 extends from a lower side of the base panel 10 via the longitudinal slot 12 . A pair of threaded retainers 50 is secured to the threaded post 42 of each of the height adjustment members 40 . The pair of threaded retainers 50 secured to each of the height adjustment members 40 respectively resist upper and lower surfaces of the base panel 10 . Thus, each of the height adjustment members 40 can be secured to the base panel 10 , and has a portion with a predetermined height protruding upwardly from the base panel 10 . The pivot holes 441 , of two of the height adjustment members 40 , are aligned with the pivot mounting slots 2212 of the first angle adjustment members 20 . Two of the pivot mounting members 60 are inserted into the pivot holes 441 and the pivot mounting slots 2212 , for pivotally mounting the first angle adjustment members 20 to the height adjustment members 40 . The pivot holes 441 of two of the height adjustment members 40 align with predetermined portions of the angled slots 341 of the second angle adjustment members 30 . Two of the pivot mounting members 60 are inserted into the pivot holes 441 and the angled slots 341 for pivotally mounting the second angle adjustment members 30 to the height adjustment members 40 .
[0016] To perform a drop test on a device (e.g., a cuboid casing with an electronic device packaged therein), the first angle adjustment members 20 and the second angle adjustment members 30 are rotated until reaching a predetermined angle and fixed at the predetermined angle by static friction. At the predetermined angle, the support panels 22 of the first angle adjustment members 20 and the support panels 32 of the second angle adjustment members 30 locate at a same plane. The device is placed on first angle adjustment members 20 and the second angle adjustment members 30 . The backrest panels 24 of the first angle adjustment members 20 resist and maintain the position of the device until the drop test begins. The drop test apparatus is quickly withdrawn in a horizontal direction by a control machine. The device loses support and falls to a rigid surface below. Faces, edges, and corners of the device are checked for damage by the impact.
[0017] In one embodiment, a height of each of the height adjustment members 40 is adjustable by a manner of adjusting a length of the each of height adjustment members 40 or adjusting a vertical position of each of the height adjustment members 40 . Furthermore, the pivot mounting members 60 can be received in the angled slots 341 of the second angle adjustment members 30 in different positions, which can also change the height of the second angle adjustment members 30 . Thus, the device can fall from various heights. The first angle adjustment members 20 and the second angle adjustment members 30 can rotate to different angles to support the device. Thus, the device can be dropped from various angles. The drop test apparatus of the present disclosure can perform various drop tests on the device. The less it improves test accuracy and reliability.
[0018] While the present disclosure has been illustrated by the description of preferred embodiments thereof, and while the preferred embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications within the spirit and scope of the present invention will readily appear to those skilled in the art. Therefore, the present disclosure is not limited to the specific details and illustrative examples shown and described. | A drop test apparatus includes a base panel, at least one height adjustment member attached to the base panel, and at least one angle adjustment member pivotally attached to the at least one height adjustment member. The at least one height adjustment member has a portion protruding upward from the base panel. A height of the portion is variable. The at least one angle adjustment member is configured for supporting a device thereon and capable of rotating to different angles. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to forming protective films on the internal surfaces of a nuclear fuel pin by oxidizing agents. More particularly, the invention relates to renewal of protective films within a nuclear fuel pin by decomposition of material within the pin to provide a source of an oxidizing agent.
2. Description of the Prior Art
Zirconium alloys have been used as clad for nuclear fuel pins which are satisfactory from many standpoints. However, vulnerability of Zircaloy to chemical reaction with iodine, and other elements, inside the fuel pin during operation has limited the performance of the fuel pins. These chemical reactions can produce stress corrosion cracking of the clad and the eventual penetration of the wall of the pin. The result is leaking of the pin. Premature failure of a number of pins in this way can result in a very expensive replacement program and loss of power generation.
If ZrO 2 can be formed and maintained on the inside surface of the cladding, the protection by this coating keeps the zirconium alloy relatively immune to chemical attack from within. Unfortunately, the natural environment inside the fuel pin has an oxidizing potential for only a short time. Reactions with the cladding, and other species present, consume the available oxygen during early operation of the fuel pin.
The oxide surface, formed initially, can be broken by mechanical interaction with the fuel pellets or by other means such as chemical breakdown in the absence of sufficient oxygen. The exposed base-metal, zirconium, cannot be filmed over if there is a lack of sufficient oxidizing potential within the pin. Therefore, the base-metal becomes subject to chemical attach by the fission products available through the material processes operating within the pin. Stress corrosion cracking has often been the result of this attack, resulting in failure by perforation of the cladding.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a continuous supply of oxidizing material within a nuclear material within a nuclear reactor fuel pin throughout the useful life of the pin.
The invention contemplates strategically locating material within a fuel pin during fabrication which will radiolytically and thermally decompose to release oxidizing chemicals, or free oxygen itself. Released within the pin, the oxidizing chemicals, or free oxygen, disperse throughout the pin and are available to form ZrO 2 , if and when the inside of the pin cladding has its oxide surface broken.
Other objects, advantages, and features of the invention will become apparent to one skilled in the art upon consideration of the written specifications, appended claims and attached drawings.
DRAWING DESCRIPTION
FIG. 1 is a sectioned elevation of a nuclear reactor fuel pin in which the present invention is embodied; and
FIG. 2 is an enlarged section of a clad wall of a pin similar to the pin of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring specifically to FIG. 1, a fuel pin 1 is disclosed. The elevation is sectioned to show the arrangement of fuel pellets 2 stacked within clad tube 3.
There is a large body of art developed around the shape, size and composition of fuel pellets 2. Also, the pellets may be spring loaded as indicated with spring 4. It is not the purpose of the present disclosure to do more than indicate the major features of pin structure which will further ready understanding of the invention.
The fuel pellets, as shown, shift position during use and expand due to thermal expansion. Also, mechanical vibration can cause the pellets to move relative to the claddings. With movement and expansion, contact occurs between the cladding and the pellets. This contact can result in abrasion of the inside wall by the pellets. Further, the expanding pellet can apply a stress directly to the cladding.
Abrasion of the tube wall can result in rupture of the protective film 5 of oxide formed on the wall. Without the protective coating 5, iodine and other chemicals can reach the cladding surface and stress corrosion cracking is a probable result. However, the film of oxide can be renewed if a source of oxidizing material is available within the pin.
There are a variety of material available for inclusion within the pin to act as a source of oxidizing chemicals, or free oxygen. One group of such materials is the oxides of the transition metals, nickel, chromium, manganese, iron and cobalt. These transition metals are all capable of existing in at least two different oxidation states and will decompose to a lower oxidation state to yield oxygen at a particular temperature level. For example, nickelic oxide (Ni 2 O 3 ) is reduced at about 600° C to yield nickelous oxide (NiO) and oxygen. Likewise, manganese dioxide (MnO 2 ) will decompose to manganic oxide (Mn 2 O 3 ) and oxygen at 535° C. The particular oxide and location of the oxide in the pin can be selected for the particular temperature and radiation conditions that exist so that there will be a gradual decomposition and a continuous supply of oxygen within the pin. Any freshly exposed zirconium surface will be rapidly oxidized by these compounds and the resulting oxide, formed on the inside surface of the clad, will protect the clad from attach by iodine and other chemicals.
In FIG. 1 the oxide is disclosed in the form of pellets 6 and 7, placed at each end of the series of the fuel pellets 2. Calculation and experience will readily combine to establish both the form of pellets 6 and 7 and their strategic location in pin 1. In general, the pellets 6 and 7 would be less likely to replace the more important positions for fuel pellets if placed at the ends of a fuel pellets series. The more active pellets are toward the middle of their stack.
FIG. 2 is an enlarged view of a portion of a fuel pin 10 similar to pin 1 of FIG. 1. Clad wall 11 has fuel pellets 12 stacked within it, very similar to the arrangement in FIG. 1. The requirement for a source of oxidizing chemical within pin 10 is comparable to the requirement for pin 1 of FIG. 1.
It is contemplated by the invention that one of the suitable oxidizing chemicals for the required service be formed and mixed with a material such as graphite. In a combination including graphite-like material, the chemical can be applied to the internal surface of clad wall 11 as a coating 13.
Abrasion of the internal surface of clad wall 11 will rupture the coating 13 as well as oxide film 14 underlying coating 13. However, the chemical in the coating is readily available, closely adjacent to the cladding, as a source of oxygen to reform the oxide film 14.
The invention contemplates a wide range of oxidizing chemicals to produce the oxide coating needed to protect the inside wall of a fuel pin. Also, the invention contemplates the oxidizing chemical in different forms and placed at various locations within fuel pin 1. So selected, formed and located, the oxidizing chemical becomes a continual source of oxygen throughout the life of the fuel pin to cure a rupture of the protecting film of oxide on the internal wall of the pin.
From the foregoing, it will be seen that this invention is one well adapted to attain all of the ends and objects hereinabove set forth, together with other advantages which are obvious and inherent to the apparatus.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the invention.
As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted in an illustrative and not in a limiting sense. | A nuclear fuel pin has positioned within it material which will decompose to release an oxidizing agent which will react with the cladding of the pin and form a protective oxide film on the internal surface of the cladding. | 6 |
DESCRIPTION
Technical Field
This invention relates to photodiode light detectors and more particularly to a novel PIN photodiode light detector which employs a novel construction and side entry to achieve a substantial improvement in performance.
BACKGROUND ART
Fiber optic communications generally employ a modulated light source, such as a light emitting diode (LED), a photodiode (PD) light detector and a glass or plastic fiber interconnecting the LED and PD. In most instances, the LED is modulated by a two-level digital signal and emits one of two light intensities depending on which of the digital signals is applied to the LED. The PD responds to the light intensity conducted by the fiber and provides an electric signal output corresponding thereto, thus, reproducing in a usable electric format the information modulated onto the LED at some remote location.
At this time PN and PIN photodiodes are available. Neither of the prior art structures is entirely suitable since neither can be easily integrated with the receiver circuit in a two-dimensional monolithic chip. A common PIN photodiode available in the prior art is illustrated in FIG. 1. This planar arrangement, in addition to its difficulty with integration, has other substantial limitations and drawbacks.
The PIN photodiode of FIG. 1 is built on a silicon chip 10 which has an I region 11, a thin P region 12, and an N region 13. A ring-like anode 14 is in contact with the thin P region 12 and a silicon oxide layer 15. An aluminum cathode 16 is deposited on the planar surface of the N region 13.
Incident light, for example, light exiting a transmission fiber, passes through the thin P region and is detected by absorption in the I region. However, some of the light passes through, especially at the longer wave lengths due to the limited thickness of the I region in the vertical direction as viewed in the drawing. This dimension must be limited in order to maintain speed since the generated carriers have to travel through the longer distances if this dimension is extended to increase response (see FIG. 4 which shows the effect on transit time with variation of I region thickness. The response curve shown in FIG. 2 illustrates a drop in response above 800 nm caused by the finite vertical dimension of the I region. The graph in FIG. 3 shows the efficiency as a function of I region thickness and wave length, again graphically illustrating the inherent constraints placed on operation by the structure of FIG. 1.
Side entry PIN photodiodes have received little attention and are not at this time commercially available. Optimum structure and characteristcs of this type photodiode have not been considered but are part of the subject matter of this invention and are discussed below.
In addition to the above region thickness tradeoffs, the thin P layer region required to pass the photo energy is electrically undesirable since its thinness increases the resistivity of the device.
The invention contemplates a novel PIN photodiode comprising a semiconductor chip having a thick planar P region separated from a planar N region by a thin planar I region provided with means for admitting photo energy directly to the I region in a direction parallel to the planar orientation of the I region and electric conducting means contacting the P and N regions for connecting the PIN photodiode to electronic circuits formed on the same or other semiconductor chip.
BRIEF DESCRIPTION OF DRAWINGS
In the accompanying drawings forming a material part of this disclosure:
FIG. 1 is a schematic diagram of a prior art PIN photodiode.
FIGS. 2, 3 and 4 are graphs illustrating the operating characteristics of the device illustrated in FIG. 1.
FIG. 5 is a schematic diagram of a PIN photodiode constructed in accordance with the invention.
FIG. 6 is a schematic diagram of a PIN photodiode according to the invention and associated electronic circuits constructed on the same semiconductor chip.
FIG. 7 is a schematic electrical diagram of the device illustrated in FIG. 6.
In FIG. 5 a semiconductor chip 20 has formed therein planar P and N regions as illustrated with a comparatively thin intervening I region. Both the P and N regions may be made as thick as required since no photo energy is passed therethrough. The I region in a vertical direction may be made quite thin since light from the glass fiber 21 enters the I region in the direction of its plane. This dimension can be made as long as required to obtain the desired response without affecting the speed of the device since the carriers formed by absorption travel in the direction perpendicular to the plane which direction is unaffected by an increase in the plane direction. Electrodes 22 and 23 are deposited on the P and N regions for connection to electronic circuits which may be formed on the same chip as illustrated in FIG. 6. The entire structure can be supported on a suitable substrate 24.
In FIG. 6 a semiconductor chip 30 mounted on a substrate 31 includes a PIN photodiode formed therein. The diode includes an anode 32 deposited on a thick P region 33, a thin I region 34 which receives photo energy from an optical fiber 35 which is cemented to the substrate 31 and a thicker N region 36 which has a cathode 37 deposited thereon.
As an example of additional circuitry, the chip 30 includes an NPN transistor 38 and a resistor 39 formed by an N region 40 within a P region 41. The transistor 38 includes an N diffused collector 42, a P diffused base 43 and an N diffused emitter 44 interconnected as illustrated in FIG. 7. It should be noted that processes other than diffusion may be utilized to fabricate the structure described above.
The schematic electric diagram of FIG. 7 is identical to the circuit formed on chip 30 of FIG. 6 and is included to more clearly illustrate the operation of the circuits built on chip 30 of FIG. 6. The resistor 39 is connected to a voltage supply VCC and the emitter to ground. The anode 37 of the PIN diode is connected to the base 43 of transistor 38 and the cathode 32 to ground. Transistor 38 amplifies the signal provided by the PIN photodiode. In a similar manner additional circuits can be added to the chip 30 as required.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. | A PIN photodiode structure uses direct side entry into the I region, thus permitting the use of thicker P and N regions with a comparatively thin I region without sacrificing speed and results in more constant spatial distribution upon carrier generation and longer wave length devices with conventional speeds or smaller devices at faster speeds, and may be integrated on the same chip with associated circuits. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a security door.
[0002] Heavy duty doors, to be used for security purposes, are well known. Such doors may be provided within or at entrances to buildings where there is a risk of unauthorised entry. One example is the security of vacant property, where a normal entrance door is replaced with a temporary steel reinforced security door. A higher degree of resistance to physical attack is available from this type of door.
[0003] Prior art security doors commonly have at least two conventional lock points, the keys to which are passed from one user to another when required. Control and tracking of the keys can become a problem or, at least, inconvenience. Time can be wasted in delivering keys between authorised users.
SUMMARY OF THE INVENTION
[0004] In one broad aspect of the present invention there is provided a security door to be mounted for hinged movement on a frame, there being a wrap-around member mounted for pivotal movement at or adjacent an edge of the door to, in use, project over a portion of the frame.
[0005] In a preferred form the wrap-around member is situated to project over the frame at a side of the doorway opposed to an opening direction of the door. Preferably, an edge of the door includes an extending portion (security strip) over the frame at the same side as the opening direction of the door.
[0006] The wrap-around member may be described simply as a hinged means, that is hinged with an edge of the door at one part and has another edge that swings (“wraps around”) to extend over the frame.
[0007] In a preferred form the present invention introduces a “dual locking” feature where one or more bolts are provided to be, in use, extendible into an adjacent doorframe, in addition to the wrap around feature. Preferably the movement of both the bolts and wrap around member is actuated from the same control means.
[0008] The present invention provides improved security to prevent break-in over the prior art. Particularly, due to the wrap-around feature on the “inside” of the door and an additional extending edge portion on the “outside” of the door, methods of forcing a door open are foiled.
[0009] Security can be further improved by including an extending portion over the frame at the hinge side of the door but on the side opposite the opening direction. This prevents the door being pulled outward from the doorframe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the accompanying drawings:
[0011] FIG. 1 is a plan view of a door and frame,
[0012] FIG. 2 is a side elevation view of a door according to the present invention,
[0013] FIG. 3 is a plan view of a section of security door according to the present invention,
[0014] FIG. 4 is a plan view of a section of a security door,
[0015] FIG. 5 is a plan detail view of an opening mechanism in a door according to the present invention,
[0016] FIG. 6 is a side elevation detail view of the door from FIG. 5 ,
[0017] FIG. 7 is a sequential view of a door opening mechanism; and
[0018] FIG. 8 is a side view of detail indicated in FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring firstly to FIG. 1 , a door arrangement such as is applicable to the present invention is shown in plan view. A main door leaf 11 is mounted to a frame F 1 by a hinge 12 in the normal way. The illustrated door also has a security strip 13 that surrounds three edges of the door (the “top” and “bottom” strips cannot be seen in the plan view). Strip 13 protects the externally visible gap between the door leaf 11 and frame F 1 /F 2 . An internal security angled member 14 extends perpendicularly (then parallel) from an edge of leaf 11 behind hinge 12 , allowing the door leaf 11 to swing in only one (outward) direction A. The overhang 14 a of member 14 with the frame F 1 prevents the door from being pulled out of the frame even if the hinges 12 were broken or the pin removed. The top and bottom extension of strip 13 prevent the door swinging the other way (inward).
[0020] A view from the inside of the door, including a mechanism according to the present invention, is shown by FIG. 2 . In this view, welded to the back of the door leaf 11 are guide tubes 15 that carry locking bolts 16 in at least two positions. Movement of bolts 16 in unison is controlled by a box section control bar 17 . When bar 17 moves in the direction of arrows B and C the bolts 16 are inserted or withdrawn respectively from corresponding holes formed in the frame F 2 . Generally, a lock bolt feature into a frame surrounding a doorway of this type is known to the prior art. Detail of the lock bolts 16 is best seen by FIG. 4 (a locked and unlocked position section X-X).
[0021] In addition to the lock bolt feature of FIG. 4 a “wrap-around” member 18 is provided, illustrated by FIG. 3 (section Y-Y taken from FIG. 2 ). Member 18 is an elongate bar with a right angle, to appear substantially L-shaped in plan view. Three hinged positions 19 , 20 and 21 operate a pivoting movement of member 18 , controlled by the same bar 17 as operates bolt 16 . The first hinge 19 is located to join door leaf 11 and an edge of member 18 at an edge 22 of said leaf. The second hinge 20 is located at the right angle of the L-shaped member 18 , pivotally connecting it via a connector 23 to the third hinge point 21 that is at the bar 17 adjacent where it contacts (slidably over the surface) door leaf 11 . Note that bar 17 is generally held in position for sliding movement by the guide tubes 15 and the lock bolts 16 that slide within them.
[0022] The elongation of member 18 may be of limited length or along most of the edge of leaf 11 adjacent F 2 .
[0023] The top view of FIG. 3 shows the wrap-around member 18 in a locked position where the leg of the L-shape distal from the first hinge 19 projects over frame F 2 . It will be clear that the door leaf 11 cannot be opened in the direction A (shown in FIG. 1 ) when the member 18 is in a locked position. As bar 17 moves in direction C member 18 swings away to allow the door to be opened. Bar 17 moves locking bolts 16 ( FIG. 4 ) at the same time to withdraw and unlock the door.
[0024] In FIG. 3 (and FIG. 1 ) the door leaf 11 also includes an elongate perpendicularly protruding surface 11 a at an edge adjacent frame F 2 , this creates a right angle within which hinge 19 is nestled and a stop means against which member 18 can swing no further to protrude over frame F 2 . However, this component is not essential.
[0025] The mechanisms of FIGS. 3 and 4 provide a dual locking combination for additional security, but operated by the common control bar 17 . The wrap-around member 18 is another line of defence, should strip 13 be pried away and bolts 16 cut with some hack-saw edge.
[0026] FIGS. 5 and 6 illustrate ways of causing movement to bar 17 that in turn operate the bolts 16 and wrap-around member 18 .
[0027] A first option is total manual operation of control bar 17 by use of two conventional lever locks (one lock 24 is shown in hard lines in FIG. 5 and another in dotted detail only). The locks are mounted either side of and with tongues 24 a facing bar 17 . One lock is used to move the control bar to the left (in FIG. 5 this corresponds to locking the door), and the other to the right (unlocking). By operating the appropriate lock with keys in sequence the door, via bar 17 , may be locked and unlocked.
[0028] FIG. 5 also illustrates a second option (but shown in the same drawing for convenience), featuring an externally accessible free moving locking block 25 . In this option, to lock the door the control bar 17 is moved to the locked (arrow B) position by locking block 25 . The control bar 17 will then become immoveable from the outside once in the locked position. Control bar 17 is fitted with a latch 26 to ensure that it does not move to the unlocked (arrow C) position.
[0029] To unlock the door a motor and gearbox combination 27 is used to which a double cam is fitted. As illustrated by FIG. 7 , one cam is used to override the latch and the other to push the bar 17 to the unlocked position (the last of the FIG. 7 sequence).
[0030] Handle 28 is available to allow personnel within the secure building to manually lock and unlock the door.
[0031] FIG. 8 shows a microswitch 28 viewed from arrow Z of FIG. 6 . The microswitch simply relays information to an electronic system as to whether bar 17 has been moved into locked (as pictured) or unlocked position by block 25 . A narrow sliding member 29 includes contours that receive the microswitch and an end that contacts block 25 .
[0032] The implementation of the lock/unlock states of the second option can be entirely motorized and controlled electronically, even at a distance (remote control) or by PIN numbers from an external keypad.
[0033] Personal Identification Numbers are not always secure and can fall into unauthorised hands; therefore a system can be implemented with the present invention that improves this security. This system includes use of a GSM (Global System Mobile) component that will allow communications with a control centre via cellular telephone networks. This communication will allow PINs to be changed and monitoring of when the door is opened, remote opening and status reports (it is intended for the system to be battery operated—e.g. with a 12 month life).
[0034] The control centre has an automated computer system that will generate random PINs and remotely program the door. As an example, at installation it is intended that the control unit will be placed in “receiver” mode. The technician will then contact the control centre to remotely programme the control unit with up to five randomly generated PINs. After receiving this information the control unit will power down to a “standby” mode. The technician will then lock the door and leave the site.
[0035] Battery drainage in standby is relatively negligible, however, on a periodic basis the unit will contact the GSM system to report its status and receive any new programming (PINs etc).
[0036] If access is required to a site, the user contacts the control centre to obtain a PIN. This PIN may only be valid for a limited period (1 use, 1 day etc). The PIN will then change after this period regardless of whether it is used.
[0037] The control centre can track all this information such that an audit will reveal who requested PINs, when they were used etc, for a large number of door installations at different sites.
[0038] The keypad interface may also enable a “manual call” to the control centre by entering a special sequence. Furthermore, the keypad/control unit can place an emergency call if it is tampered with. | A security door is mounted for hinged movement on a frame and includes a wrap-around right-angle member mounted for pivotal movement at an edge of the door. In use the wrap-around member projects over a portion of the frame and provides additional locking. In a preferred form the member is controlled by a bar that also inserts and withdraws one or more locking bolts at the same time. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a storage container, and in particular, a vacuum sealed canister apparatus that preferably provides for holding a Protective Breathing Equipment (PBE) device,
2. Prior Art
Conventionally, a PBE device for airplane crews is packaged in a clear, partially evacuated bag openable by a tear strip. The bag is placed in a fire-proof, hard shell container closed by a lid, which must first be opened to access the bag holding the PBE device. Such a system is shown in U.S. Pat. No. 5,005,700 to Rohling et al. which comprises a double-shell housing containing an evacuated, flexible envelope or pouch holding a respirator as the PBE device. The problem is that fast donning time for the PBE device is important. The use of a flexible pouch provided inside a container necessitates opening two packages to access the PBE device.
Another packaging device is shown in U.S. Pat. No. 4,726,365 to Jablonski which discloses a rip-open, thin-section pouch holding a disposable air filtration mask. The pouch includes a transparent or semi-transparent front panel through which the mask is visible and a pull tab that enables the pouch to be opened by tearing along a seam. This device does not have a hard-shell container and is not particularly adapted for use in low pressure high altitude environments. Also, the pouch is susceptible to inadvertent tearing, puncturing and like damage.
A hard-shell storage container is shown in U.S. Pat. No. 4,465,189 to Molzan which describes a waterproof container having an upper body portion sealed to a lower body portion. The upper body portion is provided with a pressure relief valve that allows air to escape from the interior of the container under high-altitude conditions. A screw type vacuum relief valve eliminates the vacuum inside the container after the container has been collapsed under the force of external pressure to facilitate entry into the container. The problem is that the screw-type relief valve is unacceptably time consuming when fast donning time of the PBE is required.
There is thus a need for a canister for holding a PBE device that prevents unwanted and inadvertent breaching of the canister integrity while providing instant access to the contents held therein. This requires that the canister have a lid that is quickly and easily removed from the container portion of the canister while being protected from inadvertent breaching when the canister is not intended to be opened.
SUMMARY OF THE INVENTION
The canister device of the present invention comprises a hard shell container having an open end that is closed by a removal closure means. The closure means can be quickly removed from a container portion of the canister apparatus to provide for fast donning time of the PBE device held therein. Several embodiments of the closure means are described including a removable "gasket seal" closure assembly sealed to the container by a gasket that allows the closure assembly to be reused. The closure assembly comprises an outer cover that is provided with a pair of hinges. The first hinge releases a handle so that pulling force on the handle moves the outer cover away from the container. This cause the second hinge to actuate and pivot a connected clamp plate away from an inner cover to move a vacuum release plug out of a vent opening in the inner cover. When the vacuum is released, further pulling movement on the outer cover causes the outer cover to completely separate from the container so that the inner cover can then separate from a gasket sealed to the container to thereby expose the breathing equipment contained therein. This canister can be reused by assembling the gasket, inner cover, clamp plate, vacuum release plug and outer cover on the container and pulling a vacuum on the system.
Another embodiment of the closure means of the present invention comprises a lid preferably made of an aluminum sheet having a polyester laminate heat-sealed to a web provided around the open end of the container. The lid sheet is protected from being inadvertently breached through puncture, tearing, cutting and like damage by a hard shell cover that is snap fitted on the container around the web and over the lid. A tab portion of the lid is connected to the cover while a handle provided on the cover serves to remove the cover from the container web and in turn the lid from its sealed relationship with the web. This is done by grasping the handle and applying one continuous pulling motion to release the cover from the container, thereby causing the lid to "peel" from the container web to expose the PBE device held therein. Such a canister apparatus allows easy and quick opening for fast donning of the PBE device.
Having the canister devices of the present invention under vacuum provides decompression protection, i.e., the canister may otherwise bulge and be damaged at low pressures encountered at high altitudes. The partially evacuated canister devices also protect the PBE device from carbon dioxide, humidity, and other gases/vapors, which can potentially degrade the efficiency of the PBE device, as is well known to those of ordinary skill in the art.
OBJECTS
It is therefore an object of the present invention to provide an improved storage container.
It is another object to provide a storage canister for a PBE device that prevents unwanted and inadvertent breaching of the canister while providing instant access to the contents held therein.
Another object is to provide a storage canister comprising a container apparatus for holding a PBE device and having a quick-opening "gasket seal" closure means that is opened by a continuous pulling force on a handle for the closure means to thereby access the PBE device held therein.
Yet another object is to provide a storage canister apparatus comprising a container for holding a PBE device and having a "peel top" closure means that is quickly opened by a continuous pulling force on a handle for the closure means to thereby access the PBE device held therein.
Still another object is to provide a partially evacuated storage canister apparatus that is capable of use in low pressured high altitude environments without breaching the canister.
Yet another object is to provide a storage canister apparatus for holding a PBE device that comprises an indicator for visual inspection of a status gauge that indicates whether the vacuum sealed integrity of the canister apparatus has been breached or not.
Finally, another object is to provide a storage canister apparatus comprising of a hard shell, fire-resistant container having a closure means that is vacuum sealed to the container and that is quickly and easily removed from the container to open the canister.
These and other objects become increasingly apparent to those of ordinary skill in the art by reference to the following description and to the drawings.
IN THE DRAWINGS
FIG. 1 is a perspective view of a "gasket seal" type storage canister apparatus 10 according to the present invention.
FIG. 2 is a broken away perspective view of the storage canister 10 shown in FIG. 1 with a handle 64 being moved into an extended position to begin opening the canister 10.
FIG. 3 is an exploded view of the storage canister 10 shown in FIG. 1.
FIG. 4 is an enlarged view, partly in section, about along line 4--4 of FIG. 1.
FIG. 5 is a partial cross-sectional view about along line 5--5 of FIG. 1.
FIG. 6 is a partial cross-sectional view about along line 5--5 of FIG. 1 but with an outer cover 20 and clamping plate 18 moved into a fully extended position to remove vacuum release plug 44 from a vent opening 42 in an inner cover 16 supported on container 12.
FIG. 7 is a perspective view of a "peel top" storage canister apparatus 110 according to the present invention.
FIG. 8 is a perspective view of the storage canister 110 shown in FIG. 7 with a cover 120 being removed from a web 140 surrounding a container 114 to expose a lid 118 sealed to web 140.
FIG. 9 is a perspective view of the storage canister 110 shown in FIG. 8 with cover 120 being pulled away from container 114 to "peel" the lid 118 from web 140.
FIG. 10 is an enlarged cross-sectional view about along line 10--10 of FIG. 7.
FIG. 11 is an enlarged cross-sectional view about along line 11--11 of FIG. 7.
FIG. 12 is an enlarged cross-sectional view about along line 12--12 of FIG. 11.
DETAILED DESCRIPTION
The terms "upper," "upwardly," "right," "left," "downwardly," and "outwardly" as used in this description simply refer to the orientation of FIGS. 1 to 12, and are not intended to be limiting.
Referring now to the drawings, FIGS. 1 to 6 show a "gasket seal" storage canister apparatus 10 for use with a protective breathing equipment (PBE) device (not shown in FIGS. 1 to 6) intended to be stored therein when not in use. As particularly shown in FIG. 3, canister 10 comprises a storage container 12 having an opening 14 leading into the interior of container 12, a closure means for the container 12 comprising an inner cover 16, a connected clamping plate 18 and an outer cover 20. PBE devices and their use are well known to those of ordinary skill in the art.
As shown in FIGS. 1 to 3, container 12 is a rigid member that can be made of a metal or a plastic material, preferably an opaque plastic material formed by an injection molding process. Container 12 includes a surrounding side wall 22 extending upwardly from a peripheral edge of a planar bottom wall 24 to form the opening 14 providing access into the interior of container 12. Surrounding side wall 22 includes spaced apart lateral walls 22A and 22B extending to and joining with right and left end walls 22C and 22D. End walls 22C and 22D are each provided with an elongated, rectangularly shaped depression 26A while the lateral walls 22A and 22B are provided with a plurality of rectangularly shaped depressions 26B spaced at uniform intervals along the width thereof. The depressions 26A and 26B serve as strengthening means for the respective walls. The junction where bottom wall 24 meets lateral walls 22A and 22B, and right and left end walls 22C and 22D is rounded in a similar manner as the unions between the lateral walls 22A and 22B, and end walls 22C and 22D.
Surrounding side wall 22 and bottom wall 24 are plated or coated (not shown) on their inside surfaces by a material that enhances the vacuum barrier protection of container 12. This coating is preferably a chrome material or an electroless nickel platings but the coating may be any material that retards permeability through the walls 22 and 24. To further enhance the vacuum barrier properties of the container 12, the outside surfaces of side wall 22 and bottom wall 24 can also be plated in a manner similar to that of the inside surface. The outside surface of container 12 is then painted, with a color suitable for it intended use (i.e. safety yellow, neutral grays etc.).
Container 12 is completed by a surrounding and upwardly extending flange 28 that joins with the outer surface of lateral walls 22A and 22B and end walls 22C and 22D adjacent to the upper edges thereof to provide an inner surrounding ledge 30. The upper edge of flange 28 serves to support a sealing means, such as a gasket seal 32 that is preferably made of an elastomeric material. Gasket 32 helps to seal the inner cover 16 to flange 28 to close the opening 14 leading into container 12 and thereby contain the evacuated atmosphere inside canister 10 to protect the PBE device housed therein, as will be explained in detail presently.
As particularly shown in FIG. 3, inner cover 16 is a unitary member having a generally rectangular shaped plate portion 34 with a surrounding channel 36 joined to the peripheral edge thereof. Channel 36 has an inverted U-shaped cross-section formed of opposed lateral channel sections 36A and 36B joined to opposed end channel sections 36C and 36D. Channel 36 serves to removably seal inner cover 16 on container flange 28 by means of intermediate gasket 32 with flange 28 disposed between the opposed side walls comprising channel 36. Plate 34 is further provided with a raised portion 38 having a generally rectangular shape with an upper surface 40 parallel to plate 34. Raised portion 38 is spaced inwardly from channel 36 and is provided with a vent opening or aperture 42 that receives a vacuum release plug 44, preferably made of an elastomeric material and having an enlarged cylindrically shaped head with a depending, frustoconically shaped extension portion (FIG. 3). Plug 44 contains the evacuated environment inside container 12 with inner cover 16 removably sealed over container opening 14 by gasket 32. The vacuum is then released from container 12 by appropriate movement of the outer cover 20 and clamping plate 18, as will be explained in detail presently.
Inner cover 16 also has a pair of opposed rails 46 (only one rail 46 shown in FIG. 3) that connect to the outer periphery of channel 36 by a web (not shown) extending therebetween. Rails 46 are provided adjacent to the lateral channel sections 36A and 36B but they only extend a portion of the length thereof. The webs joining the rails 46 to channel sections 36A and 36B help support the pivoting clamping plate 18. Inner cover 16 is completed by opposed openings or apertures 47 (only one opening 47 shown in FIG. 3) provided through the outer wall of the lateral channel sections 36A and 36B adjacent to the left end of rails 46 and proximate end channel section 36D.
Pivoting clamping plate 18 rests on the inner cover 16 and is made of a plastic or metal material, preferably metal, which is stamped to the shape shown in FIG. 3. Clamping plate 18 comprises a centrally located section 48 having an inverted U-shaped cross-section provided by a rectangular shaped plate 48A and opposed depending sides 48B and 48C. The lower surface of rectangular plate 48A contacts the upper surface 40 of inner cover plate 34 in an overlapping relationship. Rectangular plate 48A is provided with an opening 52 that in conjunction with vent opening 42 in inner cover 16 serve to mount the vacuum release plug 44 with the cylindrical head of plug 44 positioned on plate 48A and the frusto-conical portion of plug 44 extending through and received in openings 52 and 42.
Opposed horizontal webs 50A and 50B extend outwardly from the lower edge of the depending sides 48B and 48C of the central section 48 of clamping plate 18. The right edges of webs 50A and 50B are coplanar with the central section 48 while the left edges thereof extend beyond the plane of section 48. Webs 50A and 50B are in turn each provided with inverted U-shaped channels 52A and 52B joined to the outer edges thereof and having a right edge coplanar with the plane of central section 48 and coplanar with webs 50A and 50B. The left edge of channels 52A and 52B are coplanar with webs 50A and 50B except for opposed tabs 54A and 54B extending beyond the left plane thereof from the opposed outer walls of channels 52A and 52B, respectively. Tabs 54A and 54B are each provided with an opening or aperture 56 that receive a pivot means, such as a threaded screw 58 provided with an associated flat washer 60.
As shown in FIGS. 5 and 6, when canister apparatus 10 is completely assembled, screws 58 extend through the openings 56 in the tabs 54A and 54B and the openings 47 in the lateral channel sections 36A and 36B of inner cover 16 to threadingly mate with threaded inserts (not shown) provided on the inside of the inner walls of channel sections 36A and 36B. That way, clamping plate 18 is able to pivot with respect to inner cover 16 about screws 58 to release the vacuum plug 44 supported in the opening 52 in clamping plate 18 from its sealed relationship in vent opening 42 in inner cover 16 to thereby release the vacuum held inside container 12 by cover 16 sealed to flange 28 by gasket 32, as will be explained in detail presently.
Storage canister 10 is further provided with the outer cover 20 which removedly mounts over the clamping plate 18 and inner cover 16. Outer cover 20 is preferably made of a plastic material and comprises a main outer cover section 62 and a handle 64 pivotably connected thereto by a first hinge 66. Handle 64 has a planar upper surface and is provided with a generally oval shaped opening 68 and a depending skirt 70 extending downwardly from the outer edge of handle 64. First hinge 66 provides for pivoting movement of handle 64 with respect to the main outer cover section 62 along a crease 72 adjacent to the main outer cover section 62 having a step 74 adjacent to handle 64. The crease 72 and step 74 are parallel with respect to each other.
As shown in FIGS. 1 to 3, the main section 62 of outer cover 20 has a planar upper surface that is spaced below and parallel to the plane of handle 64. With canister 10 completely assembled, the main outer cover section 62 overlays the lateral channel sections 36A and 36B of inner cover 16 beginning at the right end of the rails 46 and extending to the left to provide an overlapping relationship with the end channel section 36D of channel 36 of inner cover 16.
Outer cover 20 is completed by a shirt 76 which depends downwardly from the outer edge of a left portion 63 of the main outer cover section 62 from a position beginning along a plane formed by a second hinge 78 (shown in dashed lines in FIGS. 1 to 3) jointed between left portion 63 and a middle portion 80 of outer cover section 62. Second hinge 78 is parallel to the crease 72 of first hinge 66.
As particularly shown in FIGS. 4 to 6, the under side of the middle portion 80 of the main outer cover section 62 provided between the first and second hinges 66 and 74 includes four (4) downwardly depending extensions 82 (FIGS. 4 to 6), positioned adjacent to the corners formed by the crease 72 of first hinge 66 and by the second hinge 78. Extensions 82 threadingly receive screws 84 provided through corresponding openings 86 in the opposed webs 50A and 50B of clamping plate 18 to secure the outer cover 20 thereto.
As shown in FIGS. 1, 2, 4 and 50 with canister 10 completely assembled, gasket 32 is supported along the upper edge of flange 28 surrounding the opening 14 leading into the interior of container 12. The inner cover 16 is then mounted on the container 12 with the flange 28 positioned between the side walls comprising channel 36 and with gasket 32 at an intermediate position disposed between flange 28 and channel 36 of inner cover 16. Clamping plate 16 is then pivotally attached to inner cover 16 with screws 58 extending through the openings 56 provided in tabs 54A and 54B of the inverted U-shaped channels 52A and 52B of cover 16 and received in openings 47 in the inner cover 16, adjacent to the left end of the rails 46. Threaded inserts (not shown) are molded into the inner surface of the outside wall of the inner cover channel 36 and theadingly receive screws 58 to maintain this pivotable relationship. The inside container 12 is then evacuated to provide a negative pressure held therein by the vacuum release plug 44 having its cylindrical portion resting on the upper surface of the rectangular plate 48A of the central section 48 of clamping plate 16 and the frusto-conically shaped extension portion positioned through the opening 52 in clamping plate 18 and received in the vent opening 42 in the raised section 38 of inner cover 16. This prevents the loss of the evacuated atmosphere present inside container 12 with inner cover 16 vacuum sealed to container 12 by gasket 32, as previously described in detail.
As shown in FIGS. 3 to 6, clamping plate 18 is in turn attached to outer cover 20 by screws 84 that extend through the openings 86 in the opposed webs 50A and 50B of clamping plate 18 and which are received in extensions 82 depending from the under side of the middle portion 80 of the outer cover 20. A status indicator port 88 is provided in the left portion 63 of the main cover section 62 and provides for visual inspection of a gauge means (not shown), which measures the interior pressure of container 12. The interior pressure relates to the humidity level present inside canister 10 which is an indication of the carbon dioxide level therein. Carbon dioxide is removed from the breathed air by the PBE device housed inside canister 10 and inadvertently breaching the vacuum seal and thereby admitting carbon dioxide into the canister 10 can prematurely degrade the effectiveness of the PBE device before it is ready to be used, as is well known to those of ordinary skill in the art. Another method is to provide the gauge means as a humidity indicator of the type commercially available from Humidial Corp., Colton, Calif., sold as part no. 2156-20.
In use, the closure means for container 12 is able to be quickly and easily removed to expose the PBE device held therein. This is done by grasping handle 64 with the user's fingers positioned through the oval shaped opening 68, as shown in FIGS. 2 and 6, and with the user holding container 12 in the other hand (not shown). A pulling force is then applied to handle 64 in a direction shown by arrow 90 in FIG. 2. This causes handle 64 to pivot about the first hinge 66 and with respect to the main cover section 62 of outer cover 20 to move handle 64 into an extended position. Further pulling force applied to handle 64 in the direction of arrow 90 causes the middle portion 80 of the main cover section 62 to pivot about the second hinge 78 and with respect to left portion 63 of the main cover section 62 to move the middle portion 80 into a fully extended, spaced relationship with respect to the inner cover 16. As middle portion 80 pivots, the clamping plate 18 secured to the middle portion 80 by screws 84 received in extensions 82 is caused to move away from inner cover 16, pivoting about the axis provided by screws 58 extending through the openings 56 in the extending tabs 54A and 54B and received in the openings 47 in inner cover 16. The pivoting movement of middle portion 80 and clamping plate 18 creates a moment about the axis of screws 58 which is sufficient to overcome the force of the vacuum inside container 12 acting on the vacuum release plug 44. Then, as clamping plate 18 moves away from inner cover 16 the frusto-conical portion of the vacuum release plug 44 is pulled from the vent opening 42 in the raised portion 38 of the inner cover 16 to release the vacuum and break the seal between inner cover 16 and container 12. With the vacuum removed, further pulling force on handle 64 causes the inner cover 16 to easily separately and be removed from the gasket 32 and flange 28 of container 12 to expose the PBE device housed therein. The PBE device is now able to be removed from container 12 and donned for its intended purpose, as is well know to those of ordinary skill in the art.
FIGS. 7 to 12 show another embodiment of a storage canister apparatus 110 intended to house a protective breathing equipment (PBE) device 112 (FIGS. 9 and 10) stored therein when not in use. Canister 110 is of the "peel top" type and comprises a storage container 114 having an opening 116 leading into the interior of container 114, a closure means for the container 114 comprising a flexible lid 118 serving as an inner cover and a rigid outer cover means 120 that is removable snap fitted to the container 114, over lid 118.
Container 114 is a rigid member that can be made of a metal or a plastic material, preferably an opaque plastic material formed by an injection molding process. Container 114 includes a surrounding side wall 122 extending upwardly from a peripheral edge of a planar bottom wall 124 to form the opening 116 leading into the interior of container 114. As clearly shown in FIG. 11, surrounding side wall 122 includes spaced apart lateral walls 126 and 128 extending to and joining with right and left end walls 130 and 132. Left end wall 132 has a semi-circular shape in cross- section while right end wall 130 is formed by a first angled wall section 134 joined to lateral wall 126, a second angled wall section 136 joined to lateral wall 128 with a connecting end wall 138 having a parabolic cross-section extending to and meeting with the angled wall sections 134 and 136. The junction where bottom wall 124 meets lateral walls 126 and 128, and right and left end walls 130 and 132 is rounded.
Surrounding side wall 122 and bottom wall 124 are plated or coated (not shown) on their inside surfaces by a material that enhances the vacuum barrier protection of container 114. This coating is preferably a chrome material or an electroless nickel plating, but the coating may be any material that retards permeability through the walls 122 and 124. To further enhance the vacuum barrier properties of the container 114, the outside surfaces of side wall 122 and bottom wall 124 can also be plated in a manner similar to that of the inside surface. The outside surface of container 114 is then painted, with color suitable for the intended purpose of container 12, i.e., safety yellow, neutral gray, etc.
Container 114 is completed by a surrounding web 140 that extends in a plane extending outwardly from the upper edge of surrounding side wall 122 and away from container opening 116, preferably parallel with the bottom wall 124. Web 140 is covered by lid 118 which has a sufficient area to lay over the entire upper surface 142 of web 140 with an outer edge of lid 118 being coplanar with the outer edge of web 140 to thereby serve as an inner cover means for opening 116. Lid 118 is preferably made of a flexible laminate material and has a thin cross-section that is releasable sealed to web surface 142. Preferably, lid 118 comprises a sheet of aluminum material having a polyester laminate on the bottom surface that is heat sealed to web 142. In that respect, lid 118 comprises the closure means for the opening 116 into container 114. Lid 118 also is provided with a lid tab portion 144 (FIGS. 9, 11 and 12) that extends outwardly beyond web 140 in the vicinity of right end wall 130 of container 114. As shown in FIG. 12, lid tab 144 has an extension portion 146 folded in an overlapping relationship with tab 144 along a crease 148. Crease 148 is aligned along the outermost edge 150 of web 140 in the vicinity of parabolic end wall 138 (FIGS. 11 and 12).
As shown in the drawings, canister 110 is completed by outer cover 120 which is a rigid member made of a metal or a plastic material. Cover 120 comprises the closure means and is preferably an injection molded plastic member mounted on container 114 over lid 118 thereby covering lid 118 which closes the opening 116 into container 114. Cover 120 comprises an upper plate 152 that is sized to mount over the entire annular extent of web 140 and is parallel with web 140 when so mounted. A right edge 154 of cover plate 152 is aligned along the crease 148 of lid 118 and along the outermost edge 150 of web 140 in the vicinity of the parabolic end wall 138. The extension portion 146 of lid 118 is joined to the under side of cover plate 152 from the right edge 154 of plate 152 to a position inwardly of the right end wall 130 of container 114 (FIG. 12) to connect outer cover 120 to lid 118 and provide a means for removing lid 118 from container 114 by applying a pulling force to a handle 156 mounted on cover plate 150, as will be explained in detail presently.
A depending flange or skirt 158 extends downwardly from the outer periphery of cover plate 150 and is positioned outwardly beyond the outer edge of web 140. As shown in FIGS. 7 to 9, skirt 158 has a uniform downwardly extending depth except for that portion of skirt 158 adjacent to handle 156. There skirt 58 has an increased depth that extends to a position at about a mid-point along the length of the spaced apart lateral walls 126 and 128 where skirt 158 inclines upwardly and towards the right to once again form the uniform depth extending to the right edge 154 of cover plate 150 before it terminates adjacent to the opposed ends of the crease 148 formed by the overlapping relationship between extension portion 146 and tab 144 of lid 118.
As shown in FIG. 11, skirt 158 has two opposed sets of right and left detents 160 and 162 that serve to snuggling mate cover 120 on web 140. Left detents 160 extend inwardly towards each other from skirt 158 and are spaced from the under side of cover plate 152 a sufficient distance to accommodate the thickness of web 140 in an intermediate position between cover plate 152 and detents 160. This provides a snap fitting relationship between cover 120 and that section of web 140 located in the vicinity of the junction of semi-circular cross-sectional left end wall 132 and spaced apart lateral walls 126 and 128. In a similar manners right detents 162 extend inwardly towards each other from skirt 158 spaced from the under side of cover plate 152 a sufficient distance to accommodate web 140 in an intermediate position between cover plate 152 and detents 162. This provides a snap fitting relationship between cover 120 and that section of web 140 located a short distance towards detents 158 from where the first and second angled wall sections 134 and 136 of right end wall 130 meet respective spaced apart lateral walls 126 and 128. Detents 160 are somewhat elongated whereas detents 162 have a substantially square shape extending from skirt 156. Detents 160 and 162 thus serve to hold cover 120 in place, over lid 118 and the open end 116 of container 114.
As shown in FIGS. 7 and 10, cover 120 is provided with handle 156 as an integral member having a general elongated U-shape with its opposed ends 164 and 166 connecting to cover plate 152 in the vicinity of where the opposed lateral walls 126 and 128 of container 114 join with the left end wall 132 and directly above the opposed elongated detents 160.
As shown in FIGS. 7 to 10, canister 110 is further provided with a gauge means 168 that is mounted on the inside of lateral wall 128 adjacent bottom wall 124. This is done by masking the inside and outside surfaces of lateral wall 128 during the plating and painting steps, as previously discussed, to provide a sight window 170. Gauge 168 is then mounted on the inside surface of lateral wall 128 in window 170. Gauge means 168 is shown as a vacuum gauge that measures the interior pressure of canister 110 with lid 118 vacuum sealed on web 140 of container 114. The interior pressure relates to the humidity level inside canister 110 which is an indication of the carbon dioxide level therein. Carbon dioxide is removed from the breathed air by the PBE device and inadvertently breaching the vacuum seal and thus admitting carbon dioxide into the canister 110 can prematurely degrade the effectiveness of the PBE device before it is ready to be used, as is well known to those of ordinary skill in the art. Another method is to provide gauge means 168 as a humidity indicator, as previously discussed with respect to canister 10.
In use, cover 120 is removed from container 114 by grasping handle 156 in one hand (FIG. 8) while holding container 114 in the other hand (not shown) or other suitable holding means, such as a mounting bracket (not shown). A pulling force is then applied to handle 156 in a direction shown by arrow 172 in FIG. 8. This causes cover 120 to move away from container 114 when the opposed elongated detents 160 release from their snap fitting relationship with web 140. Once this occurs that portion of cover 120 adjacent to left end wall 132 of container 114 is free to move away from web 140. Since cover 120 is a rigid member, pulling force 172 further releases square detents 162 from their snap fitting relationship with web 140 to completely release cover 120 from web 140. This causes extension portion 146 of lid 118, which is bonded to the under side of cover plate 152, to move away from its overlapping relationship with lid tab 144 while the remainder of lid 118 remains sealed around the peripheral extent of web 140. The direction of the pulling movement on handle 156 is now changed to about a 45° angle with respect to the plane of web 40, as shown by arrow 174 in FIG. 9. This causes lid 118 to begin to "peel" away from web 140 in the vicinity of that portion of web 140 adjacent to right end wall 138 of container 114. Once lid 118 begins to peel from web 140, the vacuum seal between lid 118 and web 140 is released. Continued pulling movement 174 on handle 156 of cover 120 causes lid 118 to peel from web 140 a sufficient amount to expose the PBE device 112 housed inside container 114. The PBE device 112 is now able to be removed from container 114 and donned for its intended purpose, as is well known to those of ordinary skill in the art.
It is therefore apparent that the present invention accomplishes its objects. Therefore, it is intended that the foregoing description be only representative of the present invention and that the present invention be limited only by the hereinafter appended claims. | A storage canister apparatus (10,110) particularly useful for housing a Protective Breathing Equipment (PBE) device therein, is described. A first embodiment of the storage canister comprises a container (12) provided with a removable closure means in a vacuum sealed relationship therewith to prolong the useful life of the PBE device housed therein. The closure means is secured to the container by a gasket seal (44) such that a pulling force on a handle (64) causes the closure means to move with respect to the container to release a plug (44) provided in an inner cover (16) to thereby break the vacuum seal to access the PBE device. A second embodiment comprises a "peel top" closure means that is peeled from the container in response to a pulling force applied to a handle (156) to release the vacuum sealed relationship between a container (114) and the closure means to thereby access the PBE device housed therein. Both embodiments of the storage canister provide for instant access to the PBE device which is important when the breathing equipment must be donned quickly in an emergency situation. | 0 |
FIELD OF THE INVENTION
The present invention pertains generally to smoke analyzers. More particularly, the present invention pertains to optical devices that are used for smoke analyzers. The present invention is particularly, but not exclusively useful as an optical unit for generating signals to analyze smoke, wherein the signals are based on polarization, wavelength and scattering angle considerations.
BACKGROUND OF THE INVENTION
Particles of different sizes and shapes (i.e. different materials) can become suspended in air for any of several different reasons. Tiny, condensed water droplets or ice crystals that become suspended in the atmosphere as clouds are a good example of this phenomenon. Clouds of particles, other than water, that may become suspended in air, such as dust and smoke, are also well known examples of the phenomenon. Unfortunately, smoke can be generated with many types of materials that will most likely cause undesirable consequences. In any event, and particularly in the case of smoke, it may be desirable or necessary to identify the type(s) of particles that constitute the smoke cloud.
Physically, it is well known that different types of particles, when suspended in air as a cloud, will affect light differently. In particular, it is known that particles in a cloud will scatter the light that is incident on the cloud and, depending on the nature of the particles in the cloud, the incident light will be scattered in a predictable and detectable manner. Importantly, the measurable characteristics of the scattered light depend on at least three significant factors. For one, if the incident light is polarized, when it is incident on particles in a cloud the light may change its polarization. If so, the polarization of the scattered light will be different from that of the incident light. For another, the wavelength (λ) of the incident light that interacts with the particles in the cloud will determine the extent of scattering. Further, detection of the scattered light will be influenced by where the detector is located relative to the beam path of the incident light (i.e. a scattering angle (θ)). In summary, the detection of a signal that is generated when light is scattered by a smoke cloud is dependent on the polarization of the incident light, the wavelength (λ) of the incident light, and the scattering angle (θ) where the detector happens to be located.
For purposes of the present invention, the above factors are important because different smoke and dust particles will scatter a same incident light beam differently. Further, it can be shown that relatively benign particles, though detectably different, have characteristically similar responses. Accordingly, as a group, they can be differentiated from the group of responses that are characteristically different and are typical of potentially hazardous or toxic particles (e.g. petrochemicals).
In light of the above, it is an object of the present invention to provide an optical unit for a smoke analyzer system that evaluates signals received from light scattered by a smoke cloud to determine whether the smoke includes particularly hazardous or toxic materials. Another object of the present invention is to provide an optical unit for a smoke analyzer system that generates signals for evaluation, wherein the signals are based on polarization, wavelength and scattering angle considerations. Yet another object of the present invention is to provide an optical unit for a smoke analyzer that is easy to use, is simple to manufacture and is comparatively cost effective.
SUMMARY OF THE INVENTION
A system for analyzing smoke includes a plurality of optical units, wherein each unit includes an optical emitter (E) and a pair of detectors. Each emitter is computer controlled to alternately direct a beam of horizontally polarized light (λ H ), or a beam of vertically polarized light (λ V ) along a beam path through a smoke cloud. Further, the emitters of the different optical units are controlled by the computer for sequential operation.
In addition to its emitter, each optical unit includes a horizontally polarized detector (D H ) and a vertically polarized detector (D V ). Both detectors are positioned at different locations having a same distance and a same scattering angle (θ) relative to the beam path. Preferably, the detectors are coplanar with the emitter and are therefore on directly opposite sides of the beam path. In operation, the horizontally polarized detector (D H ) generates a signal S HH in response to λ H , and it generates a signal S VH in response to λ V . Similarly, the vertically polarized detector (D V ) generates a signal S HV in response to λ H , and it generates a signal S VV in response to λ V .
For a preferred embodiment of the present invention, three coplanar optical units are used. Thus, respective emitters (E 1 , E 2 and E 3 ) are positioned on a circumference of a circle, with a separation arc length of 4θ between adjacent emitters. Within this arrangement, the emitter (E 1 ) of a first optical unit generates λ H and λ V having a same first wavelength (λ), the emitter (E 2 ) of a second optical unit generates λ′ H and λ′ V having a same second wavelength (λ′), and the emitter (E 3 ) of a third unit generates λ″ H and λ″ V having a same third wavelength (λ″). Importantly, each emitter is sequentially and individually activated by the computer for a predetermined time interval to simultaneously generate response signals (S) in all detectors of the system.
The computer is also used for evaluating all of the response signals “S” for an analysis of the smoke. More specifically, this task is accomplished by computing a polarization ratio ρ(θ): wherein
ρ(θ)=σ HH (θ)/σ VV (θ)
with σ HH (θ) and σ VV (θ) each being a differential mass scattering cross section for horizontally polarized light and for vertically polarized light, respectively. In particular, for the present invention, the polarization ratio, ρ(θ), is used to identify smoke from a petrochemical (hydrocarbon) source.
In addition to the optical units mentioned above, the system of the present invention also includes filters for minimizing noise in the response signals. One filter is for removing white noise from the response signals (S), and the other is for operationally tracking the emitters. Specifically, a pre-filter is connected to each of detectors to filter a substantially d.c. component (white noise) from the outputs of the respective detectors. Additionally, the system has an oscillator that is controlled by the computer and is connected to each of the emitters. As used for the present invention, the oscillator establishes a blink rate (e.g. 3 Hz) for the transmission of light beams (e.g. λ H and λ V ) from the respective emitters. Also, a synchronous demodulator is connected directly to the oscillator, and in series with the prefilter, for tracking the blink rate of the emitter during generation of the response signals S.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
FIG. 1 is a schematic drawing of a system for an optical smoke analyzer in accordance with the present invention;
FIG. 2 is a schematic drawing of an optical unit for use with the system of the present invention;
FIG. 3 is a schematic drawing of a plurality of optical units positioned for mutual operation as a system in accordance with the present invention;
FIG. 4 is a Table showing signals that are generated by the cooperative operations of light beam emitters and signal detectors for a system as shown in FIG. 3 ; and
FIG. 5 is a graph of signal responses showing an exemplary difference between the optical responses of benign materials and those of hazardous materials.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIG. 1 , a system for an optical smoke detector in accordance with the present invention is shown and is generally designated 10 . As shown the system 10 includes a computer 12 that is directly connected with a sequencer 14 . In turn, the sequencer 14 is connected to a plurality of emitters, of which the emitters E 1 , E 2 and E 3 are exemplary. As intended for the system 10 , each of the emitters E are positioned to direct a laser beam 16 to a point 18 in a smoke cloud 20 . The light in the laser beam 16 will then be scattered as it passes through the smoke cloud 20 , and will be received by a plurality of detectors, of which the detectors D H , D V , D′ H , D′ V , D″ H , and D″ V are exemplary. FIG. 1 also shows that these detectors (D H , D V , D′ H , D′ V , D″ H , and D″ V ) are each connected, in sequence, to a pre-filter 22 and a tracking filter 24 . Further, the system 10 is shown to include an oscillator 26 that is connected between the computer 12 and each of the emitters E 1 , E 2 and E 3 , with the oscillator 26 also connected to the tracking filter 24 .
In detail, each of the emitters E 1 , E 2 and E 3 includes two light emitting diodes (LEDs) that are specifically interrelated to each other. Importantly, the laser light beams 16 that are emitted from the LEDs of a respective emitter E 1 , E 2 and E 3 have a same wavelength (λ). They have, however, a different polarization. Specifically, the emitter E 1 will alternately transmit a horizontally polarized light beam 16 of wavelength λ H , and a vertically polarized light beam 16 of wavelength λ V . Similarly, the emitter E 2 will transmit light beams 16 of wavelengths λ′ H and λ′ V , while the emitter E 3 will transmit light beams 16 of wavelengths λ″ H and λ″ V . Preferably, λ is substantially red light, λ′ is substantially green light, and λ″ is substantially blue light. As envisioned for the present invention, the transmission of light beams 16 from the respective emitters E 1 , E 2 and E 3 is controlled by the computer 12 through a concerted action of the sequencer 14 and the oscillator 26 to create signals S for use by computer 12 for generating an output 28 .
Within the system 10 , the operational positioning and orientation of the emitters E 1 , E 2 and E 3 , relative to the detectors D H , D V , D′ H , D′ V , D″ H , and D″ V will perhaps be best appreciated with reference to the optical unit shown in FIG. 2 and generally designated 30 . For the optical unit 30 , it will be seen that a single emitter (e.g. E 1 ), and its associated detectors (i.e. D H and D V ), are positioned on the circumference of a circle 32 . As shown, the circle 32 is centered on the point 18 in smoke cloud 20 . And, the laser light beam 16 (in this case, λ) is directed from the emitter E 1 , and through the point 18 , to a reference detector 34 . This reference detector 34 may be polarized or unpolarized. In order to properly orient the optical unit 30 , the reference detector 34 is positioned on the circle 32 diametrically opposite the emitter E 1 . As shown, the detectors D H and D V are then positioned opposite the path of light beam 16 from each other. And, they are respectively distanced from the reference detector 34 by a same arc length θ. As intended for the system 10 , which preferably includes three optical units 30 , the arc length θ will be equal to thirty degrees (30°).
A preferred layout of three optical units 30 for the system 10 is presented in FIG. 3 . With reference to FIG. 3 it is to be appreciated that for this configuration of the system 10 , the arc distance θ along the circumference of circle 32 will be the same from each detector D to an adjacent emitter E or to an adjacent reference detector (e.g. reference detector 34 ). This will then establish an arc distance of 4θ (i.e. 120°) between any two of the emitters E 1 , E 2 and E 3 . Further, it is also to be appreciated that as each of the emitters E 1 , E 2 and E 3 are activated, signals “S” will be simultaneously generated at all of the detectors D H , D V , D′ H , D′v, D″ H , and D″ V in the system 10 .
By cross referencing FIG. 3 with FIG. 4 , the signal generation capability of the system 10 will be appreciated. As already disclosed, each emitter E in the system 10 is capable of transmitting a specific wavelength light with different polarizations (i.e. emitter E 1 transmits λ H and λ V , E 2 transmits λ′ H and λ′ V ; and E 3 transmits λ″ H and λ″ V ). In the Table of FIG. 4 the signals S are subscripted S (emitter)(detector) . This is done by identifying the polarization (H or V) of light transmitted by the emitter, as well as the polarization (H or V) of the particular detector D H , D V , D′ H , D′ V , D″ H , or D″ V that generates the signal in response to light transmitted from the emitter E. [Note: primes are provided depending on wavelength or optical unit 30 association]. For example, when emitter E 2 activates its horizontally polarized light beam 16 (i.e. λ′ H ), the signals S (emitter)(detector) that are generated by detectors D H , D V , D′ H , D′ V , D″ H , and D″ V are respectively, S H′H , S H′V , S H′H′ , S H′V′ , S H′H″ and S H′V″ .
In the operation of the system 10 , the computer 12 uses the sequencer 14 to sequentially activate the LEDs of emitters E 1 , E 2 and E 3 . In concert with its operation of the sequencer 14 , computer 12 also uses the oscillator 26 to establish a so-called “blink rate” for the transmission of light beams 16 from the emitters E 1 , E 2 and E 3 . Accordingly, a sequence of light beams 16 having wavelengths and polarizations λ H , λ V , λ′ H , λ′ V , λ″ H , and λ″ V are sequentially transmitted through the smoke cloud 20 , at the established “blink rate”. Consequently, for each sequence of light beams 16 , all of the signals S shown in FIG. 4 are generated.
An important aspect of the system 10 is the combined use of the pre-filter 22 and the tracking filter 24 . In detail, the pre-filter 22 is used to eliminate the substantially d.c. component of background signals from the signals S. On the other hand, the tracking filter 24 is driven at the established “blink rate” to effectively isolate the received signals S. The isolated signals S can then be identified to correspond with times when a light beam 16 is being transmitted from an emitter E.
In accordance with the operation of system 10 , after they have been generated and filtered, all of the signals S (see FIG. 4 ) are transferred to the computer 12 . The computer 12 then uses the signals S to calculate normalized polarization ratios, ρ(θ). Specifically, as used for the present invention a polarization ratio is calculated according to the expression:
ρ(θ)=σ HH (θ)/σ VV (θ)
wherein σ HH (θ) and σ VV (θ) are, respectively, a differential mass scattering cross section for horizontally polarized light, and a differential mass scattering cross section for vertically polarized light. As used by the system 10 of the present invention, the polarization ratio, ρ(θ), can then help identify smoke from a petrochemical (hydrocarbon) source. In particular, a succession of these normalization ratios are calculated and compared with empirical data to classify the origin of the smoke cloud 20 . As shown in FIG. 5 this classification will provide an output 28 to determine whether particles in the smoke cloud 20 are in a group 36 of typically benign elements, or are in a group 38 of typically toxic elements (e.g. petrochemicals).
While the particular Electro/Optical Smoke Analyzer as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims. | A system for analyzing smoke has a plurality of units, wherein each unit includes an optical emitter for alternately directing horizontally and vertically polarized light along a beam path, and into a smoke cloud, to generate scattered light. A horizontally polarized detector and a vertically polarized detector are positioned at different locations, but at a same distance and scattering angle relative to the beam path. Each unit has a different wavelength. A computer receives signals from the detectors of all units, in response to each emitter, for analysis of the smoke. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to an arrangement for generating a speech signal comprising a synthesizing section, based on the linear prediction, principle for producing a discrete signal consisting of a plurality of consecutive sub-signals, each representing a voiced or unvoiced speech segment, and an output section for converting the discrete signal into the speech signal.
The invention also relates to a method of generating a speech signal.
Arrangements of the type defined in the preamble are described in the book by J. D. Markel and A. H. Gray, Jr. entitled: "Linear Prediction of Speech" (Springer-Verlag 1976), chapter 5 of which describes the general structure of a speech synthesizing arrangement based on the linear predictive coding (LPC) principle, while chapter 10 describes the use of LPC techniques in vocoders.
An article by B. S. Atal and S. L. Hanauer entitled: "Speech Analyses and Synthesis by Linear Prediction of the Speech Wave" in The Journal of the Acoustical Society of America, volume 50, no. 2, 1971, pages 637-655 gives a clear description of an LPC speech synthesizing arrangement, which comprises an adaptive discrete filter whose pulse response is periodically changed on the basis of prediction parameters. Therein, a speech signal is produced at the output of the filter when there is applied to the input a pulse signal for voiced signals and a noise signal for unvoiced signals.
However, the speech signals generated by that type of arrangements have, as known, an annoying buzz in voiced portions of the speech signal.
To reduce this buzz in the synthesized speech signal, the literature mentions several possibilities. Inter alia M. R. Sambur et al. propose, in an article in the Journal of the Acoustical Society of America, Volume 63, no. 3, March 1978, pages 918-924 entitled: "On reducing the buzz in LPC synthesis", to use a pulse having a very special shape with rounded edges instead of, as customary, an impulse for exciting the discrete filter. Although this does indeed effect some improvement, applicants have found that this improvement is rather slight and that the speech signal gets a considerable low-pass character.
SUMMARY OF THE INVENTION
It is an object of the invention to realize a reduction of the buzz in a relatively simple manner, while avoiding considerable low-pass filtration as much as possible.
The arrangement according to the invention is therefore characterized in that the output section comprises means for modulating the subsignals of the discrete signal corresponding to varied signals with a window signal, the duration of which corresponds to the duration of a sub-signal, the amplitude of which increases first gradually from substantially zero value to a constant value, and decreases thereafter gradually to substantially zero value, so that at the instant of transition from one sub-signal to a next sub-signal, the amplitude of the speech signal is substantially zero.
DESCRIPTION OF THE DRAWINGS
Embodiments of the arrangement according to the invention will now be further explained by way of example with reference to the accompanying drawings. In these drawings:
FIG. 1 shows a first embodiment in which the modulation with the window signal is carried out in a digital manner.
FIG. 2 shows a second embodiment in which the modulation is carried out in the analog mode.
FIGS. 3A and 3B show two possible shapes of the window signal.
FIG. 4 is a flow-chart of the manner in which the modulation can be carried-out in a digital calculator.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The arrangement shown in FIG. 1 comprises a synthesizing section 1, based on the linear prediction principle, which applies a digital signal to an output section 2. The synthesizing section 1 comprises a control signal generator 3 for producing a number of control signals and a pulse generator 4, a voiced-unvoiced switch 5, a noise generator 6, a controllable amplifier 7 and an adaptive recursive digital filter 8. For synthesizing voiced speech signals, the switch 5 connects an output of the pulse generator 4 to an input of the controllable amplifier 7 and for synthesizing unvoiced speech signals, an output of the noise generator 6 is connected to the input of amplifier 7. As the signals produced by the pulse generator 4 and the noise generator 6 have a standard amplitude, the amplitude is adjusted, by means of the controllable amplifier 7, to a value which is suitable for the speech segment to be synthesized. The output signal of amplifier 7 is applied to the filter 8 as the excitation signal. The control signal generator 3 may, for example, be formed by a store in which the control signals, which were obtained on the basis of a preceding analysis of a speed signal, have been stored. These control signals are: the period of the fundamental tone which controls the pulse generator 4, a binary voiced-unvoiced parameter, which controls switch 5, the value of the amplitude for setting the controllable amplifier 7 and a number of prediction parameters which determine the coefficients of the adaptive recursive digital filter 8. In response to the output signal of amplifier 7, the filter 8 produces a digital signal which is converted into a speech signal by means of a digital-to-analog converter 9 and a low-pass filter 10 in the output section 2.
The control signals of the control signal generator 3 are changed in synchronism with the period of the fundamental tone for voiced speech and with a fixed period of, for example, 10 msec. for unvoiced speech. After each change in the control signals, the filter 8 produces a sub-signal which characterizes a speech segment either with a duration equal to the then prevailing period of the fundamental tone, when voiced speech is concerned, or with a duration equal to the fixed period (10 msec) in the case of unvoiced speech.
It should be noted that it is alternatively possible to change the control signals of the control signal generator 3 not in synchronism with the period of the fundamental tone, but independent thereof. In that case the filter 8 will not produce a sub-signal after each change in the control signals. Therefore, the expression "sub-signal" must be understood to mean that portion of the digital signal produced by the filter 8 that characterizes a speech segment.
As was found by applicants, discontinuities occur at the transition from one sub-signal to a next sub-signal which, in the opinion of applicants, cause the above-mentioned buzz in the voiced portions of the speech signal.
According to the invention, the buzz is reduced in the embodiment shown in FIG. 1 by applying the sub-signals to a multiplier 11, for multiplying the sub-signals, which correspond with a voiced speech segment, by a window signal. To that end, a digital representation of the window signal is stored in a store 12 which is also connected to the amplifier 11.
Applying the window signal from the store 12 to the amplifier 11 must be done in synchronism with the occurrence of the sub-signals for voiced speech. To that end, the output signal of the pulse generator 4 is applied as a synchronizing signal to the store 12.
The embodiment shown in FIG. 2 also comprises a synthesizing section 1 which is based on the linear prediction principle and which applies a digital signal to an output section 2. The synthesizing section 1 is constructed in a manner already described with reference to FIG. 1. However, the modulation of the sub-signals with the window signal is here carried out in an analog mode by first converting the digital signal by means of a digital-to-analog converter 9 into an analog signal which is thereafter applied to an analog modulator 13. The window signal, which is generated by a window signal generator 14, is then applied to the analog modulator 13. The window signal generator 14 is comprised of an integrator 15 and a pulse generator 16, connected to the input thereof, this pulse generator 16 supplying pulses with a duration which depends on the period of the fundamental tone.
To obtain the required synthronization between the window signal and the output signal of the digital-to-analog converter 9, not only the duration of the pulses produced by the pulse generator 16 but also the instant those pulses occur must be in synchronism with the period of the fundamental tone.
The FIGS. 3A and 3B show two possible forms of the window signal. The variation of the time is plotted on the horizontal line and the amplitude on the vertical line. The amplitude varies from 0 to 1, wherein it should be noted that a value, deviating from the value 1 between the instants t2 and t3, only results in a linear amplification, or attenuation, of the speech signal. For both forms it holds that the duration between the instants t1 and t4 is equal to the duration of the period of the fundamental tone of the speech signal. For a fundamental tone of 100 Hz this means a duration of 10 msec. A proper choice for the rise and fall times of the window signal appears to be to the order of 1 msec, so that during aproximately 80% of the time, the voiced speech signals are not changed by the modulation with the window signal. The form shown in FIG. 3B shows the variation of a window signal which is generated by means of a window signal generator as shown in FIG. 2. It should be noted that the beginning of the window signal (t1) coincides with the leading edge of the pulse generated by the pulse generator 16, while the decrease in the window signal is initiated at the instant t3 with the trailing edge of the generated pulse.
In practice, the synthesizing section of the described arrangement is often realized in a digital computer, which produces the digital signal under control of a synthesizing program. An example of such a program can be found in the above-mentioned book by J. D. Markel and A. H. Gray, Jr, in chapter 10, paragraph 10.2.5. In such a realization, the modulation with a window signal can be implemented in a particularly simple manner by means of a program. FIG. 4 shows a flow chart of such a program, a modulation being carried-out with a window signal as shown in FIG. 3A.
The program starts at block 17 by the insertion of the numbers NP, IWH and Y(1). Herein NP is the number of words in a sub-signal, and the range Y(1) to Y(NP) inclusive indicates the value of these words. IWH indicates over how many words of the sub-signal the slope of the window signal extends. In block 18 the value of the running variable J is set equal to 1. In block 19 the value J+NP-IWH is alloted to the auxiliary variable JH. For a certain value of J, block 20 gives the multiplication of a word of the sub-signal by the magnitude of the window signal. In block 21 the value of J is increased by one and in the decision diamond 22 the new value of J is compared with IWH. The multiplication process goes on until J is equal to IWH+1, whereafter the modulated sub-signal is represented by the new sequence Y(1) to Y(NP) and is led out at block 23 for further processing by the digital-to-analog converter in the output section. A practical value for IWH, with which good results were obtained, is 10, which for a sampling frequency of 10 kHz corresponds to a rise and fall time for the window signal of 1 msec each.
As the energy of the speech signal has decreased by the use of the described modulation method, the signal must still be corrected after modulation to obtain the correct level. This can be done in a simple manner by including some additional steps in the program for the digital computer, each word of the modulated sub-signal being multiplied by a factor which is equal to the square root of the ratio between the energy prior to and the energy after modulation.
It should be noted that instead of the digital signal in the embodiments shown in the FIGS. 1 and 2, it is also possible to use only time-discrete signals, provided the components suitable therefor are used, such as, for example, components built-up by means of Charge Coupled Devices (CCD's). | LPC-synthesizing device, in which a modulation of the synthesized signal with a window signal is used to reduce the buzz which is characteristic for such devices. This window signal has an amplitude which initially increases gradually from substantially zero value to a constant value, and then decreases gradually from the constant value to substantially zero value. As a result of this modulation the signal in the transition between two segments of voiced speech is forced to zero thereby eliminating any transition discontinuities, the existence of which causes the buzz. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a Continuation-In-Part of U.S. Ser. No. 018,339 filed Mar. 7, 1979 and now abandoned, which in turn is a Continuation-In-Part of U.S. Ser. No. 896,561 filed Apr. 14, 1978 and now U.S. Pat. No. 4,158,642 which in turn is a Continuation-In-Part of U.S. Ser. No. 812,530 filed July 5, 1977 and now U.S. Pat. No. 4,145,313 which in turn is a Continuation-In-Part of U.S. Ser. Nos. 790,832 and 790,837 filed Apr. 25, 1977.
BACKGROUND OF THE INVENTION
1. Field of the Invention
A new improved catalyst system for alpha-olefin type polymerizations includes at least one organo metal compound having the formula R'''M in combination with a Group IVB-VIII transition metal compound on a support, at least one unhindered Lewis base, at least one hindered Lewis base and a Group IA-IIIA metal salt of a sterically hindered carboxylate, alkoxide or aryloxide, wherein R''' is selected from the group consisting of C 1 to C 20 primary, secondary or tertiary alkyl, alkenyl or aralkyl groups, or a hydride, and M is selected from the group consisting of aluminum, gallium or indium. The improved catalyst system provides polymers having increased isotactic stereoregularity as well as lower catalyst residue.
2. Description of the Prior Art
There is extensive art on the polymerization of ethylene and higher alpha-olefins, including dienes, using Ziegler-type catalysts containing either alkyl metals or alkyl metals in which an alkyl group has been replaced by X, OR", SR", NR" 2 , etc., in combination with a transition metal compound of Groups IVB-VIII, where X=halide, and R"=C 1 to C 20 hydrocarbyl substituent.
It is well known to use various alkyl aluminum compounds in combination with transition metal compounds of Groups IVB-VIII in Ziegler-type polymerizations of alpha olefins. For stereospecific polymerization of propylene and higher alpha olefins, the most effective commercially used alkyl metal compounds are AlEt 3 and AlEt 2 Cl, although Al(n-Pr) 3 , Al(n-Bu) 3 , Al(i-Bu) 3 and Al(iBu) 2 H give similar results. Longer chain alkyl aluminums, such as Al(n-C 6 ) 3 , Al(n-C 8 ) 3 , (n-C 8 ) 2 AlCl, etc., drastically reduce stereospecificity as shown by much lower heptane insolubles (Ziegler and Montecatini, Belgium Pat. No. 543,259).
This invention claims a novel catalyst system for stereospecific polymerization of propylene and higher alpha olefins to isotactic polymers. The new compositions include a Group IVB-VIII transition metal compound on a layer lattice support, at least one triorganometal compound of aluminum, gallium or indium, at least one unhindered Lewis base, at least one hindered Lewis base, and a Group IA-IIIA metal salt of a sterically hindered carboxylate, alkoxide or aryloxide. These cocatalysts yield higher activity and/or isopecificity than the conventional di- or tri-alkyl metal compounds when used in combination with the various types of supported transition metal catalysts, such as MgCl 2 -suppported TiCl 4 , supported TiCl 3 , etc., with or without other conventional catalyst modifiers present, such as Lewis bases, alcohols, phenols, polymers, dispersants, binders and other additives.
A number of patents have been issued on the use of trialkyl metal compounds as cocatalyst for the polymerization of various monomers. These patents which are distinguishable from the instant invention are U.S. Pat. No. 3,953,414, Belgium Pat. No. 845,593, 846,314, German DT No. 2620-886, British Pat. No. 1,335,887, German DT No. 2630-585, British Pat. No. 1,140,659, German DT No. 2612-650, South African Pat. No. 7,503,470, German DT No. 2355-886, Japanese Pat. No. 51064-586, South African Pat. No. 7507-382, German DT No. 2638-429, Japanese Pat. No. 51057-789, U.S. Pat. No. 3,992,322, Japanese Pat. No. 52027-090 and U.S. Pat. No. 3,400,110.
Other patents which are distinguishable from the instant invention are U.S. Pat. No. 4,049,472; British Pat. No. 1,489,599; British Pat. No. 1,490,509; Japanese Pat. No. 1136-625; JA 7008 982-R; and Belgium Pat. No. 735,291.
It is also well-known in the art to use various unhindered Lewis bases in combination with both supported and unsupported Ziegler-type catalysts to improve stereospecificity. Representative examples of such patents include U.S. Pat. Nos. 2,238,146, 4,107,413, British Pat. No. 1,001,820, U.S. Pat. No. 4,107,416 and German DT No. 2504-036. British Pat. No. 1,335,887 and U.S. Pat. No. 3,282,907 teach the use of a Group IA metal alkoxide in combination with conventional type Ziegler catalyst, but these teachings fail to even infer the sunergistic effect of the use of alkoxides in combination with the unique and novel complex catalyst systems of the instant invention. These patents all fail to teach or suggest either the novel compositions or the improved polymerization results obtained with the compositions of this invention.
SUMMARY OF THE INVENTION
The present invention relates to unique and novel catalyst systems for the conventional alpha olefin type polymerization at significantly improved polymerization activity, wherein the resultant polymers have a high degree of isotactic stereoregularity.
An object of my present invention is to provide improved catalyst systems having a major increase in polymerization activity while being able to control over a wide range the polymer crystallinity, e.g., isotacticity, wherein the catalyst system includes a transition metal compound on a support, a metal trialkyl compound of Al, Ga or In, at least one unhindered Lewis base, and at least one hindered base.
A further object of my present invention is to provide an improved process for alpha-olefin type polymerizations, wherein the polymerization activity is increased and the formed polymer has a high degree of isotactic stereoregularity and a minimum amount of catalyst residues are formed.
A still further object of my present invention is to use directly the new improved catalyst with various types of supported transition metal compounds without substantial modification of the commercial catalyst preparation or the polymerization plant.
A still further object of my present invention is to provide new improved catalyst compositions wherein the isotacticity of the formed polymer is much less sensitive to a ratio of the cocatalyst (trialkyl metal compound) to the transition metal compound than when the conventional cocatalysts are used, thereby greatly facilitating process control to make higher quality polymers at more efficient production rates.
GENERAL DESCRIPTION
It is well known in the art to use an alkyl metal compound of Groups I-III in combination with a transition metal compound of Groups IVB-VIII as a catalyst system for olefinic polymerization. While nearly all of the alkyl metal compounds are effective for the polymerization of ethylene, only a few are effective for the preparation of isotactic polymers of propylene and higher alpha olefins and only Et 2 AlCl, AlEt 3 and i-Bu 2 AlH have any important commercial utility.
A major cost involved in the polymerization of the alpha olefins is the cost of the catalyst components. Therefore, the cost of the manufacture of the polymer can be effectively reduced by the use of catalyst systems having a higher polymerization activity. A further concern is the ability to produce polymers having a minimum amount of catalyst residues thereby eliminating a costly deashing operation. A still further concern is the ability to produce polymers having a high degree of isotactic stereoregularity thereby enabling the manufacturer to eliminate or reduce the costly operation involving the removal and separation of atactic polymer from the isotactic polymer. The improved catalyst system of the present instant invention provides a means to the manufacturer of obtaining these desirable realizations.
The improved catalyst systems of the present invention which are employed in alpha olefin polymerizations include a Group IVB-VIII transition metal compound, one or more unhindered Lewis bases, at least one metal alkyl compound at least one of which is a metal trialkyl compound of Al, Ga or In, at least one hindered base and at least one Group IA-IIIA metal salt selected from the group consisting of sterically hindered carboxylates, alkoxides and aryloxides.
The transition metal catalyst compound is a Group IVB-VIII transition metal halide, wherein the halide group is chloride or bromide and the transition metal halide is in the form of solid crystalline compounds, solid solutions or compositions with other metal salts or supported on the surface of a wide range of solid supports. For highest stereospecificity it is desirable to have the transition metal halide or its support composition, in the layer lattice structure with very small crystallites, high surface area, or sufficient defects or foreign components to facilitate high dispersion during polymerization. The transition metal halide may also contain various additives such as Lewis bases, pi bases, polymers or organic or inorganic modifiers. Vanadium and titanium halides such as VCl 3 , VBr 3 , TiCl 3 , TiCl 4 , TiBr 3 or TiBr 4 are preferred, most preferably TiCl 3 or TiCl 4 and mixtures thereof. The most preferred TiCl 3 compounds are those which contain TiCl 4 edge sites on a layer lattice support such as alpha, delta, or gamma TiCl 3 or various structures and modifications of TiCl 3 , MgCl 2 or other inorganic compounds having similar layer lattice structures. The most preferred TiCl 4 compounds are those supported on chloride layer lattice compounds such as MgCl 2 . Other anions may be also present, such as other halides, pseudo-halides, alkoxides, hydroxides, oxides or carboxylates, etc., providing that sufficient chloride is available for isospecific site formation. Mixed salts or double salts such as K 2 TiCl 6 or MgTiCl 6 can be employed alone or in combination with electron donor compounds. The most preferred transition metal compound is TiCl 4 containing MgCl 2 especially in the presence of Lewis bases (electron donor compounds).
The Lewis bases can be employed in combination with the trialkyl metal compound or with the Group IVB-VIII transition metal compound or with both components as long as they do not cause excessive cleavage of metal-carbon bonds or loss of active sites. A wide variety of both unhindered and hindered Lewis bases may be used including such types as tertiary amines, esters, phosphines, phosphine oxides, phosphates (alkyl, aryl), phosphites, hexaalkyl phosphoric triamides, dimethyl sulfoxide, dimethyl formamide, secondary amines, ethers, epoxides, ketones, saturated and unsaturated heterocycles, or cyclic ethers and mixtures thereof. Typical but non-limiting examples are diethyl ether, dibutyl ether, tetrahydrofuran, ethyl acetate, methyl p-toluate, ethyl p-anisate, ethyl benzoate, phenyl acetate, amyl acetate, methyl octanoate, acetophenone, benzophenone, triethyl amine, tributylamine, dimethyl decylamine, pyridine, N-methylpiperidine, 2,2,6,6-tetramethylpiperidine and the like. Although unhindered Lewis bases are preferred in the preparation of the supported transition metal component, hindered Lewis bases are preferably used in combination with the trialkyl metal cocatalyst. Hindered Lewis bases are those whose complexing ability toward the cocatalyst is hindered sufficiently by steric and/or electronic effects to cause appreciable dissociation of the trialkyl metal Lewis base complex under polymerization conditions. Although a wide range of mole ratios may be used, dissociation measured on a 1:1 complex is normally in the range of 5-95%, preferably greater than about 10% and less than about 90%. Steric hindrance is achieved by bulky substituents around the heteroatom which reduces the accessibility of the base functionality to the Lewis acid, that is, the trialkyl metal compound. Electronic hindering (weakening) is obtained by placing electron withdrawing substituents on the heteroatom to reduce the electron density on the basic heteroatom. Aromatic substituents are especially useful because they are relatively unreactive toward other catalyst components. Hindered Lewis bases derived from piperidines, pyrrolidines, ketones, tetrahydrofurans, secondary and tertiary aromatic amines and tertiary aliphatic amines are preferred, with the hindered nitrogen bases being most preferred. Non-limiting examples of sterically hindered bases include 2,2,6,6-tetramethyl-piperidine, 2,2,5,5-tetramethylpyrrolidine, 2,2,5,5-tetramethyltetrahydrofuran, di-tert-butylketone, 2,6-di-isopropyl-piperidine, ortho-tolyl t-butylketone, methyl 2,6-di-tert-butylphenylketone, diisopropylethylamine, t-butyldimethylamine, 6-methyl-2-isopropyl pyridine, and the like. Electronically hindered Lewis bases include diphenylamine, di-ortho-tolylamine, N,N-diethylaniline, di-ortho-tolylketone, and the like. Since aromatic substituents are also bulky, some of the electronically hindered bases also have a steric contribution to the hindrance. Especially preferred hindered amines are 2,2,6,6-tetramethyl-piperidine, 2,2,5,5-tetramethylpyrrolidine and the diarylamines. Completely hindered bases, such as 2,6-di-tertiary-butylpyridine, and the like, which complex the alkyl metal cocatalyst too weakly, are ineffective for improving stereospecificity and are excluded from this invention.
Unhindered Lewis bases have fewer and smaller substituents than hindered bases adjacent to the heteroatom such that their complexes with the trialkyl metal cocatalyst are too strong to permit sufficient dissociation under polymerization conditions to activate the catalyst or improve stereospecificity. Examples of conventional, unhindered, Lewis bases include di-n-alkyl ethers, n-alkyl esters of alkyl or aryl carboxylic acids, di-n-alkyl ketones, diaryl ketones unsubstituted in the ortho positions, secondary and teritary n-alkyl amines, piperidines containing less than three methyl groups or the equivalent steric bulk in the 2 and 6 positions, pyridines containing less than two t-butyl groups or the equivalent steric bulk in the 2 and 6 positions, and the like. Non-limiting examples of unhindered Lewis bases include di-butyl ether, ethyl acetate, ethyl p-anisate, ethyl benzoate, benzophenone, tributylamine, 2-isopropylpyridine, 2,6-diethylpyridine, 2,6-dimethylpiperidine, 2,5-dimethyltetrahydrofuran, and all related compounds containing less steric hindrance than the above examples. Obviously a somewhat less hindered base may be used in combination with a more hindered alkyl metal compound to achieve the desired dissociation.
Salts of Group IA-IIIA metals may also be employed with the instant catalysts if they are partially or wholly solubilized by reaction with the alkyl metal components. Preferred are the carboxylates, alkoxides and aryloxides of Group IIA-IIIA metal, more preferably magnesium and aluminum. Non-limiting examples include Mg(OOCR") 2 , R"OMgOOCR", ClMgOR", Mg(OR") 2 , R" 2 AlOOCC 6 H 5 , R"Al(OOCR") 2 , R" 2 AlOR", and the like, where R" is a hydrocarbyl group. Most preferred are the alkoxide and carboxylate salts of magnesium and aluminum prepared in situ by reacting the organometal compounds with R"OH or carboxylic acids in hydrocarbon solvents. Sterically hindered alkoxides and arloxides are especially preferred, where R"=t-butyl, t-amyl, 1,1-diethylpropyl, 1,1-diethylbenzyl, 2,6-di-tert-butylphenyl, 1,1-diphenylpropyl, triphenylmethyl, and the like.
The trialkyl metal compounds useful in this invention have the formula R''' 3 M wherein M=Al, Ga or In, and R''' is selected from the group consisting of a C 1 to C 20 primary, secondary or tertiary alkyl, branched primary alkyl, cycloalkyl, alkenyl or aralkyl group and mixtures thereof, more preferably at least one alkyl group having at least two carbon atoms, and most preferably having 2 to 4 carbon atoms. Preferred cocatalysts contain 1 to 2 secondary or tertiary hydrocarbyl groups. The salt of the Group IA-IIIA metal is used at a molar ratio of about 1 to 50 to about 50 to 1 moles of the salt of Group IA-IIIA metal per mole of the trialkylaluminum compound R" 3 Al, preferably about 1 to 10 to about 10 to 1 moles when the oxygen-containing group is alkoxide or aryloxide, and most preferably less than 1 to 1 when these groups are hindered. When the group is carboxylate, the ratio is about 0.1 to 1, preferably about 0.1 to 0.5 carboxylate groups per mole of the trialkyl metal compound. The use of these Groups IA-IIIA metal salts is preferably with the supported titanium catalyst systems as embodied in the instant invention.
The conventional trialkyl metal cocatalysts (R''' 3 M) useful in this invention include AlEt 3 , Al n-Pr 3 , Al n-Bu 3 , Al i-Bu 3 , Al trihexyl, Al tridecyl, Al iBu 2 H, Al tri-isoprenyl, Al tribenzyl, GaEt 3 , Ga n-Bu 3 , InEt 3 , and mixtures thereof containing more than one type of R''' group or more than one metal.
the preferred cocatalysts of the instant invention have the general formula R n MR' 3-n wherein M=Al, Ga or In, R is a secondary or tertiary hydrocarbyl group selected from the group consisting of a C 3 -C 20 secondary or tertiary alkyl, cycloalkyl, alkenyl or aralkyl group, R' is selected from the group consisting of C 1 to C 20 primary alkyl, alkenyl or aralkyl or hydride; and n=1 to 3, preferably 1 to 2, and most preferably n=2. Preferably, R' is C 2 to C 10 primary alkyl or aralkyl, or hydride with the restriction that not more than one hydride group may be present; most preferably R' is C 2 to C 4 primary alkyl. The R group is preferably about a C 4 to C 16 secondary or tertiary alkyl group or cycloalkyl group and is most preferably one which is not readily susceptible to elimination or displacement by monomer during polymerization. In addition to the simple secondary alkyl groups, other groups are also effective in which the aluminum is attached to a secondary or tertiary carbon atoms, i.e., cyclohexyl, cyclooctyl, tert-butyl, tert-amyl, s-norbornyl, and the like. The most preferred compositions have the formula R n AlR' 3-n in which the secondary and tertiary alkyl groups contain 4 to 10 carbons and n=2. Mixtures of the cocatalysts of this invention with conventional alkyl metal cocatalysts also yields improved results.
Suitable non-limiting examples of preferred cocatalysts include i-Pr 2 AlEt, s-BuAlEt 2 , s-Bu 2 AlEt, t-BuAlEt 2 , t-Bu 2 AlEt, s-Bu 3 Al, 1,1-dimethylheptyl AlEt 2 , s-Bu 2 Aln-C 16 H 33 , t-Bu 2 AlCH 2 C 6 H 5 , s-Bu(t-Bu)Aln-Bu, cyclohexyl 2 AlEt, s-pentyl Ali-Bu 2 , t-Bu 2 AlMe, t-Bu 2 Aln-C 8 H 17 , (2-ethylcyclopentyl) 2 AlEt, 2-(3-ethylnorbornyl)AlEt 2 , 2-norbornyl Ali-Bu 2 , (2-norbornyl) 2 Ali-Bu, acenaphthyl Ali-Bu 2 , cyclooctyl (i-Bu) AlH, 3-ethyl-5-ethylidinenorbornyl AlEt 2 , 9-i-bu-9-alumino-3,3,1-bicyclononane, s-Bu 2 AlH, t-Bu 2 AlH, t-Bu 2 InEt, s-Bu 2 GaEt, neopentyl AlEt 2 , neopentyl 2 AlEt and the like.
The most preferred compounds include those in the above list which have the formula R 1-2 AlR' 2-1 , especially those having the formula R 2 AlR'.
One method of preparing these secondary alkyl aluminum compounds is to react internal olefins with AliBu 3 or i-Bu 2 AlH to add Al-H across the double bond to form alkyl aluminum compounds. When the double bonds is in a strained ring compound, AlR 3 may be used to add Al-R across the double bond and obtain preferred compounds which are very resistant to displacement or elimination. Strained ring olefins include cyclopentene, norbornene, norbornadiene, ethylidine norbornene, dicyclopentadiene, and the like. This method is preferred because of raw material availability and simplicity of reaction, although this invention is not limited by the method of synthesis.
Other methods include the direct synthesis from the reactive metals and the secondary or tertiary halides, the various organometallic syntheses involving ligand exchange between Al, Ga or In compounds and secondary or tertiary alkyl metal compounds of more electropositive metals such as Groups IA and IIA, and the reaction of the metals with the alkyl mercury compounds. Particularly useful is the general reaction of secondary or tertiary alkyl lithium compounds with R'MX 2 or R' 2 MX because it takes place readily in dilute hydrocarbon solutions.
Although di-secondary alkyl aluminum compounds are preferred to mono-secondary alkyl compounds, the mono-alkyl types become more effective the greater the steric bulk of the group as long as it does not interfere with active site formation or lead to decomposition under reaction conditions.
For the alkyl metal cocatalysts of this invention, the most preferred transition metal compounds contain TiCl 4 supported on MgCl 2 and one or more Lewis bases. The concentration of the transition metal in the polymerization zone is about 0.001 to about 5 mM, preferably less than about 0.1 mM.
The molar ratio of the trialkyl metal compound to the transition metal compound is about 0.5:1 to about 200:1 or higher, more preferably about 5:1 to about 100:1. The molar ratio of Lewis base to organometal compound can vary widely but is preferably about 0.1:1 to 1:1. However, the hindered Lewis bases may be added in greater than equimolar amounts, from about 0.1 to 1 to about 10 to 1 moles per mole of organometal compound, to obtain higher stereospecificity without a major loss of activity which would occur with unhindered bases.
The catalyst system of the invention enables the process for making alpha olefin polymers having a high degree of isotactic stereoregularity to be carried out at a temperature of about 25° to about 150° C., more preferably about 40° to about 80° C., at pressures of about 1 atm. to about 50 atm. The reaction time for polymerizaion is about 0.1 to about 10 hours, more preferably about 0.5 to about 3 hours, Due to the high catalyst activity, shorter times and temperatures below 80° C. can be readily employed.
The reaction solvent for the system can be any inert paraffinic, naphthenic or aromatic hydrocarbon such as benzene, toluene, xylene, propane, butane, pentane, hexane, heptane, cyclohexane, and mixtures thereof. Preferably, excess liquid monomer is used as solvent. Gas phase polymerizations may also be carried out with or without minor amounts of solvent.
Typical, but non-limiting examples of C 2 to C 20 alpha olefinic monomers employed in the present invention for the manufacture of homo-, co- and terpolymers are ethylene, propylene, butene-1, pentene-1, hexene-1, octadecene-1, 3-methylbutene-1, styrene, ethylidene norbornene, 1,5-hexadiene and the like and mixtures thereof. Isotactic polymerization of propylene and higher olefins is especially preferred, including block copolymerizations with ethylene.
The trialkyl metal compound and the supported transition metal compound can be added separately to the reactor or premixed before addition to the reactor, but are preferably added separately.
An alternate embodiment of the instant invention with respect to the preparation of cocatalysts having the formula R n MR' 3-n is to use directly the reaction product of R 2 Mg+R'MX 2 →R 2 MR'+MgX 2 as exemplified in U.S. Ser. No. 790,832; or RMgX'+R' 2 MX→RMR' 2 +MgXX' as exemplified in U.S. Ser. No. 790,837, wherein the instant application is a continuation-in-part application of both U.S. Ser. No. 790,832 and 790,837 which were both filed Apr. 25, 1975.
In the case of the formation of R 2 MR', the metal di- or trihalide compounds which are used are selected from the group consisting essentially of a metal halide compound selected from the group consisting of R'MX 2 , MX 3 and mixtures thereof, wherein M is selected from the group consisting of Al, Ga, and In, R' is selected from the group consisting of C 1 to C 20 primary alkyl, alkenyl or aralkyl groups or hydride; X is selected from the group consisting of chloride, bromide or a monovalent anion which cannot initiate polymerization of olefinic monomers, wherein the anion is selected from the group consisting of alkoxide, phenoxide, thio-alkoxide, carboxylate, etc. and mixtures thereof. Typical but non-limiting examples are ethyl aluminum dichloride, aluminum trichloride, ethyl aluminum dibromide, ethyl chloroaluminum bromide, octyl aluminum dichloride, ethyl indium dichloride, butyl aluminum dichloride, benzyl aluminum dichloride, ethyl chloroaluminum butoxide, and mixtures thereof. Mixtures of metal halide compounds can be readily employed.
The C 2 to C 4 alkyl aluminum dihalides are most preferred for high stereospecificity and the monoalkylaluminum dichlorides are most preferred.
The diorganomagnesium compound has the general formula R 2 Mg wherein R can be the same or different and is selected from the group consisting of C 3 to C 20 , secondary or tertiary alkyl, cycloalkyl, aralkyl or alkenyl groups. Typical, but non-limiting examples are (s-Bu) 2 Mg, (t-Bu) 2 Mg or (i-Pr) 2 Mg. Mixtures of diorganomagnesium compounds can be readily employed providing at least one secondary or tertiary group is present. The most preferred organic groups are secondary and tertiary alkyl groups, e.g. t-Bu or s-Bu.
The molar ratio of the alkyl metal halide compound (R'MX 2 ) to the diorganomagnesium compound is about 0.5:1 to about 2:1, more preferably about 0.7:1, and most preferably about 1:1. For the MX 3 compound the ratio is about 1:1 to 1:3, most preferably about 2:3. The molar ratio of the metal halide compound or the diorganomagnesium compound to the transition metal compound is less than about 200:1 or higher and more preferably less than about 100:1.
The metal halide compound and diorganomagnesium compound can be added separately to the reactor containing the transition metal compound but are preferably premixed before addition to the reactor. Employing either the metal halide compound or the diorganomagnesium compound alone with the transition metal compound does not provide the improved catalyst efficiency and stereospecificity as envisioned in this application. In order to attain this, it is necessary to employ both the metal halide compound and diorganomagnesium compound in combination with the transition metal compound in the critcal proportions as previously defined. The concentration of the transition metal in the polymerization zone is about 0.001 to about 5 mM, preferably less than about 0.1 mM.
In the case of the formation of RMR' 2 , the metal alkyl compounds which are used are selected from the group consisting essentially of a metal alkyl compound selected from the group consisting of R' 2 MX or R' 3 M and mixtures thereof, wherein M is selected from the group consisting of Al, Ga and In, R' is selected from the group consisting of C 1 to C 20 primary alkyl, alkenyl, aralkyl or hydride groups; X is selected from the group consisting of a monovalent anion which cannot initiate polymerization of olefins, such as F, Cl, Br, OR", SR", and OOCR", wherein R" is selected from the group consisting of C 1 to C 20 alkyl, branched alkyl, cycloalkyl, aryl, naphthenic, aralkyl and alkenyl groups, X is more preferably Cl or Br and most preferably Cl. Typical but non-limiting examples are diethyl aluminum chloride, aluminum triethyl, diethylaluminum bromide, diethylaluminum iodide, diethylaluminum benzoate, diisobutylaluminum hydride, dioctylaluminum chloride, diethylgallium butoxide, diethylindium neodecanoate, triethylindium, dibenzylaluminum chloride and mixtures thereof. Mixtures of metal alkyl compounds can be readily employed. The C 2 to C 4 alkyl aluminum compounds are preferred for high stereospecificity, and the dialkyl aluminum chlorides are most preferred.
The mono-organomagnesium compound has the general formula RMgX wherein R is selected from the group consisting of C 3 to C 20 secondary or tertiary alkyl, cycloalkyl, aralkyl or alkenyl groups. X is selected from the group consisting of an anion which cannot initiate polymerization of olefins such as Cl, Br, OR", SR", and OOCR", wherein R" is selected from the group consisting of C 1 to C 20 alkyl, branched alkyl, cycloalkyl, naphthenic, aryl, aralkyl, allyl and alkenyl groups. Typical, but non-limiting examples are s-BuMgCl, t-BuMgCl, s-BuMgOOCC 6 H 5 , or s-BuMgOC 15 H 31 , and mixtures thereof. Mixtures of organomagnesium compounds can be readily employed. The most preferred X groups are OR" and OOCR" and the most preferred R groups are secondary or tertiary alkyls.
The molar ratio of the organomagnesium RMgX compound to the metal alkyl compound (R' 2 MX or R' 3 M) is about 2:1 to about 1:2, most preferably about 1:1. The molar ratio of the metal alkyl compound or the organomagnesium compound to the transition metal compound is less than about 200:1 or higher and more preferably less than about 100:1.
The metal alkyl compound (R' 2 MX or R' 3 M) and organomagnesium compound RMgX can be added separately to the reactor containing the transition metal compound but are preferably premixed before addition to the reactor. Employing either the metal alkyl compound or the organomagnesium compound alone with the transition metal compound does not provide the improved catalyst efficiency and stereospecificity as envisioned in this application. In order to attain this, it is desirable to employ both the metal alkyl compound and organomagnesium compound in combination with the transition metal compound in the proportions previously defined. The concentration of the transition metal in the polymerization zone is about 0.001 to about 5 mM, preferably less than about 0.1 mM.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The advantages of the unique and novel catalyst system and the novel process for the alpha olefin polymerizations of the present instant invention can be more readily appreciated by reference to the following examples and tables.
EXAMPLE 1
An aluminum alkyl compound containing both secbutyl and ethyl groups was prepared by mixing equimolar amounts of (sec-butyl) 2 Mg.0.16 Et 2 O and ethyl aluminum dichloride in heptane, heating to 65° l C., 15 min., separating the magnesium chloride solids and vacuum stripping the clear solution. NMR analysis indicated the composition sBu 2 AlEt.0.45Et 2 O. Metals analysis showed that only 0.50% Mg was present in this fraction.
The above liquid alkyl aluminum compound (0.2 g) was used as cocatalyst with 0.2 g catalyst prepared by reacting anhydrous MgCl 2 (5 moles) with TiCl 4 .C 6 H 5 COOEt (1 mole) in a ball mill 4 days, followed by a neat TiCl 4 treat at 80° C., 2 hours, washed with heptane and vacuum dried. The catalyst contained 2.68% Ti. Propylene was polymerized in 500 ml n-heptane at 65° C., 1 hour at 765-770 mm. Polymerization rate was 130 g/g catalyst/hour and the polymer insoluble in boiling heptane=97.6%.
EXAMPLE 2
Three alkyl aluminum compounds containing sec-butyl groups were prepared by reacting the proper stoichiometric amounts of sec-butyl lithium in heptane with either ethyl aluminum dichloride or diethylaluminum chloride, heating to boiling, filtering the isoluble LiCl, and vacuum stripping the clear solutions. Nearly theoretical yields were obtained of s-BuEtAlCl (A), s-Bu 2 EtAl (B) and s-BuEt 2 Al (C). Compositions were established by 1 H and 13 C NMR and by G.C. analysis of the alkyl fragments.
Polymerization were carried out as in Example 1 using 1 mmole aluminum alkyl compound and 0.2 g of the supported TiCl 4 catalyst. The results summarized in Table I are compared to those obtained using the control ethyl aluminum compounds. In all three runs with sec-butyl alkyls, both activity and stereospecificity (heptane insolubles) were higher than those obtained with the conventional ethyl aluminum compounds. The trialkyls were far superior to the dialkyl aluminum chlorides and the di-sec-butyl aluminum ethyl was clearly superior to the mono-sec-butyl aluminum diethyl compound.
TABLE I______________________________________ RateRun Al Alkyl g/g Cat/hour % HI______________________________________A Et.sub.2 AlCl control 48.9 68.0B s-Bu.sub.1.07 EtAlCl.sub.0.93 64.6 79.1C Et.sub.3 Al control 344 83.1D s-BuEt.sub.2 Al 380 90.3E s-Bu.sub.2 EtAl 357 93.0______________________________________
EXAMPLE 3
Sec-pentyl aluminum diisobutyl was prepared by reacting 19.57 g i-Bu 2 AlH with 75 ml pentene-2 in a glass lined 300 cc bomb at 135°-140° C. for 16 hours, then 150° C. for 7 hours. The solution was vacuum stripped at 25° C., yielding 28.1 g of the neat sec-pentyl aluminum compound.
Propylene was polymerized as in Example 2 using 0.212 g (1 mmole) sec-pentyl aluminum diisobutyl as cocatalyst. Polymerization rate was 383 g/g Cat/hr and % HI=92.7. Comparison with AlEt 3 control (Ex. 2, Run C) shows that the sec-pentyl aluminum compound gave substantial improvement, particularly in stereospecificity.
EXAMPLE 4
The alkyl metal cocatalysts of the invention are particularly advantageous in having a much smaller effect of concentration (or alkyl metal/Ti) on stereospecificity, thereby simplifying plant operation and permitting better control of product quality. The results are summarized in Table II for di-sec-butyl aluminum ethyl in contrast to AlEt 3 using the propylene polymerization procedure of Example 2.
TABLE II______________________________________Run Al Alkyl Conc., mM Rate % HI______________________________________F s-Bu.sub.2 AlEt 2 357 93.0G s-Bu.sub.2 AlEt 4 484 83.4H AlEt.sub.3 Control 2 344 83.1I AlEt.sub.3 Control 4 290 64.9______________________________________
The above examples illustrate that trialkyl aluminum compounds containing at least one secondary alkyl group are superior cocatalysts in Ziegler type polymerizations of alpha olefins and that di-secondary alkyl aluminum compounds are preferred.
EXAMPLE 5
Various secondary norbornyl aluminum n-alkyl compounds were prepared by reacting the stoichiometric proportions of a norbornene compound with either i-Bu 2 AlH or AlEt 3 at elevated temperatures and removing unreacted materials by vacuum stripping. Structures were shown by 1 H and 13 C NMR to be the expected addition products of Al-H or Al-Et across the norbornene double bond. These mono and di-secondary alkyl aluminum compounds were used in propylene polymerization following the procedure of Example 2.
TABLE III______________________________________Run Al Alkyl Rate % HI______________________________________J 2-Norbornyl AliBu.sub.2 * 344 90.2K (2-Norbornyl).sub.2 AliBu* 247 91.8L 3-Ethyl-2-norbornyl AlEt.sub.2 * 322 92.5M 3-Ethyl-5-ethylidine-2- 247 93.7 norbornyl AlEt.sub.2 *______________________________________ *Other isomers may also be present.
Comparison with the AlEt 3 control (Run C, Example 2) shows that all of the secondary norbornyl aluminum alkyls gave markedly higher heptane insolubles while retaining high activity.
EXAMPLE 6
Sec-alkyl aluminum hydrides also give improved results compared to the closely related primary alkyl aluminum hydride (i-Bu 2 AlH), following the procedure of Example 2.
TABLE IV______________________________________Run Al Alkyl Rate % HI______________________________________N i-Bu.sub.2 AlH control 456 83.1O s-Bu.sub.2.6 AlH.sub.0.4 462 85.8P* AlEt.sub.3 control 241 82.3Q* iBu.sub.3 Al control 264 89.3R* s-Bu.sub.2.6 AlH.sub.0.4 284 90.7S* s-Bu.sub.2.3 AlH.sub.0.7 223 90.1______________________________________ *Another catalyst preparation was used. It was made by ball milling 5 moles MgCl.sub.2 with 1 mole ethylbenzoate for one day, adding 1 mole TiCl.sub.4 and milling 3 days, then treating with neat TiCl.sub.4 at 80° C., 2 hours, washing with heptane and vacuum dried. The catalyst contained 3.44% Ti.
Run O using sec-butyl groups gave higher activity nd stereospecificity than Run N using the closely related, but primary, isobutyl groups. Improved results are also seen versus the AlEt 3 control using the same supported titanium catalyst (Example 2, Run C).
Runs R and S show substantially higher heptane insolubles using two different sec-butyl aluminum hydrides compared to control Runs P and Q using AlEt 3 and iBu 3 Al with the same catalyst.
EXAMPLE 7
The procedure of Example 2 was followed except that various Lewis bases were mixed with the aluminum alkyl solution before charging to the reactor.
TABLE V______________________________________Run Al Alkyl mmoles Base Rate % HI______________________________________T AlEt.sub.3 control 0.16 Et.sub.2 O 358 84.7U s-Bu.sub.2 AlEt 0.16 Et.sub.2 O 289 94.4V t-Bu.sub.2 AlEt 0.1 Me p-toluate 327 94.0W t-Bu.sub.2 AlEt 0.3 Et p-anisate 79 97.3X t-Bu.sub.2 AlEt 0.9 Et.sub.2 O 56 98.0Y t-BuAlEt.sub.2 0.9 Et.sub.2 O 101 97.1Z* t-Bu.sub.2 AlEt 0.2 acetophenone 196 94.2AA* t-Bu.sub.2 AlEt 0.2 ethylacetate 74 97.6______________________________________ *Used catalyst preparation described in Example 6, Runs PS.
The improved stereospecificities obtained with the cocatalysts of this invention are further increased by the addition of Lewis bases (Runs U-AA versus control Runs T and Example 2, Run C). At the higher amounts of base, 97-98% HI was obtained, which is sufficiently high to eliminate the need for rejection of atactic polymer and greatly simplify the process. Activity is decreased somewhat, but it is still 3-5 times that of the Et 2 AlCl/TiCl 3 .0.33AlCl 3 commercial catalyst (rate=20, HI=93). At somewhat lower base concentrations, activity is 10-20 times higher than the commercial catalyst while still achieving 1-2% higher heptane insolubles.
EXAMPLE 8
Following the procedures of Example 2 and Example 7, improved stereospecificity is also obtained using t-Bu 2 InEt cocatalyst.
EXAMPLE 9
The procedure of Example 6, Runs P-S was followed except that 9-i-Bu-9-alumino-3,3,1-bicyclononane was used as cocatalyst. Polymerization rate=97.5 g/g catalyst/hour; HI=85.1%.
EXAMPLE 10
The procedure of Example 9 was followed except that t-Bu 2 Al (n-octyl) was used as cocatalyst. The rate was 212 g/g catalyst/hour; HI=93.0%.
EXAMPLE 11
Polymerizations were carried out in a 1 liter baffled resin flask fitted with an efficient reflux condenser and a high speed stirrer. In a standard procedure for propylene polymerization, 475 ml n-heptane (<1 ppm water) containing 10 mmole Et 2 AlCl (1.20 g), or the mixture of cocatalysts, was charged to the reactor under dry N 2 , heated to reaction temperature (65° C.) and saturated with pure propylene at 765 mm pressure. The TiCl 3 (1.00 g) (6.5 mmole) was charged to a catalyst tube containing a stopcock and a rubber septum cap. Polymerization started when the TiCl 3 was rinsed into the reactor with 25 ml n-heptane from a syringe. Propylene feed rate was adjusted to maintain an exit gas rate of 200-500 cc/min at a pressure of 765 mm. After one hour at temperature and pressure, the reactor slurry was poured into one liter isopropyl alcohol, stirred 2-4 hours, filtered, washed with alcohol and vacuum dried.
The TiCl 3 was prepared by reduction of TiCl 4 with Et 2 AlCl followed by treatment with diisopentyl ether and TiCl 4 under controlled conditions, yielding a high surface area delta TiCl 3 having low aluminum content.
The sec-butyl magnesium in Runs B, D and E was obtained from Orgmet and contained 72% non volatile material in excess of the s-Bu 2 Mg determined by titration. IR, NMR and GC analyses showed the presence of butoxide groups and 0.07 mole diethyl ether per s-Bu 2 Mg. A second sample of (s-Bu) 2 Mg was used in Runs G and I. It was substantially pure s-Bu 2 Mg but contained 0.33 mole diethyl ether per s-Bu 2 Mg (Table VI).
TABLE VI______________________________________ Rateg Mmoles g/g/ %Run TiCl.sub.3 EtAlCl.sub.2 (s-Bu).sub.2 Mg Et.sub.2 AlCl hr HI______________________________________A(Con- 1.sup.(a) 0 0 10 33 95.2trol)B 1.sup.(a) 5 5 0 152 52.6C(Con- 1.sup.(b) 0 0 10 85 96.3trol)D 0.2.sup.(b) 0.4 0.2 1.6 123 88.0E 0.2.sup.(b) 2 2 0 210 49.2F(Con- 1.sup.(c) 0 0 5 8 79.5trol)G 1.sup.(c) 2.5 2.5 0 36 57.6H(Con- 1.sup.(d) 0 0 10 20 91.7trol)I 0.2.sup.(d) 1 1 0 200 57.4______________________________________ .sup.(a) and .sup.(b) were different preparations of low aluminum TiCl.sub.3 catalysts. .sup.(c) Stauffer HA grade TiCl.sub.3 (hydrogenreduced, dry ball milled). .sup.(d) Stauffer AA grade TiCl.sub.3 . 0.33 AlCl.sub.3 (aluminumreduced, dry ball milled).
Comparison of Runs B, D, E, G and I with their respective control runs A, C, F and H shows that each type of TiCl 3 catalyst the novel cocatalyst combination gave 2-10 times higher activity than the customary Et 2 AlCl cocatalyst.
The percent heptane insolubles (% HI) decreased substantially using the new cocatalysts. Thus, these high activity catalysts are attractive for making low crystallinity homopolymers of propylene and higher alpha olefins. They are particularly attractive for making thermoelastic polymers and amorphous copolymers and terpolymers for elastomers.
EXAMPLE 12
A titanium catalyst containing MgCl 2 was prepared by dry ball milling 4 days a mixture of anhydrous MgCl 2 (1 mole), TiCl 4 (1 mole) and δ-TiCl 3 (0.1 mole). Propylene was polymerized using the conditions in Example 11, Run B and the quantities shown in Table VII. Activity with the cocatalysts of this invention (Run L) was intermediate between those of the AlEt 3 and AlEt 2 Cl controls (Runs J and K), but the stereospecificity as shown by % HI was much higher than the controls. The large increase in % HI obtained with this MgCl 2 -containing catalyst is in contrast to the results in Example 1 using TiCl 3 catalysts in which activity increased sharply but % HI decreased.
TABLE VII______________________________________ Alkyl RateRun Catalyst Metals g/g Cat/hr % HI______________________________________J(Control) 1 10 AlEt.sub.3 79 54.4K(Control) 1 10 AlEt.sub.2 Cl 18 35.8L 0.2 1 AlEtCl.sub.2 + 42 81.0 1 (s-Bu).sub.2 Mg______________________________________
EXAMPLE 13
A titanium catalyst was prepared by dry ball milling 4 days a mixture of 5 MgCl 2 , 1 TiCl 4 and 1 ethyl benzoate, heating a slurry of the solids in neat TiCl 4 2 hours at 80° C., washing with n-heptane and vacuum drying. The catalyst contained 3.78% Ti.
Propylene was polymerized following the procedure of Example 11, Run B except that supported catalyst was used. As shown in Table VIII, all the control runs (M through S) gave substantially lower activity and/or % HI than the AlEtCl 2 +s-Bu 2 Mg combination (Run T) or AlCl 3 +s-Bu 2 Mg (Run U).
If the new cocatalysts simply reacted as the separate alkyl metal compounds, the results should have been like Runs M+Q. If the new cocatalysts simply reacted according to the equation: AlRCl 2 +R 2 Mg AlR 2 Cl+RMgCl, then the results should have been like Runs N+P. However, the results in Run T and U are dramatically better, showing the completely unexpected formation of R 2 AlR' as previously defined.
A much smaller synergistic effect was obtained by combining AlEt 2 Cl+s-Bu 2 Mg (Run S), but the results were poorer than those obtained with AlEt 3 . Combining s-Bu 2 Mg with AlEt 3 (Run R) destroyed the activity shown by AlEt 3 alone (Run O). Thus, the outstanding results were obtained only when R 2 Mg was combined with RAlCl 2 or AlCl 3 .
TABLE VIII__________________________________________________________________________ Mmoles Mmoles Time RateRun Catalyst Al Cpd Mg Cpd Hrs. g/g Cat/hr % HI__________________________________________________________________________M(Control) 0.2 1 AlEtCl.sub.2 -- 0.5 0 --N(Control) 0.2 1 AlEt.sub.2 Cl -- 1 47 61.1O(Control) 0.2 1 AlEt.sub.3 -- 1 326 82.6P(Control) 0.2 -- 0.83 s-Bu MgCl 0.25 0 --Q(Control) 0.2 -- 0.83 (s-Bu).sub.2 Mg 0.25 0 --R(Control) 0.2 1 AlEt.sub.3 0.83 (s-Bu).sub.2 Mg 0.25 -- --S(Control) 0.2 1 AlEt.sub.2 Cl 0.83 (s-Bu).sub.2 Mg 1 165 80.5T 0.2 1 AlEtCl.sub.2 0.83 (s-Bu).sub.2 Mg 1 367 91.9U 0.2 1 AlCl.sub.3 0.83 (s-Bu).sub.2 Mg 1 220 88.9__________________________________________________________________________
EXAMPLE 14
The procedure of Example 13 was followed using 0.2 g of the supported TiCl 4 catalyst together with (s-Bu) 2 Mg and variations aluminum compounds.
TABLE IX______________________________________ Rate g/gMmoles Mmoles Time Cat/Run Al Cpd (s-Bu).sub.2 Mg Hrs. hr. % HI______________________________________V 0.4 AlEtCl.sub.2 0.33 1 60 94.5W 1 AlEtCl.sub.2 0.41 1 64 76.6X 0.5 AlEtCl.sub.2 0.83 1 260 87.2Y 0.5 AlCl.sub.3 0.83 2 136 90.7Z 1 AlEtCl.sub.2 + 1 AlEt.sub.2 Cl 0.83 1 404 86.9AA 1 AlEtBr.sub.2 0.83 1 220 88.9BB 1 AlC.sub.8 H.sub.17 Cl.sub.2 0.83 1 425 88.0CC 0.63 EtClAlN(iPr).sub.2 0.53 1 6 --DD 1 Br.sub.2 AlN(iPr).sub.2 0.83 1 16 --______________________________________
Comparison of Runs V, W and X shows that the highest % HI is obtained at approximately equimolar amounts of RAlCl 2 and R 2 Mg (Run V), that a large excess of RAlCl 2 is undesirable (Run W) and that a small excess of R 2 Mg increases activity (Run X). Activity also increased upon addition of AlEt 2 Cl to the AlEtCl 2 -(s-Bu) 2 Mg system (Run Z). The remainder of the experiments show that the dibromide may be used in place of dichloride (Run AA), that long chain alkyl aluminum compounds are very effective (Run BB), but that dialkyl amide groups on the aluminum compound destroy catalyst activity (Runs CC and DD).
EXAMPLE 15
The procedure of Example 13, Run T was followed except that Lewis bases were also added to the AlEtCl 2 -(s-Bu) 2 Mg cocatalysts.
Addition of Lewis bases causes a decrease in catalyst activity until it becomes zero at a mole ratio of one strong base per mole of RAlCl 2 +R 2 Mg (Table X).
TABLE X______________________________________ Mmoles Base/ RateRun (sec-Bu).sub.2 Mg Time, Hrs. g/g Cat/hr % HI______________________________________EE 0.24 0COOEt.sup.(a) 0.5 174 94.3FF 0.5 Et.sub.3 N.sup.(b) 1 62 85.5GG 2 Diisopentyl ether 1 127 78.8HH 2 Tetrahydrofuran.sup.(c) 1 0 --______________________________________ .sup.(a) Added to the (sBu).sub.2 Mg. .sup.(b) Premixed total catalyst in 100 ml nheptane at 65° C., 5 min. before adding Et.sub.3 N. .sup.(c) Added to premixed AlEtCl.sub.2 -(sBu).sub.2 Mg.
As shown in Run EE, small quantities of Lewis base are effective in improving isotacticity (94.3% HI vs. 91.9 in Run T) while maintaining high activity (nearly 9 times the conventional AlEt 2 Cl/TiCl 3 .0.33 AlCl 3 catalyst, Example 11, Run H).
EXAMPLE 16
The procedure of Example 13, Run T was followed except that xylene diluent was used for polymerization instead of n-heptane. Activity was 676 g/g Cat/hr and the polymer gave 90.9% heptane insolubles. The polymer was precipitated with 1 liter isopropyl alcohol, filtered, dried and analyzed for metals. Found 13 ppm Ti and 83 ppm Mg. Thus at high monomer concentration and longer polymerization times the high efficiency would yield very low catalyst residues without deashing.
EXAMPLE 17
The procedure of Example 13, Run T was followed except that polymerization was carried out at 50° C. and 80° C. Both polymerization rate and % HI decreased with increasing temperature, with the largest decrease taking place above 65° C. (Table XI).
TABLE XI______________________________________ Polymer TimeRun Temp. °C. Hours Rate % HI______________________________________II 50 1 474 90.4T 65 1 367 91.9JJ 80 0.5 148 74.6______________________________________
EXAMPLE 18
Propylene was polymerized at 690 kPa pressure in a stirred autoclave at 50° C., 1 hour. A second preparation of MgCl 2 -containing TiCl 4 catalyst (2.68% Ti), made as in Example 13 except that TiCl 4 -ethylbenzoate complex was preformed, was used in combination with AlRCl 2 -R 2 Mg. High stereospecificity was obtained at high rates and catalyst efficiencies (Table XII).
TABLE XII______________________________________ g Mmoles MmolesRun Cat. AlEtCl.sub.2 (s-Bu.sub.2)Mg Rate % HI______________________________________KK 0.10 0.5 0.5 1672 88.8LL 0.10 0.25 0.25 696 95.0______________________________________
EXAMPLE 19
The procedure of Example 13, Run T was followed except that the catalyst of Example 18 was used and 1 mmole di-n-hexyl magnesium was used instead of 0.83 mmole (s-Bu) 2 Mg. The (n-hexyl) 2 Mg in Soltrol #10 was obtained from Ethyl Corporation (Lot No. BR-516). Polymerization rate was 551 g/g Cat/hr but the polymer gave 76.9% HI which is unacceptable. Thus n-alkyl magnesium compounds do not yield the high stereospecificity of the secondary and tertiary alkyl compounds of this invention.
EXAMPLE 20
The procedure of Example 15 Run EE was followed except that a new pure sample of (sec-Bu) 2 Mg was used with 0.33 mole diethyl ether instead of ethyl benzoate and the reaction time was 1 hr. Rate was 268 g/g Cat/hr and % HI=92.2.
EXAMPLE 21
A catalyst was prepared by dry ball milling 4 days a mixture of 10 MgCl 2 , 2 TiCl 4 , 2 ethylbenzoate and 1 Mg powder, heating the solids in neat TiCl 4 2 hours at 80° C., washing with n-heptane and vacuum drying (Ti=2.16%).
Propylene was polymerized 1 hour at 65° C. and atmospheric pressure using 0.20 g of this catalyst under the conditions of Example 13, Run T except only 0.4 mmole (s-Bu) 2 Mg and 0.4 mmole AlEtCl 2 was used. Rate was 240 g/g Cat/hr and % HI=93.9.
EXAMPLE 22
A catalyst was prepared by dry ball milling 1 day a mixture of 5 MgCl 2 and 1 ethylbenzoate, adding 1 TiCl 4 and milling an additional 3 days, then treating the solids with neat TiCl 4 2 hours at 80° C., washing with n-heptane and vacuum drying (3.44% Ti).
Propylene was polymerized following the procedure of Example 13, Run T, except that 1 mmole (s-Bu) 2 Mg was used instead of 0.83 mmole. Rate was 298 g/g Cat/hr and % HI=89.
EXAMPLE 23
Following the procedure in Example 18, two catalysts were made at different Mg/Ti ratios. Catalyst A was made with 1 MgCl 2 +1 TiCl 4 -ethylbenzoate and B (2.10% Ti) was made with 10 MgCl 2 +1 TiCl 4 -ethylbenzoate complex. Propylene was polymerized following the procedure of Example 13, Run T (Table XIII).
TABLE XIII______________________________________ g Mmoles MmolesRun Cat AlEtCl.sub.2 (s-Bu).sub.2 Mg Rate % HI______________________________________MM 0.107A 2 1.66 60 72.0NN 0.316B 0.25 0.25 512 60.4OO.sup.(a) 0.316B 0.25 0.25 124 84.2______________________________________ .sup.(a) Added 0.25 mmole triethylamine to the alkyl metal cocatalysts.
These results show that the 1:1 and 10:1 MgCl 2 : TiCl 4 catalyst preparations were not as effective as the 5:1 preparations in preceding examples.
EXAMPLE 24
Polymerizations were carried out in a 1 liter baffled resin flask fitted with a reflux condenser and stirrer. In a standard procedure for propylene polymerizations, 475 ml n-heptane (<1 ppm water) containing the alkyl metal cocatalysts was charged to the reactor under N 2 , heated to reaction temperature (65° C.) while saturating with propylene at 765 mm pressure. The powdered transition metal catalyst was charged to a catalyst tube such that it could be rinsed into the reactor with 25 ml n-heptane from a syringe. The propylene feed rate was adjusted to maintain an exit gas rate of 200-500 cc/min. After one hour at temperature and pressure, the reactor slurry was poured into 1 liter isopropyl alcohol, stirred 2-4 hours, filtered, washed with alcohol and vacuum dried.
A titanium catalyst supported on MgCl 2 was prepared by combining 5 MgCl 2 , 1 TiCl 4 and 1 ethylbenzoate, dry ball milling 4 days, heating a slurry of the solids in neat TiCl 4 2 hours at 80° C., washing with n-heptane and vacuum drying. The catalyst contained 3.78% Ti. Portions of this catalyst preparation were used in the experiments shown in Table XIV. Various control runs are shown for comparison with the cocatalysts of this invention (Runs A-F).
The sec-butyl magnesium was obtained from Orgmet and contained 72% non volatile material in excess of the s-Bu 2 Mg determined by titration. IR, NMR and GC analyses showed the presence of butoxide groups and 0.07 mole diethyl ether per se-Bu 2 Mg. The various s-BuMgX compounds were prepared directly by reacting an equimolar amount of ROH, RSH, RCOOH, etc. with the s-Bu 2 Mg.
TABLE XIV__________________________________________________________________________(0.2 g Catalyst, 500 ml n-C.sub.7, 65° C., 1 hr.)Mmoles Mmoles Mmoles RateRun Al Cpd Mg Cpd Base g/g Cat/hr % HI__________________________________________________________________________Control1 AlEt.sub.2 Cl -- -- 47 67.1Control1 AlEt.sub.3 -- -- 326 82.6Control1 AlEt.sub.2 Cl 0.83 (s-Bu).sub.2 Mg -- 165 80.5Control1 AlEt.sub.3 0.83 (s-Bu).sub.2 Mg -- 6 --Control-- 0.83 (s-Bu).sub.2 Mg -- 0 --Control-- 0.83 S-BuMgCl -- 0 --A 1 AlEt.sub.2 Cl 1 s-Bu Mg OOC0 -- 165 95.2B 1 AlEt.sub.2 Cl 1 s-Bu Mg OC.sub.15 H.sub.31 -- 276 91.7C 1 AlEt.sub.2 Cl 1 s-Bu Mg OC.sub.2 H.sub.5 -- 261 91.4D 1 AlEt.sub.2 Cl 1 s-Bu Mg SC.sub.12 H.sub.25 -- 310 93.2E 1 AlEt.sub.2 Cl 0.83 s-Bu MgCl 1 Et.sub.3 N 100 94.6F 1 Et.sub.2 AlOOC0 1 s-BuMgCl -- 351 90.5+ 1 Et (s-Bu)AlCl__________________________________________________________________________
Compared to the control runs, which gave either low activity or low percent heptane insolubles (% HI), the new cocatalyst combinations gave high activity and stereospecificity (>90% HI).
EXAMPLE 25
A second catalyst preparation 2.68% Ti was made following the procedure of Example 24 except that a preformed 1:1 complex of TiCl 4 .φCOOEt was used. In Runs G and H, the s-BuMgCl.Et 2 O was obtained by vacuum stripping an ether solution of the Grignard reagent. In Run I, the n+s BuMgOOCC 6 H 5 was made by reacting pure (n+s Bu) 2 Mg with benzoic acid. Propylene polymerization were carried out as in Example 24 (Table XV).
TABLE XV______________________________________Mmoles Mmoles Mmoles RateRun Al Cpd Mg Cpd Base g/g Cat/hr. % HI______________________________________G 1 AlEtCl.sub.2 1 s-BuMgCl 1 Et.sub.2 O 0 --H 1 AlEt.sub.2 Cl 1 s-BuMgCl 1 Et.sub.2 O 132 93.1I 1 AlEt.sub.3 1 n + s-Bu -- 123 89.7 MgOOCC.sub.6 H.sub.5______________________________________
Run G shows that monoalkyl aluminum compounds are not effective in combination with the mono-organomagnesium compounds in this invention. In contrast, Example 13, Run T, shows that such monoalkyl aluminum compounds are preferred when diorganomagnesium compounds are used.
Runs H and I show that dialkyl and trialkyl aluminum compounds are required with monoalkyl magnesium compounds.
EXAMPLE 26
Propylene was polymerized at 690 kPa pressure in a 1 liter stirred autoclave at 50° C. for 1 hour using the supported TiCl 4 catalyst of Example 25 (Table XV). The Mg compound was made as in Example 24, Run A.
TABLE XVI______________________________________g Mmoles Sol-Run Cat. Mmoles Mg Cpd AlEt.sub.2 Cl vent Rate % HI______________________________________J 0.05 0.5 s-BuMgOOC0 0.5 n-C.sub.7 1292 89.9K 0.10 0.4 s-BuMgOOC0 0.4 n-C.sub.7 317 96.9L 0.10 0.4 s-BuMgOOC0 0.4 xylene 517 96.5______________________________________
Comparison of Runs J and K shows that the lower alkyl metal/catalyst ratio in K gave higher heptane insolubles. Run L in xylene diluent gave higher activity than K in heptane.
EXAMPLE 27
The procedure of Example 25 was followed except that organomagnesium compounds containing alkoxy and benzoate groups were used in combination with AlEt 2 Cl together with diethyl ether. The s-BuMgOsBu was prepared by reacting a dilute solution of sBu 2 Mg containing 0.33 Et 2 O with one mole s-BuOH and used without isolation (Run M). The mixture in Run N was prepared in a similar manner by reacting 1.55 mmole n+s Bu 2 Mg with 1.10 s-butanol, adding 0.066 Et 2 O, then adding this product to a solution of 1 benzoic acid in 275 ml n-heptane.
TABLE XVII______________________________________ Mmoles Mmoles %Run Mmoles Mg Cpd AlEt.sub.2 Cl Et.sub.2 O Rate HI______________________________________M 1 s-BuMgOs-Bu 1 1/3 107 94.6N 0.45 n + s BuMgOOC0 1 0.066 101 95.90.55 n + s BuMgOsBu0.55 s-BuOMgOOC0______________________________________
Comparison with Example 25, Run H shows that superior results were obtained with smaller amounts of diethyl ether by using alkoxide and carboxylate salts instead of the chloride.
EXAMPLE 28
The procedure of Example 7, Run Z was followed except that 0.25 mmole Mg(OOCC 6 H 5 ) 2 was used in place of acetophenone as the third component. The magnesium benzoate was prepared from a dilute heptane solution of benzoic acid and n+s Bu 2 Mg. The t-Bu 2 AlEt was added to the milky slurry of Mg(OOCC 6 H 5 ) 2 , charged to the reactor and heated to 65° C., 5 min., after which the supported titanium catalyst was added.
The propylene polymerization rate was 122 g/g Cat/hr and polymer HI=97.7%.
EXAMPLE 29
The procedure of Example 6, Run P, was followed except that magnesium benzoate was used as a cocatalyst modifier. The magnesium salt was made in situ by reacting a hydrocarbon solution of (n+s-Bu) 2 Mg with two moles of benzoic acid. The salt slurry was reacted with the alkyl metal cocatalyst in 500 ml n-heptane at 25° to 65° C. to obtain a soluble product before the catalyst was added.
TABLE XVIII______________________________________ Mmoles MmolesRun Al Cpd Mg(OOC0).sub.2 Rate % HI______________________________________A(Control) 1 AlEt.sub.3 -- 241 82.3B 1 AlEt.sub.3 0.25 210 93.0C 1 AlEt.sub.3 0.50 0 --D(Control) 1 t-Bu.sub.2 AlEt -- 248 93.8E 1 t-Bu.sub.2 AlEt 0.25 125 97.7______________________________________
When used in small amounts relative to the aluminum trialkyl cocatalyst, the magnesium benzoate sharply increased stereospecificity as measured by the percent boiling heptane insolubles (Runs B and E vs. A and D). Activity decreased somewhat, but the results for both rate and % HI were superior to those of conventional TiCl 3 catalysts (Example 11, Runs A, C, F and H). At a ratio of 0.5 Mg(OOCφ) 2 to AlEt 3 , the catalyst was inactive (Run C). The modifier was effective with both types of aluminum trialkyls, but it gave the highest stereospecificity with the novel trialkyl aluminum cocatalysts of this invention.
EXAMPLE 30
The procedure of Example 29, Run B, was followed using various metal carboxylates as cocatalyst modifiers.
TABLE XIX______________________________________Run Mmoles Salt Rate % HI______________________________________F 0.25 Mg acetate 175 94.7G 0.25 Mg neodecanoate 235 91.8H 0.25 Na stearate 206 92.4I 0.25 K neodecanoate 211 90.8______________________________________
Comparison with control Run A, Example 29, shows that much higher % HI was obtained while still retaining high activity.
EXAMPLE 31
The procedure of Example 29 was followed except that various dialkyl aluminum carboxylates were used instead of the magnesium salt. The aluminum trialkyl and carboxylate were premixed 3-5 minutes at 25° C. in 30 ml n-heptanes.
TABLE XX______________________________________Run Mmoles Al Cpd Mmoles Carboxylate Rate % HI______________________________________J 1 AlEt.sub.3 1 Et.sub.2 AlOOC0 130 97.4K 1 AlEt.sub.3 1 s-Bu.sub.2 AlOOC0 232 95.5L 1 s-Bu.sub.2 AlEt 1 Et.sub.2 AlOOC0 246 94.4M 1 s-Bu.sub.2 AlEt 1 s-Bu.sub.2 AlOOC0 276 91.4N 1 AlEt.sub.3 1 Et.sub.2 AlOOCC.sub.6 H.sub.3 Me.sub.2 -2,6 262 89.1O 1 s-Bu.sub.2 AlEt 1 Et.sub.2 AlOOCC.sub.6 H.sub.3 Me.sub.2 -2,6 310 77.7P 1 AlEt.sub.3.sup.(a) 1 Et.sub.2 AlOOC0.sup. 70 70 97.8Q 2 AlEt.sub.3.sup.(b) 1 Et.sub.2 AlOOC0.sup.(b) 239 93.1R -- 1 s-Bu.sub.2 AlOOC0 0 --______________________________________ .sup.(a) Premixed 5 minutes in 30 ml nheptane at 40-50° C. .sup.(b) Premixed in 30 ml nheptane at 60° C. 30 minutes.
Comparison with control Run A, Example 29, shows that increased stereospecificity was obtained with all of the alkyl aluminum carboxylates except in Run O. Higher activities were also obtained in some cases, especially with the 2,6-dimethylbenzoates (Runs N and O). The ortho substituents are believed to hinder the carbonyl addition reaction which leads to lower activity by consumption of the aluminum trialkyl. Support for this type of side reaction can be seen in the low activity in Run P, premixed in concentrated solution, compared to Run J which was premixed in 500 ml n-heptane. When sufficient excess AlR 3 is used in a concentrated premix with the aluminum benzoate, one regains activity, but the modifier is presumed to be the aluminum alkoxide products from the carbonyl addition reaction. Run R shows that the carboxylate compound alone is not a cocatalyst, so that the improved results obtained when mixed with AlR 3 must be due to the reaction of the AlR 3 with the carboxylate modifier.
EXAMPLE 32
The procedure of Example 29 was followed except that tertiary butyl aluminum compounds were used and the ratio of aluminum trialkyl to aluminum benzoate was varied.
TABLE XXI______________________________________Run Mmoles Al Cpd Mmoles Carboxylate.sup.(a) Rate % HI______________________________________S 1 t-Bu.sub.2 AlEt 0.25 t-Bu.sub.2 AlOOC0 221 93.4T 1 t-Bu.sub.2 AlEt 0.50 t-Bu.sub.2 AlOOC0 227 94.9U 1 t-Bu.sub.2 AlEt 1.0 t-Bu.sub.2 AlOOC0 184 94.6______________________________________ .sup.(a) May contain some tBu EtAlOOC0 as it was prepared by reacting tBu.sub.2 AlEt with 0COOH.
Comparison with Example 29 shows that the dialkyl aluminum benzoates were not as efficient as magnesium benzoate, and higher ratios were needed to achieve higher stereospecificity.
EXAMPLE 33
The procedure of Example 6, Run P, was followed except that dialkyl aluminum alkoxides were used as cocatalyst modifiers.
TABLE XXII______________________________________Run Mmoles AlR.sub.3 Mmoles Al Alkoxide Rate % HI______________________________________V 0.8 t-Bu.sub.2 AlEt 0.2 t-Bu.sub.2 AlOCMeEt0 196 94.2W 0.8 t-Bu.sub.2 AlEt 0.2 t-Bu.sub.2 AlOCEt0.sub.2 191 94.6 X* 1 AlEt.sub.3 -- 506 81.6 Y* 1 AlEt.sub.3 10 Et.sub.2 AlOC.sub.15 H.sub.31 113 95.5______________________________________ *Another catalyst preparation was used (contained 3.16% Ti).
Comparison of Runs V and W with control run D, Example 29, shows that the alkoxide additives increased stereospecificity as measured by heptane insolubles. This was also true for Run Y versus its control (Run X). In this case, a large excess of alkoxide was used relative to the AlR 3 . These results are opposite to those using unsupported TiCl 3 catalysts in which it is known that dialkyl aluminum alkoxide cocatalysts produce low heptane insoluble products.
EXAMPLE 34
The procedure of Example 33 was followed except that a hindered Lewis base (2,2,6,6-tetramethylpiperidine) was used in addition to the alkoxide and another catalyst preparation was used which contained 3.38% Ti.
TABLE XXIII______________________________________ Mmoles Mmoles Mmoles %Run AlEt.sub.3 Base Al Alkoxide Rate HI______________________________________Z 1 -- -- 481 81.8(Control)A 1 -- 1 Et.sub.2 AlOCEt.sub.3 47 97.1(Control)B 1.5 -- 0.5 Et.sub.2 AlOCEt.sub.2 0 484 78.5*(Control)C 0.5 0.5 1.5 Et.sub.2 AlOnBu 24 97.5D 0.5 0.5 1.5 Et.sub.2 AlOtBu 175 98.4E 0.5 0.5 1.5 Et.sub.2 AlOAr** 241 98.0F 2 0.5 1.5 Et.sub.2 AlOCEt.sub.3 361 97.2______________________________________ *Catalyst preparation of Example 33, Run X. **Ar = 2,6di-t-butyl-4-methylphenyl.
Control runs A and B show that highly hindered alkoxides and AlEt 3 gave low activity at 1:1 AlEt 3 :alkoxide and very low % HI at 1.5:0.5 ratio. Addition of the hindered Lewis base (Rund D-F) gave both high activity and very high HI compared to control runs Z, A and B. The unhindered alkoxide (Run C) gave very poor activity compared to Runs D and E. Thus, superior results are obtained using the combinations of hindered base plus hindered alkoxide with AlEt 3 .
Since many modifications and variations of this invention may be made without departing from the spirit or scope of the invention thereof, it is not intended to limit the spirit or scope thereof to the specific examples thereof. | A new improved catalyst system for alpha-olefin type polymerizations, includes at least one metal alkyl compound having the formula R'"M in combination with a Group IVB-VIII transition metal compound on a support and at least one hindered Lewis base and one unhindered Lewis base and a Group IA-IIIA metal salt of a sterically hindered carboxylate, alkoxide or aryloxide, wherein R'" is selected from the group consisting of C 1 to C 20 primary alkyl, alkenyl or aralkyl groups, or a hydride, and M is selected from the group consisting of aluminum, gallium, or indium. The improved catalyst system provides polymers having increased isotactic stereoregularity as well as lower catalyst residue. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a computer sewing machine having two pulse motors, one for controlling the needle swinging amplitude and the other for controlling the fabric feeding amount under a predetermined program of microcomputer. More particularly, the invention relates to a computer sewing machine of Janome, in which a sensor is provided to detect an accident in operation of the sewing machine. Namely, if the drive shaft of the sewing machine is prevented from rotation for a predetermined time upon energization of the machine drive motor due to an accident such as the jamming of loop taker, the sensor detects the abnormal condition (failure in rotation of the drive shaft), and produces an electric signal. Then the microcomputer is operated with the electric signal to deenergize the machine drive motor even if the machine operator operates the controller switch of the motor to avoid the overheat of the machine drive motor. A failure in rotation of the drive shaft is caused not only by an accident but also by declutching the belt wheel from the drive shaft just when the bobbin thread winding operation is carried out. As can be seen, the bobbin thread is wound with the belt wheel which is rotated by energization of the machine drive motor while the drive shaft is left standstill. It is, however, undesirable if such a microcomputer detects failure of the drive shaft rotation and then deenergizes the machine drive motor, just as in the case of some accident. Therefore it becomes necessary in such an occasion to provide a device to produce a signal indicating that the microcomputer should not operate to deenergize the machine drive motor.
In conventional computer sewing machines using two pulse motors for controlling the needle swinging amplitude and the fabric feed amount the pulse motors are each provided with a photoelectric sensor 5 and a screening element 4 illustrated on FIG. 1 which shows together with FIG. 2 a prior art arrangement. Sensor 5 and screening element 4 are cooperated so as to determine the initial position of each pulse motor when the power source is applied to the sewing machine in the manner as described in detail in Janome U.S. Pat. No. 4,271,773. Additionally another sensor (microswitch 11) is used in relation with the bobbin thread winding device, especially in Janome computer sewing machine. The sensor 11 is operated in association with the actuating member 6 which is manually operated to bring the wheel 46 into engagement with the belt wheel of the sewing machine for winding the bobbin thread and simultaneously to cause the declutch pin 9 to declutch the belt wheel from the drive shaft of the sewing machine. The sensor 11 is operated to produce an electric signal indicating that the microcomputer should not deenergize the machine drive motor if the drive shaft is not rotated when the controller switch of the machine drive motor is operated to drive the belt wheel for winding the bobbin thread.
The conventional Janome computer sewing machine has three sensors for the two pulse motors and for the bobbin thread winding device, respectively.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to reduce the three sensors of the conventional sewing machine to a single one for simplifying the structure of the sewing machine and also for reducing the cost for production of the sewing machine.
The sewing machine according to the invention includes at least two pulse motors, in which detecting devices detect in common operations of the movable members in response to a plurality of functions thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a structure of a detector of a conventional pulse motor;
FIG. 2 shows a conventional lower thread winding device and a detector of the above;
FIG. 3 is a perspective view showing an example of the invention;
FIG. 4 is an explanatory view of the structure of FIG. 3;
FIGS. 5 and 6 are explanatory views of the structure and actuation of the pulse motor; and
FIG. 7 is a control flow chart of the control circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In reference to FIGS. 1 and 2, the prior art arrangement will be explained in detail.
The sewing machine controls a pulse motor by an electric stitch control signal, and drives a stitch forming device. Since the pulse motor has a plurality of set positions with respect to energization of determined phases, a light interrupting plate 4 is fixed on, e.g., a shaft 2 of a needle swinging amplitude control pulse motor 1, as shown in FIG. 1, together with an amplitude arm 3 in order to provide one of said set positions. The pulse motor 1 is once rotated to a position where the plate 4 interrupts a photointerrupter 5. Then, an initial setting is made to a position in response to said energization with the controlling amount from said interrupting position. In other words, the sewing machine is provided with a position detector comprising a couple having the interrupting plate and the photointerrupter. When the fabric feed is controlled with another pulse motor, an initial setting should be made with a position detector comprising an interrupting plate and a photointerrupter, as mentioned above. While rotation of an upper shaft of the sewing machine is electrically observed and in case, when the sewing machine is abnormally stopped, this abnormal stopping continues more than a certain period of time and the electric current is broken to a machine motor. However, said stopping by accident should not be regarded as stopping of the upper shaft of the sewing machine for winding the lower thread while a beltwheel is rotating. Therefore, a safety circuit is provided to break the electric current to the motor. With respect to winding of the lower thread, a thread arm 6 is turnably furnished by a step screw 7 secured to the machine body as shown in FIG. 2, and the arm 6 is engaged at either of two turning points. A pin 9 at one end 8 of the arm 6 acts on a declutch mechanism (not shown) of the machine motor and the upper shaft of the sewing machine, and switches to a thread winding condition and to a thread releasing condition. The other end 10 actuates a microswitch 11 so that it is not directed to an order causing the safety circuit to interrupt the electric current to the machine motor that the upper shaft of the sewing machine is stopped at winding the thread. Thus, the thread winding part is provided with the microswitch 11 exclusively for the position detector. Since the prior art individually provides the detectors, disorder in one of them would influence on the entire body of the sewing machine, and there are problems about the cost of the detector, or distribution wire.
Now, the present invention will be referred to. The sewing machine which forms stitch patterns by the electric control signal, includes at least one pulse motor which forms the stitches of said stitch patterns, and respectively actuates a plurality of functions, such as the lower thread winding. The sewing machine is provided with the other actuating parts such as the thread winding arm or other pulse motors, an optical detector as the photointerrupter for detecting movement of the movable member. The moving member of the detector comprises individual or common interrupting plates which are moved in relation with the pulse motor or the lower thread winding arm, and interrupts or receives the light. The detector causes the interrupting plate to detect the moving member as far as the pulse motor moves beyond the movable range where the pulse motor is set for forming stitches. In respect to the control of the movements of the lower thread winding arm the detector has moving ranges of interrupting and recieving the light. In this control the pulse motor is set to an exceeding movable range, and the detected results of the detector do not respond to the control of that movement and therefore preference is made to the control. of the pulse motor. The pulse motor is controlled to the moving range beyond said set movable range in the determined rotation phase of the upper shaft of the sewing machine, and a control circuit is initially set from the detected result of the detector in order to control actuations of a plurality of the actuators by means of the common detector.
An embodiment of the invention will be explained with reference to the attached drawings. In FIGS. 3 and 4, the reference numerals 1 to 10 are the same or common members as in FIGS. 1 and 2 showing the prior art. A needle swinging amplitude control pulse motor 1 is held on a supporting bed 12 which is fixed to a machine body (not shown) via three screw portions 13. An arm 14 of the pulse motor is secured to a shaft thereof (not shown in FIG. 3 but the same as "2" in FIG. 1). The pulse motor arm 14 is fixed with an amplitude arm 3 which holds a pin 15, and the pin 15 plays in a hole 17 of an amplitude rod 16 which carries out lateral swinging amplitude of a needle rod (not shown). The interrupting plate 4 is secured to the pulse motor arm 14 with a screw 18. The photointerrupter 5, which is an optical detector, is connected to a plate 19 fixed to the pulse motor 1. When the pulse motor is rotated in the clockwise direction to a determined rotation phase in FIG. 3, the plate 4 interrupts the photointerrupter 5. The numeral 20 designates a stopper fixed to the arm 1 and the pulse motor 14 is engaged with engaging faces 20a, 20b to avoid overrunning of the arm 14. The numeral 21 is a pulse motor for controlling the fabric feed, which is provided to the supporting bed 12. A shaft 22 is fixedly mounted with a feed actuating arm 23, and a pin 24 implanted on the arm 23 plays in a hole 26 of a feed rod 25 which actuates the feed adjusting device (not shown). The feed actuating arm 23 is defined with engaging portions 27, 27a for contacting engaging faces 28, 28a defined on the suppporting bed 12 so that the feed actuating arm 23 is not overrun. The supporting bed 12 is fixed with a plate 29 on its side with two screws 30, and the plate 29 is equipped with a rotatable interrupting shaft 31. The shaft 31 is fixed with an interrupting bed 32 on its top, and the interrupting bed 32 is fixed with an interrupting plate 33 by a screw 34. When the shaft 31 is rotated in the counterclockwise direction in FIG. 3, the photointerrupter 5 is interrupted. The shaft 31 is fixed with an arm 35 of the interrupting shaft at its lower portion, and the arm 35 energizes the shaft 31 in the clockwise direction by means of a spring 36 connected to the plate 29. The numeral 37 is an interrupting arm which is rotatably mounted on a pin 38 fixed on the plate 29, and its other end 41 engages an end portion 42 of the arm 35, and the feed actuating arm 23 rotates in the clockwise direction to rotate the arm 35 in the clockwise direction against the spring and to position the interrupting plate 33 in the interrupting position of the photointerrupter 5 at the determined rotation. The other end 41 of the interrupting arm 37 contacts an engaging portion 44 of the feed interrupting stopper 43 fixed to the plate 29 of the interrupting shaft to prevent the rotation of the interrupting arm in the clockwise direction by energization by the spring 36. Therefore, if the feed actuating arm 23 is further rotated in the counterclockwise direction under said contacting condition, a projection 40 of the actuating arm 23 is released from the end 39 of the interrupting arm 37, and the actuating arm does not move the interrupting plate 33 under such condition. A thread winding arm 6 is turnably provided to the machine body by means of a step screw 7, and the arm 6 is operated to rotate in the counterclockwise direction in FIGS. 2 and 3; a rubber wheel 46 of a thread winding wheel engages on a belt wheel 65 of the upper shaft 60, and concurrently a pin 9 implanted on one end 8 of the thread winding arm 6 actuates a declutch mechanism to release connection of the belt wheel of the upper shaft and the upper shaft of the sewing machine (not shown), which are connected to the machine motor, and when the arm 6 is turned to the clockwise direction, it is stably engaged at a determined turning position. Then the thread winding wheel 45 is released and said connection is provided. The numeral 47 is a thread winding rod which is furnished to the machine body with a step screw 48. Rod 47 has a cam portion 49 positioned above the end 10 of the thread winding arm 6. The thread winding rod 47 is energized in the counterclockwise direction by a spring 51 mounted to the machine body 50. When the thread winding arm 6 is operated in the clockwise direction and releases the thread winding, the thread winding rod 47 is rotated in the clockwise direction as shown with the solid lines in FIG. 4 without contacting the cam portion 49 at an end 10 of the thread winding arm, and the cam 49 contacts the machine body 50. When the thread arm 6 is rotated in the counterclockwise direction and winds the thread, the cam portion 49 is pushed upward so that the thread winding rod 47 is rotated in the counterclockwise direction. The thread winding rod 47 is formed with a groove 52 for connecting with the interrupting plate 33. On the other hand, the interrupting arm 33 is provided with a pin 53, so that the interrupting plate 37 is engaged with the stopper 43. Under the condition that the thread winding rod 47 is released, the pin 53 is positioned in the groove 52 but does not contact the same. Under the thread winding condition shown with the two dotted lines, the pin 53 contacts the groove 52 and rotates the interrupting bed 32 in the counterclockwise direction in FIG. 3, thereby to make a relative position for interrupting the light of the photointerrupter 5.
FIGS. 5 and 6 show respectively the pulse motors 1, 21 for controlling the needle amplitude and the fabric feed, and control systems thereof. By-polar 1-2 phase energization comprising A-phase, B-phase, A-phase, B-phase is employed.
FIG. 5 shows relation between the needle amplitude coordinate of the sewing machine and the energization phase of the pulse motor. "0-71" of the coordinate are the coordinate number at 71 divisions of the range where the needle of the sewing machine is movable. Needle dropping positions R, M, L are the right maximum, middle, and the left maximum corresponding to the coordinates 4, 34 and 64. The step of each of the coordinates responds by 1:1 to the step of the pulse motor 1. In FIG. 5, the needle dropping position R is marked on the left and L is marked on the right contrary to the movement of the needle. This is why if the pulse motor arm 14 is rotated, e.g., in the clockwise direction in FIG. 3 and contacts the engaging face 20a of the stopper 20, the amplitude rod 16 is moved to the left maximum and then the needle responds to the right maximum, that is, R. The coordinates 0-4 are ranges required to the initial setting with surplus, the coordinates 70-71 are surplus ranges, and the coordinates 66-71 shown with "S1" are ranges where the interrupting plate 4 interrupts the photointerrupter 5. With respect to circle marks in A-phase to B-phase, in the control for causing the needle to respond to each number of the coordinate, when the sole phase is energized, the coordinate corresponding to the middle mark of the three circular marks responds thereto, and when the two phases having the marks in common are energized, the coordinates having the circular marks in common respond thereto. That is to say, if A phase and B phase, for example, arre energized, they are controlled to any one of the plural coordinates 6, 14 . . . 70.
FIG. 6 shows relation between the pulse motor 21 and the amount of designating the fabric feed (which is shown in coordinate as controlling the positions of the fabric feed adjuster in accordance with FIG. 5). "0-102" of the coordinate are the coordinate number at 102 divisions of the range where the fabric feed is controllable. The feed amounts -2.5, 0, +4 (mm) are the maximum backward feed, the feed 0 and the forward feed. The step of each of the coordinates responds by 1:1 to the step of the pulse motor 21.
In FIG. 6, the progressing direction to the right of the coordinate as 0, 1, 2, . . . corresponds to the rotation in the clockwise direction of the interrupting plate 33, the coordinates 4-20 are ranges required to the initial setting with surplus, and the coordinates 98-102 are surplus ranges. The control circuit for controlling the pulse motors 1, 21 uses mainly microcomputer. As shown in detail in later flow chart, when the winding of the lower thread is designated, the initial setting is each provided in said range in response to the rotation phase of the upper shaft of the sewing machine with respect to each of the pulse motors in preference to driving of the pulse motors 1, 21 without obstructing the function of winding the lower thread. That is, since the position to be set in the energization of the specific phase has a plurality of the unspecific coordinates, the initial setting is made any one of the unspecific coordinates.
The present invention has the above mentioned structure, and the actuation will be explained in reference to the flow chart in FIG. 7. When the controlling power source is supplied, the program control is started in the main of the microcomputer. The pulse motors 1, 21 are energized at A-phase and B-phase in FIG. 5. For control as later mentioned, flags B, F, T, G are each made 0, and the pattern selecting keys are read out. Discrimination is made whether or not the photointerrupter 5 is interrupted by the interrupting plate 4 or 33, and if not interrupted, discrimination is made whether or not the upper shaft of the sewing machine is at the determined phase of the amplitude control in T=0 and G=0 as to each of the flags in order to provide the initially setting control of the pulse motors 1 and 21. If the photointerrupter 5 is interrupted, the flags T and G are not altered. Being not the amplitude phase, the program goes to ○2 , but assuming the amplitude phase, the program returns to ○1 , if flag T=1. Since T is 0 initially and B is 0 in the next process, the photointerrupter 5 is discriminated in interruption or it is not. The flag B=0 shows that the initial setting of the amplitude controlling pulse motor 1 is not completed. Apart from the abnormal case, the pulse motor causes the interrupting plate 3 to receive the light of the photointerrupter 5. That is, if the interrupting plate is at any one of 6, 14 . . . 62, the pulse motor is moved 8 steps in the counterclockwise direction, i.e., in the increasing of the coordinate number. Consequently, the movement of 8 steps is repeated until the photointerrupter 5 reaches up to the coordinate 70 in the interrupting range S1, and when the photointerrupter reaches 70, the control circuit stores 70 as an initial setting value of the amplitude coordinate, and the machine motor is designated to the high speed rotation and the flag B is 1 for showing completion of the initial setting. If the photointerupter 5 is initially interrupted and the pulse motor 1 is at the coordinate 70, the pulse motor is moved 8 steps in the clockwise direction, and when it makes the light receiving condition, the control circuit stores "62" as the initial setting value. As a result of the movement in the clockwise direction, if the photointerrupter is still at the light receiving condition, it is interrupted by the interrupting plate 33. This fact means that the pulse motor 21 does not interrupt the light at the initial stage but depends upon the winding of the thread winding arm 6. In this case, the machine motor is designated to the low speed rotation for meeting the thread winding. The flag B is made 0. Subsequently, the flag T is made 1 in order not to repeat said control by completion of the thread winding control and the initial setting. The discrimination is made whether or not the flag B is 1, and since B is 0 at designating the thread winding, the program returns to ○1 . The photointerrupter 5 continuously interrupts the light, and since the upper shaft of the sewing machine does not rotate, the amplitude phase continues. Since T is 1, the program returns to the returning point ○1 , the thread is continuously wound without altering the flags. If the pulse motor 1 is initially set at the amplitude coordinate 62 or 70 without designation of the thread winding, the pulse motor is driven in reference to these coordinates for the amplitude control. In this case, the coordinate for the needle amplitude is designated to any of 4 to 64. When the sewing machine is rotated to the feed controlling phase, and since the flags G and F are both 0, the pulse motor 21 for the fabric feed control is initially set similarly as the pulse motor 1, or when the thread winding arm 6 is operated in the feed phase, the thread winding is controlled. The initial setting value of the pulse motor 21 is, in reference to FIG. 6, the coordinate 4 by the energizations of A, B phases within the interrupting range S2, or the adjacent coordinate 12 by the same energizations. The flags G and F respond to the flags T, B and have the same function. When the initial setting of the pulse motor 21 is finished without designation of the thread winding, the flag F is 1, so that the pulse motor is driven in reference to the coordinate 4 or 12 and the fabric feed is controlled. Referring to FIG. 6, the coordinate for the fabric feed is designated to any of 20-98, and the program returns to ○1 . If the thread winding is not designated, the photointerrupter 5 is ready for receiving the light, and the flag T is 0 and the flag G is 0. At the amplitude control phase, the pulse motor 1 controls the amplitude, and at the fabric feed control phase, the pulse motor 21 controls the fabric feed, and the program returns to ○1 to control the stitches.
Depending upon the present invention, one detector serves, for example, for detections of the initial settings of the two pulse motors and the designation of the lower thread winding, and the detectors and wirings may be made simple. Also the mechanical connection for displaying the functions thereof may be made relatively simple. | An electronic sewing machine includes at least two pulse motors, in which a control detecting device detects all individual operations of the movable members in response to a plurality of functions performed by independent driving sources, such that in each of these functions the machine operates normally. The control detecting device includes two screen interrupting elements each associated with the respective pulse motor and a single photoelectric sensor cooperating with each interrupting element for producing electric signals for operating a microcomputer of the sewing machine to set each of the pulse motors to an initial position. | 3 |
[0001] This application claims the benefit of priorities to Chinese Patent Applications No. 201310319434.3 titled “RETAINING BOX FOR ZIPPER AND ZIPPER”, filed with the Chinese State Intellectual Property Office on Jul. 25, 2013, and No. 201320452378.6 titled “RETAINING BOX FOR ZIPPER AND ZIPPER”, filed with the Chinese State Intellectual Property Office on Jul. 25, 2013, the entire disclosures of which are incorporated herein by reference.
FIELD
[0002] The present application relates to the technical field of zippers, and more particularly to a retaining box for a zipper, and a zipper.
BACKGROUND
[0003] A zipper consists of zipper teeth, a slider, a top stop, a bottom stop or a fastener, etc. The zipper teeth are a critical part, which directly determines a side pull strength of the zipper. A common zipper has two zipper tapes, and each zipper tape has a row of zipper teeth, and two rows of zipper teeth are arranged to be staggered with each other. The slider clamps the zipper teeth at both sides, and slides by means of a pull tab, thus enabling the zipper teeth at both sides to be engaged with or disengaged from each other.
[0004] Presently zippers generally include a double-separating zipper and a single-separating zipper. The double-separating zipper refers to a zipper having two sliders in cooperation with the zipper teeth. Specifically, the two sliders respectively achieve objects of locking when being pulled upwards and locking when being pulled downwards, i.e., when the two sliders respectively slide in directions away from each other, the zipper is locked, and when the two sliders respectively slide in directions towards each other, the zipper is unlocked.
[0005] The single-separating zipper refers to a zipper having one slider in cooperation with the zipper. Specifically, in addition to the slider, a retaining box is further included, and the retaining box is fixed to one of the two sides and cannot slide upwards and downwards.
[0006] Hence, a technical issue to be addressed by those skilled the art is to allow the retaining box to slide upwards and downwards.
SUMMARY
[0007] In view of this, an object of the present application is to provide a retaining box for a zipper to allow the retaining box to slide upwards and downwards.
[0008] Another object of the present application is to provide a zipper having the above retaining box for the zipper.
[0009] In order to achieve the above objects, the following technical solutions are provided according to the present application.
[0010] A retaining box for a zipper, includes:
an upper panel; a lower panel arranged oppositely to the upper panel; and a connecting brace configured to connect the upper panel and the lower panel, a first insertion opening in cooperation with a left stop and a right stop is provided at one end away from the connecting brace of the upper panel and one end away from the connecting brace the lower panel, and a second insertion opening in cooperation with the left stop and the right stop is provided at another end of the upper panel and another end of the lower panel, and the connecting brace divides the second insertion opening into a left insertion opening in cooperation with the left stop and a right insertion opening in cooperation with the right stop.
[0015] Preferably, one end facing towards the first insertion opening, of the connecting brace has a cross-sectional width smaller than a cross-sectional width of another end of the connecting brace.
[0016] A zipper, includes a left zipper tape, a right zipper tape, and a slider in cooperation with the left zipper tape and the right zipper tape, wherein the left zipper tape is provided with a left stop, and the right zipper tape is provided with a right stop, wherein the slider is the retaining box for a zipper according to the above descriptions.
[0017] Preferably, in the zipper, the left stop has a cap end at the top configured to close the right insertion opening and the left insertion opening.
[0018] Preferably, in the zipper, the lower panel is provided with a position-limiting groove in cooperation with a position-limiting protrusion of the cap end.
[0019] Preferably, in the zipper, the cap end has a shape fitting a shape of an outer side edge of an opening end of the second insertion opening.
[0020] Preferably, in the zipper, a surface of the left stop facing towards the right stop is provided with a first mating member; and
a surface of the right stop facing towards the left stop is provided with a second mating member mated with the first mating member in a concave and convex form.
[0022] Preferably, in the above zipper, the first mating member is a convex, and the second mating member a concave.
[0023] According to the above technical solutions, the retaining box for the zipper according to the present application is designed to have the upper panel and the lower panel and have the connecting brace between the upper panel and the low panel, thus the retaining box for the zipper according to the present application is designed to have the functions of a slider, meanwhile, still have the effects of a retaining box in appearance. Hence, the retaining box for the zipper according to the present application has the functions of the slider and the appearance effects of the retaining box, and the retaining box is slidable upwards and downwards along the zipper tapes. In the case that the retaining box for the zipper is used in the zipper, in addition to achieving the effects of a double-separating zipper, the zipper may be used as a single-separating zipper when the retaining box is not pulled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] For more clearly illustrating embodiments of the present application or the technical solutions in the conventional technology, drawings referred to describe the embodiments or the conventional technology will be briefly described hereinafter. Apparently, the drawings in the following description are only some examples of the present application, and for the person skilled in the art, other drawings may be obtained based on these drawings without any creative efforts.
[0025] FIG. 1 is an exploded view of a retaining box for a zipper and stops according to an embodiment of the present application;
[0026] FIG. 2 is an exploded view of a retaining box for a zipper and stops according another embodiment of the present application; and
[0027] FIG. 3 is an exploded view of a retaining box for a zipper and stops according to yet another embodiment of the present application.
DETAILED DESCRIPTION
[0028] An object of the present application is to provide a retaining box for a zipper and a zipper, to enable the retaining box to slide upwards and downwards and have the function of a slider.
[0029] The technical solutions in the embodiments of the present application will be described clearly and completely hereinafter in conjunction with the drawings in the embodiments of the present application. Apparently, the described embodiments are only a part of the embodiments of the present application, rather than all embodiments. Based on the embodiments in the present application, all of other embodiments, made by the person skilled in the art without any creative efforts, fall into the scope of the present application.
[0030] Referring to FIGS. 1 to 3 , FIG. 1 is an exploded view of a retaining box for a zipper and stops according to an embodiment of the present application; FIG. 2 is an exploded view of a retaining box for a zipper and stops according to another embodiment of the present application; and FIG. 3 is an exploded view of a retaining box for a zipper and stops according to yet another embodiment of the present application.
[0031] The retaining box for the zipper according to the present application includes an upper panel 1 , a lower panel 2 , and a connecting brace 3 .
[0032] The lower panel 2 and the upper panel 1 are arranged oppositely to each other, and a space for inserting therein a left stop 6 and a right stop 5 and zipper tapes is formed between the lower panel 2 and the upper panel 1 .
[0033] The connecting brace 3 connects the upper panel 1 and the lower panel 2 , and a first insertion opening in cooperation with a left stop 5 and a right stop 6 is provided at one end away from the connecting brace 3 of the upper panel 1 and one end away from the connecting brace 3 of the lower panel 2 , and a second insertion opening in cooperation with the left stop 5 and the right stop 6 is provided at another end of the upper panel 1 and another end of the lower panel 2 , and the connecting brace 3 divides the second insertion opening into a left insertion opening in cooperation with the left stop 5 and a right insertion opening in cooperation with the right stop 6 .
[0034] The retaining box for the zipper according to the present application is designed to have the upper panel and the lower panel and be provided with the connecting brace 3 between the upper panel and the low panel, thus the retaining box for the zipper is designed to have the function of a slider, however, still have an effect of the retaining box in appearance according to the present application. The retaining box for the zipper according to the present application has the function of the slider and the appearance effect of the retaining box, hence the retaining box is slidable upwards and downwards along the zipper tapes. In the case that the retaining box for the zipper is employed in the zipper, the zipper may he still used as a zipper with a single open end when the retaining box is not pulled on the basis of achieving a zipper having double open ends.
[0035] Further, for improving the smoothness of sliding of the retaining box for the zipper, the connecting brace 3 according to the present application is configured to have a cross-sectional width at an end facing towards the first insertion opening smaller than a cross-sectional width at the other end.
[0036] The zipper according to the embodiment of the present application includes a left zipper tape, aright zipper tape, and a slider in cooperation with the left zipper tape and the right zipper tape. The left zipper tape is provided with a left stop 6 , and the right zipper tape is provided with a right stop 5 . Specifically, the slider is the retaining box for a zipper described in the above embodiment. For a zipper having two sliders, one of the sliders is designed as the retaining box for a zipper according to the above embodiment. The zipper according to the present application has the above technical effects due to employing the above retaining box, i.e., the zipper may be employed as a zipper with double open ends (the retaining box is employed as a slider), and may also be employed as a zipper with a single open end (the retaining box is employed as a retaining box).
[0037] Further, the left stop 6 has a cap end 62 at the top configured to close the right insertion opening and the left insertion opening. The lower panel 2 is provided with a position-limiting groove 21 in cooperation with a position-limiting protrusion 63 of the cap end 62 . With the cooperation between the position-limiting protrusion 63 and the position-limiting groove 21 , the retaining box for the zipper according to the present application may be prevented from falling off from the left stop 6 .
[0038] Further, the cap end 62 has a shape fitting a shape of an outer side edge of an opening end of the second insertion opening. In the case that the retaining box of the zipper is pulled to a limit position, the left stop 6 cooperates with the retaining box, and since the shape of the cap end 62 of the left stop 6 fits the shape of the outer side edge of the opening end of the second insertion opening, the cooperation between the two is aesthetical in an appearance visual effect.
[0039] Further, a surface of the left stop 6 facing towards the right stop 5 is provided with a first mating member 61 , and a surface of the right stop 5 facing towards the left stop 6 is provided with a second mating member 51 mated with the first mating member 61 in concave and convex form. In the case that the retaining box is pulled to a limit position, the first mating member 61 and the second mating member 51 are just mated, thus avoiding the shaking of the left stop 6 towards the right stop 5 in the retaining box, and improving the stability of cooperation.
[0040] In an embodiment of the present application, the first mating member 61 is a convex, and the second mating member 51 a concave. Apparently, the first mating member 61 may also be a concave, and the second mating member 51 may be a convex.
[0041] The above embodiments are described in a progressive manner. Each of the embodiments is mainly focused on describing its differences from other embodiments, and references may be made among these embodiments with respect to the same or similar portions among these embodiments
[0042] Based on the above description of the disclosed embodiments, the person skilled in the art may carry out or use the present application. It is apparent that those skilled in the art may make many modifications to the embodiments. The general principle defined herein may be applied to other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments illustrated herein, but should be defined by the broadest scope consistent with the principle and novel features disclosed herein. | A zipper comprises a left zipper belt, a right zipper belt, and a square slider. Each of the left zipper belt and the right zipper belt is provided with a left stop member ( 6 ) and a right stop member ( 5 ). The slider comprises an upper fin ( 1 ), a lower fin ( 2 ), and a connection support rod ( 3 ). Two sides of the slider are separately provided with a first inserting opening and a second inserting opening fitting correspondingly to the left stop member ( 6 ) and the right stop member ( 5 ). | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and an apparatus to regulate the supply of energy to an electric drive and other loads using a hybrid energy supply system that comprises a fuel cell and an energy storage buffer, whereby a vehicle control unit regulates the drive power or drive current required by the drive—which is supplied by a power converter—dependent on a throttle position detected by a detector, which determines the energy required by the drive. For the purposes of this invention, the term vehicle also includes other mobile devices, such as for example boats or airplanes.
2. Description of the Related Art
Known in the art is an energy supply system in a vehicle including a fuel cell consisting of individual fuel cell modules and a storage battery that may be connected in parallel to the output of the fuel cell. The fuel cell is supplied with hydrogen-containing fuel from a reformer and with air from a compressor. The reformer receives methanol from a tank and water from a further tank and generates the hydrogen-rich fuel by way of steam reforming. A DC/DC converter, which supplies a drive motor, is connected to receive power from the fuel cell. The drive motor is connected to a control system, which is connected to a sensor indicating the throttle position. Furthermore, the control system is also connected to a control unit for the hybrid energy supply system, which comprises the fuel cell, the reformer, common auxiliaries for the operation of the fuel cell, and the storage battery (DE 197 31 250 A1).
Also known in the art is a hybrid energy supply system to supply an electrical load comprising a fuel cell and a storage battery that is connected to the electrical outputs of the fuel cell, whereby the battery's state of charge is monitored. A control system ensures that after each discharge event the storage battery is recharged in as little time as possible and is available to assist the fuel cell in supplying power to the load (EP 33 44 74 B1).
Also known in the art is a fuel cell arrangement comprising a fuel cell that is supplied by a methanol reformer, and a parallel-connected storage battery, whereby a voltage-amplifier adapter is arranged between the outputs of the fuel cell and the storage battery. The fuel cell system supplies power to a speed control unit with a connected motor. The charge state of the storage battery is monitored. The battery compensates for transient variations in the power output of the fuel cell. The fuel cell operates in a load range with favorable efficiency and—if required—charges the storage battery via the appropriately set voltage-amplifier adapter (U.S. Pat. No. 6,214,484 B1).
In a known fuel-cell-powered energy generating system with a storage battery and a strongly variable electrical load, the charge state of the storage battery, which is connected in parallel to the load, is monitored and compared to a target charge state. In order to maintain the charge state at a preset minimum level, the supply of reactant gases to the fuel cell is increased if so required and a DC/DC converter that is connected on the load side of the fuel cell is regulated appropriately (Patent Abstracts of Japan, Publication Number 0121 18600 A).
In a further known fuel-cell-powered energy generating system, which comprises a fuel cell and a storage battery that is connected in parallel to the fuel cell, the charge state of the battery is monitored. When the energy generating system is powered up, a controller estimates the electrical power requirements of the common auxiliaries by way of the charge state and the gas supply to the fuel cell is adjusted in dependence on this estimate (U.S. Pat. No. 5,964,309).
Also known in the art is a fuel cell system in which a DC/DC converter is connected to the electrical outputs of the fuel cell, whereby the outputs of the DC/DC converter are connected to a battery and an inverter, which supplies power to a motor. A control unit calculates the required power output of the inverter based on the request of an acceleration setpoint generator, determines a high-efficiency operating point for the fuel cell from the characteristic curve of the output voltage of the fuel cell as a function of the output current, and adjusts the power output of the fuel cell and the level of the output voltage of the DC/DC converter so that the power required by the inverter will be supplied by the fuel cell and the battery (WO 99/67 846).
Also known in the art is a motor vehicle that can be driven by an electric motor and includes an energy storage device to supply electrical loads, additional energy sources such as an internal combustion engine, generators, or photovoltaic cells, and a control unit working as energy managing device. The control unit distributes the energy from the energy sources to the electrical loads, if the loads require energy (DE 196 17 548 A1).
Further known in the art is an energy-generating device with a fuel cell in a vehicle, which is equipped with a traction motor, which is connected via a converter to a high-voltage network that is supplied with power by the fuel cell. An on-board low-voltage network includes loads, such as lamps, windshield-wiper motors, etc., and a battery, and is connected to the high-voltage network via a DC/DC converter. Also present is an energy storage buffer, which supplies the energy for the start-up of the fuel cell and is charged during the operation of the fuel cell. In the event of elevated power requirements, the energy storage buffer delivers power to the loads and is charged during braking (WO 01/34424 A1).
Also known in the art is a power-regulating system for motor vehicles that contain an internal combustion engine and a multitude of power-converting components, the individual efficiencies of which can be determined. An overall efficiency is calculated from these individual efficiencies. One parameter for each of the respective components is adjusted to achieve an optimum overall efficiency. In particular, these parameters may include the power output or a variable that is proportional thereto, and/or the rotational speed (DE 195 05 431 A1).
BRIEF SUMMARY OF THE INVENTION
A method and an apparatus are provided to regulate the energy ratios of a hybrid energy supply system comprising a fuel cell, an energy storage device, and at least one motor drive in a vehicle, whereby good response characteristics are achieved even in the event of quick and large-value changes in the power needed by the motor drive, without negative effects on the operation of the fuel cell due to insufficient reactant supply or a reversal of the direction of current flow.
A method of the above-mentioned type implements the following features: The vehicle control unit delivers to the energy supply system a current demand signal (or current request value) that is associated with a respective throttle position detected by a detector; the output voltage of the fuel cell is measured and is checked for whether it exceeds an upper limit value that is still non-critical for the operation of the fuel cell or whether it falls below a lower limit value that is still non-critical for the operation of the fuel cell; in a first operating mode, which relates to acceleration or a constant power requirement of the motor drive, the current or torque of the motor drive is regulated dependent on the detected position of the throttle by a power converter; the power converter is supplied with current by the fuel cell via a DC/DC converter arranged between the outputs of the fuel cell and the storage battery, whereby the DC/DC converter is current-controlled if the fuel cell output voltage is between its limit values in order to raise the current delivered by the fuel cell to the demanded current level; the DC/DC converter is voltage-controlled if the fuel cell output voltage is equal or below its limit value in order to set an output voltage that corresponds to at least the lower limit value; the DC/DC converter is voltage-controlled if the fuel cell output voltage is equal or above its upper limit value in order to set an output voltage that is equal or lower than the upper limit value; in a second operating mode, which relates to decreasing the power requirements of the motor drive and operating the power converter in reverse mode, the DC/DC converter is operated with current-control in reverse mode to charge the storage battery, and the motor drive—if the output voltage is equal to or below its upper limit value—is torque-controlled or current-controlled and —if the output voltage exceeds the upper limit value—is switched to voltage-control to limit the output voltage of the fuel cell to the upper limit value. If a suitable motor is used, then the current-control results in a corresponding control of the torque. The method according to the invention makes it possible in a second operating mode, which corresponds to regeneration, to return energy into the energy storage device without endangering the fuel cell with negative currents. This saves fuel, which results in an increase of the efficiency of the energy supply system. In the first operating mode, the drive current serves to improve the acceleration performance, which results in more favorable response characteristics of the vehicle. This prevents any risk to the function of the fuel cell that would result from too high a current output due a short-term increase of the motor torque. Furthermore, during acceleration, the method according to the invention prevents any risk to the fuel cell function that could arise from admitting negative current, i.e., current from the storage battery, to the fuel cell.
In a preferred embodiment, the vehicle control unit provides a reference input variable, which corresponds to the detected position of the throttle, as torque setpoint or current setpoint—dependent on the operating mode—to a motor control unit. The motor control unit controls the motor drive via the power converter, whereby the motor control unit, taking into account the voltage-current-characteristic of the fuel cell, signals the requested current—needed for the torque called for in the respective operating mode—to a fuel cell control unit. The fuel cell control unit—dependent on the actual current delivered by the fuel cell, the fuel cell current available for the motor drive, and the charge state of the storage battery—issues a current request to the actuators for the air and fuel metering to deliver a corresponding current—taking into account the operating mode, and sets the DC/DC converter to current-control or voltage-control—dependent on the operating mode, and returns the value of the available current to the vehicle control unit. In this embodiment the vehicle control unit can match the requested current, and thus the power to be delivered to the motor, to the respective operating conditions of the energy supply system in such a manner that the motor output will correspond as closely as possible to the detected throttle position at a time determined by the rate of change of the throttle position in coordination with the current contributions of the fuel cell and the storage battery.
The actual current of the fuel cell is determined in a practical manner by measuring the current that is supplied to the power converter and off-setting it against—observing the proper sign—the current contributed by the storage battery. This method does not take into account the currents drawn from the fuel cell by the other loads in the vehicle, so that the control of the motor drive will not be affected.
In a further embodiment, the actual current is estimated by subtracting the currents that are required by the other loads, which are arranged in the vehicle in addition to the drive, from the measured total current at the output of the fuel cell. These additional currents may for example be determined based on the number of turned-on loads and their stored power-consumption data.
In particular, a storage battery control determines the temperature and charge state of the storage battery and signals to the fuel cell control unit a charge or discharge request for the storage battery. The fuel cell control unit issues an adjustment signal for the operating mode of the DC/DC converter. This signal—dependent on the charging or discharging operating mode—is checked and, if applicable, limited to preset maximum values for the charging and discharging current and the voltage. On the one hand the value of the maximum charge current is subtracted from the available current value issued by the fuel cell control unit and is supplied as value of the minimum available current to the vehicle control unit, and on the other hand the value of the maximum discharge current is added to the available current value and is supplied as maximum available current to the vehicle control unit in the first operating mode. As a result of this, the vehicle control unit can take into account the maximum available current values, which are output dependent on the battery charge state, in setting the torque setpoint, which prevents too high a demand on the fuel cell and the storage battery.
In a further preferred embodiment, the requested current value that is output by the vehicle control unit is combined—observing the proper sign—with a charge current value, and is combined with a discharge current value—both values have been output by the battery control unit, whereby for the purpose of achieving good efficiency of the energy supply system, the difference is modulated and is subsequently combined—observing the proper sign—with a fuel cell current correction value. This results in the generation of requested-current values to set the actuators for the air and fuel metering of the fuel cell. This embodiment allows the fuel cell to operate with a favorable efficiency, which saves fuel.
It is practical for the fuel cell current correction value to be determined by determining the difference between the value of the actual current and the estimated available current of the fuel cell. This difference is forwarded to PID control, and subsequently is further transmitted with a rate-of-change limitation and a time delay.
It is especially practical to subtract the fuel cell current correction value from the difference between the actual current of the fuel cell and the estimated available current (which has been forwarded to PID control), and to subtract the difference determined in this manner with a time lag from the value of the requested vehicle current and to apply it to the values of the charge current request and discharge current requests of the battery control unit to generate the setting values for the currents for the DC/DC converter.
Preferably, the difference between the setting value of the current for the DC/DC converter and a limit setting value is applied to the value of the current requested by the vehicle control unit.
The above-mentioned procedural steps allow an excellent dynamic response during accelerating and decelerating, whereby energy released during the regenerative braking is stored.
In a further preferred embodiment, which possesses independent inventive character, the fuel cell and the storage battery are operated with optimized efficiency in accordance with the following relationship:
η OPT =(η FC *η SB ) OPT ,
whereby η OPT stands for the overall efficiency, η FC stands for the efficiency of the fuel cell, and η SB represents the efficiency of the storage battery. The fuel cell efficiency depends on the output current of the fuel cell. The storage efficiency is dependent on the charge current and the discharge current.
Preferably, the battery control unit generates a discharge current request when the charge state has exceeded an upper limit value and a charge current request when the charge state of the storage battery is below a lower limit value. No request for a charge or discharge current is generated when the charge state is between the limit values. Using this procedure, one realizes a mode of operation that is optimally adapted to the different charge states with respect to achieving good efficiency.
In the event of a discharge current request, if the current required by the motor drive is higher than the current generated by the fuel cell at its highest efficiency, the fuel cell generates its highest-efficiency current and the rest of the demanded current is supplied by the storage battery, whereas if the drive requires a current that is lower than the current generated at the highest efficiency, no efficiency-optimized sharing of the current required by the drive between the fuel cell and the storage battery will take place.
In the event of a charge current request, if the current required by the motor drive is greater than zero but smaller than the current generated by the fuel cell at its highest efficiency, the current is generated by the fuel cell in highest-efficiency operation, whereby the storage battery is charged with a current that corresponds to the difference between the required current and the output current of the fuel cell. If the current required by the drive is higher than the current delivered by the fuel cell at its highest efficiency, the fuel cell generates the requested current and the charge current for the storage battery without any efficiency-optimized settings.
An arrangement of the above-described type, provides the following features: the vehicle control unit sends current request signals to the fuel cell control unit in accordance with the detected throttle position and the fuel cell control unit issues to the vehicle control unit signals with information on the available vehicle current as well as the maximum and minimum available vehicle current; a voltage sensor connected to the outputs of the fuel cell is also connected to the fuel cell control unit, which monitors whether the output voltage equals or exceeds an upper limit value that is still non-critical for fuel cell operation or whether the output voltage equals or falls below a lower limit value that is still non-critical for fuel cell operation; in a first operating mode that relates to acceleration or constant speed of the drive that is supplied by the power converter a motor control unit is used to switch it to torque-control or current-control; the fuel cell control unit is used to switch a DC/DC converter—that on one side is connected to the inputs of the power converter and the outputs of the fuel cell and on the other side is connected to the storage battery—to current-control if the output voltage is between the limit values; it sets the DC/DC converter to generate an output voltage that corresponds to at least the lower limit value if the output voltage is equal to or below the lower limit value, and it sets the DC/DC converter to generate an output voltage that corresponds to the upper limit value if the upper limit value is reached or exceeded; in a second operating mode that relates to the dynamic reduction of the power requirements of the motor drive during the reverse operation of the power converter, the DC/DC converter is switched to current-control and the drive is switched to voltage-control with the upper limit value as the maximum value if the output voltage equals or exceeds the upper limit value; the fuel cell control unit includes a current management program, which processes the values of the actual, measured, or estimated fuel cell current and of the estimated available fuel cell current, as well as the signals representing the charge state of the storage battery obtained from a battery control unit to generate values for setting the actuators of the components serving in the supply of air and fuel and in the generation of fuel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail in the following by way of an embodiment example shown in a figure, illustrating further details, features, and benefits.
FIG. 1 is a block diagram of an apparatus comprising a hybrid energy supply system that supplies an inverter, with a linked motor drive in a vehicle.
FIG. 2 is a graph of the output voltage of a fuel cell belonging to the hybrid energy supply system as a function of the output current of the fuel cell.
FIG. 3 is a block diagram of a vehicle control unit and a fuel cell control unit with a fuel cell system and a DC/DC converter connected to a storage battery.
FIG. 4 is a block diagram with details of the fuel cell control unit.
FIG. 5 is a block diagram of the design of a current management system in the fuel cell control unit.
FIG. 6 is a block diagram of the design of a correction system for current mismatches.
FIG. 7 a is a graph of the typical characteristic of the efficiency of the fuel cell as a function of the current.
FIG. 7 b is a graph of the typical characteristic of the efficiency of a storage battery as a function of the current during charging and discharging.
FIG. 8 is a diagram of control ranges for the efficiency-optimized operation of the hybrid energy supply system.
FIGS. 9A and 9B are a flow diagram of a method to regulate a supply of energy to an electric motor.
FIGS. 10A , 10 B and 10 C are a flow diagram of a method of regulating an energy supply to an electric motor based on a charge state of an energy storage buffer.
DETAILED DESCRIPTION OF THE INVENTION
An electric vehicle (not shown in any detail) includes a hybrid energy supply system, which comprises a fuel cell system 1 including a fuel cell 2 , and a storage battery 3 . In place of the storage battery 3 , it is possible to use a supercapacitor or a flywheel with a motor/generator. The electrical outputs of the fuel cell 2 are connected to a motor drive unit 4 , which comprises a bi-directional power converter or inverter 5 , a series-connected motor 6 for vehicle propulsion—connected to the power converter outputs, and further comprises a motor control unit 7 to control or regulate the power of the motor 6 via the inverter 5 .
Connected to the outputs of the fuel cell 2 and the inputs, i.e., the DC side, of the inverter 5 , is one side of a direct current/direct current converter 8 , hereafter referred to as DC/DC converter. The other side of the DC/DC converter 8 is connected to the storage battery 3 . The fuel cell system 1 includes a fuel cell control unit 9 . The output current of the fuel cell 2 is measured by a current sensor 10 while the output voltage is measured by a voltage sensor 11 . The voltage sensor 11 is connected to the fuel cell control unit 9 . The current sensor is connected to the fuel cell control unit 9 .
A vehicle control unit 12 is connected to a detector 13 , which may be a detector that detects the position of the throttle 68 (for example, an accelerator pedal or some similar adjustment device). The throttle positions are associated with specific torques of the motor drive 4 , i.e., the detector 13 specifies the setpoint values for the torque of the motor 6 . Consequently, the acceleration and deceleration of the vehicle are controlled by means of the throttle 68 .
The vehicle control unit 12 controls the motor control unit 7 via suitable signals by inputting the level of torque or of a variable corresponding to the torque, e.g. the current for certain motor types, as setpoint value to the motor control unit 7 . This active link between the vehicle control unit 12 and the motor control unit 7 is indicated by a dashed line 14 in FIG. 1 . Both the vehicle control unit 12 and the motor control unit 7 contain processors with the corresponding peripherals.
The vehicle control unit 12 and the fuel cell control unit 9 work together. In particular, the vehicle control unit 12 issues values of the requested current to the fuel cell control unit 9 . This function is represented by the dashed line 15 of FIG. 1 . The vehicle control unit 12 uses the respective signal of the detector 13 to determine the value of the requested current. The fuel cell control unit 9 monitors the fuel cell 2 and, among other functions, determines the available current, which it then signals to the vehicle control unit 12 . This data link is represented by the dashed line 16 in FIG. 1 .
The fuel cell control unit 9 sets the operating mode of the DC/DC converter 8 , in particular the current direction, the current-control, or the voltage-control. This data link between the fuel cell control unit 9 and the DC/DC converter is represented by the dashed line 17 in FIG. 1 .
The graph of FIG. 2 shows the typical shape of the fuel cell output voltage as a function of the fuel cell current I. The voltage V is plotted along the y-axis, while the current I is plotted along the x-axis. The characteristic curve 18 of the voltage V as a function of the current I is non-linear in some areas, in particular just below the no-load voltage and above a specific load current.
The range of the characteristic that is non-critical for the operation of the fuel cell 2 , i.e., for the energy supply of electrical loads, is the range between the no-load voltage V and the start of the curvature at high currents. For this reason one aims for an operation in which the fuel cell is not subjected to any voltages higher than the no-load voltage, hereafter referred to as V max , and in which the voltage does not fall below the voltage V min at the maximum permissible current.
Since the fuel cell 2 needs a certain response time to react to a change in the requested torque, the storage battery 3 supplies current to the inverter 5 to help the motor 6 to respond to rapid changes of the torque setpoints or current setpoints.
The energy supply system and the motor 6 are controlled so that no voltages above the limit value V max or below the limit value V min will be available at the outputs of the fuel cell 2 .
The vehicle control unit 12 uses the throttle position detected by the detector 13 and the setting of the torque setpoint to determine the required torque change, which may relate to the acceleration or deceleration of the vehicle or to constant speed. The working principle of the apparatus shown in FIG. 1 during acceleration or constant speed of the motor 6 is referred to as the first operating mode.
In the event of acceleration or constant speed, the motor 6 is torque-controlled or current-controlled by the inverter 5 . The vehicle control unit 12 requests from the fuel cell control unit 9 that the energy supply system generate a current corresponding to the new torque. In the first operating mode, the fuel cell control unit 9 checks the output voltage of the fuel cell 2 or the voltage of the lines between the fuel cell 2 and the inverter 5 for three criteria, in particular: is the voltage between the limit values V max and V min , is the voltage lower than the lower limit value V min , or is the voltage higher than the upper limit value V max .
If the voltage of the fuel cell V FC is in the range V max <V FC <V max , the DC/DC converter 8 will be current-controlled during acceleration of the motor 6 . If the fuel cell voltage V FC is at or below the voltage V min , the DC/DC converter 8 will be operated with voltage-control in a manner so that the voltage at the Outputs of the fuel cell 2 will be maintained at a value no lower than V min . This voltage control in particular includes the regulation of the output voltage to the value V min . If the voltage at the output of the fuel cell 2 is at or above the maximum permissible voltage V max , then the DC/DC converter 8 will be voltage-controlled in a manner so that its output voltage will not be higher than the value of V max .
This means that in the event of rapid torque increases the DC/DC converter 8 feeds current to the inverter 5 , in addition to the current delivered by the fuel cell 2 , since in the event of rapid changes the fuel cell current can not be increased in the required short time. During this, the DC/DC converter 8 is also used to ensure that the voltage will not be outside of the range established by the limit values V max and V min . Consequently, a breakdown of the fuel cell 2 due to lack of fuel or due to negative currents, i.e., cell reversal, can be prevented.
The vehicle control unit 12 also uses the throttle position detected by the detector 13 and the torque setpoint or current setpoint entered into the motor control 7 to determine whether the current requirement of the power converter or inverter 5 is less than zero. In this operating mode, which is referred to as the second operating mode, the inverter 5 and the DC/DC converter 8 are set to reverse operation, i.e., the reverse operation of the inverter 5 brakes the motor 6 and the current provided by the inverter 5 is fed to the storage battery 3 via the DC/DC converter 8 . In the second operating mode, the DC/DC converter is always current-controlled. Simultaneously, the voltage at the output of the fuel cell 2 is monitored to determine whether it exceeds or falls below the critical upper limit value V max . If the voltage is lower than V max , the power of the motor 6 will be reduced to the lower torque value by means of torque-control or current-control. If the voltage exceeds the upper limit value, then the braking takes place by way of voltage-control of the motor 6 by means of the inverter 5 . This prevents negative currents from being supplied to the fuel cell 2 .
FIG. 3 shows in more detail, the fuel cell control unit 9 of the apparatus shown in a block diagram in FIG. 1 . The fuel cell control unit 9 comprises an energy management system 19 and a battery management system 20 . The vehicle control unit 12 , which uses the throttle position values measured by the detector 13 to establish the torque setpoint values for the motor 6 , also calculates the required current to be supplied to the motor 6 in the form of current request values, which have to be raised by the energy supply system from the fuel cell 2 and the storage battery 3 . For this reason, the vehicle control unit 12 provides the values of the requested vehicle current to the energy management system 19 via a line 21 .
The energy management system 19 obtains the values of the actual current of the fuel cell 2 via a line 23 from a signal-processing unit 22 within the fuel cell control unit 9 . The values of the current available from the fuel cell 2 are supplied to the energy management system 19 via a line 24 .
The battery management system 20 , which is connected to sensors (not shown) to detect the charge state of the storage battery 3 , uses a line 26 to signal the charge state, and a line 27 to signal the temperature of the storage battery to the energy management system 19 . The signal-processing unit 22 detects the actual current of the fuel cell 2 that is part of the fuel cell system 1 , which also includes common auxiliaries, the actuators for the gas supply of the fuel cell—in this embodiment a solid polymer fuel cell, a reformer (if present), and the fuel tanks (if present). This fuel cell system 1 is also referred to herein as “fuel cell”, which is intended to denote all of the components that are necessary for the operation of the actual fuel cell.
The actual current of the fuel cell 2 can be measured or estimated. The current available for the drive is mostly estimated, since it does not include those currents that are supplied to other loads in the vehicle and are not measured to reduce the complexity of the measuring equipment. The signal-processing unit 22 uses the values of the requested fuel cell current to generate the signals for the actuators of the fuel cell system 1 to induce the fuel cell 2 to deliver the requested current.
The energy management system 19 uses a line 29 to control the setting of the DC/DC converter 8 , which is voltage-controlled or current-controlled depending on the operating mode and feeds current into the inverter 5 or is charged by current from the inverter 5 . In the case when current is fed into the inverter 5 , the DC/DC converter 8 increases the current delivered by the fuel cell 2 to the level of the current required by the drive during acceleration.
The energy management system 19 uses lines 30 , 31 , 32 to signal the available current, the maximum available current, and the minimum available current, respectively, of the fuel cell 2 . The lines that are labelled 21 , 23 , 24 , 25 , 26 , 27 , 29 , 30 , 31 , and 32 in FIG. 3 could also be replaced by one or more busses. The vehicle control unit 12 and the fuel cell control unit 9 each contain one or more processors. Consequently, the term energy management system 19 refers to the processor and the associated software. The equivalent applies to the battery management system.
FIG. 4 provides a more detailed view of the signals and data in connection with the energy management system 19 and the battery management system 20 . The energy management system 19 , which in particular processes and outputs current data, can also be referred to as a current management system. The battery management system 20 comprises a charge state control 33 and a battery current limiter 37 . The actual fuel cell current is signalled to the energy management system 19 via the line 23 . The line 24 is used to notify the energy management system 19 of the available fuel cell current, i.e., the current that is available to the motor control 7 . The available current is estimated using the current consumption of the other loads (not shown) in the vehicle. The data on the requested vehicle currents is provided to the energy management system 19 via the line 21 .
Due to its connection to sensors (not shown) at or in the storage battery 3 , the charge state control 33 is provided with measured values via a line 34 , whereby the measured values show or may be used to calculate the charge state of the storage battery. Furthermore, the temperature of the storage battery 3 is signalled to the charge state control 33 via a line 35 . The energy management system 19 is provided with the data on the charge state of the storage battery 3 from the charge state control 33 via the line 34 .
The charge state control 33 uses the level of the detected charge state to determine the required charge current or discharge current and provides the corresponding values of the current needed for the charging or discharging to the energy management system 19 via the line 36 .
A battery current limiter 37 specifies the limits for the charge currents and discharge currents. The battery current limiter 37 also is provided with the data on the charge state and temperature of the storage battery 3 .
The energy management system 19 uses the data on the actual fuel cell current, the available fuel cell current, the requested vehicle current, the charge state, and the charge current request to determine the operating mode and setting of the DC/DC converter 8 and outputs the corresponding data via a line 38 to the battery current limiter 37 , which compares the setting specified by the energy management system 19 to the limit values of the charge currents. Tuned to the limit values of the charge currents, an upper limit value for charging and a lower limit value for discharging, the current limiter issues an adjusting signal for the DC/DC converter 8 via the line 29 . The setpoint adjustment for the DC/DC converter is also signalled to the energy management system 19 .
The energy management system 19 uses the above-listed data to calculate the values for the fuel cell current request and transmits these values via the line 25 to the signal-processing unit 22 , which uses them to generate actuating signals for components for fuel generation and air supply of the fuel cell 2 . The energy management system 19 uses the line 30 to transmit values of its calculated value of the available vehicle current, which is received and processed by the vehicle control unit 12 . Using values of the actual measured or estimated fuel cell current, which reach the energy management system 19 via the line 23 , and using values of the estimated available current, which are transmitted via the line 24 , the energy management system 19 calculates values of a battery correction current, which are output on a line 39 . In a summing point 40 , the values of the available vehicle current, which have been transmitted via the line 30 , are added to the values of the maximum charge current issued by the current limiter 37 via a line 41 . The value of the battery correction current is subtracted from this sum. The result of the superposition of current values in the summing point 40 is transmitted to the vehicle control unit 12 as the minimum available vehicle current. The current limiter issues values of the maximum discharge current via a line 42 . The values of the available vehicle current and the values of the battery correction current are superimposed in a summing point 43 . The values of the maximum discharge current are subtracted from this sum. The result is transmitted via the line 32 to the vehicle control unit 12 as the maximum available vehicle current.
The processing of current values, which have been fed to the energy management system 19 , to generate output values will be explained in more detail in the following with reference to FIGS. 5 and 6 . The values of the current requested by the vehicle control unit 12 are sent via the line 21 to the energy management system 19 , where they are combined in a summing point 44 with the negative values of the charge current request that have been transmitted via the line 36 . The difference of these values is applied to a module 45 of the fuel cell request modulation, which will be explained in more detail below.
The values of the actual fuel cell current are transmitted along the line 23 , and the values of the estimated available fuel cell current are transmitted along the line 24 to a current-mismatch correction block 46 , which has two outputs. From one of the outputs the values of the fuel cell correction currents are transmitted to a summing element 47 and a time-delay block 48 . In the summing element, the values from the output of the fuel cell modulation block 45 are superimposed on the values of the fuel cell correction currents.
The sum is output as the fuel cell current request on line 25 and is transmitted to the signal-processing unit 22 . The time delay in the time-delay block 48 is tuned to the time that is required to calculate the available current from the requested fuel cell current. The output values of the time-delay block 48 are applied to a summing element 49 , where they are subtracted from the values of the estimated available fuel cell current. The difference, i.e., the values of the estimated available current without the value of the fuel cell correction current, reach a summing point 50 , where they are subtracted from the difference values between the vehicle current request and the charge current request, which results in a compensation for the slow fuel cell response.
The current-mismatch correction block 46 also calculates a battery current correction value, which is fed to a summing element 51 , where it is combined with the values of the charge current request. The sum obtained in the summing element 51 then reaches a further summing element 52 , where it is applied to the values arriving from the summing element 50 , which results in the generation of the values for the DC/DC converter setting (unbounded), which are transmitted on the line 38 . These values are at the same time fed to a summing element 53 , where the values of the DC/DC converter setting (bounded) that have been transmitted via the line 29 are subtracted from these values. The result of this difference reaches a summing element 54 and is subtracted from the values of the vehicle current request, which establishes the values of the available vehicle current, which are then transmitted to the vehicle control unit 12 via the line 30 .
FIG. 6 is a block diagram of the design of the mismatch correction block 46 . The values of the actual fuel cell current, which have been obtained by measurement or estimate and are transmitted via the line 23 , are applied to a summing point 55 , where the values of the estimated fuel cell current that is available for the drive—that have been transmitted via the line 30 —are subtracted from the actual fuel cell current values.
The difference obtained in this manner is forwarded to a PID block 56 , the output values of which are fed to a slew rate limiter block 57 and a summing point 58 . The output values of the slew rate limiter block 57 reach a time-delay block 59 , at the output of which will be available the values of the fuel cell correction current, which are then in the summing point 58 subtracted from the values arriving from the output of the PID block 56 , which results in the generation of the values of the battery correction current.
FIG. 7 a illustrates the typical efficiencies of a fuel cell and a storage battery as functions of the current. The efficiency is plotted along the y-axis while the current is plotted along the x-axis. The label 59 in FIG. 7 a indicates the efficiency characteristic of the fuel cell. The charging efficiencies of the storage battery 3 are labelled 60 and are shown by the dashed line in FIG. 7 a . The discharging efficiency of the storage battery 3 is labelled 61 and is shown by the dot-dashed line in FIG. 7 a.
In FIG. 7 b , the overall efficiency of the fuel cell 2 and the storage battery 3 for charging is labelled 63 , while the overall efficiency of the fuel cell and the storage battery for discharging is labelled 64 .
The energy management system 19 divides the vehicle current request into a fuel cell current request and a storage battery current request, which is accomplished by adjusting the DC/DC converter 8 . Dividing the requested vehicle current between the fuel cell 2 and the storage battery 3 , while taking into consideration the efficiencies of the fuel cell 2 and the storage battery 3 , makes it possible to achieve an efficiency-optimized system operation so that one achieves an optimum overall efficiency.
By depending on the charge stage of the battery, it is practical to subdivide the system operation into ranges, which are shown in FIG. 8 . FIG. 8 shows a range 64 in which no charge request has been issued, since the battery charge state is between an upper charge limit value SOCo and a lower charge limit value SOCu. FIG. 8 shows the charge state of the storage battery 3 as a percentage along the y-axis and the ranges along the x-axis. Specifying the two boundary limits SOCo and SOCu defines the ranges 66 and 67 in addition to the range 65 . The system management strategies are based on the ranges 65 , 66 , and 67 . The optimum overall efficiency is determined according to the equation:
η OPT =(η FC *η SB ) OPT
whereby η OPT is the overall efficiency, η FC is the efficiency of the fuel cell system 1 , and η SB is the efficiency of the storage battery 3 . If the battery management 20 has issued a discharge request on account of the charge state being in the range 66 , then the following strategy is used to obtain a high overall efficiency:
1. If the requested vehicle current is higher than the current of the fuel cell 2 at its highest fuel cell efficiency, then the fuel cell 2 is set to deliver this latter current. The current to be requested by the storage battery 3 is obtained as the difference of the requested vehicle current and the current of the fuel cell 2 at optimum efficiency.
2. On the other hand, if the requested storage battery current is smaller than a minimum discharge current, then this discharge current is set. If the requested vehicle current is greater than zero but smaller than the current of the fuel cell 2 at its optimum efficiency, then the energy supply system will be operated without an optimum-efficiency strategy.
If the battery management 20 requests a charge current on account of the charge state being in the range 67 , then two different procedures are implemented again, in dependence on the level of the requested vehicle current.
If the requested vehicle current is larger than the current of the fuel cell 2 at its highest efficiency, then the fuel cell current will not be set to a specific value. The fuel cell current is obtained from the difference of the requested vehicle current and the storage battery current. If the requested vehicle current is larger than zero but smaller than the fuel cell current at the highest fuel cell efficiency, then the fuel cell current is set to the value with the highest fuel cell efficiency. The storage battery current is set to the difference between the requested vehicle current and the fuel cell current.
If the battery management system 20 has issued no charge/discharge request, then the fuel cell current is set to the value of the requested vehicle current. In this case the system management strategy is as follows:
FIGS. 9A and 9B are a flow diagram of a method 100 of regulating an energy supply to an electric motor according to one illustrated embodiment. The method 100 begins at act 102 . At 104 , a vehicle current request value is produced. At 106 , the output voltage of the fuel cell is determined. At 108 , the fuel cell control unit 9 determines whether the motor 6 is in a state of acceleration or constant speed, or a state of deceleration.
If a state of acceleration or constant speed is detected, the method 100 is in a first operating mode 128 . At 110 , the fuel cell control unit 9 determines whether the output voltage of the fuel cell 2 is between the upper and lower limit values. At 112 , if the output voltage of the fuel cell 2 is between the upper and lower limit values, the DC/DC converter 8 is current-controlled so that the current supplied to the motor 6 by the fuel cell 2 is approximately equal to the vehicle current request value. At 114 , the fuel cell control unit 9 determines whether the output voltage of the fuel cell 2 is at or above the upper limit value. At 116 , if the output voltage of the fuel cell 2 is at or above the upper limit value, the DC/DC converter 8 is voltage-controlled to lower the output voltage of the fuel cell 2 . At 118 , if the output voltage of the fuel cell 2 is at or below the lower limit value, as determined in acts 110 and 114 , the DC/DC converter 8 is voltage-controlled to raise the output voltage of the fuel cell 2 .
If a state of deceleration is detected, the method 100 is in a second operating mode 130 . At 120 , the flow of current of the DC/DC converter 8 and the bi-directional converter 5 is reversed to charge the storage battery 3 . At 122 , the fuel cell control unit 9 determines whether the output voltage of the fuel cell 2 exceeds the upper limit value. At 124 , if the output voltage of the fuel cell 2 exceeds the upper limit value, the bi-directional converter 5 is voltage-controlled to limit the output voltage of the fuel cell 2 to the upper limit value. At 126 , if the output voltage of the fuel cell 2 is at or below the upper limit value, the bi-directional converter 5 is current-controlled to reduce power to the motor 6 .
FIGS. 10A , 10 B and 10 C are a flow diagram of a method 200 of regulating an energy supply to an electric motor based on a charge state of a storage battery 3 . The method 200 begins at act 202 . At 204 , the charge state of the storage battery 3 is determined. At 206 , if the charge state is between the upper and lower charge state limit values, no current request is generated and control is passed to act 228 . At act 228 , it is determined whether the energy of the storage battery 3 is maintained by recuperating energy.
If the energy of the storage battery 3 is maintained by recuperating energy, one only takes the discharge efficiency of the storage battery 3 into account. At act 230 , one determines the product of the fuel cell current at the optimum efficiency of the fuel cell 2 and the optimum efficiency of the fuel cell 2 . Continuing in act 230 , the result is added to the product of the difference between the requested fuel cell current and the fuel cell current at optimum efficiency of the fuel cell with the optimum efficiency of the fuel cell, the efficiency of the DC/DC convener 8 , and the discharge efficiency of the storage battery 3 . If this resulting value is larger than the product of the value of the requested fuel cell current and the efficiency of the fuel cell 2 for the requested fuel cell current, control passes to act 232 . If the difference between the requested fuel cell current and the fuel cell current, at the optimum efficiency of the fuel cell is larger than zero, then the fuel cell current for which the fuel cell 2 has the highest efficiency is set in act 236 . In the other cases, the fuel cell current is set to the requested value in act 238 .
If it is determined in act 228 that the storage battery 3 is not maintained by recuperating energy, but instead is charged by the fuel cell 2 , at 229 , then the product of the fuel cell current at optimum fuel cell efficiency and the optimum efficiency of the fuel cell 2 is added to the product of the difference between the requested fuel cell current and the fuel cell current at optimum fuel cell efficiency, with the optimum fuel cell efficiency, the square of the DC/DC converter efficiency, the discharge efficiency, and the charge efficiency of the storage battery 3 in act 234 . If this result is larger than the product of the requested fuel cell current and the efficiency of the fuel cell for this requested fuel cell current, then the requested fuel cell current is set to the current for which the fuel cell 2 operates at its highest efficiency in act 240 . In all other cases, the fuel cell current is set to the value of the requested vehicle current in act 238 . The above-described procedural steps are carried out in the module 45 , i.e., in the fuel cell request modulation.
If the charge state exceeds an upper charge state limit value at act 208 , a discharge current request is generated at act 210 . At 212 , if the discharge current request has been generated, it is determined whether the current that is required by the motor 6 is higher than the current generated by the fuel cell 2 at highest efficiency. If the current that is required by the motor 6 is higher than the current generated by the fuel cell 2 at highest efficiency, then at 214 , current is generated at the highest efficiency by the fuel cell 2 and current is delivered from the storage battery 3 sufficient to make up the remainder of the vehicle current request value. At 216 , if the current that is required by the motor 6 is smaller than the current generated by the fuel cell 2 at highest efficiency, the current required for the motor 6 is not efficiency-optimized partitioned between the fuel cell 2 and the storage battery 3 .
If the charge state is below a lower charge state limit value, as determined in acts 204 and 208 , a charge current request is generated at 218 . At 220 , if the charge current request has been produced, it is determined whether the current that is required by the motor 6 is greater than zero but smaller than the current generated by the fuel cell 2 at the highest efficiency: At 222 , if the current required by the motor 6 is greater than zero but smaller than the current generated by the fuel cell 2 at the highest efficiency, current is generated at the highest efficiency by the fuel cell 2 . At 224 , the vehicle current request value is delivered to the motor 6 , and the storage battery 3 is charged with the remaining current. If the motor 6 requires a current that is higher than the current delivered by the fuel cell 2 at the highest efficiency, at act 226 , current is generated by the fuel cell 2 approximately equal to the vehicle current request value and the charge current for the storage battery 3 without any efficiency-optimized setting. | Regulation of energy supplied to an electric motor from an energy supply system including a fuel cell and an energy storage buffer such as a battery, improves the dynamic response of the motor by adding current from the energy storage buffer to the current from the fuel cell during acceleration. | 1 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government for govermental purposes without the payment of any royalty thereon.
BACKGROUND OF THE INVENTION
This invention relates generally to actuators, and, more particularly to an actuator which by the application or removal of fluid from a plurality of pressure tubes is capable of providing a continuous force.
In general, actuators are designed in the form of piston and cylinder arrangements. There are many instances where such an actuation system is unacceptable, either because the motive force provided is insufficient, actuation is unreliable, and/or the overall cost of the actuator fails to fall within the cost limitations of the system in which the actuator is used.
Some systems in which currently available actuators may be less than desirable would be, for example, in driving the forming head of a sheet metal brake forming machine, driving the clamping jaws on a two-way or four-way stretch forming machine, applying appropriate force to the segmented brake shoes on wheel brakes and varying the chord or diagonal member dimensions in a variable geometry truss as applied to a variable camber leading or trailing edge device.
The latter application is of particular interest since the variable camber concept offers significant improvement in the overall aerodynamic efficiency of aircraft such as the FB-111 that operate in a variety of different mission segments. The efficiency improvement of such aircraft is obtainable by means altering the chordwise and spanwise geometry of the wings to provide optimum aerodynamic characteristics during takeoff, climb out, subsonic cruise, in-flight refueling, subsonic sea level or high altitude dash, supersonic cruise and landing.
Actuators which have been considered for varying the wing geometry generally include conventional hydraulic actuators, power hinges or screw jacks which could be utilized with cables, pulleys and actuating linkages in order to produce such movement. Unfortunately, as the operating speeds of aircraft increase, conventional actuating means have proven to be unsatisfactory and inadequate in obtaining sufficient alteration of the wing or airfoil design. Consequently, there arises a need for not only an improved actuator which is capable of providing continuous force but also an actuator which is readily adaptable for use in varying the chord or diagonal dimensions in a variable geometry truss such as found in the airfoil of today's aircraft.
SUMMARY OF THE INVENTION
The instant invention overcomes the problems encountered in the past by providing a continuous force actuator which relies upon the application or removal of fluid pressure within a plurality of elongated resilient, tubular members. The tubular members are operably interconnected to a pair of pistons capable of moving control surfaces or the like.
The continuous force actuator of this invention is made up of a pair of T-shaped pistons which are arranged between and slidable within two C-shaped housing members. The C-shaped members are bolted or fastened to a separator bar thereby forming a pair of chambers therebetween, one for each of the slidable T-shaped pistons. Tubular shaped members or pressure tubes occupy the space between the separator bar and the outer surface of the heads of the pistons as well as between the heads of the pistons and the inside flange areas of the C-shaped housing members.
Any suitable conventional fluid supply source is connected to the tubular shaped members or pressure tubes in order to provide fluid to either individual or to a predetermined number of tubes in order to precisely alter the position of the pair of T-shaped pistons. By applying the appropriate amount of fluid pressure to the various tubular shaped members the position of the T-shaped pistons may be either retracted or expanded accordingly.
Generally in use within the airfoil of an aircraft, any number of the continuous force actuators of this invention may be utilized in conjunction with a plurality of truss members. The truss members are so arranged within the airfoil structure to produce the desired leading edge excursions from the full-up supersonic cruise position to the full-down high lift position. Since the actuator of this invention is capable of providing a large force for continuous periods of time and for precise movement of the pistons, alteration of the airfoil configuration can be produced in an effective, reliable and low cost manner.
It is therefore an object of this invention to provide an actuator which produces an output of continuous force.
It is another object of this invention to provide a continuous force actuator which allows for precise movement of the components secured thereto.
It is a further object of this invention to provide a continuous force actuator which is extremely durable in construction.
It is still a further object of this invention to provide a continuous force actuator which is economical to produce and which utilizes conventional, currently available components that lend themselves to standard mass producing manufacturing techniques.
For a better understanding of the present invention together with other and further objects thereof, reference is made to the following description taken in conjunction with the accompanying drawing and its scope will be pointed out in the appended claims.
DETAILED DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded, pictorial representation of the continuous force actuator of this invention;
FIG. 2 is a pictorial, cross sectional view of the continuous force actuator of this invention;
FIG. 3 is a side elevational view, shown partly in cross section, of the continuous force actuator of this invention in use within an airfoil structure; and
FIG. 4 is a side elevational view, shown partly in cross section, of the continuous force actuator of this invention shown in use within an airfoil structure depicting a different position of the airfoil and in which the airfoil position of FIG. 3 is shown in phantom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made to FIGS. 1 and 2 of the drawing which clearly illustrates the continuous force actuator 10 of this invention. Actuator 10 is made up of a housing 12 which may be in the form of two C-shaped members 14 and 16. Members 14 and 16 are held in a spaced apart relationship by a separator bar 18 mounted therebetween. Separator 18 as well as members 14 and 16 have a plurality of aligned holes 19 formed therein in order to enable any conventional securing means such as bolts 20 to pass therethrough. Nuts 22 are fastened to bolts 20 thereby securely positioning members 14 and 16 in place. The width of separator bar 18 is designed so that a space 23 is formed at each end of housing 12 between members 14 and 16 to allow a pair of T-shaped pistons 24 and 26 to slidably move between members 14 and 16 in a manner to be described in detail hereinbelow.
Pistons 24 and 26 are of identical construction and therefore only one such piston 24 will be described in detail. For clarity, identical numerals are used in identifying similar elements of each piston 24 and 26. Piston 24 is made of an elongated element or arm 28 having a hinge-like fitting 30 at one end thereof and a head in the form of a T-shaped protrusion 32 at the other end.
Each piston 24 and 26 has elongated arm 28 slidably mounted between members 14 and 16 so as to pass through opening 23. The T-shaped protrusion 32 of each piston 24 and 26 slidably fits within chambers 34 and 36, respectively, formed between separator bar 18 and the ends of C-members 14 and 16, respectively.
Each T-shaped piston 24 and 26 is held in slidable relationship within chambers 34 and 36 by a plurality of pressure tubes which occupy the space surrounding T-shaped pistons 24 and 26. Although any number of suitable pressure tubes may be located within chambers 34 and 36 an operable embodiment of this invention would encompass the utilization of five such pressure tubes located within each chamber 34 and 36 as shown in FIG. 1 of the drawing or six such pressure tubes as shown in FIG. 2.
Since the make-up of each chamber 34 and 36 is identical, the following description will be with reference to only chamber 34 with identical numerals being utilized for the pressure tubes situated within chamber 36. For example, one or two large elongated pressure tubes 38 (or 38 and 40) are situated within chamber 34 interposed between the base of the T-shaped protrusion 32 of piston 24 and separator bar 18. Located between the inner portion of T-shaped protrusion 32 and an end of housing 12 along one side of elongated element 28 are a pair of pressure tubes 42 and 44 located on the other side of element 28 are an identical pair of pressure tubes 46 and 48. The same type of relationship between pressure tubes are set forth in chamber 36. The elongated arms 28 of each T-shaped piston 24 and 26 protrude through the openings 23 formed between adjacent C-shaped members 14 and 16.
Any conventional source of fluid, either gaseous or liquid may be supplied to the pressure tubes 38, 40, 42, 44, 46, and 48 by a series of pressure lines 50 interconnecting the tubes to a conventional pressurized fluid source 52. Two-way valves 54 may be situated within each line 50 so as to regulate the amount of fluid supplied to each of the pressure tubes. In some instances it may be desirable to simultaneously actuate and deactuate valves 54 in order to control the amount of fluid pressure to the tubes or if desired each tube may be regulated independently by valves 54 situated within the lines 50.
Generally, in use, the continuous force actuator 10 of this invention has one of the T-shaped pistons (26, for example) fixedly secured to a supporting structure while the other T-shaped piston 24 is movable with respect thereto. Applying fluid pressure to selective pressure tubes will move piston 24 to an extended position designated by line A or to a retracted position designated by line B.
The continuous force actuator 10 of this invention has many applications, as for example in driving the forming head of a sheet metal brake forming machine or driving the clamping jaws in a two-way or four-way stretch forming machine. One of the more significant uses of the continuous force actuator 10 of this invention involves varying the chord or diagonal member dimensions in a variable geometry truss as applied to a variable camber leading trailing edge device such as an airfoil. Such as device is clearly depicted in FIGS. 3 and 4 of the drawing.
Reference is now made to FIGS. 3 and 4 of the drawing wherein the continuous force actuator 10 of this invention is shown in position and in use within the airfoil 60 of an aircraft (not shown). In general, the airfoil 60 in which the actuator 10 of this invention is utilized is one which is formulated of a flexible outer skin surface 62 and therefore which is capable of taking on a variable configuration such as the configurations shown in FIGS. 3 and 4 of the drawing.
In order to provide for this variable configuration of airfoil 60, a plurality of linkages in the form of truss or support members 64 may be pivotally interconnected within skin surface 62 of airfoil 60. In order to provide the motor force necessary for positioning airfoil 60 the continuous force actuator 10 of this invention is interconnected between, for example, the upper and lower flexible skin surfaces 62 as shown in FIGS. 3 and 4 of the drawing. As indicated in FIGS. 3 and 4 of the drawing, elongated arm 28 of T-shaped piston 24 is secured at point C to outer skin 62 while the other elongated arm 28 of piston 26 is secured at point D enabling the movement of airfoil 60 to take place between the position shown in FIG. 3 of the drawing and the position shown in FIG. 4 of the drawing. The phantom lines illustrated in FIG. 4 shows the relative movement of airfoil 60. By the appropriate application and removal of fluid pressure to the pressure tubes of continuous force actuator 10 of this invention movement of T-shaped piston 24 takes place such as to regulate the configuration of airfoil 60.
For example, as shown in FIG. 3 of the drawing by the removal of pressurized fluid to pressure tubes 42, 44, 46 and 48 in chambers 34 and 36 and the application of pressurized fluid from pressure tubes 38 airfoil 60 can take on the configuration shown in FIG. 3 of the drawing. By the reversal of fluid input and output and therefore the application of pressurized fluid from pressure tubes 42, 44, 46 and 48 and the application of fluid pressure to tubes 38 airfoil 60 may take on the configuration shown in FIG. 4 of the drawing.
By utilization of continuous force actuator 10 within, for example, a variable airfoil 60 as shown in FIGS. 3 and 4 of the drawing a change in the chordwise and spanwise geometry of such an airfoil 60 is possible thereby enhancing the aerodynamic characteristics of an aircraft during takeoff, climbout, subsonic cruise, in-flight refueling, supersonic sea level or high level dash, supersonic cruise and landing.
Although this invention has been described with reference to a particular embodiment, it will be understood to those skilled in the art that this invention is also capable of further and other embodiments within the spirit and scope of the appended claims. | A continuous force actuator having a housing, a pair of slidably mounted T-shaped pistons therein and a plurality of resilient, hollow pressure tubes surrounding each of the pistons. The insertion of fluid into or the removal of fluid from the resilient tubes alters the position of the pistons relative to the housing and thereby controls the continuous force applied by the actuator. By operably connecting the continuous force actuator between opposite components of, for example, a variable configurated airfoil, continuous control of the airfoil configuration can be performed in a reliable and accurate manner. | 8 |
FIELD OF THE INVENTION
[0001] The invention relates to a process for the production of low base number essentially chloride-free calcium sulfonate.
BACKGROUND OF THE INVENTION
[0002] Low base number calcium sulfonates are generally produced by the reaction of sulfonic acid with calcium hydroxide or calcium oxide, utilizing a promoter such as an alkanol. They can also be produced from sodium sulfonate by the use of calcium hydroxide or oxide and calcium chloride. Such sulfonates may be used as highly valued additives for lubricating oils such as passenger car, diesel, and marine engine lubricants. They may be further processed into overbased sulfonates, which have higher base numbers and are also used as additives for specialty lubricating oils.
[0003] When calcium sulfonate is derived from sulfonic acid, no chloride is needed, but the concentration of the final product is limited by the concentration of the sulfonic acid. In the case of natural petroleum sulfonic acid, concentration is typically less than commercially desired. Concentrating sulfonic acid itself is difficult due to its high corrosivity.
[0004] When calcium sulfonate is made from sodium sulfonate, chloride is required to make the reaction proceed. This leads to residual contaminating chloride in the final product. The sodium sulfonate is concentrated to the required concentration using a solvent extraction process prior to conversion to the calcium product, since calcium sulfonate is more difficult to concentrate by this method.
[0005] A number of methods have been disclosed for the production of low base number calcium sulfonate.
[0006] U.S. Pat. No. 5,804,094 teaches a method of producing a low base number calcium sulfonate of greater than 500 molecular weight using carboxylic acid and a high base number calcium sulfonate.
[0007] U.S. Pat. No. 5,789,615 teaches the use of staged addition of calcium hydroxide to sulfonic acid to produce a low viscosity, low haze product without the use of promoters, especially without the use of chloride. The calcium hydroxide is added in two or more steps, with 30-180 minutes heat soak after each step.
[0008] U.S. Pat. No. 4,615,841 describes a method of producing calcium sulfonates in the presence of an alkanol.
[0009] U.S. Pat. No. 4,279,837 teaches the preparation of alkaline earth metal salts of alkyl benzene sulfonic acids by neutralization of the acid using an oxyalkylate as a promoter, thus also producing a chloride free calcium sulfonate.
[0010] U.S. Pat. No. 3,719,596 describes a method of producing calcium sulfonate in which the reaction mixture is made acidic and then basic again using an alkanolamine.
[0011] U.S. Pat. No. 2,779,784 teaches a method of producing calcium sulfonate in which sulfonic acid is neutralized with calcium hydroxide at 220° F. to 390° F. (104° C. to 199° C.), in the presence of ½ to 10 parts water per part calcium hydroxide. This would correspond to between 0.12 and 2.4 mol water per mol calcium hydroxide.
[0012] It would be advantageous to produce low base number calcium sulfonates, that are free of residual chlorine and easily concentrated, via a process suitable for use in a continuous reactor that can also produce products with a low viscosity.
SUMMARY OF THE INVENTION
[0013] A method has been discovered to produce low base number calcium sulfonate, which is essentially free of residual chlorine and easily concentrated. The method can also produce a low viscosity product. The method may also be practiced in a continuous manner.
[0014] In particular, the present invention relates to a process for the production of calcium sulfonate which comprises preparing sulfonic acid solution by adding about 1 to about 20 volumes of a miscible solvent to sulfonic acid and removing dissolved or entrained SO 2 or SO 3 if present, mixing the resultant sulfonic acid solution with about 1 to about 5 moles of water per mol of sulfonic acid and about 1 to about 10 moles of calcium hydroxide per mole of sulfonic acid to prepare a reaction mixture, heating the reaction mixture to between about 40° C. and about 200° C. for a period of time up to about 60 minutes with stirring, separating excess calcium hydroxide and calcium salts of mineral acid from such a reaction mixture, and recovering solvent and oil to make a final essentially chloride-free calcium sulfonate product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1—This figure shows a flow chart of a continuous process for producing calcium sulfonate.
[0016] [0016]FIG. 2—This figure shows the relationship between the Strong Base Number (SBNC) of the calcium sulfonate solution produced by the invention and the SBNC of the product after solvent stripping.
[0017] [0017]FIG. 3—This figure shows the relationship between product viscosity and the SBNC of the product after solvent stripping.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention provides a process for the production of low base number essentially chloride-free calcium sulfonate. In the context of the instant application, a low base number calcium sulfonate has a base number of 0 to about 50. By “essentially chloride-free” is meant a maximum chlorine content of 1000 ppm.
[0019] Sulfonic acid in an oil/solvent solution or dispersion is neutralized by calcium hydroxide in the presence of a specific amount of water. Excess hydroxide and inorganic salt are subsequently removed from the reaction mixture by a suitable means such as centrifugation or filtration before removal of the solvent. After removal of the solvent, the calcium sulfonate in oil is concentrated by suitable means such as vacuum flashing or vacuum distillation, to produce a final product with a base number between 0 and about 50, and the desired final concentration.
[0020] The sulfonic acid utilized may be derived from petroleum oil. The oil used in the process can be any suitably refined crude distillate. An example of a suitable feedstock is a vacuum distillate of appropriate molecular weight that has been refined by solvent extraction and/or hydrotreating to reduce the polynuclear aromatics content. The sulfonic acid solution used in the process is created by reacting the refined crude distillate with fuming sulfuric acid (about 27%—about 33% SO 3 ; oleum) or gaseous SO 3 . When the feedstock is contacted with fuming sulfuric acid, mono-aromatics are converted into mono-sulfonic acid and the residual poly-nuclear aromatics are converted into poly-sulfonic acid. The polysulfonic acid plus SO 3 depleted sulfuric acid form a sludge. This reaction mixture is diluted with about 1 to about 20 volumes of a miscible solvent to reduce viscosity, and the sludge is separated out by gravity settling, leaving the sulfonic acid in a solvent/oil solution. Dissolved or entrained SO 3 and/or SO 2 , produced as a byproduct of side reactions between the oil and the SO 3 , are removed from the solution if present. One method of removal is stripping with nitrogen or another inert gas. The solution can also be centrifuged to remove traces of sludge prior to removal of dissolved or entrained SO 2 or SO 3 .
[0021] Suitable solvents include any C 3 to C 10 alkane, toluene or any low viscosity, miscible solvent. Most preferred is heptane or commercially available mixtures of heptane isomers.
[0022] To the cleaned sulfonic acid/solvent/oil solution is added about 1 mol per mol to about 5 mol per mol sulfonic acid of water and about 1 mol per mol to about 10 mol per mol sulfonic acid of calcium hydroxide to form the reaction mixture.
[0023] The reaction mixture is heated with stirring to a temperature of from about 40° C. to about 200° C., preferably from about 80° C. to about 120° C. The mixture is preferably stirred for a period of time up to about 60 minutes, more preferably up to about 30 minutes.
[0024] The resulting mixture is then separated to remove excess calcium hydroxide and any salts formed from residual sludge or SO 2 . One method of separating the mixture is centrifugation. Centrifugation should be performed for a sufficient amount of time to remove the excess calcium hydroxide and any salts. This period of time can be any such sufficient amount of time, for example, 20 minutes. The presence of the solvent greatly improves the speed of separation. The solvent is recovered from the clear centrate for recycle by any convenient means such as a solvent stripper. The product may be further concentrated via distillation or vacuum flashing to remove a portion or all of the unreacted oil.
[0025] This process may be operated in a continuous fashion in a manner such as that shown in FIG. 1. Sulfonic acid 1 is added to a reactor 7 , followed by water 3 and lime 5 . The resultant mixture then undergoes separation 9 , with the lime and water being removed. The next step is solvent recovery 11 , followed by concentration 13 to produce the calcium sulfonate in base oil 15 .
[0026] The following examples are meant to further illustrate the invention without limiting its scope.
COMPARATIVE EXAMPLES—SET I
[0027] A sulfonic acid solution (75 g) containing a mixture of petroleum sulfonic acid (8 wt %, average molecular weight of about 440 g/mol), commercial heptanes (60 wt %), and lubricating oil (32 wt %) was used in the following examples. This mixture was further treated by centrifugation and nitrogen stripping before being used in the examples.
[0028] Water, calcium hydroxide and tertiary butyl alcohol (TBA), as a promoter, were added to 75 g of sulfonic acid. The resulting reaction mixture was heated with stirring for a specified time in an Erlenmeyer flask equipped with a reflux condenser. For temperatures above the boiling point of the mixture, a stainless steel reaction vessel was used to contain the mixture under pressure. After stirring, the mixture was transferred to a centrifuge tube and centrifuged for 10-20 minutes. Table I shows the resulting Strong Base Number (SBNC, measured according to ASTM D974) of the centrate for various values of pretreatment, TBA content, water content, lime content, reaction time, reaction temperature, and centrifugation time.
TABLE I COMPARATIVE EXAMPLES SET I - WITH PRETREATMENT AND WITH TBA Comp. TBA, mol/mol Water, mol/mol Lime, mol/mol Reaction Reaction Centrifugal Centrate SBNC, Example sulfonic acid sulfonic acid sulfonic acid Temp, ° C. time, min time, min mg KOH/g 1 2.1 2.4 4.0 80 10 10 2.2 2 2.1 2.4 4.0 82 30 10 2.3 3 1.0 1.7 4.0 140 30 10 2.9 4 1.2 1.9 4.0 140 30 10 3.2 5 1.2 1.7 4.0 140 30 10 3.0 6 1.2 2.7 4.0 140 30 10 2.9
[0029] As can be seen, a base number of up to 3.2 can be obtained by optimizing the amount of TBA, water, and temperature.
COMPARATIVE EXAMPLES—SET II
[0030] The Comparative Examples in Set II were performed as in Comparative Examples Set I, however, the sulfonic acid was not treated by centrifugation and nitrogen stripping prior to reaction and no TBA was added. The results from these examples are in Table II. Acidic results are shown as a negative SBNC value.
TABLE II COMPARATIVE EXAMPLES SET II - NO PRETREATMENT, NO TBA Comp. Water, mol/mol Lime, mol/mol Reaction Reaction time, Centrifuge time, Centrate SBNC, mg Example sulfonic acid sulfonic acid Temp, ° C. min min KOH/g 7 0.5 3.0 26 10 10 −7.5 8 4.6 3.0 26 10 10 −0.3 9 12.7 3.0 26 10 10 −0.3 10 0.5 3.0 82 10 10 −1.1 11 2.7 4.0 82 30 10 0.2
[0031] These Comparative Examples show the results obtained without pretreating the sulfonic acid.
COMPARATIVE EXAMPLES SET III
[0032] The Comparative Examples in Set III were performed as in Comparative Examples Set I, however, the sulfonic acid was not treated by centrifugation and nitrogen stripping prior to reaction. The results from these examples are in Table IV. Acidic results are shown as a negative SBNC value.
TABLE III COMPARATIVE EXAMPLES SET III - NO PRETREATMENT, WITH TBA Comp. TBA, mol/mol Water, mol/mol Lime, mol/mol Reaction Reaction time, Centrifuge time, Centrate SBNC, Example sulfonic acid sulfonic acid sulfonic acid Temp, ° C. min min mg KOH/g 12 10.9 0.5 3.0 26 10 10 −7.0 13 1.4 5.7 3.0 26 10 10 1.0 14 3.3 3.3 4.0 26 20 20 0.8 15 7.5 6.3 3.0 26 10 10 0.8 16 7.9 3.1 3.0 26 10 10 −0.3 17 4.5 5.0 3.0 26 10 10 1.9 18 4.6 4.1 3.0 60 10 10 2.3 19 4.2 3.9 4.0 60 20 20 2.5 20 2.1 2.1 3.0 82 10 10 2.4
[0033] These examples show results obtained without pretreating the sulfonic acid, but adding TBA to the reaction mixture. A maximum SBNC value of 2.5 was obtained.
EXAMPLES
[0034] A sulfonic acid solution (75 g) containing a mixture of petroleum sulfonic acid (8 wt %, average molecular weight of about 440 g/mol), commercial heptanes (60 wt %), and lubricating oil (32 wt %) was used in the following examples. This mixture was further treated by centrifugation and nitrogen stripping before being used in the examples.
[0035] Water and calcium hydroxide were added to 75 g of the treated sulfonic acid solution. The resulting reaction mixture was heated with stirring for the reaction time in an Erlenmeyer flask equipped with a reflux condenser. For temperatures above 82° C., a stainless steel reaction vessel was used to contain the mixture under pressure. After stirring, the mixture was transferred to a centrifuge tube and centrifuged for 10-20 minutes. Table IV shows the resulting Strong Base Number (SBNC, measured according to ASTM D974, incorporated by reference) of the centrate for various values of water content measured in mol/mol of sulfonic acid, lime content measured in mol/mol of sulfonic acid, reaction temperature measured in ° C., and reaction time and centrifugation time measured in minutes. FIG. 2 shows the correlation between the SBNC of the centrate and the concentrated product.
TABLE IV EXAMPLES Water, mol/mol Lime, mol/mol Reaction Reaction Centrifuge Centrate SBNC, Example sulfonic acid sulfonic acid Temp, ° C. time, min time, min mg KOH/g 1 2.3 4.0 60 30 10 0.4 2 2.7 4.0 60 30 10 2.7 3 3.1 4.0 60 30 10 2.3 4 3.5 4.0 60 30 10 2.1 5 2.4 4.0 82 10 10 0.9 6 2.4 4.0 82 30 10 2.2 7 2.8 4.0 82 30 10 3.3 8 1.5 4.0 117 30 10 3.5 9 1.7 4.0 117 30 10 3.6 10 1.9 4.0 117 30 10 3.3 11 2.2 1.0 117 30 10 0.7 12 2.6 1.0 117 30 10 2.5 13 3.0 1.0 117 30 10 2.3 14 2.2 4.0 140 1 10 3.4 15 2.2 4.0 140 10 10 3.5 16 1.3 4.0 140 30 10 0.5 17 1.9 4.0 140 30 10 3.5 18 2.0 4.0 140 30 10 3.6 19 2.2 4.0 140 30 10 3.5 20 3.1 4.0 140 30 10 2.8
[0036] These examples show that a base number of 3.6 can be achieved with the method of the invention. Table V and corresponding FIG. 2 show the relationship between the centrate SBNC and the stripped centrate SBNC and TBN such that a value for the stripped product can be extrapolated from FIG. 2.
TABLE V RELATIONSHIP BETWEEN CENTRATE SBNC AND STRIPPED CENTRATE SBNC AND TEN Centrate Stripped Centrate Stripped Centrate SBNC SBNC TBN Example ASTM D974 ASTM D974 ASTN D2896 1 −1.23 −2.47 0.00 2 −0.18 0.21 1.24 3 −0.10 0.17 1.28 4 0.00 0.40 1.40 5 0.16 0.75 1.56 6 0.21 1.33 2.12 7 0.30 1.32 2.48 8 0.37 1.10 2.72 9 0.41 1.18 2.44 10 0.46 1.44 2.85 11 0.85 2.61 3.56 12 1.07 2.66 3.69 13 1.67 4.29 5.67 14 1.91 4.70 6.00 15 3.35 8.36 9.16
[0037] In order to improve the product viscosity, it is advantageous to produce a higher base number product while still maintaining the product in the low base number product range. From FIG. 2, it can be seen that a base number of 3.6 correlates to a stripped centrate SBNC of about 9.1. FIG. 3 shows the relationship between the base number of the stripped product of the invention and the viscosity of the product. From Table VI and FIG. 3 it can be seen that a viscosity of about 15 cSt at 100° C. correlates to a stripped centrate SBNC of about 9.1.
TABLE VI Relationship between SBNC of Stripped Product and Viscosity of Stripped Product Stripped Centrate Stripped Centrate SBNC Viscosity/100° C. Example ASTM D974 ASTM D445 1 −2.47 22 2 −1.17 250 3 0.00 3000 4 0.50 191 5 1.00 121 6 1.68 82.2 7 2.64 47.1 8 4.59 25.5 9 6.08 15.9 10 7.27 15.6 11 8.36 14.8 | The invention relates to a process for the preparation of a low-base number calcium sulfonate that is essentially chloride free. The process involves preparing a sulfonic acid solution by adding a solvent to sulfonic acid, removing dissolved or entrained SO 2 or SO 3 , mixing the solution with a specific amount of water and calcium hydroxide, heating the mixture, separating out excess calcium hydroxide and calcium salts from the mixture, and recovering solvent and oil to capture the calcium sulfonate product. | 2 |
FIELD OF THE INVENTION
The claimed invention relates generally to the field of data storage systems and more particularly, but not by way of limitation, to a method and apparatus for caching and retaining non-requested speculative data in an effort to accommodate future requests for such data.
BACKGROUND
Storage devices are used to access data in a fast and efficient manner. Some types of storage devices use rotatable storage media, along with one or more data transducers that write data to and subsequently read data from tracks defined on the media surfaces.
Multi-device arrays (MDAs) can employ multiple storage devices to form a consolidated memory space. One commonly employed format for an MDA utilizes a RAID (redundant array of independent discs) configuration, wherein input data are stored across multiple storage devices in the array. Depending on the RAID level, various techniques including mirroring, striping and parity code generation can be employed to enhance the integrity of the stored data.
With continued demands for ever increased levels of storage capacity and performance, there remains an ongoing need for improvements in the manner in which storage devices in such arrays are operationally managed. It is to these and other improvements that preferred embodiments of the present invention are generally directed.
SUMMARY OF THE INVENTION
Preferred embodiments of the present invention are generally directed to an apparatus and method for caching and retaining non-requested speculative data from a storage array in an effort to accommodate future requests for such data.
In accordance with preferred embodiments, a cache manager stores requested readback data from the storage array to a cache memory, and transfers speculative non-requested readback data to the cache memory in relation to a time parameter and a locality parameter associated with a data structure of which the requested readback data forms a part.
The locality parameter preferably comprises a stream count as an incremented count of consecutive read requests for a contiguous data range of the storage array, and the time parameter preferably indicates a time range over which said read requests have been issued. The speculative readback data are transferred when both said parameters fall within a selected threshold range. The data structure preferably comprises a RAID stripe on a selected storage device of the array.
These and various other features and advantages which characterize the claimed invention will become apparent upon reading the following detailed description and upon reviewing the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 generally illustrates a storage device constructed and operated in accordance with preferred embodiments of the present invention.
FIG. 2 is a functional block diagram of a network system which utilizes a number of storage devices such as illustrated in FIG. 1 .
FIG. 3 provides a general representation of a preferred architecture of the controllers of FIG. 2 .
FIG. 4 provides a functional block diagram of a selected intelligent storage processor of FIG. 3 .
FIG. 5 generally illustrates a cache manager which operates to manage readback data retrieved from the storage array in accordance with preferred embodiments.
FIG. 6 shows an exemplary stream of data retrieved by the cache manager from the storage array to the cache memory.
FIG. 7 shows an alternative exemplary stream of data retrieved by the cache manager from the storage array to the cache memory.
FIG. 8 graphically illustrates a boundary curve to set forth a preferred operation of the cache manager in making decisions with regard to caching speculative non-requested data.
FIG. 9 shows a sequence of different streams concurrently maintained by the cache manager.
FIG. 10 shows a data stream comprising a plurality of adjacent data structures combined into a single, larger structure.
FIG. 11 is a flow chart for a SPECULATIVE DATA CACHING routine generally illustrative of steps carried out in accordance with preferred embodiments of the present invention.
DETAILED DESCRIPTION
FIG. 1 shows an exemplary storage device 100 configured to store and retrieve user data. The device 100 is preferably characterized as a hard disc drive, although other device configurations can be readily employed as desired.
A base deck 102 mates with a top cover (not shown) to form an enclosed housing. A spindle motor 104 is mounted within the housing to controllably rotate media 106 , preferably characterized as magnetic recording discs.
A controllably moveable actuator 108 moves an array of read/write transducers 110 adjacent tracks defined on the media surfaces through application of current to a voice coil motor (VCM) 112 . A flex circuit assembly 114 provides electrical communication paths between the actuator 108 and device control electronics on an externally mounted printed circuit board (PCB) 116 .
FIG. 2 generally illustrates an exemplary network system 120 that advantageously incorporates a number n of the storage devices (SD) 100 to form a consolidated storage array 122 . Redundant controllers 124 , 126 preferably operate to transfer data between the storage array 122 and a server 128 . The server 128 in turn is connected to a fabric 130 , such as a local area network (LAN), the Internet, etc.
Remote users respectively access the fabric 130 via personal computers (PCs) 132 , 134 , 136 . In this way, a selected user can access the storage space 122 to write or retrieve data as desired.
The devices 100 and the controllers 124 , 126 are preferably incorporated into a multi-device array (MDA) 138 . The MDA 138 preferably uses one or more selected RAID (redundant array of independent discs) configurations to store data across the devices 100 . Although only one MDA and three remote users are illustrated in FIG. 2 , it will be appreciated that this is merely for purposes of illustration and is not limiting; as desired, the network system 120 can utilize any number and types of MDAs, servers, client and host devices, fabric configurations and protocols, etc.
FIG. 3 shows an array controller configuration 140 such as useful in the network of FIG. 2 . Two intelligent storage processors (ISPs) 142 , 144 are coupled by an intermediate bus 146 (referred to as an “E BUS”). Each of the ISPs 142 , 144 is preferably disposed in a separate integrated circuit package on a common controller board. Preferably, the ISPs 142 , 144 each respectively communicate with upstream application servers via fibre channel server links 148 , 150 , and with the storage devices 100 via fibre channel storage links 152 , 154 .
Policy processors 156 , 158 execute a real-time operating system (RTOS) for the controller 140 and communicate with the respective ISPs 142 , 144 via PCI busses 160 , 162 . The policy processors 156 , 158 can further execute customized logic to perform sophisticated processing tasks in conjunction with the ISPs 142 , 144 for a given storage application. The ISPs 142 , 144 and the policy processors 156 , 158 access memory modules 164 , 166 as required during operation.
FIG. 4 provides a preferred construction for a selected ISP of FIG. 3 . A number of function controllers, collectively identified at 168 , serve as function controller cores (FCCs) for a number of controller operations such as host exchange, direct memory access (DMA), exclusive-or (XOR), command routing, metadata control, and disc exchange. Each FCC preferably contains a highly flexible feature set and interface to facilitate memory exchanges and other scheduling tasks.
A number of list managers, denoted generally at 170 are used for various data and memory management tasks during controller operation, such as cache table management, metadata maintenance, and buffer management. The list managers 170 preferably perform well-defined albeit simple operations on memory to accomplish tasks as directed by the FCCs 168 . Each list manager preferably operates as a message processor for memory access by the FCCs, and preferably executes operations defined by received messages in accordance with a defined protocol.
The list managers 170 respectively communicate with and control a number of memory modules including an exchange memory block 172 , a cache tables block 174 , buffer memory block 176 and SRAM 178 . The function controllers 168 and the list managers 170 respectively communicate via a cross-point switch (CPS) module 180 . In this way, a selected function core of controllers 168 can establish a communication pathway through the CPS 180 to a corresponding list manager 170 to communicate a status, access a memory module, or invoke a desired ISP operation.
Similarly, a selected list manager 170 can communicate responses back to the function controllers 168 via the CPS 180 . Although not shown, separate data bus connections are preferably established between respective elements of FIG. 4 to accommodate data transfers therebetween. As will be appreciated, other configurations can readily be utilized as desired.
A PCI interface (I/F) module 182 establishes and directs transactions between the policy processor 156 and the ISP 142 . An E-BUS I/F module 184 facilitates communications over the E-BUS 146 between FCCs and list managers of the respective ISPs 142 , 144 . The policy processors 156 , 158 can also initiate and receive communications with other parts of the system via the E-BUS 146 as desired.
The controller architecture of FIGS. 3 and 4 advantageously provides scalable, highly functional data management and control for the array. Preferably, stripe buffer lists (SBLs) and other metadata structures are aligned to stripe boundaries on the storage media and reference data buffers in cache that are dedicated to storing the data associated with a disk stripe during a storage transaction.
When data requests are issued by a host device (such as PCs 132 , 134 , 136 in FIG. 2 ), the controller 122 directs the movement of the requested readback data from the storage devices 100 to cache memory in preparation for subsequent transfer to the host device. To further enhance processing efficiency, the controller architecture preferably employs a novel speculative data caching methodology.
Speculative data are non-requested data that are moved to the cache memory in hopes of satisfying a subsequent request for that data by a host device. Generally, preferred embodiments of the present invention are directed to adaptively making decisions with regard to when to perform a speculative read, as well as to managing the retention of such speculative data in cache.
As shown in FIG. 5 , cached data are preferably managed on a node basis by a cache manager (CM) 190 using a data structure referred to as a stripe data descriptor (SDD) 192 . Each SDD holds data concerning recent and current accesses to the data with which it is associated. Each SDD thus preferably corresponds to and aligns with a data structure as a subset of the overall storage array, such as a corresponding RAID stripe 194 (i.e., all of the data on a selected device 100 associated with a particular parity set). Each SDD 192 further preferably conforms to a particular SBL 196 .
Each cache node managed by the CM 190 preferably references some particular SDD, with active SDD structures for a given set of logical discs (subset of the devices 100 ) being preferably linked in ascending order via a virtual block address (VBA) using a standard forward and backward linked list. The logical discs are preferably managed using an associated logical disc descriptor (LDD) 198 .
Preferably, the VBA values are aligned with the RAID data organization using a grid system sometimes referred to as a RAID Allocation Grid System (RAGS). Generally, any particular collection of blocks belonging to the same RAID strip 200 (e.g., all of the data contributing to a particular parity set) will be assigned to a particular reliable storage unit (RSU) on a particular sheet.
A book consists of a number of sheets and is constructed from multiple contiguous sets of blocks from different devices 100 . Based on the actual sheet and VBA, the books can be further sub-divided into zones, indicating the particular device or device set (when redundancy is employed).
Each SDD 192 preferably includes variables (parameters) that indicate various states of the data. SDD variables that are preferably utilized in accordance with preferred embodiments include access history, last offset, last block, timestamp data (time of day, TOD), RAID level employed, stream count, stream size, and speculative data status.
The access history of the SDD 192 preferably provide a relative measure of a rate at which accesses are made to the data associated with the SDD. For example, an accesses variable can be an incremental count that is updated upon each access to the data defined by the SDD. The accesses variable thus provides an indication of “host interest” in the data in this locality; under normal circumstances, a higher existing number of accesses might produce a higher likelihood that more accesses will occur in the near future.
The TOD variable generally provides an indication of elapsed time since the most recent access. By subtracting the TOD variable from the current time, an aging assessment can be made on how frequently (or infrequently) the SDD is being accessed.
The stream count generally provides an incremental count of successively issued requests for data from the storage array that falls into a concurrent sequence (a “stream”). Stream size provides an overall indication of the then existing size of the stream (such as in terms of overall numbers of sectors, etc.). When a request just follows a previous request as determined by the VBA matching the previous last VBA based on the last offset and last block values, the stream count is incremented and the stream size is adjusted to match the new overall range. The speculative data status value generally identifies the associated data ranges of speculatively retrieved data within the stream.
The LDD 198 preferably provides data on a logical disc basis, which can span several SDDs. The LDD 198 includes a number of variables utilized in the various preferred embodiments discussed herein including an LDD stream count and LDD stream size.
Preferably, during normal operations the cache manager 190 operates to direct the retrieval of requested data from the storage array to cache memory, such as represented by block 202 in FIG. 5 . The cache manager 190 will also operate from time to time to additionally retrieve speculative non-requested data along with the retrieval of the requested data. A timer 204 preferably characterized as a free running counter provides timing information to assess aging of the cached requested and speculative data.
In a preferred embodiment, an operation to retrieve speculative data commences upon detection of a stream; that is, detection of a number of successive requests for consecutively placed read data. An exemplary stream 206 (“STREAM A”) is represented in FIG. 6 . The stream 206 is stored in the cache memory 202 and constitutes a number of consecutive, concurrently addressed blocks (sectors).
In the present example, the CM 190 receives and satisfies a first request to retrieve a first set of data 208 (DATA SET 1 ), with a corresponding number of blocks X 1 . At some point during this processing the CM receives and satisfies a second request to retrieve a second set of data 210 (DATA SET 2 ), with blocks X 2 . Note that X 2 may or may not be the same number of blocks as X 1 , but the blocks X 1 and X 2 preferably define an overall sequential range of block addresses of a selected SDD data structure.
Upon receipt of the second read request, the CM 190 elects to proceed with the retrieval of speculative, non-requested data as represented by block 212 . The block 212 represents speculative data, in this case X 3 blocks corresponding to the rest of the SDD data structure (e.g., the rest of the associated stripe 194 in FIG. 5 from the associated device 100 ).
The decision by the CM 190 to proceed with pulling speculative data is preferably carried out through reference to both time and locality parameters: that is, the SDD stream count indicates a count of 2, the SDD stream size indicates a large enough sequence of data has been requested to indicate a stream, and the TOD value indicates that the requests are currently ongoing (i.e., “now”).
Under such circumstances, the CM 190 preferably determines that there is a likelihood of future requests for the rest of the SDD data structure, and it is sufficiently efficient from a transfer latency standpoint to proceed with pulling the rest of the SDD data (an extra seek is highly unlikely).
It will be noted at this point that while preferred, it is not necessarily required that the CM 190 operate to retrieve the rest of the entire data structure. In alternative embodiments, intermediate groups of data less than the entire data structure can be speculatively read upon detection of a stream.
An alternative exemplary stream 214 (“STREAM B) is shown in FIG. 7 . The stream 214 includes first, second and third sets of requested readback data 216 , 218 and 220 (R 1 , R 2 , R 3 ). Upon detection of these requested readback data sets, speculative non-requested data sets 222 , 224 , 226 (NR 1 , NR 2 , NR 3 ) are pulled, which may or may not extend to the full SDD data structure. Preferably, as the stream size grows, larger amounts of speculative data are increasingly requested.
FIG. 8 provides a graphical representation of a boundary curve 230 plotted against a TOD difference x-axis 232 and a stream count y-axis 234 . As will be appreciated, “TOD difference” refers to the time delta between “now” (the currently reflected TOD) and the time of the last reference to the SDD (the TOD at that time).
The curve 230 generally forms separate decision regions 236 , 238 respectively above and below the curve 230 . The curve 230 is generally indicative of the operation of the CM 190 , and can thus take any suitable shape and can further be adaptively adjusted in response to observed performance.
Generally, the decision as to whether speculative data should be pulled is preferably made in relation to where a given operational point falls in the graph. Operational point 240 corresponds to a given stream count and TOD indication that collectively indicate that it would be advantageous to proceed with a speculative data pull, as point 240 falls within “yes” region 236 . By contrast, operational point 242 provides stream count and TOD values that indicate that it would be better not to proceed with a speculative data pull at this time, since point 242 falls within “no” region 238 .
It can be seen that a speculative data pull can be triggered in response to a relatively small stream count, so long as the read commands are issued over a correspondingly short period of time. At the same time, a larger stream count will generally be required to trigger a speculative data pull if the commands are more widely spaced apart. The boundary curve 230 thus operates as respective thresholds for the time and locality parameters, both of which need be met prior to a speculative data pull.
As desired, additional boundary curves can be provided to the yes region 236 to provide gradients in the amount of speculative data that should be pulled. For example, operational points above curve 244 can trigger the speculative read of an entire SDD data structure.
Preferably, each SDD 192 provides stream count, size and TOD values relating to the associated SDD data structure. Under some scenarios the stream may extend across multiple adjacent SDDs within the logical disk, such as shown by stream 250 in FIG. 9 . It will be appreciated that the stream 250 can comprise groups of both requested and speculative non-requested data that consecutively span the overall range of the stream.
Once speculative data have been moved into the cache memory 202 , the CM 190 preferably employs additional processes to manage the retention of such data. As will be appreciated, cache memory is a valuable and limited resource. Once a selected set of memory cells in the cache memory 202 have been allocated to store a particular set of data, those memory cells are unavailable to store other data until the memory cells are deallocated. An efficient cache management methodology thus attempts to store and retain only data that has value in terms of satisfying future cache hits, and to discard the rest.
Accordingly, the CM 190 preferably operates to time out all cached data, whether requested or non-requested, if such data have not been requested by a host within a selected period of time. The timer 204 and the TOD variables of the SDD 192 can be utilized to track this. Moreover, it is preferred, although not required, that at least speculatively retrieved data is released from cache memory (deallocated) once a read request is issued for the data.
Such release can take place in relation to the access history of the SDD 192 ; for example, if the access variable indicates a relatively high level of accesses to the cached data structure, repetitive requests for the same data are more likely, thus lessening the desirability of releasing cached data (speculative or requested) from the cache 202 .
When data are discarded from cache memory, the LDD stream size and stream count values are updated based on where in the associated stream the discarded data were disposed. Thus, a single large stream made up of both requested and speculative data, such as the stream 250 in FIG. 9 , may be broken into two or more sub-streams if a set of speculative data are removed from cache. It is contemplated, however, that this is less likely than the occurrence of multiple independent and concurrent streams of host data requests, all of which can be readily accommodated by the SDD variables.
Over time the cache manager 190 may thus accumulate and track a number of different streams, such as shown by streams 252 , 254 , 256 and 258 in FIG. 10 (STREAMS C, D, E, F). As mentioned above, these may be separate and independent streams, or may result from one or more parent streams that were broken up into smaller streams. The streams can be sorted and managed by size as shown.
The CM 190 preferably carries out speculative data pulls at this level as well. For example, the CM 190 may detect a renewed interest in the data associated with a selected one of these streams, such as stream 254 (Stream B). In such case, the CM 190 preferably initiates a command to speculatively read additional data, which may include one or more SDDs that consecutively follow the range of the stream 254 .
Data retention is also preferably adaptive in view of operational requirements. In some preferred embodiments, when the last data block of a selected SDD 192 receives a cache hit, and that data block was speculatively read into the cache memory, the CM 190 may elect to retain the entire selected SDD 192 in cache memory and speculative retrieve the next sequential SDD 192 . On the other hand, if the next sequential SDD 192 already exists in the cache memory, the CM 190 may conversely decide to go ahead and release the selected SDD 192 (or a portion thereof).
Further, when data associated with a selected SDD 192 is first placed into the cache memory 202 and a first access thereto (cache hit) is made to the lowest address block in the structure, the CM 190 preferably inspects the previous SDD (i.e., the SDD that immediately precedes the selected SDD from an addressing standpoint). If the previous SDD is also cached and indicates a non-zero stream size, a larger stream is preferably detected and the stream size and stream count values are carried over. Based on these values, additional speculative data may be read and added to the stream.
In further preferred embodiments, if during a speculative read a cache hit is made upon speculative data just placed into cache, the CM 190 preferably locates the end of the stream and increases the length of the speculative read as appropriate. An ongoing speculative read is preferably terminated in relation to the stream count and stream size pairs to avoid “over shoot” (reading too much speculative data) in the LDD 198 based on the historical stream length data these pairs represent. These pairs are derived initially by determining where speculatively read data in a stream is purged because it is “stale.”
Even if a particular stream is terminated, however, if the stream is detected as continuing, the read ahead operation can be resumed and terminated according to the next highest size of the stream.
The foregoing embodiments advantageously accommodate a wide variety of operational loading requirements. However, under certain circumstances the aforedescribed system may miss opportunities to cache speculative data if sequential read requests are made with boundaries that align with existing SDD boundaries. For example, assume that a read request is issued by a host for a full SDD worth of data (e.g., 128 KB) aligned to a 128 KB SDD boundary. Normally, no speculative data pull would be triggered since the entire SDD data structure has been requested, and the data would be released from cache upon transfer to the host.
However, the CM 190 is preferably further configured operate as before at an SDD level; that is, to detect a large scale data transfer of successive SDD requests and, if so, to speculatively pull additional SDDs to sustain the data transfer. Preferably, upon receipt of a read request for a full SDD data structure the CM 190 detects whether the “next” SDD in the sequence already exists in cache memory 202 . If not, a backward check is made to the “previous” SDD. If the previous SDD is cached and has a non-zero stream size, then the latest request is handled as an additional request in an ongoing stream. Stream size and stream counts are thus carried forward as before to continue the ongoing stream.
On the other hand, if the previous SDD has a zero stream size and last block and offset values of 0, this may indicate that the previous SDD was pulled as a single block (i.e., a 128 KB request). The currently retrieved SDD is thus a second sequential SDD request, and the CM 190 preferably sets the stream size to 512 and stream count to 2.
Upon the third adjacent request for the next SDD, the CM 190 initiates speculative pulls of additional SDDs worth of data to the cache memory unless the LDD 198 indicates that 512 block transfers are occurring. If sufficient multiple large scale streams are occurring (e.g., on the order of 1 MB or more), speculative reads may further be initiated for an entire stream of the smallest size as indicated by the LDD.
The management and retention of the cached data, whether requested or non-requested, is further preferably carried out in an adaptive manner. For example, existing parameters used to set the thresholds necessary to trigger a speculative data pull, and/or to trigger a deallocation of already cached data, can be adjusted in view of hit ratios or other performance measures.
The foregoing operation can be generally illustrated by a SPECULATIVE DATA CACHING routine in FIG. 11 , which is generally illustrative of steps carried out in accordance with preferred embodiments of the present invention.
At step 302 , a system such as the network 120 of FIG. 2 is initialized for operation. The system proceeds to service data transfer requests at step 304 to transfer data between a storage array such as 122 and various host devices such as 132 , 134 , 136 .
Such requests will preferably include write data requests wherein data to be written to the array are moved to cache memory such as 202 pending subsequent transfer to the devices 100 , as well as read data requests wherein data stored on the devices 100 are moved to the cache memory 202 and then on to the requesting device. Preferably, requests for data are satisfied directly from the cache memory in the form of cache hits, as available.
A cache manager such as 190 preferably operates to detect a stream of data requests at step 306 . As discussed above, such streams are preferably detected at a variety of levels, including within a selected data structure (e.g., SDD) or among adjacent consecutive data structures, in relation to time and locality parameters of an associated data structure.
Upon detection of a stream, the CM 190 preferably operates at step 308 to initiate retrieval of speculative non-requested data into the cache memory 202 . The cached data are further managed and retained at step 310 by the CM 190 preferably in relation to performance of the system, such as a rate at which cache hits are achieved based on existing parameters. Step 310 preferably includes the concurrent management of multiple independent streams.
The foregoing embodiments provide several advantages over the art. Using both time and locality factors in making speculative cache decisions generally provides a better assessment of overall trends in performance loading, and more efficiently allocates cache resources to the retention of data. The adaptive techniques set forth above further provide a mechanism to continuously fine tune various caching parameters to meet changing needs of the system, particularly in high activity regions.
The term caching and the like will be construed consistent with the foregoing discussion as the operation to retain data in cache memory that would otherwise be immediately overwritten by new incoming data. The cache memory can be a single device or incorporated as a memory space across multiple devices.
Although not necessarily required, the caching operation preferably comprises making the decision to allocate memory cells in the cache memory currently storing the readback data so as to prevent overwriting of said cells by other data. A subsequent release of such retained data from the cache preferably comprises deallocation of said cells to permit subsequent overwriting thereof by newly introduced cached data.
For purposes of the appended claims, the recited “first means” will be understood to correspond to at least the cache manager 190 which carries out data caching operations in accordance with FIG. 11 .
It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the invention, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, the particular elements may vary depending on the particular application without departing from the spirit and scope of the present invention. | Method and apparatus for caching and retaining non-requested speculative data from a storage array in an effort to accommodate future requests for such data. A cache manager stores requested readback data from the storage array to a cache memory, and selectively transfers speculative non-requested readback data to the cache memory in relation to a time parameter and a locality parameter associated with a data structure of which the requested readback data forms a part. The locality parameter preferably comprises a stream count as an incremented count of consecutive read requests for a contiguous data range of the storage array, and the time parameter preferably indicates a time range over which said read requests have been issued. The speculative readback data are transferred when both said parameters fall within a selected threshold range. The data structure preferably comprises a RAID stripe on a selected storage device of the array. | 6 |
FIELD OF THE INVENTION
This invention relates generally to end loaders and attachments therefor, and is particularly directed to a quick attachment arrangement for allowing a first unlatched implement such as a bucket, sweeper, pallet fork, etc., to be removed from an end loader and a second replacement implement to be securely attached to the end loader without requiring the operator to leave the operating position on the end loader and manually tend to the attachment arrangement. This invention also allows an implement to be automatically attached to the end loader without operator manual intervention whether the latching mechanism is in the closed, latched configuration or the open, unlatched configuration.
BACKGROUND OF THE INVENTION
End loaders are commonly used for performing various industrial and agricultural tasks. The typical end loader is comprised of a vehicle, such as a tractor, having a pair of flexible arms typically extending from the front end of the vehicle, where the arms can be raised and lowered for performing work. Various types of implements may be attached to the ends of the arms for performing such tasks as lifting, sweeping, digging, grading, etc. Thus, the implement attached to the end loader may take the form of a scoop or a fork structure for lifting and transporting an object or loose material such as dirt or stone, a sweeper for cleaning a surface, or a grader for working the ground. In virtually all cases, the load bearing or load moving implement is of high strength and is typically comprised of a strong metal such as steel and is thus of considerable weight.
Because the various implements discussed above are designed to perform a specific task, it is necessary to change implements when the performance of various tasks is required. It is thus highly desirable to facilitate and simplify the removal of one implement from and the attachment of another implement to the end loader's movable arms. Unfortunately, there is a great variety of lift arm attachment arrangements, where the specific design of the attachment arrangement is determined by the individual implement or end loader manufacturer. Some end loader attachment arrangements make use of a pair of vertically spaced, horizontally aligned mounting pins which are adapted for engagement by upper and lower pairs of grooves, or slots, on the ends of the end loader arms. Another attachment scheme makes use of left and right brackets, each adapted to receive a generally vertically oriented connecting pin for attaching the implement to the ends of the end loader's two lift arms. The various attachment arrangements incorporate different connecting hardware and employ different installation and removal procedures in attaching and releasing the implement from the end loader and are thus incompatible.
A typical attachment device used for attaching an implement to a pair of end loader arms typically has a first side adapted for connection to the ends of the end loader arms and a second, opposed side for connecting to the implement. In some cases, part of the attachment arrangement is incorporated in the attachment device, while another part of the attachment arrangement is mounted integrally with the implement. For example, U.S. Pat. No. 4,986,722 discloses an implement attachment arrangement having a first locking pin 106 disposed on one end of a bucket 50 which is adapted for engaging an attachment carrier 30 mounted to an end of the end loader's moveable arm 22 . Also attached to the movable arm 22 is an actuator mechanism having contact pin 122 which engages a handle 118 of locking pin 106 for moving the pin to a locking position as the attachment is rocked about a pivotal axis by an attachment cylinder. This complicated arrangement requires mutually engaging components of the latching mechanism on the implement as well as on the end loader. Preferably, the entire latching mechanism would be located on either the implement or the end loader to simplify its design and eliminate the requirement for precise alignment of the implement and loader arms for attaching/detaching the implement.
The latching mechanism also typically requires manual intervention by the end loader operator in releasing an implement from or attaching an implement to the end loader's arms. More specifically, the end loader operator must set the latch mechanism to a release configuration for disconnection of the implement from the end loader or set the latch mechanism to an engagement configuration for attaching the implement to the end loader. This requires the end loader operator to leave the operating position on the end loader twice in changing the implement attached to the end loader, once to disconnect the implement to be released and a second time to connect a replacement implement. This procedure is inefficient and subjects the operator to possible injury during implement release from or attachment to the end loader's arms. In addition, the operator's manual intervention in the attachment procedure raises the possibility of subsequent implement detachment due to human error.
The present invention addresses the aforementioned limitations of the prior art by providing an attachment arrangement for mounting an implement to the arms of an end loader which is self-contained on the end loader arms and requires only a pair of fixed, spaced, parallel mounting pins on the implement. This inventive quick attachment arrangement allows an implement to be attached to the end loader's arms regardless of the configuration of the latching mechanism, and the implement may be removed and replaced with another implement attached to the arms without requiring the end loader operator to leave the operating position for the purpose of manually manipulating the latching mechanism.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved arrangement for connecting an implement to the arms of an end loader which is reliable, self-contained on the ends of the end loader arms, and does not require the end loader operator to leave the operator's seat to change implements.
It is another object of the present invention to provide a latching mechanism for removably mounting an implement to the ends of a pair of end loader arms which does not require manual intervention by the end loader operator.
Yet another object of the present invention is to provide a quick attachment device for attaching an implement to an end loader which is self-contained and includes no moving parts on either the implement or the arms of the end loader.
A further object of the present invention is to provide a connection arrangement for an implement on the end of a pair of boom arms such as on an end loader which employs a pair of latching pins which undergo linear displacement along their respective lengths as well as pivoting displacement in latching the implement to, as well as unlatching the implement from, the boom arms.
This invention contemplates apparatus for attaching an implement having upper and lower mounting pins to a movable arm of an end loader, the apparatus comprising: a bracket pivotally coupled to the movable arm; an upper support member on the bracket adapted to engage and retain the upper mounting pin of the implement; a lower slot in the bracket adapted to receive the lower mounting pin of the implement; first and second apertured members disposed on the bracket; a latch pin disposed in the apertures of the first and second apertured members and movable between a first unlatched position, wherein the latch pin is substantially clear of the lower slot and the lower mounting pin may be removed from the lower slot, and a second latched position, wherein the latch pin is disposed across the lower slot and the lower mounting pin is connected to the bracket for attaching the implement to the end loader arm; a biasing member coupled to the latch pin for urging the latch pin to the second latched position; and a catch portion of the latch pin for engaging the first apertured member and maintaining the latch pin in the first unlatched position to allow the lower mounting pin to be removed from the lower slot as the lower mounting pin engages and pivotally displaces the latch pin in a first direction for maintaining the latch pin's catch portion in engagement with the first apertured member, and wherein a second lower mounting pin attached to a second implement inserted in the lower slot engages and pivotally displaces the latch pin in a second opposed direction for removing the latch pin's catch portion from engagement with the first apertured member and allowing the latch pin to move to the second latched position by means of the biasing member in attaching the second implement to the end loader.
This invention further contemplates apparatus for attaching an implement having upper and lower mounting pins to a movable arm of a vehicle, the apparatus comprising: a bracket pivotally coupled to the movable arm; upper and lower slots in the bracket respectively adapted to engage and retain the upper and lower mounting pins; first and second apertured members disposed on the bracket; a latch pin having an angled distal end portion and disposed in the apertures of the first and second apertured members and movable between a first unlatched position, wherein the latch pin is clear of the lower slot allowing the lower mounting pin to be removed from the lower slot, and a second latched position, wherein the latch pin is disposed across the lower slot and the lower mounting pin is connected to the bracket for attaching the implement to the end loader arm; a biasing member coupled to the latch pin for urging the latch pin to the second latched position; and a catch portion of the latch pin for engaging the first apertured member and maintaining the latch pin in the first unlatched position to allow the lower mounting pin to be inserted in and removed from the lower slot, wherein the lower mounting pin engages the end of the latch pin when inserted in the lower slot with the latch pin in the first unlatched position for pivotally displacing the latch pin and removing the latch pin's catch portion from engagement with the first apertured member and allowing the latch pin to move to the second latched position under the influence of the biasing member for attaching the implement to the end loader, and wherein the lower mounting pin engages the angled distal end portion of the latch pin when inserted in the lower slot and the latch pin is in the second latched position for urging the latch pin to the first unlatched position and allowing the lower mounting pin to be inserted in the lower slot whereupon the lower mounting pin pivotally displaces the latch pin so as to disengage the latch pin's catch portion from the first aperture member allowing the latch pin to assume the second latched position in attaching the implement to the end loader.
BRIEF DESCRIPTION OF THE DRAWINGS
The appended claims set forth those novel features which characterize the invention. However, the invention itself, as well as further objects and advantages thereof, will best be understood by reference to the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings, where like reference characters identify like elements throughout the various figures, in which:
FIG. 1 is a side elevation view showing a bucket implement attached to an arm such as of an end loader by means of an attachment device in accordance with the principles of the present invention;
FIGS. 2–5 are vertical sectional views of the attachment device of the present invention illustrating the position of various components of the attachment device during insertion in and removal from the attachment device of an implement mounting pin, and further illustrating the attachment device in the unlatched and latched configurations;
FIGS. 6 , 7 and 8 are vertical sectional views illustrating the series of steps involved in attaching an implement to the attachment device of the present invention with the attachment device's latching pin, or plunger, in the up, unlatched position;
FIGS. 9 , 10 and 11 are vertical sectional views illustrating the series of steps involved in attaching an implement to the attachment device of the present invention with the attachment device's latching pin the down, latched position;
FIGS. 12 , 13 and 14 are vertical sectional views illustrating the series of steps involved in detaching an implement from the attachment device of the present invention; and
FIGS. 15 , 16 and 17 are respectively top plan, front elevation and side elevation views of a second embodiment of a quick attachment arrangement in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , there is shown a side elevation view of an implement such as a bucket 28 connected to a loader arm 22 such as of an end loader by means of a quick attachment arrangement 20 in accordance with the principles of the present invention. Attached to an aft portion of the bucket 28 is a mounting bracket 34 . Attached to the loader arm 22 is a hydraulic cylinder 24 for raising and lowering the loader arm as well as the bucket 28 attached thereto. The attachment device 26 of the present invention is attached to the hydraulic cylinder 24 and the loader arm 22 by means of respective first upper and lower mounting pins 30 a and 30 b . A second, opposed portion of the attachment device 26 is connected to the bucket mounting bracket 34 by means of second upper and lower mounting pins 32 a and 32 b.
Referring to FIGS. 2–5 , there are shown vertical sectional views of a quick attachment arrangement 20 including an attachment device 26 in accordance with the present invention illustrating the attachment device configuration when being attached to, and when removed from, a mounting pin of an implement. Referring to FIGS. 6 , 7 and 8 , there are shown vertical sectional views of the quick attachment arrangement 20 of the present invention illustrating the series of steps involved in engagement of the attachment device 26 with a bucket 28 with the latch pin, or plunger, 40 in the up, or retracted, position. Referring to FIGS. 9 , 10 and 11 , there are shown vertical sectional views of the quick attachment arrangement 20 of the present invention illustrating the series of steps involved in engagement of the attachment device 26 with bucket 28 with latch pin 40 in the down, or extended, position. Referring to FIGS. 12 , 13 and 14 , there are shown vertical sectional views of the quick attachment arrangement 20 of the present invention illustrating the disengagement sequence of attachment device 26 from bucket 28 . The configuration and operation of the quick attachment arrangement 20 shown in these figures will now be described in detail.
The attachment device 26 of the quick attachment arrangement 20 of the present invention includes a plate 27 which is pivotally connected to and through which extend first upper and lower mounting pins 30 a and 30 b . The attachment device 26 may also include a second plate (not shown) in spaced relation from plate 27 , with the first upper and lower mounting pins 30 a , 30 b connected to and extending between the two spaced, generally parallel plates. Each of the first upper and lower mounting pins 30 a , 30 b is connected to an aft portion of the attachment device's plate 27 . A forward portion of the attachment device 26 includes an upper U-shaped support groove, or surface, 36 and a lower slot 38 , each of which is integrally formed with the attachment device's plate 27 . Attachment device 26 further includes an upper catch plate 42 and a lower guide plate 44 mounted to the attachment device's plate 27 . Catch plate 42 and guide plate 44 are in vertical alignment and each includes a respective aperture within which is positioned an elongated latch pin, or plunger, 40 . Also attached to the attachment device's plate 27 is a face plate 52 which is in contact with the lower guide pin 44 and engages a lower end portion of latch pin 40 . Latch pin 40 includes a notch 40 b in the surface thereof and an angled end portion 40 a on the lower end thereof. The latch pin's notch 40 b is adapted to engage an inner edge portion of the upper catch plate 42 where the catch plate's inner edge defines the aperture through which the latch pin extends. The latch pin's angled end portion 40 a is adapted to engage a bottom mounting pin 32 b when attaching the attachment device 26 to an implement as described in detail below.
As shown in FIG. 6 , attachment device 26 is initially maneuvered so as to position the upper mounting pin 32 a of the bucket 28 within the upper U-shaped support groove 36 located within an upper portion of the attachment device's plate 27 . This is accomplished by orienting the attachment device 26 at an inclined angle and raising the attachment device in the direction of arrow 25 shown in FIG. 6 . The lower portion of the attachment device 26 is then moved toward the bucket 28 in the direction of arrow 56 shown in FIGS. 7 and 8 so as to position the bucket's second lower mounting pin 32 b within the attachment device's lower slot 38 as shown in FIG. 8 . Latch pin 40 is shown in FIGS. 6 and 7 in the raised position to allow the bucket's second lower mounting pin 32 b to be inserted in the attachment device's lower slot 38 . However, the attachment device 26 is also adapted to receive the bucket's second lower mounting pin 32 b within its lower slot 38 with latch pin 40 in the lowered position as described in detail below.
As shown in the various figures, a coil spring 46 is disposed about and attached to latch pin 40 . Coil spring 46 engages and is disposed between the upper catch plate 42 and a roll pin 43 inserted through latch pin 40 . Coil spring 46 urges latch pin 40 downward to the latched position wherein the lower end of the latch pin extends across lower slot 38 in plate 27 . As stated above, notch 40 b in latch pin 40 is adapted to engage an inner surface of upper catch plate 42 . In this manner, latch pin 40 may be securely maintained in a retracted, upraised position even while being urged in a downward direction by coil spring 46 . In the upraised position, latch pin 40 does not extend across lower slot 38 within the attachment device's plate 27 . When in the upraised, retracted position as shown in FIGS. 6 and 7 , only the lower end of latch pin 40 extends into an upper portion of the attachment device's slot 38 . Latch pin 40 may be moved to the full down, extended position by expansion of coil spring 46 by laterally displacing the latch pin so that its catch notch 40 b is no longer in engagement with the upper catch plate 42 . Latch pin 40 may be laterally displaced so as to no longer engage catch plate 42 by engagement of the lower end of the latch pin by the bucket's second lower mounting pin 32 b during automatic operation of quick attachment arrangement 20 as described in the following paragraph.
In accordance with automatic operation of the quick disconnect arrangement 20 of the present invention, the bucket's second lower mounting pin 32 b is moved in the direction of arrow 29 in FIG. 2 and into the attachment device's lower slot 38 . When this occurs, the second lower mounting pin 32 b engages the lower end of latch pin 40 forcing a lower portion of the latch pin into engagement with a pivot point 44 a on an inner surface of the lower guide plate 44 defining the aperture therein. With the lower end of pivot pin 40 displaced in the direction of arrow 29 in FIG. 2 , the upper portion of the pivot pin is pivotally displaced about the pivot point 44 a in a second direction opposed to that of arrow 29 . It is in this manner that the catch notch 40 b of pivot pin 40 becomes disengaged from catch plate 42 as shown in FIG. 2 , allowing coil spring 46 to urge pivot pin 40 downward across the lower slot 38 within the attachment device 26 as shown in FIG. 4 . It is in this manner that the attachment device 26 is automatically connected to an implement such as bucket 28 with latch pin 40 initially in the unlatched position without requiring manual intervention by the end loader operator or anyone else. This sequence of automatic operation of the attachment device 26 is also shown in FIGS. 6 , 7 and 8 .
Bucket 28 may also be automatically connected to attachment device 26 with latch pin 40 initially in the full down position as shown in FIGS. 9 , 10 and 11 . In this configuration, latch pin 40 is in the full down position prior to connecting bucket 28 to attachment device 26 as shown in FIG. 9 . As the lower portion of the attachment device 26 is displaced in the direction of arrow 51 in FIG. 9 toward bucket 28 with the bucket's second upper mounting pin 32 a disposed within the attachment device's upper U-shaped support groove 36 , the bucket's second lower mounting pin 32 b engages the latch pin's angled lower end portion 40 a as shown in FIG. 10 . Continued displacement of the second lower mounting pin 32 b into lower slot 38 causes upward displacement of latch pin 40 . In addition, the force exerted on the lower end of latch pin 40 by the second lower mounting pin 32 b causes pivoting displacement of the latch pin about pivot point 44 a on lower guide plate 44 . This causes the lower end of latch pin 40 to move in a direction opposite to that of arrow 51 in FIG. 9 and the upper portion of the latch pin to move in the direction of this arrow. This causes the latch pin's catch notch 40 b to be displaced away from the inner portion of catch plate 42 defining the aperture therein so that the latch pin is freely slidable within the upper catch plate 42 . This allows latch pin 40 to be displaced downward under the influence of coil spring 46 and to assume the full down position after insertion of the second lower mounting pin 32 b within lower slot 38 as shown in FIG. 11 . It is in this manner that latch pin 40 assumes the latched configuration even when the latch pin is in the fully extended, or down, position prior to insertion of the second lower mounting pin 32 b in lower slot 38 .
Referring to FIGS. 12 , 13 and 14 , there is shown the disengagement sequence for disconnecting bucket 28 from attachment device 26 . In FIG. 12 , latch pin 40 is shown in the full up, unlatched position. This is achieved by manually engaging handle 48 connected to latch pin 40 by nut and bolt combinations 50 a , 50 b and moving the handle in the direction of arrow 45 in FIG. 12 . Thus, handle 48 and latch pin 40 are displaced upward and to the right as shown in FIG. 12 causing the latch pin's catch notch 40 b to engage the inner surface of catch plate 42 so as to maintain latch pin in the upraised, unlatched position shown in FIG. 12 . The lower portion of attachment device 26 is then displaced in the direction of arrow 47 by moving end loader arm 22 in a rightward direction as shown in FIG. 13 . This causes the bucket's second lower mounting pin 32 b to be removed from the attachment device's lower slot 38 as shown in FIGS. 12 and 13 . As the bucket's second lower mounting pin 32 b is removed from the attachment device's lower slot 38 , the second lower mounting pin engages the lower end of latch pin 40 causing the latch pin to pivot about pivot point 44 b in the lower guide plate 44 . Latch pin 40 may also partially engage a face plate 52 attached to plate 27 and pivot about a point of contact between the latch pin and the face plate. This urges the upper end of latch pin 40 in the direction of arrow 47 in FIG. 13 so as to maintain the latch pin's catch notch 40 b in engagement with the catch plate 42 to maintain the latch pin in the fully upraised, unlatched position shown in FIG. 13 . While lower guide plate 44 and face plate 52 are shown as separate elements in the various figures, they may equally as well be in the form of a single piece of hard, high strength metal such as steel which is the preferred composition of the entire inventive quick attachment arrangement. The attachment device 26 is then lowered in the direction of arrow 49 shown in FIG. 14 by end loader arm 22 to disconnect bucket 28 from the attachment device 26 . With latch pin 40 in the fully upraised, unlatched position, the attachment device 26 is then ready for connection to another implement without requiring manual intervention or reconfiguration of the quick attachment arrangement of the present invention.
Referring to FIGS. 15 , 16 and 17 , there are respectively shown top plan, front elevation and side elevation views of a quick attachment arrangement 60 in accordance with another embodiment of the present invention. Quick attachment arrangement 60 includes a mounting bracket 62 to which are attached a top guide plate 64 and a bottom guide plate 65 . Mounting bracket 62 is adapted for attachment to an arm of an end loader (not shown for simplicity) by means of plural bolt 72 and nut 74 combinations. Each of the top and bottom guide plates 64 , 65 includes a respective aperture, with the apertures in each of these guide plates in vertical alignment. Disposed within the vertically aligned apertures of the top and bottom guide plates 64 , 65 is a movable latch pin, or plunger, 63 . Inserted through latch pin 63 is a roll pin 69 . Disposed about latch pin 63 and between the top guide plate 64 and roll pin 69 is a coil spring 70 which is shown in simplified dotted line form in FIGS. 16 and 17 . Coil spring 70 urges latch pin 63 in a downward direction as viewed in FIGS. 16 and 17 so that the latch pin assumes the latching position as shown in FIG. 17 . Latch pin 63 may be manually raised upward by means of a handle 68 so as to assume the unlatched position wherein the latched pin is clear of a slot 62 a in a lower portion of mounting bracket 62 . Latch pin 63 may be maintained in the retracted, unlatched position by engaging a notch 63 a in a lateral surface of the latch pin with an inner portion of the top guide plate 64 defining the aperture therein as in the previously described embodiment.
Slot 62 a within mounting bracket 62 is adapted to receive a mounting pin 76 attached to an implement, such as the previously described bucket; for attaching the bucket to the arms of an end loader by means of the inventive quick attachment arrangement 60 . A back stop 66 in the form of a 90° bent section of steel is attached to a lateral surface of mounting bracket 62 adjacent the inner end of slot 62 a in the bracket. Back stop 66 engages a lateral portion of a mounting pin 76 attached to an implement (not shown for simplicity) inserted in slot 62 a for maintaining the mounting pin securely in position in the slot of mounting bracket 62 . The lower end of latch pin 63 includes first and second beveled portions 63 b and 63 c . An upper portion of mounting pin 76 includes a beveled corner 76 a which is adapted for engaging the latch pin's shorter first beveled end portion 63 b when inserting mounting pin 76 into slot 62 a . The engagement of the mounting pin's beveled corner 76 a with the latch pin's shorter first beveled end portion 63 a facilitates rightward movement of mounting pin 76 and upward displacement of latch pin 63 for connecting the mounting pin to mounting bracket 62 . Engagement of the rounded upper corner 76 b of mounting pin 76 with the longer second beveled end portion 63 b of mounting pin 63 facilitates leftward displacement of the mounting pin and upward movement of the latch pin 76 for disconnecting the mounting pin from mounting bracket 62 .
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the relevant arts that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The present invention is thus intended to provide a quick attachment arrangement between an end loader and virtually any type of load bearing or work performing implement with which end loaders operate. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art. | An attachment device for releasably securing an implement such as a bucket, pallet fork, etc., to the arms of an end loader includes a self-contained latching mechanism. The latching mechanism extends between the arms and has a first upper U-shaped support groove and a lower slot for receiving and engaging respective upper and lower elongated mounting pins of the implement. A linearly movable latch pin, or plunger, is disposed adjacent the lower slot for locking the implement's lower mounting pin in position within the slot in attaching the implement to the end loader. The latch pin also undergoes a pivoting motion during mounting pin insertion and removal to allow for automatic implement attachment to and disconnection from the end loader without the end loader operator having to leave the end loader and manually tend to the attachment device. | 4 |
RELATED APPLICATION
This is a continuation-in-part of U.S. patent application Ser. No. 08/936,892, filed Sep. 25, 1997, now abandoned and assigned to the same assignee as the present Application. The subject matter of the present Application is related generally to the subject matter of U.S. patent application Ser. No. 09/198,715 and the subject matter of U.S. patent application Ser. No. 09/199,019, both filed of even date herewith, and both assigned to the same assignee as the present Application.
FIELD OF THE INVENTION
This invention relates to nuclear magnetic resonance logging, and, more particularly, to a method and apparatus for magnetic resonance logging of an earth borehole to obtain information about properties of formations surrounding the earth borehole.
BACKGROUND OF THE INVENTION
General background of nuclear magnetic resonance (NMR) well logging is set forth, for example, in U.S. Pat. No. 5,023,551. Briefly, in NMR operation the spins of nuclei align themselves along an externally applied static magnetic field. This equilibrium situation can be disturbed by a pulse of an oscillating magnetic field (e.g. an RF pulse), which tips the spins away from the static field direction. After tipping, two things occur simultaneously. First, the spins precess around the static field at the Larmor frequency, given by ω 0 =γB 0 , where B 0 is the strength of the static field and γ is the gyromagnetic ratio. Second, the spins return to the equilibrium direction according to a decay time T1, the spin lattice relaxation time. For hydrogen nuclei, γ/2π=4258 Hz/Gauss, so, for example, for a static field of 235 Gauss, the frequency of precession would be 1 MHz. Also associated with the spin of molecular nuclei is a second relaxation, T2, called the spin-spin relaxation time. At the end of a ninety degree tipping pulse, all the spins are pointed in a common direction perpendicular to the static field, and they all precess at the Larmor frequency. However, because of small inhomogeneities in the static field due to imperfect instrumentation or microscopic material heterogeneities, each nuclear spin precesses at a slightly different rate. T2 is a time constant of this "dephasing".
A widely used technique for acquiring NMR data both in the laboratory and in well logging, uses an RF pulse sequence known as the CPMG (Carr-Purcell-Meiboom-Gill) sequence. As is well known, after a wait time that precedes each pulse sequence, a ninety degree pulse causes the spins to start precessing. Then a one hundred eighty degree pulse is applied to keep the spins in the measurement plane, but to cause the spins which are dephasing in the transverse plane to reverse direction and to refocus. By repeatedly reversing the spins using one hundred eighty degree pulses, a series of "spin echoes" appear, and the train of echoes is measured and processed.
Further Background, set forth in the referenced copending parent application Ser. No. 08/936,892, is summarized as follows: The static field may be naturally generated, as in the case for the earth's magnetic field B E . The NML™ nuclear logging tool of Schlumberger measures the free precession of proton nuclear magnetic moments in the earth's magnetic field. See, for example, U.S. Pat. No. 4,035,718. The tool has at least one multi-turn coil wound on a core of non-magnetic material. The coil is coupled to the electronic circuitry of the tool and cooperatively arranged for periodically applying a strong DC polarizing magnetic field, B P , to the formation in order to align proton spins approximately perpendicular to the earth's field, B E . The characteristic time constant for the exponential buildup of this spin polarization is the spin-lattice relaxation time, T 1 . At the end of polarization, the field is rapidly terminated. Since the spins are unable to follow this sudden change, they are left aligned perpendicular to B E and therefore precess about the earth's field at the Larmor frequency f L =γB E . The Larmor frequency in the earth's field varies from approximately 1300 to 2600 Hz, depending on location. The spin precession induces in the coil a sinusoidal signal of frequency f L whose amplitude is proportional to the number of protons present in the formation. Additives in the borehole fluid are required to prevent the borehole fluid signal from dominating the formation signal. The tool determines the volume of free fluid in the formation.
A further nuclear magnetic resonance approach employs a locally generated static magnetic field, B o , which may be produced by one or more permanent magnets, and RF antennas to excite and detect nuclear magnetic resonance to determine porosity, free fluid ratio, and permeability of a formation. See, for example, U.S. Pat. Nos. 4,717,878 and 5,055,787.
Nuclear magnetic resonance has proven useful in medical applications to perform noninvasive examinations of the interior organs and structures of an organism. See P. Mansfield, Pulsed Magnetic Resonance: NMR, ESR, And Optics, 317-345 (D. M. S. Baugguley ed., Cleardon Press, Oxford, 1992). The desire for faster imaging led to the development of commercial and laboratory NMR imaging systems in the medical field which use various gradient-echo techniques consisting of radio frequency pulses, α, in combination with switched magnetic field gradients to generate an image. See Stewart C. Bushong, Magnetic Resonance Imaging: Physical And Biological Principles, 279-286, (2d edition, 1996). Known techniques such as fast low angle shot (FLASH) and fast imaging with steady state precession (FISP) require an RF excitation pulse, α, of approximately 90° while other techniques vary the flip angle between 30° and 70° to maximize magnetic resonance strength.
As pointed out in the referenced copending Application, the tools and techniques developed in the prior art have various drawbacks that limit their utility in practical applications. These limitations include a shallow depth of investigation and restrictions on the shape and size of the region of investigation.
SUMMARY OF THE INVENTION
In the referenced copending U.S. patent application Ser. No. 08/936,892 there is disclosed an apparatus and technique for NMR logging that is based on non-resonant excitation and refocusing and exhibits a number of advantageous features: The volume of investigation is large compared with the conventional resonant operation. Also, the signal coming from different depths can be differentiated by its Larmor frequency. The technique thereof utilizes a pair of magnetic field generating sources, preferable orthogonally wound coils, that can be energized with large currents in a controlled manner to produce orthogonal magnetic fields in the formation. With appropriate switching of the currents, the direction of the generated magnetic field in the formation can then be changed abruptly. The rate of change of the direction of the magnetic field in the formation has to be fast compared to the local Larmor frequency. This way, the spins cannot follow the direction of the magnetic field and the spins end up orthogonal to the applied magnetic field. Effectively, it is as though all the spins have undergone a 90° pulse. (In the conventional resonant excitation, only spins where the applied field is within a particular small range are excited. In practise, this leads to relatively thin shells of sensitive regions.) Now, the spins undergo a free induction decay with a Larmor frequency proportional to the local field produced by the presently activated coil. Since the field produced by the coil in the formation is highly non-uniform, there is a large range of Larmor frequencies and the net magnetization will decay very quickly (that is, T* 2 is very short). This dephasing can be reversed by forming an echo which is achieved by reversing the field abruptly after a time t. The sense of rotation for the precessing spins is reversed and an echo is formed at a total time 2t, when the magnetization of all the spins is in phase again. This can then be repeated over and over to obtain a train of echoes. The condition for abrupt field reversal is that the rate of change of direction of the applied field has to be fast compared to the Larmor frequency. For appropriate electromagnetic coils, Larmor frequencies generally in the range of up to 250 kHz can be expected. This would indicate that the reversal should be fast compared to about 4 μs. As described in the referenced copending Application, the condition of extremely fast reversal can be alleviated by first reducing the current in the coil to a lower level. This does not change the direction of the total field appreciably, provided it is large compared to background field. The condition of fast reversal will then be significantly reduced, because now it only has to be fast compared to the lowered Larmor frequency. The abrupt change of current direction can thus be replaced by a sine shaped modulation. A condition is that the zero crossing around values of ± background field occurs fast compared to the Larmor frequency corresponding to the background field. For the earth's magnetic field, the reversal should therefore be fast compared to a fraction of a millisecond.
As will be treated in further detail hereinbelow, a limitation on the just described operation of a pulsed gradient logging technique arises because a background magnetic field (e.g. earth's magnetic field) can cause imperfect refocusing, and very fast decay of the echoes, since it will be adding to the applied magnetic field during part of a pulse cycle and subtracting from the applied magnetic field during another part of the cycle. This disadvantage is addressed and solved by the present invention.
In accordance with an embodiment of the method of the invention, there is provided a technique for determining a nuclear magnetic resonance characteristic of formations surrounding an earth borehole, comprising the following steps: providing a logging device that is moveable through the borehole; providing, on the logging device, first and second coils having respective axes that are generally orthogonal; producing, at said logging device, a prepolarizing signal; applying pulse sequence signals to the first and second coils, the pulse sequence signals implementing repeated refocusing of spins in the formations by both adiabatic and non-adiabatic reorienting of the spins to form spin echoes; and detecting, at the logging device, the spin echoes from the formations, the spin echoes being indicative of said nuclear magnetic resonance characteristic of the formations.
In a preferred embodiment of the invention, the adiabatic reorientations are performed by varying simultaneously the signals in the first and second coils.
The technique of the invention is operative in a setting wherein a background magnetic field (e.g. earth's magnetic field, which is always present in the formations) introduces a spurious phase component to the spins during the indicated non-adiabatic reorientations. The adiabatic reorientations used in the invention are operative to rotate the spins over a range of angles such that the background magnetic field introduces a further phase component to the spins, the further phase component substantially cancelling the spurious phase component.
Further features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram, partially in schematic and partially in block form, that can be used in practicing embodiments of the invention.
FIG. 2 is a diagram of a cross-section of an embodiment of a logging device for logging while drilling that can be used in practicing embodiments of the invention.
FIG. 3, which includes FIGS. 3A and 3B, shows pulse sequences of the type used to obtain spin echoes in pulsed gradient logging as is disclosed in the referenced copending U.S. patent application Ser. No. 08/936,892.
FIG. 4 is a block diagram of a type of circuitry that is utilized in an embodiment of the apparatus set forth in the referenced copending Application, and which can be used in practicing embodiments of the present invention.
FIG. 5 is a diagram that shows the dependence of local Larmor frequency on the angle between the magnetic field produced by a coil B and the component of the static field that is perpendicular to a coil A, and which is useful in understanding the cause of imperfect refocusing due to a background magnetic field such as earth's magnetic field.
FIG. 6 illustrates signals that can be applied to coils A and B to obtain a pulse sequence in accordance with an embodiment of the invention, and in which adiabatically rotated pulses are used.
FIG. 7 is a diagram of the type first shown in FIG. 5, and which is useful in understanding how pulse sequences in accordance with embodiments of the invention can solve the problem of imperfect refocusing.
FIG. 8 illustrates signals that can be applied to the coils A and B to obtain a pulse sequence in accordance with an embodiment of the invention which compensates at every even echo the residual phase shift caused by finite duration of the non-adiabatic field reversal.
FIG. 9 illustrates signals that can be applied to the coils A and B to obtain a pulse sequence in accordance with another embodiment of the invention which compensates at every even echo the residual phase shift caused by finite duration of the non-adiabatic field reversal.
FIG. 10, which includes FIGS. 10A and 10B, shows how the angle between the applied field and the background field varies with time, how the phase accumulates (hatched lines or unhatched lines), and where echoes form, using pulse sequence in accordance with an embodiment of the invention. The first 2n-1 echoes are not perfectly refocused in the presence of the background field, the 2nth echo being perfectly refocused. In FIG. 10A, n=1, corresponding to the pulse sequence in FIG. 9. The diagram of FIG. 10B is for n=3.
FIG. 11 illustrates signals that can be applied to the coils A, B, and C as a variation of the FIG. 9 approach to obtain a pulse sequence which compensates at every even echo the residual phase shift caused by finite duration of the non-adiabatic field reversal.
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown an apparatus for investigating subsurface formations 31 traversed by a borehole 32, which is generally of the type described in the referenced copending U.S. patent application Ser. No. 08/936,892 and which, with the features described herein, can be used in practicing embodiments of the present invention. An investigating apparatus or logging device 30 is suspended in the borehole 32 on an armored cable 33, the length of which substantially determines the relative depth of the device 30. The cable length is controlled by suitable means at the surface such as a drum and winch mechanism. Surface equipment, represented at 7, can be of conventional type, and can include a processor subsystem, communicates with the downhole equipment. Although the logging device or tool 30 is shown as a single body, it may alternatively comprise separate components, and the tool may be combinable with other logging tools. Also, while a wireline is illustrated, alternative forms of physical support and communicating link can be used, for example in a measurement while drilling system.
The tool 30 has a pair of coils, respectively designated as coil A and coil B, wound on a non-conductive core 120, which may be, for example, a non-conductive, magnetically permeable core made of a suitable material such as ferrite, laminated permealloy, or tape-wound metglass. A non-conductive, non-magnetically permeable core could also be used. In the embodiment of FIG. 1, the axis of the logging tool (and the core 120) is a longitudinal axis. The coils A and B are wound on axes that are mutually orthogonal, and are both orthogonal to the longitudinal axis. The coils A and B are preferably elongated in the axial direction, with the elongated legs of the conductor loops thereof being parallel to the longitudinal axis of the tool. The angular density of the windings is preferably sinusoidal to insure a two-dimensional dipolar field distribution. The coils A and B are azimuthally offset by 90° to obtain dipolar field characteristics for the coils A and B that are orthogonal in the formation and to minimize mutual inductance of the coils A, B. The coils can be protected by a nonconductive, nonmagnetic, abrasion and impact resistant cover made of a suitable material such as fiberglass, plastic, ceramic, or a composite of these materials. Another coil, designated coil C, which can be used in embodiments of the system described in the referenced copending application Ser. No. 08/936,892, and in embodiments hereof, is wound around the longitudinal axis of the core 120. Thus, all three coils are mutually orthogonal.
As noted in the referenced copending U.S. patent application Ser. No. 08/936,892, the deep NMR gradient logging apparatus can be utilized in a logging-while drilling application. FIG. 2 illustrates a cross section of an NMR logging device 30 in the form of a logging-while-drilling tool. The tool 30 includes a mud channel 32 for carrying the borehole fluid through the drill string and a drill collar 34 which has a reduced outer diameter at the section shown. The orthogonal coils A and B are wound on a magnetically permeable, laminated core 38 made of a suitable material such as ferrite, laminated permealloy, or tape wound metglass. The protective cover is shown at 36.
FIGS. 3A and 3B illustrate types of signals and spin echoes that are utilized in the above referenced copending U.S. patent application Ser. No. 08/936,892. Coil A is used to generate a static magnetic field that polarizes the spin magnetization. The spin magnetization is polarized by applying a direct current to the coil A for a period of time approximately equal to or greater than the longitudinal relaxation time, T 1 , of the formation, thereby aligning the spins along the magnetic field from coil A, namely, B 0 . The technique of the copending U.S. Patent Application Serial No. refocuses the magnetic moment of protons (spins) in the highly inhomogeneous field B 0 by reversing the direction of precession. Following polarization, coil A is turned off and coil B, driven by either commutated direct current (FIG. 3A) or low frequency alternating current (FIG. 3B) is turned on, and produces a magnetic field B 1 . The spins initially aligned with B 0 start precessing in the plane that is perpendicular to B 1 at a precession frequency that is proportional to the strength of B 1 . Reversing the direction of precession brings the spins to the phase at which they started precession, thus generating a gradient-echo, which is shown as being detected in coil A. The free induction decay (FID) signal arising from the volume of investigation in the formation decays rapidly due to the inhomogeneous field. In the preferred embodiment of the technique set forth in the referenced copending Application, the gradient echoes are measured and the FID is not measured. As noted above, the gradient-echoes are detected using coil A.
FIG. 4 shows a type of circuitry utilized in the above referenced copending U.S. patent application Ser. No. 08/936,892 to implement pulsed gradient logging with a coil arrangement of the type shown in FIG. 1. The output of a current source 450 is coupled to coils A and B. Electronic switches S a and S b are respectively coupled in series with coils A and B, and capacitor 452 is coupled across the switch-coil combinations. The output of coil A is coupled to a receiving section that includes an amplifier 454 and an analog-to-digital converter 456. The output of the analog-to-digital converter 456 is coupled to a downhole controller/processor 458, which can be provided with the usual associated memory, timing, integer or floating point processor, and input/output circuitry (not separately shown). An output of the controller 458 is coupled to a programmable pulse generator 460 which, in turn, is coupled to the input of the current source 450. The controller/processor and programmable pulse generator also control the switches S a , S b and enable the receiving section. Telemetry/storage circuitry 462 is conventionally provided for communicating with the earth's surface. As described in the referenced copending Application, there are three modes of operation: polarization, switch-over, and measurement. The polarization phase has a duration of approximately 0.01 to 8 seconds, based on the formation and the composition of the fluid in the rock pores. During the polarization phase, the nuclear spins in the formation are brought to their thermal equilibrium state in the magnetic field of coil A. Current source 450 drives direct current through coil A. Switch S a is closed and switch S b is open. These switches are controlled by the programmable pulse generator 460 and the controller 458. The amplifier 454, analog-to-digital converter 456, and coil B are inactive. At steady state, the capacitor 452 is charged up and current through the capacitor 452 ceases to flow. The entire current output of the current source 450 flows through coil A. The amplifier 454 includes a DC blocking capacitor and a limiter to protect the amplifier from the large voltage on coil A during the polarization and switch-over phases. Once the polarization phase ends, the switch-over phase begins with turning off the current source 450. Coil A and capacitor 452 form a resonator wherein the current in coil A is supplied by capacitor 452. When the current through coil A becomes zero, switch S a opens and switch S b closes, thereby switching coil A with coil B in the resonator with minimal loss of energy. Now, the current source 450 drives the resonator formed by coil B and capacitor 452 at its resonance frequency. The current source 450 can output either commutated direct current or low frequency alternating current at the resonant frequency. In either case, the current through coil B is alternating. The period of this alternating current determines the inter-echo time, T E . The successive reversals of the magnetic field of coil B repeatedly refocus the phases of precessing spins thereby forming a sequence of equally spaced gradient-echoes. The period and the inter-echo time are preferably equal and approximately 1 msec.
As is further described in the referenced copending U.S. patent application Ser. No. 08/936,892, the frequency of the detected signal can be mapped to radial position in the formation to obtain an image of the formation, and reference can be made to said copending Application for further details of this feature.
The degree of refocusing with the pulse sequence of FIGS. 3A, 3B is affected by the presence of background fields, such as earth's magnetic field. To demonstrate this, choose at any given point in the formation a local coordinate system such that the z axis coincides with the tool axis and the x axis with the direction of the field produced by coil B: B 1 =B 1 x. An arbitrary background field can then be written as B e =B e (sinθcosφx+sinθsinφy+cosθz). The Larmor frequency at each point is proportional to the magnitude of the total field, |B 1 +B e | and is given by: ##EQU1## where γ is the gyromagnetic ratio. This is plotted in FIG. 5. When the current in coil B is reversed, the angle φ changes by 180°. If the Larmor frequency with positive current +I B in the coil is given by point "1" in FIG. 5, then the Larmor frequency with negative current -I B is shown as point "2" and is, in general, different from point "1".
Depending on the starting angle φ, each successive echo of the echo train of a pulse sequence forms incrementally a little earlier or later than in the absence of a background field. This will lead to a rapid decrease in echo amplitude, even in the absence of any relaxation or diffusion process.
The decay time can be estimated as follows. Assume that the fields of the coils can be approximated as a two-dimensional dipole field, and that the background field is uniform (e.g. earth's magnetic field). In a concentric shell around the tool, the amplitude B 1 is constant, but the angle φ is evenly distributed between 0° and 360°. At a nominal echo at time t, the background field causes an extra uncompensated phase shift of Δα(t)≈γB e tsinθcosφ. For each shell, this leads to ((Δα(t)) 2 ).sub.φ ≈1/2γ 2 B 2 e t 2 sin 2 θ. The echo amplitude decays like exp{-1/2((Δα(t)) 2 )}, leading to a 1/e decay time T t 2 of ##EQU2## It can be noted that this decay time is independent of the applied field strength, B 1 (in the limit B 1 >>B e ). Therefore, the signal from every shell will decay with the same time constant. For the earth magnetic field, 2/γB e ≈0.15 ms, the lower limit for T t 2 when the earth's field is perpendicular to the tool axis. Unless the earth's field is exactly aligned with the tool axis, Equation (2) shows that the background field causes a very fast decay of the signal. The pulse sequences hereof reduce or eliminate this decay.
[It can be noted that there is an additional decay when the background field becomes comparable to the applied field beyond a certain depth. This decay is not eliminated with the pulse sequences hereof. The cause of this decay is that the effective field before and after the non-adiabatic reversal are not exactly antiparallel. This means that some of the transverse magnetization will become longitudinal magnetization and not contribute any more to the subsequent echoes. Unlike the dephasing process discussed above, this decay process is only important when the size of the background field becomes comparable to the applied field. The echo attenuation depends on the detail of the pulse sequence, but it is of the order of 1-(B e cosθ/B 1 ) 2 per echo.]
Pulse sequences of embodiments of the invention do not suffer from the rapid dephasing discussed above. With these new pulse sequences, the echo refocuses even in the presence of a static background field, either uniform or non-uniform.
The new pulse sequences hereof consist of combinations of adiabatic and non-adiabatic (sudden) changes of the magnetic field. The non-adiabatic field reversals are already used in the original pulse sequence of FIGS. 3A, 3B above, and are essential to the formation of echoes. The new features, the additional adiabatic rotations before and after the non-adiabatic reversal, are used to average out the angular dependence of the Larmor frequency, shown in FIG. 5. Desirable pulse sequences with these features can be constructed in various ways, e.g. the rotations can be performed about different axes with different angles.
An embodiment of the new pulse sequence is shown in FIG. 6. As before, the spins are polarized by the field produced by coil A, which is then switched non-adiabatically to coil B. Next, the direction of the field is turned adiabatically by 180° degrees at every point in the formation (as long as B 1 >>B e ), by energizing the coils A and B with currents that have approximately a sin t and cos t dependence, respectively. Then, the field is switched non-adiabatically by 180° as in the original pulse sequence. [In this and subsequent diagrams, the non-adiabatic field reversals are shown in bold line.] Afterwards, the field is again rotated adiabatically by 180°. This leads to an echo (shown centered on the vertical dashed line) that is detected with coil A. Subsequent echoes are generated by repeated application of the refocusing cycle.
The key is that before and after the non-adiabatic reversal, the spins do not accumulate phase according to the Larmor frequency associated with a single angle φ (see FIG. 7), but with the whole range between point 1 and 2. After the non-adiabatic switching, the spins experience exactly the same range of values of Larmor frequency as before. This ensures that the phase accumulated before and after the switching exactly cancel, independent of background field.
The condition for adiabatic change of the field direction is, in general, that the direction has to change slowly compared with the instantaneous Larmor frequency. As noted above, this is expected to typically be in the 10 to 100 kHz range, i.e. the adiabatic change can be in the ms range or even faster. It is not critical that the two coils A and B are matched exactly, as long as the adiabatic condition is fulfilled. However, the current shapes before and after the sudden, non-adiabatic reversal should be identical. A further advantage of this pulse sequence is that it makes the echo formation immune to small dc offset in the driving circuitry.
The sign of the current in coil A between the echoes determines whether the field direction is rotated about +180° or -180°. Present analysis does not indicate whether any particular order is preferable. In the basic sequence shown in FIG. 6, positive currents are shown for all A pulses. Another possibility is to alternate the sign of the A current pairs after every echo. This might affect the accumulated Berry's phase.
In the pulse sequence shown in FIG. 6, each non-adiabatic field reversal is abrupt. As was discussed above, the abrupt change can be replaced by a more gradual change as long as the reversal is fast compared to the Larmor frequency of the background field. Essentially, the field strength is first reduced without changing the direction significantly. This is followed by the sudden, non-adiabatic reversal. Then, the field strength is increased again to the same magnitude as before. With the finite reversal time, there are now additional phase shifts associated with the period of field reduction and increase before and after the sudden reversal. In general, they do not cancel exactly, for the same reason as before: the Larmor frequency is not identical for positive and negative currents in the coil when a background field (e.g. earth's magnetic field) is present. For the sequence shown in FIG. 6, these residual phase shifts accumulate and will lead to an extra echo decay, similar to the situation in the original pulse sequence. This problem is solved with the two pulse sequences shown in the embodiments of FIGS. 8 and 9. In these sequences, the residual phase shifts have alternating signs and do not accumulate. Every second echo is unaffected.
The sequence of FIG. 8 consists of two different subcycles. The first subcycle is identical to the one shown in FIG. 6, except that the finite duration of the non-adiabatic inversion has been made explicit. This subcycle consists of an adiabatic 180° rotation, a non-adiabatic 180° rotation, followed by an other adiabatic 180° rotation. In order to cancel the residual phase shift due to the finite duration of the non-adiabatic 180° rotation, the first subcycle is followed by the second subcycle that consists of an adiabatic 360° rotation, a non-adiabatic 180° rotation, followed by another adiabatic 360° rotation.
The second sequence shown in FIG. 9 has only a single subcycle. It consists of an adiabatic 90° rotation, a non-adiabatic 180° rotation, followed by an other adiabatic 90° rotation. A single subcycle does not refocus the echo completely, even in the limit of abrupt non-adiabatic 180° rotation. However, two subcycles in series will compensate the accumulated phase shifts, both for zero and finite reversal times.
In both of the sequences (FIGS. 8 and 9), the duration of the non-adiabatic 180° reversals should be as short as possible, while the duration of the adiabatic rotations should be sufficiently slow. Spins closest to the borehole, experiencing the largest Larmor frequencies, are hardest to reverse non-adiabatically. This is a feature that could be exploited to attenuate the signal from close to the tool.
The pulse sequence shown in FIG. 9 is an example of a more general pulse sequence. In general, a compensated pulse sequence can be constructed from repeated applications of cycles of the following form:
C=A.sub.180°/2n -S.sub.180° -A.sub.180°/2n(3)
where A.sub.α indicates that the direction of the applied field direction is rotated adiabatically through an angle α, and S 180 ° indicates a sudden reversal of the applied field direction.
A single cycle C will form an echo in the absence of any background field, but will only refocus imperfectly in the presence of a background field. However, after 2n cycles, the echo will refocus completely, even in the absence of background fields. These properties can be understood with the help of the diagrams shown in FIGS. 10A and 10B. These Figures show the trajectory that the angle φ (angle between the applied field and the component of the background field orthogonal to the tool axis) undergoes during the pulse sequence. The circle indicates the starting position. After every sudden reversal, the sign of the phase accumulation changes. This is indicated in the Figure by a change from hatching to an absence of hatching. After 2n cycles, the angle φ is again at the starting position, and all the paths have been traveled twice with opposite sign--resulting in no net phase accumulation and a perfect echo formation. There will be one perfect echo and 2n-1 minor echoes.
For even values of n, it might be advantageous to reverse the direction of rotation after every 2n cycles. Using diagrams such as shown in FIG. 10, it will be understood that many new pulse sequences could be constructed from a combination of cycles with different values and/or signs of n.
A complication of the pulse sequences hereof, as described so far, is that between echoes, current is applied to the same coil as is used to detect the echoes. Note however that the applied current and the detected signal occur at different frequencies. In addition, when extra time intervals with constant currents in the B coil are inserted in the pulse sequence (as shown in FIG. 6 and FIG. 8), the echoes form when no current is applied in the detecting coil. A further approach involves the use of a third coil, C (e.g. in FIG. 1), that is orthogonal to both coil A and coil B. In this case, coil A can still be used to polarize the spins, but afterward, coil C can be used (in conjunction with coil B), instead of coil A, to refocus the echoes. The echoes will still be detected with coil A, but in such case no currents will be applied any more after the polarization period (as was the case in the pulse sequences of FIGS. 3A and 3B). An example of this approach, as a modification of the pulse sequence of FIG. 9, is shown in FIG. 11, wherein coil A is used for prepolarization and echo detection (as in FIG. 9), but not for generation of the sinusoidal component, which is now implemented in coil C. In the circuit of FIG. 4, coil C can be appropriately controlled in a manner similar to that shown for coils A and B. | A technique is provided for determining a nuclear magnetic resonance characteristic of formations surrounding an earth borehole, including the following steps: providing a logging device that is moveable through the borehole; providing, on the logging device, first and second coils having respective axes that are generally orthogonal; producing, at the logging device, a prepolarizing signal; applying pulse sequence signals to the first and second coils, the pulse sequence signals implementing repeated refocusing of spins in the formations by both adiabatic and non-adiabatic reorienting of the spins to form spin echoes; and detecting, at the logging device, the spin echoes from the formations, the spin echoes being indicative of the nuclear magnetic resonance characteristic of the formations. | 6 |
[0001] The present invention relates to a process for producing a target intended to be used in deposition processes carried out in a vacuum or in an inert or reactive atmosphere, especially by magnetron sputtering or by ion beam sputtering.
[0002] According to another aspect of the invention, it also relates to a molybdenum-based target possibly obtained by implementing said process and to the use of such a target for the purpose of obtaining films based on the material sputtered from said target, and also to a composition of the compound for producing said target by the process according to the invention.
[0003] Various techniques for manufacturing targets, including certain powder forming techniques, are known. Thus, the targets in question may result from a casting process or a powder sintering process followed by forming operations, often hot forming, and then assembly on a support, or direct assembly of sintered segments, or less conventionally a technique of thermal spraying and more particularly a plasma spraying technique.
[0004] These targets are intended to be used in processes commonly employed on an industrial scale for thin film deposition, especially on a glass substrate, such as for example the magnetron sputtering process. In this process, a plasma is created in a high vacuum close to a target comprising the chemical elements to be deposited. The active species of the plasma, by bombarding the target, tear off said elements, which are deposited on the substrate, forming the desired thin film.
[0005] In the specific case of a target intended for depositing molybdenum, a nonreactive deposition process is used in which the plasma is composed only of a sputtering gas, preferably a noble gas of the Ar, Kr, Xe or Ne type. This process is implemented for large substrates and may enable thin films to be deposited on substrates, for example flat glass sheets with sides of more than 6 m in length.
[0006] These targets have a planar geometry or a tubular geometry.
[0007] Planar targets have the advantage of being able to be integrated in cathodes of relatively simple architecture compared with cathodes dedicated to rotary targets, which are much more complex. However, planar targets have a utilization factor which is generally 50% or less, which is not the case for rotary targets that have a utilization factor substantially greater than 50%.
[0008] In the specific case of thin molybdenum films, molybdenum being a particularly expensive metal, it is preferred to use rotary targets of cylindrical geometry, as described in the U.S. Pat. No. 4,356,073 since these targets have a material yield (representing the proportion of sputtered material relative to the amount of material available on the target for producing a thin film) of greater than 70%, preferably greater than 75%. However, various other magnetron target geometries are known: planar (disk, square, rectangular) geometries and the invention is also applicable to geometries other than cylindrical ones.
[0009] The following literature data for pure molybdenum are given below:
density: 10.28 g/cm 3 ; thermal expansion: 4.8×10 −6 K −1 ; Young's modulus: 324 N/mm 2 ; electrical resistivity: 5.34 μohms·cm; thermal conductivity: 139 W/mK; melting point: 2630° C.
[0016] Furthermore, there are also other vacuum processes for depositing molybdenum other than magnetron sputtering using a target: these include laser sputtering (laser ablation using a pulsed or continuous laser) and ion beam sputtering for example. These processes may also benefit from the use of a target according to the invention.
[0017] As regards more particularly molybdenum magnetron targets or those made of other refractory metals, many inventions have been filed relating to the following processes and forming the subject matter of the patent applications listed below:
Patent applications EP 1 784 518, US 2008/0193798 and WO 2006/041730:
[0019] Pressing then sintering of an ingot or a preform (under a pressure of 200 to 250 MPa and at a temperature of 1780 to 2175° C.) followed by hot forming (at about 900° C.) of this preform by rolling or extrusion or forging. Generally, this process also includes a heat treatment in hydrogen or a reducing atmosphere in order to reduce the oxide content in the target and optionally a stress relaxation annealing treatment.
Also known, from patent application WO 2006/117145, is the complete or partial construction, or restoration, of targets by cold spraying, which consists in spraying a gas/powder mixture at supersonic velocity, the powder not being in the molten state, thereby differing from the thermal spraying processes.
[0021] Although the above documents also cover the production of targets having various compositions using these methods, pure molybdenum targets usually have the following properties:
purity: >99.95%; density: >95% of the theoretical density; fine-grained microstructure.
[0025] Targets having these characteristics are sputtered so as to obtain thin films that are used for example as electrodes for photovoltaic applications based on an active material belonging to the chalcopyrite family (CIS or CIGS for example). Molybdenum provides a good compromise between electrical conductivity (less than 30 μohms·cm), temperature resistance (refractory properties: melting point: 2610° C.) and high selenization resistance. This is because molybdenum has a higher resistance to the selenium-rich atmosphere used during the CIS or CIGS deposition step, molybdenum reacting on the surface with selenium to form an MoSe 2 passivating layer without losing its electrical conduction properties, or else for TFT (thin film transistor) applications that require extremely low defect (“pinhole”) densities. Maximum pinhole densities of 500/m 2 with a size between 1 and 5 μm may especially be mentioned. Such quality levels can be achieved only if the sputtering process is devoid of any electrical instability of the arcing type. This is especially possible when the target has significantly no porosity, i.e. with a density of at least 90%.
[0026] Although the processes for obtaining a target by plasma spraying are known not to give properties similar to those obtained previously, the present invention is applicable to a process for producing a molybdenum-based target by plasma spraying that offers performance in use at least equal to, if not better than, that obtained by conventional manufacturing processes.
[0027] For this purpose, the process according to the invention for producing a target by thermal spraying, especially by plasma spraying by means of a plasma torch, said target comprising at least one molybdenum-based compound, is characterized in that at least one fraction of said compound in the form of a powder composition of said compound is sprayed by thermal spraying onto at least one surface portion of the target in an inert gas atmosphere, and in that powerful cryogenic cooling jets directed onto the target during its construction and distributed around the torch are used.
[0028] It will be recalled that fluids with a temperature equal to or below −150° C. are considered by definition to be cryogenic fluids.
[0029] The use during plasma spraying of cryogenic cooling jets (cryogenic liquid jets or mixed cryogenic gas/liquid jets or cryogenic gas jets) enables the quality of the target to be improved, while providing two functions:
immediate cooling of the sprayed zone, thereby precluding any possibility of partial oxidation or nitriding (by the presence of even small traces of oxygen or nitrogen in the chamber) of the sprayed material; and powerful cleaning of the sprayed surface so as to provide excellent clean cohesion between the particles and successive passes.
[0032] Moreover, the use of a plasma torch and a plasma gas mixture make it possible to obtain a strong reduction in flight of the sprayed powder particles, thus reducing the oxide content present in the target compared with that present in the powder (T oc <T op where T oc is the oxygen content present in the target and T op is the oxygen content present in the powder).
[0033] Furthermore, the process according to the invention includes the following, more conventional, aspects:
a relative movement between the plasma torch and the target is established; the surface of the target is prepared prior to deposition of said compound; the surface preparation includes a step of blasting it with a jet of abrasive particles (called sandblasting) on the surface portion of the target in question, or alternatively a step of machining striations suitable for the keying of the sublayer; and the surface preparation then includes the spraying of a film of a keying material (sublayer) on the surface portion of the target in question.
[0038] In other embodiments of the invention, one and/or other of the following arrangements may furthermore be optionally employed:
the compound is sprayed in a chamber that has been purged or rinsed and then filled with inert gas, up to a pressure that may range from 50 mbar to 1100 mbar, so as to create an oxygen-depleted atmosphere within it (% O 2 <5%); the thermal spraying is carried out by a plasma torch and the plasma gas mixture used is reducing (capable of reducing the oxidized molybdenum content initially present in the powder), preferably the composition of the plasma gas mixture comprising more than 10% hydrogen or another reducing plasma gas; a keying sublayer is used, this being deposited, before thermal spraying of said compound, on the surface portion of the target in question; the target is thermally regulated during the plasma spraying; a powder composition of said sprayed compound is used comprising powder particles with a size distribution given by 5<D 10 <50 μm; 25 μm<D 50 <100 μm; and 40 μm<D 90 <200 μm; the oxygen content present in the target in oxide form is more than 5% less than that initially present in the starting powder; it includes a subsequent heat treatment step in a reducing atmosphere for the purpose of reducing the oxygen content present in the target after the thermal spraying step; and several compound injectors are used for injecting, at different points of the thermal jet, different materials for which the injection parameters are adjusted independently according to the materials injected into each injector.
[0047] Another aspect of the invention relates to a target optionally produced by the process according to the invention and intended to be used in a sputtering device, especially a magnetron sputtering device, or in any other vacuum sputtering device using a target, said target comprising predominantly molybdenum.
[0048] For this purpose, the target, according to the invention, of nominal thickness (e), comprising at least one molybdenum-based compound, is characterized in that it has:
a lamellar microstructure; an oxygen content of less than 1000 ppm, preferably less than 600 ppm, and even more preferably less than 450 ppm; and an electrical resistivity less than five times, preferably three times and more preferably twice the theoretical electrical resistivity of the compound.
[0052] This resistivity measurement is carried out using the Van der Pauw (ASTM F76) method, the relative resistivity measurement being calculated relative to the theoretical value at 20° C. of the passive compound (or the value obtained from the literature) (as a reminder, molybdenum has a resistivity of 5.34 μohms·cm).
[0053] In preferred embodiments of the invention, one and/or other of the following arrangements may furthermore be optionally employed:
the target also includes at least one addition element chosen from vanadium, niobium, tantalum, chromium, tungsten, rhenium, copper, zirconium, titanium, hafnium and rhodium, the target having 0.5 to 30% by weight of the addition element or the addition elements.
[0055] In this case, the addition element or elements may be provided by one of the following means:
use of a prealloyed powder in which each powder particle has the desired composition of the target, possibly slightly different in order to take into account any unequal losses by volatilization during the thermal spraying of the powder; use of a powder blend consisting, on the one hand, of pure or prealloyed molybdenum powder and, on the other hand, of one or more other pure or prealloyed powders so that the final composition of the target is that desired; and use of two or more powders, each being injected by a different channel into the thermal jet during the thermal spraying step.
[0059] According to another embodiment of the target, this is composed of molybdenum and silicon in molar proportions that may range from 1 mol of molybdenum per 5 mol of silicon up to 5 mol of molybdenum per 1 mol of silicon, preferably 1 mol of molybdenum per 2 mol of silicon;
the lamellar microstructure of the target is composite and comprises lamellae of pure molybdenum juxtaposed with lamellae of pure silicon; the target has a planar geometry; the target has a tubular geometry; the target has additional thicknesses of material at each of its ends; the target comprises one or more parts on which the compound is deposited; said part(s) is (are) either a planar support that can be fitted onto a sputtering machine or intermediate parts that are then bonded onto this support; the additional thicknesses are around 25 to 50% of the nominal thickness of the compound layer; the target has a density of greater than 85%, preferably greater than 90% (density measured according to the ISO 5016 standard); the nominal thickness (e) is between 1 and 25 mm, preferably between 6 and 14 mm; the target has an iron content of less than 50 ppm, preferably less than 35 ppm; the target has an Ni content of less than 20 ppm, preferably less than 10 ppm; the target has a Cr content of less than 50 ppm, preferably less than 20 ppm; the target has a tungsten content of less than 300 ppm, preferably less than 200 ppm; the target has a purity of at least 99.95%; and the target is constructed on a support material providing characteristics compatible with the expected properties of a magnetron target in use (sufficient mechanical strength, sufficient thermal conductivity, resistance to corrosion by the water for cooling the target during use, etc.), such as for example copper or a copper alloy, or austenitic stainless steel, such as for example X2CrNi18-9 or X2CrNiMo17-12-2.
[0074] According to yet another feature of the invention, this relates to a molybdenum-based or MoSi 2 -based film obtained by sputtering the above target.
[0075] In preferred embodiments of the invention, one and/or other of the following arrangements may furthermore optionally be employed:
the molybdenum film has a resistivity of less than 25 μohms·cm, preferably less than 20 μohms·cm.
[0077] According to yet another aspect of the invention, this relates to a flat display screen, which screen may be obtained by one of the following technologies: TFT (Thin Film Transistor), LCD (Liquid Crystal Display), PDP (Plasma Display Panel), OLED (Organic Light-Emitting Diode), ILED (Inorganic Light-Emitting Diode) or FED (Field Emission Display), or else to a semiconductor component that includes at least one Mo-based or MoSi 2 -based film, or else the invention relates to an MoSi 2 film that is used as a mask in the fabrication of a semiconductor component.
[0078] According to yet another aspect of the invention, this relates to at least one electrode formed from a molybdenum-based film obtained using a target as described above, this electrode being used in a photovoltaic cell or module.
[0079] According to yet another feature of the invention, this relates to a molybdenum film obtained by sputtering the above target.
[0080] In preferred embodiments of the invention, one and/or other of the following arrangements may furthermore be optionally employed:
the film has a resistivity of less than 20 μohms·cm, preferably less than 17 μohms·cm, for a film thickness of between 80 nm and 500 nm; the film has an oxygen content of less than 250 ppm, preferably less than 220 ppm; the film has a nitrogen content of less than 50 ppm, preferably less than 30 ppm; the film has an iron content of less than 50 ppm, preferably less than 40 ppm; the film has a nickel content of less than 10 ppm; the film has a chromium content of less than 20 ppm; the film has a tungsten content of less than 150 ppm; and the film also includes at least one addition element chosen from vanadium, niobium, tantalum, tungsten, rhenium, copper, zirconium, titanium, hafnium and rhodium, the film having 0.5 to 30% by weight of the addition element or addition elements.
[0089] As nonlimiting examples, the invention may be illustrated by the following figures:
[0090] FIGS. 1 a , 1 b and 1 c are views showing the microstructure in cross section of an Mo target obtained by the production process according to the invention;
[0091] FIGS. 1 a and 1 b show a very dense structure, the interparticle connections being difficult to distinguish because of the absence of oxide lamellae;
[0092] FIG. 1 c at high magnification makes it possible to distinguish the typical lamellar structure of thermal spraying processes;
[0093] FIGS. 2 a and 2 b are views showing the microstructure in cross section of an Mo target obtained by conventional production processes, namely by extrusion and sintering respectively, followed by hot forming;
[0094] FIG. 2 a relates to a tubular target, its hot forming (extrusion) with unidirectional grain texturing along the extrusion direction being clearly revealed; and
[0095] FIG. 2 b relates to a planar target, its microstructure being conventional for sintering microstructures.
[0096] Other features and advantages of the invention will become apparent over the course of the following description.
DETAILED DESCRIPTION OF THE INVENTION
[0097] The support on which the target will be constructed may be made of copper, a copper alloy, stainless steel or any other alloy suitably compatible with the production of magnetron targets. In the present invention, no particular requirement associated with the process described in the invention is required that relates to the support such that it only has to meet the usual requirements relating to magnetron targets, in terms of geometry, mechanical strength and chemical inertness with respect to the cooling water.
Surface Preparation of the Support
[0098] After having been degreased, the surface of the support is prepared by blasting it with a jet of abrasive grains. These grains may be of various kinds: corundum (fused white alumina) grains, brown corundum grains, alumina-zirconia abrasive grains, abrasive grains produced from fuse-cast slag particles (of the Vasilgrit type), almandine garnet grains or else angular steel or cast iron shot (this list not being exhaustive).
[0099] Preferably, the following abrasives are used: corundum (fused white alumina), and alumina-zirconia (for example AZ 24 from Saint-Gobain Coating Solutions) (this material is preferred for its high toughness that limits fracturing of the grains and consequently the inclusion of grain fractions in the surface—such inclusions are deleterious to adhesion of the coating). The average diameter of the abrasive grains is preferably between 180 and 800 μm, depending on the type of abrasive. The purpose of this operation is to give a surface roughness capable of ensuring correct adhesion of the tie sublayer or of the molybdenum-based compound.
[0100] An alternative method consists in machining striations that will also allow good adhesion of the sublayer or the molybdenum compound.
Production of a Tie Sublayer by Thermal Spraying
[0101] To optimize the mechanical adhesion of the functional layer of the target, a tie sublayer may be produced by thermal spraying. This operation may employ conventional thermal spraying processes taken from the following: plasma (powder) spraying, electric-arc (wire) spraying, oxy-gas flame spraying (wire or powder depending on the equipment), spraying using the HVOF (high-velocity oxy-fuel) process, the detonation gun spraying process and the cold spray process using an optionally preheated gas into which powder is injected. This operation may be carried out in the ambient air without this impairing the invention.
[0102] The tie sublayer material may be chosen from the conventional materials used commonly as sublayers:
nickel or nickel-based alloys: NiAl, NiCr or NiCrAl; iron or ferrous alloys: FeCrAl, FeCrC or FeMnC steels, X2CrNi18-9 or X2CrNiMo17-12-2 austenitic stainless steels, etc.; copper or copper alloys, such as CuAl, CuAlFe, CuZn, etc.; molybdenum or molybdenum alloys: MoCu, etc.
[0106] The above list is not exhaustive, the choice of sublayer material possibly depending on the material of the support tube and on the spraying equipment (and on the availability of filler material in suitable form).
Formation of the Functional Film of the Target According to the Invention, Preferably by Plasma Spraying
[0107] The functional film of the target is formed by thermal spraying, preferably by plasma spraying, under the following particular conditions:
plasma spraying carried out in a chamber having an “inert” atmosphere, that is to say one in which the oxygen and nitrogen content is low, the atmosphere consisting predominantly of inert gas (for example argon), and the pressure in the chamber being between 50 mbar and 1100 mbar; plasma spraying using a reducing plasma gas mixture, making it possible to lower the amount of oxygen initially present on the surface of the powder particles upon melting them and during their flight onto the substrate; use, in the immediate vicinity of the plasma spray torch, of nozzles for blowing powerful liquid or gaseous cryogenic jets of an inert fluid, the jets being distributed around the torch; relative movements between torch and target, allowing possible variation of the thicknesses formed on the target and especially at the ends of the target by forming additional thicknesses commonly referred to as a “dog-bone” target; use of one or more powder injectors, allowing better distribution of the powder within the plasma jet; and it being possible for the plasma torch to be:
either a commercially available DC blown-arc plasma torch; or an inductively coupled RF plasma torch.
[0116] The powder used to produce the target has the following typical characteristics:
defined particle size distribution such that:
D 10% (diameter such that 10% of the particles are smaller in size than this diameter): between 5 and 50 μm; D 50% (median diameter): between 25 and 100 μm; and D 90% (diameter such that 90% of the particles are smaller in size than this diameter): between 40 and 200 μm;
purity according to the purity objectives for the target, preferably greater than 99.95%; and oxygen content: <1500 ppm, preferably <1000 ppm or even <500 ppm.
[0123] The process according to the invention makes it possible to obtain a target quality superior to that conventionally obtained by spraying and having a lamellar structure (cf. FIGS. 1 a , 1 b and 1 c ), especially in the case of pure molybdenum targets, and to obtain a target having an oxygen content of less than 500 ppm directly, without a subsequent step such as a high-temperature heat treatment in a reducing atmosphere.
[0124] The fact of not using a subsequent heat treatment step has the advantage of employing any type of material for the support (tube for a tubular target or flat support for planar targets), including supports having an expansion coefficient markedly different from that of molybdenum, such as austenitic stainless steels, which would be proscribed in the case of a subsequent heat treatment for reducing the oxygen content.
[0125] Of course, a heat treatment may also be carried out, as an option, so as to further reduce the oxygen content in the target thus produced.
Planar Target Case:
[0126] The present invention makes it possible to produce planar targets according to the following procedure:
planar target support, suitable for being fitted into the magnetron for use; if the target support has a complex shape and has to be recycled after the target has been used, the target material will not be formed directly on the target support but on one or more intermediate plates (called “tiles”) which will be bonded onto the support; the target material (molybdenum) will be formed on the support or on the tile(s) following the same procedure as above; and the bonding of the tile(s) may be carried out before formation of the target material (if the support has a high mechanical strength) or after formation of the target material on the tiles in the case in which the support is not strong enough. In the latter case, the dimensions of the tiles will be determined so as to minimize the risk of them being distorted during the operation of forming the target material by plasma spraying.
IMPLEMENTATION EXAMPLE
[0131] The implementation example relates to a tubular target intended to be used in magnetron sputtering with a rotating cathode. The following process was carried out:
support tube made of austenitic stainless steel such as, for example, X2CrNi18-9 or X2CrNiMo17-12-2; surface preparation of the support tube by AZ grit 24 alumina-zirconia abrasive blasting; production of the keying sublayer by twin-arc wire spraying, carried out in air, the keying sublayer having an NiAl (95% nickel/5% aluminum) composition. In the example described, the thickness of the keying sublayer was a nominal 200 μm; formation of the molybdenum active film on the target by plasma spraying under the following conditions:
plasma torch imparting particular plasma jet velocity characteristics and consequently sprayed particle characteristics, target placed in a chamber, use of cryogenic cooling jets directed onto the target, these being distributed around the torch, the powder used for producing the target was a molybdenum powder having the following characteristics:
agglomerated-sintered molybdenum powder particle size d 50 =80 μm 99.95% purity, with in particular 20 ppm of Fe and 600 ppm of oxygen and
plasma spraying carried out with the following parameters:
a plasma torch with the following parameters was used to produce the target of the example:
[0000]
Powder
Ar flow
H 2 flow
Arc
Spraying
flow
rate
rate
current
distance
rate
Parameter
(slpm)
(slpm)
(A)
(mm)
(g/min)
Value
50
14
600
160
160
surface finishing by polishing or machining so as to obtain a roughness such that R max <15 μm.
[0146] As indicated above, thanks to the specific process according to the present invention, the oxygen content in the target obtained was 330 ppm, less than the 600 ppm content initially present in the powder. The essential characteristics of the target obtained are given in the following table (Target Example 4).
[0147] Additional results according to this protocol with different powder compositions, in comparison with a result without a cryogenic jet according to the invention, are given in the table below:
[0000]
Oxygen
Nitrogen
Oxygen
Nitrogen
content
content
content
content
Trial
in the
in the
in the
in the
reference
Process
powder
powder
target
target
A
According
657
18
340
20
to the
invention
B
According
657
18
240
20
to the
invention
C
According
922
26
340
23
to the
invention
D
According
526
29
360
18
to the
invention
E
According
526
29
360
19
to the
invention
F
According
706
31
580
30
to the
invention
G
No
560
29
960
83
cooling
jets
[0148] As the above results show, the plasma spraying process with cryogenic cooling jets distributed around the plasma torch makes it possible to reduce the oxygen content in the target compared with the oxygen content in the starting powder. It is thus unnecessary to choose a very pure starting powder, especially since it is not possible in practice to avoid the powder containing a certain amount of oxygen. The process according to the invention is thus particularly advantageous.
Properties and Advantages of the Invention
[0149] The targets according to the present invention have the following properties and advantages:
better utilization factor of the material used in tubular targets obtained by plasma spraying compared with those obtained by the sintering followed by hot-forming processes because the process according to the present invention offers the possibility of depositing additional thickness at the ends of the targets so as to compensate for the extensive localized erosion in the zones corresponding to the bending, with a small radius of curvature, of the magnetic field created by the cathodes and their magnets. This makes it possible to achieve target material yields greater than 75%, or even 80%, whereas the yields remain below 75% in flat-profile targets. As a corollary to using this type of target, films, especially molybdenum-based films, are obtained whose R □ uniformity profile, along a characteristic dimension of the substrate at the surface of which the film was deposited, deviates by no more than ±2% (for example on a substrate of 3.20 m width). This measurement is carried out using an apparatus of the “Nagy” type by contactless measurement; wide material thickness range on the target between 1 and 25 mm: the thickness of the target may be chosen according to the desired lifetime thereof (this thickness being in fact determined by the expected duration of production without stopping the line); in the case of tubular targets, it is possible to bias the target in AC mode or DC mode with power levels in excess of 30 kW/m (increase in deposition rate), without the risk of cracking (due to the thermal gradient between the support tube and the target) or the risk of braze melting; and because the molybdenum thickness is reduced to the amount strictly necessary for the user, it is possible to limit the voltage needed to sustain the high-power discharge and thus make this target compatible with current magnetron power supplies.
[0154] In the case of monolithic tubular or planar targets produced using the present invention, and in contrast with targets comprising assembled segments, the following risks are considerably reduced:
risk of the appearance of arcing, which generates parasitic particles, and the risk of fragments of the target material being separated from its support, which is known to be a source of contamination of the molybdenum films; risk of sputtering braze material or target support material via the gaps between segments; and risk of thermal or mechanical failure of the bonding (braze or conductive cement) to the support.
[0158] The targets according to the invention are particularly intended to be used in a vacuum film deposition installation (magnetron sputtering in an inert or reactive atmosphere, especially by magnetron cathode sputtering, by corona discharge or by ion beam sputtering), for the purpose of obtaining a film based on the material forming said target, this film being molybdenum-based.
[0159] This molybdenum-based film may be deposited directly on a substrate or indirectly on another film which is itself in contact with a substrate, it being possible for the substrate to be of organic nature (PMMA or PC) or of inorganic nature (silica-based glass, metal, etc.).
[0160] This thin film may form an electrode for a photovoltaic cell or panel, or else it may form part of the constitution (interconnects, etc.) of display screens using TFT, LCD, OLED, ILED or FED technologies, or any other assembly requiring a thin molybdenum film of good quality.
[0161] The films forming the subject matter of the following examples were obtained by magnetron sputtering of various targets obtained according to the prior art (Examples 1 and 3) and according to the invention (Examples 4 and 5):
[0000]
Deposition
Magnetron target
process
Mo thin film
Thickness
O
Fe
Resistivity
Power
Pressure
Thickness
Resistivity
Example
Process
(mm)
(ppm)
(ppm)
(μohms · cm)
(kW/m)
(μbar)
(nm)
(μohms · cm)
1
Sintering
9
<50
60
5.6
30 (AC)
4
88
19.6
2
Sintering
12.5
<50
50
6
10 (DC)
4
180
18.8
3
Plasma
2.2
>700
?
—
20 (DC)
2
172
24.7
spray
(prior
art)
4
Plasma
9
330
9
8.4
30 (AC)
4
88
19.0
spray
5
Plasma
4
300
15
8.5
20 (DC)
2
120
14.0
spray
[0162] The thin molybdenum-based films were deposited on extra-clear glass 3 mm in thickness, of the SGG-Diamant extra-clear glass type. These films were deposited in a horizontal magnetron deposition machine provided with a molybdenum target according to the invention, this target being supplied either in AC mode by a Hüttinger BIG150 power supply or in DC mode by a Pinnacle AE power supply, with an argon plasma of 450 sccm argon in the case of Examples 1 and 4 and 600 sccm argon for Examples 2, 3 and 5.
Comments:
[0000]
Example 4 versus Example 1 and Example 5 versus Example 2: identical or better performance for the target of the invention compared with a high-purity target of the prior art. For an oxygen content <450 ppm in the target, the oxygen content (and therefore the resistivity) in the film is governed by the limiting vacuum in the deposition chamber (amount of oxygen available under the residual pressure);
Example 5 versus Example 3: better performance in the target according to the invention compared with the target according to the prior art. When the oxygen content in the target exceeds 500 ppm, the oxygen content in the film is governed by the purity of the target.
[0165] The targets described in Examples 4 and 5 generate a perfectly stable plasma under DC or AC bias without significant arcing throughout the lifetime of the target.
[0166] As a variant, if a target possibly obtained by the process according to the invention is sputtered, this target possibly containing at least one metal cation belonging to the (Fe, Ni, Cr, W, etc.) family, a film also having a certain content of these elements is obtained.
[0167] The content of cationic impurities in a thin film produced from a rotary target stems practically only from the target. This is because the rotary technology eliminates all components for fastening the target (i.e. clamps) and therefore eliminates any possibility of parasitic sputtering above the glass.
[0168] In most applications, the resistivity of the thin Mo film is especially governed by the oxygen content in the film. It is particularly important to minimize this content so as to maintain a minimum level of oxidation of the film and therefore to obtain a resistivity close to that of pure metallic molybdenum.
[0169] The oxygen content of the film has two origins: (i) oxygen originating from the residual atmosphere (“basic vacuum”) before introduction of the sputtering gas and (ii) oxygen originating from the target.
[0170] Thus, it is possible to calculate the amount of oxygen theoretically included in the molybdenum film, coming from the residual oxygen partial pressure in the sputter coater, using the following:
J O2 (the oxygen flux reaching the glass during deposition)=3.51×10 22 (M O2 ×T) −1/2 ×P, where M O2 is the molecular weight of the oxygen gas, T is the temperature in kelvin and P is the pressure in torr and J MO (the amount of MO on the glass that can react with O 2 )=V Mo ×N Mo , where V Mo is the Mo deposition rate (in cm/s) and N Mo is the amount of Mo atoms per cm 3 in a magnetron metal film (in atoms/cm 3 ).
[0173] Assuming that all the oxygen coming into contact with the molybdenum on the substrate reacts, it is possible to calculate the maximum expected oxygen content in the Mo film; for a given deposition rate on sputter coaters of 8×10 −7 cm/s, the residual oxygen contents in the Mo layer as a function of the residual oxygen partial pressure are obtained as given in the following table:
[0000]
Calculated oxygen content
pO 2 (mbar) in the
coming from the vacuum in
sputtering atmosphere
the Mo film (ppm)
10 −7
1000
5 × 10 −8
540
2 × 10 −8
250
1 × 10 −8
110
5 × 10 −9
54
[0174] The minimum residual partial pressure measured in the sputter coater is conventionally 5×10 −8 mbar, i.e. about 540 ppm theoretical oxygen. It is therefore unnecessary to use high-purity targets with an oxygen content well below 540 ppm since the influence of the target on the purity of the final film is masked by the oxygen coming from the atmosphere in the sputter coater. The invention consists in choosing a less expensive magnetron technology for producing Mo targets, the oxygen content of which is less than 1000 ppm, preferably less than 600 ppm and even more preferably less than 450 ppm.
[0175] The residual content of metal cations (Fe, Ni, Cr, W, etc.) of the thin Mo film obtained within the context of the invention is less than that of the films obtained by conventional targets, for two reasons:
the film of the invention is obtained by sputtering a monolithic target (one single segment): no risk of sputtering the backing tube (made of titanium or stainless steel) or the material used for bonding the Mo to the backing tube (for example indium); and the film of the invention is obtained by sputtering a target of high purity in terms of metal cations, this being dependent on the choice of technology for producing the target and on its implementation: choice of a raw material powder of high purity and forming of the target by plasma spraying, i.e. without direct contact between the sprayed molybdenum and metal parts, as in extrusion or hot-rolling techniques, or contact with metal parts based on steel, stainless steel, tungsten, etc. are possible.
[0178] The molybdenum film according to the invention typically has:
an iron content of less than 50 ppm, preferably less than 40 ppm; and/or a nickel content of less than 10 ppm; and/or a chromium content of less than 20 ppm; and/or a tungsten content of less than 150 ppm. | Target of nominal thickness (e), comprising at least one molybdenum-based compound, characterized in that it has:
a lamellar microstructure; an oxygen content of less than 1000 ppm, preferably less than 600 ppm, and even more preferably less than 450 ppm; and an electrical resistivity less than five times, preferably three times and more preferably twice the theoretical electrical resistivity of the compound. | 2 |
BACKGROUND
Aspects of the present invention relate to propeller protectors, and more particularly, a propeller protector of inboard or outboard marine motor to improve safety to persons or animals in close proximity of a propeller. The blades of the propeller generally have sharp edges that can be hazardous to people or animals that come into contact with the blades. Severe injury is likely when accident occurs with an unprotected propeller.
Marine vessel or watercrafts operators often maneuver or anchor in relatively shallow water in various boating activities such as swimming, fishing, diving, snorkeling, etc. In these activities, the passengers often participate in activities in close proximity of the propeller. While the propeller may be stopped during these activities, its sharp unprotected blades can severely injury any person who may accidentally come into contact with the blades. Furthermore, underwater visibility may not be ideal, thus hindering the ability of the people above or in the water to see the propeller. It is also possible that strong current may be present in the water, and the people in the water may be pushed toward the propeller unknowingly.
Various safety devices have been used to protect a propeller in or out of the water. For example, the propeller may be encased in a cage that allows the propeller to be operated with the cage attached. However, such protective cage may create undesirable drag in the water and reduce the efficiency of the motor. The cage may also decrease the maneuverability of the boat in shallow water.
Various protective covers have been used to cover the propeller. Some covers include individual covers for each blade of the propeller. However, the individual covers may easily be lost or misplaced. Some covers include a box shape enclosure that is sized to cover all the blades. However, known examples of these type of covers generally use some forms of attachment devices or straps to secure or attach the cover to the propeller shaft, or to have an opening that is sized to be smaller than the propeller's size. While some protectors may be adjustable to accommodate different propeller sizes, the adjustment operation is often cumbersome and time consuming in order to install or remove the propeller cover. Therefore, there is still a need for a propeller protector that can be used on propeller of different sizes and can be easily installed and removed while the propeller is submerged, for example, when a boat remains stationary with its engine off in the water or being loaded into the water from a trailer.
BRIEF SUMMARY
Aspects of the present invention are directed to a propeller protector that can accommodate propeller of different sizes and is designed to be easily installed or removed from a propeller. The propeller protector includes a novel retaining device for securing the protector onto the blades of the propeller without using straps or similar devices. The novel retaining device has a high level of adaptability to accommodate blades of different sizes and shapes.
In an embodiment, a protector for protecting a propeller includes a housing having an exterior surface, an interior surface, and an opening facing a first direction for receiving the propeller. A plurality of bendable fingers extend inwardly from the interior surface toward a center portion of the housing, and the fingers are configured to engage one or more blades of the propeller when at least a portion of the propeller is received into the housing through the opening.
In various aspects of the embodiment, the protector may further include a buoyant casing covering at least a portion of the exterior surface of the housing. The buoyant casing may include a flexible material. The buoyant casing may include a plastic material. The buoyant casing may have a bright color.
In various aspects of the embodiment, the plurality of fingers may include at least two layers of bendable fingers, and the layers are spaced apart in the first direction. The at least two layers of bendable fingers may include a first layer and a second layer, and the bendable fingers of the first layer are offset from the bendable fingers of the second layer in a direction different from the first direction. The first layer and the second layer may have different numbers of fingers per layer, or the same number of fingers per layer. The plurality of fingers may be arranged in a radial pattern.
In various aspects of the embodiment, the housing may have a notch on the exterior surface. The protector may further include one or more handles attached to the exterior surface, respectively. One of the handles may be positioned on a side of the housing opposite the opening.
In various aspects of the embodiment, the protector may be configured to be secured on the propeller by utilizing only two or more of the fingers to grip on at least one of the blades.
In various aspects of the embodiment, a shape of the protector opening may be circular, elliptical, rectangular, polygonal, or irregular. The opening may have a width larger than an outside end-to-end dimension of the propeller so as to receive the propeller therein.
In various aspects of the embodiment, the housing (e.g., an inner shell) and the casing (e.g., an outer shell) each have one or more venting holes configured to allow fluid communication between an interior space and an exterior space of the propeller protector.
In various aspects of the embodiment, some of the plurality of fingers may cross each other in a direction different from the first direction (e.g., axial direction). A spacing among the plurality of fingers may be uniform or non-uniform. A space between two adjacent fingers of the plurality of fingers is smaller than a space occupied by a blade of the propeller.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the present invention will be presented in the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a conceptual drawing illustrating a side view of a propeller protector attached to an outboard motor in accordance with an embodiment of the present invention;
FIG. 2 is a conceptual drawing illustrating a front view of a propeller protector in accordance with an embodiment of the present invention;
FIG. 3 is a conceptual drawing illustrating a side view of the propeller protector of FIG. 2 ;
FIG. 4 is a conceptual drawing illustrating a cross sectional view of the propeller protector of FIG. 2 ;
FIG. 5 is a conceptual drawing illustrating a back view of the propeller protector of FIG. 2 in accordance with an embodiment of the present invention;
FIG. 6 is a conceptual drawing illustrating a perspective view of the propeller protector in accordance with an embodiment of the present invention;
FIG. 7 is a conceptual drawing illustrating a back view of a propeller protector in accordance with another embodiment of the present invention.
FIG. 8 is a conceptual drawing illustrating a front view of a propeller protector in accordance with another embodiment of the present invention.
FIG. 9 is a conceptual drawing illustrating a propeller held by two fingers from opposite sides of the blade.
FIG. 10 is a conceptual drawing illustrating a back view of a propeller protector in accordance with another embodiment of the present invention.
FIG. 11 is a conceptual drawing illustrating perspective front and back views of an inner shell for a propeller protector in accordance with another embodiment of the present invention.
FIG. 12 is a conceptual drawing illustrating a perspective view of an outer shell for a propeller protector in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Various aspects of the present invention relate to a propeller protector (e.g., protector for marine or watercraft propeller) that is designed to be utilized when the propeller is not running. Some applications of the propeller protector include keeping swimmers, people, and animals near the non-running propeller, while the propeller is in or out of the water, protected from kicking, striking, hitting, running into, or coming into contact with the propeller in various ways. The propeller protector can also be used for out of water personal protection in the same way while the watercraft or boat is on its trailer.
By way of example, and not limiting, the propeller protector may have an opening that is substantially round in shape and has a circumference that is slightly larger than an average size of a marine propeller. However, the present invention is not limited to any particular size and shape, and the propeller protector may have other suitable shapes and sizes. In some embodiments, the propeller protector may have a suitable buoyance such that the protector will stay afloat if the protector is dislodged from the propeller by accident. In an embodiment, the propeller protector may have an outer shell or casing that may be constructed of a soft buoyant bright colored (e.g., red, yellow, etc.) material (e.g., a foam or spongy material) that encompasses an inner shell partially or completely.
In some embodiments, the inner shell may be constructed of a plastic material or other suitable materials that may have any suitable shapes. A plurality of bendable fingers or resilient elongated members extend from an interior surface of the inner shell. The bendable fingers are configured to keeping the protector secured to the propeller while the propeller is under or out of the water while the propeller is in a non-running state. In some embodiments, one or more handles may extend from respective sides (e.g., back side) of the protector to facilitate handling of the protector. For example, a user may place the protector on or off of the propeller with ease using the handle. In an embodiment, a strap (e.g., a snapping strap) may be used to secure the protector to the propeller for out of water trailered travel of the boat. Hereafter, aspects of the present invention are illustrated in more detail in reference to exemplary embodiments. However, the present invention is not limited as such. Changes and modifications to the illustrated embodiments are within the scope of the present invention as defined in the appended claims.
FIG. 1 is a conceptual drawing illustrating a side view of a propeller protector 10 attached to an outboard motor in accordance with an embodiment of the present invention. The propeller protector 10 has an opening 12 sized (width) to be suitably larger than an outside end-to-end dimension (L) of a propeller 14 . The opening 12 may have any suitable shapes such as circular, rectangular, polygonal shapes, irregular, etc. The propeller protector 10 can be secured on the propeller 14 with or without using other attachment devices that attach to other parts of the outboard motor. In an embodiment, the propeller protector 10 includes a plurality of elongated members (to be described in more detailed below) extending from an interior surface of the protector for securing the protector 10 on the propeller 14 .
FIG. 2 is a conceptual drawing illustrating a front view of a propeller protector 10 in accordance with an embodiment of the present invention. FIG. 3 is a conceptual drawing illustrating a side view of the propeller protector 10 . FIG. 4 is a conceptual drawing illustrating a cross sectional view of the propeller protector 10 . FIG. 5 is a conceptual drawing illustrating a back view of the propeller protector 10 . FIG. 6 is a conceptual drawing illustrating a perspective view of the propeller protector 10 .
In an embodiment, the propeller protector 10 has a round shape opening for receiving the propeller 14 . The propeller protector 10 has a housing 20 (e.g., inner shell) and optionally a casing 22 (e.g., an outer shell, a cover, etc.) covering as least a portion of an exterior surface 25 (see FIG. 4 ) of the housing 20 . The housing 20 may be made of plastic or other suitable materials (e.g., flexible material), and the casing 22 may be made of a buoyant material (e.g., foam) such that the propeller protector 10 may float in water. Therefore, it is easier to recover the protector 10 if it is removed or accidentally dislodged from the propeller. In some embodiments, the casing 22 may be brightly colored to improve its visibility. In some embodiments, the casing 22 may have a thickness of about 1 inch to 1.5 inches.
A number of bendable (or resilient) fingers 24 or beams extend inwardly from an interior surface 26 toward a center portion 28 of the housing 20 . In an embodiment, the fingers 24 may be arranged in a radial pattern. The fingers 24 are suitably spaced apart from each other. In an embodiment, the fingers 24 may be arranged in two or more layers (e.g., see FIG. 4 ) of bendable fingers that are substantially parallel to each other and spaced apart in at least one direction (e.g., X direction in FIG. 4 ) that is substantially normal to the opening 12 . In some embodiments, the number of fingers in each of the layers may be different or the same per layer. In some embodiments, the spacing among the fingers 24 may be non-uniform, uniform, or a combination thereof. In an embodiment, the fingers 24 may be arranged in groups, and the groups are separated from each other. The fingers 24 of different layers may be offset from each other in a direction that is different from the axial direction (e.g., X direction in FIG. 4 ) of the housing 20 .
The fingers 24 have suitable flexibility or bendability so that the fingers 24 can engage at least one or more blades of the propeller 14 when at least a portion of the propeller 14 is received into the housing 20 through the opening 12 . To install the propeller protector 10 , it is orientated such that it's opening 12 faces toward and generally centers on the propeller 14 . Then, the propeller protector 10 is pushed onto the propeller 14 . Because the fingers 24 are bendable, they will be bent as the blades of the propeller 14 force their way through the fingers 24 . The fingers 24 have suitable resilience such that they tend to return to their original shape. Therefore, the blades of the propeller 14 will be held in the space among the fingers 24 because the displaced fingers 24 will exert a force on the blades. The distance (e.g., in the axial direction) between adjacent fingers 24 is suitably designed to be smaller than the space occupied by a blade of the propeller 14 . As such, some of the fingers 24 will remain in a bent position when at least a portion of the propeller (e.g., blades) are located inside the house 20 and surrounded by the bent fingers 24 . The bent fingers 24 , therefore, can exert a force on the propeller or blades from multiple directions (e.g., opposite directions) such that the propeller protector 10 can be sufficiently secured on the propeller 14 using the fingers 24 only. That is, the propeller protector 10 may be secured on the propeller 14 utilizing only two or more of the fingers to grip on at least one of the blades. FIG. 9 is a conceptual drawing illustrating a propeller 14 held by two fingers 24 from opposite sides of the blade. In FIG. 9 , the fingers 24 extend from the interior surface 26 of the housing 20 (e.g., see FIG. 2 ) toward the center portion 28 of the housing.
In some embodiments, a strap 11 (see FIGS. 1 and 6 ) or other similar devices may be used to additionally secure the propeller protector 10 to the propeller 14 . The strap 11 may have a suitable elasticity. The ends 110 of the strap 11 are attached to opposite sides of the propeller protector 10 . One or both ends of the strap 11 may be removably attached to the protector 10 . In some embodiments, the propeller protector 10 may not have the casing 22 . In some embodiments, the housing 20 has a suitable buoyancy. In an embodiment, a handle 30 may be provided at the back of the propeller protector 10 such that a user may maneuver the protector 10 with the handle 30 .
FIG. 7 is a conceptual drawing illustrating a back view of a propeller protector 100 in accordance with another embodiment of the present invention. The propeller protector 100 is substantially similar to the propeller protector 10 , therefore, only their differences will be described herein. The propeller protector 100 has a housing (not shown in FIG. 7 ) and a casing 122 covering the housing. A notch or slot 124 is formed in the housing and/or casing 122 such that when the propeller protector 100 is installed on a propeller, the slot 124 may provide clearance for objects (e.g., parts of an outboard motor, bottom portion of a boat, rudder, etc.) near the propeller. The notch 124 may have any suitable shapes and sizes. In one embodiment, the notch 124 may have a concave shape or any other suitable shapes.
FIG. 8 is a conceptual drawing illustrating a front view of a propeller protector 200 including a plurality of bendable fingers 224 in accordance with another embodiment of the present invention. The propeller protector 200 is substantially similar to the protector 10 . Therefore, only their differences will be described for clarity. While only three bendable fingers 224 are shown in FIG. 8 , the propeller protector 200 actually includes a plurality of bendable fingers 224 extending from all sides of the interior surface similar to those of the propeller protector 10 . Some of the bendable fingers 224 cross each other in a direction substantially perpendicular to an axial direction of the propeller protector 200 .
FIG. 10 is a conceptual drawing illustrating a back view of a propeller protector 300 in accordance with another embodiment of the present invention. The propeller protector 300 is substantially similar to the propeller protectors 10 , 100 , and 200 ; therefore, only their differences will be described herein. The propeller protector 300 has a housing (not visible in FIG. 10 , similar to the housing 20 ) and a casing 322 covering the housing. The propeller protector 300 may have one or more handles 330 on one or more sides of the casing 322 .
FIG. 11 is a conceptual drawing illustrating perspective front and back view of an inner shell 400 for a propeller protector in accordance with another embodiment of the present invention. The inner shell 400 may be used as the inner shell (e.g., housing) of the propeller protectors 10 , 100 , 200 , and 300 . The shape and size of the inner shell 400 may be exaggerated in the drawing for ease of illustration. The inner shell 400 may have any suitable shapes and sizes in various applications. The inner shell 400 may have one or more venting holes 420 at one or more positions. In various embodiments, the venting holes 420 may have any suitable positions, shapes, and sizes. In one embodiment, the venting holes 420 may have substantially the same size and/or shape. In another embodiment, some of the venting holes 420 may have different sizes and/or shapes. The venting holes 420 allow fluid communication between an interior space and an exterior space of the inner shell 400 .
FIG. 12 is a conceptual drawing illustrating a perspective view of an outer shell 500 for a propeller protector in accordance with another embodiment of the present invention. The outer shell 500 may be used as the outer shell (e.g., casing) of the propeller protectors 10 , 100 , 200 , and 300 . The shape and size of the outer shell 500 may be exaggerated in the drawing for ease of illustration. The outer shell 500 may have any suitable shapes and sizes in various applications. The outer shell 500 may have one or more venting holes 502 at one or more positions. By way of illustration and not limitation, two venting holes 502 are respectively located at the side and back of the outer shell 500 . In various embodiments, the venting holes 502 may have any suitable positions, shapes, and sizes. In one embodiment, the venting holes 502 may have substantially the same size and/or shape. In another embodiment, some of the venting holes 502 may have different sizes and/or shapes. The venting holes 502 allow fluid communication between an interior space and an exterior space of the outer shell 500 .
When the venting holes 420 and 502 are featured at the inner and outer shells of a propeller protector (e.g., the propeller protector 10 , 100 , 200 , or 300 ), water or fluid can easily escape from the inside of the propeller protector to the outside thereof.
Although the foregoing has been described in terms of certain embodiments, other embodiments will be apparent to those of ordinary skill in the art from the disclosure herein. Figures are illustrative and not drawn to scale. The described embodiments have been presented by way of example only and are not intended to limit the scope of the disclosure. The various features of the described embodiments may be combined in different ways in different embodiments. Indeed, the novel apparatus and methods described herein may be embodied in a variety of other forms without departing from the spirit thereof. Thus, the invention is not limited by any preferred embodiments, but is defined by reference to the appended claims. | Aspects of the present invention are directed to a propeller protector that can accommodate propeller of different sizes and is designed to be easily installed or removed from a propeller. The propeller protector includes a novel retaining device for securing the protector onto the blades of the propeller without using straps or similar devices. The novel retaining device has a high level of adaptability to accommodate blades of different sizes and shapes. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a solid state light source. It relates particularly to such a light source which is capable of emitting light over a broad spectral band.
In the construction of optical fibre devices which make use of a spectral filtering technique, it is usual to employ tungsten-halogen incandescent filament lamps in order to provide the broad spectral emission width that is necessary. Unfortunately, the filament lamp is a somewhat fragile article and this characteristic makes it unreliable in operation. The need to include such a lamp is likely to cause eventual breakdown of the complete fibre device particularly when this is used under the severe conditions of operation that are sometimes necessary. The degree of ruggedness and reliability that would be desirable in the lamp part can be found in the light emitter diode construction but these devices have inherently a rather narrow spectral emission width (typically 40 nanometers at a wavelength of 900 nanometers) so that a single conventional LED would be incapable of providing the bandwidth required.
One object of the present invention is to provide a solid state light source that will be capable of emitting light over a broad spectral band and which will be reliable in operation.
SUMMARY OF THE INVENTION
According to the invention, there is provided a solid state light source for generating light in the range of visible and infra-red radiation by the recombination of charge carriers comprising, a monolithic light emitter diode structure having an active region which has a bandgap which varies through the thickness of said region, the said region being formed from single crystal semiconductor materials of differing chemical composition, at least one of which materials has a direct energy bandgap, said materials having differing centre wavelengths of light emission, such that the charge carrier recombination occurs at different places through the thickness of the active region and the source is capable of emitting light at wavelengths which are spaced over a broad spectral range.
Preferably, the semiconductor material of the active region comprises at least one compound semiconductor material. The active region may have a bandgap which is narrower on one side than the other. The active region may comprise a gallium aluminium arsenide compound.
Alternatively, the active region may comprise a gallium indium arsenide phosphide compound.
The active region may include barriers arranged to control any charge carrier drift across said region.
BRIEF DESCRIPTION OF THE DRAWINGS
By way of example, some particular embodiments of the invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a graph showing the light wavelengths produced by some commercially available LED devices,
FIG. 2 is a diagram showing the energy bands and wavelengths associated with different compound semiconductor materials systems,
FIG. 3 is a schematic band diagram of a standard light emitter diode structure,
FIGS. 4 and 5 are schematic band diagrams of modified diode structures having graded active regions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows schematically some typical light outputs from existing light emitter diode devices. The horizontal axis gives the wavelength of emission whilst the vertical axis measures the light intensity output. It will be seen that three existing devices have output curves 1 with very sharply defined centre wavelengths. For obtaining light outputs in a short wavelength (about 0.6 to 0.9 micrometers) part of the range the semiconductors used could be based on the GaAlAs/GaAs materials system. For obtaining light outputs in a long wavelength (above 1.0 micrometers) part of the range the InP/GaInAsP materials system would generally be used.
As already explained, the present invention was devised to provide a broad band of light emission, somewhat as depicted by the output curve 2 on FIG. 1.
FIG. 2 is a diagram illustrating the useful parts of these semiconductor materials systems with the horizontal axis showing the Wavelength Corresponding to Energy Gap measured in micrometers. The vertical axis gives the Lattice Constants (in Angstrom Units) for the materials.
An upper horizontal axis shows the Energy Band (measured in electron volts), whilst at the right hand side, lines corresponding to the choice of different device substrate materials have been marked. Using a substrate of indium phosphide and GaInAsP, wavelengths between 1.0 and 1.6 micrometers could be expected. Similarly, using a substrate of gallium arsenide and GaAlAs, wavelengths between 0.6 and 0.9 micrometers should be attainable. This illustration thus confirms the figures for possible wavelength ranges already given.
A first horizontal line portion 3 highlights the properties of GaAlAs/GaAs whilst a second horizontal line portion 4 depicts those for GaInAsP/InP.
FIG. 3 is a schematic band diagram of a conventional gallium arsenide/gallium aluminium arsenide light emitter diode construction. The diagram shows on the horizontal axis 6 the distance (by which the thickness of the active region is measured) and on a vertical axis 7 the electron energy, a greater distance from the origin indicating a higher level of energy of the electrons. Conversely, for holes present in the diagram, a hole nearer the origin will have a higher level of energy than one further from the origin.
In FIG. 3, a very thin active region 8 of semiconductor material is sandwiched between cladding layers 9 and 11 of wider bandgap semiconductor material. The layer 9 is of n-gallium aluminium arsenide whilst the layer 11 is of the same chemical composition but of the p-conductivity type. The sandwiched region 8 is also of p-gallium aluminium arsenide.
In operation, electrons are injected from the wide bandgap cladding layer 9 into the p-type active region 8. Similarly, holes are injected from the cladding layer 11 into the active region 8. The recombination of the electrons and holes occurs in the region 8 and this causes the emission of light. For the construction depicted in FIG. 3, the light is emitted at substantially a single wavelength and this would therefore produce a single one of the output curves 1 of FIG. 1. The energy dimension of the bandgap thus has a single value in the conventional light emitter diode construction.
In the present invention, the energy of the bandgap is graded as in the construction of FIG. 4. With this construction, the recombination of the electrons and holes will now occur with the emission of light L1 of long wavelength from the side of the gap adjacent the p-type material and of short wavelength light L2 from the side of the gap adjacent the n-type material. Intermediate wavelengths of light are also produced as a result of the recombinations which occur at different points along the thickness of the gap.
A possible problem that might occur with this simple structure is that the substantial built-in field due to the grading could cause all the carriers to rapidly drift to the narrow bandgap region of the active layer, thus enhancing the emission at this wavelength.
FIG. 5 depicts an alternative construction that was devised to assist in reducing this effect. This construction incorporates "barriers" 12 within the active region which are intended to retard the carrier drift.
These barriers 12 were formed conveniently of p-type gallium aluminium arsenide and were designed to control tunnelling and thermal emission over the operating temperature range of the device.
The construction of the solid state light source begins with growth of the required semiconductor material which could be by metal organic chemical vapour deposition (MOCVD) or by molecular beam epitaxy (MBE).
In MOCVD, gases such as trimethyl gallium, trimethyl indium, trimethyl aluminium, arsine and phosphine are reacted at atmospheric or low pressure on a heated substrate of gallium arsenide or indium phosphide. P- or n-type dopant materials are incorporated by including dimethyl zinc, hydrogen sulphide, hydrogen selenide or other reagents in the gas stream.
In MBE, elements or compounds containing the required elements are heated in a high vacuum system and impinge upon a heated gallium arsenide or indium phosphide substrate to grow the layers required. Dopants are incorporated by introducing them into the system in the same way. Gaseous sources may also be used to provide the reagents.
After the growth of the required semiconductor material, the diode may then be fabricated using standard semiconductor processing techniques such as the following:
1. Confinement of current to a particular region by dielectric isolation, implantation, diffusion or the growth of burying or current blocking semiconductor regions.
2. Ohmic contact fabrication using diffusion, ion implantation or metallization using titanium, zinc, gold, indium, germanium, platinum, chromium, tungsten, cadmium or other suitable metals deposited by evaporation, sputtering or selective growth.
3. Contact alloying at elevated temperatures.
4. Thinning of wafers by mechanical, chemical or other techniques.
5. Etching of semiconductors using chemical reagents, ion beam milling, reactive ion etching or plasma etching.
Calculation of the required barrier heights and thickness is carried out using quantum mechanical calculations of tunnelling currents through barriers.
The foregoing descriptions of embodiments of the invention have been given by way of example only and a number of modifications may be made without departing from the scope of the invention as defined in the appended claims. For instance, it is not essential that the device construction should be based on the gallium arsenide/gallium aluminium arsenide system. This is capable of giving broadband light emission only over a particular wavelength range. For a different band of emission, alternative materials would be required and a possible choice would be indium phosphide with gallium indium arsenide phosphide. Instead of the barriers specifically described, some alternative means for slowing the charge carrier drift could of course be used. | A solid state light source comprising a monolithic light emitter diode structure having a graded bandgap active region 8 the thickness of which is graded between two materials 9, 11, the said materials having differing center wavelengths of light emission, such that the source is capable of emitting light at wavelengths L1, L2 spaced over the whole spectral width between the wavelengths exhibited by the said two materials. This can enable the light source to be used in optical fibre devices where it can provide on alternative to the filament lamp source and thus give an increased reliability in use. | 7 |
[0001] This application is a continuation of U.S. patent application Ser. No. 12/870,310 filed Aug. 27, 2010 which claims priority to U.S. Provisional Patent Application No. 61/320,957 filed on Apr. 5, 2010.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to concrete forms in general, and to adjustable reusable devices for forming concrete stairs in particular.
[0004] 2. Background Information
[0005] Concrete stairs are a desirable, durable, and relatively inexpensive option for providing pedestrian access between different elevations. As can be seen in FIG. 1 , concrete stairways 12 typically include one or more steps 14 , each having a riser 16 and a tread 18 . The riser 16 extends from bottom end 20 to a top end 22 defining a rise 24 . The riser 16 is arranged substantially parallel to, or slightly offset by an angle α (e.g., 1 to 5 degrees) from, a vertical plane (e.g., a y-z plane). A tread 18 may be described as extending from the top end 22 of the riser 16 to a distal end 26 (e.g., a bottom end 20 of a riser 16 in an adjacent step 14 ) defining a run 28 . The tread 18 is arranged offset by an angle β from the riser 16 (e.g., 90°-α). In embodiments where the treads 18 are substantially parallel to the horizontal plane, the angles α and β are typically complementary.
[0006] One of the drawbacks to concrete stairways is that they are difficult to properly produce, particularly if the stairway is wide and has a large number of steps. The concrete is initially in a semi-liquid state and must be held in place by a form. If the stairway is large enough, the semi-liquid concrete will present a substantial load on the form, and will need to be vibrated during the forming process to ensure the concrete is properly settled. The vibration typically present an additional loading on the forms. As the concrete cures, the exposed surfaces of the concrete must be carefully finished to provide the desired surface texture. In many instances, concrete stairs produced on a build-site are custom formed from lumber, which forms are discarded after the single use. This manner of forming a concrete stair is consequently time-consuming, expensive, and has a substantial risk of error (e.g., forms not assembled correctly vis-à-vis dimensions, forms deflect/warp or break under load, etc. Currently available devices for forming stairs have not met commercial success. These devices often have limited configurability, or are difficult to use, or impede the user's ability to access the concrete during the pour and finishing thereafter, or some combination thereof.
[0007] What is needed is a device that can be used to form concrete stairs, one that is reusable, one that can handle the loads associated with large stairs, one that facilitates the pour and finishing of the stairs, and one that is easily configurable to handle a variety of different stair configurations.
SUMMARY OF THE DISCLOSURE
[0008] According to an aspect of the invention, an apparatus is provided for forming steps within a concrete stairway, wherein each step has a rise and a run. The apparatus includes at least a pair of stringer rails, a plurality of riser brackets, and a plurality of fasteners. Each rail has a lengthwise-extending channel. Each riser bracket has a panel leg and a support leg, wherein one end of the support leg is attached to panel leg. The fasteners are selectively slidable within the rail channel. One of the fasteners attaches the panel leg to the rail and another of the fasteners attaches the support leg to the rail. Each fastener is configurable in a first mode where the fastener is slidably attached to the rail. Each fastener is configurable in a second mode where the fastener is fixedly attached to the rail.
[0009] According to another aspect of the present invention, the apparatus further includes a lateral brace that extends between the rails, and is attachable to each rail. The lateral brace has a length that may be adjustable to accommodate different staircase widths.
[0010] The present invention stair forming apparatus provides several advantages over the prior art. For example, it is reusable and is easily configurable to handle a variety of different stair configurations; e.g., different rise/run, number of stairs, staircase width, etc. The present device can readily handle the loads associated with large stairs. For example, the amount of concrete necessary for a wide staircase with a large number of stairs can cause prior art devices to bow and otherwise distort, particularly in the middle of the wide stair. With the present device, additional stringer rails and lateral braces can be added to accommodate the load, with each rail attached to each brace. Such an application also illustrates another advantage of the present invention, namely that it facilitates the pour and finishing of the stairs. Specifically, during the pouring and finishing processes, the user can support himself on the lateral braces without altering the form configuration and have easy access to the concrete for pouring and finishing and removal of riser panels.
[0011] The foregoing features and the operation of the invention will become more apparent in light of the following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a prior art concrete stairway
[0013] FIG. 2 is a perspective diagrammatic illustration of the present invention stair forming apparatus.
[0014] FIG. 3 is a perspective diagrammatic illustration of a portion of the present invention stair forming apparatus.
[0015] FIG. 4 is a perspective diagrammatic illustration of a section of a rail portion of the present invention stair forming apparatus.
[0016] FIG. 5 is a diagrammatic illustration of a panel leg included in the adjustable concrete form in FIG. 3 .
[0017] FIG. 6 is a diagrammatic illustration of a support leg included in the adjustable concrete form in FIG. 3 .
[0018] FIG. 7 is a perspective diagrammatic illustration of a rail saddle included in the adjustable concrete form in FIG. 3 .
[0019] FIG. 8 is a perspective diagrammatic illustration of a mounting bracket included in the adjustable concrete form in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to FIG. 2 , an adjustable concrete form 10 is provided operable to form a poured concrete stairway 12 . The adjustable concrete form 10 includes a plurality of stringer rails 30 , a plurality of riser brackets 32 , a plurality of fasteners 34 and, optionally, one or more adjustable lateral brace 36 and one or more riser panels 38 . The adjustable concrete form 10 can be used with a variety of site conditions, cheek walls, etc.
[0021] Each stringer rail 30 extends between a bottom end 40 and a top end 42 , defining a length 44 extending therebetween. As can be seen in FIG. 4 , each stringer rail 30 includes a mid section 46 (e.g., a brace mounting section) extending between a first sidewall 48 and a second sidewall 50 . In preferred embodiments, the mid section 46 includes one or more brace fastener apertures 52 , which apertures 52 are typically either circular or elongated. The first and the second sidewalls 48 and 50 extend in parallel from the mid section 46 to respective distal ends 54 and 56 . The distal ends 54 and 56 of the first and the second sidewalls 48 and 50 each include an inwardly extending flange 58 , 60 . In some embodiments, each flange 58 , 60 has a plurality of detents (e.g., teeth) disposed along a flange lip 62 . The flanges 58 , 60 of the first and the second sidewalls 48 and 50 are separated by a distance 64 defining a channel 66 therebetween. The channel 66 extends lengthwise between the bottom and the top ends 40 , 42 of the stringer rail 30 . An example of a suitable rail is a length of the MQ series, slotted stainless steel channel manufactured by Hilti Corporation. The present invention, however, is not limited to any particular type of rail.
[0022] Referring to FIGS. 3-6 , each riser bracket 32 includes a panel leg 68 and a support leg 70 . The panel leg 68 extends between a top end 72 and a bottom end 74 defining a length 76 (see FIG. 5 ). The panel leg 68 includes a first mounting section 78 and a second mounting section 80 . The first mounting section 78 typically includes at least one riser panel fastener aperture 82 . The second mounting section 80 includes a rail fastener aperture 84 and a support leg fastener aperture 86 . The rail fastener aperture 84 is disposed proximate the top end 72 of the panel leg 68 . The support fastener aperture 86 is disposed proximate the bottom end 74 of the panel leg 68 . The panel leg 68 may be formed from a length of angle iron, where the first mounting section 78 is perpendicular to the second mounting section 80 . Further, the top end 72 and/or the bottom end 74 of the second mounting section 80 can each include an acute edge 88 , 90 . The acute edge 88 of the top end 72 of the second mounting section 80 is disposed a distance 92 from first mounting section 78 , and is offset by an angle θ 1 relative to the length 76 of the panel leg 68 . The acute edge 90 of the bottom end 74 of the second mounting section 80 is offset by an angle θ 2 relative to the length 76 of the panel leg 68 . The present invention, however, is not limited to the aforesaid configuration. In other embodiments, the panel leg can be constructed from, for example, a length of the MQ series, slotted stainless steel channel manufactured by Hilti Corporation. The support leg 70 extends between a first end 94 and a second end 96 . The support leg 70 includes a panel leg fastener aperture 98 and a rail fastener aperture 100 . The panel leg fastener aperture 98 is disposed proximate the first end 94 of the support leg 70 . The rail fastener aperture 100 is disposed proximate the second end 96 of the support leg 70 .
[0023] The bottom end 74 of the panel leg 68 is pivotally attached to the first end 94 of the support leg 70 . For example, a bolt 102 can be inserted through the support leg fastener aperture 86 of the panel leg 68 and the panel leg fastener aperture 98 of the support leg 70 , and loosely secured with a nut 104 (see FIG. 3 ).
[0024] Each fastener 34 is adapted to attach one of the riser brackets 32 to a respective one of the stringer rails 30 ; e.g., the panel leg 68 and a support leg 70 of each riser bracket 32 is attached to the stringer rail 30 . In the embodiment in FIG. 3 , each fastener 34 includes a rail saddle 106 and a mounting bracket 108 . Referring to FIG. 7 , the rail saddle 106 includes a clamping element 110 and a slide element 112 . The clamping element 110 and the slide element 112 are adapted to clamp the flanges 58 and 60 of the stringer rail 30 between the clamping element 110 and the slide element 112 (e.g., see FIG. 3 ). In the embodiment in FIG. 7 , the clamping element 110 includes a threaded aperture 114 and a plurality of detents 116 . The detents 116 are adapted to mate with the detents 62 on the flanges 58 and 60 of each stringer rail 30 (see FIG. 3 ) for inhibiting lengthwise movement along the stringer rail 30 . An example of a suitable rail saddle is the MQA R Pipe Ring Saddle manufactured by Hilti Corporation. The present invention, however, is not limited to any particular rail saddle configuration.
[0025] Referring now to FIG. 8 , the mounting bracket 108 extends between two ends 118 , 120 . The mounting bracket 108 includes a riser bracket mounting section 122 and a saddle mounting section 124 . The riser bracket mounting section 122 includes a fastener 126 extending outwardly from an outer surface 128 thereof; i.e., away from the saddle mounting section 124 . The saddle mounting section 124 includes a rail saddle fastener aperture 130 . The mounting bracket 108 may, for example, be constructed from a length of angle iron, where the riser bracket mounting section 122 is disposed perpendicular to the saddle mounting section 124 . The present invention, however, is not limited to the aforesaid configuration.
[0026] Referring to FIG. 3 , the rail saddle 106 is connected to the saddle mounting section 124 of the mounting bracket 108 via, for example, a bolt 132 . Specifically, the bolt 132 extends through the saddle fastener aperture 124 (see FIG. 6B ) in the mounting bracket 108 and into the threaded aperture 114 (see FIG. 6A ) in the clamping element 110 of the rail saddle 106 .
[0027] Referring to FIG. 2 , each adjustable lateral brace 36 extends, for example, horizontally (e.g., along the x-axis) between two ends 132 , 134 . Each adjustable lateral brace 36 includes a plurality of rail fastener apertures 136 disposed along its length. An example of a suitable lateral brace is a length of the MQ series, slotted stainless steel channel manufactured by Hilti Corporation. The present invention, however, is not limited to any particular type of lateral brace. In the specific embodiment shown in FIG. 1 , each adjustable lateral brace 36 is configured having an adjustable length. For example, each adjustable lateral brace 36 can include first and second brace members 137 and 139 that are slidably connected via a brace clamp 141 .
[0028] Each riser panel 38 extends, for example, horizontally (e.g., along the x-axis) between two ends 138 , 140 . Each riser panel 38 has a height that is sized equal to the rise 28 for each respective step 14 to be formed. Each riser panel 38 includes a plurality of panel leg fastener apertures (not shown) disposed along its length. Typically, the riser panels 38 are constructed from wood planks; however, the present invention is not limited thereto.
[0029] The stringer rails 30 are disposed at an angle φ relative to the horizontal plane (i.e., the x-z plane). The stringer rails 30 on each side of the adjustable concrete form 10 can be attached to an adjacent wall 142 , 144 , or immobilized in any other suitable manner For example, the stringer rails 30 can be attached to the adjacent wall 142 , 144 via L-brackets 154 bolted to the rails 30 . The adjustable lateral braces 36 are disposed substantially perpendicularly across each of the stringer rails 30 . Each adjustable lateral brace 36 is attached to the mid section 46 of each stringer rail 30 , for example, via a bolt 146 extending through respective rail and stringer fastener apertures 136 , 52 . Advantageously, in this configuration, the adjustable lateral braces 36 can serve dual purposes of (i) laterally securing and positioning the stringer rails 30 , and (ii) providing staging such that a user can position himself over the adjustable concrete form 10 during the pouring and finishing of the stairs, using the brace 36 to support his weight.
[0030] Referring still to FIG. 2 , each riser bracket 32 is disposed along the length 44 of one of the respective stringer rails 30 . Typically, each riser bracket 32 is disposed a first distance 148 from each adjacent riser bracket 32 ; however, the present invention is not limited to such an equidistant spacing. The first distance 148 between adjacent riser brackets 32 is sized as a function of the run 24 for each tread 18 to be formed. Referring now to FIG. 3 , the panel leg 68 is disposed a second distance 150 from the support leg 70 in each respective riser bracket 32 . The second distance 150 between respective panel and support legs 68 and 70 is chosen to establish the angles α and β (see FIG. 1 ) for each step 14 to be formed (i.e., the offset angle between the riser 16 to be formed and the vertical plane, and the offset angle between the tread 18 and the riser 16 to be formed). The angle β (see FIG. 1 ) is also function of the first distance 148 between adjacent riser brackets 32 and, more specifically, the vertical distance 152 between respective ends 74 of adjacent panel legs 68 .
[0031] The riser panels 38 are typically disposed perpendicularly across each of the stringer rails 30 . Each riser panel 38 is attached to the panel legs 68 of respective riser brackets 32 on each stringer rail 30 , for example, via screws (not shown) respectively extending through the panel leg and into the riser panel 38 .
[0032] The fasteners 34 can operate in a plurality of modes of operation. For example, during a first mode of operation (e.g., when the adjustable concrete form 10 is being setup or disassembled), the bolts 132 for the fasteners 34 are loosened such that the riser bracket legs 68 , 70 can be slid along the stringer rail 30 into or out of the aforesaid configuration. In another example, during a second mode of operation (e.g., once the angles α and β the first and the second distances for each step 14 have been set), the bolts 132 for the fasteners 34 can be tightened to securely attached (e.g., clamp) the fasteners 34 to the stringer rails 30 . Each of the riser brackets 32 , therefore, are fixed relative to the stringer rails 30 and are ready to support the weight of concrete poured into the adjustable concrete form 10 .
[0033] While various embodiments of the present invention have been disclosed, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Accordingly, the present invention is not to be restricted except in light of the attached claims and their equivalents. | An apparatus for forming steps within a concrete stairway, wherein each step has a rise and a run. The apparatus includes a stringer rail, one or more riser brackets and a plurality of fasteners. The stringer rail has a lengthwise-extending channel. Each riser bracket has a panel leg and a support leg, wherein one end of the support leg is attached to panel leg. The fasteners are selectively slidable within the rail channel. One of the fasteners attaches the panel leg to the rail and another of the fasteners attaches the support leg to the rail. Each fastener is configurable in a first mode where the fastener is slidably attached to the rail. Each fastener is configurable in a second mode where the fastener is fixedly attached to the rail. | 4 |
FIELD OF INVENTION
The present invention relates to dump truck dump bodies and more particularly to apparatus for selectively cleaning the dump bed of such dump bodies. In greater particularity the present invention relates to scraping apparatus utilized to remove adhering load materials which remain in the dump body when such dump body is in an inclined position.
BACKGROUND OF THE INVENTION
The use of dump bodies affixed to a truck frame is well known in the trucking industry. When existing bodies are used to haul moist or compactible materials the efficiency of these dump bodies is somewhat limited. As existing dump bodies are raised, a large percentage of the moist or compactible load material is gravitationally discharged from the rear of these dump bodies. However, due to the clinging nature of some load material, there is a percentage of residual material that adheres to the bed of the dump body.
In order to remove the adhering material, workmen must climb into the dump body and manually remove the material. A substantial amount of work hours are wasted in an effort to clean the dump bed in this manner.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide an apparatus that is capable of selectively removing adhering material from a dump bed.
Still another object of the invention is to provide an apparatus for cleaning a dump bed that is operable from a remote position.
Still another object is to provide a system which can be readily adjusted to vary the degree of forward and rearward movement of the apparatus within the dump body.
Still another object of the present invention is to provide an apparatus for removing adhering load material from a front wall of the dump body.
These and other objects and advantages of our invention are accomplished through the use of a scraping carriage located within the dump body which is urged along the dump body by an assembly of cables and pulleys. These cables are propelled by a reversible winch which can be automatically operated under the regulation of a series of limit switches and a control circuit. The cables are connected to a rotatable drive shaft which is itself operatively connected to the reversible winch. The cables extend into the dump body but ar isolated from load material located within the dump body by a pair of cable housings.
When the winch is activated in a forward direction the cables are pulled toward the front of the dump body. The scraping carriage being secured to these cables is also pulled forward. Scrapers located on the scraping carriage dislodge adhering material from the dump bed as the carriage moves forward. Upon activating a forward limit switch the apparatus stops and may be operated in the reverse direction. The scrapers are adapted to scrape in either direction and upon reversal of the apparatus continue to dislodge adhering material allowing such material to be removed from the dump body. A rearward limit switch operates in a similar manner to the forward limit switch and restricts the rearward movement of the carriage at a predetermined distance from the tailgate of the dump body. The movement of the scraping carriage within the dump body is restricted by the limit switches but can be operated within these parameters by a remote control circuit.
The apparatus also includes two bar members suspended by a plurality of chains on the inner side of the forward wall of the dump body. As the dump body is tilted to dump its load the bars and chains are gravitationally pulled away from the front wall thereby disengaging residual load material that tends to adhere thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
Apparatus embodying features of the present invention are illustrated in the accompanying drawings which form a portion of this disclosure and wherein:
FIG. 1 is a perspective view of a dump truck equipped with the present invention;
FIG. 2 is a front elevational view of a dump body equipped with the present invention;
FIG. 3 is a sectional side view taken along lines 3--3 of FIG. 2;
FIG. 4 is a detailed elevational view of the threaded portion of the winch shaft, a limit nut threaded thereon and two limit switches;
FIG. 5 is a sectional view along line 5--5 of FIG. 4;
FIG. 6 is a detailed perspective view of a section of dump body including a scraping carriage;
FIG. 7 is a detailed sectional view taken along line 7--7 of FIG. 6;
FIG. 8 is a detailed sectional view taken along line 8--8 of FIG. 7;
FIG. 9 is a detailed perspective view of a drum and shaft portion of the present invention;
FIG. 10 is a end elevational view of the drum portion shown in FIG. 9;
FIG. 11 is a sectional view taken along line 11--11 of FIG. 10; and
FIG. 12 is a schematic of the control circuit.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to the drawings for a clearer understanding of the invention, the preferred embodiment comprises apparatus for scraping the dump bed 21 of the dump body 19 including a scraping carriage 20 laterally extending across the dump bed 21 which further includes three scrapers 22 which partially define the lateral extension of such scraping carriage 20. Such scrapers 22 are separated by a plurality of perpendicularly extending gussets 23 extending perpendicular to such scrapers 22 and are defined by a cross-sectionally curved beam portion 24 as shown in FIG. 6, such beam portion 24 being connected on both ends to plate portions 25 which further defines the scrapers 22. The anticline of such curved beam portion 24 extends upward thereby positioning the marginal edges of such curved portions 24 angularly adjacent the dump bed 21. Two end beams 30 extend parallel to the gussets 23 and are located on the lateral extensions of the plate portions 25, extending transversely thereof.
The scraping carriage 20 is urged longitudinally along the dump bed 21 by a rotatable drive shaft 31 mounted transversely across the front of the dump body 19, shown in FIGS. 2 and 3, wherein said drive shaft 31 is selectively rotated by an electric winch assembly 32 operatively connected to said drive shaft 31 by a chain and sprocket assembly 33. The drive shaft 31 can be selectively rotated by a manual crank 34 which is removably attachable to the electric winch assembly 32. A pair of winding drums 35 and 36 are axially secured to the extended ends of the drive shaft 31 and rotate in conjunction with the rotation of the drive shaft 31. Each winding drum 35 and 36 is mounted to the drive shaft 31 by a pair of adjusting plates 40 shown in FIGS. 10 and 11, each plate 40 being annularly secured to and radially extending from the drive shaft 31. Each end of the winding drums 35 and 36 is adjustably secured to the adjusting plate 40 by two securing bolts 41 extending through a pair of rotation slots 42 which are defined within each adjusting plate 40. The drive shaft 31 is rotatably mounted to the front of the dump body by three pillow blocks 43, through which said drive shaft 31 extends and is secured therein by bearings 44 as shown in FIG. 9. The pillow blocks 43 and the electric winch assembly 32 are slidably attached to the front of the dump body 19 by adjusting bolts 45 which extend through adjusting slots 46 defined within the pillow blocks 43 and the electric winch assembly 32. A pair of forward cables 52 and 53 and a pair of reverse cables 50 and 51 are attached to and wrapped several rotations around the winding drums 35 and 36 with one forward and one reverse cable on each drum as shown in FIG. 9. The reverse cables 50 and 51 are wrapped rotationally opposite the forward cable 52 and 53 but all cables extend upward and over a first pair of double pulleys 54 and 55 located at the top corners of the dump body 19, as viewed in FIGS. 2 and 3. The cables extend downward from said first pair of double pulleys 54 and 55 and under a second pair of double pulleys 56 and 57 as viewed in FIG. 3. The forward cables 52 and 53 extend longitudinally along the dump bed 21 adjacent the sides of the dump body 19 and are mounted to a rearward portion of the scraping carriage end beams 30 by a pair of first tubular joiners 60 and 61. The reverse cables 50 and 51 extend longitudinally along the dump body 19 coextensively with the forward cables 52 and 53 but continue to extend to and around a pair of single pulleys 62 and 63 located at the rear corners of the dump body 19. The reverse cables 50 and 51 continue to extend forward along the dump body 19 and are mounted to a forward portion of the scraping carriage end beams 30 by a pair of second tubular joiners 64 and 65. The cables are secured to their respective tubular joiners by being extended through a cross-sectionally circular channel 71 located within such tubular joiners, being held in tension against such joiners 64 and 65 by swedges 70 which are attached to the extended portion of such cables. The portions of the aforementioned cables and pulleys which are located within the dump body are enclosed within a pair of cable housings 72 and 73 shown in FIGS. 6 and 7 which are partially defined by cross-sectionally L-shaped cable covers 72' and 73' which co-extend the length of the dump body 19 from the single pulleys 62 and 63 to the first double pulleys 54 and 55 running parallel to the aforementioned cables. These cables are encompassed between the cable covers 72' and 73' and the side walls of the dump body 19. The cable housing 72 and 73 are further defined by a pair of scraping slots 74 and 75 found within said cable covers 72' and 73' located adjacent to said dump bed 21 through which the scraping carriage 20 extends and is longitudinally movable. The cable housings 72 and 73 are each defined by a strip of protective belting 76 connected to the cable covers 72' and 73' and extending across the scraping slots 74 and 75. As the carriage 20 moves along the dump bed, the protective belting 76 flexes to allow passage of the carriage 20. Once the carriage 20 passes, the protective belting 76 returns to its original position covering the scraping slots 74 and 75. The protective belting 76 aids in isolating the cables and pulleys located within the cable housings 72 and 73 from load material being transported within the dump body.
The winch assembly 32 is powered by a battery 90 which is connected to the winch assembly 32 by a control circuit which is shown in detail in FIG. 12.
The extent of forward and reverse movement of the scraping carriage is automatically restricted by a forward limit switch 80 and a reverse limit switch 81, physically located on the front of the dump body as shown in FIG. 2 and integrated in the control circuit as shown in FIG. 12. These limit switches 80 and 81 remain closed unless engaged by a square limit nut 82 which is axially connected to a threaded portion 83 of the drive shaft 31 as shown in FIGS. 4 and 5. The limit nut 82 is secured in a non-rotating position by a slip plate 84 which is mounted on the front wall of the dump body 19, wherein the slip plate 84 is closely contacted by a marginal edge of said square limit nut 82. As the drive shaft 31 is rotated by the winch assembly 32, the threaded portion 83 drives the limit nut 82 toward either limit switch 80 or 81 depending on the direction of rotation of the drive shaft 31. The forward limit switch 80 is located proximate the limit nut 82, being positioned in the path the limit nut 82 will move when the drive shaft 31 is rotating the winding drums 35 and 36 in a forward direction, such forward direction defined as that direction necessary to urge the scraping carriage 20 toward the front of the dump body 19. The reverse limit switch 81 is located proximate the limit nut 82, being positioned in the path the limit nut 82 will move when the drive shaft 31 is rotating the winding drums 35 and 36 in a reverse direction, such reverse direction defined as that direction necessary to urge the scraping carriage 20 toward the rear of the dump body 19. The limit switches 80 and 81 are slidably adjustable on the slip plate 84 thereby varying the distance the limit nut 82 must travel before contacting the limit switches, consequently regulating the distance the sliding carriage 20 may travel on the dump bed 21 before activating a limit switch.
The aforementioned control circuit shown in detailed form in FIG. 12 includes an ignition switch 89 being the same ignition switch utilized to start the dump truck's engine (not shown) and being connected to a positive pole of the battery 90. The ignition switch 89 is used to selectively open or close the control circuit and since the switch 89 will require a key to operate, will aid in preventing unauthorized use of the present invention. The ignition switch 89 is connected to a main disconnect switch 91 which is used to open or close the control circuit. A 12 volt, 150 amp circuit breaker 92 is connected to the main disconnect switch 91 which will operate to disconnect the control circuit should the ampere load on the circuit exceed 150 amps. An emergency shut-off button 93 is connected to the circuit breaker 92 and when manually operated will rapidly disconnect the control circuit. A method switch 94 is connected to the emergency shut-off button 93 and is used to select either a manual terminal 96 or an automatic terminal 97 for connection with the circuit. The forward limit switch 80 and the reverse limit switch 81 are independently connected to the automatic terminal 97. A forward relay switch 101 is connected to the forward limit switch 80 and a forward relay 102 is operatively connected to the forward relay switch 101. The forward relay 102 is also connected to the forward limit switch 80 from the forward relay switch 101. A reverse relay switch 103 is connected to the reverse limit switch 81 and a reverse relay 104 is connected to the reverse relay switch 103. The reverse relay 104 is also connected to the reverse limit switch 80 upstream from the reverse relay switch 104. The relay switches 101 and 103 are spring biased toward an open position and are closed only when manually activated. When one or the other relay switches 101 or 103 is activated, current flows to and activates either the forward relay 102 or the reverse relay 104 dependent on which switch is activated. Both the forward and reverse relays 102 and 104 are operatively connected to a negative pole of the battery 90, thereby completing the control circuit. As shown in FIG. 12, each relay 102 and 104 is operatively connected to the positive pole 106 of the power supply and are respectively connected to a forward drive element 107 and a reverse drive element 108 of the motor 109 which is used to rotate the winch assembly 32. A remote manual switch 110 is connected to the manual terminal 96 and selectively connects the manual terminal 96 to the forward relay 102 or the reverse relay 104. The forward relay 102, once activated, closes a circuit connected to the power supply and the forward drive element 107. The reverse relay 104, once activated, closes a circuit connected to the power supply and the reverse drive element 108.
When the forward drive element 107 is activated by current the winch assembly 32 rotates the drive shaft 31 and the winding drums 35 and 36 in the forward direction consequently moving the sliding carriage 20 toward the front of the dump body 19. The forward motion of the sliding carriage 20 dislodges adhering materials which may cling to the dump bed 21. When the reverse drive element 108 is activated by current the winch assembly 32 rotates the drive shaft 31 and the winding drums 35 and 36 in the reverse direction consequently moving the sliding carriage 20 toward the rear of the dump body 19. The reverse motion of the sliding carriage 31 further dislodges adhering materials which may cling to the dump bed 21 and removes them from the rear of the dump body 19. This apparatus can be and generally is operated while the dump body is in an inclined position. The preferred embodiment of the present invention also includes a bar and chain assembly 111 located on the inside surface of the forward wall 112 of the dump body 19. The bar and chain assembly 111 includes two bar members 113 suspended from the forward wall 112 by a plurality of chains 114. When the dump body 19 is tilted, the bar and chain assembly is gravitationally pulled away from the forward wall 112, thereby dislodging residual load material adhering to such forward wall 112.
When the dump body 19 is empty, the carriage 20 should be urged to the forward end of the dump body 19. Securing plates 120 located at the forward end of the dump body 19 and extending perpendicular from the forward wall 112 of the dump body 19 will secure the carriage 20 in a non-vibrating position at the front of the dump body 19. When load materials are placed in the dump body 19, the carriage 20 should be positioned in the dump body 19 as far forward as possible. When the dump body 19 is tilted, thereby discharging the load material, the carriage 20 being located at the front of the dump body 19 is out of the flow of load material moving down the tilted dump bed 21. After a predominant portion of the load material is discharged by the tilting of the dump body 19, the carriage 20 is urged toward the rear of the dump body 19 thereby dislodging any adhering load material from the dump bed 21 and sweeping such material out the rear of the dump body 19.
While I have shown my invention in one form, it will be obvious to those skilled in the art that it is not so limited but is susceptible of various changes and modifications without departing from the spirit thereof. | A bed cleaner for dump trucks utilizing a scraping carriage located in the bed of a dump truck and operated by cables connected to a winch assembly to dislodge and remove adhering materials from the dump bed while the dump bed is in an inclined position. The apparatus includes a device for remotely or automatically controlling the movement of the sliding carriage on the dump bed. | 1 |
The present invention relates to process for reforming the edge of a container opening cover and in particular to a method and apparatus for reforming the edge of a two piece or three piece shell before the shell is seamed to a container body to reduce scalloping or other irregularities in the shell perimeter.
BACKGROUND INFORMATION
A number of processes are used for closing or covering a container opening such as in the process of manufacturing and filling a two piece or three piece beverage or food container. Typically, a container body has a side wall which is substantially cylindrical with at least one substantially circular rim defining an open end of the container body. In a number of previous configurations, a container end shell which is substantially disk-shaped (although it may have various recesses, scores, indicia and the like) has a perimeter substantially the same shape as the container opening rim. The container may be closed by seaming the angular region of the shell perimeter to the rim region of the container body such as by a double seaming operation, as known to those of skill in the art.
In many situations, it is strongly preferred to maintain, at any circumferential position along the shell perimeter or the container body rim, a sufficient radial extent of the annular shell portion which is to be seamed, in proximity with the can body rim portion to which it is to be seamed, so as to assure that the seam will have structural integrity, form a desired, preferably hermetic, seal between the shell and the container body and will be able to withstand certain shocks or impacts such as those often encountered during transport, retailing, sale and normal end-user use.
A number of procedures often involved in providing or forming the shell 912 (FIGS. 9A and 9B) result in a shell whose perimeter departs from perfect regularity (typically, departs from perfect circularity) such as when portions of the shell periphery are somewhat indented or scalloped, as compared to a perfect circular form. These departures of the shell periphery from ideal regularity contribute to container configurations in which the amount of material provided to achieve the seaming operations exceed the materials that are, at least theoretically, minimally required. For example, when, to achieve the desired seaming integrity, an annular region with a radial extent of X is needed, if the shell edge is scalloped inwardly by radial extent equal to Y, the shell must be provided with an annular seaming region having a nominal or intended radial extent of about X+Y (so that, even in portions of the annular region where scalloping occurs, the radial extent will be at least equal to the nominal or intended extent of X+Y, less the maximum scalloping defect of Y, to provide a guaranteed minimum radial extent of X, as desired).
For this reason, some shell formation and/or seaming operations provide a double seam which is larger than that which would be theoretically minimally required, in order to maintain seam integrity even in the face of an amount of shell edge scalloping. Accordingly, it would be useful to provide a procedure which can reduce or eliminate the adverse effects of scalloping on seam sizes, so as to provide for containers with rugged and integral seams but with a reduced seam size.
In many container-forming procedures, it is desirable to provide seaming regions (or other regions) of the container end closure shell which has a degree of hardness, e.g. to assist in maintaining seam integrity, regardless of normal shocks or impacts on the container. To provide for proper seaming, the shell typically must have a diameter suited to the container body rim diameter, but which also has sufficient thickness to provide and maintain a reliable seam. Accordingly, it would be advantageous to provide a shell which provides for at least regions that are hardened, particularly in the annular seaming area. It would be advantageous to provide a process for forming shells that results in at least some increase in effective shell diameter, without thinning regions of the shell to the point that structural integrity may be compromised.
SUMMARY OF THE INVENTION
The present invention involves subjecting the shell or shell blank to the application of a forming operation such as coining, spinning or die-forming at least in the periphery or seaming area of the shell, prior to the seaming operation. Preferably, if coining is used, the coining operation involves use of a die having a wall which can define the desired (typically, regular) shape of the shell periphery, so that coining may reform a shell from a shape which may have scalloped or otherwise irregular edges to a shape which has substantially regular, substantially unscalloped edges. Preferably, the present invention allows the formation of containers having a seam size smaller than the seam size provided in correspondingly-shaped containers formed by previous procedures, substantially without sacrificing integrity or durability of the seam. The coining operation preferably provides an increase in the diameter of the shell (at least some locations around the circumference) all having relatively minor effects on the thickness of the coined region. Preferably, the coining achieves a degree of work-hardening of the coined area, which may help to offset the effects of any diminution of thickness caused by the coining operation.
In one embodiment, a non-precurled, non-curled shell is transferred to a reform station. This station contains a coin die and coin punch. The coin die has the desired round finished blank diameter machined into the die face. The die cavity has a round die wall which stops the outward flow of material during the coining process. The die wall produces the blank's final shape. During the coining process, the coining punch compresses the scalloped blank edge of the non-curled, non-precurled shell. Coining of the coined area causes the material to flow outward until it comes in contact with the die wall, forming the blanks outer diameter. This corrects the scalloped edge of the blanks and additionally work hardens the edge and increases the blank diameter. This configuration can also eliminate the need for (expensive) non-round cut edge tooling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of an unreformed shell positioned in a coining die according to an embodiment of the present invention;
FIG. 2 is a cross sectional view of the shell and die taken along line 2 — 2 of FIG. 1, also showing a coining punch, according to an embodiment of the present invention;
FIG. 3 is an enlarged detail of region 3 of FIG. 2;
FIG. 4 is a top plan view corresponding to the view of FIG. 1 but after a coining operation has been performed;
FIG. 5 is a cross sectional view taken along line 5 — 5 of FIG. 4;
FIG. 6 is a enlarged detail view of region 6 of FIG. 5;
FIG. 7 is a flow chart showing selected steps in a shell forming and seaming operation according to previous procedures; and
FIG. 8 is a flow chart showing selected steps of a shell formation and seaming procedure, including coining according to embodiments of the present invention.
FIGS. 9A and 9B are flow charts of processes according to embodiments of the present invention.
DETAILED DESCRIPTION
In typical situations, a container end shell 112 is formed of a metal, such as an aluminum alloy. As depicted in FIG. 2, the container end shell 112 , while roughly circular in shape, may have departures from strict circularity such as having one or more inwardly indented or scalloped regions 114 a,b,c,d defining earring gaps. The departures from regularity can arise from a number of sources including imperfections in the original cutting or stamping of the planar or disk-shaped blank, shaping procedures such as stamping or other procedures for forming the annular recess 116 and/or the raised 118 periphery of the shell and may have contributions from the metallurgy of the shell and/or imperfections in tooling concentricity. In any case, it is common for a shell such as that depicted in FIGS. 1 and 2 to have at least one and often plurality of scallops or earring gaps 114 a-d . The radial extent 312 (FIG. 3) of the gap will, as shown, typically vary along the circumference of the shell. In a typical shell intended for use in forming a typical 12 ounce beverage container, the gap 312 is commonly no greater than about 0.0050 inches although there can be substantial variation in this value. The resultant variations in uncurled lip height lead to a double seam size which is greater than desired, thus increasing the material cost of the container.
According to one embodiment, the shell 112 may be reformed by coining some or, preferably all, peripheral areas of the shell. As best seen in FIGS. 2 and 3, in one embodiment the shell 112 is positioned 914 (FIGS. 9A and 9B) over or within the cavity 121 of a die 122 . The die 122 has an annular surface 124 for receiving and supporting at least the annular periphery of the shell 112 . Adjacent the outer edge of the support 124 is an upstanding wall region 126 of the die. The wall 126 defines the desired shape (such as circular) and diameter of the shell.
As depicted in FIGS. 2, 3 , 5 and 6 , a punch 212 is configured to cooperate with the die 122 , to perform coining as described more thoroughly below. The punch 212 includes an outer cylindrical wall 214 with a shape and diameter to match (preferably with close tolerance) the shape and diameter of the die wall 126 . The coining surface defines a generally annular flat region 216 extending radially inward a distance 612 (FIG. 6 ). In one embodiment, when the coining includes contacting an annular region of said shell blank with a contact surface of a punch, the contact surface of the punch has a shape corresponding to the annular region.
In practice, a shell 112 is positioned in the cavity of the die 122 as depicted in FIGS. 1 and 2. The punch 212 is brought downward 218 with sufficient force to achieve coining as described below. At the maximum downward stroke of the punch 212 , as depicted in FIGS. 5 and 6, the punch 212 causes plastic deformation of the metallic peripheral region of the shell. The coining process causes the coined area 412 (FIG. 4 ), to be reduced 616 in thickness, compared to the thickness 314 of the area prior to coining. The coining also results in shell material being displaced into the scalloped or gap regions 114 a,b,c,d so that the coin material flows, generally in a net radially outward direction until it meets the die wall 126 , as depicted in FIG. 6, thus achieving a shell periphery which has the regularity (and diameter) of the die wall 126 .
In general, the total reduction in volume (the reduction in thickness) 616 times the area of the coined region 412 will not be substantially greater than the total volume of the pre-coining scalloped regions or gaps 114 a,b,c,d . Thus, it is anticipated that, for most situations, the coining will provide a reduction in thickness 616 of the periphery region of the shell which is small enough so as to not seriously affect the strength or integrity of the shell. However, to the extent that there might otherwise be some reduction in strength or integrity, there is an offsetting factor of an increase in hardness resulting from the work-hardening effect of the coining process in the coined area 412 .
As shown in FIG. 7, previous procedures typically involved receiving a planar blank 712 , forming 716 an annular recess 116 or otherwise shaping the blank. As described above, in previous procedures the shell was curled and seamed to join the can body 722 , often after a pre-curl operation 720 .
As depicted in FIG. 8, the present invention preferably adds a process of coining to achieve edge reform 818 , prior to the curling step 722 (and preferably prior to a pre-curl 720 end, and in the depicted embodiment, after other forming steps such as forming the annular recess 716 .
In view of the above description, a number of advantages the present invention can be seen. The present invention reduces or eliminates the effects of nonregularity or scalloping of blank or shell edges. Containers with smaller seam sizes can be achieved without compromising seam integrity or durability. Seam areas are provided which have been work-hardened and the increase in diameter arising form the coining operation results in savings of material.
A number of variations and modifications of the invention can be used. It is possible to use some features of the invention without using others. For example, it is possible to use the present invention for providing work hardening of the peripheral area of the shell without necessarily fully eliminating earring gaps. Although the present invention has been illustrated with examples of shells with circular ideal peripheries, the present invention could be used for shells (and containers) with noncircular shape such as ellipses, ovals, polygonal cross sections and the like. Although one example of a radial extent 612 of a coining area has been provided, the present invention can be used with larger or smaller coining areas. Although the present invention has been illustrated by examples in which the coining operation is performed as a separate operation, it is possible to design processes in which the coining operation as described herein is performed simultaneously when one or more other operations such as a scoring operation, a recess or rib-forming operation, and the like. Although the depicted embodiment provides for a annular coining area which lies in a plane substantially parallel to the plane of the major web region of the shell, the coining area can be differently oriented. Although in the depicted embodiment, the inner wall 222 of the punch is conically shaped, (to assist in punch withdrawal) while the outer wall 214 is cylindrical, it is possible to provide a (preferably slight) bevel or angle to the outer wall (preferably with a corresponding angle to the die wall) to assist in punch withdrawal and/or guidance or alignment. Although the illustrated embodiments provide a punch coining surface 216 substantially parallel to the plane of the shell, it is possible to provide for the bottom surface of the punch (and thus of the resultant coining area) with a (preferably slight) inward or outward bevel. Although the disclosure herein has included a description of coining as a forming operation, other forming operations can also be used and can reduce or eliminate irregularities in the blank periphery, e.g. to permit smaller seams. Examples of other forming operations include spinning 916 (FIG. 9A) or die-forming ( 918 FIG. 9 B). Those of skill in the art will understand how to use spinning or die-forming to reduce or eliminate irregularities, after understanding the present disclosure.
The present invention, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g. for improving performance, achieving ease and/or reducing cost of implementation.
The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. Although the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g. as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures , functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter. | A non-precurled, non-curled shell is transferred to a reform station. The reform station contains a coin die and a coin punch. The coin die has the desired round finished blank diameter machined into its face. The die cavity has a round die wall which stops the outward flow of material during the coining process. The die wall produces the blank's final shape. During the coining process, the coining punch compresses the scalloped blank edge of the non-curled, non-precurled shell. The coined area causes material to flow outward, coming in contact with the die wall, forming the blanks outer perimeter. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a torsional vibration damping means for a marine propulsion device and more particularly to an improved arrangement for damping torsional vibrations in the drive shaft of a marine drive.
As is well known, marine drives include drive shaft housing in which a drive shaft is rotatably journaled and which drives a propulsion device that is carried by a lower unit, positioned at the lower end of the drive shaft housing. The propulsion device may comprise either a propeller or other types of known devices utilized for this purpose. This type of marine drive is common to the outboard drive unit of an inboard/outboard drive or the drive shaft housing and lower unit of an outboard motor. The drive shaft is subject to a number of torsional vibrations and the marine propulsion unit itself adds to these torsional vibrations. Frequently, the unit also encounters shock loading such as when a propeller strikes an underwater object and this coupled with the torsional fatigue of the drive shaft can very well cause failure of the drive shaft.
It is, therefore, a principle object of this invention to provide an improved arrangement for damping torsional vibrations in the drive shaft of a marine drive.
It is another object of this invention to provide an improved arrangement for damping the torsional vibrations of the drive shaft of a marine propulsion unit.
SUMMARY OF THE INVENTION
This invention is adapted to be embodied in a marine outboard drive comprising a drive shaft housing journaling a drive shaft that is driven by a power source. A lower unit contains propulsion means for propelling an associated watercraft and means are provided for driving the propulsion means from the drive shaft. In accordance with the invention, torsional vibration damping means are directly connected to the drive shaft for reducing the effects of torsional vibrations on the drive shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an outboard motor constructed in accordance with an embodiment of the invention, with portions broken away and other portions shown in phantom.
FIG. 2 is an enlarged cross-sectional view showing a first embodiment of a torsional vibration damper.
FIG. 3 is a cross-sectional view, in part similar to FIG. 2, showing another embodiment of the invention.
FIG. 4 is a cross-sectional view, in part similar to FIGS. 2 and 3, showing a still further embodiment of the invention.
FIG. 5 is a cross-sectional view, in part similar to FIGS. 2 through 4, and shows a yet further embodiment of the invention.
FIG. 6 is a view taken in the direction of the line 6--6 in FIG. 5.
FIG. 7 is a cross-sectional view, in part similar to FIGS. 2 through 5, showing still another embodiment of the invention.
FIG. 8 is a cross-sectional view, in part similar to FIGS. 2 through 5 and 7, showing a still further embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As has been noted, the invention is particularly adapted for use in marine outboard drives for damping torsional vibrations of the drive shafts of either the outboard drive of an inboard/outboard or that of an outboard motor per se. In the drawings, the invention is shown in combination with an outboard motor and identified generally by the reference numeral 11. The outboard motor 11 includes a power head 12 that is comprised of an internal combustion engine 13 of any known type which has an output shaft 14 that rotates about a vertically extending axis. An outer protective cowling, shown in phantom and identified generally by the reference numeral 15, encircles the engine 13.
A drive shaft housing, indicated generally by the reference numeral 16, comprised of an outer casing 17 is affixed to the underside of the power head 12. A drive shaft 18 is journaled in the drive shaft housing 16 in an appropriate manner. The drive shaft 18 is rotatably coupled to the engine output shaft 14 by means of a coupling 19. Positioned at the lower end of the drive shaft housing 16 and within the casing 17 is a water pump 21 that is driven by the drive shaft 18 for supplying water from the body in which the motor 11 operates to the engine 13 for its cooling. This cooling water is then redischarged back to the body of water in which the motor 11 operates in a known manner.
A lower unit, indicated generally by the reference numeral 22, is affixed to the lower portion of the drive shaft housing 16. The lower unit 22 includes an outer casing 23 in which a drive shaft extension 24 is journaled. The drive shaft extension 24 carries a bevel gear 25 at its lower end that meshes with a forward, neutral, reverse transmission assembly 26 that consists of a pair of bevel gears 27 and 28 that are rotatably journaled on a propeller shaft 29 and mesh with opposite sides of the bevel gear 25 so that the gears 27 and 28 will be rotated in opposite directions. A known type of dog clutching mechanism (not shown) is provided for selectively coupling either of the gears 27 and 28 for rotation with the propeller shaft 29 to drive it and a propeller 31 which is affixed to it in a known manner, in either a forward or reverse direction. In addition, the dog clutching mechanism is provided with a neutral position wherein neither of the gears 27 and 28 will be rotatably coupled with the shaft 29 and a neutral condition will exist.
A steering shaft 32 is affixed to the drive shaft housing 16 and is journaled in a swivel bracket 33 for steering movement of the outboard motor 11 about a vertically extending axis defined by the steering shaft 32. The swivel braket 33 is pivotally connected bracket 34 by means of a tilt pin 35 for tilting movement of the outboard drive 11 about a horizontally extending tilt axis as defined by the tilt pin 35. The clamping bracket 34 is, in turn, provided with a clamping assembly 36 so that the outboard motor assembly 11 may be connected to a transom of a watercraft 37 in a known manner.
The construction of the outboard motor 11 as thus far described is conventional and for that reason only the general construction of it has been described. The conventional outboard motor or the outboard drive of an inboard/outboard unit has certain problems, as aforenoted, in that the drive shaft 18 is subject to torsional vibrations that can weaken it through fatigue through long periods of use. When the drive shaft 18 is thus fatiqued and the propeller 31 strikes an object, or even under the vibrational loadings, the drive shaft 18 may fail. In accordance with the various embodiments of this invention, a torsional vibration damper, indicated by the reference numeral 41 is affixed to the drive shaft 18 in proximity to the water pump 21 for absorbing these torsional vibrations and relieving the drive shaft 18 from such loading. A number of various embodiments of torsional dampers are illustrated in FIGS. 2, 3, 4, 5 and 6, 7 and 8 and reference will now be had to these figures for a description of the specific torsional dampers which may be employed in connection with the invention.
Referring first to FIG. 2, the damper 41 includes an inner hub member 42 that is detachably and axially affixed to the drive shaft 18 for rotation with the drive shaft 18 by means of a key 43. An outer inertial member 44 is connected to the inner member 42 by means of an elastomeric sleeve 45 so that the outer member 44 may rotate slightly relative to the inner member 44 so as to absorb torsional vibrations. The elastomeric member 45 may be affixed to the members 44 and 42 in any suitable manner as by adhesive bonding, vulcanizing or the like.
FIG. 3 shows another embodiment of this invention and the torsional vibration damper of this embodiment is identified generally by the reference numeral 51. The torsional vibration damper 51 and its manner of connection to the drive shaft 18 is slightly different from the previously described embodiment and this embodiment permits the use of a somewhat looser fit between the damper 51 and the drive shaft 18 so as to facilitate assembly.
In this embodiment, an inner hub member 52 is rotatably connected to the drive shaft 18 by means of a key 53. The inner member 52 is axially affixed relative to the drive shaft 18 by means of a pair of snap rings or "C" clips 54 that are received in grooves in the drive shaft 18. An elastomeric member 55 couples the inner member 52 to an outer inertial member 56 so as to provide vibration damping. In this embodiment, the elastomeric member 55 has a generally L-shape cross-section and includes a radially extending flange 57 that underlies the inertial member 56.
A torsional vibration damper constructed in accordance with yet another embodiment of the invention is identified by the reference numeral 61 in FIG. 4. This embodiment is similar to the embodiment of FIG. 3 in that it permits a looser fit of the vibration damper 61 to the drive shaft 18. In this embodiment, the drive shaft 18 is provided with an annular shoulder 62 that underlies an inner hub member 63 of the inertial member 61. The inner member 63 is rotatably coupled to the drive shaft 18 by means of a key 64 and it is axially held in place by its weight acting on the shoulder 62. An inertial member 65 of the damper 61 is connected to the inner member 63 by means of an elastomeric sleeve 66 so as to permit the absorption of torsional vibrations.
FIGS. 5 and 6 show a still further embodiment of the invention wherein a torsional vibration damper constructed in accordance with this embodiment is identified generally by the reference numeral 71. In this embodiment, the torsional vibration damper 71 is designed so as to operate under the level 72 of the body of water in which the outboard motor 11 is operating. Alternatively, the outboard motor 11 may be provided with an internal system wherein a water cooling jacket is maintained in the drive shaft housings 16 so that the water level 72 will be above the level of water in which the outboard motor 11 is operating. Such a water jacket may be formed and supplied in the manner as shown in U.S. Pat. No. 4,421,490, entitled "Exhaust Silencer Structure For Outboard Engines", issued Dec. 20, 1983 in the name of Ryoji Nakahama and assigned to the assignee of this application.
The torsional vibration damper 71 includes an inner hub member 73 that is affixed to the drive shaft 18 in any of the manners as shown in the embodiments of FIGS. 2 through 4, for example, by means of a key 74. An outer inertial member 75 is affixed to the inner member 73 by means of an elastomeric sleeve 76 so as to provide for relative rotation. The upper and/or lower surface of the inertial member 75 is provided with a number of fins or vanes 77 that extend beneath the water level 72. These fins or vanes 77 and their cooperation with the water will increase the effective weight or inertia of the member 75 and will additionally transfer heat generated by the torsional vibrations into the water 72 for more rapid dissipation.
Another embodiment of the invention which employs a fluid coupling rather than an elastomeric coupling is shown in FIG. 7 wherein the torsional vibration damper is identified generally by the reference numeral 81. This member 81 includes an annular housing assembly 82 that is non-rotatably affixed to the drive shaft 18 in any of the manners as shown in FIGS. 2 through 4, for example, by means of a key 83. The member 82 has a hollow opening that is filled with a viscous fluid 84 such as silicone and in which an inertial member 85 is supported. Upon torsional vibrations, the member 85 may move relative to the member 82 with the fluid 84 acting as a fluid coupling so as to achieve torsional vibration absorption.
A similar viscous torsional vibration damper is identified generally by the reference numeral 91 in FIG. 8. Like the embodiment of FIG. 7, this embodiment includes a hollow outer housing 92 that is affixed to the drive shaft 18 in any suitable manner by means of a key 93. The housing 92 has an internal cavity that is filled with a viscous fluid 94 and in which an inertial member 95 is positioned. The inertial member 95 is provided with vanes 96 that cooperate with the viscous fluid 94 so as to increase the effective inertia of the member 95 and so as to afford some cooling.
It should be readily apparent from the foregoing description that a number of embodiments of the invention have been illustrated and described each of which provides effective torsional protection for the drive shaft and which can be conveniently and easily assembled. Although a number of embodiments of the invention have been illustrated and described, various other changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims. | An outboard drive having an improved arrangement for absorbing torsional vibrations and isolating the drive shaft from them. Several embodiments of torsional vibration dampers are disclosed each of which includes a first member that is detachably connected to the drive shaft and an inertial member that is coupled to the first member. In some embodiments, this coupling is achieved by an elastomeric sleeve and in others it is achieved by means of a viscous fluid. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is the U.S. National Phase of International Patent Application Serial No. PCT/US2014/023519, filed Mar. 11, 2014, which claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/775,807, filed Mar. 11, 2013, the disclosures of which are incorporated herein by reference in their entireties.
BACKGROUND
Numerous impressive catalysts have been developed in transition metal catalysis and organocatalysis with unique activation modes. However, the utility of such catalysts is hampered by inherent drawbacks like limited reaction scopes and high catalyst loading. In an effort to improve upon these limitations, the concept of combing transition metal catalysis and organocatalysis has emerged in the last few years. Strategies, including cooperative catalysis, synergistic catalysis, and sequential/relay catalysis, have been established. However, the incompatibility between catalysts, substrates, intermediates and solvents is the potential shortcoming.
SUMMARY
The present document describes a ligand having the structure or its enantiomer:
wherein: each one of R a , R b , R c , and R d is selected from alkyl, cycloalkyl, and aryl; the bridge group is selected from CH 2 NH; *CH(CH 3 )NH(C*,R); and *CH(CH 3 )NH(C*,S); and the organocatalyst is an organic molecule catalyst covalently bound to the bridge group. In one embodiment, at least one of R a , R b , R c , and R d is an aryl moiety selected from phenyl; P—CH 3 phenyl; 3,5-di-CH 3 phenyl; 3,5-di-t-butyl phenyl; 3,5-di-CH 3 phenyl; 2-CH 3 phenyl; C 6 F 5 ; 2-naphthyl; and 1-naphthyl. In another embodiment, at least one of R a , R b , R c , and R d is an alkyl moiety selected from t-butyl and i-propyl. In an additional embodiment, at least one of R a , R b , R c , and R d is a cycloalkyl moiety selected from cyclohexyl and cyclopentyl.
Also provided is a catalyst having the structure or its enantiomer:
wherein: each one of R a , R b , R c , and R d is selected from alkyl, cycloalkyl, and aryl; the bridge group is selected from CH 2 NH; *CH(CH 3 )NH(C*,R); and *CH(CH 3 )NH(C*,S); the organocatalyst is an organic molecule catalyst covalently bound to the bridge group; and M is selected from Rh, Pd, Cu, Ru, Ir, Ag, Au, Zn, Ni, Co, and Fe. In one embodiment, at least one of R a , R b , R c , and R d is an aryl moiety selected from phenyl; P—CH 3 phenyl; 3,5-di-CH 3 phenyl; 3,5-di-t-butyl phenyl; 3,5-di-CF 3 phenyl; 2-CH 3 phenyl; C 6 F 5 ; 2-naphthyl; and 1-naphthyl. In another embodiment, at least one of R a , R b , R c , and R d is an alkyl moiety selected from t-butyl and i-propyl. In yet another embodiment, at least one of R a , R b , R c , and R d is a cycloalkyl moiety selected from cyclohexyl and cyclopentyl.
Also provided is a method for the asymmetric hydrogenation of an alkene to a corresponding alkane that includes the step of combining an alkene in a suitable solvent with an excess of hydrogen gas and a catalytically effective amount of a catalyst according to the present disclosure at a temperature and pressure effective to hydrogenate the alkene. In one embodiment, the solvent includes isopropanol. In another embodiment, at least one of R a , R b , R c , and R d in the catalyst is an aryl moiety selected from phenyl; P—CH 3 phenyl; 3,5-di-CH 3 phenyl; 3,5-di-t-butyl phenyl; 3,5-di-CF 3 phenyl; 2-CH 3 phenyl; C 6 F 5 ; 2-naphthyl; and 1-naphthyl. In yet another embodiment, at least one of R a , R b , R c , and R d in the catalyst is an alkyl moiety selected from t-butyl and i-propyl. In a further embodiment, at least one of R a , R b , R c , and R d in the catalyst is a cycloalkyl moiety selected from cyclohexyl and cyclopentyl.
DETAILED DESCRIPTION
This document describes ligands and catalysts prepared therefrom that provide unexpected improvements in conversion and selectivity in comparison with individual metal catalysts and organocatalysts by covalently bonding chiral bisphosphines with organocatalysts. Metal complexed with bisphosphine is a general catalyst and can lead many metal-catalyzed reactions with high turnovers. Organocatalysts activate substrates and influence selectivities. As used herein, the term “metallorganocatalysis” refers to catalysts and reactions catalyzed by a compound having a metal catalyst portion covalently bound to an organocatalyst portion. The high activity derived from the metal portion and high selectivity from the organocatalyst provide a useful approach in asymmetric catalysis.
As employed above and throughout the disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings:
The term “alkyl” refers to the radical of saturated aliphatic groups, including straight-chain alkyl groups and branched-chain alkyl groups. The term “cycloalkyl” refers to a non-aromatic mono or multicyclic ring system of about 3 to 7 carbon atoms. Examples of cycloalkyl groups include cyclopropyl cyclobutyl, cyclopentyl, cyclohexyl and the like.
The term “aryl” refers to any functional group or substituent derived from a simple aromatic ring, be it phenyl, thienyl, indolyl, etc.
Disclosed herein is a ligand having the structure or its enantiomer;
wherein:
each one of R a , R b , R c , and R d is selected from alkyl, cycloalkyl, and aryl; the bridge group is selected from CH 2 NH; *CH(CH 3 )NH(C*,R); and *CH(CH 3 )NH(C*,S); and the organocatalyst is an organic molecule catalyst covalently bound to the bridge group.
Each one of R a , R b , R c , and R d can be the same as or different from any of the other R groups. For example, in one embodiment, all of R a , R b , R c , and R d are the same aryl group. In another embodiment, each one of R a , R b , R c , and R d is a different aryl group. In yet another embodiment, R a and R b are different aryl groups, while R c is an alkyl group and R d is a cycloalkyl group.
Preferred aryl moieties for R a , R b , R c , and R d include phenyl; P—CH 3 phenyl; 3,5-di-CH 3 phenyl; 3,5-di-t-butyl phenyl; 3,5-di-CF 3 phenyl; 2-CH 3 phenyl; C 6 F 5 ; 2-naphthyl; and 1-naphthyl. Preferred cycloalkyl moieties (e.g. “Cy”) for R a , R b , R c , and R d include cyclohexyl and cyclopentyl. Preferred alkyl moieties for R a , R b , R c , and R d include t-butyl and i-propyl.
The term “organocatalyst” as used herein includes organic molecules capable of catalyzing a reaction. Suitable organocatalysts contain at least one moiety that can be covalently bound to a bridge group in the ligand of structure (I) or the catalyst of structure (II). Preferred organocatalysts include a thiourea moiety that can be covalently bound to a bridge group. Exemplary organocatalysts include, but are not limited to, the following structures designated as OC1-OC25:
Preferred ligands are represented by the following formulas:
Alternatively, the PPh 2 group in any of the ligands listed above can be PR a R b or PR c R d , wherein each one of R a , R b , R c , and R d is selected from alkyl, cycloalkyl, and aryl. Preferred aryl moieties for R include phenyl; P—CH 3 phenyl; 3,5-di-CH 3 phenyl; 3,5-di-t-butyl phenyl; 3,5-di-CF 3 phenyl; 2-CH 3 phenyl; C 6 F 5 ; 2-naphthyl; and 1-naphthyl. Preferred cycloalkyl moieties for R include cyclohexyl and cyclopentyl. Preferred alkyl moieties for R include t-butyl and i-propyl.
Each one of R a , R b , R c , and R d can be the same as or different from any of the other R groups. For example, in one embodiment, all of R a , R b , R c , and R d are the same aryl group. In another embodiment, each one of R a , R b , R c , and R d is a different aryl group. In yet another embodiment, R a and R b are different aryl groups, while R c is an alkyl group and R d is a cycloalkyl group.
Also disclosed herein is a catalyst having the structure or its enantiomer:
wherein:
each one of R a , R b , R c , and R d is selected from alkyl, cycloalkyl, and aryl; the bridge group is selected from CH 2 NH; *CH(CH 3 )NH(C*,R); and *CH(CH 3 )NH(C*,S); and the organocatalyst is an organic molecule catalyst covalently bound to the bridge group. In one embodiment, the bridge group is part of the organocatalyst molecule, for example, a thiourea moiety for dual hydrogen bonding.
Each one of R a , R b , R c , and R d can be the same as or different from any of the other R groups. For example, in one embodiment, all of R a , R b , R c , and R d are the same aryl group. In another embodiment, each one of R a , R b , R c , and R d is a different aryl group. In yet another embodiment, R a and R b are different aryl groups, while R c is an alkyl group and R d is a cycloalkyl group.
Preferred aryl moieties for R a , R b , R c , and R d include phenyl; P—CH 3 phenyl; 3,5-di-CH 3 phenyl; 3,5-di-t-butyl phenyl; 3,5-di-CF 3 phenyl; 2-CH 3 phenyl; C 6 F 5 ; 2-naphthyl; and 1-naphthyl. Preferred cycloalkyl moieties for R a , R b , R c , and R d include cyclohexyl and cyclopentyl. Preferred alkyl moieties for R a , R b , R c , and R d include t-butyl and i-propyl.
The term “organocatalyst” as used herein includes organic molecules capable of catalyzing a reaction. Suitable organocatalysts contain at least one moiety that can be covalently bound to a bridge group in the ligand of structure (I) or the catalyst of structure (II). Preferred organocatalysts include a thiourea moiety that can be covalently bound to a bridge group. Exemplary organocatalysts include, but are not limited to those listed above.
When a metal catalyst and an organocatalyst are linked through a covalent bond, cooperative interactions such as the following interaction modes offer high activities and selectivities.
Exemplary methods for preparing the ligands and catalysts described herein are discussed in the Examples section.
The catalysts disclosed herein are useful for a wide range of reactions, including, but not limited to, asymmetric hydrogenation, hydroformylation, aldol, Diels-Alder, hetereo Diels-Alder, Mannich, Michael addition, allylic alkylation, alkylation, Friedel-Crafts, ene, Baylis-Hillman, fluorination, and Henry reactions. In one embodiment depicted in the Examples, a method for the asymmetric hydrogenation of an alkene, imine, ketone, or thioketone to a corresponding alkane, amine, alcohol, or thiol is provided, which includes combining an alkene, imine, ketone, or thioketone in a suitable solvent with an excess of hydrogen gas and a catalytically effective amount of a catalyst disclosed herein, and at a temperature and pressure effective to hydrogenate the alkene, imine, ketone or thioketone. In one embodiment, asymmetric hydrogenation of β,β-disubstituted nitroalkenes provided up to >99% conversion and 99% enantioselectivity.
Suitable solvents include, but are not limited to, polar organic solvents. An exemplary polar organic solvent includes, but is not limited to, isopropanol. A catalytically effective amount of a catalyst can be readily determined by one of skill in the art and includes amounts effective to convert an alkene, imine, or ketone to a corresponding chiral alkane, amine, or alcohol.
The following non-limiting examples serves to further illustrate the present invention.
EXAMPLES
Materials and Methods
All reactions dealing with air- or moisture-sensitive compounds were carried out in a dry reaction vessel under a positive pressure of nitrogen or in a nitrogen-filled glovebox. Unless otherwise noted, all reagents and solvents were purchased from commercial suppliers without further purification. Anhydrous solvents were purchased from Sigma-Aldrich and transferred by syringe. Purification of products was carried out by chromatography using silica gel from ACROS (0.06-0.20 mm) and analytical thin layer chromatography (TLC) was carried out using silica gel plates from Merck (GF254). [Rh(COD)Cl] 2 , [Rh(COD) 2 ]BF 4 and [Rh(COD) 2 ]SbF 6 were purchased from Heraeus. The HPLC solvents were purchase from Alfa (n-Hexane) and Sigma-Aldrich (2-Propanol).
1 H NMR, 13 C NMR and 31 P NMR spectra were recorded on a Bruker Avance (400 MHz) spectrometer with CDCl 3 as the solvent and tetramethylsilane (TMS) as the internal standard. Chemical shifts are reported in parts per million (ppm, δ scale) downfield from TMS at 0.00 ppm and referenced to the CDCl 3 at 7.26 ppm (for 1 H NMR) or 77.0 ppm (for deuterochloroform). Data are reported as: multiplicity (s=singlet, d=doublet, t=triplet, q=quartet, m=multiplet), coupling constant in hertz (Hz) and signal area integration in natural numbers. 13 C NMR and 31 P NMR analyses were run with decoupling.
Enantiomeric excess values (“ee”) were determined by Daicel chiral column on an Agilent 1200 Series HPLC instrument or an Agilent 7980 Series GC instrument. New compounds were further characterized by high resolution mass spectra (HRMS) on a Waters Q-T of Ultima mass spectrometer with an electrospray ionization source (University of Illinois, SCS, Mass Spectrometry Lab). Optical rotations [α] D were measured on a PERKINELMER polarimeter 343 instrument.
All (E)-β,β-disubstituted nitroalkenes were prepared according the literature. (Li, S., et al., Angew. Chem. Int. Ed. 2012, 51, 8573-8576). All N—H imines were prepared according to the literature. (Hou, G., et al., J. Am. Chem. Soc. 2009, 131, 9882-9883.) The absolute configuration of products were determined by comparison of analytical data with the literature (HPLC spectra, optical rotation). The absolute configuration of others were assigned by analogy.
Example 1—Synthesis of Ligands
Ligands L1-L3 were prepared according the according the literature (Hayashi, T., et al., Bull. Chem. Soc. Jpn. 1980, 53, 1138-1151) with a slight modification: column chromatography was performed using silica gel (hexane/ethyl acetate for L1 and dichloromethane/methanol for L2) instead of alumina (hexane/benzene for L1 and ether/ethyl acetate for L2). All the spectral data are consistent with the literature values.
Under an argon atmosphere, 3,5-bis(trifluoromethyl)phenyl isothiocyanate (1.1 mmol) was added to a solution of L2 (1.0 mmol) in dry DCM (1.0 ml). After the reaction mixture was stirred overnight, the reaction mixture was concentrated in vacuo. The residue was purified by flash column chromatography on silica gel (hexane/ethyl acetate=9/1 as eluant) gave L8 as yellow solid (640 mg, 74%). L8 was characterized as follows:
1 H NMR (400 MHz, CDCl 3 ) δ 7.69 (s, 3H), 7.33-7.12 (m, 19H), 7.11-7.01 (m, 3H), 5.53 (s, 1H), 4.47 (d, J=7.2 Hz, 2H), 4.28 (s, 1H), 4.18 (t, J=2.3 Hz, 1H), 3.96 (s, 1H), 3.56 (s, 1H), 3.45 (s, 1H), 1.42 (d, J=6.6 Hz, 1H).
13 C NMR (100 MHz, CDCl 3 ) δ 178.37 (s), 139.18 (s), 138.94 (d, J=9.6 Hz), 138.82 (d, J=6.3 Hz), 138.04 (d, J=9.4 Hz), 135.55 (d, J=5.0 Hz), 134.68 (d, J=21.2 Hz), 133.71 (d, J=20.1 Hz), 133.01 (d, J=19.2 Hz), 132.20 (d, J=17.8 Hz), 129.58 (s), 128.97-127.94 (m), 124.48 (s), 124.31 (s), 121.60 (s), 119.16 (s), 95.36 (d, J=24.1 Hz), 77.63 (d, J=8.5 Hz), 75.34 (d, J=20.4 Hz), 74.16 (d, J=9.1 Hz), 73.84 (d, J=4.9 Hz), 73.37 (d, J=8.5 Hz), 73.10-72.50 (m), 71.97 (d, J=2.6 Hz), 50.87 (s), 21.86 (s).
31 P NMR (162 MHz, CDCl 3 ) δ −17.81 (s), −25.08 (s).
[α] D 25 =237.3° (c=0.30, CHCl 3 )
HRMS (ESI): [M+H + ] Calc. 869.1406. found 869.1401.
1 H NMR (400 MHz, CDCl 3 ) δ 7.54 (s, 2H), 7.42-7.38 (m, 3H), 7.34-7.14 (m, 18H), 5.13 (s, 2H), 5.13-5.07 (m, 1H), 4.48 (d, J=1.7 Hz, 2H), 4.37 (d, J=7.4 Hz, 2H), 4.19 (d, J=8.1 Hz, 2H), 4.14 (t, J=2.3 Hz, 1H), 3.65 (s, 1H), 3.57 (s, 1H), 1.46 (d, J=6.7 Hz, 3H).
13 C NMR (100 MHz, CDCl 3 ) δ 152.34 (s), 140.51 (s), 140.39 (s), 138.90 (d, J=9.7 Hz), 138.14 (d, J=9.4 Hz), 135.89 (d, J=8.1 Hz), 134.92 (d, J=21.2 Hz), 133.60 (d, J=20.0 Hz), 133.06 (d, J=19.2 Hz), 132.44 (d, J=18.8 Hz), 131.76 (d, J=33.2 Hz), 129.39 (s), 128.72 (s), 128.62-127.96 (m), 124.55 (s), 121.84 (s), 118.11 (d, J=3.1 Hz), 115.21 (s), 95.11 (d, J=23.6 Hz), 77.19 (s), 75.78 (d, J=10.3 Hz), 75.36 (d, J=19.6 Hz), 74.33 (d, J=3.0 Hz), 73.42-71.18 (m), 73.11 (d, J=4.5 Hz), 71.67 (d, J=2.2 Hz), 71.24 (d, J=1.9 Hz), 45.48 (d, J=7.1 Hz), 20.65 (s).
HRMS (ESI): [M+H + ] Calc. 853.1635. found 853.1644.
[α] D 25 =262.1° (c=0.33, CHCl 3 ).
1 H NMR (400 MHz, CDCl 3 ) δ 7.44 (t, J=7.2 Hz, 2H), 7.40-7.11 (m, 24H), 6.00 (s, 2H), 5.46 (s, 1H), 4.60 (s, 1H), 4.57-3.52 (m, 4H), 3.56 (d, J=10.8 Hz, 2H), 1.35 (d, J=6.6 Hz, 3H), 1.04 (d, J=6.2 Hz, 3H).
13 C NMR (100 MHz, CDCl 3 ) δ 178.66 (s), 141.83 (s), 139.05 (d, J=2.9 Hz), 138.97 (s), 138.23 (d, J=9.6 Hz), 136.13 (d, J=7.2 Hz), 134.71 (d, J=21.0 Hz), 133.62 (d, J=20.1 Hz), 132.98 (d, J=19.2 Hz), 132.55 (d, J=18.6 Hz), 129.29 (s), 128.98-127.45 (m), 125.65 (s), 95.44 (d, J=23.6 Hz), 77.17 (d, J=8.1 Hz), 75.25 (d, J=19.9 Hz), 74.80 (d, J=10.3 Hz), 74.08 (d, J=4.5 Hz), 73.25 (d, J=9.0 Hz), 73.13 (s), 72.72 (d, J=4.3 Hz), 72.41 (s), 71.50 (d, J=2.6 Hz), 52.79 (s), 50.51 (s), 23.82 (s), 21.45 (s).
31 P NMR (162 MHz, CDCl 3 ) δ −17.66 (s), −25.81 (s).
HRMS (ESI): [M+H + ] Calc. 761.1972. found 761.1972.
[α] D 25 =343.5° (c=0.21, CHCl 3 ).
1 H NMR (400 MHz, CDCl 3 ) δ 8.21 (t, J=9.1 Hz, 1H), 7.59 (s, 1H), 7.25-6.92 (m, 23H), 5.51-5.41 (m, 1H), 4.43-4.38 (m, 2H), 4.29 (s, 1H), 4.17 (s, 1H), 3.70 (s, 1H), 3.40 (s, 1H), 3.09 (s, 1H), 2.42 (s, 6H), 1.24 (d, J=6.9 Hz, 3H).
13 C NMR (100 MHz, CDCl 3 ) δ 178.51 (s), 140.22 (s), 139.32 (d, J=9.9 Hz), 138.56 (d, J=5.4 Hz), 138.03 (d, J=9.7 Hz), 135.93 (s), 134.64 (d, J=21.2 Hz), 133.84 (d, J=20.4 Hz), 132.76 (d, J=18.9 Hz), 132.08 (d, J=17.5 Hz), 129.27 (d, J=17.7 Hz), 128.67 (s), 128.29-127.92 (m), 96.88 (d, J=24.1 Hz), 75.39 (d, J=22.6 Hz), 73.95 (d, J=5.3 Hz), 73.65 (d, J=5.6 Hz), 72.98 (d, J=6.8 Hz), 72.81 (s), 72.56 (d, J=3.7 Hz), 72.16 (d, J=3.6 Hz), 51.84 (s), 24.43 (s), 21.48 (s).
31 P NMR (162 MHz, CDCl 3 ) δ −17.61 (s), −25.96 (s).
HRMS (ESI): [M+H + ] Calc. 761.1972. found 761.1964.
[α] D 25 =−219.9° (c=0.22, CHCl 3 )
1 H NMR (400 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.73 (d, J=8.4 Hz, 2H), 7.71-7.64 (m, 1H), 7.35-7.13 (m, 18H), 7.08-7.02 (m, 4H), 5.56-5.46 (m, 1H), 4.45 (s, 1H), 4.32 (s, 1H), 4.25 (s, 1H), 4.17 (t, J=2.4 Hz, 1H), 3.72 (s, 1H), 3.50 (s, 1H), 3.26 (s, 1H), 1.33 (d, J=6.8 Hz, 1H).
13 C NMR (100 MHz, CDCl 3 ) δ 178.11 (s), 139.79 (s), 139.14 (d, J=9.8 Hz), 138.63 (d, J=5.5 Hz), 137.96 (d, J=9.4 Hz), 135.58 (d, J=4.5 Hz), 134.68 (d, J=21.2 Hz), 133.81 (d, J=20.3 Hz), 132.83 (d, J=18.9 Hz), 132.22 (s), 130.27-129.77 (m), 128.78 (s), 128.66-128.01 (m), 127.27 (d, J=3.4 Hz), 125.01 (s), 95.87 (d, J=24.2 Hz), 77.59 (d, J=8.6 Hz), 75.42 (d, J=22.0 Hz), 73.63 (d, J=5.2 Hz), 73.14 (d, J=7.2 Hz), 72.83 (s), 72.08 (d, J=3.0 Hz), 51.60 (s), 23.10 (s).
31 P NMR (162 MHz, CDCl 3 ) δ −17.85 (s), −26.34 (s).
HRMS (ESI): [M+H + ] Calc. 801.1532. found 801.1538.
[α] D 25 =−239.5° (c=0.30, CHCl 3 )
Ligands L9-L14 were prepared according the according the literature (Zhao, Q., et al., Org. Lett. 2013, 15, 4014-4017).
Ligands L15-L17 were synthesized as follows:
SI2 was prepared according the according the literature (Zhao, Q., et al., Org. Lett. 2013, 15, 4014-4017). SI3 was prepared according the according the literature (Gotov, B., et al., New J. Chem. 2000, 24, 597-602). Under a nitrogen atmosphere, 3,5-bis(trifluoromethyl)phenyl isothiocyanate (1.1 mmol) as added to a solution of SI3 (1.0 mmol) in dry DCM (1.0 ml). After the reaction mixture was stirred overnight, the reaction mixture was concentrated in vacuo. The residue was purified by flash column chromatography on silica gel (hexane/ethyl acetate=9/1 as eluant) gave L15 as yellow solid.
L15: 1 H NMR (400 MHz, CDCl 3 ) δ 7.65 (s, 2H), 7.54 (s, 1H), 7.49-7.40 (m, 3H), 7.35-7.07 (m, 18H), 6.44 (s, 1H), 4.53 (d, J=6.0 Hz, 2H), 4.21 (d, J=15.6 Hz, 3H), 3.71 (s, 2H), 2.50 (s, 3H), 1.50 (d, J=6.7 Hz, 3H).
13 C NMR (100 MHz, CDCl 3 ) δ 180.28 (s), 141.45 (s), 138.82 (d, J=9.8 Hz), 138.30 (d, J=9.8 Hz), 135.78 (d, J=7.7 Hz), 134.88 (d, J=21.3 Hz), 133.42 (dd, J=33.4, 19.7 Hz), 132.53 (d, J=19.5 Hz), 131.28 (q, J=33.4 Hz), 129.43 (s), 129.01-128.44 (m), 128.28 (d, J=6.8 Hz), 128.16 (s), 124.61 (s), 123.89 (s), 121.90 (s), 117.57 (s), 93.41 (d, J=26.4 Hz), 75.47 (d, J=18.1 Hz), 74.42 (s), 73.56 (d, J=5.1 Hz), 73.40 (d, J=4.6 Hz), 72.18 (s), 71.75 (s), 54.83 (d, J=7.7 Hz), 31.93 (s), 15.64 (s).
31 P NMR (162 MHz, CDCl 3 ) δ −18.09 (s), −26.79 (s).
HRMS (ESI): [M+H + ] Calc. 883.1485. found 883.1583.
SI4 was prepared according the according the literature (Zhao, Q., et al., Org. Lett. 2013, 15, 4014-4017). Under an nitrogen atmosphere, 3,5-bis(trifluoromethyl)phenyl isothiocyanate (1.1 mmol) was added to a solution of SI4 (1.0 mmol) in dry DCM (1.0 ml). After the reaction mixture was stirred overnight, the reaction mixture was concentrated in vacuo. The residue was purified by flash column chromatography on silica gel (hexane/ethyl acetate=9/1 as eluant) gave L16 as yellow solid.
L16: 1 H NMR (400 MHz, CDCl 3 ) δ 8.07 (s, 1H), 7.75 (d, J=10.5 Hz, 3H), 6.29 (s, 1H), 5.30 (s, 1H), 4.26-4.15 (m, 3H), 4.08 (s, 2H), 4.03 (s, 4H), 1.60 (d, J=6.5 Hz, 3H).
13 C NMR (100 MHz, CDCl 3 ) δ 179.16 (s), 138.72 (s), 133.43 (d, J=33.7 Hz), 124.42 (s), 124.07 (s), 121.36 (s), 119.84 (s), 90.06 (s), 68.59 (d, J=3.6 Hz), 68.27 (s), 67.41 (s), 65.57 (s), 50.14 (s), 19.99 (s). HRMS (ESI): [M + ] Calc. 500.0444. found 500.0452.
SI5 was prepared according the according the literature (Zhao, Q., et al., Org. Lett. 2013, 15, 4014-4017 and Hayashi, T., et al., Bull. Chem. Soc. Jpn, 1980, 53, 1138-1151). Under a nitrogen atmosphere, 3,5-bis(trifluoromethyl)phenyl isothiocyanate (1.1 mmol) was added to a solution of SI5 (1.0 mmol) in dry DCM (1.0 ml). After the reaction mixture was stirred overnight, the reaction mixture was concentrated in vacuo. The residue was purified by flash column chromatography on silica gel (hexane/ethyl acetate=9/1 as eluant) gave L17 as yellow solid.
L17: 1 H NMR (400 MHz, CDCl 3 ) δ 7.74 (s, 3H), 7.51 (s, 2H), 7.40-7.28 (m, 5M), 7.22 (s, 3H), 7.15-7.05 (m, 2H), 5.59 (s, 1H) 4.51 (s, 1H), 4.32 (s, 1H), 3.96 (s, 5H), 3.79 (s, 1H), 1.46 (d, J=4.7 Hz, 3H).
13 C NMR (100 MHz, CDCl 3 ) δ 177.42 (s), 138.02 (s), 137.86 (d, J=6.0 Hz), 134.85 (d, J=4.5 Hz), 133.73 (d, J=20.8 Hz), 131.89 (d, J=33.9 Hz), 131.25 (d, J=17.8 Hz), 128.51 (s), 127.43-127.02 (m), 126.10-125.89 (m), 123.82 (s), 123.27 (s), 120.56 (s), 118.42 (s), 118.01-117.76 (m), 93.98 (d, J=24.2 Hz), 72.16 (s), 71.07 (d, J=4.0 Hz), 70.22 (s), 68.83 (s), 68.66 (s), 50.33 (s), 21.26 (s).
31 P NMR (162 MHz, CDCl 3 ) δ −24.67 (s).
HRMS (ESI): [M+H + ] Calc. 685.0964. found 685.0950.
Example 2—Asymmetric Hydrogenation of Nitroalkenes
In a nitrogen-filled glovebox, a solution of L (2.2 eqv.) and [Rh(COD)Cl] 2 (3.0 mg, 0.006 mmol) in 3.0 mL anhydrous i-PrOH was stirred at room temperature for 30 min. A specified amount of the resulting solution (0.25 mL) was transferred to a vial charged with 1a (0.1 mmol) by syringe. The vials were transferred to an autoclave, which was then charged with 5 atm of H 2 and stirred at 35° C. for 24 h. The hydrogen gas was released slowly and the solution was concentrated and passed through a short column of silica gel to remove the metal complex. The product (2a) was analyzed by NMR spectroscopy for conversion and chiral HPLC for ee values.
(R)-2a: 1 H NMR (400 MHz, CDCl 3 ) δδ 7.38-7.31 (m, 2H), 7.30-7.20 (m, 3H), 4.58-4.46 (m, 1H), 3.85-3.16 (m, 1H), 1.38 (d, J=7.0 Hz, 1H). 13 C NMR (100 MHz, CDCl 3 ) δ 140.93 (s), 128.98 (s), 127.57 (s), 126.90 (s), 81.87 (s), 38.65 (s), 18.73 (s). HPLC: OD, 215 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=19.4 min, t R (minor)=27.4 min. [α] D 25 =+41.4° (c=0.67, CHCl 3 ).
TABLE 1
Study of effects of pressure, concentration, and temperature. a
Entry
Solvent
Rh-L8
H 2 [atm]
S/C
V (mL)
T [° C.]
2a [%] b
ee [%] c
1
i-PrOH
[Rh(COD)Cl] 2
5
50
0.25
25
>99
99
2
i-PrOH
[Rh(COD)Cl] 2
5
100
0.25
35
>99
99
3
i-PrOH
[Rh(COD)Cl] 2
5
200
0.25
35
97
98
4
i-PrOH
[Rh(COD)Cl] 2
5
400
0.25
35
90
98
5
i-PrOH
[Rh(COD)Cl] 2
10
200
0.25
35
97
99
6
i-PrOH
[Rh(COD)Cl] 2
20
200
0.25
35
>99
98
7
i-PrOH
[Rh(COD)Cl] 2
20
400
0.25
35
95
98
8
i-PrOH
[Rh(COD)Cl] 2
30
400
0.25
35
98
98
9
i-PrOH
[Rh(COD)Cl] 2
5
100
0.5
35
99
98
10
i-PrOH
[Rh(COD)Cl] 2
5
100
1.0
35
97
98
11
i-PrOH
[Rh(COD)Cl] 2
5
400
0.25
45
90
94
a Unless ortherwise mentioned, reactions were performed with 1a (0.1 mmol) and a 1a/Rh/L ratio of 1/1.1/1.1.
b Conversions were determined by 1 H NMR spectroscopy of the crude reaction mixture and HPLC analysis.
c Determined by HPLC analysis on a chiral stationary phase.
β,β-disubstituted nitroalkanes were prepared using the general procedure set forth above with different nitroalkenes. Nitroalkenes with various substituents at the phenyl ring were tolerated. Meta and para substitutions led to excellent results whether they were electron-withdrawing or electron-donating groups. The ortho-methoxy group resulted in a lower conversion and enantioselectivity. This catalytic system also provided enantiomerically β-ethyl nitroalkane with good conversion and excellent enantioselectivity. The nitroalkanes were characterized as follows:
(R)-2b: 1 H NMR (400 MHz, CDCl 3 ) δ 7.39-6.86 (m, 5H), 4.47-4.36 (m, 2H), 3.47-3.49 (m, 1H), 2.25 (s, 3H), 1.28 (d, J=7.0 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 137.87 (s), 137.21 (s), 129.61 (s), 126.73 (s), 81.98 (s), 38.27 (s), 20.98 (s), 18.75 (s). HPLC: OD, 215 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=14.1 min, t R (minor)=23.0 min. [α] D 25 =+42.9° (c=0.51, CHCl 3 )
(R)-2c: 1 H NMR (400 MHz, CDCl 3 ) δ 7.19-7.11 (m, 2H), 6.96-6.84 (m, 2H), 4.52-4.42 (m, 2H), 3.79 (s, 3H), 3.66-3.54 (m, 1H), 1.35 (d, J=7.0 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 158.94 (s), 132.86 (s), 127.89 (s), 114.34 (s), 82.12 (s), 55.26 (s), 37.92 (s), 18.79 (s). HPLC: OD, 215 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=22.1 min, t R (minor)=40.6 min. [α] D 25 =+35.8° (c=0.51, CHCl 3 )
(R)-2d: 1 H NMR (400 MHz, CDCl 3 ) δ 7.37-7.27 (m, 2H), 7.21-7.12 (m, 2H), 4.63-4.42 (m, 2H), 3.75-3.48 (m, 1H), 1.37 (d, J=7.0 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 139.35 (s), 133.43 (s), 129.15 (s), 128.27 (s), 81.56 (s), 38.07 (s), 18.71 (s). HPLC: OD, 215 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=18.8 mm, t R (minor)=27.1 min. [α] D 25 =+39.5° (c=0.48, CHCl 3 )
(R)-2e: 1 H NMR (400 MHz, CDCl 3 ) δ 7.18-7.13 (m, 4H), 4.56-4.43 (m, 2H), 3.70-3.48 (m, 1H), 2.63 (q, J=7.6 Hz, 2H), 1.36 (d, J=7.0 Hz, 3H), 1.22 (t, J=7.6 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 143.58 (s), 138.10 (s), 128.43 (s), 126.83 (s), 82.01 (s), 38.30 (s), 28.42 (s), 18.75 (s), 15.42 (s). HPLC: OD, 215 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=11.8 min, t R (minor)=19.9 min. [α] D 25 =+54.3° (c=0.44, CHCl 3 ).
(R)-2f: 1 H NMR (400 MHz, CDCl 3 ) δ 7.37-7.32 (m, 2H), 7.18-7.12 (m, 2H), 4.56-4.43 (m, 2H), 3.69-3.51 (m, 1H), 1.37 (d, J=7.0 Hz, 3H), 1.30 (s, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 150.47 (s), 137.79 (s), 126.55 (s), 125.84 (s), 81.97 (s), 38.13 (s), 34.47 (s), 31.29 (s), 18.67 (s). HPLC: OD, 215 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=9.7 min, t R (minor)=18.4 min. [α] D 25 =+41.8° (c=1.0, CHCl 3 )
(R)-2g: 1 H NMR (400 MHz, CDCl 3 ) δ 7.30-7.22 (m, 1H), 7.16 (dd, J=7.6, 1.6 Hz, 1H), 6.96-6.88 (m, 2H), 4.68 (dd, J=11.9, 6.0 Hz, 1H), 4.46 (dd, J=11.9, 8.8 Hz, 1H), 3.97-3.90 (m, 1H), 3.88 (s, 3H), 1.38 (d, J=7.0 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 157.06 (s), 128.82 (s), 128.51 (s), 127.71 (s), 120.86 (s), 110.83 (s), 80.45 (s), 55.34 (s), 33.48 (s), 17.05 (s). HPLC: OD, 21.5 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=14.4 min, t R (minor)=17.0 min. [α] D 25 =+6.9 (c=0.2, CHCl 3 ).
(R)-2h: 1 H NMR (400 MHz, CDCl 3 ) δ 7.35-7.27 (m, 1H), 7.05-6.87 (m, 1H), 4.57-4.45 (m, 2H), 3.69-3.62 (m, 1H), 1.38 (d, J=7.0 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 164.33 (s), 161.88 (s), 143.46 (d, J=7.0 Hz), 130.57 (d, J=8.3 Hz), 122.65 (d, J=2.9 Hz), 114.59 (d, J=21.0 Hz), 113.96 (d, J=21.8 Hz), 81.51 (s), 38.37 (d, J=1.6 Hz), 18.67 (s). HPLC: OD, 215 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=20.0 min, t R (minor)=28.4 min. [α] D 25 =+33.3° (c=0.72, CHCl 3 ).
(R)-2i: 1 H NMR (400 MHz, CDCl 3 ) δ 7.31-7.21 (m, 3H), 7.12-7.10 (m, 1H), 4.56-4.45 (m, 2H), 3.70-3.55 (m, 1H), 1.37 (d, J=7.0 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 142.94 (s), 134.83 (s), 130.26 (s), 127.84 (s), 127.17 (s), 125.18 (s), 81.41 (s), 38.33 (s), 18.65 (s). HPLC: OD, 215 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=19.8 min, t R (minor)=30.5 min. [α] D 25 =+37.1° (c=0.58, CHCl 3 )
(R)-2j: 1 H NMR (400 MHz, CDCl 3 ) δ 7.26 (t, J=7.9 Hz, 1H), 6.96-6.68 (m, 3H), 4.57-4.44 (m, 2H), 3.80 (s, 3H), 3.66-3.54 (m, 1H), 1.37 (d, J=7.0 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 160.00 (s), 142.54 (s), 130.01 (s), 119.11 (s), 113.10 (s), 112.55 (s), 81.79 (s), 77.34 (s), 77.03 (s), 76.71 (s), 55.23 (s), 38.66 (s), 18.70 (s). HPLC: OD, 215 nm, hexane/2-propanol=95:5, flow rate 0.9 mL/min, t R (major)=29.3 min, t R (minor)=52.2 min. [α] D 25 =+40.6° (c=0.73, CHCl 3 )
(R)-2k: 1 H NMR (400 MHz, CDCl 3 ) δ 8.08-7.70 (m, 3H), 7.67 (d, J=1.0 Hz, 1H), 7.56-7.40 (m, 2H), 7.35 (dd, J=8.5, 1.8 Hz, 1H), 4.67-4.54 (m, 2H), 4.02-3.55 (m, 1H), 1.47 (d, J=7.0 Hz, 2H). 13 C NMR (100 MHz, CDCl 3 ) δ 138.29, 133.52, 132.78, 128.85, 127.76, 127.69, 126.44, 126.08, 125.78, 124.81, 81.80, 38.80, 18.79. HPLC: OD, 215 nm, hexane/2-propanol=80:20, flow rate 0.9 mL/min, t R (major)=19.8 min, t R (minor)=53.5 min. [α] D 25 =+36.8° (c=0.9, CHCl 3 )
(R)-2l: 1 H NMR (400 MHz, CDCl 3 ) δ 7.39-7.23 (m, 3H), 7.21-7.10 (m, 2H), 4.59-4.51 (m, 2H), 3.54-3.11 (m, 1H), 1.79-1.66 (m, 2H), 0.84 (t, J=7.4 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 139.33, 128.89, 127.56, 80.76, 46.00, 26.18, 11.49. HPLC: OD, 215 nm, hexane/2-propanol=98:2, flow rate 0.9 mL/min, t R (major)=16.0 min, t R (minor)=27.7 min. [α] D 25 =+35.5° (c=0.54, CHCl 3 )
(S)-2m: 1 H NMR (400 MHz, CDCl 3 ) δ 6.26-6.23 (m, 1H), 6.05 (d, J=3.1 Hz, 1H), 4.59 (dd, J=12.2, 6.6 Hz, 1H), 4.36 (dd, J=12.2, 8.0 Hz, 1H), 3.72-3.60 (m, 1H), 1.31 (d, J=7.0 Hz, 3H). 13 C NMR (100 MHz, CDCl 3 ) δ 152.85 (s), 141.08 (s), 109.27 (s), 104.92 (s), 78.49 (s), 31.41 (s), 15.12 (s). HPLC: OD, 215 nm, hexane/2-propanol=99.5:0.5, flow rate 0.9 mL/min, t R (major)=27.5 min, t R (minor)=30.7 min.
Example 3—Asymmetric Hydrogenation of N—H Imines
All N—H imines were prepared according the literature (Hou, G., et al., J. Am. Chem. Soc. 2009, 131, 9882-9883.). All the spectral data are consistent with the literature values.
1 H NMR (400 MHz, CDCl 3 ) δ 11.46 (s, 2H), 8.20-7.91 (m, 2H), 7.78 (t, J=7.5 Hz, 1H), 7.61 (dd, J=17.7, 9.6 Hz, 2H), 2.94 (d, J=5.2 Hz, 3H).
13 C NMR (100 MHz, CDCl 3 ) δ 186.36 (s), 136.95 (s), 129.92 (s), 129.35 (s), 129.33 (s), 21.73 (s).
General Procedure:
In a nitrogen-filled glovebox a solution of L14 (2.2 eqv.) and [Rh(COD)Cl] 2 (3.0 mg, 0.006 mmol) in 6.0 mL anhydrous i-PrOH was stirred at room temperature for 30 min.
A specified amount of the resulting solution (1 mL) was transferred to a vial charged with 1a (0.1 mmol) by syringe. The vials were transferred to an autoclave, which was then charged with 10 atm of H 2 and stirred at 25° C. for 24 h. The resulting mixture was concentrated under vacuum and dissolved in saturated aqueous NaHCO 3 (5 mL). After stirring for 10 min, the mixture was extracted with CH 2 Cl 2 (3×2 mL) and dried over Na 2 SO 4 . To the resulting solution was added Ac 2 O (300 μL) and stirred for 30 min. The resulting solution was then analyzed for conversion and ee directly by GC. The product was purified by chromatography on silica gel column with dichloromethane/methanol (90:10). All spectral data were consistent with the literature values (Hou. G., et al., J. Am. Chem. Soc. 2009, 131, 9882-9883).
TABLE 2
Study of metal salts.
H 2
Conv.
ee
Entry
Solvent
Metal
[atm]
S/C
V [mL]
T [° C.]
[%] b
[%] c
1
i-PrOH
[Rh(COD)Cl] 2
20
25
1
35
99
92
2
i-PrOH
[Ir(COD)Cl] 2
20
25
1
35
90
84
3
i-PrOH
Rh(COD) 2 BF 4
20
25
1
35
93
77
4
i-PrOH
Rh(NBD) 2 SbF 6
20
25
1
35
95
17
5
i-PrOH
Pd(OAc) 2
20
25
1
35
<1
ND
6
i-PrOH
Pd(TFA) 2
20
25
1
35
30
0
7
i-PrOH
[{RuCl 2 (p-cymene)} 2 ]
20
25
1
35
8
23
[a] Unless ortherwise mentioned, reactions were performed with 1a (0.1 mmol) and a Metal/L14 ratio of 1/1.1.
b Determined by GC analysis of the corresponding acetamides.
ND = not determined.
TABLE 3
Study of pressure and temperature.
Conv.
Entry
Solvent
H 2 [atm]
S/C
V (mL)
T [° C.]
[%] b
ee [%] c
1
i-PrOH
20
25
1
35
99
92
2
i-PrOH
20
50
1
35
99
93
3
i-PrOH
20
100
1
35
99
93
4
i-PrOH
10
100
1
25
99
94
5
i-PrOH
10
200
1
25
96
94
6
i-PrOH
10
400
1
25
86
93
7
i-PrOH
20
200
1
25
97
93
8
i-PrOH
20
200
1
35
97
92
9
i-PrOH
20
400
1
35
90
93
[a] Reactions were performed with 1a (0.1 mmol) and a [Rh(COD)Cl] 2 /L14 ratio of 1/1.1.
b Determined by GC analysis of the corresponding acetamides.
TABLE 4
Study of additives.
H 2
Conv.
Entry
Solvent
[atm]
S/C
Additive
T [° C.]
[%] b
ee [%] b
1
i-PrOH
20
50
4A MS
35
67
53
(100 mg)
2
i-PrOH
20
50
CF 3 COOH
35
99
75
(10 mmol %)
3
i-PrOH
20
50
CH 3 COOH
35
98
79
(10 mmol %)
4
i-PrOH
20
50
Et 3 N
35
63
35
(10 mmol %)
[a] Reactions were performed with 1a (0.1 mmol) and a [Rh(COD)Cl] 2 /L14 ratio of 1/2.2.
b Determined by GC analysis of the corresponding acetamides.
TABLE 5
Solvent study.
Entry
Solvent
Metal source
Covn. b (%)
ee b (%)
1
i-PrOH
[Rh(COD) 2 ]BF 4
93
77
2
i-PrOH
[Rh(NBD) 2 ]SbF 6
95
47
3
i-PrOH
[Rh(COD)Cl] 2
99
92
4
CH 2 Cl 2
[Rh(COD)Cl] 2
91
30
5
Toluene
[Rh(COD)Cl] 2
60
15
6
THF
[Rh(COD)Cl] 2
76
60
7
MeOH
[Rh(COD)Cl] 2
99
73
8
EtOH
[Rh(COD)Cl] 2
92
89
9
t-BuOH
[Rh(COD)Cl] 2
84
91
10 c
i-PrOH
[Rh(COD)Cl] 2
99
93
11 d
i-PrOH
[Rh(COD)Cl] 2
99
94
12 e
i-PrOH
[Rh(COD)Cl] 2
96
94
11 f
i-PrOH
[Rh(COD)Cl] 2
97
93
14 g
i-PrOH
[Rh(COD)Cl] 2
97
92
a Unless otherwise mentioned, reactions were performed with 1a (0.1 mmol) and a Rh/L/1a ratio of 1/1.1/25 in 1.0 mL solvent at 35° C. under 20 atm H 2.
b Determined by GC analysis of the corresponding acetamides.
c S/C = 100, 35° C., 20 atm H 2 .
d S/C = 100, 25° C., 10 atm H 2 .
e S/C = 100, 25° C., 10 atm H 2 .
f S/C = 200, 25° C., 20 atm H 2 .
g S/C = 200, 35° C., 20 atm H 2 .
COD = 1,5-cyclooctadiene, NBD = 2,5-norbornadiene.
A variety of N—H imines were tested. Most substrates with meta and para substitutions on the phenyl ring afforded high yields and enantioselectivities (96-99% yield and 90-94% ee).
However, the chloro group and methoxy group resulted in an obvious decrease of the yields (2d, 2e and 2g). The ortho-methoxy group on the phenyl ring resulted in 34% yield and 84% ee (2h). Products with 1- and 2-naphthyl group were obtained with 92% ee and 93% ee respectively. Changing the R 2 group had a significant effect on the outcome. When R 2 was ethyl, both lower conversion and enantioselectivity were observed (2k). As the R 2 group was changed to butyl, further loss of the conversion and enantioselectivity was observed (70% yield and 75% ee, 2l).
To obtain insight into this catalytic system, a series of chiral ligands were prepared and control experiments were undertaken.
TABLE 6
Ligand study.
Entry
Ligands
Covn. b (%) b
ee b (%)
1
L1
2
55
2
L2
22
66
3
L3
6
11
4
L4
72
87
5
L5
76
90
6
L6
99
94
7
L7
26
38
8
L8
2
11
9
L9
9
84
10 c
L8
5
8
11 d
L1
9
57
a Unless otherwise mentioned, reactions were performed with 1a (0.1 mmol) and a Rh/L/1a ratio of 1/1.1/100 in 1.0 mL solvent at 25° C. under 10 atm H 2 .
b Determined by GC analysis of the corresponding acetamides.
c Rh/L/1a/Ph 3 P = 1/1.1/100/2.2.
d Rh/L/1a/thiourea = 1/1.1/100/1.1.
The Rh-bisphosphine complex without a (thio)urea (L9) showed very low activity and enantioselectivity (Table 6, entry 1). Urea L10 provided 22% conversion and 66% ee in sharp contrast with the more acidic thiourea L14 (Table 6, entry 2 vs. 6). 1a The CF 3 group on the 3,5-(trifluoromethyl)phenyl moiety remained important in the catalytic system (Table 6, entries 3-5). Further, several modified ligands were prepared and screened. An N-methylation of L14 led to a dramatic decrease of the conversion and enantioselectivity (Table 6, entry 7). This finding suggested that the NH was involved in the activation of iminium salts and the stereoselectivity of hydrogenation. Furthermore, the low conversion and enantioselectivity obtained with monodentate phosphorus ligands implied that a bisphosphine moiety was essential (Table 6, entry 9). Importantly, neither the combination of the chiral phosphine with the 3,5-bistrifluoromethylphenyl thiourea, nor the combination of the chiral thiourea with the simple phosphine improved this reaction (Table 6, entry 1 vs. 11, entry 8 vs. 10), which pointed to the importance of the covalent linker for high activity and enantioselectivity.
Different counterions and additives were also investigated. When the chloride counterion in 1a was replaced with trifluoromethanesulfonate, only 20% conversion and 53% ee was observed (Table 7, entry 1). The addition of a chloride counterion increased the conversions and enantioselectivities (entries 2 and 3). However, the addition of bromide and iodide counterions decreased the conversions and enantioselectivities (entries 4-6).
TABLE 3
Substrates study and control experiments. a
Entry
1
Additive
Conv. b (%)
ee b (%)
1
1m
—
20
53
2
1m
TBAC
86
94
3
1m
LiCl
71
93
4
1a
—
99
94
5
1a
TBAB
77
90
6
1a
TBAI
32
89
a Unless otherwise mentioned, reactions were performed with 1a (0.1 mmol) and a Rh/L/1a/Additive ratio of 1/1.1/100/100 in 1.0 mL solvent.
b Determined by GC analysis of the corresponding acetamides.
c Determined by 1 H NMR.
TBAC = tetrabutylammonium chloride,
TBAB = tetrabutylammonium bromide,
TBAI = tetrabutylammonium iodide.
ND = not detertimined.
Further information about the reaction was obtained by 1 H NMR studies of mixtures generated from ligands and TBAC. The addition of varying amounts of TBAC to L14 in CDCl 3 resulted in downfield shifts of the NH proton signals. At 1.0 equivalents of TBAC, the signal for NH was at 9.73 ppm, but when 3.0 equivalents of TBAC were added, the NH signal appeared at 10.16 ppm. Analogous experiments employing a series of different ligands and TBAC gave similar results. This finding was consistent with a hydrogen-bonding interaction between the catalyst's thiourea and chloride ions. This observation, coupled with the fact that optimal yields and ee values involve chloride ions, led us to propose that catalytic chloride-bound intermediates are involved in the mechanism.
The present invention has been described with particular reference to the preferred embodiments. It should be understood that the foregoing descriptions and examples are only illustrative of the invention. Various alternatives and modifications thereof can be devised by those skilled in the art without departing from the spirit and scope of the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variations that fall with the scope of the appended claims. | A ligand having the structure or its enantiomer; (I) wherein: each one of R a , R b , R c and R d is selected from alkyl, cycloalkyl, and aryl; the bridge group is selected from CH 2 NH; *CH(CH 3 )NH(C*,R); and the organocatalyst is an organic molecule catalyst covalently bound to the bridge group. Also, a catalyst having the structure or its enantiomer: (II) wherein: each one of R a , R b , R c and R d is selected from alkyl, cycloalkyl, and aryl; the bridge group is selected from CH 2 NH; *CH(CH 3 )NH(C*,R); and *CH(CH 3 )NH(C*,S); the organocatalyst is an organic molecule catalyst covalently bound to the bridge group; and M is selected from the group consisting of Rh, Pd, Cu, Ru, Ir, Ag, Au, Zn, Ni, Co, and Fe. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of provisional application Ser. No. 60/904,458, filed Mar. 2, 2007.
TECHNICAL FIELD
[0002] This invention relates to a medical device and more particularly to a device for use with vascular or endovascular surgery.
BACKGROUND OF THE INVENTION
[0003] Endovascular surgery involves the placement of stents or stent grafts into the vasculature of a patient and in one form is particularly directed to the deployment of stent grafts into vessels of the body to span or bridge a defect in the vasculature. Such a defect can for instance be an aneurysm where part of the wall of the vessel has weakened and the vessel has expanded in that region. Placement of endovascular stent grafts in such regions requires a stable landing zone for proximal and distal ends of a stent graft so that the stent graft engages securely against the wall of the vessel preventing migration of the stent graft and endoleaks around the stent graft. Such endoleaks can exacerbate an aneurysm problem.
[0004] In some regions of the vasculature, especially in the proximity of essential vessels such as near the renal arteries, often there is only a relatively short landing zone for the proximal end of a stent graft and this can require that a stent graft should extend beyond the renal arteries which requires branch grafting or fenestrations to allow access to the renal arteries. Such a problem could be avoided if a stable landing zone was provided in a juxta-renal position such as just below the renal arteries.
[0005] It is the object of this invention to provide a device which can improve the chance of providing a successful landing zone for a stent graft or at least provide a physician with a useful alternative.
[0006] Throughout this specification the term distal with respect to a portion of the aorta, a deployment device or a prosthesis means the end of the aorta, deployment device or prosthesis further away in the direction of blood flow away from the heart and the term proximal means the portion of the aorta, deployment device or end of the prosthesis nearer to the heart. When applied to other vessels similar terms such as caudal and cranial should be understood.
SUMMARY OF THE INVENTION
[0007] In one form therefore the invention is said to reside in a vascular band comprising a substantially rectangular portion of a flexible biocompatible material, the biocompatible material being substantially inextensible, the band having a width and a length, the length being substantially greater than the width and at least three radiopaque bars extending transversely across the width of the material and spaced apart along the length of the biocompatible material, the bars providing some rigidity to the flexible material in the width direction.
[0008] The term substantially inextensible in relation to the flexible biocompatible material is intended to mean that having regard to the normal forces on the material in its intended use that the material will not stretch. In the use of the material as an aortic band according to the present invention the vascular band, under the action of blood pressure and the force applied by self expanding stents and balloon expandable stents, the length and hence diameter of the installed band should not change. This assists with the prevention of expansion of a vessel wall around which it is placed thereby providing a stable landing zone and assisting in preventing endoleaks and migration of a stent graft placed into the vessel.
[0009] Preferably the bio-compatible flexible material is selected from the group comprising Dacron, Thoralon™, a polyurethane based material, and polytetrafluoroethylene.
[0010] The band can have a width of from 10 mm to 40 mm and a length of from 40 to 200 mm. Where the band is intended for use on a juxtarenal portion of the aorta it can comprise a width of from 20 mm to 40 mm and a length of from 75 to 200 mm. Where the band is intended for use on a portion of the iliac artery of a patient it can comprise a width of from 15 mm to 25 mm and a length of from 40 to 100 mm.
[0011] The bars can be formed from a material selected from stainless steel, Nitinol™, gold or tantalum.
[0012] The bars can be spaced apart along the length of the material by a distance of from 10 to 40 mm.
[0013] In one embodiment the bars can be crimped onto the material. Alternatively the bars can be sewn, woven or stitched into or through the material across the width thereof.
[0014] In a preferred embodiment the band has a length substantially equal to the outside circumference of the vessel to which the band is to be applied and the bars extending transversely across the width are placed at each end and at least substantially midway along the length.
[0015] In another preferred embodiment the band has a length greater than the outside circumference of the vessel to which the band is to be applied and the band comprises a variable length fastening means to enable to band to be fastened around the vessel without the necessity of knowing the outer circumference thereof.
[0016] The variable length fastening means can be selected from sutures, surgical staples and hook and loop fastening systems. The hook and loop fastening system can comprise a row of hooks on one end of the band and an array of loops on the other end of the band.
[0017] In a preferred embodiment the band has a length greater than the outside circumference of the vessel to which the band is to be applied, one of the bars being fastened to the band at a first end thereof and the other end of the band defining a tail portion which is free of bars and further comprising markings thereon relating to the diameter of a vessel upon which the band is placed, the markings being measured from the first end and whereby the measurement relating to the diameter is observed where the first end engages the tail portion.
[0018] In an alternative form the invention comprises a vascular band comprising a biocompatible flexible material, the band having a width direction and a length direction, the length of the band in the length direction being at least four times greater in length than the width of the band in the width direction and a plurality of radiopaque bars extending transversely across the width of the material, the radiopaque bars being fastened to the band and spaced apart along the length of the biocompatible material, the bars providing some rigidity to the flexible material in the width direction thereby preventing buckling of the band in use and the radiopaque bars enabling visualisation of a landing zone for a stent graft during deployment thereof and wherein the band has a length greater than the outside circumference of the vessel to which the band is to be applied, one of the bars being fastened to the band at a first end thereof and the other end of the band defining a tail portion which is free of bars and further comprising markings thereon relating to the diameter of a vessel upon which the band is placed, the markings being measured from the first end and whereby the measurement relating to the diameter is observed where the first end engages the tail portion.
[0019] Where a broader landing zone is desired or required there can be placed two or more bands which may for instance slightly overlap each other.
[0020] It will be seen that by this invention there is provided a device which can be placed around the vessel to such that the vessel is supported in such a manner as to provide a landing zone within the vessel for the deployment of a stent graft.
[0021] The band can be applied by open surgical techniques or by the use of laparoscopic techniques.
[0022] The vascular band according to the present invention has several distinct additional advantages. By the use of the transverse bars the flexible material will not buckle or fold in the transverse direction as it is placed around the vessel thereby providing a smoother and more stable and reliable landing zone. The use of the radiopaque bands also means that during the deployment of the stent graft the position of the vascular band can be observed using radiographic techniques and the proximal end, for instance, of the stent graft accurately placed for best prevention of migration and endoleaks.
[0023] As discussed above the vascular band of the present invention is particularly adapted for placement just below the renal arteries as an aortic band but can also be used in the iliac arteries as an iliac band or in other parts of the human or animal body. Other sites can include the ascending aorta, aortic arch and the upper abdominal or distal thoracic aorta.
BRIEF DESCRIPTION OF THE DRAWING
[0024] This then generally describes the invention but to assists with understanding reference will now be made to the accompanying drawings which show preferred embodiments of the invention.
[0025] In the drawings:
[0026] FIG. 1 shows a first embodiment of aortic band according to the present invention;
[0027] FIG. 2 shows the use of the aortic band of FIG. 1 placed around a vessel;
[0028] FIG. 3 shows an alternative embodiment of vascular band according to the present invention;
[0029] FIG. 4 shows the use of the vascular band of FIG. 3 around a vessel of the human or animal body;
[0030] FIG. 5 shows a still further embodiment of vascular band according to the present invention;
[0031] FIG. 6 shows the use of the vascular band of FIG. 5 around a vessel of the human or animal body;
[0032] FIG. 7 shows a still further embodiment of vascular band according to the present invention;
[0033] FIG. 8 shows the use of the vascular band of FIG. 7 around a vessel of the human or animal body;
[0034] FIGS. 9A and 9B show detail of the placement of a transverse bar onto a portion of flexible material;
[0035] FIGS. 10A and 10B show alternative methods of placing a transverse bar onto the flexible biocompatible material;
[0036] FIG. 11 shows a schematic view of the placement of a vascular band of the type shown in FIG. 1 onto the vasculature of a patient adjacent the renal arteries;
[0037] FIG. 12 shows a stent graft of the type for which the use of an aortic landing zone band is useful;
[0038] FIG. 13 shows a still further embodiment of vascular band with a first form of fastening system according to the present invention;
[0039] FIG. 14 shows the use of the vascular band of FIG. 13 around a vessel of the human or animal body;
[0040] FIG. 15 shows a still further embodiment of vascular band with a second form of fastening system according to the present invention; and
[0041] FIG. 16 shows the use of the vascular band of FIG. 15 around a vessel of the human or animal body.
DETAILED DESCRIPTION
[0042] Now looking more closely at the drawings and in particular the first embodiment of vascular band shown in FIGS. 1 and 2 .
[0043] The vascular band 1 of this embodiment comprises a length of flexible bio-compatible material 2 which is approximately four times longer than it is wide. A number of transverse bars 4 of a radiopaque material such as stainless steel extend across the full width of the material 2 and are crimped onto the flexible material and a tail 6 is left at one end. The vascular band has markings 7 upon it which enable the physician when placing the band around the vasculature to know the diameter of the band and hence the vessel upon which it is placed to assist with selection and placement of the subsequent stent graft. The markings correspond to the diameter of the vessel after placement. In this example the band is for a iliac artery which is expected to have a diameter in the range of from 12 to 24 millimeters. This band may have a width of width of 15 mm and a length of 100 mm allowing for a tail 19 which can be cut off or left in place after placement. The bars are spaced apart by about 20 mm.
[0044] As can be seen in FIG. 2 the vascular band 1 is wrapped around a vessel 8 and a surgical staple or stitching 10 is used to connect the end 5 to the tail end 6 so that the vascular band is a snug fit around the vessel. A portion of the tail extends out and can be left. A stent graft can then be deployed into the vessel 8 as discussed in relation to FIGS. 11 and 12 below. The tail 6 allows a range of diameters of vessel to be accommodated.
[0045] FIGS. 3 and 4 show an alternative embodiment. In this embodiment the vascular band 12 includes a flexible material 14 which is substantially longer than it is wide and includes bars 16 extending transversely across the full width of the material at regular intervals along the length. There is a tail 19 left free bars at one end of the band. The vascular band has markings 15 upon it which enable the physician when placing the band around the vasculature to know the diameter of the band and hence the vessel upon which it is placed to assist with selection and placement of the subsequent stent graft. The markings correspond to the diameter of the vessel after placement and can be observed during placement. In this example the band is for aorta in the region of the renal arteries which is expected to have a diameter in the range of from 25 to 45 millimeters. This band may have a width of 40 mm and a length of 200 mm. The bars are spaced apart by about 15 mm.
[0046] As can be seen in FIG. 4 again the vascular band 12 is wrapped around the vessel 17 and a surgical staple or stitching 18 is used to fasten it around the vessel to give a snug fit to the vessel.
[0047] FIGS. 5 and 6 show a still further embodiment of vascular band according to the inventions. In this embodiment the vascular band 20 incorporates three bars 22 with one at each end and one in the middle. The bars extend across the full width of the material In this embodiment the vascular band is made substantially at the correct length for the circumference of the vessel so that when placed around the vessel the terminal bars 22 then can be connected by means of a surgical staple or stitching 24 and the central transverse bar 22 is substantially diametrically opposed to the connection 24 .
[0048] FIG. 7 shows a still further embodiment of vascular band according to the present invention. In this embodiment the vascular band 30 includes a flexible graft of a biocompatible graft material 32 with a plurality of transverse bars 34 or rods. The transverse bars or rods 34 are interwoven or stitched into and across the full width of the graft material 32 . By this arrangement a flexible band is provided which can be wrapped around a vessel of the human or animal body and which will not buckle in the transverse direction thereby providing a surgical support for a landing zone for an endovascular graft.
[0049] FIG. 8 shows the embodiment of vascular band shown in FIG. 7 around a vessel 36 . A surgical staple 38 is used to fasten the band around the vessel at the necessary length. The bars or rods 34 extend along the length of the vessel and prevent the band buckling and provide a radiopaque marking for defining the landing zone for an endovascularly deployed stent graft.
[0050] FIGS. 9A and 9B show a portion of the vascular band shown in FIG. 1 showing detail of the means by which the bars are crimped onto the flexible bio-compatible material. The bio-compatible material 2 has a bar 4 crimped onto it. The bar includes folded over ends 7 which are crimped over the sides 9 of the flexible material 2 to the back of the flexible material to enable the bar 4 to grip onto the flexible material.
[0051] FIG. 10A shows a detailed view of the vascular band of the embodiment shown in FIGS. 7 and 8 . In this embodiment the bar 34 is threaded into apertures 35 in the material 32 so that it extends transversely across the material 32 .
[0052] FIG. 10B shows a detailed view of an alternative embodiment of vascular band showing an alternative method of fastening a bar to the biocompatible material. In this embodiment the bar 34 is fastened to the material 32 by the means of stitching 37 .
[0053] FIG. 11 shows a deployed stent graft within an aorta with an aneurysm and incorporating a vascular band according to the present invention.
[0054] The aneurysm 150 is a ballooning of the aorta 152 between the renal arteries 153 and the iliac arteries 154 . The stent graft 110 (as shown in more detail in FIG. 12 ) is deployed into the aorta so that it spans the aneurysm and allows blood flow from the aorta to the two iliac arteries 154 .
[0055] An aortic band 1 of the type shown in FIG. 1 has been placed just distal of the renal arteries 153 and around the aorta 152 with the bars 4 substantially in line with the longitudinal direction of the aorta. Surgical staples 10 have been used to fasten the vascular band 1 in place and the tail 6 of the band extends out from the connection.
[0056] The proximal portion 114 (see FIG. 12 ) of the stent graft 110 which has the stent on the inside bears against the wall of the aorta 152 in the region of placement of the vascular band 1 above the aneurysm and below the renal arteries so that a good seal is obtained. The exposed zigzag stent 115 (see FIG. 12 ) which extends beyond the portion 114 extends over the entrances to the renal arteries but, as the wire of the stent is thin, occlusion does not occur. The distal end 123 of the long leg 120 of the stent graft 110 seals against the wall of one of the iliac arteries and the distal end 155 of the extension leg stent graft 121 bears against the wall of the other iliac artery.
[0057] FIG. 12 shows an embodiment of a bifurcated stent graft with an extension stent graft suitable for placement into an aorta and engaging against the aorta where an aortic band according to the present invention has been placed. The bifurcated stent graft 110 has a generally inverted Y-shaped configuration having a body portion 111 , a shorter leg 112 and a longer leg 120 . The body of the stent graft is constructed from a tubular woven synthetic material such as Dacron™. At the proximal end 114 of the stent graft 110 is a first zigzag stent 115 which extends beyond the end of the stent graft and has distally extending barbs 116 . The stent graft has a number of zigzag stents mounted to it and extending along its length. The stent 117 nearest the proximal end 114 is inside the tubular material so that the outside presents a smooth surface which in use engages against the inner wall of the vessel into which it is deployed to provide a barrier to endoleaks. The terminal stent 118 nearest the distal end of the shorter leg is outside the tubular material so that the inside presents a smooth surface which in use engages against the outside of the proximal end of a leg extension stent graft 121 . Between these terminal stents the rest of the stents 119 are arranged on the outside of the tubular material so that they present minimal restriction to the flow of blood through the stent graft and present minimal sites for the growth of thromboses within the stent graft.
[0058] Extension leg stent graft 121 is adapted for fitting into the shorter leg. The extension stent graft 121 is constructed from a tubular synthetic material such as Dacron and has terminal internal stents 122 and a plurality of external intermediate stents 124 .
[0059] In use the stent graft according to this embodiment of the invention is adapted for fitting into aorta such that the end 114 is just distal of the renal arteries and the first exposed zigzag stent 115 extends up to or over the renal arteries. As it is constructed from thin wire it does not obstruct the renal arteries if it extends over them. The longer leg 120 extends down one of the iliac arteries and the shorter leg terminates in the aorta just short of the other iliac artery. The extension stent graft when deployed extends down the other iliac artery.
[0060] A vascular band for use in the juxtarenal position of the aorta may have a length of from 75 to 200 mm and a width of from 20 to 30 mm. A range of bands may be manufactured with 15 mm length changes such as bands with lengths of 75 mm, 90 mm, 105 mm, 120 mm, 135 mm and 150 mm to accommodate the expected range of vessel diameters. A vascular band for the iliac arteries may have a length of from 40 to 60 mm and a width of from 15 to 25 mm. A range of bands may be manufactured with 5 mm length changes such as bands with lengths of 40 mm, 45 mm, 55 mm and 60 mm to accommodate the expected range of vessel diameters.
[0061] FIG. 13 shows a still further embodiment of vascular band with a first form of fastening system according to the present invention and FIG. 14 shows the use of the vascular band of FIG. 13 around a vessel of the human or animal body. This embodiment is similar in many respects to that shown in FIG. 1 and the same reference numerals are used for corresponding items.
[0062] The vascular band 1 of this embodiment comprises a length of flexible bio-compatible material 2 which is approximately four to five times longer than it is wide. A number of transverse bars 4 of a radiopaque material such as stainless steel extend across the full width of the material and are crimped onto the flexible material at each and a tail 6 is left at one end and a short end 40 at the other end. On the short end 40 a row of hooks 42 are fastened and on the tail 6 an array of loops 44 is fastened. As can be seen in FIG. 14 the band 1 is wrapped around a vessel 8 and hooks 42 are engaged with whichever line of loops 44 of the array of loops are closest to the required circumference.
[0063] FIG. 15 shows a still further embodiment of vascular band with a second form of fastening system according to the present invention and FIG. 16 shows the use of the vascular band of FIG. 15 around a vessel of the human or animal body. This embodiment is similar in many respects to that shown in FIG. 1 and the same reference numerals are used for corresponding items.
[0064] The vascular band 1 of this embodiment comprises a length of flexible bio-compatible material 2 which is approximately four to five times longer than it is wide. A number of transverse bars 4 of a radiopaque material such as stainless steel extend across the full width of the material and are crimped onto the flexible material and a tail 6 is left at one end and a short end 50 at the other. On the short end 50 a portion of the hook part of a hook and loop fastener system is fastened and at the tail end 6 a portion of the loop part of a hook and loop fastener system is fastened.
[0065] As can be seen in FIG. 16 the band 1 is wrapped around a vessel 8 and the hooks portion of the hook and loop fastener system is engaged against the loops portion of the hook and loop fastener system to fasten the band around the vessel. Alternatively the hooks portion and the loops portions may be provided on opposite sides of the band.
[0066] Throughout this specification unless the context requires otherwise, the words ‘comprise’ and ‘include’ and variations such as ‘comprising’ and ‘including’ will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.
[0067] Throughout this specification various indications have been given as to the scope of this invention but the invention is not limited to any one of these but may reside in two or more of these combined together. The examples are given for illustration only and not for limitation. | A vascular band ( 1 ) comprises a biocompatible flexible material ( 2 ) and a plurality of radiopaque bars ( 4 ) extending transversely across the width of the material and spaced apart along the length of the biocompatible material. The bars provide some rigidity to the flexible material in the width direction thereby preventing buckling of the band in use and the radiopaque nature of the bars enable visualisation of a landing zone for a stent graft during deployment thereof. The bars can be crimped or woven, into the material. The band can be stitched, stapled, or hooked around a vessel. | 0 |
BACKGROUND OF THE INVENTION
a) Field of the Invention
The invention relates to a rotating cutting tool, in particular a boring tool, comprising a receiving part and a front part which extend along a center axis and are detachably fastened to one another via a driver connection.
b) Description of the Related Art
Such a cutting tool designed as a boring tool can be seen from WO 2007/107294 A1. This boring tool is a modular cutting tool which has an interchangeable tool head which can be detachably connected to a fluted boring body via the driver connection. The driver connection in this case comprises a driver web arranged on the underside of the boring head and extending across a center longitudinal axis. Said driver web is inserted into a receiving pocket, corresponding to the shape of the driver web, of the boring body. The receiving pocket in this case encloses the driver web over the full circumference.
The driver connection generally serves to transmit torque between the two tool parts. In such driver connections, there is often a conflict between as robust a driver web as possible for the torque transmission and as little weakening of the boring body as possible.
The object of the invention is to specify a tool of the type mentioned at the beginning having an improved driver connection which is designed for the transmission of high torques and at the same time causes only slight weakening of the receiving part in order thus to ensure stable return of the tool.
SUMMARY OF THE INVENTION
The object is achieved according to the invention by a tool having the features of claim 1 . The tool is generally a rotary tool for machining a workpiece. The tool is of multi-piece, in particular of two-piece, design and comprises a receiving part and a front part. In the case of a boring tool, the receiving part is the boring body and the front part is the boring head. In the case of a milling tool, the receiving part would be a milling cutter shank and the front part would be a milling cutter head. These two parts extending along a center axis (axial direction) are detachably fastened to one another via a driver connection. The latter has two coupling pairs separate from one another and arranged eccentrically with respect to the center axis. Each of the coupling pairs is in this case formed by two interlocking coupling elements, namely, on the one hand, a driver pin and, on the other hand, a receiving pocket completely enclosing said driver pin. The coupling elements serve firstly to transmit the torque forces between the two parts. Secondly, the two coupling elements also serve to orient the two parts in alignment with one another; i.e. the two parts are centered relative to one another and with respect to the center axis via the coupling elements. With regard to this double function, the coupling elements are of asymmetrical design and widen—as viewed in the plane perpendicular to the center axis—with increasing distance from the center axis. Due to the asymmetrical configuration, automatic centering of the two parts is achieved, in particular when the two parts are being fitted together. At the same time, with the widening with increasing radial distance from the center axis, the driver connection is designed to be especially strong in the radially outer regions, such that high torque forces can be transmitted.
The expression “asymmetrical configuration” of the coupling elements refers in this case in particular to the fact that said coupling elements have a cross-sectional area which is oriented perpendicularly to the center axis and which does not have symmetry either with regard to an axis of rotation or with regard to a plane.
A special advantage of this configuration can be seen in the fact that the two coupling pairs are separate from one another and are each arranged eccentrically with respect to the center axis. In the region of the center axis itself, therefore, the driver connection does not alter the receiving part or the front part. The two parts preferably bear on one another in a planar manner in the region of the center axis without interlocking in this region. The individual coupling pairs are therefore shifted into a radially outer region. As a result, the core of the tool is unaffected by the driver connection.
Investigations have shown that this configuration having the two eccentric coupling pairs separate from one another, compared with the configuration as described in WO 2007/107294 A1, leads to a reduction in the stresses in the boring body, that is to say in the receiving part. The loading of the receiving part—at the same or improved torque transmission—is reduced by about 20%. Furthermore, due to the separate arrangement, the center region is free, in which coolant bores, clamping screws, etc., can now be introduced without any problems. In addition, the enlarged free space around the center axis permits greater design flexibility with regard to the configuration in particular of the flutes. The latter can now be brought much closer to the center axis.
According to an expedient configuration, the driver pin in this case is designed like a prism. In the same way, the receiving pocket is also designed as a prismatic receptacle in a manner adapted to the driver pins.
The expression “designed like a prism” refers to the fact that the two coupling elements each have a roughly polygonal base area with side walls preferably extending parallel to the center axis. In particular, a base area is provided with 4 corner regions. In an expedient manner, the corner regions in this case are designed to be rounded. The connection between the individual corner regions also need not inevitably be effected rectilinearly.
The special advantage of this prismatic configuration can be seen in the fact that adjacent side walls serve for the automatic fixing or centering of the two parts. For the purpose of as robust a design as possible, provision is preferably made in this case for the extent of the respective driver pin in the radial direction to preferably be more than 50% of the radius of the tool. The two coupling elements are designed to be preferably rotationally symmetrical to one another with respect to a rotation about the center axis. In the preferred configuration having two coupling pairs, the coupling elements are therefore designed symmetrically to one another with respect to a rotation about the center axis by 180°. Alternatively, it is in principle also possible to design the coupling elements asymmetrically to one another.
According to an expedient development, the coupling elements each comprise radially outer bearing surfaces, in particular curved outer bearing surfaces, and further driver surfaces. In the load case, that is to say during torque transmission, both the outer bearing surfaces and the driver surfaces of the two coupling elements fitted one inside the other are pressed against one another. The outer bearing surfaces and the driver surfaces are in this case separate from one another. They expediently form adjacent side faces of the prism, via which side faces the self-centering is effected.
The driver surfaces are in this case preferably oriented substantially in the radial direction in order to enable as optimum a force transmission as possible for the torque driving. The expression “oriented substantially in the radial direction” refers in this case in particular to the fact that the driver surfaces are oriented at most at an angle of +/−20°, preferably +/−10°, with respect to the radial.
The receiving pocket expediently has an outer web which comprises the outer bearing surface and widens in the direction of that region of the outer bearing surface which is loaded in the load case. In this case, the outer web, with its outer side, at the same time also forms the outer side of the tool. The outer bearing surface running substantially concentrically to the outer lateral surface of the tool therefore deviates, according to the preferred configuration, from the concentric arrangement to the effect that the width of the wall region increases toward the loaded regions.
The receiving pocket preferably comprises at least one web-like and elastic wall region. The latter is sufficiently thin and thus elastic, such that, in the load case, when the torque forces occur, an elastic deformation of the wall region can be effected, and therefore surface contact is formed between the elastic wall region and an associated surface section of the driver pin. On account of this configuration, automatic tolerance compensation is therefore effected between the two contact surfaces between the driver pin and the receiving pocket in order to achieve a desired planar bearing surface for the torque transmission. Such tolerance inaccuracies are caused, for example, by dimensional inaccuracies during the production of the receiving pocket and/or of the driver pin. It should be taken into account here that the receiving part (boring body) is designed for many front parts (borer heads), which constitute wearing parts.
In general, the wall regions of the receiving pocket which surround the driver pin are of web-like design having a small width in comparison with the driver pin.
With regard to the desired self-centering of the two tool parts relative to one another, the two coupling elements, for assembly, have clearance relative to one another and also different cross-sectional geometries in such a way that a slight relative rotation is made possible between the two coupling elements inserted one inside the other. During such a relative rotation, the coupling elements are clamped against one another. In this case, the curved outer bearing surfaces preferably come to bear against one another. Since the two coupling elements are supported against one another in the radial direction via the outer bearing surfaces, a force component directed radially inward is exerted on the respective driver pin by this measure. Since this is effected at each coupling pair, this leads to the desired automatic centering of the two tool parts. The outer bearing surfaces of the two coupling elements of a coupling pair are preferably arranged eccentrically to one another. This refers to the fact that the outer bearing surfaces run along a circular path with a defined radius of curvature, the centers of the circles being arranged offset from one another. Different radii of curvature for the outer bearing surfaces can also be additionally provided.
In this case, the clearance is preferably selected in such a way that the two coupling elements have a free rotation angle within the range of 1-5°; that is to say they can be rotated relative to one another within a limited angular range of at most 1-5°.
At least one substantially axially running bore which is in alignment with a corresponding bore in the receiving pocket extends through the driver pin. This bore is preferably a coolant bore or also a bore for receiving a fastening means, such as a screw for example. Two bores, namely one for a coolant and one for a fastening means, in particular a clamping screw, are expediently provided in the driver pin. Both bores are in alignment with corresponding bores in the receiving pocket.
The bore provided for receiving the clamping screw is in this case expediently oriented obliquely relative to the longitudinal direction, to be precise in such a way that the two coupling elements are clamped against one another when the clamping screw is tightened. The oblique position is in this case selected in such a way that clamping is preferably effected in both the circumferential direction and the axial direction. The longitudinal axis of the bore is in this case inclined approximately in the circumferential direction, to be more precise in the clamping direction in which the driver pin is clamped against the receiving pocket. The longitudinal axis of the bore therefore runs within approximately a tangential plane, to be more precise within the plane which is defined by the axial direction and the clamping direction. The bore longitudinal axis lying in this plane has an angle of inclination relative to the axial direction of greater than 1° within the range of between 3° and 20°, preferably within the region of about 10°.
According to an expedient configuration, a compensating element extending preferably in the axial direction parallel to the center axis is arranged between the receiving pocket and the driver pin, said compensating element, in the load case, bearing against both the driver pin and the receiving pocket in a planar manner. In the load case, a force exerted by the driver pin is therefore transmitted to the receiving pocket. The compensating element is in this case in particular freely rotatable about its longitudinal axis. This compensating element serves for tolerance compensation in order to make possible desired planar contact of the surfaces participating in the transmission of force. Dimensional inaccuracies caused during production or possibly also during operation are compensated for by the compensating element.
To this end, the compensating segment preferably has a circle-segment-like cross-sectional area. The compensating segment is therefore of roughly semi-cylindrical design and has a partly cylindrical bearing surface and a flat bearing surface. Furthermore, the compensating element has a cylindrical fastening shank, with which it is inserted into a shank receptacle, designed as a bore, in the receiving pocket, in which case rotatability of the compensating element inside the shank receptacle is made possible. The compensating element is in this case preferably arranged in a corner region of the prismatic coupling elements, to be precise in particular in the corner region which connects the outer bearing surfaces to the driver surfaces. Furthermore, in order to make possible the free rotatability, provision is made in an expedient configuration for the receiving pocket to have a corner hole and for the driver pin to be flattened in the corresponding corner region. A sufficient rotary movement of the compensating element is made possible on account of the corner hole.
In this case, the compensating element and at least one of the coupling elements are preferably made of materials of different hardness. The compensating element can be softer or also harder than the at least one coupling element.
Due to the different material hardness, additional adaptation and additional tolerance compensation are made possible by plastic deformation.
According to an expedient development, in order to ensure that the two parts are reliably fastened to one another in the desired position, a clamping device is provided which can be actuated from the side and via which the driver pin can be clamped together with the receiving pocket. The expression “to clamp” in this case refers in particular to clamping both in the circumferential direction and in the axial direction, such that the two coupling elements are brought into their desired position relative to one another. This clamping device is preferably used as an alternative to the already described clamping screw which is oriented substantially in the axial direction and is actuated from the end face. The lateral clamping device, which can therefore be actuated from the lateral surface of the lathe tool and is oriented in the radial direction and also in an approximately tangential direction in the lathe tool, has the advantage that no modifications to the front part have to be made.
For the design of the clamping device, a longitudinally extending clamping pin is expediently arranged on the driver pin, said clamping pin plunging into a pin receptacle of the receiving pocket. In addition, a clamping element is provided which acts laterally on the clamping pin in order to clamp the driver pin together with the receiving pocket. Due to the additional arrangement of the clamping pin, the clamping device is isolated from the driver pin. The driver pin therefore is not weakened. The clamping pin preferably lies free of stress in the pin receptacle, even in the clamped state between the receiving pocket and the driver pin. In the clamped state, too, the clamping pin therefore has clearance relative to the pin receptacle. The clamping pin in this case is expediently arranged asymmetrically and eccentrically on the underside of the driver pin.
As an alternative to the configuration having the clamping pin, the clamping device preferably has an element, for example a threaded element such as a headless setscrew or a bolt, which is adjustably mounted in one of the coupling elements, the element being supported with one of its end faces against the other coupling element for the clamping. In the configuration as a headless setscrew, said headless setscrew is therefore screwed into or out of the respective coupling element until the headless setscrew is supported against the other coupling element and therefore clamps the two coupling elements against one another. This clamping device is again designed in such a way that clamping is effected both in the circumferential direction and in the axial direction.
The element is expediently adjustably mounted in a through-hole of the one coupling element, such that the element can also be supported with its second end face against the other coupling element. This serves to release the driver connection when coupling elements are clamped together.
A development of the invention, this development being inventive on its own, consists in mounting a supporting element in the coupling region, that is to say in the region of the parting line between borer body and borer head. The supporting element can be produced from a specially adapted material and serves to specifically stabilize the tool in the coupling region. The supporting element serves to dampen any movements or vibrations of the borer body and of the borer head relative to one another. In particular, opposed vibrations of borer head and borer body are to be reduced or neutralized in order to reduce the vibration wear of the tool. In addition, the transmission of solid-borne sound in the region of the parting line between borer body and borer head is to be reduced or eliminated. This reduction in the transmission of solid-borne sound also leads to an improvement in the properties of the tool.
Such tools are especially suitable for transverse bores of considerable depth in workpieces. In addition, the tools are also suitable for bores having oblique bore exits.
In a first configuration, the supporting element is configured as a disk which is plane-parallel to the end faces, adjacent to one another, of borer body and borer head. This disk-shaped supporting element preferably projects like a sliding ring segment beyond the lateral surfaces of borer body and borer head and thus supports the boring tool relative to the bore wall. In this way, the course of the boring tool in the bore is stabilized, while the cutting edges in the borer head can machine the bore wall.
A further preferred embodiment of the supporting element has a ring-like integrally formed portion which overlaps the lateral surfaces either of the borer body or of the borer head or of borer body and borer head at the same time. This embodiment has the advantage that the supporting element bears like a sliding ring against a large area of the bore wall. In addition, in a bowl-like configuration of the supporting element having a basic body configured as a plane-parallel disk and an annular integrally formed portion, especially good mounting of the borer body and of the borer head in the coupling region is ensured. In a further configuration, recesses corresponding to the flutes formed in the borer body and in the borer head can be provided in the supporting element in order to optimize the chip removal. The comparatively large outer circumferential surface of the ring-like integrally formed portion on the supporting element enables the attachment of special guide elements for guiding the boring tool on the bore wall. These guide elements can be strip-shaped or bulged or can be designed in other geometries for improving the concentric running of the tool in the bore. These guide elements can be integrally embedded in the outer surface of the ring element. However, it is also possible to fix them in the ring element in a clamping manner.
In a further configuration, the supporting element can have a coating, in particular in the region of the ring-like integrally formed portion. This coating can serve to prevent the wear on the outer surface of the ring relative to the bore wall. The coating can also influence the other vibratory and transmission properties of the tool.
In a further embodiment of the invention, the ring-like integrally formed portion, in particular in the configuration as a receiving bowl, can at the same time be configured as a flexural spring. In this configuration, the ring element applies a spring force to the bore wall and thus counters drifting of the tool away from its centered position with the acting spring force. The tool is therefore resiliently guided on the bore wall. In this way, the supporting element forms a damping member for the tool relative to the workpiece to be machined.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention are explained below in more detail with reference to the figures. In the drawing, partly in schematic illustration:
FIG. 1 shows a perspective cutaway illustration of a modular boring tool,
FIG. 2 shows a perspective view of the rear side of a boring head of the boring tool according to FIG. 1 , having driver pins of a first embodiment variant,
FIG. 3 shows a perspective plan view of the front end face of a boring body of the boring tool according to FIG. 1 , having receiving pockets of the first embodiment variant,
FIGS. 4 a - c show a schematic plan view of the driver connection between the boring body and the boring head ( FIG. 4 a ) of a second embodiment variant and cutaway sectional views along the section lines 4 b - 4 b and 4 c - 4 c , respectively, in FIG. 4 a,
FIG. 5 shows a schematic plan view of the driver connection of the first embodiment variant,
FIG. 6 shows a schematic plan view of the driver connection similar to FIG. 4 a and FIG. 5 of a third embodiment variant,
FIG. 7 shows a perspective view of the driver region of the boring head according to the third embodiment variant,
FIG. 8 shows a perspective plan view of the driver region of the boring body according to the third embodiment variant,
FIG. 9 a, b show a plan view ( FIG. 9 a ) of the end face of the boring body and a sectional view through the borer head ( FIG. 9 b ), the section plane being determined by the section line 9 b - 9 b in FIG. 9 a,
FIG. 10 shows a perspective view of the driver connection of the borer head according to a fourth embodiment variant,
FIG. 11 shows a schematic plan view of the driver connection according to a fifth embodiment variant which forms a combination of the third and fourth embodiment variants,
FIG. 12 shows a perspective view of the driver region of the borer head according to a sixth embodiment variant,
FIG. 13 shows a schematic plan view of the driver connection according to the sixth embodiment variant,
FIG. 14 shows a partial sectional view in the region of a clamping pin according to the sixth embodiment variant along section line 14 - 14 in FIG. 13 ,
FIG. 15 shows an overall view of a section of a first embodiment of the boring tool with supporting element,
FIG. 16 shows an exploded illustration of the boring tool shown in FIG. 15 ,
FIG. 17 shows a view of the coupling surface of the borer head according to FIG. 15 ,
FIG. 18 shows a view of a supporting element according to FIG. 15 designed as a plane-parallel disk,
FIG. 19 shows a plan view of the coupling surface of the borer body from FIG. 15 ,
FIG. 20 shows the exploded illustration of a borer body and of a supporting element having a two-sided receiving bowl,
FIG. 21 shows the exploded illustration from FIG. 20 having a supporting element with a receiving bowl effective in the direction of the borer body,
FIG. 22 shows an exemplary embodiment, modified compared with the exemplary embodiment shown in FIG. 21 , of a supporting element with an enlarged receiving bowl,
FIG. 23 shows an embodiment of the supporting element having guide elements on the outer circumferential surface of the annular integrally formed portion,
FIG. 24 shows an embodiment of an annular integrally formed portion configured as a flexural spring and as a receiving bowl, and
FIG. 25 shows a section through the ring-like integrally formed portion shown in FIG. 24 and configured as a flexural spring.
Parts having the same effect are provided with the same designation in the figures. The driver connection is described below with reference to a boring tool in various embodiment variants. The driver connection can also be generally applied to other cutting tools for coupling two parts of a tool. The individual features described below with respect to the various variants and design configurations, provided they are not mutually exclusive, can also be combined with one another.
DETAILED DESCRIPTION OF THE INVENTION
The boring tool 2 shown in FIG. 1 is of modular construction and comprises a borer head 4 which forms the front part and is interchangeably fastened to a borer body 6 forming the receiving part. The boring tool 2 extends in the axial or longitudinal direction along a center axis 8 . In the exemplary embodiment, the borer head 4 has a central borer point 10 designed as a cutting insert and two cutting tips 12 arranged radially on the outside. A total of four discharge openings 14 for coolant can be seen on the front end face of the borer head 4 . The cutting tips 12 are oriented with their free flat side toward a flute 15 which starts in the borer head 4 and is continued as a helical flute 15 in the borer body 6 . The borer head 4 can be screwed to the borer body 6 by means of clamping screws 16 which are passed through the borer head 4 from the end face.
The borer head 4 and the borer body 6 are detachably fastened to one another via a driver connection.
As can be seen from FIGS. 2 and 3 , the driver connection comprises two driver pins 18 which are arranged at a distance from one another on the underside of the borer head 4 and eccentrically to the center axis 8 . In the assembled state, the driver pins engage in a respective, corresponding receiving pocket 20 of the borer body 6 . The driver pins 18 are designed as prism-like prominences starting from the bottom flat side of the borer head 4 . In the same manner, the receiving pockets 20 are designed as prism-like recesses starting from a flat end face of the borer body 6 . A coolant bore 22 and a fastening bore 24 pass through each driver pin 18 and are in alignment with respective associated bores 22 ′, 24 ′ in the flat bottom surface of the receiving pocket 20 . The coolant bores 22 , 22 ′ are fed from a central coolant passage 26 in a manner not shown in any more detail here.
Each driver pin 18 is defined by an end face which lies in a plane perpendicular to the center axis 8 and by a circumferential or lateral surface which is oriented parallel to the center axis. The respective receiving pockets 20 are also designed complementary hereto.
The separate configuration of the two driver pins 18 and the complete, enclosing reception thereof on all sides in the receiving pockets 20 is especially important. The driver pins 18 and the receiving pockets have a special geometry explained in more detail below. The cross-sectional area—perpendicular to the center axis—of each coupling element 18 , 20 is characterized by asymmetry. This ensures very good torque transmission via the driver connection with the lowest possible stress of the boring body 6 in the region of the receiving pockets 20 . At the same time, the driver pins 18 are formed and arranged in conjunction with the receiving pockets 20 in such a way that automatic self-centering of the two parts 4 , 6 relative to one another is effected. Each of the driver pins 18 forms a coupling pair with the receiving pocket associated with it; the driver pins 18 and the receiving pockets 20 form coupling elements which are designed to be generally complementary to one another and which—except for the slight differences described below—have identical cross-sectional geometries.
As can be seen from FIG. 4 a , each coupling element has an approximately polygonal cross-sectional contour (as viewed in a plane perpendicular to the center axis 8 ). In the exemplary embodiments, each coupling element 18 , 20 has four corner regions which are each of rounded design. The coupling elements generally have a trapezoidal cross-sectional area in the exemplary embodiments. Respective wall sections are formed between the individual corner regions. FIG. 4 a shows the driver connection in the loaded state, that is to say when the individual coupling elements 18 , 20 bear against one another for the torque transmission. As can be seen from FIG. 4 a , two respective wall regions bear against one another in this case. The one wall region is the radially outer wall region in which the coupling elements 18 , 20 bear against one another via outer bearing surfaces 28 to transmit forces only in the tangential direction. The latter are of curved design and run, in the exemplary embodiment in FIG. 4 a , concentrically to the outer circumferential side of the boring tool 2 . Furthermore, the two coupling elements 18 , 20 bear against one another with driver surfaces 30 adjacent to the bearing surfaces 28 . In the exemplary embodiment in FIG. 4 a , said driver surfaces 30 are arranged substantially radially to the center axis 8 . The other two wall regions of the coupling elements each have clearance relative to one another, such that the driver pins 18 overall rest with clearance in the respective receiving pocket 20 . These other wall regions therefore do not have any function with respect to the torque transmission and also do not serve to center the two parts 4 , 6 relative to one another. In the exemplary embodiment, these wall regions are oriented approximately perpendicularly to one another and run parallel to and at a distance from two respective planes which are likewise arranged at a right angle to one another and which each include the center axis 8 . As seen in FIG. 2 , the driver pin wall regions 19 closest to the center axis 8 oppose one another and define a free space or gap G therebetween.
As can be seen from the sectional illustration of FIG. 4 b , the two coupling elements 18 , 20 bear directly against one another in the region of their driver surfaces 30 . At the same time, it can be seen that the borer head 4 , with its flat underside, rests flat on the flat end face of the borer body 6 . In contrast, the underside of the driver pin 18 is at a distance from the bottom surface of the receiving pocket 20 . Finally, it can also be seen from FIG. 4 c that the rear wall regions, not participating in the torque transmission, of the two coupling elements 18 , 20 are at a distance from one another.
When the borer head 4 is being fitted onto the boring body 6 , first of all the driver pins 18 are inserted into the receiving pockets 20 . The borer head 4 is then rotated slightly relative to the borer body 6 , the borer head 4 and the borer body 6 being clamped together via the coupling elements 18 , 20 on account of this relative rotation. In FIG. 5 , to explain this action, the coupling pair is shown in the unclamped state in the left half of the figure and in the clamped state in the right half of the figure. Shown in FIG. 5 is the embodiment variant as can also be seen in FIGS. 2 and 3 .
The radii of curvature r 1 , r 2 of the outer bearing surfaces 8 of the driver pin 18 (r 1 ) and of the receiving pocket 20 (r 2 ), respectively, are depicted in FIG. 5 . As can be seen, the centers of the radii of curvature are arranged offset from one another, such that the driver pins 18 overall are arranged eccentrically to the receiving pockets 20 . The outer bearing surfaces 28 corresponding to one another are radially clamped against one another during the rotary movement by this measure. On account of the 180° symmetry of the two coupling pairs in the exemplary embodiment, the automatic centering of the borer head 4 relative to the borer body 6 is effected during this rotary movement. In the process, the coupling elements 18 , 20 can be rotated relative to one another by a free rotation angle α which is in the region of a few degrees, in the region of 2° in the exemplary embodiment.
Except for this eccentric configuration, the two coupling elements 18 , 20 are identical, i.e. they are designed with the same cross-sectional geometry. To form the clearance, which can readily be seen from the left half of FIG. 5 , the driver pins are merely designed to be somewhat smaller than the receiving pockets.
Whereas in the exemplary embodiment in FIG. 4 a the driver surfaces 30 run inward in a concavely arched manner toward the radially inner corner region, the driver surfaces 30 according to the exemplary embodiment in FIG. 5 extend substantially rectilinearly, wherein they deviate at an angle of a few degrees from the radial line which runs through the center axis 8 .
The third embodiment variant shown in FIG. 6 is based on the embodiment variant according to FIG. 5 . Here, too, the left half of the figure shows the unclamped state and the right half of the figure shows the clamped state. In contrast to the exemplary embodiment in FIG. 5 , a compensating element 32 is arranged in the corner region which connects the driver surfaces 30 to the outer bearing surfaces 28 . The compensating element is designed like a dowel pin, extends parallel to the center axis 8 and has a circle-segment-like area as viewed in cross section. On account of the compensating element 32 , that corner region of the driver pin 18 which relates thereto is of flattened design, as can best be seen from FIG. 7 . At its rear end, the compensating element 32 has a cylindrical fastening shank 34 , with which it is inserted into a cylindrical shank receptacle 36 ( FIG. 8 ) in the bottom of the receiving pocket 20 . The compensating element 32 is rotatable about its longitudinal axis in the shank receptacle 36 .
The compensating element 32 is arranged in the loaded region of the coupling elements 18 , 20 , namely between the driver surfaces 30 and the outer bearing surfaces 28 . The driver pin 18 is supported with its flattened corner region against the flat side of the compensating element 32 and the latter in turn is supported with its approximately semi-cylindrical, rounded lateral surface side against the corner region of the receiving pocket. In this case, the corner region has the same radius as the compensating element 32 . On account of the rotatability of the compensating element 32 and on account of the design flattened on the one side and rounded on the other, the compensating element adapts itself automatically to the flat side of the driver pin 18 , such that planar contact is formed between driver pin 18 and compensating element 32 . On account of the rounded design with which the compensating element 32 bears against the wall of the receiving pocket 20 , largely planar contact is formed here, too. Overall, therefore, the compensating element 32 serves for compensating for tolerances which are caused during production, for example, or also form in the course of operation. In order to prevent the compensating element 32 from falling out, said compensating element 32 can be fixed in the shank receptacle 36 by means of a fastening lacquer, for example. The fixing force is proportioned in such a way that, in the load case and during a requisite rotation for compensating for tolerances, the compensating element 32 rotates automatically into the optimum position.
The borer head 4 is fastened to the borer body 6 via an additional clamping mechanism, such that the borer head is clamped against the borer body 6 in a defined axial position and in a defined rotary position in the clamping or circumferential direction.
According to a first embodiment variant, which is explained with reference to FIGS. 9 a , 9 b , a clamping screw 16 is passed through the borer head 4 from the front end face of the borer head 4 , and this clamping screw 16 runs through the fastening bore 24 of the driver pin 18 and can be screwed into an associated fastening bore 24 ′, designed as a screw hole, in the receiving pocket 20 . The fastening bores 24 , 24 ′ are not arranged parallel to the center axis 8 but rather are arranged in an inclined manner. In this case, the center axis of the fastening bore 24 runs within a plane. This plane is defined by the axial direction and a clamping direction which is indicated in FIG. 9 a by the arrow 37 . The clamping direction 37 is in this case defined by the direction in which the driver pin 18 is clamped against the receiving pocket 20 . The clamping direction is in this case preferably oriented perpendicularly to the driver surface 30 . With regard to a line running in this plane parallel to the center axis 8 (and thus with regard to the driver surfaces 30 ), the center axis of the fastening bore is inclined by an inclination angle β of >1° within the range of 3°-20° and preferably within the region of about 10°. On account of this sloping orientation, the borer head 4 is clamped against the borer body 6 both in the axial direction and in the clamping direction 37 .
As an alternative to this clamping, running substantially in the longitudinal direction, through the tool head 4 by means of the clamping screw 16 , a lateral clamping device is provided according to a preferred alternative. Said clamping device can be actuated from the circumferential side of the borer body 6 . The special advantage can be seen in the fact that no through-bores, weakening the borer head 4 , for the clamping screw 16 have to be provided. This lateral clamping device is explained in more detail below in connection with FIGS. 10 to 14 in two different embodiment variants.
In the first embodiment variant, which is explained with reference to FIGS. 10 and 11 , the clamping device comprises a headless setscrew 38 which can be adjusted in a corresponding tapped hole in the respective driver pin 18 by means of a tool 40 . To this end, the respective driver pin 18 has a through-hole 42 which is provided with an internal thread (not shown in any more detail here) at least in one section. The headless setscrew 38 has a receptacle 44 for the tool 40 on its rear end face accessible from outside, said receptacle 44 being designed as a hexagon socket in the exemplary embodiment ( FIG. 10 ). A dog point 46 is integrally formed on its opposite end face. For clamping the two coupling elements, the headless setscrew 38 is unscrewed slightly from the through-hole 40 , such that the headless setscrew 38 is supported with a section of its rear end face against the wall region of the receiving pocket 20 and therefore clamps the driver pin 18 in the desired direction. The headless setscrew 38 is designed roughly in a spherical cap shape at its rear end face. Complementary hereto, the wall region of the receiving pocket 20 is also designed in a spherical cap shape, such that, in addition to the clamping approximately in the circumferential direction, clamping in the axial direction is also effected.
For a change of the borer head 4 , the headless setscrew is screwed in until the dog point 46 is supported against the opposite wall region of the receiving pocket 20 and thus the clamping between the coupling elements is released again, such that the borer head 4 can be removed.
A further feature concerning the compensating element 32 can additionally be seen from FIG. 11 . To be precise—as can be seen from the left half of the figure—the corner region in which the compensating element 32 is arranged is formed by a corner hole in the receiving pocket 20 in such a way that there is as far as possible free rotatability of the compensating element in order to achieve the greatest possible planar contact between the flat sides of the driver pin 18 and the compensating element 32 .
The second embodiment variant of the clamping device will now be explained in more detail with reference to FIGS. 12 to 14 . In FIG. 13 , the unclamped state between the two coupling elements is again indicated in the left half of the figure and the clamped state is indicated in the right half. In this embodiment variant, the driver pin 18 additionally comprises a respective clamping pin 48 which extends in the axial direction starting from the base side. In the exemplary embodiment, the clamping pin 48 has a roughly rectangular to elliptical cross-sectional contour and is arranged eccentrically on a marginal side.
The clamping pin 48 has a frustoconical receiving opening 50 in which a clamping element 52 designed as a screw and having a likewise frustoconical point engages ( FIGS. 13 and 14 ). Due to the frustoconical, that is to say tapering, configuration of the receiving opening 50 and of the clamping element 52 , an axial force component is also generated at the same time, in addition to the clamping in the circumferential direction, for clamping the borer head 4 in the axial direction against the boring body 6 .
The generation of the force in the axial direction on account of the frustoconical configurations can be readily seen once again from FIG. 14 . Furthermore, a slot-shaped recess 54 on the top end face of the fastening shank 34 of the compensating element 32 can be seen from this figure. This slot-shaped recess 54 permits the engagement of, for example, a screwdriver in order to be able to rotate the compensating element into the desired position during the initial assembly.
The borer head 4 in FIG. 15 has, on its cutting side 62 , the boring point 10 and two cutting tips 12 opposite one another at the circumference. Furthermore, coolant passages 65 and fastening means 66 are provided in the region of the borer head 4 . The fastening means 66 serve, for example, to fasten the cutting tips 12 or to fasten cutting tip holders or the like.
The head coupling side 67 is remote from the cutting side 62 of the borer head 4 . The head coupling side 67 has that end face of the borer head 4 which faces the borer body 6 . From this end face on the head coupling side 67 , in the exemplary embodiment, two driver pins project from the head coupling side 67 in the direction of the borer body 6 . The driver pins 18 again also have the rear openings of the coolant passages 65 .
That side of the borer body 6 which faces the borer head 4 is the shank coupling side 70 . The shank coupling side 70 and the head coupling side 67 form the coupling region between borer body 6 and borer head 4 . Two receiving pockets 20 designed to be complementary to the driver pins 18 are formed in the surface of the shank coupling side 70 . Coolant passages 65 can again be seen in the receiving pockets 20 , said coolant passages 65 being in alignment with the coolant passages 65 in the borer head 4 in the final assembled state. The coolant passages 65 therefore pass through the entire boring tool. Finally, both the borer head 4 and the borer body 6 each have a centering bore 72 . Flanks 73 on the borer head 4 and on the borer body 6 and helical flutes 15 incorporated between the flanks 73 can also be seen.
The tool mounting end (not shown in the figures) of the borer body 6 is remote from the shank coupling side 70 on the borer body 6 . With the tool mounting end, the borer body 6 is clamped in place in the boring tool.
In the exemplary embodiment according to FIG. 15 and FIG. 16 , the supporting element 75 designed as a plane-parallel plate is arranged between the borer head 4 and the borer body 6 . The supporting element 75 has through-openings 76 corresponding to the outer contour of the driver pins 18 . By means of the through-openings 76 , the supporting element 75 is slipped onto the borer head 4 in a simple manner, the driver pins 18 passing through the supporting element 75 in the through-openings 76 . The driver pins 18 thus form a form fit with the supporting element 75 . For the final assembly, shown in FIG. 15 , of the tool, the driver pins 18 first of all pass through the through-openings 76 in order to then engage in the receiving pockets 20 in the borer body 6 in a form-fitting manner. The supporting element also has a centering bore 72 . Furthermore, the supporting element 75 has recesses 77 corresponding with the flutes 15 .
It can be seen from the illustration in FIG. 15 that the supporting element 75 projects beyond the lateral surface, formed by the flanks 73 , of the borer head 4 and of the borer body 6 . In the finally assembled boring tool, the supporting element 75 therefore forms a protruding annular region 78 which projects beyond the envelope surface of the boring tool, namely of the borer head 4 and of the borer body 6 . During the boring operation, the supporting element 75 bears with this annular region 78 against the bore wall and thus guides the tool relative to the bore wall.
The exploded illustration in FIG. 20 shows a borer body identical to FIGS. 15 to 19 . In the exemplary embodiment according to FIG. 20 , the supporting element 75 has a ring-like integrally formed portion 79 . The integrally formed portion 79 overlaps both the head coupling side 67 of the borer head 4 and the shank coupling side 70 of the borer body 6 in the direction of the center axis 8 of the boring tool. The supporting element 75 shown in FIG. 20 therefore forms a two-sided receiving bowl for receiving both the head coupling side 67 of the borer head 4 and the shank coupling side 70 of the borer body 6 .
In contrast thereto, the exemplary embodiment of the supporting element 75 shown in FIG. 21 has only one annular integrally formed portion 79 , which extends in the direction of the center axis 8 of the boring tool toward the shank coupling side 70 of the borer body 6 . In other words, the annular integrally formed portion only overlaps the shank coupling side 70 of the borer body 6 and at the same time bears as a plane-parallel plate against the head coupling side 67 of the borer head 4 .
In contrast thereto, the annular integrally formed portion 79 in the exemplary embodiment shown in FIG. 20 overlaps both the shank coupling side 70 of the borer body 6 and the head coupling side 67 of the borer head 4 and thus forms a double-sided receiving bowl for both the shank coupling side 70 of the borer body 6 and the head coupling side 67 of the borer head 4 . The exemplary embodiment according to FIG. 21 , on the other hand, forms only one receiving bowl for the borer body 6 , namely the shank coupling side 70 of the borer body 6 .
The exemplary embodiment shown in FIG. 22 again shows a supporting element 75 having a receiving bowl which is effective only with regard to the borer body 6 and a plane-parallel plate bearing against the borer head 4 . In contrast to the exemplary embodiment shown in FIG. 21 , the annular integrally formed portion 79 overlaps the shank coupling side 70 of the borer body 6 by a considerably greater amount in this exemplary embodiment. When the tool is assembled, the extent of the integrally formed portion 79 in the direction of the center axis 8 is considerably greater than in the exemplary embodiment shown in FIG. 21 . In this way, it is possible to arrange guide elements 81 on the annular integrally formed portion 79 .
The exemplary embodiment shown in FIG. 23 shows, as an example of such guide elements 81 , guide studs attached in pairs to the annular integrally formed portion 79 . These guide elements 81 slide on the bore wall during the machining process.
The exemplary embodiment shown in FIG. 24 again shows a supporting element 75 having a receiving bowl effective only in the direction of the borer body 6 . In this case, the annular integrally formed portion 79 is configured as a flexural spring. For this purpose, a spring slot 82 is made in the annular integrally formed portion 79 . Furthermore, it can be seen from the illustration in FIG. 25 that the guide elements 81 are pushed from the borer body 6 into the annular integrally formed portion 79 . On account of its spring action, the annular integrally formed portion 79 is resiliently mounted on the boring tool in the transverse direction 83 running transversely to the center axis 8 . The supporting element 75 is thus designed as a flexural spring element.
It is of course possible for all the embodiments in FIG. 21 to FIG. 24 , with regard to the configuration of the supporting element 75 as a receiving bowl in relation to the borer body 6 , to also be equally applied to the borer head 4 . Configurations are also conceivable in which a receiving bowl acting on both sides overlaps not only the shank coupling side 70 of the borer body 6 but also a smaller region of the head coupling side 67 of the borer head 4 . | A boring tool has a receiving part implemented as a borer body and a front part implemented as a borer head, which extend along a central axis and can be removably fastened to one another via driver connection. The driver connection has at least two coupling pairs which are separate from one another and are disposed eccentrically relative to the central axis. Each coupling pair is formed by interlocking coupling elements, namely a receiving pocket and a driver pin. The coupling elements have an asymmetrical cross-sectional area and widen with increasing distance to the central axis. Through this design, a reliable transmission of high torques is achieved with lower strains of the borer body in the area of the driver connection. Simultaneously, an automatic centering of the two tool parts to one another is performed. | 8 |
RELATIONSHIP TO OTHER APPLICATIONS
[0001] This patent application is a continuation-in-part patent application of PCT/US2012/024726, filed on Feb. 10, 2012, which is based on Provisional Patent Application U.S. Provisional Patent Application Ser. No. 61/526,248 filed Aug. 22, 2011 and claiming the benefit of U.S. Provisional Patent Application Ser. No. 61/463,022 filed on Feb. 10, 2011 and U.S. Provisional Patent Application Ser. No. 61/525,708 filed on Aug. 19, 2011.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] This invention relates generally to systems for generating heat and power, and more particularly, to an inductive and plasma based system that generates Combined Heat and Power using multiple back up modes of operation.
Description of the Related Art
[0003] Combined Heat and Power (hereinafter, “CHP”) systems, as well as plasma based systems, are known. Although these two types of known systems have been combined in simple arrangements, such as internal combustion based systems, there is a need for a system that achieves the benefits and advantages of both such technologies.
[0004] It is, therefore, an object of this invention to provide a system the achieves the benefits of Combined Heat and Power systems, and plasma based systems.
[0005] It is another object of this invention to provide a cost-effective, commercially viable, renewable CHP system.
SUMMARY OF THE INVENTION
[0006] The foregoing and other objects are achieved by this invention which provides, a method of producing CHP, the method including the steps of:
[0007] providing a cupola for containing a plasma source.;
[0008] providing an inductive element;
[0009] providing a metal bath in the cupola; and
[0010] delivering a feedstock to the cupola.
[0011] In accordance with a specific illustrative embodiment of the invention, the feedstock is a fossil fuel. In other embodiments, the feedstock is a hazardous waste, and in still further embodiments, the feedstock is a combination of any organic compound, fossil fuel, or hazardous material.
[0012] In one embodiment, there is further provided the step of operating the inductive element to react with the metal bath to generate syngas. Additionally, there is provided the step of supplementing the step of operating an inductive element by the further step of operating a plasma torch. A plasma torch is operated on the metal bath, in one embodiment, selectably directly and indirectly. In some embodiments, the step of operating a plasma torch is performed in a downdraft arrangement, and in yet further embodiments, the step of operating a plasma torch is performed at an angle other than vertical.
[0013] There is provided the further step of supplementing the step of operating an inductive element by performing the further step of injecting steam to enhance the production of syngas. The step of operating an inductive element is supplemented by performing the further step of injecting a selectable one of air, oxygen enriched air, and oxygen. In a further embodiment, there is provided the further step of supplementing the step of operating an inductive element by performing the further step of conducting electrical energy via a conductive rod formed of a selectable one of graphite and carbon into the metal bath.
[0014] In accordance with a further method aspect of the invention, there is provided a method of producing CHP, the method including the steps of:
[0015] providing a cupola for containing a metal bath; and
[0016] operating an inductive element to react with the metal bath to generate syngas.
[0017] In one embodiment of this further method aspect there is provided the step of providing the syngas to a duct fired burner, which may also be termed an “afterburner,” to produce steam. In some embodiments of the invention, the step of providing the syngas to a duct fired burner to produce steam includes the further step of providing natural gas to the duct fired burner. In some such embodiments, the mix of syngas to natural gas delivered to the duct fired burner or simple cycle turbine ranges between 0% to 100%.
[0018] In an advantageous embodiment, there is provided the step of generating steam from the duct fired burner, and there is provided the further step of generating steam from a heat recovery system, the steam from the duct fired burner and the heat recovery system being provided to a steam turbine to make electricity.
[0019] In yet another embodiment of the invention, the mix of syngas to fossil fuel delivered to the duct fired burner or simple cycle turbine ranges between 0% to 100%.
[0020] In a still further method aspect of the invention, there is provided a method of producing CHP, the method including the steps of:
[0021] providing a cupola for containing a metal bath;
[0022] operating an inductive element to react with the metal bath; and
[0023] supplementing the step of operating an inductive element by the further step of operating a plasma torch and a pregassifier.
[0024] In yet another aspect of the invention, there is provided a method of producing CHP, the method including the steps of:
[0025] providing a cupola for containing a metal bath;
[0026] operating an inductive element to react with the metal bath; and
[0027] supplementing the step of operating an inductive element by the further step of propagating a selectable one of plasma and electricity into the metal bath to supplement heating of the cupola by the step of operating an inductive element with a pregassifier and a turbine generator and a heat recovery system (hereinafter, “HRS”).
[0028] In a still further method aspect of the invention, there is provided a method of producing CHP, the method including the steps of:
[0029] providing a cupola for containing a metal bath;
[0030] operating an inductive element to react with the metal bath; and
[0031] supplementing the step of operating an inductive element by the further step of propagating a selectable one of plasma and electricity into the metal bath to supplement heating of the cupola by the step of operating an inductive element with a pregassifier and a turbine generator which is augmented with a duct fired burner before the HRS.
[0032] In a further embodiment the duct fired burner maybe run on 100% syngas or a blend of a fossil fuel and syngas that could range to 100% fossil fuel. The turbine maybe run on 100% syngas or a blend of fossil fuel that may range to 100% fossil fuel. The steam generated by the duct fired burner and HRS is, in some embodiments, sold as thermal power or used to power a second steam turbine in a conventional duct fired burner augmented combined cycle generation system.
[0033] In one embodiment, there is provided the further step of supplementing the step of operating an inductive element by performing the further step of conducting electrical energy via a conductive rod formed of a selectable one of graphite and carbon into the metal bath.
[0034] In a further embodiment, the pregassifier has multiple stages. The first stage of the gassifier is heated by steam and the second stage is heated by higher temperature steam, air, molten salt, or any other high temperature heat transfer medium.
[0035] In accordance with a method aspect of the invention, there is provided a method of producing combined heat and power with the use of inductive furnace technology, and optionally with plasma assisted heat with direct, or indirect applications of energy. Additionally, the method of the present invention optionally employs downdraft assisted plasma energy. In accordance with a specific illustrative embodiment, the method of the present invention produces heat via an inductive heating element by exciting and heating a metal bath in a cupola. The metal bath is used, in some embodiments, to produce syngas alone as a heat source or it is supplemented by a plasma torch system. In some embodiments, the cupola is used to process renewable feedstocks, fossil fuels, or hazardous materials. The heat required to produce syngas is, in some embodiments, supplemented by injection of air, oxygen enriched air, or oxygen into the cupola. The syngas process is also supplemented, in some embodiments, by the injection of steam to the cupola.
[0036] The system is configured in a novel way to yield extremely high overall efficiency. A combination of common production components and a high efficiency system design are incorporated in a novel way to achieve the goal of a low cost CHP system. The feedstock to run the operation in some embodiments, is a renewable fuel such as Municipal Solid Waste (hereinafter, “MSW”), biomass, algae, or fossil fuels.
[0037] The invention utilizes the high temperature syngas produced by the inductive plasma process with a simple cycle turbine operating at its maximum fuel inlet temperature. A duct fired burner is located at the outlet of the turbine and before a HRS. The fuel for the duct fired burner is delivered to the system at the maximum allowable temperature. The high velocities, elevated temperatures, available oxygen, and mixing characteristics at the turbine outlet before the duct fired burner promote high efficiency in the duct fired burner and exceptionally high efficiency in the HRS for steam production. The overall system efficiency in some embodiments of the invention is over twice that of conventional coal steam generators in use today.
[0038] In a further embodiment the duct fired burner maybe run on 100% syngas or a blend of a fossil fuel and syngas that could range to 100% fossil fuel. The turbine maybe run on 100% syngas or a blend of fossil fuel that may range to 100% fossil fuel. The steam generated by the duct fired burner and HRS maybe sold as thermal power or may be used to power a second steam turbine in a conventional duct fired burner augmented combined cycle generation system.
[0039] The novel addition of natural gas in the system also allows for redundancy and scalability in the system. The steam output is be tripled in many cases by the additional injection of natural gas or other fossil fuels to the duct fired burner. In some embodiments of the invention the turbine has its syngas-derived fuel sweetened with the natural gas, if necessary. Finally an advantageous use of pregassifiers is utilized in the system to boost the overall plant efficiency and attain the goal of a cost effective production facility.
[0040] The inventive system also takes incorporates the use of inductive baths with direct acting, indirect acting, and down draft, plasma assist. Additionally, the system of the present invention incorporates a duct fired burner application on the outlet of the simple cycle turbine to improve system efficiency. The steam generated by the duct fired burner and HRS may be sold as thermal power or may be used to power a second steam turbine in a conventional duct fired burner augmented combined cycle generation system.
[0041] In accordance with yet a further method aspect of the invention, there is provided a method of producing combined heat and power, the method including the steps of:
[0042] providing a cupola for containing a metal bath;
[0043] operating an inductive element to react with the metal bath to generate syngas; and
[0044] providing the syngas to a duct fired burner to produce steam.
[0045] In one embodiment of this yet further method aspect, the step of providing the syngas to a duct fired burner to produce steam includes the further step of providing natural gas to the duct fired burner.
[0046] In some embodiments, the steam that is generated from the duct fired burner and the HRS are utilized by a steam turbine to make electricity.
[0047] The mix of syngas to fossil fuel that is delivered to the duct fired burner or to the simple cycle turbine ranges between 0% to 100%. In other embodiments, the mix of syngas to natural gas delivered to the duct fired burner or simple cycle turbine ranges between 0% to 100%.
BRIEF DESCRPTION OF THE DRAWING
[0048] Comprehension of the invention is facilitated by reading the following detailed description, in conjunction with the annexed drawing, in which:
[0049] FIG. 1 is a simplified schematic representation of a cupola arrangement constructed in accordance with the invention;
[0050] FIG. 2 is a simplified schematic representation showing in greater detail a lower portion of the cupola of FIG. 1 ;
[0051] FIG. 3 is a simplified schematic representation showing an indirect application of a plasma torch on an inductive metal bath and the cupola;
[0052] FIG. 4 is a simplified schematic representation showing a second indirect application of a plasma torch disposed at an angle relative to the cupola; and
[0053] FIG. 5 is a simplified schematic representation of a specific illustrative embodiment of a system configured in accordance with the principles of the invention for producing combined heat and power.
DETAILED DESCRIPTION
[0054] FIG. 1 is a simplified schematic representation of a cupola arrangement 100 constructed in accordance with the invention. As shown in this figure, a cupola shell 101 is provided with an inlet 104 for introducing a feedstock (not shown) that in some embodiments of the invention is a renewable feedstock, a fossil fuel, or a hazardous waste (not shown). Any combination of the three forms of feedstock can be used in the practice of the invention. There is additionally provided in an outlet port 106 for enabling removal of the generated syngas (not shown). In contrast to conventional inductive furnaces that facilitate a large outlet for metal or alloy production, there is no other outlet for such product. There is an additional small drain 110 for eliminating inorganic slag.
[0055] It is a feature of the present invention that primarily organic compounds are processed to produce syngas. The specific illustrative embodiment of the invention described herein is essentially a bucket arrangement wherein an indirect electrical arc services a non-transfer inductive furnace. This is distinguishable from the conventional use of an inductive furnace, which is to make metals and alloys.
[0056] FIG. 1 further shows cupola arrangement 100 to have a direct acting plasma torch 115 , which in some embodiments of the invention, as will be described below in relation to FIGS. 3, and 4 , is an indirect acting plasma torch, to assist in the cupola heating process. In other embodiments, plasma torch 115 is a carbon or graphite rod that is used to conduct AC or DC electrical energy into a metal bath 120 . The return path for the electrical energy has been omitted from this figure for the sake of clarity.
[0057] There is provided in this specific illustrative embodiment of the invention a cathode 122 that is coupled electrically to an inductive element 125 . Additionally, inductive element 125 has associated therewith an anode 127 .
[0058] Air, oxygen enriched air, or oxygen are injected into cupola arrangement 100 via an inlet 130 to assist in the generation of heat using chemical energy and steam that is delivered via an inlet 132 . The chemical energy and steam are injected for the further purpose of assisting in the generation of syngas. The process of the present invention can, in some embodiments, be performed in a pyrolysis, or air starved, mode of operation.
[0059] FIG. 2 is a simplified schematic representation showing in greater detail a lower portion of cupola arrangement 100 of FIG. 1 . Elements of structure that have previously been discussed are similarly designated. Inductive element 125 reacts on metal bath 120 . Metal bath 120 can consist of any metal or alloy such as aluminum for low temperature work or titanium for high temperature work. Metal bath 120 is kept at a constant fill level 134 by operation of slag drain 110 through which a slag product 135 is drained.
[0060] FIG. 3 is a simplified schematic representation showing a cupola arrangement 200 , wherein there is illustrated an indirect application of a plasma torch 115 on an inductive metal bath and the cupola for enhancing the heating process. In this specific illustrative embodiment of the invention, plasma torch 115 has a power capacity of 0.2 MW. Elements of structure that have previously been discussed are similarly designated. As shown in this figure, syngas outlet 106 is lengthened in this specific illustrative embodiment of the invention, and is shown to have vertical and horizontal portions, 106 a and 106 b , respectively. Indirectly acting plasma torch 115 is, in this embodiment, inserted in the end of vertical section 106 a . In this specific illustrative embodiment of the invention, syngas outlet 106 is refractory-lined and insulated (not shown).
[0061] In the embodiment of FIG. 3 , there is shown an inlet 107 via which is provided municipal solid waste (MSW) (not specifically designated) as a feedstock. Of course, other types of feedstock, as hereinabove noted, can be used in the practice of the invention.
[0062] The product syngas in this embodiment is forced to exit into vertical section 106 a where it communicates with the high temperature plume (not specifically designated) and the radiant heat that is issued by plasma torch 115 . The syngas and syngas outlet 106 both are heated by operation of plasma torch 115 . In this specific illustrative embodiment of the invention, the heated horizontal portion 106 b of syngas outlet 106 is subjected to a heat extraction arrangement that delivers the heat to inlet 107 for the purpose of pre-gasifying the MSW feedstock. The heat extraction arrangement is formed by an impeller 210 that urges a fluid (not shown) along a fluid loop that includes a region 212 where the fluid is heated by communication with heated horizontal portion 106 b of syngas outlet 106 . The heated fluid then is propagated to a heat exchanger 215 where a portion of the heat therein is transferred to the incoming MSW feedstock that is being delivered at inlet 107 .
[0063] There is additionally shown in this figure a steam inlet 132 , as hereinabove described. However, the steam is shown in this figure to be supplied by a steam supply 220 , and the steam then is conducted to a further heat exchanger 225 where a portion of the heat in the steam is transferred to the incoming MSW feedstock that is being delivered at inlet 107 . Heat exchangers 215 and 225 thereby constitute a pre-gassifier for the MSW feedstock, whereby the production of syngas is enhanced.
[0064] FIG. 4 is a simplified schematic representation of a cupola arrangement 250 showing a second indirect application of a plasma torch that is disposed at an angle relative to the cupola. Elements of structure that have previously been discussed are similarly designated. As shown in this figure, the outlet port 106 is fabricated in part at an angle that in some embodiments is greater than 90° to induce tumbling and mixing in the product syngas (not shown). Thus, in addition to vertical and horizontal portions, 106 a and 106 b , respectively, there is shown in this specific illustrative embodiment of the invention an angular portion 106 c . Plasma torch 115 is shown to be inserted in angular portion 106 c.
[0065] FIG. 5 is a simplified schematic representation of a specific illustrative embodiment of a system 500 configured in accordance with the principles of the invention for producing combined heat and power. As shown in this figure, a main feed tube 501 serves as an input for feedstock, in the form of Municipal Solid Waste 504 (“MSW”) for fueling the system. Feed tube 501 is preheated in a novel way to increase efficiency with a heat transfer system 502 that is, in the embodiment, operating on waste low pressure steam heat generated from sensible heat that is recovered from the inductive/plasma process taking place in a plasma/inductive chamber 505 .
[0066] In this embodiment, sensible heat is recovered using a syngas quench system 512 that serves to generate waste heat steam 514 . This steam, which is delivered to the pregassifier along steam conduit 507 , is typically below 400° F. A second stage of pregassifier energy is provided to the feedstock to improve system efficiency, at a higher temperature at pregassifier loop 503 . Pregassifier loop 503 extracts heat from syngas 510 by operation of an impeller, such as compressor 508 , which urges a flow of heated fluid (not specifically designated) through the loop. At least a portion of the heated fluid, in this specific illustrative embodiment of the invention, is delivered to plasma/inductive chamber 505 at an input 526 . Plasma/inductive chamber 505 incorporates, in some embodiments, a cupola arrangement (not specifically designated in this figure), as described above.
[0067] This added energy serves to improve overall performance by the use of waste heat recovered from sensible energy on the outlet of the plasma/inductive chamber 505 . In this case the transfer media is typically air or extreme high temperature steam. More exotic heat transfer media like molten salt are used in some embodiments. It is to be understood that the system of the present invention is not limited to two stages of pregassification heat process and transfer, as multiple such gassifier systems are used in the practice of some embodiments, of the invention.
[0068] As noted, MSW 504 is used as a feedstock in this process example. Inductive coil 506 and plasma torch 509 are the primary energy sources or inputs that react with MSW 504 to produce Syngas 510 . Inductive coil 506 reacts against a molten metal bath (not shown) in plasma/inductive chamber 505 .
[0069] A filter 511 and quench system 512 are portions of the emission reduction system. Sorbents (not shown) are injected and used in some embodiments, but have been omitted in this figure for sake of clarity of the drawing. The semi-processed syngas 510 is split out through conduit 513 and fed directly into a duct fired burner 517 at the highest temperature available. The balance of the syngas is fed into a compressor 515 and boosted in pressure to be fed into turbine 516 . Fossil fuel such as natural gas from pipe 523 and 525 may be mixed with the syngas in concentrations from 0 to 100%. Other fossil fuels such as, but not limited to, butane, propane, or diesel may also be used. Air (not specifically designated) enters turbine 516 , and the high temperature, high velocity, and turbulent air at the outlet (not specifically designated) of turbine 516 is boosted to a higher energy state through the added energy of duct fired burner 517 . A heat recovery system (“HRS”) 518 is shown to be in direct communication with the energy-rich outlet gas from the turbine produces steam 521 , which is sold to customers or could be routed to a low turbine (not shown) to produce electricity in a combined cycle configuration (not shown).
[0070] Electrical power 523 is generated at electrical generator 527 , which as shown, receives rotatory mechanical power in this embodiment from turbine 516 . As noted electrical energy may also be generated from an additional steam turbine driven off of steam pipe 521 . Electrical output power 522 from the electrical generator is used to run the process in plasma chamber 505 . Also, electrical output power 523 or the steam turbine generated electrical power driven off of pipe 521 is available for sale to a third party. Natural gas or other fossil fuel gas is boosted into turbine 516 at input 525 to enhance performance and reliability. Natural gas or other fossil fuel energy is boosted into input 523 of duct fired burner 517 . This too enhances overall system performance and reliability.
[0071] This process of the present invention also serves as a system backup if the production of syngas 510 is for any reason stopped or reduced. A second back up boiler 520 functions as a redundant steam generator to expand the production range of the facility and to add another level of redundancy to the steam production. As shown, back-up boiler 520 receives water in this embodiment at an input 530 and issues steam at an output 532 . Back-up boiler 520 is, in some embodiments, operated on syngas, fossil fuel, or a combination of both. In addition, a natural gas source 519 is shown to supply back-up boiler 520 and also serves as a boost to turbine 516 at an input 525 .
[0072] Although the invention has been described in terms of specific embodiments and applications, persons skilled in the art can, in light of this teaching, generate additional embodiments without exceeding the scope or departing from the spirit of the invention described and claimed herein. Accordingly, it is to be understood that the drawing and description in this disclosure are proffered to facilitate comprehension of the invention, and should not be construed to limit the scope thereof. | A method of generating syngas as a primary product from renewable feedstock, fossil fuels, or hazardous waste with the use of a cupola. The cupola operates on inductive heat alone, chemically assisted heat, or plasma assisted heat. Cupola operation is augmented by employing carbon or graphite rods to carry electrical current into the metal bath that is influenced by the inductive element. The method includes the steps of providing a cupola for containing a metal bath; and operating an inductive element to react with the metal bath. A combination of fossil fuel, a hazardous waste, and a hazardous material is supplied to the cupola. A plasma torch operates on the metal bath directly, indirectly, or in a downdraft arrangement. Steam, air, oxygen enriched air, or oxygen are supplied to the metal bath. A pregassifier increases efficiency and a duct fired burner is added to a simple cycle turbine with fossil fuel augmentation. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a fiber having a multi-ply laminar structure and to a structure employing the same, particularly to a color-developing composite short fiber which reflects visible or invisible rays and interferes with them to develop a color with high transparency and has sophisticated design and which also has excellent optical properties. Also, a color-developing structure is disclosed which is formed by adhering the fiber on a support such as a sheet, a film or a metal plate or to a color-developing structure having the form of a sheet, nonwoven fabric, paper or the like formed by binding such fibers.
DESCRIPTION OF THE RELATED ART
[0002] Recently, fibers having expressiveness such as bulkiness are being developed by using fibers with modified cross sections instead of simple round cross sections and by combining two or more kinds of fibers so as to satisfy demands for high-quality textures in fabrics, and they made entries as new fibers into the market. Fibers having more sophisticated expressiveness or functions are now in demand, and what is required of the fibers includes color deepness and luster. However, if a fiber having a deep color and luster is to be obtained, an unvivid dull-colored fiber results, although it may have a deep color. whereas if one tries to obtain a lustrous fiber, a gaudy glittery fiber results. Accordingly, a technique has not been developed so far for producing fibers fully satisfying both color depth and luster.
[0003] The reason is that dyes and pigments have been employed for developing colors in the prior art, and since dyes and pigments develop colors based on light absorption, the deeper the color one tries to obtain, the smaller becomes the reflected light thereby causing the luster to be lost. In the natural world, there are creatures satisfying both color depth and luster, for example, jewel beetles and morpho butterflies, and they have colors satisfying color depth and luster simultaneously. These creatures develop colors respectively by resorting to reflection and interference of light as the mechanism of color development, and extensive studies are being made so as to find out whether this color-developing mechanism can be utilized in synthetic fibers.
[0004] For example, Japanese Patent Publication No. Sho 43-14185 discloses a coated three-layer composite fiber having pearl effect. It is true, however, such fibers having merely three layers may develop colors based on light reflection and interference, but the degree of color development is too limited to be able to satisfy the demands for higher expressiveness. Meanwhile, as described in Japanese Patent Publication No. Sho 601048, a multilayered synthetic fiber whose interfaces are all substantially parallel to one another can be obtained by combining different kinds of polymers alternately and repeatedly in a spinning pack equipped with a stationary mixer, and the resulting polymer is injected through injection orifices. In this official gazette, there is described an example of a composite fiber consisting of polyethylene terephthalate and nylon 6 formed by layering them via a multilayered film component employing a stationery mixer, and this fiber can give textiles having pearl effect.
[0005] However, if a multilayered fiber is to be obtained according to this method, the laminar flow is disturbed little by little each time two polymers are combined with each other. Although a multilayered structure can be obtained somehow, this technique is not satisfactory to obtain a multilayered structure having a thickness controlled with optical accuracy. Particularly, when a multilayered structure having 10 or more layers is to be formed, polymers must be combined several times or more, so that the layers are likely to have an irregular thickness giving coherent beams of light having insufficient intensity and the coherent beams of light have various wavelengths. Turbidity in color is observed and results in the failure of obtaining a color having satisfactory expressiveness.
[0006] Further, Japanese Patent Publication No. Sho 57-20842 describes a static fluid mixer; and Japanese Patent Publication Nos. Sho 53-8806 and Sho 53-8807 describe methods of spinning blended yarns and associated apparatuses. According to these methods, fibers are obtained by combining two kinds of polymers and separating them repeatedly. The polymers are mixed due to complications of the polymer flows and the method is
[0007] unsuccessful in forming a multilayered structure having optical dimensions. Japanese Unexamined Patent Publication Nos. Sho 62-170510 also discloses a method for obtaining coherent beams of light by forming a fine unevenness on the fiber surface. According to this method, interference of light is induced by forming a diffraction grating on the fiber. A like method is disclosed in Japanese Unexamined Patent Publication No. Hei 4-202805. In these methods, although such fibers may show color development based on interference of light, the wavelength of coherent beams of light in fabrics woven with such fibers varies depending on the angle of view like in the thin film as described above. Accordingly, the colors of the fabrics vary only to give cheap and unsatisfactory expressiveness.
[0008] In addition, Japanese Unexamined Patent Publication Nos. Sho 59-228042 and Sho 63-64535, Japanese Patent Publication No. Sho 60-24847, etc. propose color-developing fibers and fabrics developed taking a hint from the morpho butterflies in South America which are famous for their variable color tone depending on the angle of view and bright color effect. However, the fibers employed in the inventions described in the above official gazettes are flat yarns formed by laminating different kinds of polymers together, so that it is almost impossible to obtain a thickness so as to induce interference of light even if these polymers are laminated. Such structures merely serve to control reflection of light. Meanwhile, another proposal is described in Japanese Unexamined Patent Publication No. Sho 54-42421 disclosing a method for obtaining a multi-ply lamination fiber of different kinds of polymers. However, in this method, the laminated portion is allowed to assume a hollow annular form, and one component in the laminated portion is melted to obtain a superfine fiber. Accordingly, this proposal does not suggest such fibers which give the effect of interference in which multiple layers are all allowed to have optical dimensions.
[0009] Also published is a technique for obtaining a material which shows color development by employing a sandwich structure of a molecule-oriented anisotropic film between a pair of polarizing films (e.g., Journal of Textile Machinery Society, Vol. 42, No. 2, p.55 (1989), and Vol. 42, No. 10, p. 160 (1989), ibid.). Further, Japanese Unexamined Patent Publication Nos. Hei 7-97766 and Hei 7-97786 disclose fiber fabrics each having on its surface a light interference film provided with a substantially transparent thin film layer which can develop color. The fabrics give their effects with the aid of the reflected light of incident light from the front surface and the light reflected by the rear surface. The wavelength of coherent beams of light provided by such thin films varies depending on the angle of view, so that the color of the fabric changes depending on the angle of view, thereby yielding a poor expressiveness.
[0010] The present invention enables the formation of a multilayered structure having more than ten plies so as to obtain a single color development. A composite polymer fiber is disclosed which has a uniform ply thickness and a thin-layer laminar portion formed by laminating alternately two kinds of polymers which develop effective interference color. A technique for forming the fibers and a spinneret for forming them is also taught.
[0011] However, when a color-developing composite fiber obtained according to this technique is woven into plain weave fabric or used as stitch yarns, it is difficult to obviate torsion of the yarns and to orient accurately all of the faces exhibiting optical properties to face forward on an article. This torsion inevitably brings about a reduction in chromaticity, i.e. a reduction in the ability of developing the desired color which is the optical property characteristic of color-developing composite fibers. Meanwhile, the smaller the compression rate of the cross section, the higher becomes the likelihood of the occurrence of torsion. Further, even when the faces exhibiting optical properties are oriented accurately to face forward, their excellent optical properties can be reduced or impaired slightly if the fiber particles are overlapping one another. In other words, the chromaticity of high reflectance, and high transparency can be slightly impaired.
[0012] The present invention relates to a composite fiber which maintains high reflectance and develops a color with high transparency and excellent designability, and also relates to various forms of color-developing structures (coat, resin tapes, nonwoven fabrics, etc.) utilizing the composite fiber.
SUMMARY OF THE INVENTION
[0013] The means employed for achieving the above objectives in the present invention can be divided into the two categories set forth below.
[0014] The first means is a color-developing composite short fiber composed of two or more polymer compounds having different refractive indices laminated alternately which reflects visible rays and interferes with them. The fiber has a length of 0.01 to 100 mm. Also a color developing structure is formed by binding the fiber particles to one another, or by dispersing or mixing the fiber particles with other materials to be bound therewith, or by adhering the fiber particles on the surface of a support. Since visible rays make colors perceptible to the human eye, the structures of the present invention can realize a deep and lustrous color due to reflection and interference of visible rays, thereby providing excellent chromaticity.
[0015] The second means is a color-developing composite short fiber, which is formed by laminating alternately two or more kinds of polymer compounds having different refractive indices. The fiber is composed of a layer which reflects visible rays and interferes therewith and a layer which reflects invisible rays and interferes with the visible rays and has a length of 0.01 to 100 mm.Also, a color developing structure is formed by binding the fiber particles to one another, or by dispersing fiber particles or mixing them with other materials to be bound therewith, or by adhering the fiber particles on the surface of a support. Infrared rays are heat rays, and since reflection and interference of infrared rays means interruption of heat rays, fiber products employing such fibers have the effect of inhibiting the increase of temperatures in substances and human bodies. While ultraviolet rays are harmful to human bodies, fiber products employing the fibers of the present invention have the effect of controlling the malicious influence of such rays.
[0016] In principle, short-cut particles of color-developing composite fiber can be distributed without causing torsion, if they are dispersed on a plate-like body. Particularly when the short-cut particles have flat cross-sections, faces exhibiting optical properties can be orientated to face forward in most particles. If the short-cut fiber particles are dispersed a little more carefully, they can also be dispersed so as not to overlap much. Accordingly, the problems inherent in the prior art can be solved according to such a simple technique, and effects specific to composite fibers having the optical properties as described above can fully be exhibited.
[0017] Meanwhile, in the case of non-cut long fibers, since changes in the orientation directions of the faces exhibiting optical properties is attributed to torsion, such changes occur gradually. However, in the case of short fibers which are masses of short fiber particles, the orientation directions of the fiber particles do not depend. on one another, orientation directions of the faces exhibiting optical properties of adjacent fiber particles can be changed abruptly. Accordingly, in this respect, it was found that there are differences between the long fibers and short fibers in their optical properties.
[0018] As described above, short fibers can be utilized in forms which cannot be realized by long fibers, even if they are of the same color developing fiber materials. Various forms of structures, which cannot be expected to be realized using long fibers, for example, nonwoven fabrics, paper, etc. can be formed.
[0019] The color-developing composite short fiber according to the present invention is described below in terms of its structure, production technique, and characteristics, etc.
[0020] [0020]FIG. 1 shows a cross section of a color-developing composite fiber taken perpendicular to the long axis of the fiber, and the cross-sectional configuration as shown in FIG. 1 is necessary so that the fiber may exhibit the desired characteristics of reflecting and refracting visible or invisible rays according to the present invention. The fiber shown in FIG. 1( a ) is of a structure in which two kinds of polymer compound materials having different refractive indices are merely laminated alternately; while the fiber shown in FIG. 1( b ) is of a structure in which the laminated structure as shown in FIG. 1 is covered with one of the polymer compound materials; and the fiber shown in FIG. 1( c ) is of a laminar structure having two kinds of ply thicknesses so as to effect reflection and interference of two kinds of rays, i.e. visible rays and invisible rays such as infrared rays. Fibers having such cross-sectional configurations are to be all included in the composite fibers for forming short fibers according to the present invention.
[0021] In order to allow these composite fibers to reflect visible rays and interfere with the rays to develop color, the cross-sectional configurations of the fibers are required to satisfy the below requirements. In the laminated portion of a fiber structure, when the optical refractive index and thickness of a high-refractive index material are na and da, and those of a low-refractive index material are nb and db, respectively, na, da, nb and db shall satisfy the following relationship:
0.38 μ m ≦λ1≦0.78 μ m wherein λ1=2(nada+nbdb), with the proviso that
1.0≦na≦1.8, 1.3≦nb≦1.8 μm and 1.01≦nb/na≦1.8.
[0022] Here, λ1 means peak wavelengths (μm) in a reflection spectrum, and in this case the primary peak wavelength. In these expressions, nada and nbdb show “the product of optical refractive index and thickness” of the high-refractive index material and that of the low-refractive index material respectively. “The product of optical refractive index and thickness” is generally referred to as “optical thickness”. Accordingly, the sum of the optical thickness of the high-refractive index material and that of the low-refractive index material multiplied by 2 gives the desired peak wavelength λ1.
[0023] Meanwhile, in order to allow a layer to reflect invisible rays such as infrared rays, an infrared reflection and interference layer and an ultraviolet reflection and interference layer should satisfy the requirements 0.78 μm≦λ1≦2 μm and 0.2 μm≦λ1≦0.38 μm, respectively, under the above conditions.
[0024] Under the above conditions, the thicknesses of the layers are: infrared reflecting layer>visible ray reflecting layer>ultraviolet reflecting layer. Incidentally, the ply numbers N of these three layers having optical functions of reflecting visible rays, infrared rays and ultraviolet rays respectively depend on which function is selected primarily. For example, in the case where the color developing function is selected as the primary function and the other functions are secondary functions, the ply number N of the visible ray reflecting layer is increased compared with those of the reflecting layers having other functions, and thus not only the reflectance at the peak wavelength λ1 can be increased, but also the function of the layer can be improved.
[0025] Referring to the arrangement of the visible ray reflecting layer and two other invisible ray reflecting layers, in terms of the layered cross section, it may not particularly be limited, and any of these three layers may be located on the inner side. For example, when an infrared reflecting layer and an invisible ray reflecting layer are to be laminated, the thin invisible ray reflecting layer may be located on the inner side, or it may be arranged on the outer side and the infrared ray reflecting layer may be located on the inner side. Further, this fiber preferably has a cover so as to be surrounded entirely on the surface, as shown in FIGS. 1 ( b ). Thus, an improved fiber structure can be obtained, since the layered side faces are prevented from being exposed directly, as shown in FIG. 1( a ), and ply separation between lamination planes can be prevented from occurring at the lamination interfaces. Abrasion resistance of the fiber can also be improved. If a material having a low melting point is used for forming the cover, it can be utilized for fusing the fiber particles on the surface of a support or fusing them with one another.
[0026] Further, referring to the cross-sectional configuration of the fiber, it preferably has a flat profile such that the faces exhibiting optical properties have a larger surface area and the faces orthogonal thereto have a smaller surface area. Thus, the face exhibiting optical properties can accurately be orientated to face forward and to develop a uniform color having high reflectance and transparency. However, the present invention is not to be limited to such configurations, and various kinds of cross-sectional configurations such as a square overall configuration can be employed. When a cross-sectional configuration having a low compression ratio is employed, faces other than those exhibiting optical properties are very likely to be oriented to face-forward, and although it is inevitable that the fiber has a high reflectance and that its transparent color is lightened, there is not a reduction in the chromaticity as would be induced by torsion in long fibers. On the contrary, orientation directions of the faces exhibiting optical properties can be changed even between adjacent fiber particles, and thus the short fibers, unlike the long fibers, have the benefit that they can give color-developing structures having excellent designability (decorativeness) since the color tone varies depending on the angle of view.
[0027] Incidentally, polymer compounds employable for the fiber structures are exemplified by the following for high-refractive index and low-refractive index, polymer compounds such as polyethylene, polybutylene, polyester, polyacrylonitrile, polystyrene, polyamide, polyolefin, polyvinyl alcohol, polycarbonate, methyl polymethacrylate, polyether ether ketone, polyparaphenylene terephthalamide and polyphenylene sulfide as single substances; blends of these compounds; or copolymers of two of more kinds of these compounds. Further, low-refractive index polymer compounds are exemplified by fluoroplastics, whereas high-refractive index polymer compounds are exemplified by resins such as polyvinylidene chloride, polyethylene terephthalate and polyethylene naphthalate, and polyphenylene sulfide. Suitable combinations of low-refractive index polymer compounds and high-refractive index polymer compounds include combinations of the former compound selected from fluoroplastics and the latter compound selected from polyvinylidene chloride, polyester resins and polyphenylene sulfide.
[0028] Next, the length of the composite fiber will be described. FIG. 2 shows a composite short fiber of the present invention, and this short fiber is formed by cutting a composite fiber.
[0029] In the color-developing composite short fiber according to the present invention, while the fiber is required to have a length in the range of 0.01 to 100 mm, the preferred range of length varies depending on the kind of structure to be formed employing the short fiber. For example, when the composite short fiber is used in the form of a dispersion or mixture with other materials such as a coating material, the fiber conveniently has a length in the range of 0.01 to 2 mm. When the composite short fiber is used in the form of a dispersion in or mixture with a coating material or the like, short fibers longer than the specified range will undergo torsion during dispersion and are likely to be bent. Color-development is hindered at such distorted portions, while color changes at the bent portions are due to a change in the structure. In the case of the short fiber having a length of 2 mm or less, even when the short fiber of the present invention is mixed with an adhesive and the resulting mixture is sprayed, clogging of spray nozzle does not occur, thereby facilitating the operation. Meanwhile, in the case of a short fiber which is shorter than the specified range, it is technically difficult to cut a fiber material into fiber particles having a suitable size and suitable state in a large amount, leading to cost increases. Consequently, the cut edges of the short fiber particles are deformed by the shear as shown in FIG. 2 to have no flat end which develops the original color of the fiber, and the color developed is changed.
[0030] On the other hand, when short fiber pieces are intertwined and bound to one another like in a nonwoven fabric, the short fiber suitably has a length of 2 to 30 mm.
[0031] Next, configuration and production techniques of a color-developing structure formed by adhering the short fiber of the present invention on the surface of a support such as a sheet and a metal plate, and a color-developing structure such as a sheet formed using a binder resin in which the short fiber of the present invention is dispersed is described. A nonwoven fabric formed by intertwining the short fiber of the present invention, and a paper formed by dispersing in a paper raw material and bound therewith are described below.
[0032] First, the color-developing structure formed by adhering the short fiber of the present invention on a surface of a support such as a sheet can be obtained by dispersing the short fiber by means of spraying or sprinkling utilizing gravity over the surface of the support. The support is coated on the surface with a material having adherence such as an uncured adhesive or coating thereon, followed by curing of the uncured material. When the short fiber is applied over the entire surface of the support, a material having adherence may be applied over the entire surface of the support. However, for example, when a special pattern or the like is to be formed locally, an adhesive is applied patternwise beforehand, and the short fiber is dispersed on the surface of the adhesive layer thus formed. After solidification of the adhesive, the short fibers present on the other portions of the support having no adhesive layer are removed to give the desired neat chromatic pattern.
[0033] The material of the support on which the short fiber is bonded is not particularly limited, and various materials such as metals, wood, plastics, rubbers, ceramics, paper, fibers and glass can be employed, not only singly but also as a mixture or laminate of two of more kinds. While the support can suitably be in the form of thin plate or thick plate, such as a film, a sheet or a plate, it is not necessarily limited to plate-like bodies and can be of various kinds of threedimensional structures. For example, patterns can be formed on toys using the short fiber, and articles whose designability and chromaticity are matters of great importance in daily lives can be decorated with the short fibers to show the characteristics of the short fibers. In the case of structures employing the composite short fiber capable of reflecting both visible rays and invisible rays (e.g., infrared rays) and interfering with the rays where the support is a fabric, a metal plate or the like can exhibit excellent chromaticity and also can inhibit temperature rise.
[0034] Meanwhile, if the color-developing structure is formed using as the plate-like support a transparent sheet 49 having a wavy surface as shown in FIG. 3, there is obtained a color-developing structure of excellent designability in that the orientation directions of the faces having optical properties are delicately changed along the wave such that the color tone is varied delicately. Also, the wavy surface can be oriented not to be exposed but to be on the rear side, and thus the surface of the structure can securely be prevented from being soiled or damaged. It is also possible to control securely damage, soiling, etc. of the structure by applying a transparent sheet layer or forming a transparent coating layer on the surface of the support on which the color-developing short fiber is adhered as shown in FIGS. 4 ( b ) and 4 ( c ). In the case of the former, since the surface of the structure can be flattened, it can be cleaned easily by wiping. The resulting sheetlike color-developing structure can be applied easily to various kinds of articles if an adhesive layer is formed on the rear side of the structure to readily exhibit fully its optical properties.
[0035] Further, this short fiber can be used in combination with other surface decorating materials such as coating materials. In such a case, the short fiber may first be bonded to a support, followed by coating of the resulting support with a coating material. Also, a coating material may first be applied to the support, followed by dispersion of the short fiber before the coating material is dried to bind the short fiber onto the support with the aid of the adhesion of the coating material. Further, the short fiber may be used in the form of mixture with an adhesive or a coating material, and the resulting mixture can be sprayed. As the coating material to be employed, those which do not affect color-developing properties of the short fiber are preferably selected. Particularly, when orientation of the color-developing surface characteristic to the short fibers is not very important, mixing of the short fibers with coating materials presents no problem, and further the short fiber can be used in the form of a mixture with various kinds of materials which are required to develop color.
[0036] Next, nonwoven fabric consisting only of color-developing composite fiber particles which are bound to one another, paper obtained by dispersing the short fiber particles in and bound with other paper materials, and the like can be prepared in the following manner.
[0037] A composite fiber filament is first cut into particles of several millimeters, and the fiber particles are dispersed homogeneously in a paper-making raw material mixture containing water, a dispersant, a precipitant and a glue. Subsequently, the resulting dispersion is applied to paper-making equipment having at the bottom a fine mesh as used in ordinary paper making to prepare a wet paper sheet. The sheet is then dried to give a paper sheet as a final product containing the color-developing composite short fibers dispersed therein. Also, the composite fiber filament can be cut into particles of several millimeters, the fiber particles are dispersed homogeneously in a binder resin solution, and the resulting dispersion is made into the form of sheet or film. If an adhesive layer is formed on one side of the sheet obtained, it can be applied to various kinds of articles easily.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] [0038]FIG. 1 shows cross-sections of composite fiber structures before being cut into the form of short fibers taken orthogonal to the longitudinal axes of the structures;
[0039] [0039]FIG. 1( a ) is a diagram of the structure where a high-refractive index material and a low-refractive index material are laminated alternately;
[0040] FIGS. 1 ( b ) is a diagram of the structure having two polymer materials laminated alternately, and this multilayered structure is covered entirely with one of the polymer materials so that the layered faces are not be exposed;
[0041] [0041]FIG. 1( c ) shows a laminar structure having two kinds of ply thicknesses, i.e. a thick central layer as an infrared reflection and interference layer and visible ray reflection and interference layer as outer layers;
[0042] [0042]FIG. 2 shows a short fiber formed by cutting the composite fiber where the cut planes (side edges) are deformed by cutting;
[0043] [0043]FIG. 3 is a cross section of the color-developing structure according to the present invention showing the orientation direction of the faces having optical properties of the fiber which are bound to a transparent sheet support having a wavy surface;
[0044] [0044]FIG. 4 shows a cross section of the color developing structure according to another embodiment of the present invention employing a transparent sheet support having a wavy surface;
[0045] [0045]FIG. 5 shows a pair of nozzle plates 1 , 1 ′ attached to a spinneret for spinning the composite fiber;
[0046] [0046]FIG. 5( a ) is a plan view of the combined pair of nozzle plates 1 , 1 ′;
[0047] [0047]FIG. 5( b ) is a front view of the combined pair of nozzle plates 1 , 1 ′;
[0048] [0048]FIG. 5( c ) is a cross-sectional view taken along the line X-X′ in FIG. 5( b );
[0049] [0049]FIG. 5( d ) is a cross-sectional view taken along the line Y-Y′ in FIG. 5( b );
[0050] [0050]FIG. 6 shows how the layered cross-section of the composite fiber changes in the spinneret;
[0051] [0051]FIG. 6( a ) shows the structure of the composite fiber immediately after passing through openings 2 , 2 ′ of the nozzle plates;
[0052] [0052]FIG. 6( b ) shows the structure of the composite fiber squeezed by passing through a funnel-like portion 4 ;
[0053] [0053]FIG. 7 shows a cross-sectional view the nozzle plates and a funnel-like portion 4 contiguous thereto;
[0054] [0054]FIG. 8 shows an overall vertical cross-sectional view of a disc-like spinneret 50 incorporated with the nozzle plates taken along the longitudinal axis;
[0055] [0055]FIG. 9 is a plan view of an upper spinneret disc of the spinneret 50 ;
[0056] [0056]FIG. 10 shows the spinneret according to another embodiment of the present invention, that is, an overall vertical cross-sectional view of a cylindrical spinneret 60 taken along the longitudinal axis, which is suitably employed for spinning a composite fiber having the cross-sectional configuration as shown in FIG. 1( b ); the right half and the left half of the drawing showing cross sections taken along different lines;
[0057] [0057]FIG. 11 is a view taken along the line a-a′ of FIG. 10 between an upper distribution disc and a lower distribution disc of the spinneret;
[0058] [0058]FIG. 12 is a view taken along the line b-b′ of FIG. 10 between an upper distribution disc and a lower distribution disc of the spinneret;
[0059] [0059]FIG. 13 shows an upper distribution disc 26 of the spinneret shown in FIG. 10;
[0060] [0060]FIG. 13( a ) is an enlarged cross-sectional view of the left half of the upper distribution disc 26 taken along the line a-a′ of FIG. 10;
[0061] [0061]FIG. 13( b ) is a vertical cross-sectional view of the upper distribution disc;
[0062] [0062]FIG. 14 shows a lower distribution disc 27 of the spinneret shown in FIG. 10;
[0063] [0063]FIG. 14( a ) is an enlarged cross-sectional view a′ of the right half of the lower distribution disc taken along the line a-a′ of FIG. 10;
[0064] [0064]FIG. 14( b ) is a vertical cross-sectional view of the lower distribution disc;
[0065] [0065]FIG. 15 illustrates an example of the technique of mass-producing a short fiber;
[0066] [0066]FIG. 16 is a schematic drawing of a high-speed cutting machine employed for cutting the composite fiber;
[0067] [0067]FIG. 17 show duplicates of pictures illustrating black panels on which short fibers are adhered with an adhesive;
[0068] [0068]FIG. 17( a ) is a duplicate of a picture showing a black panel on which the short fiber is dispersed over the entire surface;
[0069] [0069]FIG. 17( b ) is a duplicate of a picture showing a black panel on which an adhesive is applied patternwise with the short fiber being dispersed on the adhesive layer;
[0070] [0070]FIG. 17( c ) is a duplicate of a picture of an embroidered pattern using the composite fiber structures as stitch yarns for comparison;
[0071] [0071]FIG. 18 shows a process for producing a nonwoven fabric according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0072] (1) Spinning of Color-developing Composite Fiber
[0073] A process for producing a composite fiber having such characteristics will first be described below specifically.
[0074] [0074]FIG. 5 shows a combined pair of nozzle plates 1 , 1 ′ of a spinneret for spinning a composite fiber having the cross-sectional configuration as shown in FIG. 1( a ). FIG. 5( a ) is a plan view of the combined pair of nozzle plates; FIG. 5( b ) is a front view; FIG. 5( c ) is a cross-sectional view taken along the line X-X′ in FIG. 5( b ); and FIG. 5( d ) is a cross-sectional view taken along the line Y-Y′ in FIG. 5( b ). When introduced through inlets 3 , 3 ′ defined at the tops of the nozzle plates 1 , 1 ′ and fed to nozzle plate chambers 13 , 13 ′, two kinds of molten polymer materials A and By are injected out of a row of openings 2 , 2 ′ defined in the nozzle plates 1 , 1 ′ respectively, and the thus injected two molten polymer materials are fed forward in the form of laminate of the molten polymer materials A and B to a meeting chamber 14 . The channel following contiguous to the pair of nozzle plates is a funnel-like portion 4 having at the lower end an outlet, as shown in FIG. 7.
[0075] [0075]FIG. 8 shows an actual spinneret 50 incorporated with such nozzle plates. The spinneret 50 consists of an upper distribution disc 9 , a lower distribution disc 10 , an upper spinneret disc 6 , an intermediate spinneret disc 7 and a lower spinneret disc 8 and the discs are all fastened with bolts 17 . The upper spinneret disc 6 contains a multiplicity of nozzle plates which are arranged radially as shown in FIG. 9, and the same number of inlets 3 , 3 ′ as that of the nozzle pairs are defined in the upper distribution disc 9 and the lower distribution disc 10 so as to supply the molten polymer materials A and B to each pair of nozzle plates 1 , 1 ′, while the same number of funnel-like portions 4 and the same number of outlets 15 as that of the nozzle plate pairs are defined in the intermediate spinneret disc 7 and the lower spinneret disc 8 so as to allow composite polymer fibers to be formed in the respective nozzle plates as shown in FIG. 6( b ).
[0076] To describe formation of a composite fiber structure using spinneret 50 , the molten polymer material A is first distributed through the inlets 3 defined in the upper distribution disc 9 and the lower distribution disc 10 to the nozzle plates 1 , and the molten polymer material B is likewise distributed through the channels 3 ′ to the nozzle plates 1 ′. Subsequently, the polymer materials A and B are injected through the openings 2 , 2 ′ of the nozzle plates 1 , 1 ′, respectively, to be laminated with each other. The thus laminated polymer is injected through the outlets 15 to be spun through final spinneret orifices 16 to provide composite fibers which are of high reflectance and can develop colors with high transparency.
[0077] When a composite fiber structure having the cross-sectional configuration as shown in FIG. 1( c ), i.e., a fiber structure having a visible ray reflection and interference layer and an invisible ray reflection and interference layer is to be formed, nozzle plates 1 , 1 ′ each having two kinds of opening diameters are employed, although the method therefor will not specifically be described here. For example, there may arranged large-diameter openings in the central area and small-diameter openings on each side area.
[0078] FIGS. 10 to 14 illustrate a spinneret 60 which is suitable for forming composite fiber structures having the cross-sectional configuration as shown in FIG. 1( b ). This spinneret 60 consists of an introduction disc 25 , an upper distribution disc 26 , a lower distribution disc 27 , a funnel-like portion-containing disc 28 and a spinneret orifice containing disc 29 , downstream. In this spinneret 60 , the portion of the upper distribution disc 26 and that of the lower distribution disc 27 which contain rows of openings serve also as the nozzle plates 1 and 1 ′, respectively.
[0079] [0079]FIG. 10 shows an overall view of the spinneret 60 , in which the left half is a simple vertical cross section taken along the axis of the spinneret and also along the center of the row of nozzles, whereas the right half is a cross section which is an outward view taken orthogonal to the row of nozzles at a position away from the axis of the spinneret. FIG. 11 is a view taken along the line a-a′ in FIG. 10 between the upper distribution disc and the lower distribution disc, i.e., the upper surface of the lower distribution disc 26 .
[0080] [0080]FIG. 12 is a view taken along the line b-b′ in FIG. 10 between the upper distribution disc and the lower distribution disc, i.e. the lower surface of the upper distribution disc 27 .
[0081] To describe more specifically about the spinneret, FIG. 13( a ) shows the upper surface of the upper distribution disc 26 shown in FIG. 10; and FIG. 13( b ) is a vertical cross-sectional view of the same part as described above, i.e. the upper distribution disc. FIG. 14( a ) shows the upper surface of the lower distribution disc 27 also shown in FIG. 10, whereas FIG. 14( b ) is a vertical cross-sectional view of the same part, i.e., the lower distribution disc 27 . Each pair of these upper and lower distribution discs 26 and 27 contain rows of twelve openings 2 and 2 ′ respectively. Each pair of opening rows constitute one nozzle block. The row of openings 2 in one block is shown in the enlarged view in FIGS. 13 and 14. FIG. 13 shows the row of openings 2 in the upper distribution disc 26 , while FIG. 14 shows the row of openings 2 ′ in the lower distribution disc 27 .
[0082] These rows of openings are arranged such that the openings 2 in the upper distribution disc 26 may oppose the openings 2 ′ in the lower distribution disc 27 via a narrow overflow section such that the former openings are shifted horizontally by {fraction (1/2)} pitch from the latter openings. The structure following this narrow overflow section, i.e. the structure on the downstream side of the flow of the molten polymer compounds, is bent once downward at a right angle, with a vertical groove having on the downstream side an expanded channel 21 extending via a sloped portion. On the downstream side of the channel 21 , a funnel-like portion 22 having a channel tapering off is formed. Further, on the downstream side of the funnel-like portion 22 , an annular groove 23 is formed in the spinneret disc 29 along the boundary with the funnel-like portion-containing disc 28 to surround the funnel-like portion, and the molten polymer supplied to the lower distribution disc 27 is designed to be supplied partly to this groove 23 . The groove 23 has on the downstream side a final spinneret orifice 24.
[0083] Fibers are spun employing this spinneret 60 as follows. Molten polymer materials A and B are introduced through the inlets 3 , 3 ′ to the rows of openings defined in the upper distribution disc 26 and the lower distribution disc 27 , respectively. The molten polymer material A is injected through the row of openings 2 , whereas the molten polymer material B is injected through the row of openings 2 ′, and the polymer materials A and B are laminated with each other immediately after injection. The thus laminated polymer passes through the channel 21 and is reduced in the thickness of each ply by the funnel-like portion 22 of the funnel-like portion-containing disc 28 . The polymer materials of the laminar structure passed through this funnel-like portion 22 are covered there with the polymer compound material distributed partly from the lower distribution disc 27 and supplied to the groove 23 formed to surround the funnel-like portion to be spun through the final spinneret orifice 24 .
[0084] Incidentally, in a cross-sectional structure of the composite short fiber as shown in FIG. 1( b ), when the short fiber is to be fused onto a support under heating, it can be carried out by selecting as the material for covering the laminar structure a material which has a low melting point and does not affect color development instead of using one of the materials constituting the fiber. Such fibers can be formed if the structure of the spinneret 60 is modified slightly. That is, an extra inlet for the material to be supplied to the groove 23 is formed, and the material having the properties as described above, including a low melting point etc. can be supplied to the inlet.
[0085] With reference to formation of monofilament, FIG. 16 shows an example of high-speed cutting machine 31 employable for obtaining the short fiber of the present invention. This high-speed cutting machine 31 consists of a delivery device 32 , a cutter 35 , a product recovery box 37 , etc. When the composite fiber is to be cut, a bundle of the composite fiber is further bundled into the form of cord or plate to provide a fiber bundle, and then a roll of the fiber bundle is set in the delivery device 32 . The fiber bundle set in the delivery device 32 is then fed out via feed rollers 33 and a guide 34 to the cutter 35 to be cut into particles with a predetermined size. The thus obtained fiber particles are transferred by a suction pump 38 to be recovered into the product recovery box 37 . The fiber particles thus recovered are the short fiber of the present invention. The structure of the cutting machine employable here may not be limited to the structure described above, but any known cutting machines which are capable of cutting fibers can suitably be employed.
[0086] When composite fibers are to be cut using such a high-speed cutting machine as illustrated in FIG. 16, it is efficient to cut a bundle of fiber filaments, e.g., several thousands to several tens of thousands, occasionally several hundreds of thousands of filaments instead of cutting them singly, and thus the fibers can be cut with high accuracy. To describe the manner of bundling the composite fibers, it is common to bundle them into the form of a cord or plate, and while both cords and plates can be employed in the present invention, they have both advantages and disadvantages respectively. Although the fibers can be bundled into the form of cord easily, the cutting accuracy is lowered if a large number of the fibers are to be cut, and the bundle of fibers exhibits low rigidity. There are countermeasures for improving this drawback, for example, the bundle of fibers can be fixed with one another with a water-soluble glue and dried so as to be able to withstand the delivery strength. Meanwhile, according to the technique of bundling the fibers into the form of plate, it is possible to bundle a large number of fibers and to cut the fibers with high accuracy. However, extra jigs and the like are required for forming plate-like bundles. The manner of bundling may not be limited to those as described above, but any of the known methods which are suitable for cutting fibers are employable.
[0087] Reference will be made to FIG. 15 to describe a typical example of the technique of obtaining a large amount of short fibers. As shown in FIG. 15( a ), first, twenty pieces of bobbins 41 are each wound with a 105-denier color-developing composite fiber yarn, and these twenty fiber yarns are taken up together by another bobbin 42 to form a 2100-denier doubling. Further, fifteen pieces of bobbins 42 each having the 2100-denier doubling wound around them are provided, and then the doublings are taken up by 100 times by a hank winder 43 to provide a 31500-denier doubling. The 100-time wound loop-like hank of the doubling on the hank winder is cut open orthogonal to the rotational direction of the hank winder to be straightened and obtain a thick cord 44 of 3,150,000 denier. This cord 44 is fed to a cutting machine 45 to be cut into pieces with a predetermined length with the cutter 45 , and thus a great number of cut fibers 46 can be obtained by one cutting motion, enabling efficient formation of color-developing composite short fiber.
[0088] (2) Measurement of the Length of Short Fiber
[0089] Forty filament bundles each consisting of eleven filaments of violet composite fiber having flat cross-sections were put together and were further bundled into the form of cord and fixed with a water-soluble glue to provide a cord-like fiber bundle which was then fed to a high-speed cutting machine, as shown in FIG. 16, to be cut therewith. The preset cutting width and the measured cutting width are as follows.
Results of size measurement Present cutting width Measured cutting width (mean) 0.5 (mm) 0.47 (mm) 0.1 0.08 0.05 0.04 2.0 2.05 10 10.0 40 39.5 80 80.7
[0090] (3) Adhesion of Short Fiber onto Support
[0091] When the short fiber having a length of about 0.5 mm obtained in this example was sprinkled over a black panel and fixed with a glue to observe its color, the short fiber developed the violet color more intensively compared with the uncut long fiber. The reason is that the short fiber obtained by cutting the long fiber can be dispersed uniformly over the panel and that the fiber can be oriented so that the reflection and interference faces may be arranged along the panel surface without torsion or bending. Consequently, unlike the long fibers, the short fibers do not have any reduction of the reflected light which can occur when the fiber particles are overlapped one another, and the occurrence of distorted reflection and interference faces can be avoided., This obviates any deterioration of chromaticity. Accordingly, the reflection and interference faces in the short fiber according to the present invention are not induced by torsion and the like. It was also successful to reduce orientation of the side faces which are nonreflection and interference faces to face forward.
[0092] [0092]FIG. 17 shows examples of color-developing structures obtained using the short fiber of the present invention so as to help explain the utilization of the short fibers of the present invention and characteristics in forming the color-developing structures of the present invention, and contains duplicates of pictures showing black panels on which short fibers are adhered with an adhesive. FIG. 17( a ) shows a black panel on which the short fiber is dispersed over the entire surface. FIG. 17( b ) shows a black panel on which an adhesive is applied patternwise with the short fiber being dispersed on the adhesive layer. FIG. 17( c ) shows an embroidered pattern formed using yarns of the composite fiber structures for the purpose of comparison.
[0093] (4) Preparation of Optical Coating Material
[0094] When short fibers having a length of about 2 mm was mixed with a coating material and the resulting mixture was sprayed against an object, the coating film formed presented a face having transparency and high reflectance.
[0095] (5) Preparation of Nonwoven Fabric
[0096] The process for preparing a nonwoven fabric will be described below specifically referring to FIG. 18. Filaments of composite fiber prepared are crimped using crimper rollers 51 , and the crimped filament are cut with a cutter 52 of a cutting machine into pieces having a length of 3 to 5 cm to give crimped short fiber. The mass of short fiber obtained was subjected to opening using a card to form a fleece-like laminar sheet, as shown in FIG. 18( c ). This laminar sheet is then subjected to needle punching so as to allow the short fiber pieces to be intertwined and bound with one another, as shown in FIG. 18( d ). This needle punching is carried out using needles 53 or water, followed by embossing treatment by pressing the thus treated laminate between embossing rollers 54 to achieve both embossing and thinning of the intertwined laminar sheet thereby giving a nonwoven fabric as a final product.
[0097] In the present invention, the composite fiber was crimped before cutting and then cut into pieces having a length of about 10 mm. The short fiber thus obtained was used for forming a nonwoven fabric by going through the steps as shown in FIG. 18. As a result, a nonwoven fabric having transparency and high reflectance was obtained. | A color-developing composite short fiber having a length of 0.01 to 100 mm is obtained by cutting a color-developing short fiber capable of reflecting visible rays and interfering therewith consisting of two or more kinds of polymer compounds having different refractive indices which are laminated alternately, while a color-developing structure is formed by binding particles of the short fiber one another, dispersing the short fiber in or mixing it with other materials to be bound therewith or adhering the short fiber on the surface of a support. Further, a color-developing composite short fiber having a length of 0.01 to 100 mm is obtained by cutting a color-developing composite fiber comprising two or more polymer compounds having different refractive indices which are laminated alternately to constitute a layer capable of reflecting visible rays and interfering therewith and a layer capable of reflecting invisible rays and interfering therewith, while a color-developing structure is formed by binding particles of the short fiber one another, dispersing the short fiber in or mixing it with other materials to be bound therewith or adhering the short fiber on the surface of a support. These color-developing short fibers and structures maintain high reflectance to develop colors with high transparency and exhibit excellent designability. | 8 |
BACKGROUND OF THE INVENTION
[0001] Much research has been conducted to date to study the behavior of reinforced concrete (RC) beams strengthened with prestressed fiber reinforced polymer (FRP) sheets and plates. By inducing prestressing the FRP system can be used more efficiently, leading to an increase in the flexural capacity and serviceability of the strengthened beams (Triantafillou et al., 1992; Char et al., 1994; Quantrill and Hollaway, 1998; El-Hacha et al., 2001a; 2001b; El-Hacha et al., 2003). Literature review shows that strengthening of RC beams with prestressed FRP sheets and plates can be grouped under three installation methods.
[0002] The first installation method consists of an indirect method for achieving prestress in the FRP system. Saadatmannesh and Ehsani (1991) have investigated an indirect method for prestressing glass FRP (GFRP) plates. Stressing in the GFRP system was achieved by initially cambering the beam upwards with the use of hydraulic jacks followed by bonding the plates to the underside of beams. After the epoxy adhesive was properly cured the cambering system was released; thereby, inducing prestressing in the GFRP plates. Some of the disadvantages associated with this method are that it is labor intensive, only low levels of prestressing can be induced in the plates, not easy to achieve the desired level of prestressing in the plates or sheets, and the reacting floor or foundation must be capable of sustaining the applied vertical loads.
[0003] Researchers have also investigated two other methods consisting of directly or indirectly applying the prestress to the FRP system. These next two methods include three phases to achieve the desired level of prestressing. First, the stress is applied with a power operated hydraulic jack or similar device and the prestressing in the FRP system must be controlled with either strain gages or load cells. Second, the sheets or plates are bonded to the concrete surface with an epoxy adhesive or simply anchored to the beam itself. Finally, after the epoxy adhesive has properly cured, the sheets are cut near the ends and the prestressing device is removed.
[0004] In the second method or designated as the direct method, the FRP sheets or plates are first anchored at one end (dead end) and then tensioned from the other end (live end) using a power operated hydraulic jack (Wight et al., 2001; Saeki et al., 1997; El-Hacha et al., 2001b). According to this method the FRP sheets or plates must be anchored to the beam itself at either end. The dead end is first anchored before stressing and the live end is subsequently anchored after the stress is applied to the FRP system. In many instances these anchors serve as a permanent anchorage to the FRP system leading to a costly solution due to the high costs associated with fabricating the specialized prestressing anchors and plates. To achieve a cost effective solution these anchorages can be optionally removed for usage in further applications. If left in place, permanent steel anchors are likely to be exposed to significant weathering or galvanic corrosion due to contact with the carbon fibers. Also, the anchors may need to be removed for aesthetics reasons, leading to potential debonding of the prestressing sheets or plates. In order to avoid premature debonding it may be necessary to install U-wraps before removal of the anchors and plates. However, because of the presence of these anchors and plates, the U-wraps must be placed away from the ends of the prestressed FRP system. Other disadvantages that can be associated with this method are that it tends to be laborious, and the beam surface must be properly treated (ACI 546, 1996) prior to drilling for installation of the anchors.
[0005] A third method consists of first bonding the end of FRP sheets or plates to steel plates or other devices, which are then tensioned against an external reacting frame (Triantafillou et al., 1992; Char et al., 1994; Garden et al., 1998; Quantrill and Hollaway, 1998). In many of the systems proposed in the literature the prestressing release was carried out by cutting the sheets in specified unbonded regions. In many of these systems the release method was carried out under high strain rates leading to premature debonding and further accentuating the need for end anchorages. In addition, many of the systems proposed in the literature require the use of specialized equipment.
[0006] The new innovative external mechanical device was invented for prestressing FRP sheets, which follows within this third method. The invention can overcome some of the disadvantages outlined for each of the three methods. An attractive feature of the device is that the prestressing was achieved with a manual torque wrench without the need for using power operated hydraulic jacks or any other type of sophisticated equipment. In typical prestressing applications, transfer of the prestressing is achieved under high strain rates, which increases the propensity for end debonding at low prestressing levels (Pornpongsaroj and Pimanmas, 2003). This issue can be mitigated by the proposed device because the prestressing release is achieved under low strain rates. For higher prestressing levels in which debonding of the CFRP sheets cannot be prevented solely by controlling the strain rate at transfer, U-wraps can be easily installed at the ends of the prestressing FRP system.
BRIEF SUMMARY OF THE INVENTION
[0007] A simple mechanical device was invented for prestressing of carbon fiber reinforced polymer (CFRP) sheets that can overcome on some of the disadvantages of currently used prestressing systems. Significant features of this device are that the CFRP sheets are directly anchored to the mechanical device itself, the prestressing forces are applied with a manual torque wrench without the need for power operated hydraulic jacks, and the prestressing transfer is accomplished under slow strain rates. Experimental investigation clearly corroborates that the device was efficient in applying prestressing to the CFRP sheets and prestress losses during stressing were maintained at a minimum.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] As shown in FIGS. 1 and 2 , the mechanical device consists of one WT steel section and four regions, including two anchorage and two loading regions. A summary of main components and dimensions of the mechanical device is also presented in Table 1. Located at each end of the WT section, each anchorage region consists of: (1) a removable steel plate, designated as part A, (2) a steel plate welded to the WT-section, designated as part B, and (3) the corresponding bolts and nuts. Located away from the anchorage regions, each loading region consists of: (1) one steel strip welded to two steel threaded rods, designated as parts C and D, respectively, and (2) two steel nuts and two thrust bearings, designated as parts E and F, respectively.
[0009] The system with one CFRP sheet under prestressing is shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
Main Components
[0010] Referring to FIGS. 1 and 2 , the mechanical device consists of one WT steel section and four regions, including two anchorage and two loading regions. A summary of main components and dimensions of the mechanical device is also presented in Table 1. Located at each end of the WT section, each anchorage region consists of: (1) a removable steel plate, designated as part A, (2) a steel plate welded to the WT-section, designated as part B, and (3) the corresponding bolts and nuts. Located away from the anchorage regions, each loading region consists of: (1) one steel strip welded to two steel threaded rods, designated as parts C and D, respectively, and (2) two steel nuts and two thrust bearings, designated as parts E and F, respectively. The thrust bearings are a vital component because they must be used to decrease the friction between the steel nuts and the WT section.
Assemblage
[0011] The first step in the assembly operation consisted of impregnating the CFRP sheets to their full length with an epoxy resin, similar to the process used to prepare FRP sheets for tension tests (ACI, 2004). The epoxy resin was a mixture of two components, which works as a matrix to protect the fibers and transfer the stresses between the adjoining fibers (Karbhari, 2001). After the epoxy resin has cured, the CFRP sheets were bonded to the removable steel plates (part A) using the same epoxy resin (see FIG. 1 b ).
[0012] The next step consisted of fixing the removable steel plates and bonded CFRP sheets to the welded steel plates (part B) by tightening four steel nuts in the anchorage regions ( FIG. 2 a ). High pressure was applied to the CFRP sheets through these steel plates to avoid bond slip and to prevent prestress losses during prestressing.
[0013] Design of the Anchorage Region Steel Plates: A total of 3 bond tests were performed according to the test setup shown in FIG. 3 a. These tests were performed to estimate the average bond strength between the CFRP sheets and the anchorage plate A (see FIG. 1 ), and to subsequently size anchorage plates A and B. Unlike in the mechanical device, these tests were performed without applying the clamping force between plates A and B. This will clearly lead to conservative values and a safe design for the anchorage square plates.
[0014] As shown in FIG. 3 a, these specimens consisted of two steel plates separated by a 50 mm (2 in.) gap and bridged across with CFRP sheets on either side of the steel plates. The CFRP sheets were 51 mm (2 in.) wide by 0.165 mm (0.0065 in.) thick and were bonded to the steel plates with an anchorage length of 254 mm (10 in.).
[0015] The computed average strain gage data obtained from the three tests and from the strain gages installed along the length of the CFRP sheets is shown in FIG. 3 b and summarized in Table 2. These results were further investigated to obtain the average bond stress distribution. Average bond stresses, μ ave , are shown in FIG. 3 b and were determined using the following expression
[0000]
μ
ave
=
t
f
E
f
Δ
ɛ
Δ
x
=
0.165
×
228
,
000
×
(
9
,
300
-
6
,
375
)
50.8
(
S
I
)
=
2.20
MPa
(
314
psi
)
(
1
)
[0000] where t f and E f are the thickness and the elastic modulus of the CFRP sheets, respectively, and Δε and Δx are the variations in strain and distances between the strain gages, respectively. Based on material properties the results presented in Table 4 and Eq. (1) the computed average bond strength was 2.20 MPa (314 psi). This bond strength was then used to size the plates necessary to develop the required bonding surface area. Finally, the length of the plates in the longitudinal direction was based the relation
[0000]
b
p
=
λ
cr
f
fu
A
f
μ
ave
b
f
=
0.55
×
3
,
709
×
(
203
×
0.165
)
2.2
×
203
=
153
mm
(
6.0
in
.
)
(
2
)
[0000] where b f is the width of the CFRP sheet, λ cr is the creep rupture stress limit in FRP composites where for carbon fibers this is limited by ACI 440 (2002) at 0.55, f fu and A f are the tensile strength and area of the CFRP sheets, and μ ave is the average bond strength determined from the tests shown in FIG. 3 and results presented in Eq. (1). Since the anchorage plates in the mechanical device were 279 wide×203 long mm (11×10 in.), results presented in Eq. (2) clearly show that the design of the plates was well within safe limits and will certainly prevent pull-out of the CFRP sheets from the anchorage plates during stressing.
[0016] Stressing the CFRP Sheets: After the anchorage regions were created, the desired prestress level was achieved by alternately tightening the steel nuts (part E) in the loading region (see FIG. 2 b ). This action displaces the threaded rods (part D) and forces the steel strips upwards (part C), thereby creating an uplift displacement in the CFRP sheets ( FIGS. 2 and 4 ). It is this uplift, ΔH, that imposes the desired prestressing in the CFRP sheets.
[0017] Leveling of the CFRP sheets was easily controlled in the transverse and longitudinal direction, namely across the length of the steel strips (part C) and CFRP sheets, respectively, by using a carpenter leveler. Leveling is necessary to ensure a uniform and planar surface that is free of significant twisting and warped edges before bonding of the prestressed CFRP sheets to the RC beam.
[0018] The removable steel plates and steel strips were fabricated with a slight rounding at the corners to decrease any stress concentrations in the CFRP sheets due to the change in the sheets direction and to prevent damage to the CFRP sheets during prestressing. FIGS. 2 and 4 show the mechanical device with the CFRP sheets depicting well the uplift displacement of the CFRP sheets. At this stage, the weight of the device was nearly 100 kg (220 lb), and the length was 3.35 m (11 ft). The mechanical device after prestressing was easily handled in the laboratory without also the need for heavy lifting equipment.
Theoretical Prestress
[0019] In order to simplify usage of the device it is advantageous to relate the vertical displacement, ΔH (see FIG. 2 ), to the stress in the CFRP sheets, σ 2 . Establishing a relationship between ΔH and σ 2 avoids the need for electronic measuring devices, such as strain gages, or linear variable differential transformers (LVDT's) in field applications.
[0020] The theoretical prestress was derived based on the geometric relations of the prestressing system and the deformed CFRP sheets. As shown in FIG. 4 b and before prestressing, the FRP sheet has a straight ABCD profile. After the sheets are deformed upwards by the vertical displacement, ΔH, this straight profile changes to the three segment AB 1 C 1 D profile. At this stage, the prestress in the horizontal B 1 C 1 segment, σ 2 , and the total elongation of the sheet, ΔL, are, respectively
[0000]
σ
2
=
σ
1
cos
θ
=
σ
1
L
1
L
1
2
+
Δ
H
2
(
3
)
Δ
L
=
σ
2
E
f
L
2
+
2
σ
1
E
f
L
1
2
+
Δ
H
2
=
2
(
L
1
2
+
Δ
H
2
-
L
1
)
(
4
)
[0000] where σ 1 is the prestress in the diagonal AB 1 and C 1 D segments, E f is the elastic modulus of the CFRP sheets, and θ is the angle between the original segment AB and the deformed segment AB 1 . Finally, based on Eqs. (3) and (4), the normalized prestress, σ 2 /f fu is
[0000]
σ
2
f
fu
(
%
)
=
2
L
1
(
L
1
2
+
Δ
H
2
-
L
1
)
L
1
L
2
+
2
(
L
1
2
+
Δ
H
2
)
E
f
f
fu
×
100
%
(
5
)
[0000] where dimensions L 1 and L 2 are measured directly from the device, and f fu is the ultimate tensile strength of the CFRP sheets (see FIG. 4 b ). When ΔH is known by straight measurement, the prestress in the CFRP sheet, σ 2 , can be derived from Eq. (5).
[0021] In this research program the vertical displacement was measured by using LVDT's for added precision and continuous reading and subsequently correlated to the prestress in the CFRP sheet, σ 2 , by Eq. (5). In field conditions a Vernier caliper can be used to measure ΔH and by using design charts one can easily estimate σ 2 . A Vernier caliber is a standard measuring devise used to get high precision readings. For example, FIG. 5 shows a chart that can be used to calculate σ 2 when the vertical uplift displacement ΔH is known.
[0022] In this figure different geometric relations were considered as a function of length L 2 , and L 1 was kept constant at 457 mm (18 in.). It is clear that as length L 2 increases so does the required vertical uplift and for very long sheets, say L 2 greater than 11 m (36 ft) the vertical uplift is within 230 mm (9 in.). Although not investigated in this program, future research should concentrate on developing design charts that can be used to design the diameter of the threaded rods as a function of the desired prestress level and length of the CFRP sheet, L 2 . These charts will be very much like FIG. 5 and will be based on preventing buckling or significant bending of the vertical threaded rods, shown as part D in FIG. 2 b.
Application of the Invention in Strengthening of RC Beams
[0023] After the CFRP sheets were prestressed, the next step consisted of bonding the prestressed CFRP sheet to the RC beam, as shown in FIG. 6 . Another advantage of this device is that end anchors can be easily installed before the sheets are released because there is adequate clearance between the sheets and the WT steel section. According to the design guidelines set by ACI 440 committee (2002), the surface of the beam was roughened until the aggregates were exposed, followed by vacuum cleaning to remove dust and loose particles. After bonding, the prestressing device stayed in place for at least 80 hours, which was more than sufficient time to properly cure the epoxy resin.
[0024] Prestressing Transfer: Transfer of the prestressing was carried out by slowly releasing the threaded rods (part D) in the loading region. This process was accomplished by alternately completing 2 full turns in all four steel nuts (part E). The total time taken to release the prestress in all beams was nearly 5 minutes. For the beam prestressed with 40% (see Table 3) this corresponds to a rate of nearly 180 N/sec (40 lbs/sec). For the other beams the release was performed at a slower rate and the rates are reported in Table 2. After release of the CFRP sheets was achieved, the sheets were cut close to the steel strips and the mechanical device was removed and cleaned for further applications. Properties for the materials used in this research are shown in Table 4. The CFRP sheets used were 0.165 mm (0.0065 in.) thick and 203 mm (8 in.) wide leading to a total reinforcement area of 33.55 mm 2 (0.052 in. 2 ).
[0025] Test Matrix: Of a total of eight RC beams investigated in this research program, six RC beams were retrofitted with prestressed CFRP sheets that were stressed using the device developed in this research. The other two beams were used as the control specimens and consisted of one unstrengthened beam and one strengthened beam with CFRP sheets, but without prestressed. The remaining beams were strengthened with CFRP sheets that were prestressed to 15%, 30% and 40% of the tensile strength of the CFRP sheets. The RC beams were then tested under a four-point bending system. Test results show that the device was efficient in prestressing the CFRP sheets to the specified stress levels, initial prestress losses were negligible, and prestress losses after transfer were within 10% of the initial prestress. Furthermore, test results clearly showed that the beams strengthened with the prestressed CFRP sheets achieved a higher yielding and ultimate loading.
[0026] Creep-Rupture Limits: According to ACI-440 (2002) after consideration of a long-term environmental factor, the sustain stress limit for CFRP composites is f fs =0.55 f fu , where f fu is the design strength. Therefore, in the retrofit of RC beams using prestressed CFRP sheets consideration was given to the creep-rupture limit because in these applications the sheets are continuously subjected to high sustained stresses after prestressing. As such, the levels of prestressing investigated in this research are below the permissible limit of 55%.
[0027] Field Application Setup: It is recognized that these laboratory conditions do not match exact field conditions for strengthening in positive moment regions, in which the prestressing apparatus needs to be “hanging” from the RC beams. This is to some extent, more complex than the simpler “from the top” procedure shown in FIG. 6 . This should not constitute, however, a limitation of the proposed mechanical device for the following: i) the fully assembled device with the prestressed CFRP sheets was easily moved and rotated in the laboratory, ii) the device weight was close to 1 kN (200 lbs) and iii) it was easily maneuvered by two people.
[0028] A potential field application on the underside of a beam is shown in detail in FIG. 7 . As in laboratory conditions, prestressing can be easily accomplished in a location near the beam to be strengthened and with the device conveniently positioned, as shown in FIG. 4 . Next the device can be easily lifted to the underside of the beam and because of its light weight it can be supported by U-straps and fastened to the sides of the RC beam with anchor bolts. In field applications other lighter materials such as aluminum may be considered for construction of the mechanical device.
[0000]
TABLE 1
Summary of Mechanical Device Main Components Dimensions
Component ID
Dimensions US
(see FIGS. 1 and 2)
ID
Dimensions SI
Customary
Removable Plate
A
279 × 254 × 9.5 mm
11 × 10 × ⅜ in.
Welded Plate
B
279 × 254 × 9.5 mm
11 × 10 × ⅜ in.
Steel Strip
C
203 × 63.5 × 25 mm
8 × 2.5 × 1.0 in.
Threaded Rods
D
400 × 19 mm
16 × ¾ in.
Nuts
E
25 mm Ø × 19 mm
1 in Ø × ⅜ in.
Thrust Bearings
F
38 (o.d.) × 19 (i.d.) mm
1.5 (o.d.) × 0.75 (i.d.) in.
WT 8 × 18 Section
—
178 (b) × 201 (d) mm
7 (b) × 7.93 (d) in.
Plate A & B Clamping Bolts
—
4-19 Ø mm
4-⅜ Ø in.
o.d. outside diameter
i.d. inside diameter
[0000]
TABLE 2
Bonding Test Results (Average results from three tests)
Load
Measured Strain
Measured Strain
Calculated Stress
Applied Force
Level
at x = 0 mm (0 in.)
at x = 50.8 mm (2 in.)
MPa (ksi)
kN (kips)
1
9300
6375
2116 (306.9)
17.8 (4.0)
2
7500
5125
1707 (247.5)
13.3 (3.0)
3
6000
4000
1366 (198.0)
11.1 (2.5)
4
4875
2750
1110 (160.9)
8.9 (2.0)
5
3700
2000
842 (122.1)
6.7 (1.5)
6
2750
1125
626 (90.75)
4.4 (1.0)
7
1250
500
285 (41.25)
2.2 (0.5)
[0000]
TABLE 3
Strengthening Schemes
Prestress/tensile
End
Prestress Release Rate
Beam
strength (%)
Anchors
N/sec (lbs/sec)
A
—
—
—
B
0
—
—
C
15
—
68 (15)
D
15
—
68 (15)
E
15
U-Wraps
68 (15)
F
30
—
135 (30)
G
30
U-Wraps
135 (30)
H
40
—
180 (40)
[0000]
TABLE 4
Material Properties
Tensile strength
Ultimate
Elastic modulus
Compressive strength
MPa (ksi)
strain (%)
GPa (ksi)
MPa (ksi)
Concrete
—
—
—
43.4 (6.3)
Steel bars
432
(62.7)
—
195
(28,300)
—
CFRP sheet*
3790
(550)
1.7
228
(33,000)
—
Saturant
55
(8.0)
7.0
1.8
(260)
—
*Af = 0.165 mm (0.0065 in.) thick × 203 mm (8 in.) wide = 33.55 mm 2 (0.052 in. 2 ).
REFERENCES
[0000]
ACI Committee 440 (2002) “Guide for Design and Construction of Externally Bonded FRP Systems for Strengthening Concrete Structures (440.2R-02),” American Concrete Institute, Farmington Hills, Mich., 2002, 45 pp.
ACI Committee 440, (2004), “Guide Test Method for Fiber Reinforced Polymers (FRP) for Reinforcing or Strengthening Concrete Structures (440.3R-04),” American Concrete Institute, Farmington Hills, Mich., 2004, 40 pp.
ACI Committee 546, (1996), “Concrete Repair Guide (ACI 546R-96),” American Concrete Institute, Farmington Hills, Mich., 1996, 26 pp.
Char, M. S., Saadatmanesh, H., and Ehsani, M. R., (1994), “Concrete Girders Externally Prestressed with Composite Plates”, PCI Journal, May-June 1994, Vol. 39, no. 3, pp 40-51.
El-Hacha, R., and Elbadry, M., (2001 a), “Strengthening Concrete Beams with Externally Pre-Stressed Carbon Fiber Composites Cable,” Proceedings of Fiber-Reinforced Plastic for Reinforced Concrete Structures (FRPRCS-5), 2001, Cambridge, UK: pp. 699-708.
El-Hacha, R., Wight, R. G., and Green, M. F. (2001b), “Prestressed Fiber-Reinforced Polymer Laminates for Strengthening Structures,” Progress in Structural Engineering and Materials Journal, 2001; Vol. 3, pp. 111-21.
El-Hacha, R., Wight, R. G., and Green, M. F. (2003), “Innovative System for Prestressing Fiber-Reinforced Polymer Sheets,” ACI Structural Journal, 2003, Vol. 100, No. 3, pp. 307-313.
Garden, A. M., Hollaway, L. C., and Thorne, A. M., “The strengthening and deformation behavior of reinforced concrete beams upgraded using prestressed composite plates,” Materials and Structures, 1998; Vol. 31, No. 4, pp. 247-258.
Karbhari, V. M., (2001), “Materials Consideration in FRP Rehabilitation of Concrete Structures,” ASCE Journal of Materials in Civil Engineering, 2001, Vol. 13, No. 2, pp. 90-97.
Pornpongsaroj, P., Pimanmas, A., (2003), “Effect of End Wrapping of Peeling Behavior of Pre-Strengthened Beams,” Proceeding of Fiber-Reinforced Plastic for Reinforced Concrete Structures (FRPRCS-6), Singapore, 2003, pp. 277-86.
Quantrill, R. J., and Hollaway, L. C., (1998), “The flexural rehabilitation of reinforced concrete beams by the use of prestressed advanced composite plates”, Composite Science and Technology, Vol. 58, pp. 1259-75.
Saadatmannesh, H, and Ehsani, M., (1991), “RC Beams Strengthened with GFRP Plates: Part I: Experimental Study,” Journal of Structural Engineering, ASCE, Vol. 117, No. 11, pp 3417-3433.
Saeki, N., Shimura, K., Lzumo, K., Horigushi, T., (1997), “Rehabilitation of Reinforced Concrete Beams Using Prestressed Fiber Sheets,” Proceedings of the International Conference on Engineering Materials, Ottawa, Canada, Paper No. 104.
Teng, J. G., Chen, J. F., Smith, S. T., and Lan L., FRP - strengthened RC structures, New York: Wiley, 2002; pp. 45-60.
Triantafillou, T. C., Deskovic, N., and Deuring M., (1992), “Strengthening of Concrete Structures with Prestressed Fiber Reinforced Plastic Sheets”, ACI Structural Journal, Vol. 89, No. 3, pp. 235-44.
Wight, R. G., Green, M. F., and Erki, M. A., (2001), “Prestressed FRP Sheets for Post-strengthening Reinforced Concrete Beams,” ASCE Journal of Composites for Construction, Vol. 5, No. 4, pp. 214-220.
Yang, C., Nanni, A. and Dharani, L. (2001), “Effect of Fiber Misalignment on FRP Laminates and Strengthened Concrete Beams,” Proceedings of the 9th International Conference on Structural Faults and Repair, London, UK, Jul. 4-6, 2001, M. C. Forde, Ed., Engineering Techniques Press, CD_ROM, version, 10 pp. | A mechanical device was invented for prestressing of carbon fiber reinforced polymer (CFRP) sheets. Significant features of this device are that the CFRP sheets are directly anchored to the mechanical device itself, the prestressing forces are applied with a manual torque wrench without the need for power operated hydraulic jacks and the prestressing transfer is accomplished under slow strain rates. Experimental investigation clearly indicates that the device was efficient in applying prestressing to the CFRP sheets and prestress losses during stressing were maintained at a minimum. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Divisional Application of U.S. Ser. No. 12/356,163 filed Jan. 20, 2009, which is a Continuation application of U.S. Ser. No. 11/940,375 filed Nov. 15, 2007 (abandoned), herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to the field of agronomy, more particularly to agricultural fertilizing compounds.
BACKGROUND OF THE INVENTION
Higher plants are autotrophic organisms that can synthesize all of their molecular components from inorganic nutrients obtained from the local environment. Nitrogen is a key element in many compounds present in plant cells. It is found in the nucleoside phosphates and amino acids that form the building blocks of nucleic acids and proteins, respectively. Availability of nitrogen for crop plants is an important limiting factor in agricultural production, and the importance of nitrogen is demonstrated by the fact that only oxygen, carbon, and hydrogen are more abundant in higher plant cells. Nitrogen present in the form of ammonia or nitrate is readily absorbed and assimilated by higher plants.
Because of the dependence of plants upon nitrogen, farmers frequently include nitrogen in their fertilization efforts of their fields in an effort to increase yield. This practice may be traced back to the 1800's, when it was discovered that when external sources of water soluble forms of nitrogen (along with phosphorus and potassium) provided to plants, yield increased. These fertilizers are typically applied to the soil, but can also be applied to plant leaves directly.
Nitrogen fertilizers are often synthesized using the Haber-Bosch process, which results in the production of ammonia. The ammonia is then either applied to the soil or used to produce other nitrogen compounds, such as ammonium nitrate or urea. These compounds are then applied to crop fields in order to increase yield in areas where the nitrogen content of the soil is low.
Unfortunately, the production and use of nitrogen fertilizers has significant drawbacks. For example, it is currently estimated that ammonia production accounts for 5% of the global consumption of natural gas. With the increase of natural gas prices over the course of the past decade, the cost of producing ammonia has correspondingly increased. In addition, overuse of nitrogen fertilizer can lead to pest problems by increasing the birth rate, longevity, and overall fitness of certain crop pests. Also, there are substantial concerns regarding fertilizer runoff, which can add undesirable compounds to rivers, streams, and ground water supplies.
It would therefore be desirable to minimize the application of inorganic fertilizers to field crops while finding a way that the increased yield those fertilizers typically provide may still be obtained.
Another source of plant nutrition historically has been humus, which is commonly referred to as organic matter. Humus is sometimes referred to simply mean mature compost, and is often thought to make up the structural component of soil. Most humic compounds are produced via the composting process, but others are available from other sources, such as peat moss, manure, and coal.
Such humic compounds have been used as soil enhancers or fertilizers for quite some time, but the greater benefit seen by artificial application of inorganic compounds such as nitrogen described above have proven more beneficial in most farming applications, or at least more cost effective.
Because of this perceived greater benefit to the application of inorganic nitrogen and other compounds (such as potassium and phosphorus), the level of humic compounds present in the soil has progressively declined with the increase in commercial farming and the lack of replenishment. As a result, greater amounts of inorganic fertilizers are needed in order to achieve the same or similar fertilizing effect, as the soil in many instances is less able to retain the chemical fertilizers applied to it, and as a result plants are less able to utilize such fertilizers unless they are applied in greater quantities. This shift in soil dynamics over the course of time has contributed to the negative impacts of chemical fertilizers noted above, as with increased application of such fertilizers, there is a corresponding increase in the potential for occurrence of the negative side effects of such fertilizers.
While these problems have been recently identified, a suitable solution has yet to be found. Combining various humic substances with various inorganic fertilizing materials, such as nitrogen, phosphorus, and potassium, does result in a somewhat improved fertilizing effect. However, previously used substances have not yet achieved desired results based on the vast numbers of alternative sources of both humic compounds and inorganic complements, as well as the vast number of possible differences in composition and method of preparation. As a result, there has been a need for a compound that is able to deliver both for the benefits of humic compounds and inorganic fertilizers with a high degree of fertilizing efficacy.
BRIEF SUMMARY OF THE INVENTION
The present invention therefore relates to a fertilizer compound that reduces or eliminates one or more of the drawbacks of traditional inorganic fertilization techniques. The present invention also relates to a fertilizer compound that produces a synergistic affect between inorganic fertilizers and humic compounds. The present invention further relates to a method for producing such a fertilizer compound. Additional details regarding preferred embodiments of the present invention will become evident from the further description provided.
DETAILED DESCRIPTION
In accordance with the claims, the inventors herein disclose a novel fertilizer compound that reduces the necessity of traditional nitrogen and other inorganic fertilizations. Embodiments of the invention also can contribute to soil quality, water retention, nitrogen retention, and improved aeration.
In another aspect, a method of production of a novel fertilizer compound is disclosed by which one or more of the above-described benefits may be obtained. Further detail of the invention will be evident in the additional description herein provided.
Humic Fertilizer Composition
The claimed fertilizer composition has at least four predominant components. These include nitrogen, phosphoric acid, potassium hydroxide (potash), and an organic component. Preferably, the organic component is either lignite or leonardite. Most preferably, the organic component is lignite. Lignite may be obtained from any appropriate source, such as coal mines or their distributors.
The nitrogen in the composition may be obtained from any acceptable source, such as fertilizer dealers, farm cooperatives, and the like.
The phosphoric acid is preferably fertilizer grade phosphoric acid, rather than the more highly purified food grade phosphoric acid that is also available. It is believed that this improves the properties of the fertilizer as the fertilizer grade phosphoric acid contains additional impurities which also are sometimes present in soil and utilized by plants in small amounts. The phosphoric acid may be obtained from many chemical companies, such as Hydrite Chemical, or can be produced by various methods, such as that disclosed in U.S. Pat. No. 4,462,972. The potassium hydroxide, or potash, may also be obtained from any acceptable source, such as from any number of chemical companies.
The composition herein claimed is preferably a liquid fertilizer. It may contain between about 25% and about 63% nitrogen, between about 10% and about 50% lignite, between about 5% and about 30% phosphoric acid, between about 5% and about 10% potassium hydroxide (potash), and the remainder of the composition water. Preferably, the nitrogen makes up between about 30% to about 55% of the composition, and most preferably between about 40% and about 50% of the composition. These percentages of nitrogen are based upon a 28% liquid solution, and therefore these percentages would change if a solution with a different concentration is utilized. For example, if a 32% liquid solution is used, the fertilizer may contain between about 20% and about 60% nitrogen, preferably between about 25% and about 48%, and most preferably between about 40% and about 46%.
Preferably, the lignite makes up between about 15% and about 25% of the composition, and most preferably between about 18% and about 22% of the composition. Also, the lignite is preferably between 50 mesh size and 250 mesh size, and most preferably the lignite is 200 mesh size.
The phosphoric acid preferably makes up between about 8% and about 20% of the composition, and most preferably between about 12% and about 15% of the composition. These percentages are based upon a 75% phosphoric acid solution, and as a result the percentages will change if a different concentration solution is used. Also, the phosphoric acid is preferably fertilizer grade. Similarly, the potash preferably makes up between about 6% and about 9% of the composition, and most preferably between about 7% and about 9% of the composition. These percentages are based upon a 45% solution of potash, and as a result the relevant amounts will change if a different concentration is used. The potash may be obtained from any acceptable source, for example from a commercial chemical company such as Hydrite Chemical in Waterloo, Iowa.
This composition is applied to the target field preferably at a rate of about one-third gallon per acre. The compound is sprayed much like any other liquid fertilizer, although for best results, a 20 mesh screen should be used in order to minimize clogging of most standard spray applicators.
Applying the disclosed compound provides a substantially improved fertilizing effect over and above that expected with other fertilizing compounds, such as nitrogen or other inorganic compounds alone, organic fertilizers alone, or even pre-existing combinations of inorganic or organic compositions in fertilizer compounds.
In addition, application of the disclosed compound allows the soil to retain water and other nutrients, which provides at least two beneficial effects. First, it minimizes the likelihood of runoff of fertilizer in areas where the fertilizer is not desired, such as rivers, streams, or groundwater, thereby reducing the potential for negative environmental impact. Also, because various soil nutrients are retained at a higher rate, a lower amount of inorganic fertilizers are required to achieve the same fertilizing effect with future applications of either this fertilizing compound or other inorganic, or combination fertilizing compounds. As a result, the compound herein described provides an unexpectedly high level of benefit to both soil quality and increased fertilizing efficiency, over and above that previously achieved with similar fertilizing compounds.
Method of Production
In order to produce the above-described compound, it is preferable to use a stainless steel horizontal mixing tank with a mixer installed on each end. First, the nitrogen solution is added to the tank, followed by the lignite. While these ingredients may be added in reverse order, adding the nitrogen first is preferable as the lignite is suspended in the mixture more quickly. The nitrogen and lignite mixture is then mixed at high speed for eight minutes.
Then the phosphoric acid is added to the mixture. This also assists with suspension of the composition into a liquid. During this mixing phase, the compound may produce visible vapor. The compound should be mixed about ten to twelve minutes.
The water is then added, and the composition is mixed for a further ten minutes. Adding the water at this stage is preferable because it is easier to keep the lignite suspended in the mixture when added after the nitrogen and phosphoric acid. Finally, the potash is added. For safety reasons, it is preferable to add the potash slowly, because if it is added too fast to the mixture an explosive reaction may occur. Adding the potash also increases heat of the compound, and causes a strong odor to be emitted. The potash neutralizes the pH of the mixture, balancing out the phosphoric acid. Once the potash is added, the compound should be mixed for approximately twenty minutes.
Once the product is done with the mixing steps, it is then ready for filtration. The product is preferably slowly added to a filter screen, and preferably filtered by gravity flow. The preferred filter size is a between 20 and 70 mesh.
A majority of the product will pass through the filter, but a small amount will not pass through. The product that does not pass through should be discarded.
Once the compound has been filtered, it may be appropriately packaged for distribution to field sites. When packaging, it is preferable to add a small amount of defoaming agent before filling so that foam is minimized and containers do not have to be refilled after the foam produced in the filling process settles out. The containers may then be sealed and stored for shipment for application.
This method of production is preferable to previous methods used in several ways. For example, by adding the water later in the process, the lignite stays suspended more completely in the solution, thereby reducing clumping in the final product, which can cause clogging in the equipment used to spray the compound onto fields. Further, the use of gravity flow through the filter as opposed to a pumping procedure results in a superior product, because changes to the final structure occur when the product is forced through the screen as opposed to letting it naturally proliferate through the screen.
It should be understood that the forgoing invention has been described in the context of preferred embodiments, and that modifications apparent to one of ordinary skill in the art are intended to be encompassed within the invention. Further, the scope of the claimed invention should only be limited by the appended claims, not the scope of the specific examples provided herein. | The disclosed invention relates to novel fertilizing compounds comprising a combination of inorganic fertilizers and humic compounds. The combination produces a marked benefit over either type of substance individually, and also over previously known combinations of organic and inorganic fertilizers. The invention also relates to a method of production of such compounds. | 2 |
RELATED APPLICATIONS
This application is related to co-pending U.S. patent application Ser. No. 620,476 filed on June 14, 1984, issued Dec. 2, 1986, U.S. Pat. No. 4,625,471.
FIELD OF THE INVENTION
This invention relates to apparatus for supporting or erecting structures, and in particular to brackets for connecting panels to substantially horizontal rails or other elongate support members.
In this specification the word structures is used to mean partitions and space divider panels, parts of portable buildings, shelving whether industrial or domestic, cupboards, bins, racks, shelves, desks, display units for use in retailing or at exhibitions or conferences. Such display units may be fitted or assembled units for dividing and using space.
BACKGROUND OF THE INVENTION
It has been proposed in U.K. patent application No. 83-26708 that panels forming parts of structures be suspended from a wall or ceiling using an elongate support member (herein also called a rail) extending horizontally and an interfitting arrangement between the rail and the panel so that the panel is supported by the rail, the latter being fixed to the wall or ceiling.
The reader is referred to the said application No. 83-26708 whose contents are hereby incorporated in this Specification.
BRIEF SUMMARY OF THE INVENTION
According to one aspect of the present invention, there is provided a bracket specially designed so that a panel fixed to the bracket can be easily and reliably engaged with the rail.
According to another aspect of the invention, a die cast bracket for use in supporting a panel has a first slot in a vertical edge and a second slot in a horizontal edge, and has a web located in a substantially vertical plane in use, the web having means whereby the panel can be fixed thereto.
PARTICULAR EMBODIMENTS
According to an embodiment of the invention, a bracket according to the invention has slots or steps, one slot or step being in an upper surface of the bracket and one slot or step being in a surface which is to be forwardly-presented in use, the bracket also having means such as a web or a pair of flanges whereby a panel can be secured thereto.
In the case of a bracket having a pair of slots, which is presently-preferred arrangement, each slot preferably has a lesser width at its base than it does at its mouth.
A bracket according to one embodiment of the invention has a pair of substantially parellel, planar, similarly-shaped walls joined by a bridge piece, each such wall having a first notch or step in a vertical edge and a step or termination or a second notch in a substantially horizontal edge. There are preferably aligned holes in the walls for receiving screws, pins, bolts, rivets or the like whereby a corner of a panel can be placed between the walls and secured to the bracket.
The bracket mentioned in the preceeding paragraph may be made of sheet metal although of course it may be made of other materials which have sufficient strength and rigidity. In a preferred form of bracket, the bridge piece is planar and located in a plane about 30° to 60° to the vertical, preferably 45° when the bracket is located in its usual position of use. In an alternative form of bracket, the bridge piece is substantially horizontal and extends between and joins parts of the lower edges of the walls.
In this specification, in the interest of clarity of description and to aid brevity, the words horizontal, vertical, upper and lower are used in relation to brackets in their normal position of use in suspending or supporting panels and like members; these words are not intended to have a strict geometrical meaning since a man of average skill in this art will appreciate that minor deviations from strictly vertical or strictly horizontal can be tolerated in some instances without affecting the satisfactory operation of the invention in assembling structures.
In another alternative version of the invention, the bridge piece on the bracket is vertical, and is provided with holes whereby a rear panel defining a space, e.g. the rear panel of a cupboard or the like, can be located parallel and adjacent to, and be bolted to, the bridge piece.
An important advantage of brackets according to the invention, when used with the rails generally described herein, is that they are durable and facilitate the ready attachment of panels to the rails; the panels may be located as desired with their planes either perpendicular or parallel to the length of the rail and my be attached and removed frequently, if desired, without deterioration of the panel.
According to another aspect of the invention, there is provided a kit for supporting a wall-supported item of furniture having vertical panels, the kit including at least one the elongate support member, the elongate support member having a vertical web and a horizontal web, the horizontal web having a vertically downwardly extending flange and the vertical web having a horizontal extending flange, and the panel having or carrying a bracket or the like having one slot to receive the vertical flange and one slot to receive the horizontal flange when the panel is assembled to a horizontally-extending elongate support member.
The invention may be employed in apparatus consisting of or including a structure having at least two vertical panels serving as side walls and at least one vertical rear wall panel, the structure being suspended from a horizontal elongate support member which is itself supported by a pair of vertical stanchions.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from the following non-limiting description of examples thereof given with reference to the accompanying drawings in which:
FIGS. 1-4 are respectively perspective, front elevation, underplan, and cross-sectional views of a first embodiment of an elongate support member (herein also referred to as a rail) useful with the present invention, the support member being such that it can be attached to a wall or a ceiling or other support surface to extend horizontally;
FIG. 5 is a profile of a blank for making one form of bracket according to the invention;
FIG. 6 is a side view of a bracket made from the blank of FIG. 5 shown in co-operation with a panel and an elongate support member;
FIG. 7 is a plan view of the bracket and part of a panel shown in FIG. 6;
FIGS. 8-11 are respectively plan, side elevation, end elevation, and plan of a blank of another form of bracket according to the invention;
FIG. 12 illustrates the bracket of FIGS. 8-11 in co-operation with a second embodiment of elongate support member, here also called a rail;
FIGS. 13-16 are respectively a side elevation, a front elevation, a cross section in a horizontal plan, and a perspective view of a telescopic vertical stanchion and rails which may be used in a system according to the invention, FIG. 16 showing the stanchion connected to rails which can be used with the brackets of the general kind shown in FIGS. 5-7;
FIGS. 17-20 are respectively vertical medical cross section of, top plan view of, end elevation, and profile of a blank for making a bracket according to another embodiment of the invention, this bracket being intended for fixing a panel parallel to a rail rather than perpendicular to it;
FIG. 21 is a vertical cross section illustrating use of the bracket of FIGS. 17-20 and also showing a stanchion and a bottom clip used to hold a lower region of a panel to a lower rail;
FIGS. 22 and 23 show a clip which can be used to secure a lower region of a panel to a rail;
FIGS. 24-27 show a further version of a bracket according to the invention; and
FIGS. 28 and 29 are a front view and an end view of an elongate support member (also herein called a rail) specially designed for use with the bracket of FIGS. 24-27.
DETAILED DESCRIPTION OF EMBODIMENTS
Brackets according to the invention utilize the principles outlined in the aforesaid Patent Application No. 83-26708 in that the "lift and rotate" method of assembly to a rail is employed. For a full description, the reader is referred to the said application, which is to be regarded as incorporated in its entirety in the disclosure of the present application. Put briefly, the rail has a vertical web and a horizontal web and the vertical web has a horizontally extending flange. The horizontal web has a vertically extending flange and the rail is constructed to co-operate with a bracket secured to a panel. An engaging means (e.g. a notch, step, or slot) is provided between the upper edge of the panel and the rail and arranged to preclude horizontal separation of the panel and the rail once they are assembled together in the manner hereinafter stated. The bracket has a notch or slot in its inner edge, the notch being positioned and dimensioned to receive the horizontally extending flange when the bracket is engaged with the rail. This supports the panel against vertical movement.
In accordance with a preferred embodiment of the present invention, the bracket has therein a notch dimensioned and positioned to be entered by a vertically and downwardly extending flange of a rail; this serves to prevent horizontal separation of the bracket and panel from the rail once they are assembled as described hereafter. The notch in the upper bracket edge is preferably of decreasing width and is defined by a vertical surface and a curved or inclined surface, the latter surface being located further from the rail (when the rail and bracket are assembled) than the former. The bracket is located on what will be the top inner corner of the panel when it is suspended from the rail; for brevity of description this corner is herein referred to as the support corner. This construction allows a panel to be hung by a simple procedure in which the panel is presented manually to the rail substantially in a vertical plane perpendicular to the length of the rail, with its support corner slightly lower than its other top corner. The top surface notch in the bracket is then brought adjacent the downwardly extending flange and the panel is lifted so that this flange partly enters the notch. Simultaneously, the panel (still substantially vertical) is rotated slightly about an axis perpendicular to its plane, so that the horizontally extending flange at the lower part of the rail enters the notch in the inner edge of the bracket. This rotation movement of the panel is continued until the panel inner edge is vertical and both flanges are fully seated in their respective notches. In this position the bracket and hence the panel is stably and firmly supported by the rail. Shelves can then if desired be supported by an adjacent pair of panels which are themselves supported by a single horizontal rail.
Only one rail need be fixed to the wall or ceiling so erection and assembly of shelves, cupboards or cabinets is particularly simple.
Referring now to FIGS. 1-4 the illustrated rail is a linear elongate support member having a horizontal web 10 and a vertical web 12. These webs may have holes 14 or slots 16 as appropriate to enable the rail to be fixed in position as desired. A vertical flange 18 extends downwardly from the horizontal web and a horizontal flange 20 having castellations at regular intervals extends from the lower region of the vertical web 12. The castellations illustrated have upturned tabs 22. The rail of FIGS. 1-4 is intended to receive a bracket such as is shown in FIGS. 5-7. The rail is mounted horizontally by being bolted or screwed to a wall, with the web 12 engaging the wall and the flange 20 downwardly and the web 10 upwardly. A modification of the rail of FIGS. 1-4 mounted with flange 20 uppermost and web 10 extending horizontally from the web 12 at its lower end is appropriate for receiving a bracket in accordance with FIGS. 8-10 herein, as can be seen from an inspection of FIG. 12. The modification is that the flange 20 is continuous rather than recessed and that there is a continuous flange instead of the spaced lugs 22 at right angles to the flange 20.
One embodiment of bracket (which can also be termed a butterfly clip) is illustrated in FIGS. 5-7. The bracket has substantially parallel walls 50,52 joined by a bridge piece 54. In the use of such a bracket, a top inner corner of a panel to be supported is positioned between the walls 50 and 52 and is secured therein in any convenient manner. For example holes 58 may be provided, so that bolts, pins, rivets, or other suitable securing devices can be passed through the bracket walls and the panel fixed therebetween. Each of the walls 50 and 52 of the bracket has a notch 60 in its inner edge, to receive a flange of a horizontal rail. As illustrated in FIG. 6, the rail employed may be the rail of FIGS. 1-4 but a rail as shown in FIG. 16 may equally well be employed in association with a matching bracket, i.e. one of appropriate dimensions and with appropriately positioned slots or steps. Each of the walls 50 and 52 has a further notch 64 in its upper edge which is to receive the vertical flange 18 of the rail. As seen in FIGS. 6 and 7, a panel 68 is located with its upper inner corner between the walls 50 and 52. The panel 68 may be a simple rectangular piece of wood, metal or plastics, with an L-shaped part of its top corner removed as indicated by the dotted line 69. In accordance with the principles explained in patent application No. 83-26708, the notches 60,64 are defined by one vertical wall and one sloping or curved wall. The corners 65 (FIG. 5) may be radiused if desired.
FIGS. 8-11 illustrate an alternative form of bracket according to the invention. This has substantially parallel walls 70 and 72 joined by a bridge piece 74. The walls are substantially rectangular as illustrated, one corner of each being cut off as seen best at 79 in FIG. 9. A slot 76 is let into the top edge of each wall 70, 72 near to the inner end, and a slot 78 is let into the bottom edge of wall 70,72 as illustrated. Each slot 76, 78 has one straight surface and one sloping surface. The purpose of these slots can be seen from FIG. 12 which shows how they co-operate with a rail 80. Each wall 70,72 has holes 82 to receive bolts, pins or other suitable securing means whereby a panel 84 is attached to the bracket.
FIG. 12 shows part of a cupboard or bookcase assembled using the invention. The cupboard has a floor member 88 which is supported between an adjacent pair of panels 84. The panels may have horizontal grooves to receive the opposed edges of the floor member 88. As seen in FIG. 12, a track 86 for slidably supporting the lower edge of a sliding door 90 is secured to the front edge of the floor member 88.
An alternative form of bracket according to the invention is illustrated in FIGS. 17-20. This form of bracket makes possible the erection of space dividing structures, for example the sub-division of a large space into rooms, offices or cubicles in an extremely simple, convenient and rapid manner. The system described involves the use of vertical telescopic stanchions, which are located at intervals throughout the space to be divided. They can be regarded as linearly-spaced pillars extending between floor and roof. These pillars are joined to and support horizontal rails, the stanchions and the rails being provided with slots so that these members can be readily bolted together. The rails are of the form illustrated at 110 in FIG. 16, or in FIG. 28, and co-operate with brackets (such as an appropriately-dimensioned bracket according to FIGS. 5-7 or one according to FIGS. 24-27) chosen in accordance with the kind of panel to be supported. The panels serve as the walls which divide the space as required.
Reverting now to FIG. 13, one example of stanchion is illustrated. It is formed by a first metal profile 90 sliding within a second metal profile 92. A suitable jack mechanism, cam mechanism, or rack and gear mechanism may be provided to allow the inner profile 90 to be urged upwardly, relatively to the profile 92, towards the ceiling 102 in order to engage the same and clamp the stanchion between floor and ceiling. Such a mechanism is known as per se and so is not described in detail in this specification. Alternatively, the stanchion may be simply bolted between floor and ceiling. A load spreading pad 94 is attached to the top of the profile 90. A like load spreading pad 96 is attached to a further length of inner profile 98, similar to profile 90. As seen in FIG. 14, bolt holes indicated at 100 are provided whereby the outer profile 92 can be bolted to the lower inner profile 98. The ceiling level is indicated at 102. The profile 92 has spaced openings 104 therein (FIG. 14); these are to allow services such as electric cables to be led into and out of the central volume of the stanchion. Provision is made for holes as indicated at 106 (FIG. 15) whereby the load spreading plate 96 may be bolted to the floor, if desired.
FIG. 16 illustrates a stanchion such as is shown in FIGS. 13-15, connected to two horizontal rails 110 and 112. These rails may be bolted to the stanchion and for this purpose elongated slots 114 are provided in each of the webs of the rails 110,112 and in the webs 92a and 92b of the profile 92.
Describing the rail 110 for example, this has a horizontal web 120, a vertical web 122, a downwardly extending flange 124, and a horizontally extending flange 126. Unlike the rail shown in FIG. 1, both the flanges 124 and 126 are continuous. The rails 110 and 112 are intended to co-operate with a bracket such as is shown in FIGS. 17-20, the assembled position of the parts being seen in FIG. 21.
The bracket is shown in FIGS. 17-19. The bracket illustrated in these figures has substantially parallel walls 130,132, connected by a bridge piece 134. The bridge piece 134 has an extension consisting of an upwardly sloping portion 136 and a substantially horizontal portion 138. Each wall 130,132 has a slot 140, and there is a step 142 in the top edge 144 of each wall; this step in conjunction with the edge of the sloping wall portion 136 defines a second slot 146, there being one slot 146 on each side of the bridge portion 134. The purpose of these slots is to receive the downwardly extending flange 124 of the rail 110, and the purpose of slots 140 is to receive the horizontally extending flange 126 of the same rail. It can be understood, therefore, that the bracket according to FIGS. 17-19 can be inserted into and firmly supported by the rail 110 by essentially the same "lift and rotate" procedure as has been described previously in relation to the rail of FIG. 1 and the bracket of FIGS. 5-7.
Suitable holes 150 are indicated in FIG. 18; these are to receive screws or bolts whereby a panel can be suspended with its plane parallel to the length of the rail 110 or 112 as the case may be.
Details of this suspension are best seen from FIG. 21. Referring now to FIG. 21, a stanchion 160 which may be a stanchion according to FIG. 13 supports horizontal rails 162,164. These rails are of the construction of rails 110,112 in FIG. 16. The upper rail 162 supports a bracket 129, which is preferably of the kind shown in FIGS. 17-19 and this bracket in turn supports a panel 166. As shown, screws 168 extending through the holes 150 and other holes in the wall 134 hold the panel 166 to the bracket 129. To assist in bearing the weight, a slot is cut in the rear wall of the panel to receive the flange 135 of the bracket 129.
In some circumstances it may be desirable to retain the lower region of the panel against outward movement. For this purpose, a clip 170 is provided, fixed to the panel 166 by screws 172. The clip 170 is illustrated in FIGS. 22 and 23, FIG. 22 being a view looking in the direction of the arrow A in FIG. 21, and FIG. 23 being an end or edge view. The illustrated clip 170 is preferably a flat plate of metal having a central slot 174, a lower flange 176, and a turned over portion 178 which as seen, clips over an upstanding flange 164a of the rail 164 (FIG. 21). The screws 172 pass through the slot 174, and during installation are initially only partially tightened in order to allow the clip to slide vertically.
Using the system and parts illustrated in FIGS. 13-23, a space can readily be divided as desired. An advantage of the system is that supply services such as electrical cables can readily be housed in the space 180 behind the panels 166, and moreover the central volume of the stanchion 90, 92 or 160 and, optionally, the space 180, can be filled with fire resistant and/or sound insulating and/or heat insulating material. The method of erection of the system, as can be seen from the preceeding description, is simple and foolproof and is well within the capacity of unskilled workers. The system is versatile and utilises only a relatively small number of parts, all of which can be inexpensively manufactured.
FIGS. 24-29 illustrate an alternative rail and a bracket for use therewith, in accordance with the invention. The rail 200 shown in FIGS. 28 and 29 is an elongate support member having a horizontal web 202 and a web 204 to engage a wall or other support. A continuous horizontal flange 206 extends outwardly from the web 204, and the web 202 has a downwardly depending flange 210. The web 204 has a curved or bulged portion 212, bulging outwardly away from the wall or support surface in the mounted position of the rail, and this bulged portion has a series of substantially vertical through slots 214 at regular intervals. The purpose of these is to locate the brackets (228) along the length of the rail 200, for which purpose a blade portion (234) of the brackets extends into one of the slots 214. The web 204 has holes 208 therein whereby it may be screwed, bolted, riveted or otherwise secured to a generally vertical surface of a support such as a wall, or to a stanchion such as that illustrated in FIG. 13.
The bracket 228 illustrated in FIGS. 24-27 may be made as a metal die-casting. It has a main body portion 230 from which extends a first blade portion 232 and a second blade portion 234, the latter being intended to co-operate with (extend into) one of the slots 214 to locate the bracket. The blade portion 232 is for attachment of a panel to the bracket. In the case of a wooden panel, a saw cut maybe provided in one corner of the panel, parallel to the planes of the panel surfaces, and the blade portion 232 is inserted in the saw cut. Then bolts or screws are passed through previously-provided holes in the panel which register with holes 236 in the blade portion 232, so attaching the panel (not shown) to the bracket 228. This may be done either before or after the bracket 228 is engaged with the rail 200 but in some practical applications, especially where ceiling headroom is limited, it may be preferable, or even necessary, to engage the bracket 228 with the rail 200 using the "lift and rotate" procedure described herein, prior to attaching the panel to the bracket. The body portion 230 has laterally extending upward and outward webs 238 and 240, respectively, into which respective notches 242 and 244 (FIG. 24) extend. The upper notch 242 is defined by a sloping wall 248 and a substantially vertical wall 246, the former wall being sloped so as to facilitate employment of the "lift and rotate" method of engaging the bracket 228 with the rail 200. The walls of the lower notch 244 are substantially parallel. The overall height of the bracket 228, measured from its top surface 250 to the upper wall defining the notch 244 is slightly less than (e.g. 2% to 4% less than) the height of the rail measured from the lower surface of web 202 to the upper surface of the flange 206. This, in conjunction with the shape of the notch 242, enables the "lift and rotate" procedure of engaging the bracket 228 with the rail 200 to be employed without sticking or binding between the parts. | There is disclosed a bracket specially designed so that a panel fixed to the bracket can be easily and reliably engaged with the rail.
A die cast bracket for use in supporting a panel has a first slot in a vertical edge and a second slot in a horizontal edge, and has a web located in a substantially vertical plane in use, the web having means whereby the panel can be fixed thereto.
A kit for supporting a wall-supported item of furniture having vertical panels, the kit including at least one elongate support member, the elongate support member having a vertical web and a horizontal web, the horizontal web having a vertically downwardly extending flange and the vertical web having a horizontal extending flange, and the panel having or carrying a bracket or the like having one slot to receive the vertical flange and one slot to receive the horizontal flange when the panel is assembled to a horizontally-extending elongate support member.
Brackets as disclosed are durable and allow panels to be hung and removed, without deterioration. | 0 |
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